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Home My WebLink About32389-Z FORM NO.4 TOWN OF SOUTHOLD BUILDING DEPARTMENT Office of the Building Inspector Town Hall Southold, N.Y. CERTIFICATE OF OCCUPANCY No: Z-31920 Date: 10/18/06 THIS CERTIFIES that the building STOVES Location of Property: 4505 ALVAHS (HOUSE NO.) County Tax Map No. 473889 Section 101 LA (STREET) Block ~ CUTCHOGUE (HAMLET) Lot 23 Subdivision Filed Map No. Lot No. conforms substantially to the Application for Building Permit heretofore filed in this office dated SEPTEMBER 14, 2006 pursuant to which Building Permit No. 32389-Z dated SEPTEMBER 26, 2006 was issued, and conforms to all of the requirements of the applicable provisions of the law. The occupancy for which this certificate is issued is "AS BUILT" INSTALLATION OF A WOOD B=ING STOVE & DIRECT VENT GAS HEATER IN EXISTING SINGLE FAMILY DWELLING AS APPLIED FOR. The certificate is issued to LISA E CALLAGHAN & PATRICK METTES (OWNER) of the aforesaid building. SUFFOLK COUNTY DEPARTMENT OF HEALTH APPROVAL N/A ELECTRICAL CERTIFICATE NO. N/A PLUMBERS CERTIFICATION DATED N/A ~~ Authorized Signature Rev. 1/81 . Form No.6 TOWN OF SOUTHOLD BUILDING DEPARTMENT TOWN HALL 765-1802 '1b~ ~mD '\ ~ \U {A\f-S APPLICATION FOR CERTIFICATE OF OCCUPANCY i, This application must be filled in by typewriter or ink and submitted to tbe Building Department with the following: A. For new building or new use: 1. Fiual survey of property with accurate locatiou of all buildings, property lines, streetr;, and unusual natural or topographic features. i 2. Final Approval from Healtb Dept. of water supply and sewerage-disposal (S-9 form)L __:. _ 3. Approval of electrical installation from Board of Fire Underwriters. 4. Sworn statement from plumber certifying that the solder used in system contains less than 2/10 of I % lead. 5. Commercial building, industrial building, multiple residences and similar buildings and installations, a cerli ficate of Code Compliance from architect or engineer responsible for the building. 6. Submit Planning Board Approval of completed site plan requirements. 6 B. For existing buildings (prior to April 9, 1957) non-conforming nses, or buildings and "pre-existing" land uses: 1. Accurate survey of property showing all property lines, streets, building and unusual natural or topographic features. 2. A properly completed application and consent to inspect signed by the applicant. If a Certificate of Occupancy is denied, the Building Inspector shall state the reasons therefor in writing to the applicant. C. Fees 1. Certificate of Occupancy - New dwelling $25.00, Additions to dwelling $25.00, Alterations to dwelling $25.00, Swimming pool $25.00, Accessory building $25.00, Additions to accessory building $25.00, Businesses $50.00. 2. Certificate of Occupancy on Pre-existing Building - $100.00 3. Copy of Certificate of Occupancy - $.25 4. Updated Certificate of Occupancy - $50.00 5. Temporary Certificate of Occupancy - Residential $15.00, Commercial $15.00 Date. Jf) /6/0(:. New Construction: Old or Pre-existing Building: 1..____ s.{ Location of Property: House No. Street ~ .~"~ Owner or Owners of Property: {'i T I?- I C It ' -, I I '1 ;./ /D ( frjEFrr:;S c2 Lot Suffolk County Tax Map No 1000, Section cJ3 Block Subdivision Filed Map. Lot: fA-, (( I de H ETrE S Permit No. Date of Permit. Applicant: Health Dept. Approval: Planning Board Approval: Underwriters Approval: Request for: Temporary Certificate Final Certificate: ./ (check one) Fee Submitted: $ d- S-. Db ~ / Applicant Signature / - ~.l f1~~ co..-E 31 P 0 FORM NO. 3 TOWN OF SOUTHOLD BUILDING DEPARTMENT Town Hall Southold, N.Y. BUILDING PERMIT (THIS PERMIT MUST BE KEPT ON THE PREMISES UNTIL FULL COMPLETION OF THE WORK AUTHORIZED) PERMIT NO. 32389 Z Date SEPTEMBER 26, 2006 Permission is hereby granted to: LISA E CALLAGHAN NEW YORK,NY 10025 for "AS BUILT" INSTALLATION OF A WOOD BURINING STOVE & DIRECT VENT GAS HEATER IN A ONE FAMILY DWELLING AS APPLIED FOR PER MANUFACTURER SPECIFICATIONS at premises located at 4505 ALVAHS LA CUTCHOGUE County Tax Map No. 473889 Section 101 Block 0002 Lot No. 023 pursuant to application dated SEPTEMBER 14, 2006 and approved by the Building Inspector to expire on MARCH 26, 2008. Fee $ 300.00 ORIGINAL Rev. 5/8/02 :v.1*1'f) ~ 1t\lF- \,leu ~ E . t::>urn<, ~ :{ I iJ SEAS. LAND IMP. /OOfJ - /6/-~-.2.? TOWN OF SOUTHOLD PROPERTY RECORD CARD OWNER STREET 4.>);/.<' VILLAGE DIST. SUB. ~~)1-' ~/I~9~~~ ... 14 ;;/8 ~ '.r~clI)H_ lil/r;. ~AI g<./~ /:;... FORMER OWNER N /I. _ ___ 1/ E , v . ACR. . I Lil /'TILL... a I "., I, ~ l."'- / S W TYPE OF BUILDING 1 T 15 0 tV J< (") S K: I / I (j c IV Ko oS;:: I FARM COMM. CB. MISe. Mkt. Value 11-/J LOT VL. TOTAL DATE REMARKS IoJatpfct::l.- LIloo4ooo1 DumS E~+. +0 r-cd~4-eli'\ "'W+-155.DO() ~ au fc1g -I 1/003 /\/i ~o-_ H:J I~j'()"'wr -Iv ~aIJct~ha{) -wILl. ~d~~DOi"> l-laO /l> 00 /{,()O --1..000 -/" 0 0 J .3 /.R/ 7/ ; ~"'O AGE NEW FARM NORMAL BUILDING CONDITION BELOW ABOVE Acre Value Per Value Acre f'. \ XC 0 r ~u ~ d-\:)I~ \ , ~/ \ <{ . ~v rillable 1 rulable 2 'illable 3 Vaadland -- FRONTAGE ON WATER FRONTAGE ON ROAD 17pf~ ~ b ~ 10 02" DEPTH 2 67JJf BULKHEAD ,wampland irushland louse Plat -- 'otal DOCK -: c/',' / i~ , ,? \1 . '" ''I, I / COLOR ..-'.:.. " , ~ lit '\ .'-'\ " , :.- " . 13l..vt: , 0. l~ , TRIM ;) . - .." - .- """~ " 'II .' - 'i 'I' ,,)#,....,::: l" , . - i . , :- ., , \ I"; , i.- ~ ~ '0. -0:::"" ,.,...,,--~ . '0 .. 'I> . '", .I 1/, / ' ( ~/ 'b' I~ ~ I . , ., ..' ., .....J M. Bldg. <., Foundation Both I Dinette It> I( 1 L ~ It. I-'/L~ ~ Pi I' e> ~ Extension I.... )( ..l.I .:lS'~ ( L/I.V "coD lJ II. &/~ Basement PA"'~ Floors :PI Ii [" K. ~ Extension oJ tP l( I" ~ .3 ... ",,", '54 Ext. Walls 06n." 5'-'1"1' Interior Finish Ulf;L>- BCl LR. ---- Extension ~$ I' S!jJ~(..1 .'1 DD /9'IJ Fire Place tJi) Heat vE '"' DR. ./;:~~-" ,_._~.-=... . j /." )( /" " , <?, 1 ~(J /f , Type Roof Cl'\iHk Rooms 1st Floor BR. Parch C Lt::o'i.'.c; I:::;. Recreation Room Rooms 2nd Floor FIN. B. $';1.10 " ..-I,) /" . ~-o Porch r K :i- , ...- ,. $'), Dormer . , <:> "" Breezeway Driveway Garage ltM >JIJ A1---,l'_~,:. t/ ' It> J , - ---- ,.- Patio . O. B. Total 110; </ ~" 1008 ~.. J c.l / 3::L3't; Z- TOWN OF SOUTHOLD BUILDING DEPT. 765.1802 INSPECTION [ ] FOUNDATION 1 ST [] ROUGH PLBG. [ ] FOUNDATION 2ND [] INSULATION [ ] FRAMING I STRAPPING MINAL [ ] FIREPLACE & CHIMNEY [ ] FIRE SAFETY INSPECTION REMARKS: vJ ~ ~ rI ~II~ ~ ~ ok, Jo--r-ofo DATE INSPECTOR ~~ fIELD INSPECTION REPORT DATE COMMENTS FOUNDATION (1ST) FOUNDATION (2ND) ROUGH FRAMING & PLUMBING INSULATION PER N. Y. STATE ENERGY CODE FINAL ADDITIONAL COMMENTS .. . IJJ V.;;! ~~ ~-- rt;;; - J,-- t- >> .2 i~ 1:>.Qj$) (!PI'" ~- :+. ::- d -'- ~t - -' ' Z P +~ ,/) ~ o l"l V\'"' )? ~ ::" U' r== .) 1: r ~ '"' (? i- + r T ''\ ;, t ~~~ ,) z . m ;0 I L,~ )' l"l ~ .., ~ ~ c) ::l c,.-,O \ Z == l"l <-~ - ---== 2p[;l .., :-' TOWN OF SOUTHQLD. BUILDING DEPARTMENT TOWN HALL SOUTHOLD, NY 11971 TEL: (631) 765-1802 FAX: (631) 765-9502 www.northfork.net/Southold/ ,_""""0 BUILDING PERMIT APPLICATION CHECKLIST Do you have or need the following, before applying? Board of Health 4 sets of Building Plans Planning Board approval Survey Check Septic Form N.Y.S.D.E.C. Trustees Contact: Mail to: 11/E7TP> l(. <:])r-tlrvA hs!JJ et/TQI.~ /19 -3~ Phone: S-fl, '11;5"-7 'II) 'f PERMIT NO. 3P2,3'iS'9~ Examined c;/;u. 1 Ju.. . Approved Disapproved ale ,20~ ,20-k- Expiration ,2q~ ("~ /\ ; , , J/> I 9 06 , , i j Building Ins e ,--_I.-:.,-~___-,,___ ____'-'~)LD APPLICATION FOR BUILDING PERMIT Date fIr { , 20 <9, INSTRUCTIONS a. This application MUST be completely filled in by typewriter or in ink and submitted to the Building Inspector with 4 sets of plans, accurate plot plan to scale. Fee according to schedule. b. Plot plan showing location oflot and of buildings on premises, relationship to adjoining premises or public streets or areas, and waterways. c. The work covered by this application may not be commenced before issuance of Building Permit. d. Upon approval of this application, the Building Inspector will issue a Building Permit to the applicant. Such a permit shall be kept on the premises available for inspection throughout the work. e. No building shall be occupied or used in whole or in part for any purpose what so ever until the Building Inspector issues a Certificate of Occupancy. f. Every building permit shall expire if the work authorized has not commenced within 12 months after the date of issuance or has not been completed within 18 months from such date. If no zoning amendments or other regulations affecting the property have been enacted in the interim, the Building Inspector may authorize, in writing, the extension of the permit for an addition six months. Thereafter, a new permit shall be required. APPLICATION IS HEREBY MADE to the Building Department for the issuance of a Building Permit pursuant to the Building Zone Ordinance of the Town of South old, Suffolk County, New York, and other applicable Laws, Ordinances or Regulations, for the construction of buildings, additions, or alterations or for removal or demolition as herein described. The applicant agrees to comply with all applicable laws, ordinances, building code, housing code, and regulations, and to admit authorized inspectors on premises and in building f6r necessary inspe~ns. _ ~ ~ - . (Signature of applicant or name, if a corporation) A:~ftED AS NOTED 'L.(/.7ff({ L.# 'iff&< <<c (NJ S- DATE: 9 b. B.P. # 3.9:<' 8''/ ~ (Mailing address ofapp cant) Stat~~~&~~e, agent, architect, engineer, general contractor, electrician, plumber or builder ~ ~~~J~r.T~~~S' FOR THE 1 FOUNDATION. TWO REQ~IR I Name'~tJl'IE~I000~T ~<?i<: A{!TIC~ ;: ,(/,)',1 GtLL?1ff(/f# 2. ROUGH - FRAMING & PL (As on the tax roll or latest deed) If ap~i~~lih-ll~rporation..shmature of duly authorized officer 4. FINAL - CONSTRUCTION MUtir ALM~~o1~~~ffi~er) REQUIREMENTS OF THE CODES OF NEW Buil~*iSlm~.NN0T RESPONSIBLE FOR PlumbmlWiceRs~TRUCTION ERRORS. Electricians License No. Other Trade's License No. OCCUPANCY OR USE IS UNLAWFUL WITHOUTCERTIFICA TE OF OCCUPANCY I. (/j< 'Rl.f( 0 't{ C Hamlet County Tax Map No. 1000 Section Subdivision 10 I Block 'd- Filed Map No. Lot ~3 Lot (Name) . 2. State existing use and occupancy of premises and intended use and occupancy of proposed c6n~truction: a. Existing use and occupancy hiv!'trC f(!J,t(C- . b. Intended use and occupancy I'~tlttrc -f{c:J~C , 3. Nature of work (check which applicable): New Building Repair Removal Demolition Addition Alteration Other Work {)..bDb~?5fp~ /kA f IP~ (Descrip IOn) Fee /'S{} I~ .fIb d.J'(: (To be paid on filing this application) Number of dwelling units on each floor 4. Estimated Cost 5. If dwelling, number of dwelling units If garage, number of cars I k/A 6. Ifbusiness, commercial or mixed occupancy, specify nature and extent of each type of use. 7. Dimensions of existing structures, if any: Front Height Number of Stories Rear Depth Dimensions of same structure with alterations or additions: Front Rear Depth Height Number of Stories 8. Dimensions of entire new construction: Front Height Number of Stories Rear Depth 9. Size oflot: Front Rear Depth 10. Date of Purchase Name of Former Owner II. Zone or use district in which premises are situated 12. Does proposed construction violate any zoning law, ordinance or regulation? YES_NO ~ 13. Will lot be re-graded? YES_ NO~ Will excess fill be removed from premises? YES_NO r 14. Names of Owner of premises f;1r#k. IICrn;~ Address Is~~ -rft:.r/;4t(~ -<:'</ Phone No. CJ(- '1J{- <It?? Name of Architect Address Phone No Name of Contractor Address Phone No. 15 a. Is this property within 100 feet of a tidal wetland or a freshwater wetland? *YES _NO ~ * IF YES, SOUTHOLD TOWN TRUSTEES & D.E.C. PERMITS MAY BE REQUIRED. b. Is this property within 300 feet of a tidal wetland? * YES_NO L * IF YES, D.E.C. PERMITS MAY BE REQUIRED. 16. Provide survey, to scale, with accurate foundation plan and distances to property lines. 17. If elevation at any point on property is at 10 feet or below, must provide topographical data on survey. STATE OF NEW YORK) ~ SS. COUNTY OF it) . ~ r1L Ie h 11~ being duly sworn, deposes and says that (s)he is the applicant (Name of individual signing contract) above named, (S)H<:is the (Contractor, Agent, Corporate Officer, etc.) .~ () "r' r.", _ ~ i\ 0 i ;'., "; ,'''- of said owner or owners, and i~ d~ly autli"onzed to perform or have performed the said work and to make and file this application; that all statement.s;e9tit~nW. ih,tlii~ al1Plip.nrQi}!are true to the best of his knowledge and belief; and that the work will be perform~ ip~~.~~:.~~ ~r41 t3\~f !~~~,~tion filed therewith. swomtobefOreme$~! ""~."', ",'. j i day 0;;' '" '- . :j, 20 lJt:: ~4~~~A~) , Notary P IC LORRAINE KLOPFER Notary Public, State of New YOlk No. 4828373 Q~811~led in Suffolk County CommiSSion Expires Nov. 30. ~f Signature of Applicant I \ ~ \ l': " t: 4"~-~ ~ t ~ I Defiant Wood burning Stove Model 1945 Homeowner's I nstallation and Operating Manual For use in the 096B United States and Canada SAFETY NOTICE: IF THIS APPLIANCE IS NOT PROPERLY INSTALLED, OPERATED AND MAINTAINED, A HOUSE FIRE MAY RESULT. TO REDUCE THE RISK OF FIRE, FOLLOW THE INSTALLATION INSTRUCTIONS. FAILURE TO FOLLOW INSTRUCTIONS MAY RESULT IN PROPERTY DAMAGE, BODILY INJURY OR EVEN DEATH. CONTACT LOCAL BUILDING OFFICIALS AaOUT RESTRICTIONS AND INSTALLATION INSPECTION REQUIREMENTS IN YOUR AREA. . Do Not Discard This Manual: Retain for Future Use 30001693 8/02 nov.? Vermont Castings Defiant \\elcome Congratulations on your choice of a Vermont Castings Defiant stove. With this purchase you have made a commit- ment to make the hearth a place of warmth, beauty and comfort in your home. At Vermont Castings, we share that joy and appreciation for the hearth. We assure you that your cast-iron Vermont Castings stove has been made with the utmost care and will provide you with many years of service. As you become acquainted wilh 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 and fireplaces available today. As an owner of a Vermont Castings stove, you make a strong statement for pollution-free energy. However, clean burning depends on both the manufacturer and the operator. Please read this manual carefully to understand how to properly operate and maintain your stove. At Vermont Castings, we are equally committed to your satisfaction as a customer. That is why we maintain an exclusive network of the finest dealers in the industry. Our dealers are chosen for their expertise and dedication to customer service. They are factor-trained and knowledgeable about every Vermont Castings product. Feel free to contact your Authorized Vermont Castings Dealer anytime you have a particular question about your stove or its performance. This manual contains valuable instructions on the installation and operation of your Vermont Castings Defiant. tt also contains usefut information on maintenance. Please read the manual thoroughly and keep it as a reference. Sincerely, All of Us at Vermont Castings This manual describes the installation, operation, and maintenance of the Vermont Castings Defiant Model 1945 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 I, 1990. Under specific test conditions this heater has been shown to deliver heat at rates ranging from 10,600 to 55,000 Btu/hr. The Defiant Model #1945 has been tested and is listed by Canadian Standards Association (CSA). The test stan- dards are ANSI/UL-14B2 and ANSI/UL-737 for the United States, and ULC S627 and CAN/CSA-B366.2 for Canada. The Defiant is listed for burning wood only. Do not burn other fuels. The Defiant is approved for use in manufactured (mobile) homes only in the United States, and only when installed with Vermont Castings Mobile Home Kit No. 1900. We recommend that you hire a professional installer certified by the Wood Heat Education and Research Foundation (WHERF) or the Wood Energy Technical Training (WETT) to install your stove, or to advise you on the installation should you allemptto install it yourself. Please read this entire manual before you install and use your new stove. Failure to follow instructions may result in property damage, bodily injury, or even death. Save These Instructions for Future Reference 2 Vermont Castings Defiant The story of the Defiant No wood-burning appliance, save for Ben Franklin's Pennsylvania Fireplace, has a stronger heritage than the Ver- mont Castings Defiant. Named for a 19th-century steamship, the original Vermont Castings Defiant Wood Stove came to epitomize America's resolve and independence during the Energy Crisis of the 1970s. The year was 1975. With energy prices going through the roof, and not an attractive or efficient wood stove to be found anywhere, two entrepreneurs set out to create a stove that was a thing of beauty as well as utility. Finely crafted from cast iron, the Defiant was the first wood stove to combine an artistically designed exterior with a methodically engineered interior, using new technologies for efficient combustion. Americans purchased over a quarter-million Defiants, as they rediscovered the common sense of heating with wood, a home-grown fuel with none of the political and economic entanglements of foreign oil. Thirteen years later, in 1988, Vermont Castings 'retired' the Defiant, replacing it with modern wood-burners such as the Encore. With its 1998 return, the new Defiant incorporates all the finest aesthetic, convenience, and performance features to be found on any wood stove. In a sense, the new Defiant has been 23 years in the making. Due to its significant role in American history, the original model Defiant is in the permanent collection of the Smithsonian Institution. Each new purchase of the Defiant stove continues that history. Table of Contents Installation Accessories , Specifications .................................... 4 Installation ......................................... 5 Clearance Charts ............................ 14 Assembly......................................... 18 Operation ........................................ 19 Maintenance ....................................29 Appendix: Catalytic Combustor .......35 Appendix: Chimney & Fireplace Hazards ...36 Parts Diagram ................................. 37 #1560 Warming Shelf #1900 Mobile Home Kit #1904 Outside Air Adaptor #1905 Bottom Heat Shield Kit #1901 Rear Heat Shield Kit #1907 Firescreen #18606" x 12" Oval Starter Pipe A line of porcelain enamel stove pipe is available in Sand, Moonlight, and Forest Green colors. .1 Vermont Castings Defiant Specifications Defiant, Model 1945 Range of heat output.......... 10,600 to 55,000 Btu's/hr: Maximum heat output ........................ 55,000 Btu's/hr:' Area heated............................ Up to 2,400 Square feet Fuel Size/type ................................. 22 - 24" hardwood Fuel capacity................................................ 50 pounds Loading ...................................................... Front or top Chimney Connector: for S" flue collar ..................... S" (200mm) diameter Chimney Flue Size: with S" Chimney Connector. S" (200mm) minimum with 6" Chimney Connector. 6" (150mm) minimum Flue exit position ........................................ Top or Rear Primary Air ... Manually set, thermostatically maintained Secondary Air ........................................ Self-regulating Ash handling system ..................... Removable ash pan Glass panels ....................... High-temperature ceramic Weight ................................................ 4S0 Ibs. (220kg.) Width (leg to leg) ...................................... 33" (S26mm) Depth (leg to leg)................................... 19W' (362mm) Height to top of flue collar ..................... 30W' (775mm) (Jr;awiIlQ Nolto Scale I~ u r 29./ (737mm) 'i 25V. (654mm) 23'1. (S91mm) ~- 19V.. (<l89mm) u..j Fig. 1 Defiant dimensions. 4 30'/0" (7fiRmm) L ~ .-.-- 19'1." _,1 (489mm) . This value can vary depending on how the stove is operated, the type and moisture content of the fuel used, as well as the design, construction and climatic location of your home. Figures shown are based on maximum fuel consumption obtained under laboratory conditions and on average efficiencies. ., These values are based on operation in building code-conforming homes under typical winter climate conditions in New England If your home is of nonstand- ard construction (e.g. unusually well insulated, not insulated, built underground, etc.) or if you live in a more severe or more temperate climate, these figures may not apply. Since so many variables affect perfor- mance consult your Authorized Dealer 10 determine realistic expectations for your home. U.S. and foreign design and mechanical patents pending. I T-- .1 J"t L-J I 21'h" 546mmJ J .. ... r--- _ __ 32\'/ (826mm) '1 lfi93 Vermont Castings Defiant Installation SAFETY NOTICE: IF YOUR DEFIANT IS NOT PROPERLY INSTALLED, A HOUSE FIRE MAY RESULT. TO REDUCE THE RISK OF FIRE, FOLLOW THE INSTALLATION INSTRUCTIONS. CONTACT LOCAL BUILDING OR FIRE OFFICIALS ABOUT RESTRICTIONS AND INSTALLATION INSPECTION REQUIREMENTS IN YOUR AREA. Before you begin an installation, be sure that: . Your stove and chimney connector will be far enough from combustible material to meet all clearance requirements. . The floor protector is large enough and is con- structed properly to meet all requirements. . You have all necessary permits from local authori- ties. Your local building official is the final authority for approving your installation as safe and determining that it meets local and state codes. The metal label permanently attached to the back of every Vermont Castings' stove indicates that the stove has been tested to current UL and ULC standards, and gives the name of the testing laboratory. Clearance and installation information also is printed on the label. When the stove is installed according to the information both on the label and in this manual, local authorities usually will accept the label as evidence that the installation meets codes and can be approved. However, codes vary in different areas. Before starting the installation, review your plans with the local building authority. Your local dealer can provide any additional information needed. For any unresolved installation issues, refer to the National Fire Protection Association's publication ANSI/ NFPA 211 Standard for Chimneys, Fireplaces, Vents and Solid Fuel Burning Appliances. For Canada, the equivalent publication is CSA CAN-B365 Instal/ation 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 authorilies. Your local dealer or your local building official may have a copy of these regulations. IMPORT ANT: Failure to follow these installation instructions may result in a dangerous situation, including a chimney or house fire. Follow all instructions exactly, and do not allow makeshift compromises to endanger property and personal safety. Outside Air In some modern, super-insulated homes, there is inadequate air supply for combustion because of insufficient air infiltration into the building. Such air enters a home through unsealed cracks and openings. Exhaust fans for kitchen or bath can compete with the stove for available air and compound the problem. When poor draft is caused by a low infiltration rate, opening a ground floor window on the windward side 01 the house and near the stove will usually alleviate the problem. A better solution is to install a permanent outside air supply to the stove andlor room. In fact, bringing air for combustion from outside the home directly to the air inlel of the stove is required for new conslruction in some areas. Pressure variations within the house do not affect a stove equipped wilh an outside air supply, and im- proved stove performance often results. An Outside Air Adaptor Kit for the Defiant is available from your local dealer. Chimney Height Altitude affects chimney performance. When using an B" oval to 6" flue collar adapter on the Defiant, refer to Figure 1 for suggested chimney heights at various altitudes. Chimney height should be measured from the flue collar to the top of the chimney. The recommended minimum chimney height is 161eet (5 meters). 30 7 /' -- .. -.-- -------- ------ -- ~. /' /' /' , 25 E '" :i1 20 15 o 2000 4000 6000 8000 10000 12000 5T491 Altitude Fig. 2 Chimney height requirements with 6" chimney andlor chimney connector. :, Vermont Castings Defiant What Kind of Chimney to Use You must connect the Defiant to a code-approved masonry chimney with a flue liner, to a relined masonry chimney that meets local codes, or to a prefabricated metal chimney that complies with the requirements for Type HT chimneys in the Standard for Chimneys, Factory-Built, Residential Type and Building Heating Appliance, UL 103. Figure 3 illustrates the two types. The chimney and chimney connector must be in good condition and kept clean. If you use an existing masonry chimney, it must be inspected to ensure it is in a safe condition before the stove is installed. Your local professional chimney sweep, building inspector, or fire department official will be able to inspect the chimney or provide a referral to someone who can. See 'Chimney and Fireplace Hazards', in the appendix, for particulars. A prefabricaled double- wall insulaled chimney ^ tile-lined masonry chimney - Sr?41 Fig. 3 Approved chimney types. The chimney must extend at least 3' (900 mm) above the highest point where it passes through or past a roof, and at least 2' (600 mm) higher than any part of a building within 10' (3 m) horizontally. (Fig. 4) For proper draft and good performance, any chimney used with a Defiant should extend at least 16 feet (5 m) above the flue collar of the stove. Reference Point AC617 Fig. 4 The 2'-3'10' Chimney Rule. (, Masonry Chimneys An inspection of the Chimney must confirm that It has a lining. Do not use an unlined chimney. The chimney must 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 repair the chimney liner. Openings sealed with pie plates or wallpaper are a hazard and must be sealed with mortar or refractory cement. In a chimney lire, flames and smoke may be forced out of these unused thimbles. The chimney should be thoroughly cleaned before use. A newly-buill 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. Ma- sonry chimneys must be lined, either with code- approved masonry or pre-cast refractory tiles, stainless steel pipe, or a code-approved, "poured-in-place" liner. The chimney's clean-out door must seal tightly. A loose or leaky clean-out door can weaken chimney draft to the stove, causing performance problems. Prefabricated Chimneys A prefabricated metal chimney must be one tested and listed for use with solid-fuel burning appliances to the High-Temperature (H.T.) Chimney Standard UL-103- 1985 (2100" F.) for the United States, and High Temperature (6500C) Slandard ULC S-629 for Canada. DO NOT CONNECT THIS UNIT TO A CHIMNEY FLUE SERVING ANOTHER APPLIANCE. Chimney Size The Deliant is approved for venting into a masonry chimney with a nominal flue size of 8" x 8" (200 x 200 mm) or 8" x 12" (200 x 300 mm), and into a round flue with nominal flue size of 8" (200 mm). A Deliant with a 6" (150 mm) flue collar adapter is approved for venting into a masonry chimney with a nominal flue size of 8" x 8" (200 x 200 mm), and into a round flue with nominal flue size ot 6" (150 mm). NOTE: When installed with a 6" chimney connector adapter, the Defiant may not be operated with the front doors open. The Defiant may be vented into larger chimneys as well. However, chimneys with liners larger than 8" x 12" (200 x 300 mm) may experience rapid cooling of smoke and reduction in draft, especially if the chimneys are located outside the home. These large chimneys may need to be insulated or have their flues relined for proper stove performance. Vermont Castings Defiant Accessories to help make the connection between stainless steel chimney liners and your Defiant are available through your local dealer. Chimney Connector Guidelines A chimney connector is the single-wall pipe that connects the stove to the chimney. The chimney itself is the masonry or prefabricated structure that encloses the flue. Chimney connectors are used only to connect the stove to the chimney. Single-wall connectors should be made of 24 gauge or heavier steel. Do not use galvanized connector; it cannot withstand the high temperatures that smoke and exhaust gases can reach, and may release toxic fumes under high heat. The connector may be 6" (150 mm) or 8" (200 mm) in diameter. If possible, do not pass the chimney connector through a combustible wall or ceiling. If passage through a combustible wall is unavoidable, refer to the section on Wall Pass-Throughs. Do not pass the connector through an attic, a closet or similar concealed space. The whole connector should be exposed and acces- sible for inspection and cleaning. In horizontal runs of chimney connector, maintain a distance of 24" (610 mm) from the ceiling. Keep it as short and direct as possible, with no more than two 90 degree turns. Slope horizontal runs of connector upward 1/4" per foot (20 mm per meter) going from the stove toward the chimney. The recommended maxi- mum length of a horizontal run is 3 feet (1 meter), and the total length of the chimney connector should be no longer than 8 feet (2.5 meters). In cathedral ceiling installations, extend the prefabricated chimney down- ward to within 8 feet (2.5 meters) of the stove. This will help maintain a good drafl by keeping the smoke warm, so that it rises readily. Wear gloves and protective eyewear when drilling, cutting or joining sections of chimney connector. Single-wall Chimney Connectors . Begin assembly at the flue collar of the stove. Insert the first crimped end into the stove's flue collar, and keep each crimped end pointing toward the stove. Fig. 4. Use the holes in the flue collar as guides to drill 1/8" (3 mm) holes in the bottom of the first section of chimney connector and secure it to the flue collar with three #10 x 1/2" sheet metal screws. Lift off the griddle, and shield the stove's surface between the griddle opening and the front of the flue collar to protect the finish when you drill the front hole. . Fasten each joint between sections of chimney connector, including telescoping joints, with at least three sheet metal screws. Holes in the top of each section of chimney connector serve as guides when you drill 1/8" (3 mm) holes in the bottom of the next section. . Fasten the chimney connector to the chimney. Instruc- tions for various installations follow. Figure 5 illustrates the general layout of chimney connec- tor parts. . Be sure the installed stove and chimney connector are correct distances Fig. 5 Chimney connector. from nearby combustible materials. NOTE: Special slip pipes and thimble sleeves that form telescoping joints between sections of chimney connec- tor are available to simplify installations. They often eliminate the need to cut individual connector sections. Consult your local dealer about these special pieces. O bli~:c~;~ ST242 Securing the Single-wall Connector to a Prefabricated Chimney Follow the installation instructions of the chimney manufacturer exactly as you install the chimney. The manufacturer of the chimney will supply the accesso- ries to support the chimney, either from the roof of the house, at the ceiling of the room where the slove is installed, or from an exterior wall. Special adaptors are available from the chimney manufacturer to make the connection between Ihe prefabricated chimney and the chimney connector. The top of such adaptors attaches directly to the chimney or to the chimney's ceiling support package, while the bottom of the adaptor is screwed to the chimney connector. These adaptors are designed so the top end will fit outside the inner wall of the chimney, and Ihe bottom end will fit inside the first section of chimney connector. 7 Vermont Castings Defiant Chimney -_ Flue Elbow _.~ ......-Flue Inner Slip Pipe~. 0 ~. Standard _ Connector ---------0 Oval 10 Round Adaptor -~A r. \~~ ~_.,- Flue Collar ST 492 Fig. 6 An exploded view 01 the chimney connection in a freestanding masonry installalion. Securing the Single-wall Connector to a Masonry Chimney Both freestanding masonry chimneys and fireplace masonry chimneys may be used for your installation. Freestanding Installations " the chimney connector must pass through a combus- tible wall to reach the chimney, follow the recommen- dations in the Wall Pass-Through section that follows. The opening through the chimney wall to the flue (the "breach") must be lined with either a ceramic or metal cylinder, called the "thimble", which is celJ)ented securely in place. Most chimney breaches incorporate thimbles, but the fit must be snug and the joint between the thimble and the chimney wall must be cemented firmly. A special piece called the "thimble sleeve: slightly smaller in diameter than standard connectors and most thimbles, will ease the removal of the chimney connec- tor system for inspection and cleaning. (Fig. 7) Thimble sleeves should be available from your local dealer. To inslall a thimble sleeve, slide it into the breach unlil it is flush with the inner flue wall. Don't exlend it into the actual flue passage, as this could interfere with the drart. The thimble sleeve shoUld protrude 1-2" (25-50 mm) into the room. Use furnace cement and thin gasketing to seal the sleeve in place in the thimble. Secure the chimney connector to the outer end of the sleeve with sheet metal screws. 8 Thimble Sle~ Chimney Connector Q]~ o ~ Flue ~ - Keep sleeve end flush with nue tile ST243 Fig. 7 The thimble, made of either ceramic or metal, must be cemented securely in place. Without a thimble, a suitable length of chimney connec- tor can be extended through the breach to the inner face of the flue liner, and cemented securely in place. Additional pieces of connector are theR attached with sheet metal screws. Fireplace Installations The chimney connector may be connected to the chimney above the fireplace opening. Above the Fireplace The Defiant may be connected to a chimney above a fireplace opening. In such installations, the stove stands on the hearth in fronl of the fireplace and the chimney connector rises from the stove top and then angles ninety degrees back into the chimney. The chimney liner should extend to the point at which the chimney connector enters the chimney. (Fig. 8) Check These Clearances L_til_.J.:l---.0 t * j EI [DO] ST244a Fig. 8 In this installation, the chimney connector attaches to the chimney above the fireplace opening. Vermont Castings Defiant If the chimney connector in your installation enters the chimney above a fireplace, follow all the guidelines mentioned 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. . Check the clearance between the chimney connec- tor and the ceiling. The clearance should be at least 18" (457 mm). . The fireplace damper must be sealed to keep room air from escaping up the flue. However, it must be possible to reopen the damper to inspect or clean the chimney. Through the Fireplace If your fireplace opening height is at least 29" (737mm), you may install the Defiant through the opening using a "positive connection" kit, available from your local dealer. These positive connection kits ensure a tight fit between the stove flue collar and the chimney flue as shown in Figure 9. Fireplace installation, whether connected to the flue above or through the fireplace opening, have special clearance requirements to adjacent trim and the mantel. You will find the required safe clearances for the Deliant fireplace installation on Page 14. JJ 0 Flexible Connector Fig. 9 Through the fireplace installation. Floor protection requirements also apply to fireplace installations. Refer to page 10. Wall Pass-Throughs Whenever possible, design your installation so that the connector does not pass through a combustible wall. If you are considering a wall pass-through in your installation, check with your building inspector before you begin. Also, check with the chimney connector manufacturer for any specific requirements. Accessories are available tor use as wall pass- throughs. If using one of these, make sure it has been tested and listed for use as a wall pass-through. In the United States, the National Fire Protection Association (NFPA) has established guidelines for passing chimney conneclors through combustible walls. Many building code inspectors follow these guidelines when approving installations. Figure 10 shows one NFPA-recommended method. All combustible material in the wall is cut away from the single-wall connector to provide the required 12" (300 mm) clearance. Any material used to close up the opening must be noncombustible. Wall Stud . Chimney Connector 12" of ~ Noncombustible Malerial Floor Protection -- sr493 Fig. lOAn approved wall pass. through for the United Stales. Three other methods are also approved by the NFPA: . Placing a section of chimney connector inside a ventilated thimble, which in turn is separated trom combustibles by 6" (150 mm) 01 fiberglass insulating material. . Placing a section of chimney conneclor inside a section of 9" (230 mm) diameter, solid-insulated, tactory-built chimney, with two inches of air space between the chimney section and combustibles. 'J Vermont Castings Defiant . Using a seclion of solid-insulated double-wall High Temperature chimney, with an inside diameter the same as the chimney connector, at least one inch of solid insulation, and a minimum of 9 inches (229mm) air space between the outer wall of the chimney section and combustibles. In Canada, The Canadian Standards Association has established different guidelines for wall pass-throughs. Figure 9 shows one method, in which all combustible material in the wall is cut away to provide the required 18" (460 mm) clearance for the connector. The resulting space must remain empty. A flush-mounted sheet metal cover may be used on one side only. If covers must be used on both sides, each cover must be mounted on noncombustible spacers at least 1" (25 mm) clear of the wall. 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. -",- ST494 18" (460mm) clearance between pipe and sidesltoplbottom of opening "- o oj 4 if Fi9. 11 An approved wall pass-through for Canada. NOTE: Do not vent your Defiant into a factory-buill (zero-clearance) fireplace. These appliances and their chimneys are specifically designed as a unit for use as fireplaces. Il may void the listing or be hazardous to adapt them for any other use. DO NOT CONNECT A DEFIANT TO ANY AIR DISTRIBUTION DUCT OR SYSTEM. III Floor Protection A tremendous amount of heat radiates from the bottom plate of your Defiant. The floor area directly under and around the stove will require protection from radiant heat as well as from stray sparks or embers that may escape the firebox. Heat protection is provided through the use of a Vermont Castings Bottom Heat Shield #1905. Spark and ember protection must be provided by a floor protector constructed with noncombustible materials as specified. Most installations will require that the bottom heat shield be attached. Only when the stove is placed on a completely noncombustible surface such as unpainted concrete over earth may it be used without the heat shield. Even when the bottom heat shield is installed, you must provide special protection to the floor beneath. For installation with the heat shield attached, use a noncombustible ffoor protector such as 1/4" non- asbestos mineral board or equivalent, or 24 gauge sheet metal. The floor protector may be covered with a noncombustible decorative material if desired. Do not obstruct the space under the heater. Protection requirements vary somewhat between the ~ed States and Canada as follows: . In U.S. installations, the floor protector is require under the stove and must extend at least 16 inches (not including the ash lip) from the front of the stove ('F', Fig. 12), and at least 6 inches from the sides and rear ('0' and 'E', Fig. 12). Il must also extend under the chimney connector and 2 inches to eilher side ('C', Fig. 12). For the 8" (200 mm) connector, the protector must be a minimum of 12" (300 mm) wide. For the 6" (150 mm) connector, the protec- tor must be 10" (250 mm) wide. The protector must be centered under the connector. To meet these requirements, a floor protector must be at least 42" wide and 43" deep. In anada, a noncombustible floor protector is required under the heater also. The floor protector must extend 18 inches (460 mm) to the fronl ('F', Fig. 12), and 8 inches (203 mm) from the sides and rear ('0' and 'E', Fig. 12). To meet these requirements, a floor protector must be at least 46" (1168 mm) wide and 47" (1194 mm) deep. ) Vermont Castings Defiant <E> B <E E <E> F F Fig. 12 -~-\ I 1< ~ Canada A. 42" 46" (1168mm) B. 43" 47" (1194mm) C. 12" 12" (300mm) 8" Connector ...........~ 10" (250mm) 6" Connector ~ 8" (203mm) E. 6" 8" (203mm) F. 16" 18" (460mm) Required floor protection dimensions. A ST500 Floor Protection for Fireplace Installation Do not assume that your fireplace hearth is completely noncombustible. Many fireplace hearths do not satisfy the "completely noncombustible' requirement because the brick or concrete in front of the fireplace opening is supported by heavy wood framing. Because heat passes readily through brick or concrete, it can easily pass through to the wood. As a result, such fireplace hearths can be a fire hazard and are considered a combustible floor. For all fireplace installations, follow the floor protection guidelines described above. Keep in mind that many raised hearths will extend less than the required clearance form the front of the heater. In such cases, sufficient floor protection as described above must be added in front of the hearth to satisfy the minimum floor protector requirement from the front of the stove: 16" (410mm) in the United States and 18" (460mm) in Canada. Hearth rugs do not satisty the requirement for floor protection as they are not fire proof. Fireplace installation also have special clearance requirements to the side walls, side decorative trim and fireplace mantel. Refer to the information on fireplace and mantel trim shields in this section. Keep the Stove a Safe Distance from Surrounding Materials Both a stove and its chimney connector radiate heat in all directions when operating, and nearby combustible materials can overheat dangerously if they are too close to the heat source. A safe installation requires that adequate clearance be maintained between the hot stove and its connector and nearby combustibles. Clearance is the distance between either your stove or chimney connector, and nearby walls, floors, the ceiling, and any other fixed combustible surface. The Defiant has specific clearance requirements that have been established aller careful research and testing. These clearance requirements must be strictly ob- served. In addition, keep furnishings and other combustible materials away from the stove. In general, a distance of 48" (1220 mm) must be maintained between the stove and moveable combustible items such as drying clothes, furniture, newspapers, firewood, etc. Keeping those clearance areas empty assures that nearby surfaces and objects will not overheat. Safe Ways to Reduce Clearances Clearance requirements are established to meet every installation possibility, and they involve the combina- tion of these variables: . When the stove has no listed heat shield mounted on it. . When the wall has no heal shield mounted on it. . When the wall has a heat shield mounted on it. . When the wall and stove have heat shields. In general, the greatest clearance is required when you place a stove and its connector near a wall with no heat shield. For example, when the Defiant is installed parallel to the rear wall and no shield is used, it must be at least 33" (815 mm) from the wall behind it and at least 24" (610 mm) from walls on either side. If the Defiant is installed in a corner and no shield is used, the corners of the stove must be at least 23" (585 mm) from nearby walls. Ciearances may be reduced only by means approved by the regulatory authority, and in accordance with the clearances listed in this manual. Refer to Pages 10 - 13 for approved clearance reduction specifications. Use only Vermont Castings Defiant Rear Heat Shield #000-1901. NOTE: Alcove installation of the Defiant is not permitted. Wall Shields One way to reduce clearances is with a wall shield constructed of 24 gauge or heavier sheet metal, or of another noncombustible material such as 1/2" (13 mm) insulation board such as Durock'" or Wonderboard"', or common brick "laid on flat," with the 3W' (90 mm) side down. Shields must be spaced out from the combustible surface 1" (25 mm) on noncombustible spacers, as in 1/ Vermont Castings Defiant Figure 13. The spacers should not be directly behind the stove or chimney connector. Air must be able to flow between the wall and the shield. At least 50% of the bottom 1" (25 mm) of the shield must be open, and the shield must be open at the top. Metal screening across the top will keep small stray objects from being trapped behind the shield. (Fig. 13) The shield must be a minimum of 48" (1220 mm) tall, and must extend at least 20W (520mm) higher than the top of the stove, whichever is higher. The shield behind the chimney connector must be 30" (760 mm) wide, centered behind the pipe; for installations that use an approved prefabricated chimney to pass through the ceiling, the shield behind the chimney connector must stop 1" (25 mm) below the ceiling. ~ Air Flow Screen \ ' Wall Shield I . t t Stud Wall Framing @ " Noncombus- tible Spacers and Fasteners ~ Shield t Metal Spacer -- Drywall \."../ AirFlow ST248 Fig. 13 Approved wall shield construction. Fireplace and Mantel Trim Shields A fireplace installation requires special clearance between the side of the stove and the right and left walls, between the side of the stove and the decorative side trim on the fireplace face, and between the top of the stove and the mantel. Noncombustible shields installed 1" (25mm) away form the combustible surface on noncombustible spacers, called ventilated shields, may be used to reduce clearances. To protect a mantel from the heat of a stove in a fireplace installation, use a custom-made ventilated mantel shield that is at least 48" (1220mm) long, that is centered over the stove. (Fig. 14) Ventilated shields for side trim must extend the full length of the trim. An unprotected mantel ("A", Fig. 15) cannot be more than 9" (230mm) deep and must have a minimum clearance of 39" (991 mm), measured from the stove's 12 1"(25mm) ST501 Fig. 14 A cuslom-formed manlel shield. top plate. With a ventilated shield, this clearance may be reduced safely to 23" (584mm). Unprotected top trim (B) protruding 9" (230mm) or less from the face of the fireplace must be a minimum of 39" (991 mm) from the stove's top surface. With a ventilated trim shield, this clearance may be reduced safely to 23" (584mm). Unprotected side trim (e) that protrudes 2" (50mm) or less from the face of a fireplace must have a minimum clearance of 14" (356mm), measured from the stove's top side edge. With a ventilated trim shield, the clearance may be reduced safely to 6" (152mm). If the trim extends more than 2" (50mm), it is subject to the requirements for wall clearance. The charts and sample installations that follow list all the clearances required for the various installation configurations of the Defiant. c. ST253b Fireplace and Mantel Trim Clearances Unprotected Protected 39" (991mm) 23" (584mm) 39" (991mm) 23" (584mm) 14" (356mm) 6" (152mm) A. Mantel B. Top Trim C. Side Trim Fig. 15 Maintain clearances to combustible components of the mantelpiece. Vermont Castings Defiant Defiant Clearance Chart for use with either a 6" or 8" chimney connection Stove Clearance Unprotected Surfaces Protected Surfaces Stove Installed Stove Stove Installed Stove In in Parallel to Wall Corner Parallel to Wall Corner Side Rear Corners Side Rear Corners No stove (A) 24" (B) 33" (C) 23" (0) 14" (E) 28" (F) 18" heat shields (610mm) (840mm) (585mm) (355mm) (710mm) (460mm) ------.- __..n_____ Stove, top exit with rear (G) 24" (H)21" (I) 17" (J) 14" (K) 17" (L) 12" heat shield, no connector (610mm) (533mm) (430mm) (355mm) (430mm) (305mm) heat shields - - -- - ---- --- Stove, top exit with rear (M)24" (N) 17" (0)17" (P) 14" (Q)17" (R) 12" heat shield, and heat (610mm) (430mm) (430mm) (355mm) (430mm) (305mm) shields on connector - -- -- -- -- --- ---- Stove, top exit with rear (8) 24" (T) 17" (U) 17" (V) 14" (W) 15" (X) 12" heat shield, and double- (610mm) (430mm) (430mm) (355mm) (380mm) (305mm) wall chimney connector' -----_..-. .-"--- ------- ---------- Stove, rear exit with rear (Y) 24" (Z)21" N/A (AA) 14" (BB) 17" N/A heat shield only (610mm) (533mm) (355mm) (430mm) Chimney Connector Clearance Unprotected Vertical Surfaces Protected Vertical Surfaces - - ---- -- ----- ---- Single-wail connector 30" (760 mm) 25" (635 mm) .-...----- --------- - -.----------- - __u_ __u I. ---- Single-wail connector; rear heat shield on 18" (460 mm) 14" (355 mm) stove only ____on - - - ----- Single-wail connector with shields, and rear heat 14" (355 mm) 14" (355 mm) shield on stove -----------------.-- _____0._____--- - -- Double-wail chimney 14" (355 mm) 12" (305 mm) connector __"0___0'- .. . ______n____ ----- - -- --------------------.- -.- -- - --- Single-wail connector Unprotected or Protected Ceiling Surfaces 24" (610mm) Clearance to Combustibles in Front of Stove - All Installations 48" (1220 mm) . Using a listed double wall oval to round connector. 1.l Vermont Castings Defiant Defiant Clearance Diaqrams for use with either a 6" or 8" chimney connection Unprotected Surfaces Stove Installed Parallel to Wall Stove in Corner Top Exit Installat\:ns, no heat shields B ~f -A}-OJ I Gel ell 1- Protected Surfaces Stove Installed Parallel to Wall Stove in Corner I. 1F@ I. L 1'@ Top Exit Installations, heat shield on stove, heat shields on single-wall connector I. N (OJ -~MI 0 I I. c . if) . Top Exit Installations, heat shield on stove, no shields on single-wall connector 1 I. I. 1- K ,,@ -i,bc1J I. o . if) 11 Q _ p~CJjl . I. R 1R@ I. T (CJ] -r'- Top Exit Installations, heat shield on stove, double-wall chimney connector I. iU@ Rear Exit Installations, rear heat shields 14 N/A II I~AA I. X 1'@ N/A ST4B6A Vermont Castings Defiant 48" ~220m T 48" J- (1220mm) ~ '. f 48" 1220mm) Fig. 16 Parallel installation, vertical chimney connector, two wall shields. Reduced clearances for both rear and side walls. Wall shields may meet al corner if desired. Shielding for connector is centered behind connector. ". .~'"'' I ". (1220n"" r ". 1220mm) -------- .~ /~/ //...0 --:<>-;;:/" /0;:::> SH9B Fig. 17 Parallel installation with rear wall pass"through, two wall shields. Reduced clearances to both rear and side walls. Wall shields may meet at corner if desired. Wall pass-through musl comply with codes. Refer to "Special Installations." I- T ". (1220mm)-- - ". (1220mon) -I " 1 . ;:-; . ~', .t<>" ..t!o '".:<,;;',~;::,:\;~(1220'm") , "~)~it!11 ..,!,,~ ... (1220mm) Fig. 18 Corner installation, vertical chimney connector, two wall shields. Reduced side clearances. Wall shield MUST meet at corner. Stove Heat Shields The Vermont Castings Delianl Rear Heat Shield, shown below, is one way to reduce the clearance to the rear wall. The rear heat shield can be installed in any setting. However, since the chimney connector also radiates heat toward the wall, you must use a chimney connector shield whenever you use the rear heat shield. 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 clear- ance requirement in corner installations may be re- duced. = - Flue Collar Heal Shield Rear Heat Shield .. = - Spacers ,-,~,>'" Phillips screws~" ~..:..- KI:W7 Fig. 19 Defiant rear heal shield with flue collar heat shield for top exit configuration. J!i Vermont Castings Defiant Distance from the Center of the Flue Collar to the Wall The information on this page is helpful in planning stove placement, particularly in those installations with chimneys that pass through the ceiling. However, this is not a clearance chart. Final stove clearances must adhere to the guidelines in the clearance chart on Page 12. Note thai rear dimensions differ for installations with 6" or 8" chimney connectors. Defiant With Rear Heat Shield only Unprotected Surfaces Parallel Installations H_U _. ...... . Side (A) 39'12' (1 003mm) Rear (B) 6" chimney: 27" (685mm) 8" chimney: 28" (710mm) Protected Surfaces Corner Installations Parallel Installations Corner Installations Corner (C) Side (0) Rear (E) ---. . 6" chimney: 21" (535mm) 8" chimney: 22" (560mm) Corner (F) 28" (71 Ornm) ___ u 29W' (710mm) 25" (635mm) Defiant With Rear Heat Shield and Shielded Connector: Side (A) 39Yi' (1003mrn) Rear (B) 6" chimney: 17" (685mm) 8" chimney: 18" (710mm) Corner (C) Side (0) Rear (E) . --~~----- ~-----~---~- .----. 28" (710mm) 29Yi' (710mm) 6" chimney: 17" (535mm) 8" chimney: 18" (560mm) Corner (F) 25" (635mm) Defiant With Rear Heat Shield and Double-wall Connector: Side (A) Rear (B) Corner (C) Side (0) Rear (E) Corner (F) . -.--.--- I. - .-- 39'12' (1 003mm) 6" chimney: 28" (710mm) 29'12' (710mm) 6" chimney: 25" (635mm) 17" (685mm) 15" (535mm) 8" chimney: 8" chimney: 18" (710mm) 16" (560mm) -- A F~ill (g* t (~Jt ~ ~ F' g liJJ ~ . This distance, from the center of the flue collar to the front edge of the hearth, is the same for all installations on this page: 34" (865mm) in the United States and 36" (914mm) in Canada. II> Vermont Castings Defiant Assembly Set Up Your Stove Cast iron stoves are heavy, and it will take two to four people to move your Defiant into position. Wipe the protective coating of oil from the griddle with a clean dry rag or a paper towel. Install the handle on the griddle. Slip the bolt through a washer, a nylon bushing, then through the handle and the other bushing, then through the steel spacer and into the griddle tab. (Fig. 20) Tighten securely. Bushings ~.'" ...............Knob ~ i-oot------- Washer 1----- Bolt 8T536 Fig. 20 Attach the griddle handle. Install Stove Legs Remove and discard the four large slot-head screws from the stove bottom. Install the stove legs (Fig. 21) using the hex head bolts from the parts bag. Use 3/B" washers with all four legs; the door handle holder installs on the right front leg. Position the holder so the hole to accept the handle hub faces out from the right side of the stove. Tighten the bolts firmly. CAUTION: Overtightening can strip tapped threads. - ----~~ Leg Bolt and Washer o . l'.)__- ,., ,f ~1 Leg~-/~U ST466a Fig. 21 Attach the slove legs with leg levellers. Storing the Handle Use the removable handle to open or close the doors. After using it, remove the handle so it will not get hot. Store the handle in the handle holder installed behind the right front leg. (Fig. 22) ST564 Fig. 22 Handle holder and heat shield positions. Install the Optional Bottom Heat Shield NOTE: The Bottom Heat Shield is required in most installations. Refer to Floor Protection, Page 10, for further details. 1. Remove the four 10-24 x 1/2" hex head bolts from the corners of the ash drop on the stove bottom. 2. Screw the four 1 %" spacers into the holes from which you removed the bolts, finger-tight. 3. Align the bottom heat shield against the spacers with the stepped side toward the rear of the stove. 4. Secure the shield with the four hex head bolts removed from the stove bottom previously. Tighten securely. (Fig. 23) ...- I- , , , fl., __: s /.n -,--:? pacers -::. ! (l~ I , ' ~- , -n r A' i 81531 . . Jl Fig. 23 Attach the optional bottom heal shield. /7 Vermont Castings Defiant Install the Optional Ash Door Heat Shield 1. Remove the two Phillips pan head screws from the ash door. 2. Insert the screws through the ash door heat shield (from the painted side), place the 5/16" spacers over the screws, and carefully thread them back into the original holes. (Fig. 24) The curved lip should be upward, under the ashlip of the stove. 3. Tighten securely. ~~~~ " ~ Spacers ST538 Fig. 24 Install the ashdoor heat shield. Adjust the Leg Levellers Lift the stove slightly so there is no weight on the leg while making the adjustment. Reverse the Flue Collar (If Necessary) Reverse the flue collar by removing the two screws that attach it to the back of the stove. Be sure the gasket around the flue collar opening is in position when you screw the collar back onto the stove. Attach the Damper Handle Use the 1/4" -20 x 3" screw to attach the damper handle to the damper stub on the left side. Refer to the chart on Page 35 for hardware sizes. Attach the Primary Air Thermostat Handle The primary air thermostat handle is the smaller of the two black handles. Secure the handle to the stub on the right side of the stove with an 8-32 x 2" slot head machine screw. (Fig. 25) Assemble the Removable Insert Handle The ceramic removable insert handle opens and closes the front doors. Remove after each use, and store it in the handle holder behind the right front leg. Assemble the handle by passing the 3%" screw through the ceramic shafl and into the bright metal nub. (Fig. 26) Tighten carefully until snug. JR 5T540 'Fig. 25 Attach the thermostat handle. ~~ ~ , ST540 Fig. 26 Assemble the front door handle. Operation The Defiant Controls Two controls regulate the performance of the Defiant: a primary air control supplies oxygen for the fire, and a damper directs air flow within the stove to activate and deactivate the catalytic combustor. (Fig. 27) Symbols cast into the stove are reminders of the correct directions for using the controls. 'Left' and 'right' in these directions mean as you face the stove. D Griddle Handle ~ amper Handle Door Handle Andiron Air r Control \ Lever Door Handle Holder (Behind Leg) ST541 Fig. 27 The Defiant's controls are conveniently located and easy to operate. Vermont Castings Defiant A Single Air Control Regulates Heat Output and Burn Time The primary air control lever, on the right side of the stove, controls the amount of incoming air for starting, maintaining, and reviving a fire. More air entering the stove makes the fire burn hotter and faster, while less air prolongs the burn at a lower heat output level. (Fig. 2B) For the greatest air supply and maximum heat output (but the shortest burn time), move the lever toward the front of the stove. For a fire that will last longer with less heat, move the lever toward the rear of the stove. The Defiant's air control system includes an automatic thermostat to ensure an even heat output at whatever manual setting you select. The thermostat senses the heating and cooling of the stove surface and adjusts the air valve accordingly. Air Control Positions low Heat Range 4~'_~. r(t fr!~~ .~.--'"':~'--'"'~~'~' _.:-::~:-::~~=:.::..-~~- Medium Heat Range 4 fu c=. .~~:J fl1 jf{~~~ c=il -'- ~- High Heal Range ...._~_.._~~~.-~j- ~ml'. ~W.C~.~"~~lnl. rfl~~-~j C==1 tilL ST542 Fig. 28 The handle also may be positioned anywhere between the two extremes for diHerent 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 for- ward. Smoke travels through the catalytic combustion system where it can be further burned, before passing up the chimney. (Fig. 29) The damper is 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. Damper Positions . ~.""'~".~~. . . . ~ji5] . l Open ST543 (Updraft Mode) -----~~._-- ~:l..~.~.l - ~ . . ~~JT::ill. ~ I Closed (Calalytrc Mode) '. Fig. 29 The Defiant's damper operating positions. Two Ways to Add Fuel The Defiant's griddle lifts for convenient top-loading of logs, and is the easiest way to add fuel. (Fig. 30) fli: ~.>="C'. :l Imll rc=~7\ 81521 Fig. 30 Top loading is the best way to add fuel during regular use. Front loading is useful for kindling a fire. However, the front doors open as well for adding an occasional log to a fire. If the stove is equipped with B" (200 mm) stove pipe, the front doors may be opened (or even removed) and the optional Deliant spark screen placed in the opening for open-fire viewing. The Defiant is nof approved for operation with the front doors open if equipped with a 6" (150 mm) chimney connector. To open the fronl doors, insert the handle into the door latch stub and turn it to the left and up. (Fig. 31) To close them, always close the left door lirst. Turn the handle in the right door to the lell and up (to the open position) and close it. Finally, 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. 1'1 Vermont Castings Defiant Clockwise 10 Open 4 Counler - clockwise to Close m ST544 Fig. 31 To open Ihe lronl doors, turn the handle clockwise. To reduce the risk of breaking the glass, avoid striking the glass or slamming the doors. When you're not using the door handle, store it in the holder behind the left front leg of the stove. Be careful to not drop the handle, since it is breakable. 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. The Defiant may be used as a fireplace with the front doors open or removed, BUT only when it is equipped with 8" (200mm) stove pipe and only when the optional spark screen is placed correctly in the opening to protect against the possibility of sparks and embers leaving the stove. Use only the Defiant spark screen, Item #1907, with your Defiant. Defiant spark screens are available from your Vermont Castings Dealer. Infra-Red Reflective Glass Panels for Clear Fire Viewing The outer surfaces of the ceramic glass panels have an infrared-reflective coating which keeps the inner surfaces warm. This design, along with a pre-heated 'airwash,' makes clear fire viewing possible at most firing levels. Andirons Help Protect the Glass Your stove has andirons to keep logs away from the glass panels. The andirons are essential to maintain clear fireviewing, and should be left permanently in place. Since the andirons may slightly hinder refueling through the front doors, most stove owners will prefer the convenience of top loading through the griddle. Do not place fuel between the andirons and the doors. 2/J Burn Only High-Quality Wood The Defiant is designed to burn natural wood only; do not burn fuels other than that for which it was de- signed. You'll enjoy the best results when burning wood that has been adequately air-dried. The wood should be 22-24" (559-610 mm) in length. Avoid burning "green" wood that has not been properly seasoned. Do not burn construction materials; they often contain chemicals and metals that can damage the catalytic combustor or pollute the air. Do not burn ocean drift- wood; when it burns, the salt it absorbs 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. 11 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 wood under cover to keep it dry. The longer it is stored, the better heating and fire-viewing performance you will enjoy. Even for short-term storage, however, keep wood a safe distance from the heater and keep it out of the areas around the heater used for refueling and ash removal. I I A Surface Thermometer is a Valuable Guide to Operation An optional surface thermometer tells you when to adjust the air control, and when to refuel. (Fig. 32) ,C 1----- ~ L -Q Sf523 Fig. 32 Take temperature readings with a thermometer located in the middle of the griddle. For example, when the thermometer registers at least 450oF. (230oC) after start-up you know that the stove is hot enough to begin cataly1ic combustion and that it may be time to close the damper. Note that the stove will warm up much sooner than the chimney, though; a warm chimney is the key to easy, effective stove operation. Please review the draft management information on Page 26 to see how the size, type, and location of your chimney will affect your stove opera- tion. When thermometer readings drop below 350"F. (175"C) it's time to adjust the air conlrol for a higher burn rate or to reload the stove. A temperature reading over 750"F. (3850C) is a sign to cut back on the air supply to slow the burn rate. Vermont Castings Defiant Use the following temperature ranges as a guide: . Readings in the 350o-500oF. (1750-260oC) range indicate low to medium heat output. . 500-600oF. (2600-3150C) readings indicate medium heat output. . Readings of 6000-750oF. (315-3B50C) indicate high heat output. Operating your Defiant continuously at griddle temperatures of 7500 F. (3B50C) or higher 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 bum; 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. See Page 26 for details on how the installation affects performance. Too much draft may cause excessive temperatures in the Defiant, and could even damage the combustor. On the other hand, too little draft can cause backpuffing into the room and/or the "plugging" of the chimney or combustor. How do you know if your draft is excessively high or low? Symptoms of too much draft include an uncon- trollable bum or a glowing-red stove part. Signs of weak draft are smoke leaking into the room through the stove or chimney connector joints, low heat, and dirty glass. In some newer homes that are well-insulated and weather-tight, poor draft may result from insufficient air in the house. In such instances, an open window near the stove on the windward side of the house will provide the fresh air needed. Another option for getting more combustion air to the stove is to duct air direclly from the outside to the stove. In some areas provisions for outside combus- tion air are required in all new construction. With an optional outside air adapter, No. 1904, your Defiant will accept a duct to deliver outside air for combustion. When first using the stove, keep track of the air control sellings. 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 bum you should expect from various settings. Most installations do not require a large amount 01 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 adjust- ment range outlined in these directions. Use the following air control settings as a starting point to help determine the best settings for your installation. Each is described as a fraction of the total distance the lever may be moved from right to left. Defiant Control Settings (Refer to Figure 27, Page 19) Burn Rate Low Primary Air Control From far right to 1/3 the distance to left From 1/3 to 2/3 the distance to left From 2/3 the dislance to left, 10 far left Medium High High-Efficiency Wood Burning with Catalytic Combustion A Defiant leaves the factory with the combustor installed. In the United States, it is against the law to operate this wood heater in a manner inconsistent with operating instructions in this manual, or if the catalytic combustor is deactivated or removed. The components of the catalytic combustion system in your Defiant work together to produce optimum conditions for secondary combustion. When the damper is closed, smoke travels through the catalytic element, which causes ignition of smoke at temperatures of 500-600" F (260-3150C), half the temperature normally required for unaided secondary combustion. The catalytic element is a ceramic "honeycomb" coated with the catalytic material. The element is located in the secondary combustion chamber, molded from a special high-temperature insulating relractory material. The chamber provides the correct environment neces- sary for secondary combustion of the fuel (smoke). Closing the damper exposes the smoke to the combus- tor. If the combustor is at least 600'F (315"C), it will begin to bum the smoke. Closing the stove damper may also reduce the draft, so to avoid putting out the fire or deactivating the combustor, close the damper only when a fire is well- established and the chimney is thoroughly warmed. When starting a fire, wait until the fire is well estab- lished and there is an ember bed of at least 3-4 inches belore closing the damper. 2/ VemlOlIl Castillgs Defiallt Never kindle a fire with colored paper or paper that has colored ink or a glossy surlace, and 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 fhe combustor and cause smoke to spill into the room. Coal smoke also can poison the catalyst so that it won't operate properly. In general, the fire must be sufficiently well-established to ensure that catalytic activity is initiated. When first starting a fire, a medium- to high- firing rate must be maintained until the stove, catalyst, and fuel are all stabilized at the proper operating temperatures, and the chimney is warmed. Even though it is possible lor the fire to get quite hot within a few minutes after a fire is started, the combus- tor may stop working or the fire may go out if the fire dies down immediately as a result of the damper being closed. Once the combustor starts working, heat generated by burning the smoke will keep it working. To determine whether the combustor is operating, observe the amount 01 smoke leaving the chimney when the damper is activated and when it is not. This procedure is described on Page 31. Avoid using a tullload of very dry wood in the firebox. Tbis may result in continuous very high temperatures in the secondary combustion area and damage the combustor. Wood which has been split, and stored under cover for more than 18 months may be consid- ered very dry. "you must burn extra-dry wood, mix it with greener wood for a longer fire and less stress on the combustor. Also, do not use a full load of dry slab wood or scrap wood. For long burns, use a mix of dry and moderately dry wood. Conditioning Your Stove Cast iron is extremely strong, but it can be broken with a sharp blow from a bammer or from the thermal shock of rapid and extreme temperature change. Tbe cast plates expand and contract with changes in temperature. When you first begin using your Defiant, minimize thermal stress by letting tbe plates adjust gradually during three or four initial break-in fires following Steps 1-3 below. Starting and Maintaining a Wood Fire Burn only solid wood in the Defiant, and burn it directly on the grale. Do nol elevale Ihe fuel. Do not burn coal or other fuels. Tbe damper must be open when starting a fire or wben refueling II Do not use chemicals or fluids to start the fire. Do not burn garbage or flammable fluids such as gasoline, naphtha, or engine oit. 1. Open tbe stove damper, and open the primary air control fully. 2. Place several sheets of crumpled newspaper in Ihe slave. Do NOT use glossy advertisements or colored paper, as they can poison Ihe catalyst. Place on Ibe paper six or eighl pieces of dry kindling split to a finger- width size, and on fhe kindling lay two or Ihree larger sticks of split dry wood approximately 1-2" (25-50 mm) . in diameter. (Fig. 33) ; / sInn Fig. 33 Start the lire with newspaper and dry kindling. Also, never use gasoline-Iype lantern fuel, kerosene, charcoalligbter fluid, or similar liquids to start or "freshen up" a fire. Keep all such liquids well away from Ihe Defiant while il is in use. 3. Light the newspaper and close tbe door. Gradually build up the fire by adding a few 3-5" (80-120 mm) diameler splits. If this is one of the first few "break- in" fires, let the fire burn brightly, and then let it die out. During the break-in fires, do nollel the stove get hotter than 500oF. (260"C) as measured on an optional stove- top thermometer. Adjust the air control lever as neces- sary to conlrol the fire. Some odor from Ihe stove's hot metal, the paint, and the cement is normal for the lirst few fires. NOTE: Some chimneys must be "primed," or warmed up, before they will draw sufficiently to start a fire. To correct this situation, roll up a couple pieces of newspa- per, place them on top of the kindling and toward tbe back of the stove, light them, and close the doors. This will encourage the smoke to rise rapidly, making it easier fa establish a good draft. Once the draft is established, open the front door and light the rest of the fuel from the bottom. Do not light the main bed of fuel until the chimney begins drawing, and repeat the procedure as often as necessary it tbe initial attempt is unsuccessful. Vermont Castings Defiant 4. If your Defiant has been broken-in previously using Steps 1-3, continue to build the fire gradually. Add larger wood with a diameter of 3-4" (75-100 mm). Continue adding split logs of this size to the briskly- burning fire until there is a glowing ember bed at least 3" (75 mm) deep. (Fig. 34) A good ember bed is neces- sary for proper functioning of the catalytic system and may take an hour or more to establish. 5. Close the damper when the griddle temperature reaches 4500F (230oC). 6. Adjust the air control for your desired heat output. ST264 fig. 34 Add larger pieces of wood as the fire begins to burn well. NOTE: Stove installations vary widely, and the operat- ing guidance given here is only a starting point. The draft management information on Page 26 will explain in detail how the features of your installation may help or hinder good draft, and how you may need to vary your firing technique if your installation doesn't encour- age a good draft. ST264a fig. 35 Add full size logs after the ember bed is 3" (75mm) deep. Refuel While the Embers Are Still Hot When reloading, best resufts will be achieved if you first de-ash the stove by stirring the fuel bed to allow ash to fall through the grate into the ash pan. Do not break the charcoal into very small pieces or pound or compress the charcoal bed. ft is important that air can circulate through the char- coal bed during the burn. Larger pieces of charcoal allow more air to circulate under the wood, resulting in the fire reviving more quickly. (Fig. 35) For best results when refueling, wear long-cuffed stove gloves to protect your hands and forearms, add fuel while the stove still has plenty of glowing embers to re- kindle the fire, and include some smalter pieces of wood in the new fuel toad to help the stove regain its operating temperature quickly. Use this sequence as a guide to successful refueling: 1. Open the damper. 2. De-ash the stove as described above. Open the ashdoor and check the level of ash in the ash pan. Empty the pan if necessary and replace it in the stove. Close the ash door. 3. Open the griddle, load the wood (smaller pieces first), and close the griddle. 4. Close the damper_ S. When the surface temperature reaches 450" F. (2300C), adjust the air control for the amount of heat you desire. NOTE: II the remaining charcoal bed is relatively thick and if your fuel is well seasoned, it is possible to add fresh fuel (smaller pieces first), close the door and damper, and reset the primary air thermostat for the desired heat output. WARNING: Osperate your Defiant only with the doors either fufty open or fully closed. CAUTION: The Defiant will be hot while in operation. Keep children, clothing and furniture away. Contact may cause skin burns. DO NOT OVER FIRE THIS HEATER. Overfiring may cause a house fire, or can resull in permanent damage to the stove and to the catalytic combustor. II any part ot the Defiant other than the baffle and/or catalytic combustor glows, you are overfiring. The throat is made of a special cast iron which can withstand higher temperatures Ulan most other parts ot your stove. II protects the catalytic element from direct flame impingement, which can shorten the catalyst's life. Since the throat is in the direct path of flame between the firebox and the catalyst, it reaches higher temperatures than other firebox parts, and it may glow at times. If it does glow, you will see this direclly through the front doors. The glow is normal and does not indicate a problem. At times you may see a glow from the catalyst shining through the ports of the throat. This is also normal and does not indicate a problem. The catalytic element, .. !.l Vermollt Castillgs Defiallt located below and behind the throat, can glow at high temperatures. This is also normal. However, the element can be active and operate properly without glowing. The lack of a glow does not indicate that the catalyst isn't working. Note that the catalyst is most likely to glow at its higher temperatures, which it reaches when the firebox is in its lower range - the catalyst is an afterburner, and the more waste fuel there is in tile smoke, the hotter the catalyst gets. We strongly advise the use of a stove-top thermometer as a guide to stove performance. Normal operating temperatures are between 450"F (220"C) and 7000F (370"C). Lower temperatures can indicate incomplete combustion and weak draft; higher temperatures can shorten the life of the castings. Ash Disposal Routine ash removal is important for ease of mainte- nance, 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. Slice or stir the ash with a shovel or poker so thai 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: o Open the damper. o 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. o Close the griddle or doors, and unlatch the ash door. (Fig. 36) It will pivot, swinging the ash pan out of the stove. o Slide the cover onto the pan, making sure it is securely closed. (Fig. 37) -":..=.~lLlL~.': -J" ~ III ru_u~J ~ Open 815-16 Close Fig. 36 Turn the ashdoor handle clockwise to open and counlerclockwise to close. N ST566 Fig. 37 Be sure the cover is securely attached before removing the ash pan. o Remove the ash pan, making sure to keep it level. o To keep the cover from sliding off and to keep ash from falling on the floor, do not till the ash pan forward. o 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. o Properly dispose 01 the ash in a melal container with a tight-filting lid. Store the container outdoors away from all combustible material. o Return the ash pan to its original position in the stove, and close and latch the ash door. (Fig. 37) o 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 everyone to three days. The frequency will vary depending on how you operate your Defiant: ash will accumulate fasler at higher heat outputs. Remove ash frequently and place it outdoors in a metal container with a tight-filting lid. Place 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. You can use wood ash as a garden fertilizer. CAUTION: Never use your household or shop vacuum cleaner to remove ash from the slove; always remove and dispose of the ash properly. Vermont Castings Defiant Draft Management A stove is part of a system, which includes the chim- ney, the operator, the fuel, and the home. The other parts of the system will affect how well the stove works. When there is a good match between all the parts, the system works well. Wood stove or insert operation depends on natural (unforced) draft. Natural draft occurs when the smoke is hotter (and therefore lighter) than the outdoor air at the top of the chimney The bigger the temperature difference, the stronger the draft. As the smoke rises from the chimney it provides suction or 'draw' that pulls air into the stove for combustion. A slow, lazy fire with the stove's air inlets fully open indicates a weak draft. A brisk fire, supported only by air entering the stove through the normal inlets, indicates a good draft. The stove's air inlets are passive; they regulate how much air can enter the stove, but they don't move air into it. Depending on the features of your installation - steel or masonry chimney, inside or outside the house, matched to the stove's outlet or oversized - your system may warm up quickly, or it may take a while to warm up and operate well. With an 'airtight' stove, one which restricts the amount of air getting into the firebox, the chimney must keep the smoke warm all the way to the outdoors in order for the stove to work well. Some chimneys do this better than others. Here's a list of fea.tures and their effects. Masonry Chimney Masonry is a traditional material for chimneys, but it can perform poorly when it serves an 'airtight' stove. Masonry is a very effective 'heat sink' - it absorbs a lot of heat. It can cool the smoke enough to diminish draft. The bigger the chimney, the longer it takes to warm up. It's often very difficult to warm up an outdoor masonry chimney, especially an oversized one, and keep it warm enough to maintain an adequate draft. Steel Chimne Most factory-made steel chimneys have a layer of insulation around the inner flue. This insulation keeps the smoke warm. The insulation is less dense than masonry, so a sleel chimney warms up more quickly than a masonry chimney. Steel doesn't have the good looks 01 masonry, bul it performs much better. Indoor/Outdoor Location Because the chimney must keep the smoke warm, it's best to locate it inside the house. This uses the house as insulation for the flue and allows some heat release into Ihe home. An indoor chimney won't lose its heat to the outdoors, so it takes less heat from the stove to heat it up and keep it warm. 26 . . The common wisdom tells us that a taller flue draws better than a short one. This isn't necessarily so. If a chimney is tall enough to meet the safety requirements of the 2/3/10 foot rule, then adding more height isn't the right answer to a draft problem. In fact it could make the problem worse, by adding more mass to the chimney system, which the smoke must warm up, at the far end from the heat source (the stove). Don'l make a chimney taller unless you must to meet the safety rules, or unless there's some nearby feature causing a downdraft. Even then, there are downdraft- preventing chimney caps available, which are probably the smarter choice. Flue Sizing The inside size of a chimney for an 'airtight' stove should match the size of the stove's flue outlet. When a chimney serves an airtight, more is not better; in fact, it can be a disadvantage. Hot gases lose heat through expansion; if we vent a stove with a six-inch flue collar (28 square inch area) into a 10 x 10" flue, the gases expand to over three times their original size. This cools the gases, which weakens dralt strength. If an oversized flue is also outside the house, Ihe heat it absorbs gets transferred to Ihe outdoor air and the flue usually stays cool. It's common for a masonry flue, especially one serving a fireplace, to be oversized for the stove. It can take quite a while to warm up such a flue, and the results can be disappointing. The best solution to an oversized flue is an insulated steel chimney liner, the same diameter as the stove or insert's flue outlet; the liner keeps the smoke warm, and the result is a stronger draft. An un insulated liner is a second choice - the liner keeps the smoke restricted to its original size, but the smoke still must warm up the air around the liner. This makes the warm-up process lake longer. Pipe & Chimney Layout Every turn the smoke must take as it travels to the chimney top will slow it down. The ideal pipe and chimney layoul is straight up lrom the stove, to a completely straight chimney. If you're starting from scratch, use this layoul if possibte. If the stovepipe must elbow to enter a chimney, locale the thimble about midway between the stove top and the ceiling. This achieves several goals: illets tile smoke speed up before it must turn, it leaves some pipe in the room for heat transfer, and it gives you tong-term flexibility for installing a different stove withoul relocahng the thimble. 2,r; Vermont Castings Defiant There should be no more than eight feet of single-wall stove pipe between the stove and a chimney; longer runs can cool the smoke enough to cause draft and creosote problems. With prefabricated chimney, bring it down to six to eight feet from the stove. With a ma- sonry chimney, arrange the pipe layout to elbow into the chimney within eight feet of the stove. Single Venting Each 'airtight' stove requires its own flue. If an airtight stove is vented to a flue that also serves an open fireplace, or a leakier stove, it's easier for the chimney draft to pull air in through those channels than it is to pull air through the airtight, and pertormance suffers. Imagine a vacuum cleaner with a hole in the hose to see the effect here. In some cases the other appliance can even cause a negative draft through the airtight, and result in a dangerous draft reversal. Creosote Creosote is a by-product of slow wood-burning. It's an organic tar that can condense in the flue if it's dense in the smoke, and slow-moving, and cools off to less than 290 degrees F (130'C). Condensed creosote is vola- lile, 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 will encourage good draft and minimize creosote production. Because letting the smoke cool off and slow down is one of the keys to creosote production, it makes sense to line a chimney to match the stove's oullet size, for safety reasons as well as pertormance. 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 recommends one if the flue is more than three times bigger (in square area) than the oullet 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 pertorm well with poor fuel. The best fuel is hardwood that has air- dried 12-18 months. Softwood burns, but not as long as hardwood. Fairly 'green' wood has a lot of moisture in it; it will burn, but some of the heat potential is used to drive the remaining moisture off 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. ff you get it green, lift a piece and get a sense of its weight; it lh 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, especially catalytic ones, the wood can be too dry. While extra-dry wood has little creosote in it, the remainder can 'gas out' from the wood quickly and densely enough to overload the catalytic burner. ff you hear a rumbling or roaring noise, like a propane torch, from the stove, that is a sign that the catalyst is seriously overtiring. The catalyst is a platinum film on a ceramic base; the metal can get to higher temperatures than the ceramic can take, and overtiring the catalyst can break it. Dry wood can also burn out faster than you want. If your dry wood burns out too quickly or overloads the catalyst you can mix in greener wood to slow the fire down. Back-puffing 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 till they're dense enough and hot enough to ignite. ff your stove back-puffs, you should open up the damper to let the smoke rise to the flue more quickly, let more air into the firebox, and avoid big loads of firewood. You should always see lively, dancing flames in the firebox; a lazy, smoky fire is inefficient and can contribute to creosote buildup in the chimney. Draft Testing An easy way to test your chimney draft is to close the stove's damper, wait a few minutes to let the airtlow 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 have an effect on the fire. If there's no change, then the draft isn't strong enough yetta let you close the damper, and you'll need to open it for a while longer and manage the fire with the air inlet until the draft strengthens. ff you keep track of your burning habits and relate them to their effects on the stove's opera- tion, you'll be rewarded with good pertormance and a safe system. Negative Pressure Good draft also depends on a supply of air to the stove; a chimney can't pull in more air than is available to it. Sluggish draft results when a house is tight enough to prevent the ready flow of air to the stove, or by competition between the stove and other equipment that sends indoor air outside - especially power-driven equipment like range hoods, clothes dryers, etc. If the chimney draws well with all other equipment turned off (or sealed, in the case of fireptaces and/or other stoves), then you simply need to be careful with timing the use of the other gear. If you need to crack a nearby window or door to enable the chirnney to pull well, that's a sign that you should install an outside-air intake to bring combustion air directly to the stove. An outside air adapter will attach to the stove to connect an air duct for outdoor combustion air. 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 opera- tion, you'll be rewarded with good performance and a sale system. Vermollt Castillgs Deliallt 27 Vermont Castings Defiant Maintenance Keep Your Stove Looking New and Working Its Best Let the lire in the stove go oul and allow the stove to cool completely before beginning any maintenance procedure. Care of the Cast Iron Surface An occasional dusting with a dry rag will keep the painted cast iron 01 your Defiant looking new. The stove's paint can be touched up as needed. First, mask the areas, such as enamelled parts, glass, or I"",dles, 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 line-bristle wire brush, or steel wool. Then, touch up the stove with Vermont Castings' 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. Cleaning the Glass Mosf of the carbon deposits on the glass will bum 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. II you need to replace the glass, use only the high temperature ceramic glass supplied by Vermont Cilstings. Do not use substitutes. Be sure to specily left or right glass; Ihe panels are not interchangeable, due to a heat-reflective coating on the side toward the room. J8 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 enamelled doors. 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 fhat 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. Be sure to place the glass so that the infrared reflective coating is on the exterior side, facing toward the room. 2. Secure the glass on both doors with the retainer clips. Tighten all screws. (Fig. 38) 3. Replace the doors on the stove. 4. Open and close the doors to check that they fit and work properly. Adjust as necessary. Jj'.Z.~~Door Gasket ___:>L_____ ___~ \ . . . {:\ Right Door Left Door , Glass Gasket - '~ -;A / / /' Glass Panel Retainer Clip ./ Retainer Clip Sl547 Fig. 38 An exploded view 01 the glass assembly. Vermont Castings Defiant Check the Operation of the Primary Air Shutter The primary air shutter is at the back of the ash drop and is visible from the back of the stove. (Fig. 39) The shutter must open and close freely when you move the thermostat lever. If it doesn't, remove any obstruction. II you need assistance, consult your local Vermont Castings Authorized Dealer. Do not change the adjustment of the cable in an attempt to gain increased firing. The air shutter controls how much air can enter the stove, but chimney draft is the force that pulls air into the stove. If changing the thermostat handle position does not lead to changes in the fire's intensity within four or five minutes, it's probably due to weak chimney draft (in the case of a weak fire you can't increase) or an air leak in the stove (in the case of a fire you can't decrease). . '<c,. i-" f:] :~\. ~~= t'A\- r If IJ rC J ,..;..; ~ ~ Primary Air Shutter 51'548 Fig. 39 The primary air shutter must move freely. Adjust the Damper as Needed The tension on the Defiant's damper is adjustable to compensate for compression of the gasket that seals the damper to the upper fireback. To adjust the damper: 1. Remove tile griddle. Loosen the lock nut at the center of the damper. (Fig. 40) 2. Turn Ihe 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-tesl the damper. Pressure Adjusting Screw _... Lock Nul Allen Wrench _._ Dampor t)1~!l4 Fig. 40 Adjust the damper with the Allen wrench. 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. How to Adjust the Door Latches The Defiant's doors should close securely to prevent accidental opening and to keep air from leaking into the stove. On adequately adjusted doors, the handles should resist slightly as they are turned to the closed position and the doors themselves should be drawn slightly toward the slave. Over lime, the gasket around the doors will compress and the latches may need adjustment. To adjust the latches, loosen the small lock nut, rotate the striker screw a half-turn, and re-tighten the small lock nut. (Fig. 41) Your stove kit includes an Allen wrench for latch adjustments. Hold the striker screw to keep it from turning as you tighten the lock nut. Make repeated small adjustments until the setting is right. Pawl Small Locking Nut \ ...--'- St,iker Screw Set Screw - Ildlldle Stub -- Sl:,:ll Fig.41 Turn the door latch striker screw III or Ollila liglllull of loosen the screw. .!,) Vermont Caslinf.Js Defiant The Catalytic Element 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 Ihis wood heater in a manner inconsistent with the operating instructions in this manual, or if the catalytic elemenl is deactivated or removed. Under normal operating conditions, the catalytic combustor should remain active for two 10 six years (depending on the amount of wood burned). However, it is important 10 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 resuit in a loss of heating efficiency, and an increase in creosote and emissions. Inspection and Cleaning Inspect the combustor "in place" for fly ash accumula- tion and physical damage three times per year. Clean the combustor as needed. Do nol remove the combus- tor unless a more detailed inspection is warranted because of diminished performance as outlined in the next sectioll. The refractory package that houses the catalytic combuslor should be inspected annually 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 Defianl'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: o 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 chim- ney. o Then, open the stove damper and once again check the smoke leaving the chimney. You should see significantly more smoke when the slave damper is open and exhaust does not pass through the combuslor. However, be careful not to confuse smoke with steam from wet wood. Steam dissipales in the air quickly; smoke does not. ff Ihis 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 tl1ese conditions. 111 Burning "green" (insufficiently seasoned) wood will result in poorer performance than burning properly seasoned fuel. 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 com- bustor if necessary. Be sure to protect any surface you use for setting the stove parts aside. Inspecting the Combustor 1. Lift the throat off its support brackets, and then remove it from the stove and place it on a protected surface. (Fig. 42) 2. Use a flashlight, and a mirror if necessary, to exam- ine the combustor. If no fly ash or damage is visible, the inspection is complete and you may replace the baffle. If closer examination or cleaning is needed, go to the next section. rr~~~~ ~---~/ -----_J "I :\ Catalytic Element 5T555 \~ Fig. 42 lift Ihe baffle off its supports to inspect the catlys!. Removing and Cleaning the Combustor 1. Remove the firebricks. Lift off the steel clip and remove the bricks individually. (Fig. 43) 2. Tap the left and right wedges upward, and remove the lower fireback by pulling it forward. You can either let it lie face down on the firebox floor, or remove it from the stove, through Ihe front door opening. (Fig. 44) Vermont Castings Defiant Alignment Notches Len Wedge Right Wedge Bricks ST556 Fig. 43 Remove the bricks and the brick retainer. ~ Lower Fireback 5T557 Fig. 44 Remove the lower lireback. 3. Carefully remove the catalytic combustor's refractory access cover, then remove the combustor. The refractory material is brittle; handle it carefully. (Fig. 45) 4. 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 honey- comb; 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. ~- ST558 Catalytic ~,':~f';',,,;,'l!"':' ".' "." L Element l'::.":;ik1i'~'~"',",-": "';~,:. _ ~:~~rtic Access Fig. 45 Remove and inspect the calalytic element. 5. Inspect the element for damage or degradation. Although small hairline cracks will not affect perfor- mance, 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 CastingsMajestic Products Company Authorized Dealer for a replacement element. While the catalytic element is removed, check the condition of the secondary air probe. Use an inspection mirror to locate the probe within the combustion chamber. (Fig. 46) The probe should extend 1" to 1 Vi' into the chamber and show no signs of excessive deterioration, such as warping, corrosion, or short length. A damaged secondary air probe can affect catalytic performance. If the probe needs replacement, contact your local dealer. \ 1 -. =J 51559 Fig. 46 Use an inspection mirror 10 check the rellected view of the secondary probe. .1/ Vermont Castings Defiant 6. If the elemenl is in good condition and clean, re- install it in the stove and replace the refractory access cover. 7. Replace the fireback, the five bricks and their clip, the left and right wedges, and the throat. When you install the lower fireback, be sure to align the two slight recesses in its bottom forward edge behind the mating tabs on the firebox floor. (Fig. 43) When you install the wedges, be sure to place their rear vertical edges againsl the outermost left and right edges of the lower fireback, to ensure a good seal between the lower fireback and the stove's outer back. Tap them downward to seat them snugly, bul do not overly tight. B. Clean the chimney and chimney connector. 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, it is likely that the performance change was 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 calalytic element will need to be replaced. Contact your nearest Vermont Castings' Authorized Dealer for informalion about a replacement element. NOTE: Use only the replacement catalyst supplied by a Vermont Castings Majeslic Products Company dealer. Replace the Stove Gaskets as Needed Your Defiant uses fiberglass 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 gasket are listed below, along with their applications. Gasket Diameter... ...And the Parts it Seals 5/16" The griddle to the stove top (wire reinforced gasket) 5/16" The damper to the upper fireback; the front doors to the stove front; and the doors to each other. 3/B" The ash door to the front of the bottom panel If you need 10 change a gasket, first obtain an appropri- ate replacement from your Vermont Castings Majeslic Products Company Authorized Dealer. .12 Wait until the fire is out and the slave 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 eight steps: 1. Remove the existing gasket by grasping an end and pulling firmly. (Fig. 47) 2. Use a wire brush or the tip of a screwdriver to clean the channel of any remaining cement or bits of gasket. Ftemove stubborn deposits of cement with a cold chisel if necessary. (Fig. 47) ST561 Fig. 47 Remove gasket then clean channel with wire brush. 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 utilily knife. Twist the ends slightly to keep the gasket from unravel- ing. 5. Lay an unbroken 1/B" (3 mm) bead of gasket cement in the newly-cleaned channel. (Fig. 4B) 6. Starting at one end, press the gasket into the channel. (Fig. 4B) Ensure a good joint where the gasket meets before trimming any excess. Do not overlap the gasket ends or leave ends with ragged edges. "'={,' <>,," =-- 'S","'~'___ ~ ""={ 0 ST561 "::J Fig. 48 Laya bead 01 gasket cement then press gasket in place. Vermont Castings Defiant 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. Adjust the Door Latch If Necessary 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 compression of the new gasket. The directions for adjusting the latches are on page 28. Permanent Defiant Gaskets Other gaskets form seals between non-moving parts, but these are not subject to the same wear and dete- rioration 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 Ihe case, the job should be done only by a qualified service technician. 5/16" diameter gasket seals the following parts: . The lower fireback to the back panel . The left and right air plates (inner sides) The Chimney System Creosote Your Defiant 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. When wood is burned slowly, it produces tar, organic vapors and moisture that combine to form creosote. The creosote vapors condense in the relatively cool chimney flue of a slow-burning fire. As a result, creo- sote 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. If you do experience a chimney fire, act promptly to: . Close the damper and thermostat 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. Annual Maintenance Every Spring, at the end of the heating season, per- form a thorough cleaning, inspection and repair: . Thoroughly clean the chimney and chimney connector. . Inspect the chimney for damage and deterioration. Replace weak sections of prefabricated chimney. Have a mason make repairs to a masonry chimney. . Inspect the chimney connector and replace any damaged sections. . Check gasketing for wear or compression, and replace if necessary. . Inspect and clean the catalytic elemenl. Lightly clean the refractory assembly that houses the element but be careful not to damage the refractory material, which is very fragile. . Clean the glass. Ash left on the glass can etch it, resulting in a chalky appearance. Also check for cracking; replace if needed. . Check door and damper handles for tightness. Adlust if needed. . Check heat shield screws. Tighten as necessary. . Clean dust from the inner sides of bottom, rear and connector heat shields. . Use a clean, dry, fine-bristle wire brush to remove any built-up accumulation on the top of the griddle. It is normal for the griddle to darken with use, and this is not treatable. . Remove ashes from the ash pan and replace wilh moisture absorbing material (such as cat litter) to keep the stove interior dry. . Touch up the paint on black stoves. JJ Vermont Castings Defiant Appendix: Catalytic Combustor In any chemical react ian, including the cambustian process, there are certain canditians which must be met before the reactian can take place. Far example, a reactian may require a certain temperature, or a certain cancentratian .of the reactants (the cambustian gases and .oxygen), .or a certain amaunt .of time. Catalysts act at a malecular level ta change these requirements, thaugh they are nat changed themselves during the reactian. In the Defiant's secandary cam- bustian chamber the catalyst reduces the temperature at which secandary cambustian can start from the 1000 - 1200" F. (540 - 650" C) range ta the 500- 600"F. (260 - 3150 C) range, increasing efficiency, and reducing creasate and emissians. The catalytic reactian daes have same limitatians .of its awn. Primary amang these is that the reactants (the gases) came inta c1ase physical cantact with the catalyst itself. Ta ensure the necessary cantact, the catalytic element in yaur Defiant is a ceramic base in the shape .of a haneycamb. Each .of the haneycamb's many surfaces carries a caating .of the catalyst (usually a nable metal such as platinum .or palladium). The large surface area expased in this way ensures that the cambustian gases have the greatest .opportunity ta came in cantact with the catalyst. Lass .of catalytic activity will be apparent in several ways. First yau may natice an increase in fuel can- sumptian. Secand, there will be a visible increase in the rate at which creasate builds up in yaur chimney cannectar system. Yau may alsa natice a heavy discharge .of smake from the chimney. There are a number .of catalytic problems which can cause lass .of activity: Blockage While the haneycamb pattern ensures gaad cantact, it alsa increases the resistance ta flaw .of the cambustian gases, and, because .of the many surfaces, provides more places far creasate and fly ash ta depasit. It is irnpartant ta fallaw the .operating instructians in .order ta minimize these depasits, and ta periadically inspect yaur catalyst far signs .of blackage. Masking and Poisoning While the catalyst itself daes nat enter inta the cam- bustian process, certain elements, such as lead and sulfur, can attach ta the active sites an the surface .of the haneycamb. Thaugh the catalyst is still there, it is cavered, .or masked, by the cantaminant, and cannat functian. T a avaid this situatian, it is impartant nat ta burn anything in yaur Defiant that is a saurce .of these cantaminants. Particularly avaid painted .or treated 34 waad, caal, hausehald trash, calored papers, metal fails, .or plastics. Chemical chimney cleaners may alsa cantain harmful elements. The safest approach is ta burn .only untreated, natural waad. Flame Impingement The catalytic element is nat designed far expasure ta direct flame. If yau cantinually averfire yaur Defiant, the chemistry .of the catalyst caating may be altered, inhibiting the cambustian process. Da nat use yaur Defiant with the baffle remaved .or damaged, as it shields the catalytic element fram direct flame. Thermal degradatian .of the ceramic base may alsa .occur, causing the element ta disintegrate. Stay within the recammended guidelines .of the Operatian sectian. Overfiring At law firing rates, especially with a large laad .of fuel, the catalytic element can became averlaaded with gases which da nat burn in the firebax. This puts increased strain an the catalytic element, causing il ta .operate near .or even beyand the high end .of its narmal temperature range. An immediate sign .of this is a law rumbling saund, .or a saund like a small gas tarch, caming from the stave's rear chamber. If yau frequently hear such a saund, .or cantinually see a bright glaw through the baffle, .open up the stave's primary air valve ta make the fire burn mare cleanly in the firebax, and cut back an the size .of yaur firewaad laad. Essen- tially the catalyst is an afterburner, and will last langer under lighter laads. Mechanical Damage If the element is mishandled, damage may .occur. Always treat the element carefully. Remember the catalyst is made .of a ceramic material; treat it as yau wauld fine china. Hairline cracks will nat affect the performance .of the catalyst, as lang as the steel sleeve halds the element in the proper pasitian. Peeling The surface caat may peel if the catalytic element is frequently subjected ta excessive temperatures. Fallaw the .operating instructians carefully ta avaid this type .of damage. General Every Vermant Castings' Defiant is equipped with either a Carning "Lang-Life"@ .or an Applied Ceramics cambustar. The products are equivalent. If yau must ship yaur catalytic element far any reasan, remember its fragile nature. Place the element in a plastic bag, and package it with a generous amaunt .of shack absorbing material. ,1') Vermont Castings Defiant Appendix: Chimney and Fireplace Hazards ~(F) ST562 General - A. Improper chimney height. The top of the chimney must be at least 3 feet higher than the spot where it passes through or past the roof, or two feet higher than everything else within ten feet horizontally, whichever is higher. B. Deteriorated chimney cap C. Structural defects indicated by creosote stains on outside of chimney D. Blockage within chimney E. Improper clearance between chimney and nearby combustibles (less than 2" - check local codes) K. Loose or leaky cleanout door For a fireplace - F. Improper clearance between smoke chamber and framing materials - (less than 2" - check local codes) G. Creosote buildup on smoke shelf H. Structural deterioration I. Loose or broken bricks or mortar J. Insufficient hearth depth. The hearth must extend 16" (18"/460mm in Canada) beyond the fireplace opening. With a fireplace insert, or a free-standing stove vented through a fireplace, the hearth must extend 16" (18"/460mm in Canada) beyond the front door opening of the stove or insert. ,1S Vermont Castings Defiant @) ~ (;j7 ~T~~JV . ~ t28'-'L ~ 5 , ~-. . ~~ ~r~ :: CD-f. e? (.) , , , , , , , , , '" // Q~ ) .\@'"L'C;'/~ ~-----~------- /'~'~ I II \\./ ~ "0 ,''<:} .~~ -@,--" .~ \@ cQl @-@- @-~"'.f."" , . . ,. fo)~!J @) - - , , , fs2\- J ',',"~ I \::'.:1'1... \ - _" I ~ , @ ;, @ 75 @ 7: fl ~':- ~.~-@ 67) ~8) @ Vermont Castings, Majestic Products reserves the right to make changes in design. materials, specifications, prices and discontinue colors and products8.t any time, without notice. Defiant Woodburning Stove itel'l.iModei Number 1. Secondary AirCover Plale 2. Secondary Air Probe Assy 3. Secondary Air Link 4. Secondary Air Flap 5. Griddle Gaskel 6. Back '-'.piirtJ.juiii1i~r. 1601492 1601489 1601486 1601490 . _ _ ~ . u _ 1203668 30001581 -~iieiijiModefNumber 7. Jell l:leatD.~f1ector 8'_F1ighJ_Heal [Jefleclor. 9. Gefracto'Y_l\.s'>}l (Body only) 10. c;atalyticc;()mbustor 11.. Gelractory A_ccess Panel 12. Thermostat Friction Spring .--- --------Pa,fNurnber 1608629 1608630 1602512 30001152 1602511 1201846 36 Vermont Castings Defiant Defiant (continued) 11~Il1IPII()ll~L!l-"ITI!>~r 13. L~tt C;>ridlll~ Qu~cjr~nl 14. Right Gricjcjl"Q~~cjr~nt 15. Griddle 16. . Qriddl~ I-l~"dl~. . ...._ .17. _C;>riel<ll" H~ng~ ~p~gllr 18. Qricjcjl" H-"ndl" Bolt 19. . Upp"r firebagk A~~y _gQ, . Ramp"rFl"mp'____ g 1, _lJppllr fir"brigk' gg. D~mpeJ'u g3, .. [l~mllpr Tab' __ g4. [l~m'p"r Floll'__ _____ 25. GJicjcjl" H"ncjl" Bu~hing 26. Tllr""t B"me 27. ~""'"! fir,,!>ack . g8, Uppll!fJr"ll"gk BoiL 29. P~rn'p"r I-l~ndl" ::;gr"", . ~O D~rn.Pll! I-l~ndl" ~ 1. [l"m'p"rH~ncjl" El"s" A"sy 32. L"tt ::;ide _ _ ~3. ~lltt/\irPI~t" (J"""r_::;ide) __ 34. Ri9.hl Air Plale (Inner !3i<lll) 35. Right ::;ide 36. Th"rmostat Handle Base Assy 37. Th"rmost~t As~y 38. Grate 39. Primary Air Cover Plate 40. Top A~hdoor Hinge Support 41. Door Handle Holder 42. Bottom 43. Ashlip 44. Lell Side Wedge 45. Right Side Wedge 46. Fire!>rick (1 V," x 4W x 9") 47. Firebrick Retainer ---- ,.- ----- 48. Andiron .. !'~rt.,..,~mber 1301807 _11()1~32 .1301641 JjJQ06~7. . . ..1jJQ()Q7Q_ 1200907 - ----------- . _ ~OQQQ3Q . 1300643 -- ----------------- 13QOjJ3..L . ____.._l1QQ6~L ljJQ 141l1L_ __ ljJ()QQjJL ._lg0189~ l~OQjJ:3~ 1300638 ------..--------- 1301374 - __ _~ .0-- .._______ _12Ql~1ll..._ 1600644 -----.--'-..------- 5004265 - --- ----- ~00015~1 1300637 - -- -..--------- ..1300jJ36 3000157~ ~00426'L _ 5005470 1300639 1300622 1300620 1600059 1300618 1300621 30001577 1300644 1601103 1600066 1300646 NOTES: In this diagram and throughout this manual, 'left' and 'right' mean as you face the stove. When ordering parts, be sure to mention the stove's model number. When ordering external pars, be sure to specify color. l.Included in lIern #19, #5000030 Upper Fireback Assy. 2.Not interchangeable, due to a heat-reflective coating on the room side of the glass. 3. Included in lIem #59, 5000024 Primary Air Assy. 4. Included in #5004282 Ceramic Handle Assy. The hardware in the Defiant is in standard sizes; most bolls are 1/4" diameter by 20 threads per inch. Any hardware store can supply replacement hardware if you specify boll diameter, number of threads per inch and length. lIemlPIIOllell'l~ml>er 49. Andiron Shelf - ___un __ _ . 50. Leg Leveller 51. Ashdoor Han<!le Shall 52. Door L"tch Msy 53. Ashdoor .__________'n'_ _ 54. Ashdoor Hanelle (W"od) 55. Ashgoor Hi"g" Rod .!)6,__C"tter pin,A""g""r _g A~lld_oor Elllllc>m Hi"g,,!;iupport . ~8,_Ashp"n Elr"g~.ll~A~sy _!5L Primary Air V"lv" A!,sy 60, Primary Air Fr~mll.'_ 61. Primary Air Ro<!' 62. Primary Air Valve' 63. Thermostat Handle _n ____ ------ ----- 64. Airwash Manifold ---- -..-- 65. Front ---------- -- 66. Thermostat Cable ----- -- - --- 67. . ~eft [loor 68.. Door Hinge !;itrip jJ9..Top .10. Glass Clip 71, glass Clip (Right Door only) 72. Fronl Door Handle & Shaft 73. Right [)oor 74. Door Gasket 75. Glass Gasket 76. Left Door Glass' 77. Right Door Glass' 78. Lower Door Hinge Pin 79. Spacer (for Damper Rod) 80. Upper Door Hinge Pin 81. Handle Base Stub' 82. Ceramic Handle4 83. Handle Boll' 84. Thermostat Handle Boll 85_ Ash Pan Assy 86. Flat Washer 87. Flue Collar 88. Leg Finish Bag Part Number 1300640 1201745 1600622 50040258 1300619 1600663 1206061 30001749 1300642 30001688 5000024 1307411 1600058 1307412 1600660 1300627 30001578 5005471 1300626 1300645 30001582 30001715 30001578 5004237 1300625 1203589 1203512 1600064 1600062 1600547 1201779 1600547 1600650 1600620 1201294 1201243 30001690 1202475 30001576 30001583 0005928 .17 .' DIRECT VENT GAS HEATER DV25 OwNER's GUIDE , INSTALLATION, OPERATION AND MAINTENANCE PROCEDURES FOR 112642 N025 AND 112643 LP25 WARNING: If the Information in this manual is not followed exactly, a fire or . explosion may result causing property damage, personal Injury or loss of life. Do not store or use gasoline or other flammable vapors and liquids In the vicinity of this or any other appliance. WHATTO DO IFYOU SMELL GAS · Turn off gas supply. · Do not try to light any appliance. . Do not touch an~ electrical switch: do not use any phone in your building. · Immediatelt cal your gas supplier from a neighbor's phone. Follow the gas suppliers's nstructions. · If you cannot reach your gas supplier, call the fire department. Installation and service must be performed by a qualified installer, service agency or the gas supplier. WARNING: Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. Refer to this manual for correct installation and operational procedures. For assistance or additional Information consult a qualified installer, service agency, or the gas supplier. . @.I".OYII NOT UL l,'dd\ Tested and listed to ANSI Z21.44-1995 and CAN/CQA.2.19.M86 SAVE THIS MANUAL FOR FUTURE REFERENCE. Table of Contents Specifications/Shell Dimensions ........................1 General Information .......................................... 2 Installation Requirements .................................. 4 Assembly Procedures ....................................... 9 Operation..................... ..... .......... ..... ...... .... .... 16 Maintenance.............. ........ ......... ........... ......... 18 Illustrated Part List ........................................... 21 Wiring Diagrams ............................................. 22 Appendix ....................................................... 23 Warranty ........................................... Back Cover ATTENTION CONSUMER: IN ORDER TO ENSURE SAFE AND EFFECTIVE INSTALLATION, THIS UNIT MUST BE INSTALLED ONLY BY A QUALIFIED AGENCY, INDIVIDUAL, FIRM, CORPORATION, OR COMPANY THAT IS EXPERIENCED IN THE INSTALLATION, REPAIR AND SERVICING OFTHIS TYPE OF APPLIANCE AND IS FAMILIAR WITH THE BUILDING CODES AND INSTALLATION TECHNIQUES APPROPRIATE IN YOUR AREA. CONTACT YOUR HEARTH PRODUCTS DEALER OR LOCAL GAS SUPPLIER FOR THE NAME OF A QUALIFIED SERVICE PERSON. INSTALLER: PLEASE READ THIS MANUAL CAREFULLY BEFORE YOU BEGIN THE INST ALLATJON PROCEDURES. FAILURE TO FOLLOW INSTRUCTIONS MAY RESUL TIN PROPERTY DAMAGE, BODILY INJURY OR LOSS OF LIFE. THIS MANUAL CONTAINS IMPORTANT USER INFORMATION. KEEP THIS MANUAL WITH THE FIREPLACE AFTER INSTALLATION IS COMPLETE. Specifications DV25 Direct Vent Gas Heater I NG 2642 and LP 2643 1 Fuel Manifold Pressure - Min./Max.: Min.lnlet Supply Pressure for adjustment: Steady State Efficiency: AFUE: Input, BTU/hr. Min./Max. : Ignition: Piezo Thermostat: Not supplied - use only 500 millivolt type Weight; Firebox wi Glass & Logs: - 110 Ibs. Fully assembled in Freestanding Shell: - 200 Ibs. Dimensions Freestanding Stove Shell NO LP 2.2 '/3.5' 6.4' 110.0' 5.0'W.C. 11.0'W.C. 72.2% 74.8% 65.8% 69.7% 19,500 I 25,000 Sse Page 5 for Rue Collar Centerline Dimensions. 25' -J To cIsar Stove Leg Chack local codas for approvad fillings. D D J~ Valve Inlel 37/8' 1-'---- 14'-..j DRAWINGS NOT TO SCALE 2 General Information The Direct Vent Gas Heater, DV25, Models #2642 and #2643, is a vented gas appliance listed to the ANSI standard Z21.44-1995 and CAN/CGA-2.19-M86 for Direct Vent Wall Furnaces. It is also tested to CGA Interim Requirement #41 for Direct Vent Gas Fire- places. This appliance is approved for bedroom installation. in the U.S. and Canada. This appliance may be installed in an aftermarket' manufactured (mobile) home, where not prohibited by state or local codes. This appliance is only for use with the type of gas indicated on the rating plate. This appliance is not convertible for use with other gases, unless a certified kit is used. "Direct vent' is a term used to describe a sealed combustion system in which incoming outside air for combustion and outgoing exhaust enter and exit through two separate concentric passageways within the same sealed vent system. The direct vent system permits the gas appliance to be vented directly to the outside atmosphere through the side of the house, unlike conventional venting systems that take air from the room for combustion and vent the exhaust vertically through the roof to the atmosphere. The installation of the DV25 must conform to local codes. or in the absence of local codes, with National Fuel Gas Code, ANSI Z223.1 -latest edition and CAN 1 B 1-149.1 and -.2 Installation Code. (EXCEPTION: Do not derate this appliance for altitude. Maintain the manifold pressure at 3.5 inches W.C. for Natural Gas and 10 inches W.C. for LP gas.) Installation and replacement of gas piping, gas utilization equipment or accessories, and repair and servicing of equipment shall be performed only by a qualified agency. The term "qualified agency' means any individual, firm, corporation, or company that either in person or through a representative is engaged in and is responsible for (a) installation or replacement of gas piping, or (b). the connection, installation, repair, or servicing of equipment, who is experienced in such work, familiar with all precautions required, and has complied with all the requirements of the authority having jurisdiction. . Aftermarket: Completion of sale, not for purpose of resale, from the manufacturer. The DV25 should be Inspected before use and at least annually by a qualified service agency. More frequent cleaning may be required due to excessive lint from carpeting, bedding material, etc. It Is Imperative that control compartments, burners, and circulating air passageways of the heater be kept clean, The appliance and its individual shut-off valve must be disconnected from the gas supply piping during any pressure testing of that system at test pressures in excess of 1/2 psig. (3.5 kPa). The appliance must be isolated from the gas supply piping system by closing its individual manual shut-off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psig. A 1/8-inch N.P.T. plugged tapping, accessible for test gage connection, should be installed on the inlet gas connection. The DV25, when installed, must be electrically grounded in accordance with local codes or, in the absence of local codes, with the National Electrical Code ANSI/NFPA 70, (latest edition), or of the current Canadian Electrical Code C22. 1. Due to high temperatures, the Direct Vent Gas Heater should be located out of traffic and away from furniture and draperies. WARNING: This appliance is hot while In operation. Keep children, clothing, and furniture away. Contact may cause burns or Ignition of combustible materials. Children and adults should be alerted to the hazards of high surface temperatures and should stay away to avoid burns or clothing Ignition. Young children should be carefUlly supervised when they are In the same room as the appliance. Clothing or other flammable materials should not be placed on or near the appliance. Any safety screen or guard removed for servicing an appliance must be replaced prior to operating this appliance. The appliance area must be kept clear and free from combustible materials, gasoline, and other flammable vapors and liquids. The flow of combustion and ventilation air must not be obstructed. WARNING: Do not operate this appliance with the glass panel removed, cracked or broken. Replacement of the panel should be done by a licensed or qualified service person. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to Inspect the appliance and to replace any part of the control system and any gas control which has been under water. Do not burn wood, trash or any other material for which this appliance was not designed. This appliance Is designed to burn either natural gas or propane only. 3 This gas appliance must not be connected to a chimney flue serving a separate solid fuel burning appliance. CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. Installation and repair should be done by a qualified service person. The appliance should be Inspected before use and at least annually by a qualified service person. more frequent cleaning may be required due to excessive lint from carpeting, bedding material, etc. It is imperative that control compartments, burners and circulating air passageways of the appliance be kept clean. Figure 1. The DV25 Gas Heater / Controls. Safety Switch - Supply Line Inlet -- Logsel - Base Plate - Pilot Assembly Piezo Ignitor Variable Regulator OFF/ON/Pilot Control Knob 4 Installation Requirements The installation must conform with local codes or, in the absence of local codes, with the National Fuel Gas Code, ANSI Z223. 1 -latest edition. (EXCEPTION: Do nol derate this appliance for altilude. Maintain the manifold pressure at 3.5 inches W.C. and 10 inches WC. for Propane). In Canada, installation must be in accordance with the current CAN 1 B 1-149.1 and -.2 Installation Codes and/or local codes. The Installation should be done by a quail. fled service person who Is familiar with the building codes and installation techniques appropriate for your area to accomplish a safe and effective Installation. Your dealer or your local gas supplier will be able to refer a qualified service person. WARNING: DUE TO HIGH TEMPERATURES, THE HEATER SHOULD BE LOCATED OUT OFTRAFFIC AND AWAY FROM FURNITURE AND DRAPERIES. THE SURFACE OF THE HEATER IS HOT WHEN IT IS IN USE. YOUNG CHILDREN SHOULD BE WATCHED CAREFULL YWHENTHEY ARE IN THE SAME ROOM WHEN THE HEATER IS IN USE, AND THEY SHOULD BE TAUGHTTO AVOIDTHE HOT SURFACE.KEEPANYOBJECTSTHATCAN BURN WELL AWAY FROM THE HEATER, AND OBSERVE THE RECOMMENDED CLEARANCES THATF Hearth Requirements The OV25 Heater must be installed on rigid flooring. Any carpeting under the unit must be removed. When the heater is installed directly on any combustible surface other than wood flooring, a metal or wood panel extending the full width and depth of the unit must be used as the hearth. There are nootherh rth rents. Keep the Stove a Safe Distance from Surrounding Materials The OV25 Heater will heat nearby surfaces when operating. A safe installation requires that adequate clearance be maintained between the stove and nearby combustible materials to ensure that such materials clo not overheat. The diagrams that follow illustrale the minimum clearances for the appliance in parallel. corner. and alcove installations. For further information on ventilation guidelines and sizing specifications follow the National Fuel GasCode NI'PA 5~/ANSI Z223.1 Section 5.3. Clearance Requirements Minimum Clearances to Combustible Materials The OV25 heater is approved for installation into an alcove constructed of combustible materials to the dimensions and clearances shown below. The same clearances apply in a standard parallel installation. ..-...- B &\115omm) <:g5 50mm) 37" (939 mm 48' (1220 m) Figure 2. Minimum side clearances and alcove dimensions ..~ ;(r- B ~ I rf I 1 I I D I I L ! / I LA~r~all~ B . Cove Dep!!V C: m. 81g1 0: Min. Height ~50ji \ Im~ 2 11 ~ (650 mm) . ,. 521/4' (1327 ml)l)" / . needed for ills/a/ling Vent System "5084 . /-/' .---. Figure 3. ~imension earances to ceiling or Alcove. Wall Thimble Centerline from Floor ~ r 423/4"Min. (1086 mm) L Combuollblo Coiling A Jl c Figure 4. Minimum clearances to ceilingormantel. Effective Minimum using Wall Thimble and 2- RearCleBrance: A B --.-, 5 c 9112" 241mm 251/2" 650 mm 521/4" 1327mm Flue Collar Centerline from the Wall J- 152mm f -.16" .- 152mm Figure 5. Flue collar cenlerfine lrom wall; Corner Installation l _181/2"--..1 I...... 470mm I 1.- 2- 50 mm t' 61/2" 165mm r Figure 6. Flue collar centerline from wall; Paralfellnstalfation (; Venting Requirements and Options Approved Vent System Components The DV25 Heater is approved to be vented to the outdoors through an adjacent exterior wall or through the roof. The venting system must be comprised of the appropriate listed venting compo- nents specified in Table 1. These parts are available from DuraVent Corporation or your DV25 dealer. All Straight vent pipe sections have a net length 1 1/2' (37mm) less than the nominal dimension; i.e., a 6" (152mm) Straight pipe section has an effective length of 4 1/2" (115mm). The Appliance Adaptor 923V, when installed, terminates 9 1/4" (235mm) above the stove. See Fig. 6 for dimensions relevant to the #5064 Standard Vent System pipe. Table 1. Approved Venting Components VCI NO. COMPONENT OURAVENT NO. 923V APPLIANCE AOAPTOR" 923V 990B 90' ELBOW, BLK.' 990B N/A 90' ELBOW, GAL. 990 945G 45' ELBOW, GAL. 945 90BB 6' STRAIGHT, BLK." 908B 9078 9' STRAIGHT, BLK. 907B 906B 12' STRAIGHT, BLK. 906B 906G 12' STRAIGHT, GAL. 906 904B 24' STRAIGHT, BLK. 904B 904G 24' STRAIGHT, GAL. 904 903B 36' STRAIGHT, BLK. 903B 903G 36' STRAIGHT, GAL. 903 N/A 4B' STRAIGHT, BLK. 902B N/A 4B' STRAIGHT, GAL. 902 911B 11'-145/B'STRAIGHT 911B 984B HORIZONTAL VENT CAP" 9B4 940B WALL THIMBLE / CEILING SUPPORT BOX" 940 950B VINYL SIDING STANOOFF 950 9B2B SNORKEL TERMINATION - 14' 9B2 981B SNORKEL TERMINATION - 36' 981 5084 MINIMUM HORIZONTAL VENT KIT N/A 988G WALL STRAP 988 941B CATHEORAL CEILING SUPPORT BOX 941 953G STORM COLLAR 953 963G FIRESTOP SPACER 963 943G FLASHING 0/12 - 6/12 943 943S FLASHING 6/12 -12/12 943S 991G VERTICAL TERMINATION CAP 991 -'ncluded In Vermont Castings Standard Vent System #5084 Figure 8. Standard Vent System #5084 through a combustible wall with the minimum approved rear ciearance, (2'). . The to' x la' wall cut-out wiil provide the required clearance of 1- around the vent pipe. Horizontal Termination The maximum permissible horizontal run is 6 ft (204m). The maximum vertical run ending in a horizontal terminations is 12 ft. (3.6m). The vent run must extend a minimum of 2 ft. (.6m) See Fig. 7 for specifications concerning offsets and overall vent run lengths. Figure 7. 12 ~10 I: ~ .. 8 i!: I: I 8 .. l! " I 4 OK TO ---------n:~T-------- ELBOW' __________EQa_________ OFFS..-r 2 UI. ONLY OHI 10' IUOW WITH :t' 011 U" VIII11CAL Rill Min. o o . 2 I 4 8 8 HORIZONTAL RUN I nIT u_J____::_ 63/4" (170mm) t 91/4" (235mm) IT 26314" (680mm) 251/2" (648mm) H923V 10' x 10" Wall Cut-out* 42 3/4" (1085mm) Figure 8. Minimum vent dimensions. Vertical Vent Termination The maximum permissible vertical run is 25 ft. (7.5m) measured from the heater flue collar to the lowest discharge opening at the termination. See Figs. 9 and 10 for offset and run length specifications. 25 = 20 .. - .. ~ 15 ALL VERTICAL .. TERMINATIONS i!! REQUIRE USE !: OF THE 2" = 10 RESTRICTOR I PLATE. ; I II: I i I 5 I -----"I I I > I I 0 0 2 HORIZONTAL RUN I FEET Figure 9. Maximum OffseWent Run. Lowest D1sCha~el Opening lIsledCap .. ~ ~ listed ~ I Gas Vent H /7_ X /: 12" t Roof Pilch Is X/12 H - Minimum Height from Roof 10 Lowest Discharge Opening Rool Pitch Fletlo 6/12 6/12107112 Ove' 7/12 to 8/12 Over 8/12 10 9/12 Ove, 9/12 to 10/12 Over 10/1210 11/12 Over 11112to 12112 Figure 10. Vent(Chimney) Height. H(Mln.)Ft. 1.0 1.25 1.5 2.0 2.5 3.25 4.0 7 Vent Terminus Clearances When planning the installation, the location of the vent terminal and clearances must be considered. Some of the most common clearances to keep in mind are shown in Fig. 48. IMPORTANT: ALL VENT CLEARANCES MUST BE MAINTAINED. CHECK YOUR VENT TERMINUS. CLEARANCES AGAINST FIG. 48, PAGE 23, APPENDIX A. The vent should be placed so that people cannot be burned by accidentally touching the vent surfaces when the stove is operating. The vent termination should be located where il cannot be damaged by such things as automobile doors, lawn mowers or snowblowers and il should be located away from areas where it could become obstructed by snow, etc. Some considerations are: . Obstructions or impediments to venting. . Nearby combustible materials that could come into contact with combustion exhaust gases. . Other nearby openings (within 9' (23mm)) through which exhaust gas could re-enter the building. . All vegetation within 3' (.9m) that may interfere with the draft. . Vinyl .Idlng require. protection from vented heat Immediately around the vent opening. U.e Vinyl Siding Heat Shield Kit 11950 or 950B. Other factors that influence where the installation will be sited include the location of outside walls, where additional heat may be desired in the home, where the family members gather most regularly, and perhaps most importantly, the distance limita- tions of the venting system. ./ <() HOT ./"/ Standard vent cap Vinyl shield Fig. 1O-A. Positioning the vinyi siding shield. 8 & WARNING: . ALWAYS MAINTAIN REQUIRED CLEAR- ANCES (AIR SPACES) TO NEARBY COMBUS- TIBLES TO PREVENT FIRE HAZARD. DO NOT FILL AIR SPACES WITH INSULATION. ALL VENTING COMPONENTS MUST MAINTAIN A 1" (25MM) CLEARANCE TO COMBUSTIBLE MATERIALS. . THE GAS APPLIANCE AND VENT SYSTEM MUST BE VENTED DIRECTL YTOTHE OUT- SIDE OFTHE BUILDING AND NEVER BE ATTACHED TO A CHIMNEY SERVING A SEPARATE SOLID FUEL OR GAS-BURNING APPLIANCE. EACH DIRECT VENT APPLI. ANCE MUST USE IT'S OWN SEPARATE VENT SYSTEM. COMMON VENTS ARE PROHIB. ITED. . REFER TO THE MANUFACTURER'S IN. STRUCTIONSINCLUDEDWITHTHEVENTING SYSTEM FOR COMPLETE INSTALLATION PROCEDURES. & IMPORTANT . The horizontal termination must not be re- cessed into the exterior wall or siding. . Horizontal vent runs must be level or rise 1/4' per foot toward the vent termination. . Clearances around the vent termination must be maintained. . Parallel installations with minimum wall clear- ance have restricted access for connecting the Horizontal Vent Cap straps to the vent pipe. See Page 13 of the Assembly section for recommended installation procedures. Assembly Procedures WARNING FAILURE TO POSITION THE PARTS IN ACCORDANCE WITH THESE DIAGRAMS OR FAILURE TO USE ONLY PARTS SPECIFICALLY APPROVED FOR USE WITH THIS HEATER MAY RESULT IN PROPERTY DAMAGE OR PERSONAL INJURY. THIS HEATER AND COMPONENTS ARE VERY HEAVY. HAVE ASSISTANCE AVAILABLE FOR ASSEMBLY. Unpack the DV25 Firebox, Logset and Stove Shell 9 Rear Shroud Carton Remove - packing material. Control Switch Cover Cut the shipping straps and remove the Rear Shroud from its carton. Remove the cardboard packing material from Figure 12. DV25 Firebox with Switch Cover as shipped. the top of the firebox, Fig. 12. Do not remove the firebox from the shipping pallet yet. Tools Required . Phillips screwdriver (stub) . power drill . utility knife . reciprocating saw . metal drill bits: size 28 (.140'/3.5mm) and 1/2" dia. Parts Bag Contents: . 9 Phillips 1/4-20 x 5/8" screws . 4 Phillips 1/4-20 x 3/8" screws . 4 Phillips # 10 x 1/2" sheet metal screws . 3 Phillips # 10 xl" sheet metal screws . 1 Wire tie . 1 Vent Gasket . 1 Vent Restrictor Plate . Owner Registration Card See Page 22, Fig. 47/ Scew Identification Chart. Remove the Log Set The Log Set has been packed inside the firebox in a protective wrap. The Glass Panel must be removed to install the Log Set onto the burner. . Use a Phillips screwdriver to remove the three screws from the glass retainer frame. Fig. 13. Keep the screws for later re-installation with the other 9, 1/4-20 x 5/8' phillips screws in the parts bag. . Carefully remove the glass and frame assembly and place it out of the way on a tlat, padded surface such as a counter protected by a towel. Unpack the cast iron stove shell parts tram the shipping carton. Inspect each part for shipping damage and set it aside on a protective surface. Porcelain enamelled surfaces are 'ragl/e. Handle porcelain enam- elled castings tenderly, Before you begin assembly, read this section of the manual to familiarize yourselt with the procedures. The installation Will be most easy if you follow the steps in the order presented. Figure 13. Remove the three frame screws from the locations indicated. Elbow Lock and orient the Elbow and Outer Adaptor together in the appropriate direction before drilling the pilot holes into the Adaptor. Outer Adaptor - (crimped end down) -cJ.j Drilj_c . Drill j- , ~ Figure 14. Pre-drili pilol holes into the Outer Adaptor pipe. l,U Venting Pre-assembly The vent Outer Adaptor pipe must be pre-fit and its pilot holes drilled before proceeding with the heater assembly. - Insert the Outer Adaptor Pipe, seam facing back, into the flue collar. If applicable, insert and fully engage an elbow into Ihe Outer Adaptor pipe and rotate the pipe so Ihat the elbow is facing the appropriate direction for connection to the vent termination. Fig. 14. . Drill .14" dia. pilot holes into the pipe Ihrough the three existing screw holes in the firebox flue collar. Remove the pipe. Heater Assembly 1. Attach the Rear Shroud to the Lelt End plate by aligning the key holes with the two wingbolts in the side. II necessary, turn the wing bolts to orient the blades vertically. Fig.15. Slide the shroud downward to engage it behind all three washers on the side plate bolts and then lighten both wingbolls. 2. Repeat Step 1 to attach the Right Side Plate to the Rear Shroud. Fig. 16. Move this assembly close to the stove's final position. Align the two side plates to be perpendicular to Ihe Back Panel as in Fig. 17. 3. Hang the Switch Cover over the flue collar rim, as in Fig.17, to keep it out of the way while installing the firebox. DO NOT PULL ON THE SAFETY RELAY WIRE LOCATED OVER THE FiREBOX. Lilt the DV25 firebox assembly as a unit and slide it back to position it within the shell. The base of the firebox should rest on the side support shelves as in Figs.17 and 18. The large washer at the forward leg of each Side Plate should engage the corresponding notch in the underside of the firebox base as shown in Fig. 18. Properly posi- tioned, the firebox will be level and locked in place. If not, adjust the levelling screw in the foot of each leg to keep the entire unit level. IMPORTANTI Confirm that the Safety Switch Is properly positioned. See FigAO, page 19. If you are installing the optional convection Fan Kit #5081, proceed to Step 4. If you will not install a Fan Kit, proceed to Step 7. / Wlngbolt Lell Side Rear Shroud "'R 0" 8 .....8 Wingboll Figure 15. Secure Left End to the Rear Shroud Wlngboll """\ & ..' &/ ~ ! Wingboll Figure 16. Secure Right End to the Rear Shroud. Hang Switch Covsr over Flue Cot/ar. Rear Shroud Safety Switch Figure 17. Align both sides with the rear. Figure lB. Instat/lhe Firebox Assembly. Be sure that the two large front washers engage the notches on both ends of the Base. 4. The fan kit consists of a Blower Assembly and a Rheostat Assembly that are connected by a cable. Fig. 19. The Blower Assembly mounts to the bollom rear of the the stove and the Rheostal mounls within the switch box on the left rear corner of the stove. The Rheostat contains a "snapsta!" which senses the temperature within the stove heat exchanger and automatically turns the fan On (or Off) above (or below) approximately 109". The Rheostat also provides a range of fan speed sellings tram Off (which overrides the snapstal function) to High. Unpack and inspect the Blower assembly. Confirm that the fan spins freely. WARNING THIS APPLIANCE IS EQUIPPED WITH A THREE-PRONG (GROUNDED) PLUG FOR YOUR PROTECTION AGAINST SHOCK HAZARD AND SHOULD BE PLUGGED DIRECTLY INTO A PROPERLY GROUNDED THREE-PRONG RECEPTACLE. DO NOT CUT OR REMOVE THE GROUNDING PRONG FROM THIS PLUG. V - -.- "" _~-_-------I _~ Blower Assembly SlJ/ Rheostat I Snapstat Extension Assembly ~1/~ ,V Figure 19 Fan Kit Components "~O.'-'---=--,-,,~= " ~--~~. Back Panel Hex Bolts -'1 'f/\ [} J~ ~ow:r Panel f -------1__ Figure 20. Install Blower. 11 5. Remove the panel at the bollom of the Rear Shroud and secure the blower assembty to the firebox base using the two hex bolls supplied with the kit. Fig. 20. 6. Remove the plug from the Control Switch. Reach under the Back Panel and feed the Fan Rheostat/Snapstal assembly up to the top of the firebox. Secure the rheostat assembly to the Switch Cover the sheet metal screws supplied with the fan kit. Fig. 21. 7. Install the Control Switch Cover onto the Back Panel using the four #10 x 1/2" sheet melal screws supptied in the parts bag. Fig. 22. Push the Control Knob onto the rheostal shaft. Secure the wire harness to the hole in the side of the shroud using the plastic wire tie supplied. Fan Kit users: Be sure that the snaptat extension is positioned against the cast iron at the top of the firebox Engage the snaptstat extension through the &. notch in the Cover. Hhax Nut '. .....L::.:~ _.. _ _. -<=---~._ =_ _ ;/" . 0" ,,~-"O ~f - ..;-.:_:-~~~-~-- ;-6-- ~.~- A JI ~ Il :' \~o Q 0 / 1/2" sheet : J \0" metal , ~_ screws :____ 0 a Figure 21. Install Rheostat/Snapsta! assembly. , Control Knob :(2) , , h' .,~~---~-:'~m-~~ ::/ / b 0"- =-:.....---=---"---=- #/-- o " ~--T-l\~,-~O- _ 0" ___f , ~ , , , /-~;--. ~ ....-/ : 21-- o L..c. -'_._-'~~------=--~--=-~~~~--==---4 ~ V 112- sheet metal screws , , o Wire Harness _.Ji' --- -.. ~ c:=---.:..::~~~--_ / WireTie - --~ c.~-:..:.:..:.~~~_ ~ C~__ ---~------.:..:::-~) -'<, Figure 22. Install Oil/On SWitch Cover plate Place the four sheet metal screws as SflOWn. Pus!) on the knob. 12 8. Connect nle walllhermostat leads to the double lerminal block at the lower left corner of the firebox base. Fig. 23. Either wire may be connected to either terminal. Note in the table below the appropriate gauge wire to use for the length of lead needed. Use ollly a 500 millivolt thermostat. Wire Gauge 18 20 22 Maximum Run 40' 25' t6' To ease accBss,remove the lower panel (5 screws) from the rear shroud. Terminal Btock V' Figure 23. 500 Millivolt Thermostat Connection. Attach the Venting The DV25 is approved for installation only with the vent components listed on Page 6. Follow the vent manufacturer's instructions exactly. Paint Option. Porcelain Enamel Stove. You may wish to use the Medium-temperature paint provided to paint the vent components to match your slave before assembling the system. Appliance Adaptor Connection 1. Attach the adhesive-backed gasket (located in the parts bag) to the flat flange of the Inner Adaptor Pipe. Fig.24. It you need to use the Restrictor Plate, attach the gasket to thai plate and install the plate, gasket~side down, under the Inner Adaptor Pipe. See Figs. 7 and 9 to determine if you need to install the Restrictor Ptale. 2. Attach the Inner Adaptor Pipe to the slave with three 1/4- 20 x 3/8" Phillips screws (see parts bag). Fig. 25. 3. Insert the Outer Adaptor pipe into the flue collar as previously fit and secure with three # 10 x I" sheet metal screws supplied in the parts bag. Fig. 26. Adhesive-backed Gasket Inner Appliance Adaptor Pipe Figure 24. Attach the gasket to the Inner Adaptor Inner Adaptor 1/4-20 x 3/8" Phillips screws Vent Gasket Restrictor Plate ~ See Figs. 7 and 9. Page 6- 7 Inner Flue Collar Figure 25. Secure the Inner Adaptor to the flue collar. 3 Sheet metal screws Use a stub-handle screwdriver. "~ \ Figure 26 Instail the Outer Adaptor . Complete the Vent System Install the rest of the vent system according to the manufaclurer's inslruclions included with the components. NOTE, II the heater will be inslalled parallel to the wall with minimum rear clearance (2.) use the following procedure, in conjunction with the vent manufacturer's instructions, to complete the vent connection. Be sure to follow the venting guidelines in the Installation section and Appendix A of Ihis manual as well as those specified by the vent manufacturer. Standard Parallel Installation (min. rear clearance) 1. Cut the opening Determine the location and cut and frame an 8 5/8" x 8 5/8 square hole in the wall. Be sure that the exterior and interior cutouts are level with each other. 2, Trim the Straps. Install the Vinyl Siding Stand-off it applicable. Position the Horizontal Venl Cap wilhin the opening on the outside wall and temporarily secure it in place with one of the wood screws provided. Mark and trim each of the mounting straps to extend no more than 2 1/4. (55mm) beyond the interior wall. See Flg.27. Remove the Venl Cap from Ihe outside wall. 3. Drill Wall Thimble. With the stove installed at minimum clearance, insufficient room exists to back Ihe wall thimble away from the cutout 10 allow access for allaching Ihe vent cap mounting slraps. Before assembly, dnll one 9/16" dla. access hole through the side of the thimble near Ihe seam to allow allachment of Ihe straps. Fig.28. 4. Locate the Stove. Position the slove wittl vent assembly (including appliance adaptor, elbow, slraight section and wall thimble) in Ihe final location. Be sure to center the straight pipe section within the wall cutout. 5. Install the Vent Cap. Run a bead of non- hardening mastic to seal around the outside edge of the Honzontal Venl Cap. The arrow on the vent cap stlould point UP. Position the cap in the center of the hole on Ille outside wall, making cerlaln that the cap and pipe mate properly. Also, be sure thaI tile mount- ing slraps are visible through the wall thimble access hole_ Secure the Vent Cap to the wall with the wood screws provided. 6. Secure the Straps. Ilotate 1I1e Wall Ttlimble mound lI)e elbow to provide access to secure the two mounting stmps to the straight vent pipe. Allach the straps willl the sheet melal screws supplied with Ihe Vent Cop. Fig. 29. 7. Secure the Wall Thimble. Rotate tile IIlimble to 111Cle the access hole. Secure tile thimble plate to the interior wall uSIng the lour screws provided. Horizontal Vent Cap Exterior Wall - . -- Interior Wall ~~~ m~ 21/4. _ (55 mm) Trim Figure 27. Trim the mounting straps. Wall Thimble Plate 9/16- dia. Access Hole 13 Mounting Strap Figure 28. Drill oul the walllhimble access hole. Seal around the entire edge of the Vent Cap 811t(JJ.<~ ----- 8llUU<- ----. 1 1/4' (30mm) -j u/ Secure Cap and Thimble to walls II II I I Figure 29 Secure tile straps 10 the vent. Wall Thimble Secure straps through Access Hole ~""'I\I B 11 Install the Log Set 1. The logs are pre-assembled and install as a unit. Center the Log Set on the burner behind the cast iron tabs. The Logs must set tight against the top of the burner plate. Fig 30. 2. Position the glass and frame against the firebox and hold it in piace with one hand against the top center of the frame. The bottom of the frame will be sup- ported by the iron ledge. Adjust the glass as needed so that il contacts the gasket evenly ail around. In the parts bag, find the 9 1/4-20 x 5/8" screws needed. Instail and turn them so that they are only finger tight. 3. To avoid uneven pressure on the glass when tighten- ing the screws, tighten them alternately, one half-turn at a time, until they are all snug. Fig. 31. Tighten the screws only by hand, and do not over-tighten. Do not use power lools. Over-tightening can break the glass. Figure 30. Align the Logset wilh the screws on the burner pIa/e. Figure 31. Tigh/en the screws in an alternating se- quence. Install the Front and Top Plates 1. Grasp the Front Plate by the window bars and lift it into position engaging the two steel tabs behind the adja- cent bosses in the Side Plates. Fig. 32. Then seat the Front against the sides so that the tabs at the bottom lip engage wilh the notches in the stove legs. When properly installed. lhe bottom of the Front Plate cannol be pulled away from the sides without also lifting it . NOTE. Be sure that the steel safety swilch relay cable is positioned over the Heat Exchanger door on top of the firebox. See Figs. 32 and 40a. 2. Place the Top Plate over the sides and front. The upper edge of lhe side plates should seat into lhe channel in the underside of the Top. Fig. 33. F=9 Engage stssl tabs behind the CBst Iron bosses. Control Door Bottom Tabs engage nolch In the leg. Figure 32. InstaH the Front Plate. Figure 33. Ins/aH the Top Plate. Burner Conversion I I The DV25 Gas Bumer 2642 Is shipped config- ured to bum Natural Gas only. The DV25 Gas Bumer 2643 Is shipped config- ured to bum Propane only. The label on the front of the stove Indicates which fuel the bumer Is configured to use. If conversion for use of either altem_tlve gas Is necessary It should be done at this time, before connecting the gas supply line. Conversion should be made only by a quallfted service technician following the Instructions supplied with the Kit. To convert from Natural Gas to Propane, use only LP Conversion Kit .2659 with this stove. To convert from Propane to Natural Gas, use only NG Conversion Kit .2658 with this stove. WARNING THE CONVERSION KIT SHALL BE INSTALLED BY A QUALIFIED SERVICE AGENCY IN ACCOR- DANCE WITH THE MANUFACTURER'S INSTRUC- TIONS AND ALL APPLICABLE CODES AND REQUIREMENTS OF THE AUTHORITY HAVING JURISDICTION. IF THE INFORMATION IN THE INSTRUCTIONS IS NOT FOLLOWED EXACTLY, A FIRE, EXPLOSION, OR PRODUCTION OF CARBON MONOXIDE MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE. THE QUALIFIED SERVICE AGENCY PERFORMING THIS WORK ASSUMES RESPONSIBILITY FOR THE PROPER CONVERSION OF THIS APPLIANCE WITH THE KIT. Safety Switch I I This heater Is equipped with a safety switch which will prevent bumer operation If the relay pin becomes disengaged for any reason. Check that the relay pin Is In place before attempting to operate the heater. See Fig. 40, Page 19. Also, confirm that the switch body has not been damaged In transit. It should not be bent. If the relay pin has become disengaged during transit or installation, follow the reset procedure outlined on Page 19. " the r.'av DIn become. d'.enaaoed durin a norma' DD.ratlon. DO NOT attema' to ,..lnsf.II 'h. aln. Tum oN the aas SUDD'V and call vaur 'oca' dea'.r lor a..lstance. 15 Connect the Gas Supply Check the rating plate on the cable under the valve to confirm that you have the appropriate burner for the type of fuel to be used. CAUTION THIS APPLIANCE SHOULD BE CONNECTED TO THE GAS SUPPLY ONLY BY A QUALIFIED GAS SERVICE TECHNICIAN. FOllOW All lOCAL CODES. The DV25 Heater and its individual shutoff valve must be disconnected from the gas supply piping during any pressure testing of that system altest pressures in excess of 1/2 psig (3.5 kPa). The DV25 Heater must be isolated from the gas supply piping system by ciosing its individual manual shutoff valve during any pressure testing of the gas supply piping syslem attest pressures equal to or less Ihan 112 psig. 1. Connect the main Gas Supply to the control valve inlet. Fig.34. A 1/8-inch N.P.T. plugged tapping, accessible for lest gauge connection, must be installed on the inlet gas connection. 2. Test for leaks at all joints before operating. This completes assembly procedures for the DV25 Gas Heater. CAUTION THERE MUST BE A GAS SHUTOFF BETWEEN THE STOVE AND THE SUPPLY. With Natural Gas, use a 3/8' or 1/2' natural gas supply line with an input of 25,000 STUs at a manifold pressure of 3.5' and minimum inlet supply for adjustment of 5.0' W.C. With Propane, use a 3/8' or 1/2' propane gas supply line with an input of 25,000 STUs at a manifold pressure of 10.0' and minimum inlet supply for adjustment of 11.0' W.C. Gas Supply Inlet Figure 34. The gas supply line connects to the inlet to the lelt of the control valve. 16 Operation Your First Fire Read these instructions carefully and familiarize yourself with the burner controls shown in Figs. 35 and 36. Locate the Pilot assernbly, Fig. 37. Follow the lighting instructions on Page 17 exactly. During the first fire, it is not unusual to smell some odor associated with new logs, paint and metal being heated. Odors should dissipate within an hour or so, however, you can open a window to provide fresh air 10 alleviate the condition. & CAUTION If the entire burner Is not lit within five (5) seconds of turning the switch ON, immediately push the switch OFF. Allow 5 minutes for gas to dissipate and repeat from Step 5. If unsuccessful again, completely turn off all gas to the heater and call your local gas service technician. Pilot and Burner Inspection Each time you light your heater check that the pilot flame and burner flame pattern are as shown in Fig. 37 or Fig. 38. If flame patterns are incorrect, turn the heater off. Contact your dealer or a qualified gas technician for assistance. Do not operate the heater unlilthe pilot flame is correct. Follow regular maintenance procedures as described on Page 18. 3-Way Switch Settings ON: Continuous burning. OFF: Gas is shut off. T'STAT: Gas flow to burner is coni rolled by external thermostat setling. [m::0 ~' --- Figure 35. 3.way Control Switch Gas Control Knob ---- Pieza Ignitor Figure 36. Valve Controls and Ignitor. "'-._-_.~........ ___L Figure 37. Pilot Assembly location and flame pattern. ~I .U\ Figure 38. Correct burner flame pattern. - 17 FOR YOUR SAFETY READ BEFORE LIGHTING - WARNING: IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY, A RRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY, OR LOSS OF UFE. A. This appliance has a pilot. When lighting the pilot, follow these instructions exactly. B. BEFORE OPERATING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. WHAT TO DO IF YOU SMELL GAS o Do not try to light any gas appliance. o Do not touch any electric switch; do not use any phone in your building. o Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instruc- tions. o If you cannot reach your gas supplier, call the fire department. C. Use only your hand to turn the gas control knob. Never use tools. If the knob will not turn by hand, don't try to repair it. Call a qualified service technician. Force or attempted repair may result in a fire or explosion. D. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control that has been under water. 1. STOPI Read the safety information above on this label. 2. Turn off all electric power to the appliance. 3. Turn the thermostat to the lowest setting, (if applicable). 4. Place the OFF/ONIT'STAT switch in the OFF position. 5. Push in gas control knob slightly and turn Clockwise~to "OFF." NOTE: Knob cannot be turned from "PILOT" to "OFF" unless knob is pushed in slightly. Do not force. 6. Wait five (5) minutes to clear out any gas. If you then smell gas, STOPI Follow "B" in the safety information above on this label. If you don't smell gas, go to the next step. 7. Turn knob on gas control counterclockwise~ to "PILOT." 8. Find pilot. The pilot Is located below the logset in the forward lower right area of the firebox. 9. Push in control knob all the way and hold in. Immediately light the pilot by pushing the red ignitor button. Continue to hold the control knob in for about one (1) minute after the pilot is lit. Release knob and it will pop back up. Pilot should remain lit. If it goes out, repeat steps 5 through 9. o If knob does not pop up when released, stop and immediately call your servi<:e technician or gas supplier. o If the pilot will not stay lit after several tries, turn the gas control knob to "OFF" and call your service technician or gas supplier. 10. Turn gas control knob counterclockwise~ to "ON." 11. Place the OFF/ONIT'STAT switch in the ON orT'STATposition. 12. Turn on all electric power to the appliance. LIGHTING INSTRUCTIONS TO TURN OFF GAS TO APPLIANCE Conlrol + Knob Pilot Assembly 1. Turn off all electric power to the appliance if service is to be performed. 2. Push in gas control knob slightly and turn clockwise ~ to "OFF." NOTE: Knob cannot be turned from "PILOT" to "OFF" unless knob is pushed in slightly. Do not force. 18 Maintenance . Your DV25 Gas Heater will provide years of service with minimal upkeep. The following procedures will help ensure that your stove continues to function properly. Annual System Inspection Have the entire heater and venting system inspected annually by a qualified gas technician. Repiace any worn or broken parts. Logset and Bumer I Cleaning and Inspection Cleanliness is critical to the proper function of the heater. The log set and burner must all be kept free of dust and unobslructed by debris. Inspect these areas before each use and clean as necessary. 1. Turn the burner OFF and lei the heater cool com- pletely before cleaning. 2. Remove the Top plate. 3. Lift the Front Plate up and then swing the bollom out to disengage it from the heater shell. 4. The glass panel and frame must be removed to gain access to the firebox and log set. . Use a Phillips screwdriver to first alternately loosen and then remove the twelve screws that hold the glass frame to the stove. Follow the pattem shown In Fig. 39. Uneven pressure can break the glass. . Carefully remove the glass and frame assembly and place it out of the way on a flat, padded surface such as a counter protected by a towel. Disengage the side clips 10 remove the screen from Ihe Firebox. 5. Carefully inspect the Logset for damage. Contact your local dealer if any damage is evident. DO NOT OPERATE THE HEATER WITH A DAMAGED LOGSET. Use a soft bristled brush to sweep dust or debris from the Logsel. Pilot and Burner. Use care as the Logset is fragile and susceptible to damage. DO NOT USE A VACUUM TO CLEAN THE LOG SET OR BURNER. 8. Replace the Glass panel and frame. Allernalely tighten the screws in the same pattern as was followed in removing them. 00 not use power toots, and do not over-tighten the screws. Over-tightening can break the glass. 7. Replace the Fronl and Top Plates. Figure 39. Remove the glass frame screws in an alternating pattern. Care of Cast Iron An occasional dusting with a dry rag will help keep the painted surfaces looking new. Use high-temperature stove paints, available through your local dealer, to touch-up areas as needed. Clean areas to be painted with a wire brush and be sure to cover the Logset, Burner and Valve assembly. Apply the paint sparingly; two light coats of paint will give beller results than a single heavy coat. 8::::, WARNING TURN THE PILOT OFF BEFORE PAINTING ALLOW THE HEATER TO COOL COMPLETELY BEFORE PAINTING. Porcelain enamet surfaces should be cleaned with a soft, damp cloth. Do not use abrasive cleaning agents. If necessary, use only a cleaning agent formulated specifi- cally for use on porcelain enamel surfaces. Cleaning the Glass Glass should be cleaned only with a soft, damp cloth. Do not use abrasive cleaning agents. WARNING, Let the glass cool completely before attempting to clean. Glass Replacement Replace glass only with V.C.1. ParI # 160-1691. See Fig 39. and previous instruclions for removal of the damaged glass panel. Gasket Replacement The DV25 Gas Heater uses 5/16' rope-type fiberglass gaskets to seal between the glass panel and the firebox. In time, this gasket can become brittle and compressed and should be replaced. New gasket is available trom your dealer. Shut off the gas supply and allow the stove to cool. Wear safety goggles and a dust mask. 1. Remove the Front, Glass Frame and Glass Panel as Remove the old gasket. Use a wire brush to clean the channel of any remaining cement or bits of gasket. Use a cold chisel if necessary. 2. Determine the correct length of gasket by laying it out in the channel. Allow an extra 1-2' (25-50 mm), and mark the spot to be cut. Use a utility knife. Twist the ends slightly to prevent unraveling. 3. Lay an unbroken 1/8' (3 mm) bead of gasket cement in the channel. Starting at one end, press the gasket into the channel. Ensure a good jOint where the gasket ends meet before trimming excess. Do not overlap the gasket ends or leave ends with ragged edges. 4. Press the glass frame firmly against the gasket to seat it evenly in its channel. 5. Clean excess cement from around the channel. Allow the cement to dry for at ieast 24 hours before using your stove. Safety Switch The DV25 heater is equipped with a safety switch which will prevent burner operation if the relay pin becomes disengaged from its normal position for any reason. Normally set, the pin will be engaged with the switch through the hole in the top of the switch box. If the relay pin has become disengaged during transit or installation, follow the reset procedure outlined below. Confirm that the switch box has not been bent and that the release pin and cable are free to move. " the ,slav aln become. dl..naaoad durlna norma' oD.ratlon. DO NOT aft.mat to ,a.lnstall the Din. Turn "ff the aas .U~D'V and call vaur 'Dca' de.'.r lor assIstance. It I. '".aorlan' to determine what condition caused the aln to b. ramoved. 1. Push the switch lever fully back as shown in Fig.40 and inserl the cotler pinlcable all the way through the lop and bottom of the switch box. The pin must hold the lever back to engage the switch mechanism. 2. Be sure that the switch cable is slack and positioned over the top of the Heat Exchanger Door as in Fig. 40b. 19 <> Push lever all the way back toward the rear of the stove. Figure 40. Reset the relay pin into the Safety Switch Figure 40a. Check that the switch box is not bent and that nothing can interfere with the release pin. Safety Switch Relay Pin o Switch Cable J Heat Exchanger Door Figure 40b. Switch Cable Position. 20 Burner Adjustment An air shutter, located on the burner, has been set at the factory for either Propane or Natural gas and should not require further adjustment. Installation characteristics vary, however, and adjustment may be necessary to improve flame picture or eliminate sooting. Generally, the shutter should be set open 5/16. for Natural gas and 71 16. open for Propane. Closing the shutter, (less air), produces a yellow flame, (more prone to sooting). Opening the shutter, (more air), produces a bluer flame. . After adjusting the shutter, the stove should be burned for at least one hour to see the effect of the setting change. If soot appears on the glass, logsel. or firebox, the air shutter must be opened to eliminate the condition. Adjustment should be made onl, b, a qualified gas technician. Step t. Shut ofl the gas supply to the stove. Turn off all power to the stove. Remove the Front Panel, Glass, and Log Set as described on Page 18 of the Owner's Guide. Step 2. Remove the two Burner retainer screws. Lifting the back of the Burner, slide it to the rear and lift it out of the firebox to access the air shutter on the end of the J- tube. Fig. 41. Step 3. Loosen the shutter locking screw enough to adjust the setting as needed and re-tighten. Fig. 42. Step 4. Set the burner back into the firebox taking care to ensure that the end of the J-tube fully engages and aligns with the injector, Fig. 43. Step 5. Replace the retainer screws, log set, glass, and Front Panel. Figure 41. Remove the burner retainer screws. For Natural Gas For Propane Figure 42. Air Shutter Settings. o 0 o -\- -- o I 0 o ---- ~ / '\ 0 J-tube i ./ J ~tor >~- --=-~-o __U -I ." Figure 43. Align the J-tube with the injector. Parts List DV25 FIREBOX #2642 (NO) AND #2643 (LP) 21 For replacement parts, or for information about parts or service. contact your local dealer. For the name of the dealer nearest you, call or write: The Majestic Products Corp. 1000 E. Market SI. Huntington, In. 46750-2579 1-800-227-8683 1. Firebox Assembly 1 NG FireboxAssembly 1 LP 2. Rear Shroud 3. Top Cover, Shroud 4, End, Left 5. End, Right 6. TopPlate 7. Front Plate 8. Hinge, Control Door 9. Control Door 10. Top Heat Shield 11. Tab,Steel 12. 1/4-20x3/8'PhillipsScrew 13. 1/4-20xl/2' Hex Head Screw 000-2642 000-2643 500-2968 140-8881 130-1085 130-1086 130-1102 130-1084 160-1670 130-1087 140-8868 160-1488 120-0993 120-1338 14. Washer, Wingbolt 15. Washer 16. FenderWasher 17. 1/4-20Wingbolt 18. Snap Ring 19. Levelling Bolt 20, Glass 21. Gas Log Set 22. Door, Heat Exchanger 23. Air Passage 24, Firebox Baffle 25. Firebox 26. Flue Outlet 27. Gasket. Flue Pipe 28. Flue Restrictor Plate 29. Gasket, Glass Panel 30. Frame, Glass Panel 31. Bottom Heat Shield 32. Safety Switch Assy II 33. OFF/ON Switch 34. Gasket. Heat Exchanger 35. Gasket, Firebox ~~ C'?-Y ~ ..~ ~-- '--------G? I -~- <r_~~J ------.- -'- ~ .. t0v' c---=: 3 r'---- 8 (~ ["- ---- _~ iJP ~~ I _-.... j II fr---...;;" ~C-.L (,2) .~-~ ~~ @ ~~ ~- l!l ('! -', 8 ("I 0;Jv~ (1." (I'!)."" fi. I & Q ~~ rw ~,-----~ ~.... )}~-./ If f .~ \ I ' ; liJ (1~ I @ 30 ~- ~ '1";.- I //" (~(- Y . 'y/ Figure 44. Illustrated Parts 120-2470 120-2474 120-2527 120-3110 120-1987 120,1745 160-1691 500-2964 130-1095 130-1097 130-1099 130-1100 130-1101 120-3686 140-8869 700-0909 140-8865 140-8822 500-3000 160-1597 120-3689 120-3588 11[' ( ~J ,... (18) 22 Wiring Diagrams rigure 45. DV25 Firebox CirCllit Figure 46 DV25! Convection Fall Circuit Y'SYAY OFF ON TP ~TERtqcK , ' , , . REO'uumm' RED THfTP w '~ID~--~~@' 1-, - , , ~/ /THERMOSTAT , w -' Cl. o ::!: a: w I I- TH GAS VALVE BLACK NOTE: IF ANY OF THE ORIGINAL WIRE, AS SUPPLIED WITH THE APPLIANCE, MUST BE REPLACED, IT MUST BE REPLACED WITH TYPE SF-2, 200'C WIRE OR ITS EQUIVALENT. Screw Identification Chart I" I . ~:~ 1iS~ 5/B" --;-~ :::..:, (k:;; '("I:-, Phillips" 10 Phillips sheet metal 1/4-20 Phillips # 1 0 sheet metal Phillips 1/4-20 rigur" 47. POWER CORD FAN FAN JUNCTION BOX r--------------, I , , , , I BLK I T BLK t----mmmo. Strain Relief --..----- , , , , I , , I I QfII/QFF Rheos18' (3 , , ~ ... - _s~ae0'!a~ .' '. I , " , " W ". .,: I i""" .. - ..-' . Chassis Ground RHEOSTAT t SNAPSTAT _ BOX CONNECTION DIAGRAM L1 I SNAPSTAT ,--------, I I I I BlK WHT GRN ":" SCHEMATIC DIAGRAM Appendix A FiSHYC 48. Venting Terminal CletlrtHlCcS _:::--- f A ~i0J4 C{ ~ Key F,l 9" U.S. only A,B,C,E,F,I,J 12"/JOcm D 18"/46cm H,L 1'/9001\ G,M 6'/1.8m K 7'/2.lm l / ~ ~ ~ -~"r </ J ~ r-1 ~./~./ -t ]'"'''''-l- I " /J '; \ t< l> ./ // .~ ~ ~/ ~ <<~">//> ... __L_~ __________ "I'; , / l'>' A. Clearance to a non~ll1cchanical air supply inlet or comhustion air inlet of any mhcr appliance. It Clearance under a deck, porch, veranda or halcony. Must he fully open on a minimum of two sides beneath the floor. ...,~ /.... '':::C\ ...~) C. Clearance ahove grade, deck, porch, veranda or halcony. n. Clearance to a ventilated soffit located above the terminal within a horizontal distance of 2 feet (60 em) from the center line of the terminal. E. Clearance to an adjaccnr wall (inside (orner). F. Clearance to a permanently closed window. n. Clearance around a service regulator vent outlet. II. Clearance arollnd a center line ahove service regulator. I. Clearance to a door or window lhat may he opened. I. Clearance to a non~ventilated soffir. K. Clearance ahove a paved sidewalk or driveway Dn puhlic property. May not terminate ahDve a sidewalk or driveway which is hetween two singlc~family dwellings and serves hoth dwdlings. L Clearance to vegetal ion. M. Clearance to a mechanical air supply. NlJtc: All clearances (IS slll:cibd III !he Niltwlla! Fld (JUS COLk,1992 wul CAN J BI-/4lJ Imwlbwm (:otll'\ Lond (()de~ or l'egHbljum Illay rel/lme l110lc ~mngelll clearances ~~~ k ~ ) J 2.J \ Troubleshooting Follow these procedures in the order presented, & WARNING TURN OFF HEATER AND ALLOW TO COOL COMPLETELY BEFORE SERVICING. CONDITION POSSIBLE CAUSE 24 SOLUTION No spark at pilot when Ignitor button Is pressed. 1, Ignition Electrode is discon- nected from ignition wire, broken, or incorrectly posi- tioned, 2, Piezo Ignitor nut is loose, 3, Bad Piezo Ignitor. 1, Inspect and re-connect, replace or repair as necessary, 2, Tighten the nut to establish secure contact to the valve bracket. See Fig, 48. 3, Replace Piezo Ignitor. The Ignitor Electrode sparks, but Pilot does not light. 1, Gas supply is turned off or supply line shut-off valve is closed, 2, Control Knob is not in PILOT position, 3, Control Knob not pressed in while in PILOT position, 4, Air present in gas lines, 5, Inlet supply pressure is not within correct settings. 6, Other conditions that should be identified only by a quali- fied gas technician, 1, Turn on gas supply or open supply line shut-off valve, 2, Turn Control Knob to PILOT. 3, Press Control Knob in while in the PILOT position, 4, Continue holding in Control Knob and repeat ignition procedure until air is bled from the lines, 5, Call local gas supplier. Adjust inlet supply pressure to specifi- cation: Natural Gas: 5' W,C, - 11' W,C, Propane: 11.0- 13.0'W,C, 6. Call qualified gas technician, Figure 48, DV25 Control Valve Assembly. Gas LIne from supply _______ r: Control Knob Gas LIne to Pilot Control Valve Body Thermostat or On/Offl Tstat switch wires (top and bottom terminals) Thermocouple wires (middle and bottom terminals) CONDITION POSSIBLE CAUSE 25 SOLUTION Pilot light. but flame goes out when Control Knob I. relea.ed. Thermocouple Pilot flame Is weak - does not touch Thermocouple. Figure 49. Incorrect Pilot Flame Figure 50. Correetpilot lIame. 1. Control Knob not fully de- pressed or held in long enough. 2. Gas supply line shut-off valve is not fully open. 3. Thermocouple connection is loose at the Control Valve. See Fig. 48. 4. Pilot flame does not touch the Thermocouple. Fig. 49. This can be caused by: A) Incor- rect gas pressure, and / or B) other conditions that should be identified only by a quali- fied service technician. 5. Thermocouple is damaged. 6. Control Valve is damaged. 1. Depress Control Knob fully and hold in for a lull 30 seconds. 2. Fully open gas supply line shut-oil valve. 3. Inspect and tighten securely. 4. A) Contact the local gas company. Inlet supply pres- sure should be between 5' W.C. and 11"W.C. for NG or 11' W.C.- 13' W.C for LP. Adjust as necessary. B) Call local gas service technician. 5. Call local gas service techni- cian. 6. Call local gas service techni- cian. Pilot light. but Main Burner doe. not. 1. Gas supply line shut-off valve is not fully open. 2. Foreign material is blocking Burner ports. 3. Main Burner orifice is clogged. 4. If unit is wired to a thermostat, the thermostat is not calling for heat. 1 . Fully open gas supply line shut-off valve. 2. Inspect and clear debris away from Burner ports. 3. Call local gas service techni- cian. 4. Turn On/OIlIT-stat switch 10 'On', or turn up thermostat. Main Burner .hut. 0" and Pilot flame goes out while In operation. 1. Incorrect inlet supply pressure. 1. Contact the local gas com- pany. Inlet supply pressure should be between 5' WC. and 11'W.C. for NG or 11' W.C.- 13' W.C for LP. Adjust as necessary.