Vermont Castings 2040-CAT-C Encore Wood Burning Stove Owner’s Manual

Vermont Castings 2040-CAT-C Encore Wood Burning Stove

INSTALLER: Leave this manual with party responsible for use and operation.
OWNER: Retain this manual for future reference. Contact your dealer with questions on installation, operation, or service.

Installation and service of this appliance should be performed by qualified personnel. Hearth & Home Technologies recommends HHT factory-trained or NFI- certified professionals.

WARNING
If the information in these instructions is not followed exactly, a fire may result causing property damage, personal injury, or death.

• Do not store or use gasoline or other flammable vapours and liquids in the vicinity of this or any other appliance.
• Do not over fire – If an appliance or chimney connector glows, you are overfiring. Overfiring will void your warranty.
• Comply with all minimum clearances to combustibles as specified. Failure to comply may cause a house fire.

WARNING
HOT SURFACES!
Glass and other surfaces are hot during operation AND cool down. Hot glass will cause burns.

• Do not touch the glass until it is cooled
• NEVER allow children to touch glass
• Keep children away
• CAREFULLY SUPERVISE children in the same room as the fireplace.
• Alert children and adults to the hazards of high temperatures
• High temperatures may ignite clothing or other flammable materials.
• Keep clothing, furniture, draperies and other flammable materials away.

NOTE
To obtain a French translation of this manual, please contact your dealer or visit www.vermontcastings.com Pour obtenir une traduction française de ce manuel, s’il vous plaît contacter votre revendeur ou visitez www.vermontcastings.com

Congratulations on your choice of a Vermont Castings Encore® Model 2040-CAT-C Wood Burning Stove. At Vermont Castings we take American craftsmanship seriously. We assure you that your cast-iron Vermont Castings stove has been made with the utmost care and will provide you with many years of service. As you become acquainted with your new stove, you will find that its appearance is matched by its functionality, due to cast iron’s unique ability to absorb and radiate heat. Also, Vermont Castings products are among the cleanest- burning wood stoves available today. 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, we are committed to your satisfaction as a customer. That is why we maintain an exclusive network of the finest dealers in the industry. Our dealers are chosen for their expertise and dedication to customer service. 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 operation of your Vermont Castings Encore® Model 2040-CAT-C Wood Burning Stove. It also contains useful information on maintenance. Please read the manual thoroughly and keep it as a reference.

Note: Cast iron is an artisan-crafted material, which is made the same way today as nearly 2000 years ago. Due to the intrinsic primitive nature of the casting process, part-to-part variation is normal and adds to the character of a hand built cast iron appliance.This heater meets the U.S. Environmental Protection Agency’s emission limits for wood heaters sold on or after May 15, 2020. Please read this entire manual before you operate your new stove. Failure to follow instructions may result in property damage, bodily injury, or even death.

Proposition 65 Warning: Fuels used in gas, wood burning or oil-fired appliances, and the products of combustion 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

Safety Alert Key:

• DANGER! Indicates a hazardous situation which, if not avoided will result in death or serious injury.
• WARNING! Indicates a hazardous situation which, if not avoided could result in death or serious injury.
• CAUTION! Indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.
• NOTICE: Indicates practices that may cause damage to the appliance or to property.

Warranty Policy

Hearth & Home Technologies LLC LIMITED LIFETIME WARRANTY

Hearth & Home Technologies LLC (“HHT”) extends the following warranty for HHT gas, wood, pellet and electric hearth appliances (each a “Product” and collectively, the “Products)”) and certain parts set forth in the table below (“Component Part(s)”) that are purchased from a HHT authorized dealer or distributor.

WARRANTY COVERAGE
HHT warrants that the Products and their Component Parts will be free from defects in materials and workmanship for the applicable period of Warranty coverage outlined in the table below (“Warranty Period”). If a Product or Component Parts are found to be defective in materials or workmanship during the applicable Warranty Period, HHT will, at its option, repair the applicable Component Part(s), replace the applicable Component Parts), or refund the purchase price of the applicable Products). The maximum amount recoverable under this Warranty is limited to the purchase price of the Product. This Warranty is transferable from the original purchaser to subsequent owners, but the Warranty Period will not be extended in duration or expanded in coverage for any such transfer. This Warranty is subject to conditions, exclusions, and limitations as described below.

WARRANTY PERIOD:
Warranty coverage begins at the date of installation. In the case of new home constructions, Warranty coverage begins on the date of first occupancy of the dwelling or six months after the sale of the Product(s) by an independent, authorized HHT dealer or distributor, whichever occurs earlier. However, the Warranty coverage shall commence no later than 24 months following the date of Product shipment from HHT, regardless of the installation or occupancy date. The term “Lifetime” in the table below is defined as: 20 years from the beginning date of warranty coverage for gas appliances, and 10 years from the beginning date of warranty coverage for wood and pellet appliances. These time periods reflect the minimum expected useful lives of the designated Component Parts under normal operating conditions.

WARRANTY CONDITIONS

• Because HHT cannot control the quality of any Products sold by unauthorized sellers, this Warranty only covers Products that are purchased through an HHT authorized dealer or distributor unless otherwise prohibited by law; a list of HHT authorized dealers is available on the HHT branded websites.
• This Warranty is only valid while the applicable Product remains at the site of original installation.
• This Warranty is only valid in the country in which the HHT authorized dealer or distributor that sold the applicable Product is authorized to sell applicable Product.
• Contact your installing distributor or dealer for Warranty service. If the installing dealer or distributor is unable to provide necessary parts, contact the nearest HHT authorized dealer or supplier. Additional service fees may apply if you are seeking Warranty service from a dealer other than the dealer from whom you originally purchased the applicable Product.
• No HHT consumer should bear cost of warranty service or costs incurred while servicing warranty claims (i.e., travel, gas, or mileage) when the service is performed within the terms of this Warranty. Check with your dealer or distributor in advance for any costs to you when arranging a warranty call. Travel and shipping charges for parts are not covered by this Warranty.

WARRANTY EXCLUSIONS
This Warranty does not cover the following:

• Changes in surface finishes as a result of normal use. As a heating appliance, some changes in color of interior and exterior surface finishes may occur. This is not a flaw and is not covered under the Warranty.
• Damage to printed, plated, or enamelled surfaces caused by fingerprints, accidents, misuse, scratches, melted items or other external sources and residues left on the plated surfaces from the use of abrasive cleaners or polishes.
• Repair or replacement of parts that are subject to normal wear and tear during the Warranty Period are not covered. These parts include: paint, wood and pellet gaskets, firebricks, grates, flame guides, batteries and the discoloration of glass.
• Minor expansion, contraction, or movement of certain parts causing noise. These conditions are normal and complaints related to this noise are not covered by this Warranty.
• Damages resulting from: (1) failure to install, operate, or maintain the applicable Product in accordance with the installation instructions, operating instructions, and listing agent identification label furnished with the applicable Product; (2) failure to install the applicable Product by local building codes; (3) shipping or improper handling; (4) improper operation, abuse, misuse, continued operation with damaged, corroded or failed components, accident, or improperly/incorrectly performedrepairs; (5) environmental conditions, inadequate ventilation, negative pressure, or drafting caused by tightly sealed constructions, insufficient make-up air supply, or handling devices such as exhaust fans or forced air furnaces or other such causes; (6) use of fuels other than those specified in the operation instructions; (7) installation or use of components not supplied with the applicable Product or any other components not expressly authorized and approved by HHT; (8) modification of the appliance not expressly authorized and approved by HHT in writing; and/or (9) interruptions or fluctuations of electrical power supply to the applicable Product.
• Non-HHT venting components, hearth connections or other accessories used in conjunction with the applicable Product.
• Any part of a pre-existing fireplace system in which an insert or a decorative gas applicable Product is installed.
• HHT’s obligation under this Warranty does not extend to the Product’s capability to heat the desired space. Information is provided to assist the consumer and the dealer in selecting the proper Product for the application. Consideration must be given to the Product location and configuration, environmental conditions, insulation and air tightness of the structure. This warranty is void if:
• The applicable Product has been over-fired, and operated in atmospheres contaminated by chlorine, fluorine, or other damaging chemicals. Over-firing can be identified by, but not limited to, warped plates or tubes, deformation/warping of interior cast iron structure or components, rust colored cast iron, bubbling, cracking and discoloration of steel or enamel finishes.
• The applicable Product is subjected to prolonged periods of dampness or condensation.
• There is any damage to the applicable Product due to water or weather damage which is the result of, but not limited to, improper chimney or venting installation.

LIMITATIONS OF REMEDIES AND LIABILITY

• EXCEPT TO THE EXTENT PROVIDED BY LAW, HHT MAKES NO EXPRESS WARRANTIES OTHER THAN THE WARRANTY SPECIFIED HEREIN. The owner’s exclusive remedy and HHT’s sole obligation under this Warranty or in contract, tort or otherwise, shall be limited to replacement of the Component Parts), repair of the Component Parts), or refund of the original purchase price of the applicable Product(s), as specified above; provided, however, that (i) if HHT is unable to provide replacement of the Component Part(s) and repair of the Component Parts) is not commercially practicable or cannot be timely made, or (ii) the customer is willing to accept a refund of the purchase price of the applicable Product(s), HHT may discharge all such obligations by refunding the purchase price of the applicable Product. In no event will HHT be liable for any incidental or consequential damages caused by defects in the applicable Product. Some States do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you. This Warranty gives you specific legal rights and you may also have other rights which vary from State to State. THE DURATION OF ANY IMPLIED WARRANTY IS LIMITED TO THE DURATION OF THE EXPRESSED WARRANTY SPECIFIED ABOVE FOR THE APPLICABLE PRODUCT. Some States do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.

Product Listing and Important Safety Information

Appliance Certification

BTU & Efficiency Specifications

Catalytic Information
6PA Certified 6missions:|  . g hr
*6PA Default LHV:|   .
**Actual tested HHV:**|   .
***EPA BTU Output:|   ,   –  ,
****Peak BTU/Hour Output:|   ,
Other Important Information
Vent Size:**|   Inch    mm

Inch    mm

Firebox Size:|  . cu. ft.
Max. Wood Length:|   ” aximum
Ideal Wood Length:|  ” Top Load
Fuel| Seasoned Cordwood

moisture

The Vermont Castings Encore® Model 2040-CAT-C Wood Appliance meets the U.S. Environmental Protection Agency Certified to comply with the 2020 particulate emission standards using cordwood.

California

WARNING
This product and the fuels used to operate this product (wood), and the products of combustion of such fuels, can expose you to chemicals including carbon black, which is known to the State of California to cause cancer, and carbon monoxide, which is known to the State of California to cause birth defects or other reproductive harm. For more information go to: www.P65Warnings.ca.gov

Mobile Home Approved (USA & Canada)

• This appliance is approved for mobile home installations in the USA & Canada when not installed in a sleeping room and when an outside combustion air inlet is provided.
• The structural integrity of the mobile home floor, ceiling, and walls must be maintained.
• The appliance must be properly grounded to the frame of the mobile home with #8 copper ground wire, and the chimney must be listed to UL103 HT or a listed UL-1777 full-length six-inch (152mm) diameter liner must be used.
• Outside air must be provided in a mobile home installation.

Glass Specifications
This appliance is equipped with 5mm ceramic glass. Replace glass only with 5mm ceramic glass. Please contact your dealer for replacement glass.

WARNING

Fire Risk.
Hearth & Home Technologies disclaims any responsibility for, and the warranty will be voided by, the following actions:

• Installation and use of any damaged appliance.
• Modification of the appliance.
• Installation other than as instructed by Hearth & Home Technologies.
• Installation and/or use of any component part not approved by Hearth & Home Technologies.
• Operating appliance without fully assembling all components.
• Operating appliance without legs attached (if supplied with appliance).
• Do NOT Overfire – If an appliance or chimney connector glows, you are overfiring.

Any such action that may cause a fire hazard.

Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. For assistance or additional information, consult a qualified installer, service agency or your dealer. In the United States it is against the law to operate this wood heater in a manner inconsistent with the operating instructions in this manual.

NOTE: Hearth & Home Technologies, manufacturer of this appliance, reserves the right to alter its products, their specifications and/or price without notice.

Vermont Castings is a registered trademark of Hearth & Home Technologies.

Operating Instructions

Appliance Controls
Two controls regulate the performance of the Encore® Model 2040-CAT-C: a primary air control supplies oxygen for the fire, and a damper directs air flow within the stove to activate and deactivate the combustion system, Figure 2.1. Symbols on the stove are reminders of the correct directions for using the controls. The words ‘Left’ and ‘Right’ in these directions are facing the stove.

Figure 2.1 – The Encore® Model 2040-CAT-C controls are conveniently located and easy to operate.

A Single Air Control Regulates Heat Output and Burn Time
The primary air control lever, on the right of the stove, controls the amount of incoming air for starting, maintaining, and reviving a fire. Once the air control is manually set, a bi-metallic thermostat automatically maintains the heat output at a constant level for a more even heat over the life of the burn. More air entering the stove makes the fire burn hotter and faster, while less air prolongs the burn at a lower heat output level. For the greatest air supply and maximum heat output (but the shortest burn time), move the lever toward the front of the stove. For a fire that will last longer with less heat, move the lever toward the rear of the unit, Figure 2.2.

WARNING
This wood heater has a manufactured-set minimum low burn rate that must not be altered. It is against federal regulations to alter this setting or otherwise operate this wood heater in a manner inconsistent with operating instructions in this manual.

Figure 2.2 – The handle may be positioned anywhere between the two extremes for different heat levels.

A Damper Directs Air Flow Within the Stove
The damper handle on the left side of the stove operates the damper to direct air flow within the stove. The damper is open when the handle points to the rear, enabling smoke to pass directly into the chimney. The damper must be open when starting or reviving a fire, and whenever the griddle or doors are opened. The damper is closed when the handle points down. Smoke travels through the secondary combustion system where it can be further burned, before passing up the chimney, Figure 2.3. The damper should always be either fully open or fully closed. There are no intermediate positions. When closing the damper, be sure to pull firmly enough to snap the handle into the locked position.

Figure 2.3 – The damper is either open or closed. There are no intermediate positions.

Conditioning Your Stove
Cast iron is extremely strong, but it can be broken with a sharp blow from a hammer or from the thermal shock of rapid and extreme temperature change. The cast plates expand and contract with changes in temperature. When you first begin using your Encore® Model 2040-CAT-C, minimize thermal stress by letting the plates adjust gradually during three or four initial break-in fires.

Wood Burning Operation
Burn only solid wood in the Encore® Model 2040-CAT-C Wood Stove, and burn it directly on the grate. Do not elevate the fuel. Do not burn coal or other fuels. In the United States, it is against the law to operate this wood heater in a manner inconsistent with operating instructions in this manual. The bypass damper must be open when starting a fire or when refuelling. Do not use chemicals or fluids to start the fire. Do not burn garbage. Never use flammable fluids such as gasoline, gasoline-type lantern fuel, kerosene, charcoal lighter fluid, naptha, engine oil or similar liquids to start or “freshen up” a fire in this heater. Keep all such liquids well away from the heater while it is in use. The following procedures are important for the reliable, clean and efficient operation of your wood stove. Recommend 16″ logs Properly seasoned (up to a year for denser woods) Split to 3″ to 6″ cross- sections

Cold start
When starting your stove at room temperature and when no burning coals are present the following kindling procedure is the most reliable. Stack about 4 Ibs of finely split kindling (1″ diameter or less 10 to 20 pcs) in a ‘log cabin’ style directly against the rear wall. Place a small amount of newspaper on top of this pile with one or two small pieces of kindling on top. This is referred to as a top-down method and while providing a slower start, also serves to preheat the combustion properly resulting in a reliable start., Figure 2.4.

Figure 2.4 – Start the fire with newspaper and dry kindling.

With the bypass damper open and the primary air set to its highest position, light the newspaper. Leave the front door cracked until the kindling ignites, then close the doors. After most of the kindling has burned into coals (15 to 20 minutes), open the front doors and push remaining coals and unburned wood against the rear wall. Add several pieces of larger split wood between 2 to 3 inches in diameter (about 6 Ibs) directly against the rear wall and on top of the kindling coals. Close the doors and bypass to engage the combustion system. The air should remain on high for up to one hour or until the wood is mostly converted to coals. After a hot bed of coals is produced, open the door and bypass damper and push the remaining coals again toward the rear wall. Add large pieces of wood starting against the rear wall and on top of the coals. Close the doors and bypass immediately after loading the stove. Ideally, allow this wood load to burn at the highest air setting for the entire wood load. If this is not possible, the wood should burn for at least 30 minutes prior to reducing the primary air setting.

Ways to Add Fuel
To open the front doors, insert the handle into the door latch stub and turn it clockwise, Figure 2.5. To close them, always close the left door first. Turn the handle in the right door to the left and up (to the open position) and close it. Finally, push on the door as you turn the handle counterclockwise. The doors will draw in slightly, and the handle should offer some resistance as you turn it to the closed position. To reduce the risk of breaking the glass, avoid striking the glass or slamming the doors. When you are not using the door handle, store it in the holder behind the left front leg of the stove.

Figure 2.5 – To open the front doors, turn the handle clockwise.

WARNING
Fireplace stoves equipped with doors should be operated only with doors fully open or doors fully closed. If doors are left partly open, gas and flame may be drawn out of the fireplace stove opening, creating risks from both fire and smoke.

For best results when refuelling, wear long-cuffed stove gloves to protect your hands and forearms.

Reloading a hot stove:
When a wood load is added to a hot bed of coals (continuous use), open the bypass damper and either the top or front loading doors. Stir the hot coals to allow ash to fall through the grate. Hot coals should then be pushed against the rear wall and leveled depending on the amount of coals. Add fresh wood and close the loading door and bypass the damper. If the coals are glowing and hot, it is possible to set the air control to any setting immediately after loading the stove.

Reloading a warm stove:
If the stove is relatively cold (for instance after a long overnight burn, the coal bed may need to be re-energized prior to adding a large load of wood. Open the bypass damper and either the top or front loading door. Stir the coals to allow ash to fall through the grate. Push the remaining coals toward the rear wall. Close the doors) and bypass the damper and set the primary air to the highest position. Allow the coals to re-ignite and heat the system for 10 to 15 minutes. Once the coals are glowing, a fresh batch of wood may be added following the “hot stove” procedure above. A proper bed of coals is critical to the performance of the Encore stove. The rear refractory wall of the stove should be almost entirely white in color with proper operation. This indicates the combustion system is running at a proper elevated temperature. If the rear wall is black with creosote or develops a dark brown color, likely, the coal bed is not sufficiently large enough or hot enough. Revisit the above instructions and adjust the amount of kindling or time at high air settings to get the system hotter. Wood size or excessive moisture may also cause lower-than-desirable stove temperatures. While not required, operating your stove with the catalytic combustor installed creates optimum conditions for secondary combustion and will increase your efficiency up to 15% on low burn, making sure you get the most heat out of each load of wood. The catalytic element is a metal “honeycomb” coated with the catalytic material. The element sits at the bottom of the secondary combustion chamber. Smoke, gases and particulates that are not fully combusted during the secondary combustion process pass through the catalyst, creating a tertiary burn. This results in higher efficiency and ower emissions.

The catalytic element is a metal “honeycomb” coated with the catalytic material. The element sits at the bottom of the secondary combustion chamber. Smoke, gases and particulates that are not fully combusted during the secondary combustion process pass through the catalyst, creating a tertiary burn. This results in higher efficiency and lower emissions. The catalyst will initiate combustion of smoke and particulates at 500° – 600°F (260° – 315°C), half the temperature normally required for unaided secondary combustion. If you followed the startup operation steps in the previous section the stove will be sufficiently hot to allow the combustor to work. Once the combustor starts working, heat generated by burning the smoke will keep it working. To determine whether the combustor is operating, refer to the temperature probe which shows the operating range of the catalytic combustor. This is located on the back of the stove and is viewed from the top.

NOTE: It will take several minutes after closing the bypass damper for the temperature probe to fully adjust to the new temperature. If the probe indicator is below the operating catalyst range, add fuel or open the bypass damper to allow the fire to further build before engaging the catalyst again. If the probe indicator is above the operate catalyst range, the catalytic combustor is running too hot and may be damaged. In many cases, decreasing the primary air can reduce the catalyst temperature and adding less wood with each loading can also help if overheating is persistent. Do not add wood to the stove if the probe reads above the operating catalyst range. Avoid using a full load of very dry wood in the firebox, such as dry slab wood or wood with below 14% moisture content. This may result in continuous very high temperatures in the secondary combustion area and damage the combustor. Never burn treated wood, garbage, solvents or trash. All of these may poison the catalyst and prevent it from operating properly. Never burn cardboard or loose paper except for kindling purposes. Never burn coal; doing so can produce soot or large flakes of char or fly ash that can coat the combustor and cause smoke to spill into the room. Coal smoke can also poison the catalyst so that it won’t operate properly.

NOTE: The catalytic combustor is fragile and will crack if subjected to thermal shock. Thermal shock can occur when refuelling with wet wood or closing the bypass damper too early after refuelling.

WARNING

DO NOT OPERATE THE STOVE WITH THE ASH DOOR OPEN. OPERATION WITH THE ASH DOOR OPEN CAN CAUSE AN OVER-FIRING CONDITION TO OCCUR. OVERFIRING THE STOVE IS DANGEROUS AND CAN RESULT IN PROPERTY DAMAGE, INJURY OR LOSS OF LIFE.

Andirons Help Protect the Glass
Your stove has andirons to keep logs away from the glass panels. The andirons are essential to maintain clear fire viewing and should be left in place. Since the andirons may slightly hinder refuelling through the front doors, most stove owners will prefer the convenience of top-loading through the griddle. Do not place fuel between the andirons and the doors.

Burn Only High-Quality Wood
The Encore® Model 2040-CAT-C is designed to burn natural wood only; do not burn fuels other than that for which it was designed.

IMPORTANT: Do not burn any type of artificial materials such as fire starter logs (containing wax) in this appliance. Never burn liquid-based fuels such as kerosene, gasoline or alcohol.

Burning any materials not allowed in these instructions, or over-firing the stove, may void the warranty. You’ll enjoy the best results when burning wood that has been adequately air-dried. The wood should be 16″ – 18″ (406-457 mm) in length. Avoid burning “green” wood that has not been properly seasoned. (Note: Properly seasoned firewood has a moisture content below 20 per cent.) Do not burn construction materials; they often contain chemicals and metals that can damage the inside surfaces of the stove and pollute the air. Do not burn ocean driftwood; when it burns, the salt it contains will attack the cast iron. The best hardwood fuels include oak, maple, beech, ash, and hickory that has been split, stacked, and air-dried outside under cover for at least one year. If hardwood is not available, you can burn softwoods that include tamarack, yellow pine, white pine, Eastern red cedar, fir, and redwood. These should also be properly dried. Store split wood under cover to keep it dry. Even for short-term storage, be sure to keep wood a safe distance from the stove and keep it out of the areas around the stove used for refuelling and ash removal.

Surface Thermometer is a Valuable Guide to Operation An optional surface thermometer tells you when to adjust the air control, and when to refuel, Figure 2.8.

Figure 2.8 – Take temperature readings with a thermometer located in the middle of the griddle.

For example, when the thermometer registers at least 450°F (230°C) on the stovetop after start-up you know the stove is hot enough and it may be time to close the damper if a sufficient ember bed has also been established. Note that the stove will warm up much sooner than the chimney, though; a warm chimney is the key to easy, effective stove operation. When thermometer readings drop below 350°F. (175°C) it’s time to adjust the air control for a higher burn rate or to reload the stove. A temperature reading over 650°F. (340°C) is a sign to reduce the air supply to slow the burn rate.

Use the following temperature ranges as a guide:

• Readings in the 350°-500°F. (175°-260°C) range indicates low to medium heat output.
• 500°-600°F. (260°-315°C) readings indicate medium heat output.
• Readings of 600°-650°F. (315-340°C) indicate high heat output. Operating your Encore® Model 2040-CAT-C continuously at griddle temperatures higher than 650° F (340°C) may damage the cast iron or enamel finish.

Use the Air Control Settings that Work Best for You
No single air control setting will fit every situation. Each installation will differ depending on the quality of the fuel, the amount of heat desired, and how long you wish the fire to burn; outdoor air temperature and pressure also affect draft. The control setting also depends on your particular installation’s “draft,” or the force that moves air from the stove up through the chimney. Draft is affected by such things as the length, type, and location of the chimney, local geography, nearby obstructions, and other factors. Too much draft may cause excessive temperatures in the Encore® Model 2040-CAT-C, and could even damage the stove. On the other hand, too little draft can cause back puffing into the room and/or the “plugging” of the chimney. How do you know if your draft is excessively high or low? Symptoms of too much draft include an uncontrollable burn or a glowing red stove part. Signs of weak draft are smoke leaking into the room through the stove or chimney connector joints or low heat output.

In some newer homes that are well-insulated and weather-tight, poor draft may result from an insufficient air supply in the house. In such instances, an open window near the stove on the windward side of the house can provide the combustion air supply needed. Another option for getting more combustion air to the stove is to duct air directly from outside to the stove. In some areas provisions for outside combustion air are required in all new construction.When first using the stove, keep track of the air control settings. You will quickly find that a specific setting will give you a fixed amount of heat. It may take a week or two to determine the amount of heat and the length of burn you should expect from various settings. Most installations do not require a large amount of combustion air, especially if adequate draft is available. Do not for any reason attempt to increase the firing of your heater by altering the air control adjustment range outlined in these directions.

Ash Disposal
DO NOT OPERATE THE STOVE WITH THE ASH DOOR OPEN. OPERATION WITH THE ASH DOOR OPEN CAN CAUSE AN OVER-FIRING CONDITION TO OCCUR. OVERFIRING THE STOVE IS DANGEROUS AND CAN RESULT IN PROPERTY DAMAGE, INJURY OR LOSS OF LIFE.
Routine ash removal is important for ease of maintenance and is important for the stove’s durability. Remove ash before it reaches the top of the ash pan. Check the level at least once a day. Every few days, clear any ash from the outer edges of the firebox. Most of the ash will fall through the grate. Stir the ash with a shovel or poker so that it falls through the grate slots.

IMPORTANT: Check the level of ash in the ash pan before reloading the stove. If the ash level is close to the top edge of the pan, empty the pan according to this procedure:

• Open the damper.
• Open the griddle or front doors, and use a shovel or poker to stir excess ash through the ash slots in the grate down into the ash pan.
• Close the griddle or doors, and unlatch the ash door, Figure 2.9. It will pivot, swinging the ash pan out of the stove.
• Figure 2.9- Turn the ash door handle clockwise to open and counterclockwise to close.
• Slide the cover onto the pan, making sure it is securely closed, Figure 2.10.
• Figure 2.10 – Be sure the cover is securely attached before removing the ash pan.
• Remove the ash pan, making sure to keep it level.
• To keep the cover from sliding off and to keep ash from falling on the floor, do not tilt the ash pan forward.
• If the stove is in operation, close the ash door while disposing of the ash. You may need to lift the latch end of the door slightly to align the latch with the mating part on the stove bottom.
• Properly dispose of the ash in a metal container with a tight-fitting lid. Store the container outdoors away from all combustible material.
• Return the ash pan to its original position in the stove, and close and latch the ash door.

WARNING
Do not operate the stove with the ash door open. This will result in over- firing and could cause damage to the stove, void the warranty, or even lead to a house fire.

Empty the ash pan regularly, typically every one to three days. The frequency will vary depending on how you operate your Encore® Model 2040-CAT-C: ash will accumulate faster at higher heat outputs. Removed ash should be placed outdoors in a metal container with a tight-fitting lid. Keep the closed container of ash on a noncombustible floor or on the ground, well away from all combustible materials, pending final disposal. If the ash is disposed of by burial in soil or otherwise locally dispersed, it should be kept in the closed container until all cinders have thoroughly cooled.

CAUTION
Never use your household or shop vacuum cleaner to remove ash from the stove; always remove and dispose of the ash properly.

Opacity (Visible Smoke)
This is the measure of how cleanly your appliance is burning. Opacity is measured in per cent; 100% opacity is when an object is totally obscured by the smoke column from a chimney, and 0% opacity means that no smoke column can be seen. As you become familiar with your appliance, you should periodically check the opacity. This will allow you to know how to bum as nearly smoke-free as possible (goal of 0% opacity).

WARNING
Fire Risk

• DO NOT BURN GARBAGE OR FLAMMABLE FLUIDS SUCH AS GASOLINE, NAPTHA OR ENGINE OIL.
• Do NOT burn treated wood or wood with salt (driftwood).
• May generate carbon monoxide if burns material other than wood.

May result in illness or possible death.

WARNING
Fire Risk
Keep combustible materials, gasoline and other flammable vapours and liquids clear of the appliance.

• Combustible materials may ignite.
• Do NOT store flammable materials in the appliance’s vicinity.
• DO NOT USE GASOLINE, LANTERN FUEL, KEROSENE, CHARCOAL LIGHTER FLUID OR SIMILAR LIQUIDS TO START OR “FRESHEN UP” A FIRE IN THIS Appliance.
• Keep all such liquids well away from the appliance while it is in use.

CAUTION
When burning your first fire, you will experience smoke and odor from the appliance resulting from the curing of paint and burning off of any oils remaining from manufacturing. OPENWINDOWS DURING INITIALBURNTODISSIPATE SMOKE AND ODORS!

• Odors may be irritating to sensitive individuals.
• Smoke detectors may activate.

Negative Pressure

WARNING
Asphyxiation Risk

• Negative pressure can cause spillage of combustion fumes, soot and carbon monoxide.
• The appliance needs to draft properly for safety.

Negative pressure results from the imbalance of air available for the appliance to operate properly. It can be strongest in lower levels of the house.

Causes include:

• Exhaust fans (kitchen, bath, etc.)
• Range hoods
• Combustion air requirements for furnaces, water appliances and other combustion appliances
• Clothes dryers
• Location of return-air vents to the furnace or air conditioning
• Imbalances of the HVAC air handling system
• Upper-level air leaks such as:
  • Recessed lighting
  • Attic hatch
  • Duct leaks

To minimize the effects of negative air pressure:

• Install outside air to the stove with the intake facing prevailing winds during the heating season
• Ensure adequate outdoor air for all combustion appliances and exhaust equipment
• Ensure furnace and air conditioning return vents are not located near the appliance
• Avoid installing the appliance near doors, walkways or small isolated spaces
• Recessed lighting should be a “sealed can” design
• Attic hatches weather-stripped or sealed
• Attic-mounted ductwork and air handler joints and seams taped or sealed

Important Information

Creosote is a by-product of slow wood burning. It’s an organic tar that can condense in the flue if it is present in the exhaust, slow-moving, and cools to less than 290°F (130°C). Condensed creosote is volatile, and can generate chimney fires if it gets hot enough. All the features that affect chimney draft also affect creosote condensation – so use whatever combination of installation features and operational steps that will encourage good draft and minimize creosote production. Because letting the exhaust cool off and slow down is one of the keys to creosote accumulation, it makes sense to line a chimney to match the stove’s outlet size, for safety reasons as well as performance. Canadian law requires a matching liner to serve any stove or insert vented through a fireplace chimney; in the US, the National Fire Protection Association (NFPA) recommends a chimney liner if the flue is more than three times bigger (in square area than the outlet on the stove or insert. Some localities enforce the NFPA guidelines as part of their building codes.

Fuel: Even the best stove installation will not perform well with poor fuel. The best fuel is a hardwood that has air-dried 12-18 months. Softwood burns, but not as long as hardwood. ‘Green’ wood contains a lot of moisture; it will burn, but some of the heat potential is used to boil the extra moisture from the wood. This reduces the amount of heat that reaches your home and can contribute to a creosote problem. There are moisture meters available for firewood; you can also judge your wood by its appearance and weight (Moisture content of 20% or less is best). If you get it green, lift a piece and get a sense of its weight; it can lose a third or more of its weight as it dries. Also, look at the ends of a log; as it dries it shrinks and often cracks. The more weathered and cracked a piece is, the drier it is. Dry wood burns readily with a good chimney draft. But with modern stoves, wood can be too dry and too volatile. Smoke and combustible gases can ‘gas out from the wood quickly and densely enough to overload the combustion system. If you hear a rumbling or roaring noise (like a propane torch) from the stove, that is a sign that the stove is over-firing.

Back-puffing results when the fire produces volatile gases faster than the chimney draft pulls them out of the firebox. The gases back up in the firebox until they are concentrated enough and hot enough to ignite. If your stove back-puffs, the stove needs to cool down. You should open the damper to let the smoke rise to the flue more quickly, allow more air into the firebox, avoid big loads of firewood and check that the wood moisture is not too low.

Draft Testing: An easy way to test your chimney draft is to close the stove’s damper, wait a few minutes to let the airflow stabilize, then see whether you can vary the strength of the fire by swinging the air control open and closed. Results are not always instant; you may need to wait a few minutes for a change in the air control setting to affect the fire. If there’s no change, then the draft isn’t strong enough yet to let you close the damper, and you’ll need to open it for awhile longer and manage the fire with the air inlet until the draft strengthens. If you keep track of your burning habits and relate them to their effects on the stove’s operation, you’ll be rewarded with good performance and a safe system. Conclusion: Wood-burning is an art rather than a science. Once the stove and chimney system are in place, you can only vary your technique, mostly your timing, to achieve good results. If you keep track of your burning habits and relate them to their effects on the stove’s operation, you’ll be rewarded with good performance and years of reliable heating.

Maintenance

Keep Your Stove Looking New and Working Its Best
Let the fire in the stove go out and allow the stove to cool completely before beginning any maintenance procedure. This wood appliance needs periodic inspection and repair for proper operation. It is against federal regulations to operate this wood appliance in a manner inconsistent with the operating instructions in this manual.

Care of the Cast Iron Surface
An occasional dusting with a dry rag will keep the painted cast iron of your Encore® Model 2040-CAT-C looking new. The stove’s paint can be touched up as needed. First, mask the areas, such as enamelled parts, glass, or handles, around the spot to be painted. Clean the spot with a wire brush. Remove the griddle and set it aside. It is normal for the griddle to darken after use. You can clean it with a fine-bristle wire brush, or steel wool. Then, touch up the stove with high-temperature stove paint. Apply the paint sparingly; two light coats of paint are better than a single heavy one.

Care of the Porcelain Enamel Surface
Use a dry or slightly damp rag or soft brush to remove spills or stains. For difficult jobs that require a cleaning agent, use only a kitchen appliance cleaner or polish recommended for use on enamel surfaces.If porcelain enamel becomes chipped or scratched during use, apply “enamel epoxy” to the damaged area and allow to dry. Once the epoxy has dried, sand the area to blend with the surrounding area and apply appropriate colour touch-up paint. Allow to dry completely before operating the stove.

Cleaning and Replacement of Glass
Most of the carbon deposits on the glass will burn off during hot fires. However, the ash residue that accumulates on the glass surface should be removed regularly to prevent etching. To clean the glass, follow this procedure:

• Be sure the glass is completely cool.
• Clean the glass with water or a cleaner made especially for this purpose. Do not use abrasive cleaners. Use cleaning agents sparingly and be sure to keep them off the outer surfaces of the stove.
• Rinse the glass thoroughly.
• Dry the glass completely.

Replace Broken Glass Immediately
Do not operate your stove if the glass in the doors is damaged. If you need to replace the glass, use only the high-temperature 5 mm ceramic glass supplied by Vermont Castings. Do not use substitutes.

Removing the Glass

1. Remove the right and left door assemblies by raising the door until the lower hinge pin clears its hole; then, angle the door bottom slightly outward and pull down to release the upper hinge pin. Place the doors face down on a padded work surface. Be especially careful with enameled
2. Remove the screws that hold the glass retainer clips in place, and remove the clips.
3. Carefully lift the broken glass panel from the door.

Installing the Glass
Check the gasket around the window; it should be soft and resilient so that the glass will seal properly against the door. Replace the gasket if it has hardened or if it is compressed.

1. Center the glass on the gasket.
2. Secure the glass on both doors with the retainer clips. Tighten all screws, Figure 3.1.
3. Replace the doors on the stove.
4. Open and close the doors to check that they fit and work properly. Adjust as necessary.

Damper Adjustment (as Needed)
The tension on the Encore® Model 2040-CAT-C’s damper is adjustable to compensate for the compression of the gasket that seals the damper to the upper fireback. To adjust the damper:

1. Remove the griddle. Loosen the lock nut at the centre of the damper, Figure 3.2.
2. Turn the pressure screw approximately one half turn clockwise with an Allen wrench provided with your stove.
3. Tighten the lock nut. Prevent the pressure screw from turning as you tighten the nut. Re-test the damper.

Tighten the Damper Handle as Needed
A handle on the left side of the stove controls the damper. The handle attaches to the damper rod with a set screw. Periodically check the set screw and tighten as necessary.

Front Door Adjustment
The load doors are factory-adjusted for clearance, proper sealing and latch operation. However, the doors can sometimes shift in transit or from use and may need to be readjusted. The adjustment/alignment procedure is simple and only requires a 7/16″ wrench and a few minutes. We have provided a detailed video explaining how to properly adjust and align the doors.

Ash Door Adjustment
Just like the load doors, the ash door is factory-adjusted for proper operation and minimal sag. If the door does require adjustment to minimize sagging at the latch side, a simple adjustment requiring only a 7/16″ wrench will get the door back into proper alignment. We have provided a detailed video explaining how to properly adjust the ash door.

Note: For video instruction please refer to www.vermontcastings.com. Click on the YouTubelink located in the upper right-hand corner next to the “Search” bar .

Gasket Replacement (as needed)
Your Encore® Model 2040-CAT-C uses fibreglass rope gaskets to make a tight seal between some parts. With use, particularly on moving parts, gaskets can become brittle and compressed and can begin to lose their effectiveness. These will need periodic replacement. The sizes of replaceable gaskets are listed below, along with their applications.

Gasket Diameter……And the Parts it Seals

• 5/16™ The griddle to the stovetop (wire-reinforced gasket)
• 5/16″ The damper to the upper fireback
• 3/8″ The front doors to the stove front; and the doors to each other.
• 3/8″ The ash door to the front of the bottom panel
• 3/16″ The outer glass panes to the door

If you need to change a gasket, first obtain an appropriate replacement from your Vermont Castings Authorized Dealer. Wait until the fire is out and the stove has cooled. Be sure to follow the standard safety procedure for working with dusty materials: wear safety goggles and a dust mask. The procedure for replacing gaskets is the same, regardless of the gasket location. Follow these steps:

1. Remove the existing gasketby grasping an end and pulling firmly, Figure 3.4.

2. Use a wire brush or the tip of a screwdriver to clean the channel of any remaining cement or bits of gasket. Remove stubborn deposits of cement with a cold chisel if necessary, Figure 3.4.

3. Determine the correct length of the appropriate-sized gasket by laying it out in the channel. Allow an extra 1-2″ (25-50 mm), and mark the spot to be cut.

4. Remove the gasket from the channel, place it on a wood-cutting surface, and cut it at the marked spot with a utility knife. Twist the ends slightly to keep the gasket from unravelling.

5. Lay an unbroken 1/8″ (3 mm) bead of silicone or cement in the newly cleaned channel, Figure 3.5.
   Figure 3.5 – Lay a bead of gasket silicone or cement then press gasket in place.

6. Starting at one end, press the gasket into the channel, Figure 3.5. Ensure a good joint where the gasket meets before trimming any excess. Do not overlap the gasket ends or leave ends with ragged edges.

7. Press the gasketed part firmly against its normal mating surface to seat the gasket evenly in its channel. Close and latch the door to do this, or tap other parts with the rubber mallet (or hammer/block of wood).

8. Clean any excess cement from around the channel, then let the cement that holds the new gasket dry thoroughly.

9. The stove’s doors may need adjustment after you have regasketed them. Initially, it may require loosening the latch to accommodate the new gasket; after a few weeks, it may need tightening to compensate for the compression of the new gasket.

All Gasketed Construction Gaskets
Other gaskets form seals between all other non-moving parts, but these are not subject to the same wear and deterioration as gaskets on moving parts. It is unlikely that you will ever need to replace these gaskets unless the involved parts are disassembled and then put back together. If this is the case, the job should be done only by a qualified service technician.A  5/16″ diameter gasket seals the following parts:

• The lower fireback to the back panel
• The left and right air plates (inner sides)
• All connections between the stove plates.

The Chimney System

Creosote
Your Encore® Model 2040-CAT-C is designed to reduce creosote build-up significantly. However, regular chimney inspection and maintenance must still be performed. For safety, good stove performance, and to protect your chimney and chimney connector, inspect your chimney and chimney connector on a regular schedule. Clean the system if necessary. Failure to keep the chimney and connector system clean can result in a serious chimney fire.

WARNING
Inspect and Clean Chimney Frequently – Under certain conditions of use, creosote buildup may occur rapidly. When wood is burned slowly, it produces tar, organic vapours and moisture that combine to form creosote. The creosote vapours condense in the relatively cool chimney flue of a slow- burning fire. As a result, creosote residue accumulates on the flue lining. When ignited, this creosote makes an extremely hot fire within the flue system that can damage the chimney and overheat adjacent combustible material. If a significant layer of creosote has accumulated —1/8″ (3 mm) or more — it should be removed to reduce the risk of a chimney fire. You can never be too safe. Contact your local fire authority for information on what to do in the event of a chimney fire, and have a clearly understood plan on how to handle one. If you do experience a chimney fire, act promptly to:

• Close the damper and air control lever.
• Get everyone out of the house.
• Call the Fire Department.

Inspect the system every two weeks during the heating season as part of a regular maintenance schedule. To inspect the chimney, let the stove cool completely. Then, using a mirror and a strong light, sight up through the flue collar into the chimney flue. If you cannot inspect the flue system in this fashion, the stove must be disconnected to provide better viewing access. Clean the chimney using a brush the same size and shape as the flue liner. Flexible fiberglass rods are used to run the brush-up and down the liner, causing any deposits to fall to the bottom of the chimney where they can be removed through the clean-out door. Clean the chimney connector by disconnecting the sections, taking them outside, and removing any deposits with a stiff wire brush. Reinstall the connector sections after cleaning, being sure to secure the joints between individual sections with sheet metal screws. If you cannot inspect or clean the chimney yourself, contact your local Vermont Castings dealer or a professional chimney sweep.

Maintenance Schedule – The Stove Daily:

• Clear any ash build-up from around the air holes and combustion flow path in the lower fireback.
• Ashes should be removed before they reach the top of the ash pan. Check accumulation at least once a day.
• Keep the area around the stove clear of any combustible materials such as wood, furniture or clothing.

Two Months:

• Check the door handle to be sure it is working properly. Gasketing becomes compressed after some time. Adjust handle tightness if necessary.
• Check leg bolts and heat shield screws; tighten if necessary.

Annual Spring Cleaning

• Check gasketing for wear, and replace if necessary.
• Remove ashes from the ash pan and replace them with a moisture-absorbing material (such as kitty litter) to keep the interior of the stove dry.
• Clean the dust from the inner sides of the bottom, rear or pipe heat shields if your stove is equipped with them. Clean surfaces are better heat reflectors than dirty surfaces.
• Touch up the black paint.
• Inspect for and remove ash build-up behind the combustion package. This should be done in conjunction with the annual cleaning of the chimney connector. Inspect the passage behind the combustion package (a mirror will be helpful) and vacuum away ash using a flexible vacuum hose inserted in the passage, Figure 3.6.

The Chimney Connector

Two Weeks
• Inspect the chimney connector and chimney. Clean if necessary.

Two Months:
• Inspect the chimney and chimney connector. Pay particular attention to the horizontal runs of chimney connector, and the elbows. Clean the system if necessary.

Annual Spring Cleaning

• Disassemble the chimney connector and take it outdoors for inspection and cleaning. Replace weak sections of the connector.
• Inspect the chimney for signs of deterioration. Repairs to a masonry chimney should be made by a professional mason. Replace damaged sections of the prefabricated chimney. Your local Vermont Castings dealer or a chimney sweep can help determine when replacement is necessary.
• Thoroughly clean the chimney.

The Catalytic Element

CAUTION
BURN UNTREATED WOOD ONLY. OTHER MATERIALS SUCH AS WOOD PRESERVATIVES, METALS, FOILS, COAL, PLASTIC, GARBAGE, SULPHUR, OR OIL, MAY DAMAGE THE CATALYST.

This wood heater contains a catalytic combustor, which needs periodic inspection and replacement for proper operation. In the United States it is against the law to operate this wood heater in a manner inconsistent with the operating instructions in this manual. Under normal operating conditions, the catalytic combustor should remain active for two to six years (depending on the amount of wood burned). However, it is important to monitor the combustor periodically to ensure that it is functioning properly, as well as to determine when it needs to be replaced. A non-functioning combustor will result in a loss of heating efficiency, and an increase in creosote and emissions.

Inspection and Cleaning
Inspect the combustor for fly ash accumulation and physical damage two to three times per year. Clean the combustor as needed. The refractory package that houses the catalytic combustor should be inspected for a buildup of fly ash and cleaned if necessary. This may be done when you examine the combustor.

When to Suspect a Combustor Problem
The best way to evaluate the performance of your appliance’s combustor is to observe the amount of smoke leaving the chimney — both when the combustor has “lighted off” and when it has not. Follow these steps:

• With a fire going and the combustor properly activated, with the damper closed to route smoke through it as described in the Operation Section, go outside and observe the smoke leaving the chimney.
• Then, open the stove damper and once again check the smoke leaving the chimney.

You should see significantly more smoke when the stove damper is open and exhaust does not pass through the combustor. However, be careful not to confuse smoke with steam from wet wood. Steam dissipates in the air quickly; smoke does not. If this test indicates a problem, consider other possible factors as well, such as the weather or a change in the quality of your fuel. In warm weather, draft is weaker than it is in colder winter weather, and fires can burn sluggishly. Small, hot fires are a good solution under these conditions. Burning “green” (insufficiently seasoned) wood will result in poorer performance than burning properly seasoned fuel. Reloading with green wood can also thermal shock the catalyst, resulting in cracking, or the eventual fallout, of the ceramic honeycomb substrate. You may have to run your stove hotter (more air) to achieve acceptable performance using green or wet wood. Also, consider any changes in your operating routine. Once you have ruled out any other possible causes for a decline in performance, inspect and clean the combustor if necessary. Be sure to protect any surface you use for setting the stove parts aside.

NOTE
Burning “green” (insufficiently seasoned) wood will result in poorer performance than burning properly seasoned fuel. Reloading with green wood can also thermal shock the catalyst, resulting in cracking, or the eventual fallout, of the metal honeycomb substrate. You may have to run your stove hotter (more air) to achieve acceptable performance using green or wet wood. Also, consider any changes in your operating routine. Once you have ruled out any other possible causes for a decline in performance, inspect and clean the combustor if necessary. Be sure to protect any surface you use for setting the stove parts aside.

Inspecting the Combustor
Remove access door and inner firebrick. Remove the catalytic combustor by lifting up and pulling towards you, Figure 3.7.

To ensure a long life for the combustor, it is recommended to service the combustor regularly based on the amount of use. This procedure takes about five (5) minutes and requires no tools except for a vacuum if cleaning is necessary.

Cleaning the Combustor

1. Check the combustor’s honeycomb-like element for a buildup of fly ash. If any is evident, take the combustor outside and clean it by blowing air gently through it. Do not push anything through the honeycomb; do not use compressed air to clear the passages. Such abrasion can scrape the thin coating of platinum (the catalyst) off the ceramic base, shortening the catalyst’s life and reducing its effectiveness.
2. Inspect the element for damage or degradation. Although small hairline cracks will not affect performance, the element should be essentially intact. If the element is broken in pieces or has sections missing, it should be replaced. Call your local Vermont Castings Authorized Dealer for a replacement element.
3. If the element is in good condition and clean, re-install it in the stove and replace the refractory inner fireback and access door.

Operate the stove in your usual manner for two weeks, inspecting the chimney and the chimney connector frequently during this period. If creosote does not build up as fast, the performance change was likely caused by fly ash deposits on the catalytic element. However, continue the inspections of the chimney system for a few weeks to ensure that proper performance continues.

If you continue to find a significant creosote buildup or if you continue to see excessive smoke from the chimney, the catalytic element will need to be replaced. Contact your nearest Vermont Castings’ Authorized Dealer for information about a replacement element.

NOTE: Use only the replacement catalyst supplied by a Vermont casting dealer.

Troubleshooting Guide

With proper installation, operation, and maintenance your wood appliance will provide years of trouble-free service. If you do experience a problem, this troubleshooting guide will assist you or a qualified service person in the diagnosis of a problem and the corrective action to be taken.

•    Can not get fire started

•    Excessive smo e spillage

•    Burns too slowly

•    Not enough heat output

| Not  enough  kindling paper  or  no

idling paper

| Use dry kindling and more paper. Arrange

kindling & wood for air movement.

Not enough air for fire to ignite

| Check for restricted termination cap
Check for blockage of the outside air kit (if installed.
Check for flue blocage.
Pre-warm the flue before starting a fire.
Check for adequate vent height (refer to Chimney Height Section.
Refer to Negative Pressure section
 ood condition is too wet, too large| Use dry, seasoned wood  refer to

ood Burning Operation .

Bed of coals not established before adding wood| Start with paper & indling to establish bed of coals refer to ood Burning Operation .
Flue blockage such as birds’ nests or leaves in termination cap| Have chimney inspected for creosote and cleaned by a certified chimney sweep.
Down draft or negative pressure Competition with exhaust devices| Do not use exhaust fans during start-up

refer to Negative Pressure Section .

Fire burns too fast

|

Extremely dry or soft wood

|  ix in hardwood.
 ix in larger pieces of wood after fire is established.

Overdrafting

| Chec for correct vent height; too much vertical height creates overdrafting.
Check the location of vent termination (refer to the Chimney Termination Requirement Section in the Installation manual.

Low Heat Output

|

Coal Bed is too small

| Open damper. Establish a deeper coal bed and move coals to the rear of the firebox.
Excessive Coal Bed| Operating on high for extended periods| Reduce burn rate and allow coals to burn down before reloading.

Reference Materials

Service & Maintenance Log

• Date of Service
• Performed By
• Description of Service

Service Parts & Accessories

• Beginning Manufacturing Date: Mar 2019
• Ending Manufacturing Date: Active
• 2040-CAT-C (Classic Black)
• 2041-CAT-C (Biscuit) – Ending Manufacturing Date: Dec 2021
• 2042-CAT-C (Majolica Brown)
• 2044-CAT-C (Bordeaux)
• 2046-CAT-C (Twilight)
• 2040T-CAT-C (Classic Black w/TransitionDoors)

IMPORTANT: THIS IS DATED INFORMATION. Parts must be ordered from a dealer or distributor. Hearth and Home Technologies does not sell directly to consumers. Provide model number and serial number when requesting service parts from your dealer or distributor.| Stocked at Depot
---|---
ITEM| DESCRIPTION| COMMENTS| PART NUMBER
1| Brick Support Bracket| | 30005279|
2| Griddle Gasket, 10’| | 1-00-1203668| Y
3| Back| | 30005289A|
4| Refractory Right End| | 30005497|
5| Refractory Left End| | 30005498|
6| Refractory Support| | 30005233|
7| Gasket, Refractory Support| | 30005237|
8| Back Insulation Board| | 30005269|
9| Outer Back| | 30005261|
10| Left Griddle Quadrant| | 30002399A|
11| Right Griddle Quadrant| | 30002401A|
12| Griddle| | 30002386A|
13| HS Flue Collar| | 30005266|
14| Bracket Upper Side| | 30005267|
15| Catalyst, Ceramic| | 30006623|
16| Damper Gasket, 15’| | 1-00-1203588| Y
17| Damper Ramp| | 2-00-1301811S| Y
18| Damper Housing| | 30005293A|
19| Damper| | 30006467|
20| Damper Tab| Pkg of 10| 1601488-10|
21| Damper Rod| | 1600851|
22| Griddle Handle Assembly| | 30002775| Y
23| Gasket, Back Refractory, 10’| | 1-00-30005270|
24| Rheostat Bracket| | 30002863|
25| Refractory, Engine – E/D| | 30005202|
26| Damper Handle Screw (Qty 2 req)| Pkg of 10| 1201310-10|
27| Damper Handle| Qty 2 req| 1600664| Y
28| Damper Handle w/Screw| | 30002720A| Y

29

| ****

Left Side

| Classic Black| 30002388A|
Biscuit| SRV30003052|
Bordeaux| SRV30006679|
Ebony| SRV30003072|
Majolica Brown| SRV30004876|
Twilight| SRV30007027|
30| Left Air Manifold| | 30002408|
31| Right Air Manifold| | 30005290|
IMPORTANT: THIS IS DATED INFORMATION. Parts must be ordered from a dealer or distributor. Hearth and Home Technologies does not sell directly to consumers. Provide model number and serial number when requesting service parts from your dealer or distributor.| ****

Stocked at Depot

---|---
ITEM| DESCRIPTION| COMMENTS| PART NUMBER

32

| ****

Right Side

| Classic Black| 30002405A|
Biscuit| SRV30003053|
Bordeaux| SRV30006680|
Ebony| SRV30003073|
Majolica Brown| SRV30004877|
Twilight| SRV30007028|
33| Thermostat Handle Base| | 30002716| Y
34| Washer Damper Rod| Pkg of 10| 30007257-10|
35| Refractory Gasket Plate, S/S (Included w/SRV8787-021)| No longer available| SRV8000-008|
36| Inner Bottom| | 30005291|
37| Ashdoor Hinge Upper| | 1-00-30002403|
38| Door Handle Bracket| | 30002909|
39| Bottom Outer| | 30007510A|

40

| ****

Ashlip

| Classic Black| 30002402A|
Biscuit| SRV30003051|
Bordeaux| SRV30006678|
Ebony| SRV30003071|
Majolica Brown| SRV30004862|
Twilight| SRV30007026|
41| Gasket, Fireback (Included w/SRV8787-021)| No longer available| 30005209|
42| Gasket, Slotted Refractory (Included w/SRV8787-021)| No longer available| SRV8344-001|
43| Refractory, Fireback ( Pre HF2522164 must also order SRV8340-011 & SRV8787-021)| SRV8340-012|
44| Retainer, Fireback Refractory| Qty 2 req| 30005248|
45| Refractory, Inner Cover| | 30005205| Y
46| Andiron| Qty 2 req| 30002397A| Y
47| Refractory, Access Cover| Pre HF2522164| 30007251|
Post HF2522164| SRV8340-011|
48| Leg Leveler| Pkg of 10| 1201745-10|
49| Ashdoor Handle Shaft| | 1600622|
50| Pawl Assembly| Qty 2 req| 30005157| Y
51| Ashdoor| | 30002392A|
52| Ashdoor Handle (Wood)| | 1600663| Y
53| Hinge Hardware| | 1-00-2473|
54| Ashdoor Hinge Lower| | 1-00-30002404|
55| Ashpan Bracket| | 1601039|
56| Lower Side Bracket| | 30005268|
57| Thermostat Handle| | 1600660| Y
58| Front Manifold| | 30002407|
IMPORTANT: THIS IS DATED INFORMATION. Parts must be ordered from a dealer or distributor. Hearth and Home Technologies does not sell directly to consumers. Provide model number and serial number when requesting service parts from your dealer or distributor.| ****

Stocked at Depot

---|---
ITEM| DESCRIPTION| COMMENTS| PART NUMBER

59

| ****

Front

| Classic Black| 30002393A|
Biscuit| SRV30003054|
Bordeaux| SRV30006681|
Ebony| SRV30003074|
Majolica Brown| SRV30004878|
Twilight| SRV30007029|
60| Flue Collar Gasket| 15 Ft| 1-00-30002422| Y

61a

| ****

Left Door (Shell Enamel Parts)

| Classic Black| 30003938A|
Biscuit| SRV30003958|
Bordeaux| SRV30006685|
Ebony| SRV30003962|
Majolica Brown| SRV30004884|
Twilight| SRV30007033|

Left Door Sub Assembly (Shell Enamel Parts) (Does not contain glass or glass gasket)

| Classic Black| 30003974|
Biscuit| 30003984|
Bordeaux| 30006687|
Ebony| 30003988|
Majolica Brown| 30004882|
Twilight| 30007072|

61b

| ****

Left Door (Transition Door Enamel)

| Classic Black| 30007081A|
Biscuit| SRV30007083|
Bordeaux| SRV30007087|
Majolica Brown| SRV30007085|
Twilight| SRV30007107|

Left Door Sub Assembly (Transition Door Enamel)

| Classic Black| 30007165|
Biscuit| 30007167|
Bordeaux| 30007169|
Majolica Brown| 30007171|
Twilight| 30007173|
62| Door Hinge Strip| | 1308634A|

63

| ****

Top

| Classic Black| 30002387A|
Biscuit| SRV30003055|
Bordeaux| SRV30006682|
Ebony| SRV30003075|
Majolica Brown| SRV30004879|
Twilight| SRV30007030|
IMPORTANT: THIS IS DATED INFORMATION. Parts must be ordered from a dealer or distributor. Hearth and Home Technologies does not sell directly to consumers. Provide model number and serial number when requesting service parts from your dealer or distributor.| ****

Stocked at Depot

---|---
ITEM| DESCRIPTION| COMMENTS| PART NUMBER
64| Glass Clip| Pkg of 4| SRV1601394| Y

65A

| ****

Right Door (Shell Enamel Parts)

| Classic Black| 30003939A|
Biscuit| SRV30003959|
Bordeaux| SRV30006684|
Ebony| SRV30003963|
Majolica Brown| SRV30004883|
Twilight| SRV30007032|

Right Door Sub Assembly (Shell Enamel Parts) (Does not contain glass or glass gasket)

| Classic Black| 30003975|
Biscuit| 30003985|
Bordeaux| 30006686|
Ebony| 30003989|
Majolica Brown| 30004881|
Twilight| 30007073|

65B

| ****

Right Door (Transition Door Enamel)

| Classic Black| 30007080A|
Biscuit| SRV30007082|
Bordeaux| SRV30007086|
Majolica Brown| SRV30007084|
Twilight| SRV30007106|

Right Door Sub Assembly (Transition Door Enamel)

| Classic Black| 30007166|
Biscuit| 30007168|
Bordeaux| 30007170|
Majolica Brown| 30007172|
Twilight| 30007174|
66| Door Gasket, 15’| | 1-00-1203588| Y
67| Glass Gasket, 10’| | 1-00-1186258229| Y
68| Left Door Glass| | 30005300|
69| Right Door Glass| | 30005299|
70| Door Hinge Pin| Qty 2 req| 30002727| Y
71| Spacer (for Damper Rod)| Pkg of 10| 1201779-10|
72| Primary Air Valve Assembly| | 30005324|
| Primary Air Frame| | 1307411|
| Primary Air Rod| | 30005260|
73| Front Door Handle and Shaft| | 30002717| Y
74| Thermostat Friction Spring| Pkg of 10| 1201846-10|
75| Thermostat Handle Bolt| Pkg of 10| 1201243-10|
76| Cable Assembly| Call Tech| 5005471|
IMPORTANT: THIS IS DATED INFORMATION. Parts must be ordered from a dealer or distributor. Hearth and Home Technologies does not sell directly to consumers. Provide model number and serial number when requesting service parts from your dealer or distributor.| ****

Stocked at Depot

---|---
ITEM| DESCRIPTION| COMMENTS| PART NUMBER
77| Ash Pan Assembly| | 5005746|

78

| ****

Flue Collar, 6” Round

| Classic Black| 0001580|
Biscuit| 0001595|
Bordeaux| SRV30006683|
Ebony| SRV30003162|
Majolica Brown| 0001589|
Twilight| SRV30007031|

Flue Collar, 8” Oval

| Classic Black| 0000555|
Biscuit| 0000556|
Bordeaux| 0000560|
Ebony| SRV30003032|
Majolica Brown| 0000557|
Twilight| 0000561|

79

| ****

Single Leg

| Classic Black| 30002396A|
Biscuit| SRV30003050|
Bordeaux| SRV30006677|
Ebony| SRV30003070|
Majolica Brown| SRV30004874|
Twilight| SRV30007025|
80| Hex Head Jam Nut (Qty 2 req)| Pkg of 10| 1203290-10|
81| Bottom Heat Shield| | 30002470|
82| Bottom Heat Shield Right Wing| | 30005030|
83| Bottom Heat Shield Left Wing| | 30005031|
84| Grate Bottom| | 30005294|
85| Thermostat Assembly| | 5005470|
86| Washer| Pkg of 10| 1202471-10|
87| Handle Base Sub| | 30002714|
88| Fallaway Handle Complete| | 30004175K|
89| Thermostat Handle Assembly| | 30007067|
90| Primary Air Cover| | 30007069|
91| Primary Air Base| | 30007071|
92| Temperature Probe| | 30007274|
93| Bracket, Temperature Probe| | 30007278|
| Tempertature Probe Assembly| | 30007283A|
94| Gasket, Ceramic Fiber| | SRV30007513|
95| Fireback Plate & Gaskets| | SRV8787-021|
| Finish Bag| | SRV30007514|
IMPORTANT: THIS IS DATED INFORMATION. Parts must be ordered from a dealer or distributor. Hearth and Home Technologies does not sell directly to consumers. Provide model number and serial number when requesting service parts from your dealer or distributor.| Stocked at Depot
---|---
ITEM| DESCRIPTION| COMMENTS| PART NUMBER
 | Warming Shelf Kit| Classic Black| 0000200|
Biscuit| 0000205|
Bordeaux| 0000199|
Majolica Brown| 0000208|
Twilight| 0000198|
 | Shelf| Classic Black| 30002477A|
Biscuit| SRV30003094|
Bordeaux| SRV30006689|
Majolica Brown| SRV30004850|
Twilight| SRV30007074|
 | Dragon Bracket| Classic Black| 1302220A|
Biscuit| SRV30002948|
Bordeaux| 30006690A|
Majolica Brown| SRV30004818|
Twilight| SRV30007075|
 | Bracket, Left|  | 30002478A|
 | Bracket, Right|  | 30002479A|
 | Outside Air Kit|  | 1-10-09542|

Contact Information

CONTACT INFORMATION
Hearth & Home Technologies 352 Mountain House Road Halifax, PA 17032

Please contact your Vermont Castings dealer with any questions or concerns. For the number of your nearest Vermont Castings dealer log onto www.vermontcastings.com

CAUTION
DO NOT DISCARD THIS MANUAL

• Important operating and maintenance instructions are included.
• Read, understand and follow these instructions for safe installation and operation.
• Leave this manual with the party responsible for use and operation.

We recommend that you record the following pertinent information for your heating appliance.

• Date purchased/installed:
• Serial Number:
• Dealership purchased from:
• Location on appliance:
• Dealer Phone:
• Notes:

This product may be covered by one or more of the following patents: (United States) 5341794, 5263471, 6688302, 7216645, 7047962 or other U.S. and foreign patents pending.

References

• Vermont Castings Stoves & Fireplace Inserts | Forge & Flame
• Vermont Castings Stoves & Fireplace Inserts | Forge & Flame

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