Encore®

Non-Catalytic / Catalytic
Woodburning Stove
Model 2040

Homeowner’s Installation
and Operating Manual

For use in the
United States and Canada
Safety Notice: If this appliance is not properly installed, operated and2425
maintained, a house fire may result.
EncoreNCto
Cover
To reduce the risk of fire, follow the installation instructions.
Failurefollow instructions may result in property damage, bodily injury
5/05or evendeath. Contact local building officials about restrictions and installation
inspection requirements in your area.

Do Not Discard This Manual: Retain for Future Use
30005295 5/11 Rev. 7

Nous recommandons que nos appareils de chauffage
au bois soient installés et entretenus apr desprofessionnels qui ont été accrédités aux É.-U. par le
National Fireplace Institute® (NFI) comme étant desspécialistes du NFI en matière d’appareilsde chauffage

Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove

WelcomeCongratulations on your choice of a Vermont Castings Encore stove. With this purchase you have made a commitment to make the hearth a place of warmth, beauty and comfort in your home. At MHSC, 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 careand will provide you with many years of service.
As you become acquainted with your new stove, you will find that its appearance is matched by its functionality, due tocast iron’s unique ability to absorb and radiate heat.
Also, MHSC products are among the cleanest-burning wood stoves and fireplaces available today. As an owner of a
Vermont Castings stove, you make a strong statement for pollution-free energy. However, clean burning depends on
both the manufacturer and the operator. Please read this manual carefully to understand how to properly operate andmaintain your stove.
At MHSC, we are equally committed to your satisfaction as a customer. That is why we maintain an exclusive networkof the finest dealers in the industry. Our dealers are chosen for their expertise and dedication to customer service.
They are factory-trained and knowledgeable about every MHSC product. Feel free to contact your Authorized Vermont
Castings Dealer anytime you have a particular question about your stove or its performance.
This manual contains valuable instructions on the installation and operation of your Vermont Castings Encore. It also
contains useful information on maintenance. Please read the manual thoroughly and keep it as a reference.
Sincerely,

All of Us at MHSCThis manual describes the installation, operation, andmaintenance of the Vermont Castings Encore Model
2040 Non-Catalytic / Catalytic wood burning heater. This
heater meets the U.S. Environmental Protection Agency’s emission limits for wood heaters sold on or after July
1, 1990. Under specific test conditions this heater has
been shown to deliver heat at rates ranging from 9,900
to 34,000 Btu/hr.
The Encore Model #2040 has been tested and is listed
by OMNI-Test Laboratories of Portland, Oregon. The test
standards are ANSI/UL-1482 and ANSI/UL-737 for theUnited States, and ULC S627 for Canada. The Encore
is listed for burning wood only. Do not burn other fuels.
We recommend that you hire a professional installer
certified by the Wood Heat Education and Research
Foundation (WHERF) or the Wood Energy TechnicalTraining (WETT) to install your stove, or to advise you on
the installation should you attempt to install it yourself.
Please read this entire manual before you install and use
your new stove. Failure to follow instructions may resultin property damage, bodily injury, or even death.
The Encore 2N1 is approved for use in mobile homes in
the United States and Canada when installed with Vermont Castings Mobile Home Kit. Refer to and follow the
instructions provided with the Mobile Home Kit (#0336_
to ensure safe installation.
Proposition 65 Warning: Fuels used in gas, woodburning or oil fired appliances, and the products of combustion of such fuels, contain chemicals known to the Stateof California to cause cancer, birth defects and otherreproductive harm.
California Health & Safety Code Sec. 25249.6


Table of Contents

Specifications.........................................................3
Installation..............................................................4
Clearance Charts.................................................12
Mobile Home Installation......................................16
Assembly..............................................................17
Operation..............................................................20
Draft Management................................................26
Maintenance.........................................................29
The Catalytic Element..........................................33
Replacement Parts...............................................35
Warranty...............................................................39

Installation Accessories
Warming Shelf#0200 Classic Black#0205 Biscuit#0207 Ebony#0201 Bordeaux#0208 Brown Majolica		
#3265* Outside Air Kit#3185 Outside Air Adapter#0336* Mobile Home Kit#0127 Firescreen
FK26 Fan Kit#3190 Connector Pipe Heat Shield
A line of porcelain enamel stove pipe is available in
Biscuit, Bordeaux, Ebony, Brown Majolica colors.
*If you order #3265 or #0336, you must also need
#3185.

Save These Instructions for Future Reference
30005295

Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove

Specifications

Encore, Model 2040

EPA Emissions rating - Noncatalytic................. 1.6 g/hr*
Range of heat output - Noncatalytic........9,900 - 34,000
EPA Emissions rating - Catalytic ..................... 1.1 g/hr*
Range of heat output Catalytic..........................11,800 to 30,000 BTU/hr.*
Peak heat output................................. 65,000 BTU/hr.**Area heated..........................Up to 1,800 Square feet***Fuel length.................................................................22”
Fuel capacity............................... 50 pounds, hardwood
Loading......................................................Front and top
Chimney Connector:
for 6” flue collar..................... 6” (152 mm) diameterfor 8” oval flue collar.............. 8” (203 mm) diameter
Chimney Flue Size:with 8” Chimney Connector...8” (203 mm) minimum
with 6” Chimney Connector...6” (152 mm) minimum
Flue exit position......................................... Top or Rear
Primary Air....... Manually Set, Thermostatically Maintained
Secondary Air................................Fixed, self-regulating
Ash handling system...................... Removable ash pan
Glass panels......................... High-temperature ceramic
Weight................................................ 475 lbs. (215 kg.)
Width (leg to leg)...................................... 27” (686 mm)
Depth (leg to leg)...................................... 15” (381 mm)
Height to top of flue collar......................... 25” (635 mm)*Under specific conditions during EPA emissions testing.
** This value can vary depending on how the stoveis operated, the type and moisture content of the fuelused, as well as the design, construction and climatic
location of your home. Figures shown are based on
maximum fuel consumption rates obtained under laboratory conditions and on average 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 nonstandard 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 performance
consult your Authorized Dealer to determine realistic
expectations for your home.

Drawing Not to Scale

226M"(578 mm)

36M"(95 mm)

16M"(44 mm)27"(686 mm)
1856O"(470 mm)

2256M"(565 mm)
1556O"(394 mm)25"(635 mm)
Top exit
flue collar
height256M"(654 mm)5"(127 mm)2(6 " (73 mm)
236M"(603 mm)

756M"(184 mm)27"(686 mm)15"(381 mm)Fig. 1 Encore 2040 dimensions.

30005295
Encore 2N1
dimensions

Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove

Installation
safety NOTICE: IF YOUR Encore IS NOT PROPERLY INSTALLED, A HOUSE FIRE MAY RESULT.
TO REDUCE THE RISK OF FIRE, FOLLOW THE
INSTALLATION INSTRUCTIONS. CONTACT LOCALBUILDING 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 constructed properly to meet all requirements.
• You have all necessary permits from local authorities.
WARNING: Do not install in sleeping room.
Your local building official is the final authority for approving your installation as safe and determining that itmeets local and state codes.
The metal label permanently attached to the back ofevery Vermont Castings’ stove indicates that the stove
has been tested to current UL and ULC standards, andgives 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 Installation
Code for Solid Fuel Burning Appliances and Equipment.
These standards are the basis for many national codes.
They are nationally recognized and are accepted bymost local authorities. Your local dealer or your local
building official may have a copy of these regulations.
Important: 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 may beinadequate air supply for combustion because of insufficient air infiltration into the building. Such air enters ahome through unsealed cracks and openings. Exhaustfans in kitchens or bathrooms can compete with thestove for available air and compound the problem.
When poor draft is caused by a low infiltration rate,
opening a ground floor window on the windward side of
the house and near the stove will usually alleviate theproblem.
A better solution is to install a permanent outside air
supply to the stove and/or room. In fact, bringing air
for combustion from outside the home directly to the
air inlet of the stove is required for new construction insome areas.
Pressure variations within the house do not affect astove equipped with an outside air supply, and improved stove performance often results. An Outside Air
Kit for the Encore is available from your local dealer.

What Kind of Chimney to Use
You must connect the Encore to a code-approved
masonry chimney with a flue liner, to a relined masonrychimney that meets local codes, or to a prefabricatedmetal chimney that complies with the requirements
for Type HT chimneys in the Standard for Chimneys,
Factory-Built, Residential Type and Building Heating
Appliance, UL 103. Figure 2 illustrates the two types.
The chimney and chimney connector must be in goodcondition and kept clean.
A prefabricated doublewall insulated chimney

A tile-lined
masonrychimney

ST241

Fig. 2 Approved chimney types.

ST241
chimney types
12/13/99 djt

30005295

Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
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 tosomeone who can.
The chimney must extend at least 3’ (914 mm) above
the highest point where it passes through or near aroof, and at least 2’ (610 mm) higher than any part of abuilding within 10’ (3 m) horizontally. (Fig. 3)
For proper draft and good performance, any chimneyused with a Encore should extend at least 16’ (5 m)above the flue collar of the stove.
0 To 10'
2' Min.

3'Min.

0 To 10'
2' Min.

3'
Min.

Reference
Point

A prefabricated metal chimney must be one tested andlisted for use with solid-fuel burning appliances to theHigh-Temperature (H.T.) Chimney Standard UL-1031985 (2100°F) for the United States, and High Temperature (650°C) Standard ULC S-629 for Canada.
DO NOT CONNECT THIS UNIT TO A CHIMNEY FLUESERVING ANOTHER APPLIANCE.

Chimney Size
An Encore with an 8” (203 mm) flue collar is approvedfor venting into a masonry chimney with a nominal flue
size of 8” x 8” (203 x 203 mm) or 8” x 12” (203 x 305mm), and into a round flue with nominal flue size of 8”(203 mm). An Encore with a 6” (152 mm) flue connector
is approved for venting into a masonry chimney with anominal flue size of 8” x 8” (203 x 203 mm), and into around flue with nominal flue of 6” (152 mm).
NOTE: When installed with a 6” flue collar, theEncore may not be operated with the front doors
open.

AC617

Fig. 3 The 2’-3’10’ Chimney Rule.
AC617Chimneys
Masonry
RLTSKC8

2/11/98 must confirm that it has
An inspection of the chimney
a lining. Do not use an unlined chimney. The chimney
should have no cracks, loose mortar, other signs ofdeterioration, and blockage. Repair any defects before
the chimney is used with your stove.

Unused openings in an existing masonry chimney must
be sealed with masonry to the thickness of the chimneywall, and the chimney liner should be repaired. Openings sealed with pie plates or wallpaper are a hazard
and should be sealed with mortar or refractory cement.
In the event of a chimney fire, flames and smoke may
be forced out of these unused thimbles.
The chimney should be thoroughly cleaned before use.
A newly-built masonry chimney must conform to thestandards of your local building code or, in the absenceof a local code, to a recognized national code. Masonrychimneys 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, causing performance problems.

30005295

Prefabricated Chimneys

Whatever the flue collar size, an Encore may be vented
into larger chimneys as well. However, chimneys
with liners larger than 8” x 12” (203 x 305 mm) may
experience rapid cooling of smoke and reduction indraft, especially if the chimneys are located outside thehome. These large chimneys may need to be insulatedor have their flues relined for proper stove performance.
Accessories to help make the connection between
stainless steel chimney liners and your Encore areavailable 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 themasonry or prefabricated structure that encloses theflue. Chimney connectors are used only to connect thestove to the chimney.
Single-wall connectors should be made of 24 gaugeor heavier steel. Do not use galvanized connector; itcannot withstand the high temperatures that can bereached by smoke and exhaust gases, and may release toxic fumes under high heat. The connector may
be 6” (152 mm) or 8 “ (203 mm) in diameter.
If possible, do not pass the chimney connector througha 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 wholeconnector should be exposed and accessible for inspection and cleaning.

Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
In horizontal runs of un shielded chimney connector,
maintain a distance of 30” (762 mm) from the ceiling.
Keep it as short and direct as possible, with no morethan two 90° turns. Slope horizontal runs of connector
upward 1/4” per foot (6mm per meter) going from thestove toward the chimney. The recommended maximum length of a horizontal run is 3’ (1 m), and the total
length should be no longer than 8’ (2.4 m). In cathedral
ceiling installations, extend the prefabricated chimney
downward to within 8’ (2.4 m) of the stove. This will help
maintain a good draft by keeping the smoke warm, sothat it rises readily.

Chimney

Flue

Elbow

Flue Inner

Slip Pipe
ThimbleStandard
Connector
Oval toRound Adapter

Flue Collar

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
Towardstove. Insert theStovefirst crimped end
into the stove’s flue
collar, and keepeach crimped end
pointing toward
Flue Gas
the stove. (Fig. 4)
Direction
Using the holes in
the flue collar as
ST242
guides, drill 1/8” (3mm) holes in theFig. 4 Chimney connector.
bottom of the first
ST242
section of chimney connectorChimney
andsecure it to theconnector
12/13/99 djt
flue collar with three #10 x 1/2” sheet metal screws.
Lift off the griddle, and shield the stove’s surface
between the griddle opening and the front of the flue
collar to protect the finish when you drill the front
hole.
Fasten each joint between sections of chimney
connector, including telescoping joints, with at least
three (3) sheet metal screws. The pre-drilled holes inthe top of each section of chimney connector serve
as guides when you drill 1/8” (3 mm) holes in thebottom of the next section.
Fasten the chimney connector to the chimney.
Instructions for various installations follow. Figure 5
illustrates the general layout of chimney connector
parts.
Be sure the installed stove and chimney connector
are correct distances from nearby combustible materials.

NOTE: Special slip pipes and thimble sleeves that form
telescoping joints between sections of chimney connector are available to simplify installations. They often
eliminate the need to cut individual connector sections.
Consult your local dealer about these special pieces.


ST492

Fig. 5 An exploded view of the chimney connection in a freestanding masonry installation.
ST492
Defiant

freestanding Connector to a
Securing the Single-wallinstallation
PrefabricatedChimney
11/00

Follow the installation instructions of the chimney
manufacturer exactly as you install the chimney. The
manufacturer of the chimney will supply the accessories to support the chimney, either from the roof ofthe house, at the ceiling of the room where the stove isinstalled, or from an exterior wall.
Special adapters are available from your local dealer
to make the connection between the prefabricatedchimney and the chimney connector. The top of such
adapters attaches directly to the chimney or to thechimney’s ceiling support package, while the bottom of
the adapter is screwed to the chimney connector.
These adapters are designed so the top end will fit outside the inner wall of the chimney, and the bottom end
will fit inside the first section of chimney connector.

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
If the chimney connector must pass through a combustible wall to reach the chimney, follow the recommendations in the Wall Pass-Through section that follows.
The opening through the chimney wall to the flue(the “breech”) must be lined with either a ceramic or
metal cylinder, called the “thimble”, which is cemented
securely in place. Most chimney breeches incorporate
30005295

Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
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 andmost thimbles, will facilitate the removal of the chimney
connector system for inspection and cleaning. (Fig. 6)
Thimble sleeves are available from your local dealer.
To install a thimble sleeve, slide it into the breech until
it is flush with the inner flue wall. Do not extend it into
the actual flue passage, as this could interfere with thedraft.

Check These
Clearances**
Mantel
Seal
This OffThimble Sleeve
Flue
Chimney Connector
Keepsleeveend flushwith flue
tile

ST243

Fig. 6 The thimble, made of either ceramic or metal, must be
cemented securely in place.

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 theST243chimney connector
to the outer end of the sleeve withthinble connection
sheet metal screws.
12/13/99 djt
Without a thimble, a suitable length of chimney connector can be extended through the breech to the innerface of the flue liner, and cemented securely in place.
Additional pieces of connector are then attached withsheet metal screws.

Fireplace Installations
The chimney connector may be connected to thechimney above the fireplace opening or through thefireplace.

Above the Fireplace
The Encore may be connected to a chimney abovea fireplace opening. (Fig. 7) In such installations, thestove is positioned on the hearth in front of the fireplace
and the chimney connector rises from the stove top andthen angles ninety degrees back into the chimney. The
chimney liner should extend to the point at which thechimney connector enters the chimney.
If the chimney connector in your installation enters thechimney above a fireplace, follow all the guidelines
mentioned above for freestanding installations. In addition, give special consideration to the following points:
30005295

ST244

Fig. 7 In this installation, the chimney connector attaches tothe chimney above the fireplace opening.

• Check the clearance between the mantel and theST244chimney connector,
and any combustible trim or the
Plymouthmantel.
fplc over mantel
12/99between the chimney connec• Check the clearance
tor and the ceiling. The clearance should be at least30” (762 mm) with unshielded connectors. Consult
the clearance charts for other installation options.
• The fireplace damper must be sealed to preventroom air from escaping up the flue. However, it
must be possible to re-open the damper to inspect
or clean the chimney.

Through the Fireplace
If your fireplace opening height is at least 29" (737 mm),you may install a Encore through the opening using a“positive connection” kit, available from your local dealer. Positive connection kits ensure a tight fit between
the stove flue collar and the chimney flue. (Fig. 8)
Fireplace installations, whether connected to the flue
above or through the fireplace opening, have special
clearance requirements to adjacent trim and the mantel. You’ll find the required safe clearances for Encore
fireplace installations on Page 12.
Floor protection requirements also apply to fireplaceinstallations. This information is on Page 9.

Wall Pass-Throughs
Whenever possible, design your installation so 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.
Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove

Flexible
Connector

Mantel Shield
Fireplace Adapter Kit“Positive Connection”

ST245

Fig. 8 Through the fireplace installation.

Accessories are available for use as wall passthroughs. If using one of these, make sure it has beentested and listed for use
as a wall pass-through.
ST245

fireplaceIn the United States, theNational Fire Protection Asflex connectorsociation (NFPA) has establishedguidelines for passing
12/99
chimney connectors through combustible walls. Manybuilding code inspectors follow these guidelines whenapproving installations.

Figure 9 shows one NFPA-recommended method. All
combustible material in the wall is cut away from thesingle-wall connector to provide the required 12” (305mm) clearance. Any material used to close up the opening must be noncombustible.

Three other methods are also approved by the NFPA:• Placing a section of chimney connector inside aventilated thimble, which in turn is separated fromcombustibles by 6” (152 mm) of fiberglass insulating material.
• Placing a section of chimney connector inside a
section of 9” (230 mm) diameter, solid-insulated,factory-built chimney, with 2” (51 mm) of air space
between the chimney section and combustibles.
• Using a section of solid-insulated double-wall hightemperature chimney, with an inside diameter thesame as the chimney connector, at least one inchof solid insulation, and a minimum of 9” (229 mm)
air space between the outer wall of the chimney
section and combustibles.
In Canada, The Canadian Standards Association has
established different guidelines for wall pass-throughs.
Figure 10 shows one method, in which all combustible
material in the wall is cut away to provide the required18” (457 mm) clearance for the connector. The resulting
space must remain empty. A flush-mounted sheet metal
cover may be used on one side only. If covers must be
used on both sides, each cover must be mounted on
noncombustible spacers at least 1” (25 mm) clear of thewall.
18” (460mm) clearance between pipe andsides/top/bottom of
opening

T
DE
FI AN

Wall Stud

Chimney
Connector

ST494

Fig. 10 An approved wall pass-through for Canada.

DE
FIA N

12” ofNoncombustible
Material

Floor Protection

ST493

Fig. 9 An approved wall pass-through for the United States.

Your local dealer or your local building inspector can
provide details for other ST494
approved methods of passing
steel a combustible wall in youra chimney connector throughwall pass thru
area. In Canada, this typeof installation must conform
11/00
to CAN/CSA-B365, Installation Code for Solid FuelBurning Appliances and Equipment.
NOTE: Do not vent your Encore into a factory-built(zero-clearance) fireplace. These appliances and theirchimneys are specifically designed as a unit for use as
fireplaces. It may void the listing or be hazardous toadapt them for any other use.
DO NOT CONNECT THE ENCORE TO ANY AIR DISTRIBUTION DUCT OR SYSTEM.
30005295

Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
Floor Protection
A tremendous amount of heat radiates from the bottom
plate of your stove. The floor area directly under andaround the stove will require protection from radiantheat as well as from stray sparks or embers that may
escape the firebox.

In Canada: A noncombustible floor protector is required
under the stove as well. The floor protector must
extend 18” (457 mm) to the front (“F”, Fig. 11), and 8”(203 mm) from the sides and rear. (“D” and “E”, Fig. 11)
To meet these requirements, a floor protector must be
at least 43” (1092 mm) wide and 49” (1245 mm) deep.

Heat protection is provided with the use of the Bottom
Heat Shield supplied with the stove.
Most installations will require the bottom heat shield
to be attached. Only when the stove is placed on acompletely noncombustible surface such as unpainted
concrete over earth may it be used without the heatshield.
Even when the bottom heat shield are installed, most
installations require special thermal protection (insulation) for the floor beneath. Use an approved 1” (25 mm)
noncombustible hearth pad with k = 0.84 BTU/in ft2 hr°F or an equivalent material with an R-value of at least
1.18. (Refer to “How to Determine if Alternate Floor
Protection Materials are Acceptable” section.) The floor
protector may be covered with a decorative noncombustible material if desired. Do not obstruct the space
under the heater.
When using a fire screen with doors open, UL737,
Standard for Fireplace Stoves, use an approved 1” (25mm) noncombustible hearth pad with k = 0.84 Btu/in
ft2 hr °F or an equivalent material with an R-value ofat least 1.18. (Refer to “How to Determine if alternate
Floor Protection Materials are Acceptable” section.)
The floor protector may be covered with a decorative
noncombustible material if desired. Do not obstruct the
space under the heater. An 8” chimney and chimney
connector is required an the bypass damper must be in
the fully open position.
Important: All installations on a combustible floor
require the use of the supplied bottom heat shield.
Protection requirements vary somewhat between theUntied States and Canada as follows:
In U. S. installations the floor protector is required
under the stove and must extend at least 16” (notincluding the ash lip) from the front of the stove (“F”,
Fig. 11), and at least 6” from the sides and rear. (“D”
and “E”, Fig. 11)
In rear venting configurations, floor protection must also
extend under the chimney connector and 2” to eitherside. (“C”, Fig. 11) For the 8” (203 mm) connector, theprotector must be a minimum of 12” (305 mm) wide.
For the 6” (152 mm) connector, the protector must be10” (254 mm) wide. The protector must be centeredunder the connector.
To meet these requirements, a floor protector must be
at least 39” wide and 45” deep.
30005295

C

D
B
E

E

E

E

F

F

A

A

		 U.S.	Canada
A.
B.
C.
		
D.
E.
F.

39”
45”
12”
10”
6”
6”
16”

43” (1092 mm)
49” (1245 mm)
12” (305 mm) 8” Connector
ST500(250 mm) 6” Connector
10”
Defiant
8”(203 mm)floor protection
8”(203
1/31/02 djt mm)
18” (460 mm)
ST500

Fig. 11 Required floor protection dimensions.

How to Determine if Alternate Floor
Protection Materials are Acceptable
All floor protection must be noncombustible (i.e. metals, brick, stone, mineral fiber boards, etc.). Any organic
materials (i.e. plastics, wood paper products, etc.) are
combustible and must not be used. The floor protection
specified includes some form of thermal designationsuch as R-value (thermal resistance) or k-factor (thermal conductivity).
Procedure:
1. Convert specifications to R-value:i. R-value given - no conversion needed.
ii. k-factor is given with a required thickness (T) in
inches: R = 1 x T
kiii. K-factor is given with a required thickness (T) in
inches: R = 1
xT
K x 12
iv. r-factor is given with a required thickness (T) in
inches: R = r x T
2. Determine the R-value of the proposed alternate
floor protector:
i. Use the formula in Step 1 to convert values not
expressed as R.
ii. For multiple layers, add R-values of each layer todetermine overall R-value.

Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
3. If the overall R-value of the system is greater thanthe R-value of the specified floor protector, the alternate is acceptable.
EXAMPLE: The specified floor protector should be 1/2inch thick material with k-factor of 0.84. The proposed
alternate is 4” brick with an r-factor of 0.2 over 1/8”
mineral board with a k-factor of 0.29
Step a: Use formula above to convert specification to
R-value: R = 1 x T = 1 x 0.5 = 0.59
k
0.84
Step b: Calculate R of proposed system.
4” brick of r = 0.2, therefore:		Rbrick = 0.2 x 4 = 0.8
1/8” mineral board of k = 0.29, therefore
1		Rmineralboard =x 0.125 = 0.431
0.29
		Rtotal = Rbrick + Rmineralboard = 0.8 + 0.431 = 1.231
Step c: Compare proposed system Rtotal of 1.231 to
specified R of 0.59. Since proposed system Rtotal isgreater than required, the system is acceptable.
Definitions(ft2)(hr)(°F)
Btuk=(Btu)(in)= K x 12(ft2)(hr)(°F)

K = (Btu)(ft)(ft2)(hr)(°F)r=(ft2)(hr)(°F) 1=(Btu)(in)kR=

Keep the Stove a Safe Distance
From Surrounding Materials
Both a stove and its chimney connector radiate heat inall 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 Encore
has specific clearance requirements that have been
established after careful research and testing. These
clearance requirements must be strictly observed.
In addition, keep furnishings and other combustible
materials away from the stove. In general, a distanceof 48” (1219 mm) must be maintained between thestove 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 combinationof these variables:

Floor Protection for Fireplace Installation• When the stove pipe has no listed heat shield

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 heatpasses readily through brick or concrete, it can easily
pass through to the wood. As a result, such fireplacehearths can be a fire hazard and are considered a combustible floor.

• When the wall has no heat shield mounted on it.
• When the wall has a heat shield mounted on it.
• When the wall and stove pipe have heat shields.

For all fireplace installations, follow the floor protection
guidelines described above, including the need for abottom shield. Keep in mind that many raised hearths
will extend less than the required clearance from thefront of the heater. In such cases, sufficient floor protection as described above must be added in front of thehearth to satisfy the minimum floor protector requirement from the front of the stove: 16” (410 mm) in the
United States and 18” (460 mm) in Canada. Hearthrugs do not satisfy the requirement for floor protection
as they are not fire proof.
Fireplace installations also have special clearance
requirements to the side walls, side decorative trim andfireplace mantel. Refer to the information on fireplaceand mantel trim shields in this section.

10

mounted on it.

In general, the greatest clearance is required when you
place a stove and its connector near a wall with no heatshield.
For example, when the Encore is installed using 6” connector pipe parallel to the rear wall and no connector
shield is used, it must be at least 15” (381 mm) from thewall behind it and at least 19” (483 mm) from walls oneither side. These dimensions are measured from theback of the rear shroud and the side edge of the castiron top to the combustible wall.
If the Encore is installed in a corner and no shield isused, the corners of the stove top must be at least 18Z\x”(470 mm) from nearby walls.
Clearances may be reduced only by means approvedby the regulatory authority, and in accordance with theclearances listed in this manual. Refer to Page 12 forapproved clearance reduction specifications.
Note: Installation of the Encore is not permitted inalcoves.

30005295

Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
Wall Shields
One way to reduce clearances is with a wall shield constructed of 24 gauge or heavier sheet metal, or of anothernoncombustible material such as 1/2” (13 mm) insulation
board such as Durock® or Wonderboard®, or common brick“laid on flat,” with the 3¹⁄₂" (90 mm) side down.
Shields must be spaced out from the combustible surface
1" (25 mm) on noncombustible spacers, as in Figure 12.
The spacers should not be directly behind the stove or
chimney connector.
Air must be able to flow between the wall and the shield.
At least 50% of the bottom 1" (25 mm) of the shield must
be open, and the shield must be open at the top. Metal
screening across the top will keep small stray objects frombeing trapped behind the shield. (Fig. 12)
Air Flow
ScreenStud Wall
FramingDrywall1" (25mm)

To protect a mantel from theheat of a stove in a fireplaceinstallation, use a custommade ventilated mantel shieldthat is at least 48” (1220 mm)
long, centered over the stove. ST501
1/4" (6mm)(Fig. 13) Ventilated shields forside trim must extend the full Fig. 13 A custom-formed
mantel shield.
length of the trim.
An unprotected mantel (“A”, Fig. 14) cannot be more than
ST501clearance of9” (230 mm) deep and must have a minimum
manteland With
28” (711 mm), measured from the stove’s
top plate.
trimshielda ventilated shield, this clearance may be reduced safely
11/10/00 djt
to 15” (381 mm).
Unprotected top trim (B) protruding 3/4” (19 mm) or lessfrom the face of the fireplace must be a minimum of 25”(635 mm) from the stove’s top surface. With a ventilated
trim shield, this clearance may not be reduced safely.

Wall Shield

Noncombustible Spacersand Fasteners

Noncombustible shields
installed 1” (25 mm) away fromthe combustible surface on
noncombustible spacers, called
ventilated shields, may be used
to reduce clearances.

Unprotected side trim (C) that protrudes 3/4” (19 mm) or
less from the face of a fireplace must have a minimum
clearance of 22” (554 mm), measured from the stove’s top
side edge. If the trim extends more than 3/4” (19 mm), it
is subject to the requirements for wall clearance.

ShieldMetal
Spacer

Air Flow
ST248

The charts and sample installations that follow list all
the clearances required for the various installation
configurations of the Encore.

Fig. 12 Approved wall shield construction.

The shield mustST248
be a minimum of 48" (1219 mm) tall, andshieldmust extend at wall
least
19"construction(483 mm) higher than the top
12/14/99 is
djthigher. The shield behind theof the stove, whichever
chimney connector must be 30" (760 mm) wide, centeredbehind the pipe; for installations that use an approved
prefabricated chimney to pass through the ceiling, theshield behind the chimney connector must stop 1" (25mm) below the ceiling.

A

C

Side
Wall

B

C
D

With 8” connections and chimneys, because of potentiallyhigher pipe temperatures, the shield must extend the fullheight of the wall (up to 9’ (2.7 m)) and stop 1” (25 mm)
below the ceiling.

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 thefireplace face, and between the top of the stove and themantel.
30005295

ST253b		

Fireplace and Mantel Trim ClearancesA. Mantel
B. Top Trim
C. Side Trim
D. Side Wall

Unprotected	Protected
28” ST253b(711 mm)15” (281 mm)
25” Encore(635 mm)15” (281 mm)
22” trim(554clearancesmm)11” (280 mm)
djt
22” 02/01(559 mm)11” (280 mm)

Fig. 14 Maintain clearances to combustible components ofthe mantelpiece.

11

Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove

Encore 2N1 Clearance Chart

For use with either 6” or 8” flue collar/chimney connection

Unprotected Surfaces	Protected Surfaces
Stove Clearance
Stove Installed	Parallel to Wall

Stove
Stove Installedin Corner	Parallel to Wall

Stove
in Corner1

Side
Top Exit, 8” single
		wall connector without(A) 19”shields, vertical flue col(483 mm)
lar heat shield installed

To Rear	Corners
Side
Shroud			(B) 20”(C) 18Z\x”(D) 5”(508 mm)(470 mm)(127 mm)

To Rear	Corners
Shroud(E) 7”(F) 12”(178 mm)(305 mm)

Top Exit, single-wallchimney connector heatshield2, vertical flue collar h.s. installed(G) 19”(483 mm)(H) 10”(254 mm)(152 mm)(152 mm)(305 mm)(M) 22”(559 mm)(N) 12”		
(305 mm)n/a(P) 11”(279 mm)(Q) 12”(305 mm)n/a(G) 18”(457 mm)(H) 7”(178 mm)(J) 4”(102 mm)(K) 5”(127 mm)(L) 5”(127 mm)

Rear Exit
No flue collar heatshieldTop Exit, double-wallchimney connector3,
vertical flue collar heatshield installed(I) 18Z\x”(470 mm)(I) 12”(305 mm)(J) 6”(K) 6”(L) 12”

Clearance to Combustible in Front of StoveAll Installations (S) 48” (1219 mm)
The provided rear shroud must be used in all installations. The flue collar heat shield must be used in all verticalinstallations.
1. A ceiling heat shield 24” (610 mm) in diameter and suspended 1” (25 mm) from the ceiling must surround thepipe in installations where chimney penetrates the ceiling.
2. The connector pipe heat shield must extend 36” (914 mm) above flue collar.
3. Using listed double wall oval to round adapter when installing optional 8” oval flue collar.

6” Chimney Connector ONLY
Top Exit, single wall6” connector without
shields, vertical flue collar heat shield installed

12(A) 19”(483 mm)(B) 15”(381 mm)(C) 18Z\x”(470 mm)(D) 5”(127 mm)(E) 7”(178 mm)(F) 12”(305 mm)

30005295

Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove

Encore 2N1 Clearance Diagrams
For use with either 6” or 8” flue collar/chimney connector

Unprotected Surfaces
Stove Installed
Parallel to Wall

Protected Surfaces
Stove Installed
Parallel to Wall

Stove in Corner

Stove in Corner

Top Exit Installations, No Stove Heat Shields, collar heat shield installed.

B

A

C

C

E

D

F

F

Top Exit Installations, vertical collar heat shield, and chimney connector heat shields or double-wall connector.

H

G

I

K

J

I

L

L

Rear Exit Installations.

N

Q

N/A
M

N/A
P

ST628
Encore Clearance
Diagrams
02/01

30005295

13

Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove

Distance from the Center of the Flue Collar to the Wall in Top-Exit Installations
The information on this page is helpful in planning stove placement for top-exiting installations, particularly those installations with chimneys that pass through the ceiling. However, this is not a clearance chart. Final stove clearances
must adhere to the guidelines stated in the clearance chart on Page 13.
Dimensions indicated are valid for installations with either 6” or 8” flue collars.

Encore: WITHOUT Chimney Connector Heat Shields
Unprotected Surfaces

Protected Surfaces

	Corner 		Corner	Parallel Installations	Installations**	Parallel Installations	Installations**
Side (A)Rear (B)Side (A)Side (D)Rear (E)

Corner (F)32¹⁄₂”(826 mm)23Z\v”(591 mm)22Z\x”(572 mm)18¹⁄₂”(470 mm)

10Z⁄₄”(260 mm)18Z\x”(470 mm)

A

B

D

C

E

F

*

*

ST632

* This distance, from the center of the flue collar to the front edge of the hearth, is the same for all installations on this page:
35Z\v” in the United States and 37Z\v” (946 mm) in Canada.

ST632
Encoreflue centerline
Encore: WITH Chimney
Connector Heat Shields
Diagrams
Unprotected Surfaces
Protected Surfaces
2/01
	Corner 		Corner	Parallel Installations	Installations**	Parallel Installations	Installations**

Side (A)Rear (B)

Corner (C)Side (D)Rear (E)

Corner (F)32¹⁄₂”(826 mm)

13Z⁄₄”(337 mm)22Z\x”(572 mm)19¹⁄₂”(495 mm)

9Z⁄₄”(235 mm)18Z\x”(470 mm)

A

B

D

C

E

F

ST632a**To locate center of flue collar for corner installation, add 6Z\x” (165 mm) to the clearance distance from stove corner to wall.
Mark off the resulting distance from the corner along both walls. Next, measure the same distance from these two points out
from the walls. These last two measurements will meet at a point representing the center of the flue collar. Refer to the diagrams above.

14

ST632aEncoreflue centerline
Diagrams
02/01

30005295

Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove

48"(1220 mm)48"
(1220 mm)48"
(1220 mm)48"
(1220 mm)

ST497

ST499

Fig. 15 Parallel installation, vertical chimney connector, twowall shields. Reduced clearances for both rear and side walls.
Wall shields may meet at corner if desired. Shielding for connector is centered behind connector.

Fig. 17 Corner installation, vertical chimney connector, twowall shields. Reduced side clearances. Wall shield MUST
meet at corner.
ST499
Defiant
Wall Shield C
11/00

ST497
Defiant
wall shield A
11/00
48"
(1220 mm)

ST498

Fig. 16 Parallel installation with rear wall pass-through, twowall shields. Reduced clearances to both rear and side walls.
Wall shields may meet at corner if desired. Wall pass-throughST498
must comply with codes. Defiant
Wall shield B
Refer to “Special Installations.”
11/00

30005295

15

Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
Mobile Home Installation
You must use an MHSC Vermont Castings Kit #0336 for
installation into a mobile home.
1. An outside air inlet must be provided for combustion and must remain clear of leaves, debris, ice
and/or snow. It must be unrestricted while stoveis in use to prevent room air starvation which cancause smoke spillage and an inability to maintain afire. Smoke spillage can also set off smoke alarms.
2. Stove must be secured to the mobile home structure using the fasteners provided in the Mobile
Home Kit.
3. Stove must be grounded with #8 solid copper
grounding wire or equivalent and terminated ateach end with N.E.C. approved grounding device.
4. Stove must be installed with an approved UL103
HT ventilated chimney connector, UL103 HT chimney and terminal cap with spark arrestor. Neveruse a single wall connector (stove pipe) in a mobile
home installation. Use only double-wall connector
pipe, Dura-Vent DVL, Selkirk metalbestos DS, Security DL double wall connector or any listed double
wall pipe connector.
5. Refer to Pages 12, 13 and 14 of this manual or theserial number label on the back of the stove forclearances to combustibles.
6. Floor protection requirements on Page 9 must be
followed precisely.
7. In Canada, this appliance must be connected to a
6 inch (152 mm) factory-built chimney conforming
to CAN/ULC 629M, STANDARD FOR FACTORYBUILT CHIMNEYS. Floor protection referenced onPage 10 must be followed.
8. Use silicone to create an effective vapor barrier at
the location where the chimney or other component
penetrates to the exterior of the structure.
9. Follow the chimney and chimney connector manufacturer’s instructions when installing the fluesystem for use in a mobile home.
NOTE: Offsets from the vertical, not exceeding 45°, areallowed per Section 905(a) of the Uniform Mechanical Code (UMC). Offsets greater than 45° are
considered horizontal and are also allowed, providing the horizontal run does not exceed 75% of thevertical height of the vent. Construction, clearance
and termination must be in compliance with the
UMC Table 9C. This installation also complies with
NFPA 211.
NOTE: Top sections of the chimney must be removable
to allow maximum clearance of 13.5 ft. (411 cm)
from ground level for transportation purposes.
10. Burn wood only. Other types of fuels may generatepoisonous gases (e.g. carbon monoxide).

11. If unit burns poorly while exhaust blower is on in
home, (i.e. kitchen range hood) increase combustion air.
WARNING: NEVER DRAW COMBUSTIBLE AIR
FROM A WALL, FLOOR OR CEILING CAVITY OR
FORM ANY ENCLOSED SPACE SUCH AS AN ATTIC OR GARAGE.
CAUTION: THE STRUCTURAL INTEGRITY OF
THE MOBILE HOME FLOOR, WALL AND CEILING/
ROOF MUST BE MAINTAINED. (i.e., DO NOT CUTTHROUGH FLOOR JOIST, WALL STUD, CEILING
TRUSS, etc.).

WARNING:
DO NOT INSTALL IN SLEEPING ROOM
Spark
Arrestor
Cap

Storm Collar

RoofFlashing

Joint
Shield/Firestop

Listed Chimney
Connector

Floor
Protection
Outside Air Kit
Connector

Outside Air Floor Vent

KT1190Fig. 18 Mobile home installation.

16

30005295

ST1190mobile home installEncore® 2040 Non-Catalytic / Catalytic Woodburning Stove

Assembly
Set Up Your Stove

Storing the Handle

Cast iron stoves are heavy, and it will take two to four
people to move your Encore into position.

Use the removable handle to open or close the doors.
After using it, remove the handle so it will not get hot.
Store the handle in the handle holder installed behind
the right front leg. (Fig. 21)

Wipe the protective coating of oil from the griddle with aclean dry rag or a paper towel.
Install the handle on the griddle. First, place the griddle
upside down at the edge of a flat surface and assemble
the handle as shown.
With the handle pointing 45° from its final position,tighten the nut as
far as possible withthe pliers. Move thehandle to its final
position while still
holding the nut withthe pliers.

Bottom Heat Shield
Door Handle Holder
Leg Bolt and Washer

Fig. 21 Handle holder and heat shield positions.

Install the Bottom Heat Shield

ST516

Fig. 19 Attach the griddle handle.

ST516
Install Stove Legs

AttachThe stove is shipped with the legs attached.
some
griddle In
handleinstances, the legs may have been removed.
11/17/00Foldjt
low these instructions to reattach the legs. Install thestove legs (Fig. 20) using the hex head bolts from theparts bag. Use 3/8” washers with all four legs; the door
handle holder installs on the right front leg. Position theholder 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.
NOTE: When moving the stove, lift the stove to takeweight off the legs whenever possible. Dragging or
sliding the stove, especially across rough surfaces cancause the legs to loosen or even break.

ST564

NOTE: The Bottom Heat Shield is required in most inhandle holder
stallations. Refer to Floor Protection, Page 9, for further
12/13/00
details.
1. Loosen the four 1/4-20 hex head bolts from the corners of the ash drop on the stove bottom.
2. Align the bottom heat shield holes with the fourbolts. The outside air cutout hole should be toward
the rear of the stove. The unpainted side must face
up towards the stove.
3. Pass all four bolts through the large end of the keyholes and then pulling the shield forward to engage
the smaller ends of the keyhole slots. (Fig. 22)
4. Attach the heat shield sides by passing the slots
over the bolt heads. Tighten the hex head bolts.

Leg Bolt andWasher

Bottom Heat Shield

ST857a
ST858

ST564

Fig. 22 Attach the bottom heat shield.

Fig. 20 Attach the stove legs.

30005295

34
ATTACH LEGS


ST857
abottom heat shield
12/05
1/10

17

Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
Adjust the Leg Levellers

Attach the Damper Handle

Lift the stove slightly so there is no weight on the leg
while making the adjustment.

Use the 1/4” -20 x 3” screw to attach the damper handle
to the damper stub on the left side.

Reverse the Flue Collar (If necessary)

Attach the Primary Air Thermostat Handle

Reverse the flue collar by removing the two screws that
attach it to the back of the stove. Be sure the gasket
around the flue collar opening is in position when you
screw the collar back onto the stove.

The primary air thermostat handle is the smaller of thetwo black handles. Secure the handle to the stub on
the right side of the stove with an 8-32 x 2” slot headmachine screw. (Fig. 24)

Adjust Air Deflector

Assemble the Removable Insert Handle

If you have the optional fan kit, you may decide toadjust the air deflector to blow heat across the top ofyour stove. (Fig. 23) Loosen the two (2) screws on eachside and raise or lower the deflector. After adjustment,tighten the screws.

The ceramic removable insert handle opens and closes
the front doors. Remove after each use, and store it in
the handle holder behind the right front leg. Assemble
the handle by passing the 3³⁄₈" screw through theceramic shaft and into the bright metal nub. (Fig. 25)
Tighten carefully until snug.

Attach Flue Collar Heat Shield
WARNING: The flue collar heat shield must be attached to the Encore stove. Use four #10 sheet metalscrews supplied to secure the flue collar heat shield tothe rear of the stove. (Fig. 23)
Air Deflector
Air Deflector
Sheet
Metal
ScrewsST635

Fig. 24 Attach the thermostat handle.
Flue Collar
Heat Shield

Sheet
Metal
Screws

ST635
EncoreInstall thermostat
handle2/01

ST540

Fig. 25 Assemble the front door handle.
ST1180Fig. 23 Install flue collar heat shield.

WARNING: The flue collar heat shield must be installed
in all vertical installations. The flue collar heat shield is
not used when the flue collar isST1180
in the rear exit position.

flue collar heat shield

18

ST540
Assembly
handle11/00

30005295

Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
Fan Kit Installation
1. Attach the fan assembly at the bottom edge of the inner back with two (2) 1/4-20 x 3/4” hex head screws.
2. Attach snapstat to the mounting holes on the underside of the bottom with two (2) 1/4-20 pan headscrews.
3. Attach the rheostat holder (provided with the stove)
under the right front wing of the bottom heat shieldwith two (2) #10 sheet metal screws.
4. Attach the rheostat to its holder by inserting the rheostat control shaft through the holder hole. Install theretaining ring and rheostat knob onto the shaft.
5. Secure the rheostat cable to the underside of thebottom heat shield using the wire tie provided andthe hole at the right rear edge of the heat shield.
6. Fan will not operate until stove reaches approximately 109°F.
7. Plug blower cord into a grounded outlet. Do notremove ground prong from plug. Route power cord
to avoid heat from the stove or other damage. Do notroute cord under or in front of appliance.

AccessCover

ST1187

Fig. 27 Remove access cover.
Inner Cover

ST1187
remove access coverHole for Wire
Tie to Secure
Cable
Rheostat
Knob

ST1188Fig. 28 Remove inner cover.
Rheostat
HolderRheostatSnapstat

Screws

ST848

ST1188
remove inner coverFig. 26 Fan installation (Kit # 2767).

Installing or Removing Catalyst
34
1. Remove the access cover by gently lifting up and
FAN INSTALL
pulling out from the bottomedge. (Fig. 27)

2. Remove the inner coverby pulling it straight out.

(Fig. 28)
3. Remove the catalyst by gently pulling it straight out.
(Fig. 29) Place the catalyst where the catalyst’s
ceramic components will not be damaged.
Remove Catalyst

ST1189Fig. 29 Remove catalyst.

30005295

ST1189remove catalyst

19Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove

Operation
The Encore Controls
Two controls regulate the performance of the Encore: aprimary air control supplies oxygen for the fire, and adamper directs air flow within the stove to activate anddeactivate the combustion system. (Fig. 30)

Low Heat

Symbols cast into the stove are reminders of the correct
directions for using the controls. The words ‘Left’ and‘right’ in these directions are facing the stove.
Damper Handle

Griddle Handle
Door Handle

High Heat

Air Control
Lever
ST637

Fig. 31 The handle may be positioned anywhere between thetwo extremes for different heat levels.
Door Handle
Holder (Behind leg)
Ashdoor
HandleAndirons

ST636

Fig. 30 The Encore controls are conveniently located andeasy to operate.

ST633

A Single Air Control Regulates
EncoreHeat Output and Burn Time

controls

The damper is closed when the handle points forward.
Smoke travels through the non-catalytic combustion
system where it can be further burned, before passing
up the chimney. (Fig. 32)

ST637
encoreDamper Positions Air control
2/01

The damper should always be either fully open or
fully closed. There are no intermediate positions.
When closing the damper, be sure to pull firmly
enough to snap the handle into the locked position.

Open(Updraft Mode)

The primary air control
lever, on the right side of the
2/01
stove, controls the amount of incoming air for starting,
maintaining, and reviving a fire.
More air entering the stove makes the fire burn hotter
and faster, while less air prolongs the burn at a lower
heat output level. (Fig. 31)
For the greatest air supply and maximum heat output(but the shortest burn time), move the lever toward thefront of the stove. For a fire that will last longer withless heat, move the lever toward the rear of the stove.

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 therear, enabling smoke to pass directly into the chimney.
The damper must be open when starting or reviving afire, and whenever the griddle or doors are opened.

20

Closed(High Efficiency
Mode)
ST638

Fig. 32 The damper is either open or closed. There are nointermediate positions.

High-Efficiency Wood Burningwith Catalytic Combustion

ST638
A Encore leaves the factorywith the combustor packEncore
aged separately.
In the United States, it is against
the law tocontrol
operate thisdamperwood heater in a manner inconsistent with operating
instructions in this manual.
The components of the cata2/01
lytic combustion system in your Encore work together toproduce optimum conditions for secondary combustion.
30005295

Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
When the damper is closed, smoke travels throughthe catalytic element, which causes ignition of smoke
at temperatures of 500°-600° F (260°-315°C), half thetemperature normally required for unaided secondary
combustion.

combustor. Also, do not use a full load of dry slab woodor scrap wood. For long burns, use a mix of dry andmoderately dry wood.

The catalytic element is a ceramic “honeycomb” coatedwith the catalytic material. The element is located in thesecondary combustion chamber, molded from a special
high-temperature insulating refractory material. The
chamber provides the correct environment necessary
for secondary combustion of the fuel (smoke).

The Encore’s griddle lifts for convenient top-loading oflogs, and is the easiest way to add fuel. (Fig. 33)

Two Ways to Add Fuel

Closing the damper exposes the smoke to the combustor. If the combustor is at least 600°F (315°C), it will
begin to burn 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. Whenstarting a fire, wait until the fire is well established andthere is an ember bed of at least 3-4 inches before closing the damper.
Never kindle a fire with colored paper or paper thathas colored ink or a glossy surface, and never burntreated wood, garbage, solvents, or trash. All of thesemay 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 cancoat the combustor and cause smoke to spill into theroom. Coal smoke also can poison the catalyst so that it
won’t operate properly.
In general, the fire must be sufficiently well-establishedto ensure that catalytic activity is initiated. When firststarting 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 thechimney is warmed.
Even though it is possible for the fire to get quite hot
within a few minutes after a fire is started, the combustor 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 of smoke leaving the chimney when
the damper is activated and when it is not. This procedure is described on Page 33.
Avoid using a full load of very dry wood in the firebox.
This may result in continuous very high temperaturesin the secondary combustion area and damage the
combustor. Wood which has been split, and stored under cover for more than 18 months may be consideredvery dry. If you must burn extra-dry wood, mix it withgreener wood for a longer fire and less stress on the30005295

Def

iant

ST521

Fig. 33 Top loading is the best way to add fuel during regularuse. Front loadingis useful for kindling a fire.
ST521
Intrepid
However, the front
doors open as well for adding anoccasional logloading
to a fire. If the stove is equipped with 8”
11/00(203 mm) stove pipe, the front doors may be opened(or even removed) and the optional Encore spark
screen placed in the opening for open-fire viewing. The
Encore is not approved for operation with the front
doors open if equipped with a 6” (152 mm) chimney
connector or chimney.

To open the front doors, insert the handle into the door
latch stub and turn it to the left and up. (Fig. 34)
Clockwise to
Open

Counterclockwise
to Close

ST544

Fig. 34 To open the front doors, turn the handle clockwise.

To close them, always close the left door first. Turn thehandle in the right door to the left and up (to the open
position) and close it. Finally, push on the door as you
turn the handle to the right and down. The doors willdraw in slightly, and the handle should offer some resistance as you turn it to the closed position.
To reduce the risk of breaking the glass, avoid striking
the glass or slamming the doors.

When you are not using the door
handle, store it in theST544
holder behind the right front leg of the stove. Be careful
open
to not drop the handle, since itdoor
is breakable.

11/00

21

Encore® 2040 Non-Catalytic / Catalytic Woodburning StoveWARNING: 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.
WARNING: For safety and greatest efficiency, operate your stove only with all doors/griddles fully
closed. The test standard for your stove when it isoperated in this mode is UL 1482.
The Encore may be used as a fireplace with thefront doors open or removed, BUT only when it
is equipped with 8” (203 mm) stove pipe and only
when the optional spark screen is secured correctlyin the opening to protect against the possibility of
sparks and embers leaving the stove. The test standard for your stove when it is operated in this modeis UL 737. 1” floor protection is also required. Refer
to “Floor Protection” section on Pages 9 - 10.
Use only the Encore spark screen, Item #1907, withyour Encore.
Encore spark screens are available from your Vermont Castings Dealer.

Andirons Help Protect the GlassYour stove has andirons to keep logs away from theglass panels. The andirons are essential to maintainclear fire viewing, and should be left permanently inplace. Since the andirons may slightly hinder refuelingthrough the front doors, most stove owners will prefer
the convenience of top loading through the griddle. Do
not place fuel between the andirons and the doors.

Burn Only High-Quality Wood
The Encore is designed to burn natural wood only; do
not burn fuels other than that for which it was designed.
You’ll enjoy the best results when burning wood thathas been adequately air-dried. The wood should be18”-20” (457-508 mm) in length. Avoid burning “green”
wood that has not been properly seasoned. Do notburn construction materials; they often containchemicals and metals that can damage the insidesurfaces of the stove and pollute the air. Do not burnocean driftwood; when it burns, the salt it contains will
attack the cast iron.
The best hardwood fuels include oak, maple, beech,
ash, and hickory that has been split, stacked, and airdried outside under cover for at least one year.
If hardwood is not available, you can burn softwoods
that include tamarack, yellow pine, white pine, Eastern red cedar, fir, and redwood. These should also beproperly dried.
Store wood under cover to keep it dry. The longer it isstored, the better heating and fire-viewing performance22

you will enjoy. Even for short-term storage, be sure tokeep wood a safe distance from the heater and keep
it out of the areas around the heater used for refuelingand ash removal.

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. 35)

ST523

Fig. 35 Take temperature readings with a thermometer located in the middle of the griddle.

For example, when the thermometer registers at least
450°F. (230°C) after start-up you know the stove is
hot enough and it may be time to close the damper.
Note that the stove will warm up much sooner than thechimney, though; a warm chimney is the key to easy, effective stove operation. Please review the draft management information on Page 27 to see how the size,
type, and location of your chimney will affect your stove
operation. When thermometer readings drop below
350°F. (175°C) it’s time to adjust the air control for ahigher burn rate or to reload the stove. A temperature
reading over 750°F. (385°C) is a sign to cut back on the
air supply to slow the burn rate.

ST523
Intrepid• Readings in the 350°-500°F. (175°-260°C) range
indicate low to medium
heat output.
temp
readings• 500°-600°F. (260°-315°C) readings indicate medium
11/00
heat output.
Use the following temperature ranges as a guide:• Readings of 600°-750°F. (315-385°C) indicate highheat output. Operating your Encore continuously
at griddle temperatures of 750° F. (385°C) 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. Eachinstallation will differ depending on the quality of thefuel, the amount of heat desired, and how long you wish
the fire to burn; outdoor air temperature and pressure
also affect draft.
The control setting also depends on your particularinstallation’s “draft,” or the force that moves air from thestove up through the chimney. Draft is affected by suchthings 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.
30005295

Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
Too much draft may cause excessive temperatures inthe Encore, and could even damage the stove. On theother hand, too little draft can cause backpuffing into
the room and/or the “plugging” of the chimney.
How do you know if your draft is excessively high or
low? Symptoms of too much draft include an uncontrollable burn or a glowing-red stove part. Signs of weakdraft are smoke leaking into the room through the stoveor chimney connector joints or low heat output.
In some newer homes that are well-insulated andweather-tight, poor draft may result from an insufficient
air supply in the house. In such instances, an open
window near the stove on the windward side of thehouse can provide the combustion air supply needed.
Another option for getting more combustion air to thestove is to duct air directly from outside to the stove. In
some areas provisions for outside combustion air are
required in all new construction.
The Encore is equipped to deliver outside air for combustion and outside air kit #3265 is available.
When first using the stove, keep track of the air control
settings. You will quickly find that a specific setting will
give you a fixed amount of heat. It may take a week or
two to determine the amount of heat and the length ofburn you should expect from various settings.
Most installations do not require a large amount of
combustion air, especially if adequate draft is available.
Do not for any reason attempt to increase the firingof your heater by altering the air control adjustment
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 thelever may be moved from right to left.

Conditioning Your Stove
Cast iron is extremely strong, but it can be broken witha sharp blow from a hammer or from the thermal shockof rapid and extreme temperature change.
The cast plates expand and contract with changes intemperature. When you first begin using your Encore,minimize thermal stress by letting the plates adjust
gradually during three or four initial break-in fires following Steps 1-3 below.

Non-Catalytic Wood Burning
Burn only solid wood in the Encore, and burn it directlyon the grate. Do not elevate the fuel. Do not burn coalor other fuels.
The bypass damper must be open when starting afire or when refueling.
Do not use chemicals or fluids to start the fire. Do
not burn garbage. Never use flammable fluids suchas gasoline, gasoline type lantern fuel, kerosene,
charcoal lighter fluid, naptha, engine oil or similar
liquids to start or “freshen up” a fire in this heater.
Keep all such liquids well away from the heater
while it is in use.
1. Open the stove bypass damper, and open the primary air control fully.
2. Place several sheets of crumpled newspaper in thestove. Place six or eight pieces of dry kindling split to afinger-width size on the paper. On the kindling, lay twoor three larger sticks of split dry wood approximately
1-2” (25-51 mm) in diameter. (Fig. 36)

Encore Control Settings(Refer to Page 20)
Burn Rate
Low		
Medium			Primary Air Control
From far right to 1/3 the distanceto left
From 1/3 to 2/3 the distanceto leftHigh		

From 2/3 the distance 		to left, to far left

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

30005295

ST263

Fig. 36 Start the fire with newspaper and dry kindling.

3. Light the newspaper and close the door. Gradually build up the fire by adding a few 3-5” (80-120 mm)
diameter pieces of split firewood. If this is one of thefirst few “break-in” fires, let the fire burn brightly,
ST263
and then let it die out.

starting a fire

During the break-in
fires, do not let the stove get hotter
12/99
than 500°F. (260°C) as measured on an optional stovetop thermometer. Adjust the air control lever as necessary to control the fire.
23

Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
Some odor from the stove’s hot metal and the paint isnormal for the first 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 newspaper, place them on top of the kindling and toward
the back of the stove, light them, and close the doors.
This will encourage the smoke to rise rapidly, making iteasier to establish a good draft.

It is important that air can circulate through the charcoal
bed during the burn. Larger pieces of charcoal allow
more air to circulate under the wood, resulting in thefire reviving more quickly. (Fig. 38)

Once the draft is established, open the front door andlight the rest of the fuel from the bottom. Do not lightthe main bed of fuel until the chimney begins drawing,
and repeat the procedure as often as necessary if theinitial attempt is unsuccessful.
4. If your Encore has been broken-in previously using Steps 1-3, continue to build the fire gradually. Addlarger 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 2-3” (51-75mm) deep. (Fig. 37) A good ember bed is necessary forproper functioning of the non-catalytic system and may
take an hour or more to establish.

ST264

Fig. 37 Add larger pieces of wood as the fire begins to burnwell.

5. Close the damper when the griddle temperaturereaches 450°F (230°C).
6. Adjust the airST264
control for your desired heat output.

NOTE: Stove installations
good fire vary widely, and the operating guidance given
here is only a starting point . The
12/99
draft management information on Page 26 will explainin 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 encourage a good draft.

Refuel While the Embers Are Still Hot
When reloading, best results will be achieved if you firstde-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 orpound or compress the charcoal bed.
24

ST264aFig. 38 Add full size logs after the ember bed is 3” (75mm)
deep.

For best results when refueling, wear long-cuffed stove
gloves to protect your hands and forearms, add fuelwhile the stove stillST264a
has plenty of glowing embers to
re-kindle the fire, and include some smaller pieces of
add wood firewood in the new fuel load to help the stove regain its
11/00
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 theashdoor and check the level of ash in the ash pan.
Empty the pan if necessary and replace it in thestove. Close the ash door.
3. Open the griddle, load the wood (smaller pieces
first), and close the griddle.
4. Close the damper.
5. When the surface temperature reaches 450°F.
(230°C), adjust the air control for the amount of heat
you desire.
NOTE: If the remaining charcoal bed is relatively thick(2-3”/51-75 mm) and if your fuel is well seasoned, it ispossible to add fresh fuel (smaller pieces first), closethe door and damper, and reset the primary air control
for the desired heat output within five minutes.
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 FIREPLACESTOVE OPENING CREATING RISKS FROM BOTH
FIRE AND SMOKE.
Caution: The Encore will be hot while in operation. Keep children, clothing and furniture away.
Contact may cause skin burns.

30005295

Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
DO NOT OVERFIRE THIS HEATER. Overfiring may
cause a house fire, or can result in permanent damage to the stove. If any part of the Encore glows, you
are overfiring.

Ash Disposal
Routine ash removal is important for ease of maintenance, and is important for the stove’s durability.
Remove ash before it reaches the top of the ash pan.
Check the level at least once a day. Every few days,
clear any ash from the outer edges of the firebox. Mostof the ash will fall through the grate. Slice or stir the ashwith a shovel or poker so that it falls through the grate
slots.
IMPORTANT: Check the level of ash in the ash pan
before reloading the stove. If the ash level is close to
the top edge of the pan, empty the pan according to thisprocedure:• Open the damper.
• Open the griddle or front doors, and use a shovel or•

poker to stir excess ash through the ash slots in thegrate down into the ash pan.
Close the griddle or doors, and unlatch the ash door.
(Fig. 39) It will pivot, swinging the ash pan out of thestove.

ST566

Fig. 40 Be sure the cover is securely attached before removing the ash pan.

34• Properly dispose of theREMOVE
ash in aASHPAN
metal container witha tight-fitting lid. Store the container outdoors awayfrom all combustible material.
• Return the ash pan to its original position in thestove, and close and latch the ash door. (Fig. 40)• 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 ahouse fire.
Empty the ash pan regularly, typically every one tothree days. The frequency will vary depending on how
you operate your Encore: ash will accumulate faster athigher heat outputs.
Remove ash frequently and place it outdoors in a
metal container with a tight-fitting 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 insoil or otherwise locally dispersed, it should be kept in
the closed container until all cinders have thoroughlycooled.

Open

Close
ST545

Fig. 39 Turn the ashdoor handle clockwise to open and counterclockwise to close.

• Slide the cover onto the pan, making sure it is se-

You can use wood ash as a garden fertilizer.
CAUTION: Never use your household or shop vacuum
cleaner to remove ash from the stove; always remove
and dispose of the ash properly.

ST545

curely closed. (Fig. 40)• Remove the ash pan, making sure to keep it level.
ashdoor• To keep the cover from sliding off and to keep ash

11/00

•

from falling on the floor, do not tilt the ash pan forward.
If the stove is in operation, close the ash door while
disposing of the ash. You may need to lift the latch
end of the door slightly to align the latch with themating part on the stove bottom.

30005295

25

Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove

Draft Management
A stove is part of a system, which includes the chimney,the operator, the fuel, and the home. The other parts ofthe 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 exhaustis 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 hot gases risethrough the chimney they provide suction or ‘draw’ thatpulls air into the stove for combustion. A slow, lazy firewith the stove’s air inlets fully open indicates a weakdraft. A brisk fire, supported only by air entering thestove through the normal inlets, indicates a good draft.
The stove’s air inlets are passive; they regulate howmuch 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 - yoursystem may warm up quickly, or it may take a while towarm up and operate well. With an ‘airtight’ stove, one
which restricts the amount of air getting into the firebox,
the chimney must keep the stove’s exhaust 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 features 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 lotof heat. It can cool the chimney gases enough to diminish draft. The bigger the chimney, the longer it takes towarm up. It’s often very difficult to warm up an outdoor
masonry chimney, especially an oversized one, andkeep it warm enough to maintain an adequate draft.

Steel Chimney
Most factory-made steel chimneys have a layer of
insulation around the inner flue. This insulation keeps
the chimney warm. The insulation is less dense thanmasonry, so a steel chimney warms up more quickly
than a masonry chimney. Steel doesn’t have the good
looks of masonry, but it performs much better.

Indoor/Outdoor Location
Because the chimney must keep the smoke warm, it’sbest to locate it inside the house. This uses the houseas insulation for the flue and allows some heat release
into the home. An indoor chimney won’t lose its heat26

to the outdoors, so it takes less heat from the stove toheat it up and keep it warm.

Chimney Height
The common wisdom tells us that a taller flue draws
better than a short one. This isn’t necessarily so. If achimney is tall enough to meet the safety requirementsof the 2/3/10 foot rule, then adding more height isn’t theright answer to a draft problem. In fact it could make theproblem worse by adding more mass to the chimneysystem, which must be warmed up, a distance from theheat source (the stove). Don’t make a chimney taller
unless you must in order 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’ stoveshould match the size of the stove’s flue outlet. Whena chimney serves an airtight stove, more is not better;in fact, it can be a disadvantage. Hot gases lose heatfaster as they travel slower through a chimney; if wevent a stove with a six-inch flue collar (28 square incharea) into a 10 x 10” flue, the gases slow to one third
their original speed. This allows the gases to cool more
rapids, which weakens draft strength. If an oversizedflue is also outside the house, the heat it absorbs gets
transferred to the outdoor air and the flue usually stays
cool.
It is common for a masonry flue, especially one serving
a fireplace, to be oversized for the stove. It can takequite a while to warm up such a flue, and the results
can be disappointing. The best solution to an oversizedflue is an insulated steel chimney liner, the same diameter as the stove or insert’s flue outlet; the liner keeps
the exhaust warm, and the result is a stronger draft. An
non-insulated liner is a second choice - the liner keeps
the exhaust restricted to its original size, but the hotgases still must warm up the air around the liner. This
makes the warm-up process take longer.

Pipe & Chimney Layout
Every turn the exhaust must take as it travels to thechimney top will slow it down. The ideal pipe and chimney layout is to vent vertically into a completely straightand vertical chimney. If you are starting from scratch,
use this layout if possible. If the stovepipe must elbow
to enter a chimney, locate the thimble about midway
between the stove top and the ceiling. This achieves
several goals: it allows the gases to speed up before
they must turn, it leaves some pipe in the room for heat
30005295

Encore® 2040 Non-Catalytic / Catalytic Woodburning Stovetransfer, and it gives you long-term flexibility for installing a different stove without relocating the thimble.
There should be no more than eight feet of single-wallstove pipe between the stove and a chimney; longer
runs can cool the exhaust enough to cause draft andcreosote problems. With prefabricated chimney, bring it
down to six to eight feet from the stove. With a masonrychimney, arrange the pipe so that it turns into the chimney within eight feet of the stove.

Single Venting
Each ‘airtight’ stove requires its own flue. If an airtightstove is vented to a flue that also serves an open fireplace, or a leakier stove, it’s easier for the chimney draftto pull air in through those channels and performanceof the stove suffers. Imagine a vacuum cleaner with ahole in the hose to understand the effect here. In somecases the other appliance can even cause a negative
draft through the stove, and result in a dangerous draft
reversal.

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

Fuel
Even the best stove installation will not perform wellwith poor fuel. The best fuel is hardwood that has airdried 12-18 months. Softwood burns, but not as long as
hardwood. ‘Green’ wood has a lot of moisture in it; it willburn, but some of the heat potential is used to boil theextra moisture from the wood. This reduces the amountof heat that reaches your home and can contribute to acreosote problem. There are moisture meters available
for firewood; you can also judge your wood by its appearance and weight. If you get it green, lift a piece and30005295

get a sense of its weight; it can lose a third or more of
its weight as it dries. Also look at the ends of a log; as it
dries it shrinks and often cracks. The more weathered
and cracked a piece is, the drier it is.
Dry wood burns readily with a good chimney draft.
But with modern stoves, wood can be too dry and too
volatile. Smoke and combustible gases can ‘gas out’
from the wood quickly and densely enough to overload
the combustion system. If you hear a rumbling or roaring noise (like a propane torch) from the stove, that is asign that the stove is overfiring.

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

Draft TestingAn easy way to test your chimney draft is to close thestove’s damper, wait a few minutes to let the airflow
stabilize, then see whether you can vary the strength of
the fire by swinging the air control open and closed. Results are not always instant; you may need to wait a few
minutes for a change in the air control setting to havean effect on the fire. If there’s no change, then the draft
isn’t strong enough yet to let you close the damper, andyou’ll need to open it for awhile longer and manage thefire with the air inlet until the draft strengthens. If you
keep track of your burning habits and relate them totheir effects on the stove’s operation, you’ll be rewarded
with good performance and a safe system.

Negative Pressure
Good draft also depends on a supply of air to thestove; a chimney can’t pull in more air than is available to it. Sluggish draft results when a house is tightenough to prevent the ready flow of air to the stove, orby competition between the stove and other equipmentthat sends indoor air outside - especially power-driven
equipment like range hoods, clothes dryers, etc. If thechimney draws well with all other equipment turnedoff (or sealed, in the case of fireplaces and/or otherstoves), then you simply need to be careful with timing
the use of the other air consuming equipment. If you
need to crack a nearby window or door to enable thechimney to flow well, it may be a good idea to install an
outside-air intake to bring combustion air directly to thestove. An outside air kit is available to connect the stove
directly to a source of outdoor combustion air.
27

Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
Conclusion
Wood-burning is an art rather than a science. Once thestove and chimney system are in place, you can only
vary your technique, mostly your timing, to achieve
good results. If you keep track of your burning habits
and relate them to their effects on the stove’s operation,
you’ll be rewarded with good performance and year of
reliable heating.

28

30005295

Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove

Maintenance
Keep Your Stove Looking New
and Working Its BestLet the fire in the stove go out and allow the stove tocool completely before beginning any maintenanceprocedure.

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

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

If you need to replace the glass, use only the hightemperature 5 mm ceramic glass supplied by Vermont
Castings. Do not use substitutes.

Removing the Glass
1. Remove the right and left door assemblies by raising the door until the lower hinge pin clears its hole;then, angle the door bottom slightly outward and pull
down to release the upper hinge pin. Place the doors
face down on a padded work surface. Be especiallycareful 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 softand resilient so that the glass will seal properly against
the door. Replace the gasket if it has hardened or if it iscompressed.
1. Center the glass on the gasket.
2. Secure the glass on both doors with the retainer
clips. Tighten all screws. (Fig. 41)
3. Replace the doors on the stove.
4. Open and close the doors to check that they fit andwork properly. Adjust as necessary.
Right Door
GasketCleaning the Glass

Glass Panel

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

Retainer
Clips (4)• Be sure the glass is completely cool.
• Clean the glass with water or a cleaner made espe-••

cially for this purpose. Do not use abrasive cleaners.
Use cleaning agents sparingly and be sure to keepthem 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 isdamaged.
30005295

ST854

Fig. 41 Exploded view of the glass assembly for the right
door.

ST854
glass xview
7/05

29

Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
Adjust the Damper as Needed

Roller

The tension on the Encore’s damper is adjustable tocompensate for compression of the gasket that seals
the damper to the upper fireback. To adjust the damper:
1. Remove the griddle. Loosen the lock nut at the center of the damper. (Fig. 42)
2. Turn the pressure screw approximately one half turnclockwise with an Allen wrench provided with yourstove.
3. Tighten the lock nut. Prevent the pressure screwfrom turning as you tighten the nut. Re-test thedamper.

Shoulder Screw

Lock Nut
Set Screw
Flat Washer

Pressure Adjusting Screw
Allen
WrenchLock Nut
DamperST554

Fig. 42 Adjust the damper with the Allen wrench.

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

How to Adjust the Door Latches
The front door of the stove should close securely toprevent accidental opening and should close tightly toprevent air from leaking into the fire chamber. The door
handle will be positioned vertically when the door isclosed.
Over a period of time, the gasket around the door willcompress and the latch may need adjustment. To adST554
just the handle, follow thisprocedure:

Damperadjustment
1. Remove and retain thelock nut witha 9/16” wrench.
(Fig. 43)
11/00
2. Loosen the set screw with a 1/8” Allen wrench.
3. Rotate the pawl 180°. Replace the lock nut. Tighten
the set screw.
4. Additional adjustment can be made by removing theflat washer. Or any combination of washer removal
and/or pawl rotation.
Test the door seal. Close the door on a dollar bill andattempt to pull it free. If the bill is freed with little resistance, the gasket isn’t snug enough at that spot.
Continue to make small adjustments until the setting isright.
30

Handle Stub

ST1154

Fig. 43 Rotate pawl and/or remove flat washer to adjust
latch.

If additional adjusting of the latch does not enable theST1154
door to seal sufficiently
in one area, try “adjusting” thedoormorepawlcement or a smaller
gasket in that area. Pack
diameter gasket into the channel beneath the gasket so
the main gasket is raised and makes contact with thedoor frame. If this procedure doesn’t solve the problem,
replace the gasket. Instructions for gasket replacement
are given later in this section.

Replace the Stove Gaskets as NeededYour Encore uses fiberglass rope gaskets to makea tight seal between some parts. With use, particularly on moving parts, gaskets can become brittle andcompressed and can begin to lose their effectiveness.
These will need periodic replacement.
The sizes of replaceable gasket are listed below, alongwith 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
3/8”
		

the front doors to the stove front; andthe doors to each other.

3/8”
		

The ash door to the front of the bottom
panel

3/16”

The outer glass panes to the door

If you need to change a gasket, first obtain an appropriate replacement from your Vermont Castings’ Authorized Dealer.
Wait until the fire is out and the stove has cooled. Be
sure to follow the standard safety procedure for working
with dusty materials: wear safety goggles and a dust
mask.
The procedure for replacing gaskets is the same, regardless of the gasket location. Follow these steps:
30005295

Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
1. Remove the existing gasket by grasping an end andpulling firmly. (Fig. 44)
2. Use a wire brush or the tip of a screwdriver to clean
the channel of any remaining cement or bits of gasket.
Remove stubborn deposits of cement with a cold chisel
if necessary. (Fig. 44)

ST560

Fig. 44 Remove gasket then clean channel with wire brush.
ST559

3. Determine the correctRemove
length of the appropriate-sizedgasket by laying it out ingasket
the channel. Allow an extra
11/30/00 djt
1-2” (25-50 mm), and markthe spot to be cut.
4. Remove the gasket from the channel, place it on awood cutting surface, and cut it at the marked spot witha utility knife.
Twist the ends slightly to keep the gasket from unraveling.
5. Lay an unbroken 1/8” (3 mm) bead of silicone or cement in the newly-cleaned channel. (Fig. 45)

etask
ve G ent
Sto Cem

ST561

Fig. 45 Lay a bead of gasket silicone or cement then press
gasket in place.

6. Starting at one end, ST559
press the gasket into the channel. (Fig. 45) Ensure a Remove
good joint where the gasket
meets before trimming gasket
any excess. Do not overlap thegasket ends or leave ends
with djt
ragged edges.
11/30/00
7. Press the gasketed part firmly against its normal
mating surface to seat the gasket evenly in its channel.
Close and latch the door to do this, or tap other parts
with the rubber mallet (or hammer/block of wood).
8. Clean any excess cement from around the channel, then let the cement that holds the new gasket dry
thoroughly.
9. The stove’s doors may need adjustment after you
have regasketed them. Initially, it may require loosening
30005295

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 30.

All Gasketed Construction Gaskets
Other gaskets form seals between all other non-moving
parts, but these are not subject to the same wear anddeterioration as gaskets on moving parts. It is unlikelythat you will ever need to replace these gaskets unlessthe involved parts are disassembled and then put back
together. If this is the case, the job should be done only
by a qualified service technician.
5/16” diameter gasket seals the following parts:• The lower fireback to the back panel• The left and right air plates (inner sides)• All connections between the stove plates.

The Chimney System
Creosote
Your Encore is designed to reduce creosote build-up
significantly. However, regular chimney inspection andmaintenance must still be performed. For safety, goodstove performance, and to protect your chimney andchimney connector, inspect your chimney and chimney
connector on a regular schedule. Clean the system ifnecessary. 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, creosote residue
accumulates on the flue lining. When ignited, this creosote makes an extremely hot fire within the flue systemthat can damage the chimney and overheat adjacentcombustible material. If a significant layer of creosote
has accumulated —1/8” (3 mm) or more — it should be
removed to reduce the risk of a chimney fire.
You can never be too safe. Contact your local fire
authority for information on what to do in the event ofa chimney fire, and have a clearly understood plan on
how to handle one.
If you do experience a chimney fire, act promptly to:• Close the damper and air control lever.
• Get everyone out of the house.
• Call the Fire Department.
Inspect the system every two weeks during the heating season as part of a regular maintenance schedule.
To inspect the chimney, let the stove cool completely.
Then, using a mirror and a strong light, sight up throughthe 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.
31

Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
Clean the chimney using a brush the same size andshape 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.

The Chimney Connector
TWO WEEKS:• Inspect the chimney connector and chimney. Clean if
necessary.

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.

TWO MONTHS:

If you cannot inspect or clean the chimney yourself,contact your local Vermont Castings dealer or a professional chimney sweep.

Annual Spring Cleaning:

Maintenance Schedule
The Stove• Inspect the chimney and chimney connector. Pay

particular attention to the horizontal runs of chimney
connector, and the elbows. Clean the system if necessary.

• Disassemble the chimney connector and take it•

DAILY:• Clear any ash build-up from around the air holes andcombustion flow path in the lower fireback.
• Ashes should be removed before they reach the topof the ash pan. Check accumulation at least once aday.
• Keep the area around the stove clear of any combustible materials such as wood, furniture or clothing.
TWO MONTHS:• Check door handle to be sure it is working properly.
Gasketing becomes compressed after a period oftime. Adjust handle tightness if necessary.
• Check leg bolts and heat shield screws; tighten if
necessary.
Annual Spring Cleaning:• Check gasketing for wear, and replace if necessary.
• Remove ashes from the ash pan and replace with amoisture absorbing material (such as kitty litter) to
keep the interior of the stove dry.
• Clean the dust from the inner sides of bottom, rear or
pipe heat shields if your stove is equipped with them.
Clean surfaces are better heat reflectors than dirty
surfaces.
• Touch up the black paint.
• Inspect for and remove ash build-up behind the combustion package. This should be done in conjunction with annual cleaning of the chimney connector.
Inspect the passage behind the combustion package(a mirror will be helpful) and vacuum away ash using a flexible vacuum hose inserted in the passage.
(Fig. 46)

32•

outdoors for inspection and cleaning. Replace weaksections of connector.
Inspect the chimney for signs of deterioration. Repairs to a masonry chimney should be made by aprofessional mason. Replace damaged sections ofprefabricated chimney. Your local Vermont Castings
dealer or a chimney sweep can help determine whenreplacement is necessary.
Thoroughly clean the chimney.

Clean
out anyash buildup

Remove these components

ST1162

Fig. 46 Inspect and clean out ash accumulation behind the
combustion system.

ST1162ash clean out

30005295

Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
The Catalytic Element
This wood heater contains a catalytic combustor, whichneeds periodic inspection and replacement for proper
operation. In the United States it is against the law tooperate this wood heater in a manner inconsistent withthe operating instructions in this manual.
Under normal operating conditions, the catalytic combustor should remain active for two to six years (depending on the amount of wood burned). However, it
is important to monitor the combustor periodically toensure that it is functioning properly, as well as to determine when it needs to be replaced. A non-functioning
combustor will result in a loss of heating efficiency, andan increase in creosote and emissions.

Once you have ruled out any other possible causes fora decline in performance, inspect and clean the combustor if necessary. Be sure to protect any surface you
use for setting the stove parts aside.

Inspecting the Combustor
Remove access door and inner fireback. Remove thecatalytic combustor by lifting and sliding it towards you.
(Fig. 47)

Catalyst

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

When to Suspect a Combustor Problem
The best way to evaluate the performance of your
Encore’s combustor is to observe the amount of smoke
leaving the chimney — both when the combustor has“lighted-off” and when it has not. Follow these steps:• With a fire going and the combustor properly activated, with the damper closed to route smoke throughit as described in the Operation Section, go outside
and observe the smoke leaving the chimney.

• Then, open the stove damper and once again checkthe smoke leaving the chimney.		
You should see significantly more smoke when thestove damper is open and exhaust does not passthrough the combustor. However, be careful not to
confuse smoke with steam from wet wood. Steam dissipates in the air quickly; smoke does not.

If this test indicates a problem, consider other possible
factors as well, such as the weather or a change in thequality of your fuel. In warm weather, draft is weaker
than it is in colder winter weather, and fires can burnsluggishly. Small, hot fires are a good solution underthese conditions.
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.
30005295

Inner Fireback

Access Door

ST1180Fig. 47 Inspect the catalytic combustor.

To assure a long life for the combustor, it is recomST1180
mended to service the
combustor on a regular basis
based on the amountcatalystof use.accessThis procedure takes
about five (5) minutes and requires no tools except for a
vacuum if cleaning is necessary.

Cleaning the Combustor
1. Check the combustor’s honeycomb-like element
for a buildup of fly ash. If any is evident, take the
combustor outside and clean it by blowing air gently
through it. Do not push anything through the honeycomb; do not use compressed air to clear the passages. Such abrasion can scrape the thin coating of
platinum (the catalyst) off the ceramic base, shortening the catalyst’s life and reducing its effectiveness.
2. Inspect the element for damage or degradation.
Although small hairline cracks will not affect performance, the element should be essentially intact.
If the element is broken in pieces or has sections
missing, it should be replaced. Call your local Vermont Castings Authorized Dealer for a replacement
element.
33

Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
3. If the element is in good condition and clean, re-install it in the stove and replace the refractory inner
fireback and access door.
Operate the stove in your usual manner for two weeks,
inspecting the chimney and the chimney connector
frequently during this period.
If creosote does not build up as fast, it is likely that theperformance change was caused by fly ash deposits
on the catalytic element. However, continue the inspections of the chimney system for a few weeks to ensurethat proper performance continues.
If you continue to find a significant creosote buildup or if
you continue to see excessive smoke from the chimney,the catalytic element will need to be replaced. Contact
your nearest Vermont Castings’ Authorized Dealer for
information about a replacement element.
NOTE: Use only the replacement catalyst supplied by a
Vermont Castings dealer.

34

30005295

Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
9a

9b

14

17

9

12

20

11

2

21
22

56

63
19
33

80
3
16

57

1

10

78

58
18

60

32
41

23

35

8

13

23
25
44

84
46
43

15

42

6

43
38

4

86

31

36

85

7

76

71

87 27 26

39

65
72

24
77

45

68

40

82
49

74
26

30

29

37

67

34

28 73

75

47

5

72

81

70

59
79

61

27

16
55

49

79
65

82

48
83

69
62

83b

83a
53

52

50

51

54

MHSC reserves the right to make changes in design, materials, specifications, prices and discontinue colors and products at any time, without
notice.

Encore Noncatalytic/Catalytic Woodburning Stove
30005295

35

Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove

Encore Noncatalytic/Catalytic Woodburning Stove Model 2040 (continued)
		Item Description	Part Number
1.
2.
3.
4.
5.
6.
7.
8.
9.
9a.
9b.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.

36

Brick Support Bracket
Griddle Gasket
Back
Refractory Rt End
Refractory Lt End
Refractory Support
Gasket, Fiber, Refractory Support
Back Insulation Board
Outer Back
Right Air Deflector
Left Air Deflector
Left Griddle Quadrant
Right Griddle Quadrant
GriddleHS Flue Collar
Bracket Upper Side
Catalyst, Ceramic
Damper Ashdoor Gasket
Damper Ramp
Damper Housing
Damper1
Damper Tab1
Damper Rod1
Griddle Handle Assy
Gasket, Fiber Back Refractory
Rheostat Bracket
Refractory, Engine - E/D
Damper Handle Screw
Damper Handle
Damper Handle w/Screw Assy
Left Side
Left Air Manifold
Right Air Manifold
Right Side
Thermostat Handle Base Assy
Washer Damper Rod
Fireback Plate, S/S
Inner Bottom
Ashdoor Hinge Upper
Door Handle Bracket
Bottom Outer
AshlipGasket, Fireback
Refractory, Fireback
Retainer, Inner Cover Refractory
Refractory, Inner CoverAndironRefractory, Access Cover
Leg Leveller
Ashdoor Handle Shaft
Pawl Assy
Ashdoor

30005279
1203668
30005289
30005497
30005498
30005233
30005237
30005269
30005261
30005314
30005315
30002399
30002401
30002386
30005266
30005267
30005353
1203588130181130005293
30002389
16014881600851
30002775
30005270
30002863
30005202
12013101600664
30002720
See Chart Pg. 37
30002408
30005290
See Chart Pg. 37
30002716
1202560
30005217
30005291
30002403
30002909
30005292
See Chart Pg. 37
30005209
30005302
30005248
30005205
30002397
30005303
1201745160062230005157
30002392

		Item Description	Part Number
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
74a.
74b.
75.
75a.
76.
77.
78.
79.
80.
81.
82.
83.
83a.
83b.
84.
85.
86.
87.

Ashdoor Handle (Wood)
Ashdoor Hinge Rod
Cotter Pin, Ashdoor
Ashdoor Hinge Lower
Ashpan Bracket
Lower Side Bracket
Thermostat Handle
Front Manifold
Front
Flue Collar Gasket
Left Door
Door Hinge Strip
Top
Glass Clip Long
Front Door Handle & Shaft
Right Door
Door Gasket
Glass Gasket
Left Door Glass
Right Door Glass
Door Hinge Pin
Spacer (for Damper rod)Primary Air Valve Assy.
Primary Air Frame
Primary Air Rod
Complete Handle Assy
Handle Base Stub
Thermostat Friction Spring
Thermostat Cable
Thermostat Handle Bolt
Ash Pan Assy
Flue Collar
Leg
Hex Head Jam Nut
Bottom Heat Shield
Bottom Heat Shield Rt Wing
Bottom Heat Shield Lt Wing
Grate Bottom
Thermostat Assy.
WasherHandle Base Stub

1600663
30002473
30001749
30002404
1601039
30005268
1600660
30002407
See Chart Pg. 37
30002422
See Chart Pg. 37
1308634
See Chart Pg. 37
1601396
30002717
See Chart Pg. 37
12035881203556
30005300
30005299
30002727
1201779
30005324
130741130005260
30004175
30002714
1201846500547112012435005746
See Chart Pg. 37
See Chart Pg. 37
1203290
30002470
30005030
30005031
30005294
50054701202471
30002714

30005295

Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove

Encore Noncatalytic/Catalytic Woodburning Stove Model 2040 (continued)
Shell Enamel Parts - Encore Model 2040						

Brown
	Part Name	Classic	Biscuit	Bordeaux	Ebony
Majolica
Top
30002387
30003055
30002615
30003075
30004879
Left Side
30002388
30003052
30002613
30003072
30004876
Right Side
30002405
30003053
30002612
30003073
30004877
Flue Collar
1305050
30003160
2325050
30003162
30004873
Front
30002393
30003054
30002614
30003074
30004878
Ashlip
30002402
30003051
30002610
30003071
30004875
Left Door						Subassy*
30003974
30003984
30003976
30003988
30004882
Left Door
30003938
30003958
30003950
30003962
30004884
Right Door						Subassy*
30003975
30003985
30003977
30003989
30004881
Right Door
30003939
30003959
30003951
30003963
30004883
Single Leg
30002396
30003050
30002611
30003070
30004874*Does not contain glass or glass gasket.

NOTES:In the 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 parts, be sure to specify color.
The hardware in the Encore is in standard sizes; most bolts are 1/4”
diameter by 20 threads per inch. Most hardware stores can supply replacement hardware if you specify bolt diameter, number of threads perinch and length. Fasteners inside the firebox should be replaced withstainless steel for ease of future disassembly.

30005295

37

Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove

38

30005295

Encore 2040
Non-Catalytic / Catalytic Woodburning Stove
LIMITED LIFETIMEWARRANTY®

Limited Lifetime Warranty

MHSC warrants that all refractory brick and material used in this productwill be warranted against deterioration not resulting from physical damage or overloading of the woodstove for the lifetime of this product. This
coverage includes the components of the 2N1 System: “engine, innercover, access cover and fireback.” In addition all cast iron parts are warranted against breakage, cracking or burn-through and glass door panels
against thermal breakage. Coverage is provided only to the original purchaser. MHSC will also pay labor associated with repairing or replacing
the component described above for up to five years.

Limited 5 Year Warranty

The porcelain finish is warranted to be free of defects in material andworkmanship for a period of five years from the date you purchase thestove. Warranty excludes chipping, scratching or other surface damage
to the porcelain that might result from normal wear and tear and also
excludes failure of porcelain coating due to misuse or overfiring.

Limited 1 Year Warranty

The following parts of the woodburning stove are warranted to be free of
defects in material and workmanship for a period of one year from the date
you purchase the stove: handles, gasketing and thermostat assembly
As designated in the descriptions above, MHSC will repair or replace, at
its option, any part found to be defective upon inspection by a Vermont
Castings, Authorized Dealer. The customer must return the defective partor the stove, with shipping prepaid, to the Authorized Dealer or pay for
any Authorized Dealer in-home travel fees or service charges for in-home
repair work. It is the dealer’s option whether the repair work will be donein the customer’s home or in the dealer’s shop. If, upon inspection, thedamage is found to be the fault of the manufacturer, repairs will be authorized at no charge to the customer for parts and/or labor. Labor rates
will be determined by MHSC’s published labor rates in effect at the timelabor is performed.
Any parts repaired or replaced during the limited warranty period will bewarranted under the terms of the limited warranty for a period not to exceed the remaining term of the original limited warranty or six (6) months,
whichever is longer.

Limited Catalyst Warranty

The catalyst will be warranted for a six year period as follows: If theoriginal catalyst or a replacement catalyst proves defective or ceases tomaintain 70% of its particulate emission reduction activity (as measured
by an approved testing procedure) within 24 months from the date thestove is received, the catalyst itself will be replaced free.
From 25 - 72 months a pro-rated credit will be allowed against a replacement catalyst and the cost of labor necessary for its installation at thetime of replacement.
A third year (25 - 36 months) of no charge replacement will be madewhen combustor failure is due to thermal degradation of the substrate(crumbling of ceramic material). The customer must pay for any in-hometravel fees, service charges, or transportation costs for returning thestove to the Authorized Dealer.
Amount of Time
Credit Towards
Since Purchase
Replacement Cost
0 - 24 months
100%
25 - 36 months
50%
37 - 48 months
30%
49 - 60 months
20%
61 - 72 months
10%
Any replacement catalyst will be warranted under the terms of the catalyst
warranty for the remaining term of the original warranty. The purchaser
must provide the following information in order to receive a replacement
catalyst under the terms of this limited warranty:
1. Name, address and telephone number.
2. Proof of original purchase date.
3. Date of failure of catalyst.
4. Any relevant information or circumstances regarding determination of
failure.
5. In addition, the owner must return the failed catalyst.

30005295

Exclusions & Limitations

1. This product must be installed or serviced by a qualified installer,
preferably NFI or WETT (Canada) certified, as prescribed by the local jurisdiction. It must be installed and operated at all times in accordance with the Installation and Operating instructions furnishedwith the product any alterion, willful abuse, accident or misuse of thisproduct shall nullify this warranty.
2. This warranty does not cover misuse of the stove. Misuse includes
overfiring which will result if the stove is used in such a manner as tocause one or more of the plates to glow red. Overfiring can be identified later by warped plates and areas where the paint pigment hasburned off. Overfiring in enamel fireplaces is identified by bubbling,
cracking, chipping and discoloration of the porcelain enamel finish.
MHSC offers no warranty on chipping of enamel surfaces. Inspect
your woodburning stove prior to accepting it for any damage to theenamel.
3. This warranty does not cover misuse of the stove as described in the
Owner’s Guide, nor does it cover an stove which has been modified
unless authorized by a MHSC representative in writing. This warranty
does not cover damage to the stove caused by burning salt saturated
wood, chemically treated wood, or any fuel not recommended in the
Owner’s Guide.
4. This warranty does not cover a stove repaired by someone otherthan a Vermont Castings Authorized Dealer.
5. Damage to the unit while in transit is not covered by this warranty but
is subject to a claim against the common carrier. Contact Vermont
Castings Authorized Dealer from whom you purchased your stove or
MHSC if the purchase was direct. (Do not operate the stove as thismay negate the ability to process the claim with the carrier.)
6. Claims are not valid where the installation does not conform to local
building and fire codes or, in their absence, to the recommendations
in our Owner’s Guide.
7. The salt air environment of coastal areas, or a high-humidity environment, can be corrosive to the porcelain enamel finish. These conditions can cause rusting of the cast iron beneath the porcelain enamel
finish, which will cause the porcelain enamel finish to flake off. This
warranty does not cover damage caused by a salt air or high-humidity environment.
8. MHSC shall have no obligation to enhance or update any unit once
manufactured.
IN NO EVENT SHALL MHSC BE LIABLE FOR INCIDENTAL AND CONSEQUENTIAL DAMAGES. ALL IMPLIED WARRANTIES, INCLUDINGTHE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS,
ARE LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY.
THIS WARRANTY SUPERCEDES ALL OTHER ORAL OR WRITTENWARRANTIES.
Some states do not allow the exclusion or limitations of incidental andconsequential damages or limitations on how long an implied warranty
lasts, so the above limitations may not apply to you. This warranty gives
you specific rights and you may have other rights which vary from state
to state.

How to Obtain Service

If a defect is noted within the warranty period, the customer should contact a Vermont Castings Authorized Dealer or MHSC if the purchase was
direct with the following information:
1. Name, address, and telephone number of the purchaser.
2. Date of purchase.
3. Serial number from the label on the back.
4. Nature of the defect or damage.
5. Any relevant information or circumstances, e.g., installation, mode ofoperation when defect was noted.
A warranty claim will then start in process. MHSC reserves the right towithhold final approval of a warranty claim pending a visual inspection of
the defect by authorized representatives.

39

Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove

MHSC

149 Cleveland Drive • Paris, Kentucky 40361
www.mhsc.com

40

30005295