Installation & Operating Manualdownloads.hearthnhome.com/installManuals/20000966_Intrepid_38.pdfThe French language version of this manual is available online: La version ... Installation

1 Vermont Castings • Intrepid II Installation & Operating Manual_R49 • 04/18 3-90-2000966

The French language version of this manual is available online: www.vermontcastings.comLa version française de ce manuel est disponible en ligne: www.vermontcastings.com

DO NOT DISCARD THIS MANUAL

SAFETY NOTICEIF THIS APPLIANCE IS NOT PROPERLY INSTALLED, OPERATED AND MAINTAINED, A HOUSE FIRE MAY RESULT. TO REDUCE THE RISK OF FIRE, FOLLOW THE INSTALLATION INSTRUCTIONS. FAILURE TO FOLLOW INSTRUCTIONS MAY RESULT IN PROPERTY DAMAGE, BODILY INJURY OR EVEN DEATH. CONTACT LOCAL BUILDING OFFICIALS ABOUT RESTRICTIONS AND INSTALLATION INSPECTION REQUIREMENTS IN YOUR AREA.

0966Intrepid Cover11/00

For use in the United States and Canada

Installation & Operating ManualInstallation and Appliance Setup

Intrepid® II Wood Burning StoveModel 1990

INSTALLER: Leave this manual with party responsible for use and operation.OWNER: Retain this manual for future reference.

NOTICE: SAVE THESE INSTRUCTIONS

Please read this entire manual before installation and use of this wood-burning room heater. Failure to follow these instructions could result in property damage, bodily injury or even death.

• Donotstoreorusegasolineorotherflammablevaporsand liquids in the vicinity of this or any other appliance.

• Donotoverfire-Ifanyexternalpartstartstoglow,youareoverfiring.Closeaircontrols.Overfiringwillvoidyour warranty.

• Comply with all minimum clearances to combustibles asspecified.Failuretocomplymaycauseahousefire.

WARNING!

Testedandapprovedforusewithdry,seasonedcordwoodonly. Do Not Burn Wet or Green Wood. Burning any other type of fuel will void your warranty.

CAUTION!


WelcomeCongratulationsonyourchoiceofaVermontCastingsIntrepidII.Withthispurchase,youmadeacommitmenttomakethehearthaplaceofwarmth,beautyandcomfortinyourhome.AtVermontCastings,wesharethatjoyandappreciationofthehearth,andweshowitinallourcastironstovesandfireplaces.

Asyoubecomeacquaintedwithyournewstove,youwillfindtheaestheticappealofcastironismatchedonlybyitssuperbcapacity to absorb and radiate heat.

Also,VermontCastingsproductsareamongthecleanestburningwoodstovesandfireplacesavailabletoday.AsanownerofaVermontCastingsstove,youaremakingastrongstatementforpollution-freeenergy.Butcleanburningdependsonboth the manufacturer and the operator. Please read this manual carefully to understand how to properly operate your stove.

AtVermontCastings,weareequallycommittedtoyoursatisfactionasacustomerandthatiswhywemaintainanexclusivenetworkofthefinestdealersintheindustry.Chosenfortheirexpertiseanddedicationtocustomerservice,ourdealersarefactory-trainedandknoweachVermontCastingsproductindetail.FeelfreetocontactyourAuthorizedVermontCastingsDealer anytime you have a question about your stove or its performance.

WehavebuiltyourVermontCastingsIntrepidIIwiththeutmostcare.Withnormaluseandpropercare,itwillprovideyouwith many years of service.

This manual contains valuable instructions on the installation and operation of your Vermont Castings stove. You will also findusefulinformationonassemblyandmaintenanceprocedures.Weurgeyoutoreadthemanualthoroughlyandtokeepit as a reference.

Sincerely,Vermont CastingsThismanualdescribestheinstallation,operation,andmaintenanceoftheVermontCastingsIntrepidIIModel1990catalytic-equippedwoodburningheater.Thisheatermeets theU.S.EnvironmentalProtectionAgency’semission limits forwoodheaterssoldonorafterMay15,2015.Underspecifictestconditionsthisheaterhasbeenshowntodeliverheatatratesrangingfrom8,200to26,700Btu/hr.

TheIntrepidIIModel1990hasbeentestedandislistedbyCanadianStandardsAssociation(CSA).TheteststandardsareANSI/UL-1482-2011andANSI/UL-737for theUnitedStates,andULCS627-00andCAN/CSA-B366.2 forCanada.TheIntrepidIIislistedforburningwoodonly.Donotburnotherfuels.TheIntrepidIIisapprovedforuseinmanufactured(mobile)homesonlyintheUnitedStates,andonlywheninstalledwithVermontCastingsMobileHomeKitNo.3248.

InstallationorserviceofthisWoodburningstoveshouldonlybecompletedbyaqualifiedinstaller,preferablyNFIorWETT(Canada)certified.

Please read this entire manual before you install and use your new stove. Failure to follow instructions may result in property damage,bodilyinjury,orevendeath.


AskyourVermontCastingsdealerhowtheseinstallationaccessoriescanenhancetheversatility,appearance,andsafetyofyourIntrepidStove.0172 RearHeatShieldChimney connector heat shieldsHeavy-gaugeenamelpipetomatchthestove’scolorWarming shelves:0098 ClassicBlack 1380 Bordeaux1373 BrownMajolica 1376 Biscuit3258 Outsideairkit0136 Sparkscreenforopen-fireplaceuse

Proposition 65 Warning: Fuels used in gas,Woodburning or oil fired appliances, and the products ofcombustionof such fuels, contain chemicals known totheStateofCaliforniatocausecancer,birthdefectsandother reproductive harm.CaliforniaHealth&SafetyCodeSec.25249.6

Specifications ............................................................4Dimensions ................................................................5Installation ..................................................................6 OutsideAir ............................................................6 MasonryChimneys ...............................................7 ChimneySize ........................................................7 Chimney Connector Guidlines ..............................7 Single Wall chimney Connector ............................8 FreestandingChimneyInstallations ......................8 FireplaceChimneyInstallations ............................9 FloorProtectionforFireplaceInstallations .......... 11 ReducingClearances ..........................................12 AlcoveInstallations .............................................14Clearances ...............................................................15Assembly..................................................................19 StoveSet-Up .......................................................19 SmokeandCODetectors ...................................20 Safety Tips ..........................................................20

Table of Contents

= Contains updated information

Operation ..................................................................21 Stoves Controls ...................................................21 BuildingandMaintainingaWoodFire ................25 AshDisposal .......................................................26 DraftManagement ..............................................26Maintenance .............................................................29 CareofCastIronSurface ...................................29 Care of Porcelain Enamel Finish ........................29 GlassCleaningandReplacement ......................29 Care of the Catalytic Combustion System ..........30The Chimney System ..............................................33Catalytic Combustor ...............................................34Service Parts List ....................................................35Warranty ..................................................................40


SpecificationsMODEL: IntrepidIIModel1990LABORATORY: IntertekTestingServicesREPORT NO. J97011860-231

TYPE: SolidFuelTypeRoomHeaters/SpaceHeatersforUsewithSolidFuel

STANDARD(s): UL1482-1996,ULC-S627-00

EPA Certification Number: 456EPA Certified Emissions: 2.1g/hr*LHV Tested Efficiency: 87.0%**HHV tested Efficiency: 81.1%***EPA BTU Output: 8,300-26,700****Peak BTU/Hour Output: 37,300Other Important InformationVent Size: 6Inch(152mm)Firebox Size: 3.1cu.ft.Max. Wood Length: 17"MaximumIdeal Wood Length: 16"Fuel Seasoned Cordwood

(20%moisture)

*Weighted average LHV (Low Heating Value) efficiency using Douglas Fir dimensional lumber and data collected during EPA emission test.**Weighted average HHV (High Heating Value) efficiency using Douglas Fir dimensional lumber and data collected during EPA emission test.***A range of BTU outputs based on EPA Default Efficiency and the burn rates from the low and high EPA tests, using Douglas Fir dimensional lumber.****A peak BTU out of the appliance calculated using the maximum first hour burn rate from the High EPA Test and the BTU content of cord wood (8600) times the efficiency.This wood heater needs periodic inspection and repair for properoperation.Itisagainstfederalregulationstooperatethis wood heater in a manner inconsistent with operating instructions in this manual.

Area Heated...................................600-1,800SquarefeetLoading ............................................................ Front or TopChimney Connector: ......................................6"(152mm)Flue Exit Position ...........................Reversible,toporrearPrimary Air ........Manuallyset,thermostaticallymaintainedSecondary Air ............................................Self-RegulatingGlass Panels ...........................High-TemperatureCeramicWeight ......................................................223lbs.(101kg.)


25-1/4"(640 mm)

Top exitflue collar

height

21-1/4"(540 mm)

24"(610 mm)

7-1/8"(180 mm)

21-1/2"(545 mm)

0966Intrepid IIspecifications11/00

21-1/4"(545 mm) 14"

(356 mm)

CL

22-1/2"(540 mm)

18"(460 mm) 1-1/4"

(31 mm)

20-1/2"(520 mm)

13-3/4"(350mm)

Figure 1-IntrepidII1990dimensions.

Drawings not to Scale

Dimensions


InstallationSAFETY NOTICE: IF YOUR STOVE IS NOT PROPERLY INSTALLED, A HOUSE FIRE MAY RESULT. TO REDUCE THE RISK OF FIRE, FOLLOW THE INSTALLATION INSTRUCTIONS. CONTACT LOCAL BUILDING OR FIRE OFFICIALS ABOUT RESTRICTIONS AND INSTALLATION INSPECTION REQUIREMENTS IN YOUR AREA.Beforeyoubeginaninstallation,reviewyourplanstoseethat:

• Your stove and chimney connector will be far enough from combustible material to meet all clearance requirements.

• Thefloorprotectorislargeenoughandisconstructedproperly to meet all requirements.

• You have all necessary permits from local authorities.Yourlocalbuildingofficialisthefinalauthorityforapprovingyour installation as safe and determining that it meets local and state codes.ThemetallabelpermanentlyattachedtothebackofeveryVermont Castings stove indicates the stove has been tested to currentULCstandards,byCanadianStandardsAssociation (CSA).The test standardsareANSI/UL-1482andANSI/UL-737fortheUnitedStatesandULCS627andCAN/CSA-B366.2 forCanada.Clearance and installationinformation also is printed on the label. When the stove is installed according to the information both on the label and inthismanual,localauthoritiesinmostcaseswillacceptthelabel as evidence that the installation meets codes and can be approved.However,codesvaryindifferentareas.Beforestartingtheinstallation,reviewyourplanswiththelocalbuildingauthority.You local dealer can provide any additional information needed.Foranyunresolvedinstallationissues,refertoCSACAN-B365InstallationCode for Solid Fuel BurningAppliances andEquipment. These standards are the basis for many national codes.Theyarenationallyrecognizedandareacceptedbymost local authorities. Your local dealer or your local building officialmayhaveacopyoftheseregulations.IMPORTANT: FA ILURE 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.

ST241chimney types12/13/99 djt

Aprefabricateddouble-wallinsulated chimney

Atile-linedmasonry chimney

Figure 2-Standardchimneytypes.

Outside Air:Insomemodern,super-insulatedhomes,thereisnotenoughairforcombustionbecauseofinsufficientairinfiltrationintothebuilding.Suchairentersahomethroughunsealedcracksandopenings.Kitchenorbathexhaust fanscancompetewith the stove for available air and compound the problem.Whenpoordraftiscausedbyalowinfiltrationrate,openingagroundfloorwindowonthewindwardsideofthehouseandin the vicinity of the stove will usually alleviate the problem.Anothersolutionistoinstallapermanentoutsideairsupplytothestoveand/orroom.Insomeareas,infact,bringingairfor combustion from outside the home directly to the air inlet of the stove is required for new construction. Anoutsideairsupplyisnotaffectedbypressurevariationswithin the house, and improved stove performance oftenresults.AnOutsideAirAdaptor Kit for the Intrepid II isavailable from your local Vermont Castings dealer. What Kind of Chimney to Use:Your Intrepid II must be connected to a code-approvedmasonry chimney with a flue liner, to a relined masonrychimneythatmeetslocalcodes,ortoaprefabricatedmetalchimney thatcomplieswith the requirements forTypeHTchimneys in the Standard for Chimneys, Factory-Built,ResidentialTypeandBuildingHeatingAppliance,UL103,ortheHighTemperature(650°C)StandardULCS-629forCanada.Whateverkindyouuse,thechimneyandchimneyconnectormustbeingoodconditionandkeptclean.Figure2 shows the two chimney types.


Figure 3-The2’-3’-10’ChimneyRule.

2' Min.

2' Min.

3'Min.

0 To 10'

3'Min.

0 To 10'

AC617RLTSKC8

2/11/98

ReferencePoint

Chimney Size:AnIntrepidIIisapprovedforventingintoamasonrychimneywithamaximumfluesizeof8"x8"(203x203mm),andintoaroundfluesizeof6"(150mm).Itmaynot be vented into larger chimneyswithout a linerto reduce theeffective flue size to 6"(150mm)diameter.Larger chimneysmust have their flues relined for properstove performance. AccessoriestomaketheconnectionbetweenstainlesssteelchimneylinersandyourIntrepidIIareavailablethroughyourlocal dealer.Chimney Connector Guidelines:Chimney connector is the double-wall or single-wall pipethat connects the stove to the chimney. The chimney is a masonryorprefabricatedstructure thatencloses theflue.Chimneyconnectorsareusedonlytomaketheconnectionfrom the stove to the chimney.Double-wallchimneyconnectorsmustbetestedandlistedforusewithsolid-fuelburningappliances.Single-wallchimneyconnectorsshouldbemadeof24gaugeorheaviersteel,andshouldbe6"(150mm)indiameter.Donotusegalvanizedconnector; it cannot withstand the high temperatures that canbereachedbysmokeandgases,andmayreleasetoxicfumes under high heat.Ifpossible,donotpass thechimneyconnector throughacombustiblewallorceiling.Ifpassagethroughacombustiblewall isunavoidable, refer to thesection followingonWallPass-Throughs.Donotpassthechimneyconnectorthroughanattic,acloset,oranysimilarconcealedspace.Thewholeconnectorshouldbeexposedandaccessibleforinspectionand cleaning. Inhorizontalrunsofsingle-wallchimneyconnectorwithoutprotectiveshields,maintainaclearanceofatleast26"(660mm)fromtheceiling.Forinformationonreducedclearancesusing shields on single-wall chimney connector or usingdouble-wallconnectors.Keep the horizontal run of chimney connector as shortanddirect as possible,with nomore than two90° turns.Slopehorizontalrunsofconnectorupward1/4"perfoot(20mmperm)goingfromthestovetowardthechimney.Therecommendedmaximumlengthofahorizontalrunis3’(914mm).Therecommendedtotallengthofchimneyconnectoris8’(2.4m).In cathedral ceiling installations, extend theprefabricatedchimneydowntowithin8’(2.4m)ofthestove.SAFETY NOTE: ALWAYS WEAR GLOVES AND PROTECTIVE EYE WEAR WHEN DRILLING, CUTTING OR JOINING SECTIONS OF CHIMNEY CONNECTOR.

Masonry Chimneys:Aninspectionofthechimneymustconfirmthatithasalining.Do not use an unlined chimney. The chimney should have no cracks,loosemortar,othersignsofdeterioration,orblockage.Repairanydefectsbeforeusingthechimneywithyourstove.Sealanyunusedopeningsinanexistingmasonrychimneywithmasonry to the thickness of the chimneywall, andrepairthechimneyliner.Openingssealedwithpieplatesorwallpaperareahazard;sealthemwithmortarorrefractorycement.Intheeventofachimneyfire,flamesandsmokemay be forced out of these unused thimbles.The chimney should be thoroughly cleaned before use.A newly-built masonry chimneymust conform to thestandardsofyourlocalbuildingcodeor,intheabsenceofalocalcode,toarecognizednationalcode.Masonrychimneysmustbelined,eitherwithcode-approvedmasonryorpre-castrefractory tiles, stainless steel pipe, or a code-approved,“poured-in-place”liner.Thechimney’sclean-outdoormustseal tightly.Prefabricated Chimneys:A prefabricated metal chimney must be one tested andlistedforusewithsolid-fuelburningappliancestotheHighTemperature(650°C)StandardULCS-629forCanada.DO NOT CONNECT THIS UNIT TO A CHIMNEY FLUE SERVING ANOTHER APPLIANCE.

Ifyouuseanexistingmasonrychimney,itmustbeinspectedto ensure safe condition before the stove is installed. Your localprofessionalchimneysweep,buildinginspector,orfiredepartment officialwill beable to inspect the chimneyorprovide a referral to someone who can.Thechimneymustextendat least3’(914mm)abovethehighestpointwhereitpassesthrougharoof,andatleast2’(610mm)higherthananyportionofabuildingwithin10’(3m).(Figure3)Forproperdraftandgoodperformance,anychimneyusedwithanIntrepidIIshouldextendatleast16’(5m)abovethefluecollarofthestove.


Double-wall Chimney Connector:ThelistingfortheIntrepidIIfortheU.S.andCanadaincludesuseofdouble-wallchimneyconnectorsthathavebeentestedand listed for usewith solid-fuel burning appliances by arecognizedtestinglaboratory.Information on assembling and installing double-wallconnector isprovidedby themanufacturerof thedouble-wall pipe. Follow themanufacturer’s instructions exactlyas you assemble the connector and attach it to the stove and chimney. Using connectors and chimneys from the samemanufacturermakes the assembly and installationstraightforward.NOTE: For installations using double-wall connectors, minimum clearances must conform to the listed clearances in the clearance chart.Single-wall Chimney Connector:• Beginningat thefluecollarof thestove,assemble the

chimneyconnector.Insertthefirstcrimpedendintothestove’sfluecollar,andkeepeachcrimpedendpointingtoward the stove.Using theholes in the fluecollar asguides, drill 1/8" (3mm)holes in the bottom of the first section of chimney connector and secure it to thefluecollarwiththree#10x1/2"sheetmetalscrews.

• Secureeachjointbetweens e c t i o n s o f c h i m n e y connec t o r, i n c l u d i ngtelescoping joints, with atleast three sheet metal screws.Thepre-drilledholesin the top of each section of chimney connector serve as guideswhenyoudrill1/8"(3mm)holesinthebottomofthenextsection.

• Securethechimneyconnectortothechimney.Instructionsfor various installations follow.

• Be sure the installed stove and chimney connector are correct distances from nearby combustible material.

NOTE: Special slip pipes and thimble sleeves that form telescoping jointsbetweensectionsofchimneyconnectorare available to simplify installations. They often eliminate the need to cut individual connector sections. Consult your local dealer about these special pieces.Securing the Single-wall Connector to a Prefabricated Chimney:Forprefabricatedchimneys,followtheinstallationinstructionsofthechimneymakerexactlyasyouinstallthechimney.Themakerofthechimneywillsupplytheaccessoriestosupportthechimney,eitherfromtheroofofthehouse,attheceilingoftheroomwherethestoveisinstalled,orfromanexteriorwall.

ST242Chimney connector

12/13/99 djt

Figure 4 - The crimpedend of the connector points toward stove.

ST243thinble connection

12/13/99 djt

Thimble Sleeve

Chimney Connector

Flue

Keepsleeve endflushwithfluetile

Figure 5 -Thethimble,madeofeitherceramicormetal,mustbecemented securely in place.

Freestanding Chimney Installations:Ifthechimneyconnectormustpassthroughacombustiblewall to reach thechimney, followtherecommendations intheWallPass-throughsectionthatfollows.The opening through the chimneywall to the flue (the“breach”)mustbelinedwitheitheraceramicormetalcylinder,calledthe“thimble,”whichiscementedfirmlyinplace.Thefitmustbesnugandthejointbetweenthethimbleandthechimneywallmustbecemented.(Figure6)Aspecialpiececalledthe“thimblesleeve,”slightlysmallerindiameterthanstandardconnectorandmostthimbles,willfacilitate the removal of the chimney connector system for inspection and cleaning. Thimble sleeves should be available fromyourlocaldealer.(Figure5)Toinstallathimblesleeve,slideitintothebreachuntilitisflushwiththeinnerfluewall.Donotextenditintotheactualfluepassage,asthiscouldinterferewiththedraft.Thethimblesleeveshouldprotrude1-2"(25-50mm)intotheroom.Use furnacecementand thingasketing toseal thesleeve in place in the thimble. Secure the chimney connector to the outer end of the sleeve with sheet metal screws.Withoutathimble,asuitable lengthofchimneyconnectorcanbeextendedthroughthebreachtotheinnerfaceoftheflueliner,andcementedsecurelyinplace.Additionalpiecesof connector are then attached with sheet metal screws.

Special adapters are available from your local dealer to maketheconnectionbetweentheprefabricatedchimneyandthe chimney connector. The top of such adapters attaches directlytothechimneyortothechimney’sceilingsupportpackage,whilethebottomoftheadaptorisscrewedtothechimney connector.Theseadaptersaredesignedsothetopendwillfitoutsidetheinnerwallofthechimney,andthebottomendwillfitinsidethefirstsectionofchimneyconnector.Whenassembledinthisway,anysootorcreosotefallingfromtheinnerwallsofthe chimney will stay inside the chimney connector. Securing the Single-wall Connector to a Masonry Chimney:For masonry chimneys, both freestanding and fireplacechimneysmaybeusedforinstallationofyourIntrepidII.


ST492aIntrepid IIfreestanding installation11/00

INTREPID II

Chimney

Elbow

Slip Pipe

Standard Chimney Connector

Flue Collar

Flue

Flue Liner

Thimble

Figure 6 - Chimney connection in a freestanding installation.

ST244Plymouthfplc over mantel12/99

Chimney Connector Shields

*CheckTheseClearances

*

*

Mantel

Seal the Damper

Figure 7-Chimneyconnectorenterschimneyabovethefireplace.

Through a Fireplace:Ifyourfireplaceheight isat least25"(635mm),youmayinstallanIntrepidIIwithstandardlegsthroughthefireplaceopeningusinga“positiveconnection”kitavailablefromyourlocaldealer.Thesepositiveconnectionkitsensureatightfitbetweenthestovefluecollarandthechimneyflue.(Figure8)Fireplaceinstallations,whetherconnectedtotheflueaboveor through the fireplace opening, have special clearancerequirementstoadjacenttrimandthemantel.Floor protection requirements also apply to fireplace installations. Wall Pass-Throughs:Wheneverpossible,designyourinstallationsotheconnectordoes not pass through a combustible wall. If you areconsideringawallpass-throughinyourinstallation,checkwithyourbuildinginspectorbeforeyoubegin.Also,checkwith thechimneyconnectormanufacturer foranyspecificrequirements.Accessoriesareavailableforuseaswallpass-throughs.Ifusingoneofthese,makesureithasbeentestedandlistedforuseasawallpass-through.

Fireplace Chimney InstallationsAbove a Fireplace:TheIntrepidIImaybeconnectedtoachimneyaboveafireplaceopeningalso.Insuchinstallations,thestoveispositionedonthehearthinfrontofthefireplaceandthechimneyconnectorrisesfromthestovetopandthenanglesninetydegreesbackintothechimney.(Figure7)Thechimneylinershouldextendtothepointatwhichthechimney connector enters the chimney. If thechimneyconnector fromyour installationenters thechimneyaboveafireplace,followalltheguidelinesmentionedaboveforfreestandinginstallations.Inaddition,givespecialconsideration to the following points:• Checktheclearancebetweenthestoveandthechimney

connector,andanycombustibletrimorthemantel.Usethenecessarycombinationofmantel,trim,andconnectorheat shields to achieve the required clearances.

• Check the clearance between the chimney connectorandtheceiling.Ifnoheatshieldsareused,theclearanceshouldbeatleast26"(660mm).Tofindouthowmuchthis clearance may be reduced with heat shields

• Thefireplacedampermustbesealedtopreventroomairfromescapinguptheflue.However,itmustbepossibletore-openthedampertoinspectorcleanthechimney.


ST245fireplace flex connector12/99

FlexibleConnector

MantelShield

FireplaceAdapterKit

Figure 8 -Chimneyconnectorenterschimneythroughthefireplaceopening.

T

ST493aBrick pass thru11/00

I NTIP D

REII

Wall Stud

Chimney Connector

Floor Protection

12"ofNoncombustible Material

Figure 9-Anapprovedwallpass-throughfortheUnitedStates.

T

ST494steelwall pass thru11/00

I NTIP D

REII

18"(460mm)clearanceall around the pipe

FlushMountedSheetMetalCover

Figure 10-Anapprovedwallpass-throughforCanada.

NOTE: DonotventyourIntrepidIIintoafactory-built(zero-clearance)fireplace.Theseappliancesandtheirchimneysarespecificallydesignedasaunitforuseasfireplaces.Itmayvoidthelistingorbehazardoustoadaptthemforanyother use.DO NOT CONNECT AN INTREPID II TO ANY AIR DISTRIBUTION DUCT OR SYSTEM.

ThreeothermethodsarealsorecommendedbyNFPA:

• Usingasectionofdouble-wall chimneywitha9" (230mm)clearancetocombustibles.

• Placing a section of chimney connector inside a ventilated thimble,whichinturnisseparatedfromcombustiblesby6"(150mm)offiberglassinsulatingmaterial.

• Placingasectionofchimneyconnectorinsideasectionof9"(230mm)diameter,solid-insulated,factory-builtchimney,with2"(50mm)ofairspacebetweenthechimneysectionand combustibles.

In Canada, The Canadian Standards Association hasestablished installation guidelines. The following illustration showsonemethod,inwhichallcombustiblematerialinthewall is cut away to provide the required 18"(460mm)clearancefortheconnector.Theresultingspacemustremainempty.Aflush-mountedsheetmetalcovermaybeusedononesideonly.Ifcoversmustbeusedonbothsides,each cover must bemountedonnoncombustiblespacersatleast1"(25mm)clear of the wall.Your local dealer or your local building inspector can provide details for other approved methods of passing a chimney connectorthroughacombustiblewallinyourarea.InCanada,this typeof installationmust conform toCAN/CSA-B365,InstallationCode for Solid Fuel BurningAppliances andEquipment.

In the United States,theNationalFireProtectionAssociation(NFPA) has established guidelines for passing chimneyconnectors through combustible walls. Many buildingcode inspectors follow these guidelines when approving installations. Figure 9 shows one NFPA-recommended method. Allcombustible material in the wall is cut away from the single-wallconnectortoprovidetherequired12"(305mm)clearance.Anymaterialusedtocloseuptheopeningmustbe noncombustible.


U.S. CANADAA 34" 38"(965mm)B 40" 44"(1118mm)C 10" 10"(254mm)D 6" 8"(203mm)E 16" 18"(457mm)

D

E

D D

A

B

D

D

A

E

D

C

ST500intrepidfloor protection11/10/00

Top Exit Rear Exit

Figure 11-Requiredfloorprotectordimensions.

ST247Rear exit floor dgrm12/14/99 djt

Wood framing requires protection from radiant heat

Figure 12 - Supporting timbers under fireplace hearth are considered to be combustible.

Keepinmindthatmanyraisedhearthswillextendlessthanthe required clearance from the front of the heater when it is installed. In such cases, sufficient floor protectionasdescribed above must be added in front of the hearth to satisfy theminimumfloor protector requirement from thefrontof thestove:18"(460mm)fromthe front inCanada.Fireplace hearths must also offer the required protection of 8"(203mm)oneitherside.Optional3"(76mm)shortlegsmaybeusedonlyonsuchhearths that meet the width and depth requirements outlined previouslyunder“floorprotection.”Hearth rugs do not satisfy the requirements for floorprotection. Fireplace installations also have special clearance requirements to the sidewalls, side decorative trim, andfireplacemantle.Refertotheinformationonfireplaceandmantel trim shields in this section.

In Canada,thefloorprotectorrequiredunderthestovemustextend18"(460mm)tothefront(labeled‘E’,Figure11),and8"(203mm)fromthesidesandrear.(‘D’,Figure11)TomeetCanadianrequirements,afloorprotectormustbeatleast38"(965mm)wideand44"(1118mm)deep.Floorprotectionalsomustextendunderthechimneyconnectorand2"(51mm)toeitherside.(‘C’,Figure11)For6"(152mm)connectorusedwiththeIntrepidII,theprotectormustbeaminimumof10"(254mm)wide,centeredundertheconnector.Floor Protection for Fireplace Installations Do not assume your fireplace hearth is completely noncombustible. Many fireplace hearths do not satisfy the “completelynoncombustible”requirementbecausethebrickorconcreteinfrontofthefireplaceopeningissupportedbyheavywoodframingasinFigure12.Becauseheatpassesthroughbrickorconcretereadily,itcaneasilypassthroughtothewood.Asaresult,suchfireplacehearthscanbeafirehazardandareconsideredacombustiblefloor.

Floor Protection:AtremendousamountofheatradiatesfromthebottomplateofanIntrepidII,andthefloorbeneathrequirestwokindsofspecial protection. Heatprotection isprovidedbyaBottomHeatShield,part#0307.Sparkandemberprotectionisprovidedbyafloorprotector,which may be any noncombustible material. Foranewhearth,werecommendanoncombustiblefloorprotector suchas 1/4" non-asbestosmineral board or itsequivalent,or24gaugesheetmetal.Ifcarpetingispresent,itmustberemovedbeforeinstallationofthefloorprotector.Thefloorprotectormaybecoveredwithanoncombustibledecorativematerial if desired.When using brick, tile, orstone,individualpiecesmustbemortaredsosparkscannotfall through.Most installations will require that the bottom heat shield be attached. Only when the stove is placed on a completely noncombustible surface, such as unpainted concrete over earth, may it be used without the bottom heat shield.Evenwith thebottomheatshield installed,youmustalsouseafloorprotector.In the United States,thefloorprotectorrequiredunderthestovemustextendatleast16"fromthefrontofthestove-notfromtheashlip-(Labeled‘E’inFigure11),andatleast6"fromthesidesandrear(‘D’,Figure11).TomeettherequirementintheUnitedStates,afloorprotectormustbeatleast34"wideand40"deep.


ST248wall shield construction12/14/99 djt

AirFlow

Stud Wall Framing

Wall Shield

Noncombustible spacers and fasteners

Drywall

AirFlow

Shield

MetalSpacer

Figure 13 -Approvedwallshieldconstruction.

The shiny shield surface facing the heat source must be left unpainted,enablingittoreflectheatbacktowardsthestoveor connector and away from the wall.Shieldsareneverusedondouble-wallconnectors.Clearances may be reduced only by means approved by the regulatoryauthority,andinaccordancewiththeclearanceslisted in this manual.NOTE: ALCOVE INSTALLATION OF THE INTREPID II IS NOT PERMITTED IN CANADA.Stove Heat ShieldsTheIntrepidIIRearHeatShieldisonewaytoreducetheclearance to the rear wall. The rear heat shield may be installedoneitherrear-ortop-exitingstoves.However,sincethe chimney connector also radiates heat toward the wall intop-exitinginstallations,eithersingle-wallconnectorwithconnectorheatshields,orlistedandapproveddouble-wallchimney connector should be used whenever the rear heat shieldisusedontop-exitingstoves.Clearance reductions with the rear heat shield apply only to the wall to the rear in parallel installations. Neither the side clearance requirement nor the clearance requirement in corner installations may be reduced.Wall ShieldsClearances may be reduced by using a wall shield constructed of 24 gauge or heavier sheet metal, or of another non-combustiblematerialsuchas1/2"(13mm)insulationboardorcommonbrick“laidonflat,”withthe3-1/2"(90mm)sidedown.Figure13showssuchawallshield.

Keep the Stove and Connector a Safe Distance from Surrounding Materials:Both a stove and its chimney connector radiate heat in all directionswhenoperating, and dangerous overheating ofnearby combustible materials can occur if they are too close to theheat.Asafeinstallationrequiresthatadequateclearancebe maintained between the hot stove and its connector and nearby combustibles.Clearance is the distance between either your stove (measuredfromthebackedgeofthestove’stopplate)orchimneyconnector,andnearbywalls,floors,theceiling,andanyotherfixedcombustiblesurface.Yourstovehasspecialclearance requirements that have been established after careful research and testing to UL and ULC standards. These clearance requirements must be strictly observed.Inaddition,furnishingsandothercombustiblematerialsmustbekeptawayfromthestoveaswell.Ingeneral,adistanceof48"(1220mm)mustbemaintainedbetweenthestoveandmovablecombustibleitemssuchasdryingclothes,furniture,newspapers,firewood,etc.Keepingthoseclearanceareasempty assures that nearby surfaces and objectswill notoverheat. Reducing Clearances:Stove clearances may be reduced by using heat shields attached to the stove. Chimney connector clearances may bereducedbyusingheatshieldsonsingle-wallconnector,orbyusingdouble-wallconnector.Clearancesmayalsobereducedbyusingwallshields.Allshieldingusedtoreduceclearancesmustbelistedbyarecognizedtestinglaboratoryand approved by the local regulatory body. Clearance requirements are established for many different installations.Ingeneral,thegreatestclearanceisrequiredwhen you are placing a stove and its connector with no heat shields near a wall with no heat shield. Forexample,whentheIntrepidIIisinstalledparalleltotherearwallandnoshielding isused, itmustbeat least30"(760mm)fromthewallbehinditandatleast24"(610mm)from walls on either side. If theIntrepidII is installedinacornerandnoshieldsareused,thecornersofthestovemustbeatleast20"(510mm)from nearby walls.The least clearance is required when both the stove and its connector,aswellasthewall,haveheatshields.Whenshieldsareattachedtothestoveorchimneyconnector,theyaremounted1"-2"(25-51mm)awayfromthestoveorconnectorsurfaceonnon-combustiblespacers.Airflowingbetweenthestove(and/orchimneyconnector)andnearbyshieldscarriesawayheat.Donotblocktheairflowbyfillingthis empty space with any insulating material.


1" (25mm)

1/4" (6mm)

ST501mantel andtrim shield11/10/00 djt

Figure 14 -Acustom-formedmantelshield.

Fireplace Mantel and Trim ClearancesMeasuredfromthetopandsidesofthestove

Unprotected Protected

A.Mantel 30"(762mm) 14"(356mm)B. Top Trim 24"(610mm) 14"(356mm)C. Side Trim 15"(381mm) 10"(254mm)

ST253trim clearances12/15/99 djt

C C

A B

Figure 15-Maintainclearancestocombustiblecomponentsofthemantelpiece.

Unprotectedtoptrim(B)protruding2"(50mm)orlessfromthefaceofthefireplacemustbeaminimumof24"(610mm)fromthestove’stopsurface.Withaventilatedtrimshield,thisclearancemaybereducedsafelyto14"(360mm).Unprotectedsidetrim(C)thatprotrudes2"(50mm)orlessfromthefaceofafireplacemusthaveaminimumclearanceof15"(380mm),measuredfromthestove’stopsideedge.Withaventilatedtrimshield,theclearancemaybereducedsafelyto10"(254mm).Ifthetrimextendsmorethan2"(51mm),wallclearancerequirementsapply.

Shieldsmustbespacedoutfromthecombustiblesurface1"(25mm)onnoncombustiblespacers.Thespacersshouldnotbe directly behind the stove or chimney connector.Airmustbeabletoflowbetweenthewallandtheshield.Atleast50%ofthebottom1"(25mm)oftheshieldshouldbeopenandtheshieldmustbeopenatthetop.(Figure13)Thewallshieldforastovemustextend10"(254mm)abovethetopofthestove,oraheightof35"(890mm).Thewallshieldforthechimneyconnectormustbe36"(914mm)wide,centered behind the connector; for installations that use an approvedprefabricatedchimneytopassthroughtheceiling,thechimneyconnectorshieldusedwithsingle-wallconnectormuststop1"(25mm)belowtheceiling.Chimney Connector Clearance ReductionsChimney connector clearances may be reduced by using heatshieldsonsingle-wallconnectororbyusingdouble-wallconnector.Oneofthesemethodsshouldbeusedwheneverthe rear heat shield is used in top-exit installations, or inany other situation when it is necessary to protect nearby combustibles from the heat of the chimney connector. The ceilingabovehorizontalrunsofchimneyconnectormustbeprotectedaswelliftheclearanceisinadequate.RefertotheClearance Charts.Intop-exitinginstallationsinwhichthesingle-wallconnectorextends to the ceiling and connects to a prefabricatedinsulatedmetalchimney,theconnectorshieldmustextendtowithinaninchoftheceiling.Aceilingheatshieldmustbeinstalledthatis22"(560mm)indiameterand,asexplainedabove,thatextends1"(25mm)belowtheceiling.Theceilingshieldmustbeconstructedof 24gaugeorheavier sheetmetal,mustbecenteredonthechimney,andmustmeetanywall protector that is also a part of the installation. For double-wall connector the tested and listed clearances given in this manual must be used. Fireplace and Mantel Trim Shields:Afireplaceinstallationrequiresspecialclearancebetweenthesideofthestoveandtherightandleftwalls,betweenthesideofthestoveandthedecorativesidetrimonthefireplaceface,andbetweenthetopofthestoveandthemantel.Noncombustible shields installed 1" (25mm) away fromthecombustiblesurfaceonnoncombustiblespacers,calledventilatedshields,maybeusedtoreduceclearances.(Figure14)ToprotectamantelfromtheheatofanIntrepidIIinafireplaceinstallation,theventilatedmantelshieldmustbeatleast48"(1220mm) long,and itmustbecenteredover thestove.Ventilatedshieldsforsidetrimmustextendthefull lengthof the trim.Anunprotectedmantel(‘A’,Figure15)cannotbemorethan9"(230mm)deepandmusthaveaminimumclearanceof30"(760mm),measuredfromthestove’stopplate.Withaventilatedshield, thisclearancemaybereducedsafelyto14"(360mm).


36" Max.

48" Min.

ST502Intrepid Alcove floor plan11/10/00 djt

Use recommended floorprotection

7/16"Durock®(orequivalent)spaced1"offwood studs on noncombustible spacers

Figure 16 - Alcove floor plan.Sheetrock on front face butts toDurock®(orequivalent)alcovelining.

ST503Alcove side view11/10/00 djt

MetalStud

Combustible facing may overlap metal studsbyonly1"

1"airgaptopandbottom,on both sides andbackwall

7/16"Durock®(orequivalent)

Joist Shield (Suppliedby Chimney Manufacturer)

Figure 17-Alcovesidesection.

St504Alcove cutaway11/00

Figure 18-Cutawayperspectiveofalcoveinstallation.

24"

14-1/4"

48" Min.

11"Min.

36" Max.

ST505Alcove Ceiling plan11/00

ExistingCombustibleFraming

Metalstudssupport7/16"Durock®(orequivalent)ceiling

Figure 19-Reflectedceilingplan.

Figure 20 Front view: 65"minimum clearance form hearth tocombustibles on front face. Combustible facing may overlap metal studs by only 1". It should not extend below the height of thenoncombustible ceiling.

65"62" Min. to AlcoveCeiling

ST506Alcove front view11/00

Ceiling support packageextends2"belowDurock®(orequivalent)ceiling

1"airgap,top,bottom,onbothsidesandbackwall

NOTE: From62"to65"mustbecoveredby a noncombustible material.

The charts and sample installations that follow list the clearancesrequiredforthevariousinstallationconfigurationsoftheIntrepidII.

Alcove Installations:Because of their restricted air flow and heat retentioncharacteristics, specific construction requirements andspecial clearances apply to installations into alcoves. No stove or chimney connector heat shields are used in alcove installations. ALCOVE INSTALLATION OF THE INTREPID II IS NOT PERMITTED IN CANADA.Construction Requirements:The following illustrations show noncombustible ceiling framingandmaximumandminimumpermitteddimensionsfor alcove construction.


Clearances

*Clearanceswithdouble-wallconnectorsandprotectedsurfaceshavenotbeentestedfortheIntrepidII.

1. Shieldingforatopexitstovemustincludethestoverearheatshieldinserttoprotecttheareabehindthefluecollar.

2. Chimneyconnectorheatshields,inaninstallationthatgoesthroughacombustibleceiling,mustextendto1"(25mm)belowtheceilingheatshield,whichis22"(559mm)indiameter.Theceilingheatshieldshouldbe24gaugeorheaviersheetmetal,centeredonthechimneyconnector,andmountedonnoncombustiblespacers.

3. Rearexit—horizontalfromfluecollardirectlybackthroughwall.

4. Theceilingheatshieldrequiredwhenchimneyconnectorshieldsareusedshouldmeetthewallprotector.Thiswillrequiretrimmingthe ceiling shield along the line of intersection with the wall protector.

5. Intopexitinstallations,thisclearancerequirestheuseoftherearheatshieldwiththeshieldinsertinstalled.

See the folloing pages for illustrations of these clearances.

Unprotected Surfaces Protected SurfacesStove Clearances

Stove InstalledParallel to Wall

Stove in Corner

Stove InstalledParallel to Wall

Stove in Corner

Side Rear Corners Side Rear Corners

No stove heat shields (A)24"(610mm)

(B)30"(762mm)

(C)20"(508mm)

(D)12"(305mm)

(E)16"(406mm)

(F)10"(254mm)

Topexit,rearstoveh.s.,single-wall chimney connector with connector heat shields 1,2

(G)24"(610mm)

(H)16"(406mm)

(I)12"(305mm)

(J)12"(305mm)

(K)9"(229mm)

(L)10"(254mm)

Rearexit,rearstoveh.s.,heatshield3

(M)24"(610mm)

(N)14"(356mm) N/A (P)12"

(305mm)(Q)9"

(229mm) N/A

Topexit,rearstoveh.s.,double-wallchimneyconnector5

(G)24"(610mm)

(H)16"(406mm)

(I)12"(305mm) *

Chimney Connector ClearanceSingle-wallchimneyconvector,no connector heat shields 26"(660mm) 12"(305mm)

Single-wallchimneyconnector,with connector heat shields 10"(254mm) 5"(127mm)

Double-wallconnector5 12"(305mm) *

Front Clearance to Combustibles

AllInstallations 48"(1219mm)


Clearances

Unprotected Surfaces Protected SurfacesStove InstalledParallel to Wall

Stove in CornerStove InstalledParallel to Wall

Stove in Corner

D

E

F

F

C

C

A

B

J

K

L

L

I

I

G

H

ST507Intrepid ClearanceDiagrams11/00

P

Q

M

N

TopExitInstallations,noheatshields

TopExitInstallations,rearheatshield,andchimneyconnectorheatshieldsordouble-wallconnector

RearExitInstallations,rearheatshields.

N/A N/A

See the chart on the previous page for dimensions indicated by letter in the diagrams below.


Wall Shield Requirements for Some Common Installations

INTREPID II

CC

CC

D

F

A B

E

D

ST508Intrepid IIwall shield11/00

Figure 21 -Parallel installation,verticalchimneyconnector, twowallshields.Reducedclearancesforbothrearandsidewalls.Wallshields may meet at corner if desired. Shielding for connector is centered behind connector.

A=36"(914mm)

B=30"(762mm)

C=1"(25mm)

D=35"(889mm)

E=44"(1118mm)

F=40"(1016mm)

INTREPID II

B

F

GC

D

CE

A

D

ST509Wall shieldBB11/00

A=36"(914mm)

B=13"(330mm)

C=35"(889mm)

D=1"(25mm)

E=40"(1016mm)

F=30"(762mm)

G=44"(1118mm)

Figure 22-Parallelinstallationswithrearwallpass-through,twowallshields.Reducedclearancesforbothrearandsidewalls.Wallshields may meet at corner if desired. Shielding for connector is centeredbehindconnector.Wallpass-throughmustcomplywithcodes.

B B

A

D

A

C C

A

D

A

ST510Wall shieldcc11/00

A=1"(25mm)B=34"(864mm)C=48"(1219mm)D=35"(889mm)

Figure 23 -Corner installation,verticalchimneyconnector,withrear,stove,connectorandwallshields.WallshieldsMUST meet atcorner.Connectorheatshieldextends28"(710mm)abovefluecollar.A24"(610mm)diameterceilingheatshieldmustsurroundthechimneyandbesuspended1"(25mm)fromceiling.

INTREPID II

CC

CC

D

F

A B

E

D

ST508Intrepid IIwall shield11/00

A=36"(914mm)

B=30"(762mm)

C=1"(25mm)

D=35"(889mm)

E=44"(1118mm)

F=40"(1016mm)

Figure 24-Parallel installation,verticalchimneyconnector,withstove, connector andwall shields.Maximum reduction for rearandsidewalls.Wallshieldsmaymeetatcorner.Aheatshield24"(610mm)indiametersuspended1"(25mm)belowtheceilingmustsurround the chimney.

B

F

GC

D

CE

A

D

ST509aWall shieldBB11/00

A=36"(914mm)

B=13"(330mm)

C=35"(889mm)

D=1"(25mm)

E=40"(1016mm)

F=30"(762mm)

G=44"(1118mm)

Figure 25-Parallel installationwithrearwallpass-through,withstove,connectorandwallshields.Wallshieldsmaymeetatcorner.Connectorheatshieldextends28"(710mm)abovefluecollar,orbelowelbow,whichever is less.Wallpass-throughmustcomplywith codes.

B B

A

D

A

C C

A

D

A

ST510Wall shieldcc11/00

A=1"(25mm)

B=34"(864mm)

C=48"(1219mm)

D=35"(889mm)

Figure 26 -Corner installation, vertical chimney connector, twowallshields.Reducedsideclearances.WallshieldsMUST meet at corner.


Distance from the Center of the Flue Collar to the Wall in Top-Exit Installations

Theinformationonthispageishelpfulinplanningstoveplacementfortop-exitinginstallations,particularlythoseinstallationswithchimneysthatpassthroughtheceiling.However,thisisnotaclearancechart.Finalstoveclearancesmustadheretothe guidelines stated in the clearance charts located on the previous pages.

Intrepid II: WITH Stove and Chimney Connector Heat ShieldsUnprotected Surfaces Protected Surfaces

Parallel Installations Corner Installations** Parallel Installations Corner

Installations**Side(A) Rear(B) Corner(C) Side(D) Rear(E) Corner(F)

34-3/4"(883mm) 15"(381mm) 18-3/4"(476mm) 22-3/4"(578mm) 8"(203mm) 16-3/4"(426mm)

**Tolocatecenteroffluecollarforcornerinstallation,add7"(180mm)totheclearancedistanceformstovecornertowall.Markofftheresultingdistancefromthecorneralongbothwalls.Next,measurethesamedistanceformthesetwopointsoutfromthewalls.Theselasttwomeasurementswillmeetatapointrepresentingthecenterofthefluecollar.Refertothediagramsabove.

ST511aIntrepid flue centerlineDiagrams11/16/00

A B C D E F

Intrepid II: WITHOUT Stove and Chimney Connector Heat ShieldsUnprotected Surfaces Protected Surfaces

Parallel Installations Corner Installations** Parallel Installations Corner

Installations**Side(A) Rear(B) Corner(C) Side(D) Rear(E) Corner(F)

34-3/4"(883mm) 29"(737mm) 26-3/4"(680mm) 22-3/4"(578mm) 15"(381mm) 16-3/4"(426mm)

ST51Intrepid flue centerlineDiagrams11/16/00

*

A B C

*

D E F

*Thisdistance,fromthecenterofthefluecollartothefrontedgeofthehearth,isthesameforallinstallationsonthispage:31"intheUnitedStatesand33"(840mm)inCanada.


Assembly

10-3/4"

9-3/4"

ST512Attachbottom heatshield11/00

Figure 27-Attachbottomheatshield.

ST514Bottom heat shield& clips11/00

DoorHandleHolder

BottomHeatShield

Bracket

Wing Bolt

Figure 28-Handleholderandheatshieldpositions.

ST515reverse flue collar11/17/00 djt

Flue Collar Screws

Figure 29 - Reversingthefluecollar.

Reversing the Flue Collar:Youcanreversethefluecollarbyremovingthetwoscrewsthatattachthecollartothebackofthestove.(Figure29)Besurethegasketaroundthefluecollaropeningisinpositionwhenyouscrewthecollarbackontothestove.

Clean the Griddle Before Use:Atthefactorythegriddleiscoatedwithvegetableoiltopreventrustingwhilethestoveisintransitandstorage.Removetheoil with a dry rag or paper towel before you use the stove. Set Up the Stove:Remove any loose parts from inside the stove. Place aprotectivepadonthefloor,arrangesomesectionsof4x4lumberon thepad forsupport,andcarefully tip thestoveontothem,onitsback.Removeanddiscard the four3/8"hexboltsandshippingbracketsfromthestovebottom.Usethehandleholderanda3/8"bolttoinstallthefrontrightleg.Positiontheholdersothe hole to accept the handle nub faces out from the right side ofthestove.Usetheremaining3/8"boltsandwashersfromthebagtoinstalltheother(3)legs.Tightentheboltsfirmly.Install the Bottom Heat Shield:Abottomheatshieldmustbeusedunless thestove is tobesituatedonacompletelynoncombustiblehearth,suchas unpainted concrete over earth. To install the bottom heat shield,loosenthelegbolts,andslipthebottomheatshieldC-clipsontothebolts.AttachthebottomheatshieldtotheC-clipswiththewingnuts,andtightenthelegbolts.AligntheshieldasshowninFigure27.Storing the Handle:Usetheremovablehandletoopenorclosethefrontdoors,ortochangethepositionofthedamper.Afterusingit,removeitsoitwon’tgethot,andstoreitinthehandleholderinstalledbehindtherightfrontleg.(Figure28)


ST516Attach griddle handle11/17/00 djt

Figure 31-Attachingthegriddlehandle.

ST518Intrepid IIcontrols11/20/00 djt

AirControlLeverGriddle Handle

DamperHandle

DoorHandle

DoorHandleHolder(BehindLeg)

AshPan

Andiron

Figure 32-TheIntrepidIIcontrols.

Figure 30-Attachthetemperatureprobe.

Removethefastenerandinstallthebracket.Re-installthescrew.

Foldbracketstrapovercatalyst probe shaft and screw with screw.

Remove the hole plug andinsert the catalyst probe throughcast ironback,twistandpushthroughfiberpanel.

Smoke and CO Detectors:The use of smoke and carbonmonoxide (CO) detectorsthroughout the home is strongly advised, even if notrequired by building codes or insurance regulations. It is a good idea to install a smoke detector in the livingareasandeachbedroom.Follow the smoke/COdetectormanufacturer's placement and installation instructions and maintain regularly.You may not, however, wish to install a detector in theimmediate vicinity of the stove. Depending on the sensitivity oftheunit,thealarmcanbesetoffwhileyouaretendingthefireoremptyingtheashes.Ifyouinstalladetectorinthesameroom,locateitasfarawayfromthestoveaspossible.Safety Tips:Convenientlylocatea"ClassA"fireextinguishertocontendwith small fires. Be sure the fire extinguisher works andisclearlyvisible.Alloccupantsof thehouseshouldknowwhereitis,andhowitoperates.Haveheavystoveglovesavailablenear thestove.Havespecialsafetyaccessories(e.g.,ChildGuardScreen)availableforuseifsmallchildrenwill be in the home.In the event of a stove pipe or chimney fire….• Evacuate the house immediately• Notifythefiredepartment• If the fire isn't too threatening, closing down the stovetight,(damper,primaryair,alldoors)willhelptosmotherthefire.

• Inspect your stove, stove pipe and chimney for anydamage caused by the fire and correct any damagebefore using your stove again.

Attach the Griddle Handle:Install thehandleon thegriddle.Place thegriddleupsidedownattheedgeofaflatsurfaceandassemblethehandleasshown.(Figure31)Withthehandlepointing45°fromitsfinalposition,tightenthenutasfaraspossiblewithpliers.Movethehandletoitsfinalpositionwhilestillholdingthenutwiththepliers.Takecarenottoovertighten,astabmaysnap.

Attach the Catalyst Temperature Probe:Toinstallthecatalysttemperatureprobe,removetheholeplugfromthecastironwallandinserttheprobe.ReferringFigure30,removefastenerontherightsideof thestove.Installthebracketandsecuretheprobetothebracketusingthe#10sheetmetalscrewsupplied.


Operation

Figure 33-Thethermostathandlemaybepositionedanywherebetweenthetwoextremesfordifferentheatlevels.

ST517Intrepid IIThermostat positions11/17/00 djt

HighHeat

LowHeat

Rear View

Your Stove’s Controls and What They Do:The stove has two controls to regulate performance: a primary air control supplies oxygen for the fire, and a damper directsairflowwithin thestove toactivateanddeactivatethe catalytic combustor. Additional air for catalytic combustion is regulatedautomatically,anddoesnotrequireoperatorcontrol.Symbols cast into the stove are reminders of the correct directions for opening and closing the controls. In thesedirections, ‘left’and ‘right’assume thatyouare facing thefront of the stove.A Single Air Control Regulates the Amount of Heat the Fire Will Produce and How Long it Will Burn:The primary air control lever,locatedattherightrearcornerofthestove,controlstheamountofincomingairforstarting,maintaining,andrevivingafire.Moreairenteringthestovemakesthefireburnhotterandfaster,whilelessairprolongsthe burn at a lower heat level.Forthegreatestairsupplyandmaximumheatoutput(buttheshortestburntime),movethelevertotheleft.Forafirethatwilllastlongerwithlessheat,movethelevertotheright.You can set the lever anywhere in between the left and right extremes.(Figure33)TheIntrepidIIfeaturesanautomaticthermostattoensureaneven heat output at any setting you select. The thermostat senses the heating and cooling of the stove surface and adjuststheairshutteraccordingly.

ST519Intrepid IIdamper11/20/00 djt

Open(UpdraftMode)

Closed(CatalyticMode)

Figure 34 -Thedamper iseitheropenorclosed.Therearenointermediate positions.

Side View

When closing the damper, push firmly and snap it into the locked position to ensure that the stove remains in the catalytic mode.Glass Door Panels:Theglasspanelsinthedoorshaveaheat-reflectivecoatingontheoutsidesurface.Heatreflectedbacktotheinsideoftheglasshelpskeeptheinnersurfaceatahighertemperaturethan the outside. In combinationwith pre-heated primarycombustionair ‘washing’over the insideof theglass, thishelpsprovideclearfire-viewingatmostoperatinglevels.WARNING!

Thiswoodheaterhasamanufactured-setminimumlowburn rate thatmustnotbealtered. It isagainst federalregulations to alter this setting or otherwise operate this wood heater in a manner inconsistent with operating instructions in this manual.

A Damper Directs Air Flow Within the Stove:The damper handle opens and closes the damper to direct airflowwithinthestove,andisnextto,andtotherightof,the primary air control lever on the right side of the stove. (Figure34)When thehandlepoints to thefloor, thedamper isopen,lettingsmokepassdirectly into thechimney.Thedampermustbeopenwhenstartingorrevivingafire,andwheneverthe griddle or doors are opened.Whenthehandlepointstothefront,thedamperisclosed.Smokefromthefiretravelsthroughthecatalyticcombustionsystemwhereitcanburnfurtherforgreaterefficiency,beforepassing up the chimney. Thedamperhasnointermediatepositions.Figure34showsthehandle’sopenandclosedpositions.


ST520Intrepidandirons11/20/00 djt

Figure 35-Removetheandironsforfrontloading.

INTREPID II

ST521Intrepidloading11/00

Figure 36-Toploadingisthebestwaytoaddfuelduringregularuse.Frontloadingisusefulforkindlingafire.

ST522Intrepidclose doors11/00

OpenPosition

Closed Position

Figure 37-Toopenthefrontdoors,turnhandleclockwise.

Avoidstrikingtheglassorslammingthedoorstoreducetheriskofbreakingtheglass.Whenyou’renotusingthedoorhandle,storeitintheholderbehind the right front leg of the stove.

For safety and greatest efficiency, operate your stove only with all doors/griddles fully closed. The test standard for your stove when it is operated in this mode is UL 1482.

Youcanopen(orevenremove)thefrontdoorsandplacetheoptionalIntrepidIIsparkscreeninthefrontopeningforopen-fireviewing.

Two Ways to Add Fuel:TheIntrepidII’sgriddleliftsforconvenienttop-loadingoflogs,andistheeasiestwayofregularlyaddingfuel.However,thefront doors open as well for adding an occasional log to a fire.(Figure36)

Andirons:Yourstovehasandironstokeeplogsawayfromtheglasspanels. The andirons are important tomaintain clear fireviewing and should be removed only while reloading through the front doors. Wearheavystovegloveswhenremovingtheandirons,andplace them on a noncombustible surface until you replace them inthestove.Moststoveownerswillprefertheconvenienceoftoploadingthroughthegriddle,andwillleavetheandironsin place permanently.

WARNING!

Your stove may be used as a fireplace with the front doors open or removed only when the spark screen is placed correctly in the opening to protect against the possibility of sparks and embers leaving your stove. The test standard for your stove when it is operated in this mode is UL 737.Use only the Intrepid II spark screen, part #0136, with your Intrepid II.Intrepid II spark screens are available from your Vermont Castings’ Authorized Dealer.Toopenthefrontdoors,insertthehandleintothedoorlatchstubandturnittotheleftandup.Toclosethem,alwaysclosetheleftdoorfirst.Turnthehandleintherightdoortotheleftandup(totheopenposition)andclosethedoor.Pushonthe door as you turn the handle to the right and down. The doorswilldrawinslightly,andthehandleshouldoffersomeresistanceasyouturnittotheclosedposition.(Figure37)


ST523Intrepidtemp readings11/00

Figure 38-Taketemperaturereadingswithathermometerlocatedin the middle of the griddle.

When thermometer readings drop below 350°F (175°C)it’stimetoadjusttheaircontrolforahigherburnrateortoreload the stove. • Atemperaturereadingover650°F(340°C) isasignto

reduce the air supply to slow the burn rate.• Readingsinthe300-400°F(150-200°C)rangeindicate

low to medium heat output.• Readingsof500-650°F(260-340°C) indicatehighheat

output.OperatingyourIntrepidIIcontinuouslyatgriddletemperatureshigherthan650°F(340°C)orhighermaydamageinnerpartsortheenamelfinish.

Temperature Probe:Your stove is equipped with a temperature probe which shows the operating range of the catalytic combustor. This islocatedonthebackofthestoveandisviewedfromthetop. If the probe indicator is below the operate catalystrange,add fueloropen thebypassdamper tooallow thefiretobuild.Closingthebypassdampershouldthenresultin an increase in catalyst temperature to within the operate catalyst range.Iftheprobeindicatorisabovetheoperatecatalystrange,thecatalytic combustor is running to hot and may be damaged. Inmanycases, increasing theprimaryaircanreduce thecatalyst temperature and adding less wood with each loading canalsohelpifoverheatingispersistent.Overlydrywoodcan also cause overheating of the catalyst element. Do not add wood to the stove if the probe reads above the operate catalyst range.Use the Air Control Settings that Work Best for You:Nosingleaircontrolsettingwillfiteverysituation.Settingswilldifferdependingonthequalityofthefuel,theamountofheatdesired,andhowlongyouwishthefiretoburn.Thecontrolsettingalsodependsonyourparticularinstallation’s“draft,”ortheforcethatmovesairfromthestoveupthroughthechimney.Draftisaffectedbysuchthingsasthelength,type,andlocationofthechimney,localgeography,nearbyobstructions,andotherfactors.Toomuchdraftmaycauseexcessive temperatures in theIntrepidII,andcouldevendamagethecombustor.Ontheotherhand, too littledraftcancausebackpuffing into theroomand/orthe“plugging”ofthechimneyorcombustor.Howdoyouknowifyourdraft isexcessivelyhighorlow?Symptoms of too much draft include an uncontrollable burn or a glowing-red stovepart.A sign of inadequate draft issmokeleakingintotheroomthroughthestoveorchimneyconnectorjoints,lowheat,anddirtyglass.

Burn Only High-Quality Wood:TheIntrepidIIisdesignedtoburnnaturalwoodonly;donotburn fuels other than that for which it was designed. IMPORTANT: Do not burn any type of artificial or synthetic materials such as fire starter logs (containing wax) in this appliance. Never burn liquid-based fuels such as kerosene, gasoline or alcohol. Burning any materials not allowed in these instructions, or over-firing the stove, may void the warranty.You’llenjoythebestresultswhenburningwoodthathasbeenadequatelyair-dried.Avoidburning“green”woodthathasnotbeenproperlyseasoned.Thewoodshouldbe16"(410mm)in length. Do not burn construction materials; they often contain chemicals and metals that can damage the catalytic combustor or pollute the air. Do not burn ocean driftwood; whenitburns,thesaltitabsorbswillattackthecastiron.Thebesthardwoodfuels includeoak,maple,beech,ash,andhickorythathasbeensplit,stacked,andair-driedoutsideunder cover for at least one year.Forareasthatdonothaveasupplyofhardwood,commonlyburnedsoftwoodsincludetamarack,yellowpine,whitepine,Easternredcedar,fir,andredwood.These tooshouldbeproperly dried. Storefirewoodundercovertokeepitdry.Dry,well-seasonedwood isbest forheatingandfire-viewing.However,avoidwood dried more than two years. This wood burns very quickly,reducingburntime.Evenforshort-termstorage,keepwoodasafedistancefromtheheaterandkeepitoutof theareasaroundtheheaterused for refueling and ash removal.A Surface Thermometer is a Valuable Guide to OperationAnoptionalsurface thermometer tellsyouwhen toadjusttheaircontrol,whentorefuel,andhelpstotellwhenyourcatalyst is operating properly.Forexample,whenthethermometerregistersatleast450°F(230°C)afterstart-upyouknowthestoveishotenoughtobegin catalytic combustion and it may be time to close the damper.Place the thermometer in the center of the griddle, as inFigure38,andusethefollowingtemperaturerangesasaguide to operation:


High-Efficiency Wood Burning with Catalytic Combustion:ThecatalyticcombustionsysteminyourIntrepidIIproducesthe best conditions for secondary combustion. Whenthestovedamperisclosed,smokegoesthroughthecatalytic element, burningat temperaturesof 500-600°F(260-315°C), half the temperature normally needed forunaided secondary combustion. The catalytic element is a ceramic “honeycomb” coatedwithanoblemetal,usuallyplatinum.Theelementisinthesecondary combustion chamber,madeofaspecialhigh-temperature insulating refractory material. The chamber provides the correct environment necessary for secondary combustionofthefuel(smoke).Closing the damper may also reduce draft. Closing the damper toosoonmayputoutthefireordeactivatethecombustor.Closethedamperonlywhenthefireiswellestablished.Whenstartingafire,waituntilthereisanemberbedofatleast3-4"(76-102mm)beforeclosingthedamper.Neverkindleafirewithcoloredpaperorpaperthathascoloredinkoraglossysurface,andneverburntreatedwood,garbage,solvents,ortrash.Allofthesemaypoisonthecatalystandprevent it from operating properly. Never burn cardboard or loosepaperexceptforkindlingpurposes.Neverburncoal;doingsocanproducesootorlargeflakesofcharorflyashthatcancoatthecombustorandcausesmoketospillintotheroom.Coalsmokealsocanpoisonthecatalystsothatitwon’toperateproperly.In general, the fire must be sufficiently well-establishedto ensure catalytic activity is initiated.When first startinga fire,maintain amedium- to high- firing rate for at leasttwentyminutes.Thisensuresthestove,catalyst,andfuelareallstabilizedattheproperoperatingtemperatures.Thismay be long enough to warm the chimney well enough to support a good draft; some installations may need more time.PleasereadtheDraftManagementinformationtoseeif your installation has features that may require more time to warm up. Eventhoughitispossibleforthefiretogetquitehotwithinafewminutes,thecombustormaystopworkingorthefiremaygooutifthefireisallowedtodiedownimmediatelyasaresultofclosingthedamper.Oncethecombustorstartsworking,heatgeneratedbyburningthesmokewillkeepitworking.Todeterminewhetherthecombustorisoperating,observetheamountofsmokeleavingthechimneywhenthedamperis activated and when it is not.Conditioning Your Stove:Castironisextremelystrong,butitcanbebrokenwithasharpblowfromahammerorfromthethermalshockofrapidandextremetemperaturechange.The cast plates expand and contract with changes intemperature.When you first begin using your Intrepid II,minimize thermal stress by allowing the plates to adjustgraduallyduringthreeorfourinitialbreak-infiresfollowingSteps 1-3onthenextpage.

Insomenewerhomesthatarewell-insulatedandweather-tight,poordraftmayresultfrominsufficientairinthehouse.Insuchinstances,anopenwindownearthestoveonthewindward side of the house will provide the fresh air needed. Anotheroptionforgettingmorecombustionairtothestoveistoductairdirectlyfromoutdoorstothestove.Infact,insomeareas provisions for outside combustion air are required in all new construction.Your Intrepid II will accept a duct carrying outside air forcombustion. Whenfirstusingthestove,keeptrackoftheaircontrolsettings.Youwill quickly find thataspecificsettingwill giveyouafixedamountofheat.Itmaytakesometimetodeterminetheamountofheatandthelengthofburnyoushouldexpectfromvarioussettings.PleasereadtheDraftManagementsectionfor more information on how installation features affect draft. Mostinstallationsdonotrequirealargeamountofcombustionair,especiallyifadequatedraftisavailable.Do not for any reason attempt to increase the firing of 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 the lever may be moved from right to left.

Before you start using the stove, please read the DraftManagement section to see how the features of yourinstallationwillaffectthestove’sperformance.Youandthestovearepartsofasystem,andotherpartsofthesystemhave a strong effect on operation; you may need to vary your firingtechniquetogettheperformanceyouwant.How to Build a Wood Fire and Keep it GoingAnIntrepidIIleavesthefactorywiththecombustorinstalled.IntheUnitedStates,itisagainstthelawtooperatethiswoodheater in a manner inconsistent with operating instructions inthismanual,or if thecatalyticcombustor isdeactivatedor removed.

Intrepid IV Control SettingsBurn Rate Primary Air Control

Low Fromfarrightto1/3thedistancetoleft

Medium From1/3to2/3thedistancetoleft

High From2/3thedistancetolefttofarright


ST263starting a fire12/99

Figure 39-Startthefirewithnewspaperanddrykindling.

ST264good fire12/99

Figure 40 - Addlargerpiecesofwoodasthefirebeginstoburnwell.

During the break-in fires, don’t let the stove get hotterthan500°F(260°C)asmeasuredonanoptionalstove-topthermometer.Adjust the air control lever as necessary tocontrolthefire.Someodorfromthestove’shotmetal,thepaint,andthecementisnormalforthefirstfewfires.NOTE:Somechimneysneedtobe“primed,”orwarmedup,beforetheywilldrawsufficientlytostartafire.Tocorrectthissituation,rollupacouplepiecesofnewspaper,placethemontopofthekindlingandtowardthebackofthestove,lightthem,andclose thedoors.Thisshouldheat thechimneyenough to initiate a draft. Oncethedraftisestablished,openthefrontdoorandlightthe rest of the fuel from the bottom. Do not light the main bedof fuel until the chimney begins drawing, and repeatthe procedure as often as necessary if the initial attempt is unsuccessful.4. If your Intrepid II has been broken-in previously using

Steps1-3,continuetobuildthefiregradually.Addlargerwoodwithadiameterof3-4"(76-102mm).(Figure40)

Continueaddingsplitlogsofthissizetothebriskly-burningfire until there is a glowingember bedat least 3" (75mm)deep.Agoodemberbed isnecessary forproperfunctioningofthecatalyticsystemandmaytakeanhouror more to establish.

5. Closethedamperwhenthegriddletemperaturereaches450°F(230°C).

6. Adjusttheaircontrolforyourdesiredheatoutput.

DO NOT USE CHEMICALS OR FLUIDS TO START THE FIRE. DO NOT BURN GARBAGE OR FLAMMABLE FLUIDS SUCH AS GASOLINE, NAPHTHA, OR ENGINE OIL. Also, never use gasoline-type lantern fuel, kerosene, charcoal lighter fluid, or similar liquids to start or “freshen up” a fire. Keep all such liquids well away from the Intrepid II while it is in use.3. Lightthenewspaperandclosethedoor.Graduallybuild

upthefirebyaddingafew3-5"(76-127mm)diametersplits. If this is one of the first few “break-in” fires, let the fire burn brightly, and then let it die out.

NOTE:Effectivenessofa"top-down"methodtostartafire.Smoke emissionswhen starting a fire can be difficult tocontrol because the stove is not yet heated to its optimum temperature.Onemethodof reducingemissionsduringacoldstart-upistheuseofa"top-down"kindlingprocedure.Inthis,placelargerpiecesofkindlingonthebottomofthekindlingpilefollowedbysmallerandsmallerpiecesasthepileisaddedto.Veryfinelysplitpiecesshouldbeonthetop.Lightthekindlingpilewithamatchatthetopandallowthekindlingtoburndownwardintothelargerpieces.Thisreducessmokebyslowlyincreasingthefiresizewithoutcreatinganair-starvedcondition.

Starting and Maintaining a Wood Fire:Burn solid wood fuel only in the IntrepidII,andburnitdirectlyon the grate. Do not elevate the fuel. Do not burn coal or other fuels. The damper must be open when starting a fire or when refueling. 1. Openthestovedamper,andopentheprimaryaircontrol

fully.2. Place several sheets of crumpled newspaper in the stove.

Do NOTuseglossyadvertisementsorcoloredpaper,astheycanpoisonthecatalyst.Placeonthepapersixoreightpiecesofdrykindlingsplittoafinger-widthsize,andonthekindlinglaytwoorthreelargersticksofsplitdrywoodapproximately1-2"(25-50mm)indiameter.(Figure39)


ST264aadd wood fire11/00

Figure 41-Addfullsizelogswhentheemberbedis3"(75mm)deep.

Ash Disposal:Removeashbeforeitreachesthetopoftheashpan.Checkthelevelatleastonceaday,andbeforeeachre-fueling.Iftheashisclosetothetopedgeofthepan,emptyitaccordingto this procedure:1. Openthedamper.2. Openthefrontdoorsfully.3. Usingstovegloves,pulltheashpanoutofthestoveby

its handle. 4. Removetheashpanandproperlydisposeoftheashes.

Besuretokeepthepanlevelduringdisposal.5. Returntheashpantothestove.Empty theashpan regularly, typically every one to threedays. The frequency will vary depending on how you operate yourIntrepidII;ifyouburnmorewoodathigherheatoutputsettings,ashwillaccumulaterapidly.Remove ash frequently and place it outdoors in a metalcontainerwithatight-fittinglid.Puttheclosedcontainerofashonanoncombustiblefloororontheground,wellawayfromallcombustiblematerials,pendingfinaldisposal.Iftheashisdisposedofbyburialinsoilorotherwiselocallydispersed,keepitintheclosedcontaineruntilallcindershavethoroughlycooled.Youcanusewoodashasagardenfertilizer.

Refuel While the Embers are Still Hot:ReloadtheIntrepidIIwhileitisstillhotandthereareplentyofglowingemberstore-kindlethefire.Includesomesmallerpieces of wood in the new load of fuel to help the stove rebuild itsoperatingtemperaturequickly.Wear stove gloves, and follow this procedure when youreload your stove:1. Openthethermostatlever.2. Openthedamper.3. Checktheashlevelintheashpan;empty,ifnecessary,

and replace the pan.4. Openthegriddle.5. Positionthecharcoalinthemiddleofthefirebox(Figure

41)thenloadwood—smaller,splitpiecesfirst.Increasethe amount of fuel you load into the stove as you become familiar with your stove and the heating needs of your home.

NOTE:Iftheremainingcharcoalbedisrelativelythickandifyourfueliswellseasoned,itispossibletoaddfreshfuel(smallerpiecesfirst),closethedooranddamper,andresetthe primary air thermostat for the desired heat output.Donotbreakthecharcoalintoverysmallpiecesorpoundorcompress the charcoal bed.Itisimportantthataircancirculateunderthewoodforthefiretobequicklyrevived.WARNING: Operate your Intrepid II only with the doors either fully open or fully closed.CAUTION: The Intrepid II will be hot while in operation. Keep children, clothing and furniture away. Contact may cause skin burns.DO NOT OVERFIRE THIS HEATER. Overfiringmaycauseahousefire,orcanresultinpermanentdamagetothestoveandtothecatalyticcombustor.IfanypartoftheIntrepidIIglows,youareoverfiring.

Draft Management:A stove is part of a system,which includes the chimney,theoperator,thefuel,andthehome.Theotherpartsofthesystemwillaffecthowwellthestoveworks.Whenthereisagoodmatchbetweenalltheparts,thesystemworkswell.Woodstoveoperationdependsonnatural(unforced)draft.Naturaldraftoccurswhenthesmokeishotter(andthereforelighter)thantheoutdoorairatthetopofthechimney.Thebiggerthetemperaturedifference,thestrongerthedraft.Asthesmokerisesfromthechimneyitprovidessuctionor‘draw’thatpullsairintothestoveforcombustion.Aslow,lazyfirewiththestove’sairinletfullyopenindicatesaweakdraft.Abriskfire,supportedonlybyairenteringthestovethroughthenormalinlet,indicatesagooddraft.Thestove’sairinletispassive;itregulateshowmuchaircanenterthestove,butitdoesn’tmoveairintoit.Depending on the features of your installation - steel ormasonrychimney,insideoroutsidethehouse,matchedtothestove’soutletoroversized-yoursystemmaywarmupquickly,oritmaytakeawhiletowarmupandoperatewell.Withan‘airtight’stove,onewhichrestrictstheamountofairgettingintothefirebox,thechimneymustkeepthesmokewarm all the way to the outdoors. Some chimneys do this betterthanothers.Here’salistoffeaturesandtheireffects.

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


Pipe & Chimney Layout:Everyturnthesmokemusttakeinitstravelfromthestovetothe chimney top will slow it down. The ideal pipe and chimney layoutisstraightupfromthestove,toacompletelystraightchimney. If you’re starting fromscratch, use this layout ifpossible. If thestovepipemustelbow toenterachimney,locate the thimble about midway between the stove top and the ceiling.Thisachievesseveralgoals:itletsthesmokespeedupbeforeitmustturn,itleavessomepipeintheroomforheattransfer,anditgivesyoulong-termflexibilityforinstallinga taller stove without relocating the thimble. Thereshouldbenomorethaneightfeetofsingle-wallstovepipe between the stove and a chimney; longer runs can cool thesmokeenoughtocausedraftandcreosoteproblems.Usedouble-wallstovepipeforlongruns.Single Venting:Each‘airtight’stoverequiresitsownflue.Ifanairtightstoveisventedtoafluethatalsoservesanopenfireplace,oraleakierstove, it’seasierforthechimneydrafttopullair inthroughthosechannelsthanitistopullairthroughtheairtight,andperformancesuffers.Imagineavacuumcleanerwithaholeinthehosetoseetheeffecthere.Insomecasestheother appliance can even cause a negative draft through the airtight,andresultinadangerousdraftreversal.Creosote:Creosoteisaby-productofslowwood-burning.It’sanorganictarthatcancondenseintheflueifit’sdenseinthesmoke,andslow-moving,andcoolsofftolessthan290°F.Condensedcreosoteisvolatile,andcangeneratechimneyfiresifitgetshotenough.All thefeaturesthataffectchimneydraftalsoaffectcreosotecondensation-sousewhatevercombinationof installation features and operational steps will encourage gooddraftandminimizecreosoteproduction.Because letting thesmokecooloffandslowdown isoneofthekeystocreosoteproduction,itmakessensetolineachimneytomatchthestove’soutletsize,forsafetyreasonsas well as performance. Canadian law requires a matching linertoserveanystoveorinsertventedthroughafireplacechimney;intheUS,theNationalFireProtectionAssociationrecommendsoneiftheflueismorethanthreetimesbigger(insquarearea)thantheoutletonthestoveorinsert.SomelocalitiesenforcetheNFPAguidelinesaspartoftheirbuildingcodes.

Masonry Chimney:Masonry is a traditionalmaterial for chimneys, but it canperformpoorlywhenitservesan‘airtight’stove.Masonryisaveryeffective‘heatsink’-itabsorbsalotofheat.Itcancoolthesmokeenoughtodiminishdraft.Thebiggerthechimney,thelongerittakestowarmup.It’softenverydifficulttowarmupanoutdoormasonry chimney, especially an oversizedone,andkeepitwarmenoughtomaintainanadequatedraft.Steel Chimney:Mostfactory-madesteelchimneyshavealayerofinsulationaroundtheinnerflue.Thisinsulationkeepsthesmokewarm.Theinsulationislessdensethanmasonry,sotheinnersteellinerwarmsupmorequicklythanamasonrychimney.Steeldoesn’t have the good looks ofmasonry, but it performsmuch better. Indoor/Outdoor location:Becausethechimneymustkeepthesmokewarm,it’sbesttolocate it inside the house. This uses the house as insulation fortheflueandallowsalittleheatreleaseintothehome.Anindoorchimneywon’tloseitsheattotheoutdoors,soittakeslessheatfromthestovetogetitwarmandkeepitwarm.Flue sizing:The insidesizeofachimney foran ‘airtight’stoveshouldmatchthesizeofthestove’sflueoutlet.Whenachimneyserves an airtight,more is not better; in fact, it can be adisadvantage.Hotgasescooloffthroughexpansion;ifweventastovewithasix-inchfluecollar(28squareincharea)intoa10x10"flue,thegasesexpandtooverthreetimestheiroriginalsize.Thiscoolsthegases,whichweakensdraftstrength.Ifanoversizedflueisalsooutsidethehouse,theheat it absorbs gets transferred to the outdoor air and the flueusuallystayscool.It’scommon foramasonryflue,especiallyonebuilt forafireplace, tobeoversized foranairtightstove. Itcan takequiteawhiletowarmupsuchaflue,andtheresultscanbedisappointing.Thebestsolutiontoanoversizedflueisaninsulatedsteelchimneyliner,thesamediameterasthestoveorinsert’sflueoutlet;thelinerkeepsthesmokeatitsoriginalvolume,andtheresultisastrongerdraft.Anuninsulatedlinerisasecondchoice-thelinerkeepsthesmokerestrictedtoitsoriginalsize,butthesmokestillmustwarmuptheairaroundtheliner.Thismakesthewarm-upprocesstakelonger.


Negative Pressure:Good draft also depends on a supply of air to the stove; a chimneycan’tpullinmoreairthanisavailabletoit.Sluggishdraft results when a house is tight enough to prevent the readyflowofairtothestove,orbycompetitionbetweenthestoveandotherequipmentthatsendsindoorairoutside-especiallypower-drivenequipmentlikerangehoods,clothesdryers,etc.Ifthechimneydrawswellwithallotherequipmentturnedoff(orsealed,inthecaseoffireplacesand/orotherstoves),thenyousimplyneedtobecarefulwithtimingtheuseoftheotherequipment.Ifyouneedtocrackanearbywindowordoortoenablethechimneytodrawwell,that’sasignthatyoushouldinstallanoutside-airintaketobringcombustion air directly to the stove. Vermont Castings dealers carry adapters to attach to the stove to connect an air duct for outdoor combustion air.Conclusion:Wood-burningisanartratherthanascience.Oncethestoveandchimneysystemareinplace,thestoveusercanonlyvarytechnique,mostlyyourtiming,toachievegoodresults.Ifyoukeeptrackofyourburninghabitsandrelatethemtotheireffectsonthestove’soperation,you’llberewardedwithgood performance and a safe system.

Fuel:Even the best stove installation will not perform well with poorfuel.Thebestfuelishardwoodthathasair-dried12-18months.Softwoodburns,butnotaslongashardwood.Fairly‘green’woodhasagoodamountofmoistureinit;itwillburn,butsomeoftheheatpotentialisusedtodrivetheremaining moisture off the wood. This reduces the amount that reaches your home and can contribute to a creosote problem.Therearemoisturemetersavailableforfirewood;youcanalsojudgeyourwoodbyitsappearanceandweight.Ifyougetitgreen,liftapieceandgetasenseofitsweight;itcanloseathirdormoreofitsweightasitdries.Alsolookattheendsofalog;asitdriesitshrinksandoftencracks.Themoreweatheredandcrackedapieceis,thedrieritis.Dry wood burns readily with a good chimney draft. But with modernstoves,especiallycatalyticones,thewoodcanbetoodry.Whileextra-drywoodhas little creosote in it, theremaindercan‘gasout’fromthewoodquicklyanddenselyenoughtooverloadthecatalyticburner.Ifyouheararumblingorroaringnoise,likeapropanetorch,fromthestove,thatisasignthatthecatalystisseriouslyoverfiring.Thecatalystisaplatinumfilmonaceramicbase;themetalcangettohighertemperaturesthantheceramiccantake,andoverfiringthecatalystcanbreakit.Drywoodcanalsoburnoutfasterthanyouwant.Ifyourdrywoodburnsouttooquicklyoroverloadsthecatalystyoucanmixingreenerwoodtoslowthefiredown.Back-puffing:Back-puffingresultswhenthefireproducesvolatilegasesfasterthanthechimneydraftpullsthemoutofthefirebox.Thegasesbackupinthefireboxtillthey’redenseenoughandhotenoughtoignite.Ifyourstoveback-puffs,youshouldopenupthedampertoletthesmokerisetothefluemorequickly,letmoreairintothefirebox,andavoidbigloadsoffirewood.Runyourstovewithenoughprimaryairso thatyoualwaysseelively,dancingflamesinthefirebox;alazy,smokyfireisinefficientandcancontributetocreosotebuildupin the chimney. Draft Testing:Aneasywaytotestyourchimneydraftistoclosethestove’sdamper,waitafewminutestolettheairflowstabilize,thenseewhetheryoucanvarythestrengthofthefirebyswingingtheaircontrolopenandclosed.Resultsarenotalwaysinstant;you may need to wait a few minutes for a change in the aircontrolsettingtohaveaneffectonthefire.Ifthere’snochange,thenthedraftisn’tstrongenoughyettoletyouclosethedamper,andyou’llneedtoopenitforawhilelongerandmanagethefirewiththeairinletuntilthedraftstrengthens.Ifyoukeeptrackofyourburninghabitsandrelatethemtotheireffectsonthestove’soperation,you’llberewardedwithgood performance and a safe system.


Maintenance

KT160Intrepidglass replacementaddendum11/00

RopeGasket

Figure 42-Doorglassinstallation.

Letthefireinthestovegooutandallowthestovetocoolcompletely before beginning any maintenance procedure.Care of the Cast Iron Surface:AnoccasionaldustingwithadryragwillkeepthepaintedcastironofyourIntrepidlookingnew.Thestove’spaintcanbetouchedupasneeded.First,cleantheareastobepaintedwithawirebrush.Then,touchupthestovewithhightemperaturestovepaint.Applythepaintsparingly,andkeepinmindthattwolightcoatsofpaintarebetter than a single heavy one.Care of Porcelain Enamel Finish:Use a dry or slightly damp rag or a soft brush to remove spills orstains.Fordifficultjobsthatrequireacleaningagent,useonlyakitchenappliancecleanerorpolishrecommendedforuse on enamel surfaces.Cleaning the Glass:Mostofthecarbondepositsontheglasswillburnoffduringhotfires.However,theashresiduethataccumulatesontheglass surface should be removed regularly to prevent etching. Follow this procedure to clean the glass:

• Be sure the glass is completely cool.• Clean the glass with water or a cleaner made especially

for this purpose. Do not use abrasive cleaners.• Rinsetheglassthoroughly.• Dry the glass completely.

Glass Replacement:ReplaceglassonlywithPartno.140-1156 right sideand140-1157leftsideglasspanels.Theglasspanelrestsonacushionprovidedbyaropegasketpartno1203556,andisheldinplacebyclips.(Figure42)TheglassisIRcoatedononesidewhichismarked“THISSIDEOUT”.1. Removethedoorfromthestoveandplaceitonasturdy,

levelworksurface.Useatoweltoprotecttheporcelainenamelfinish.

2. Removetheretainerclips.(Twophillipsheadscrewsoneachclip.)

3. Inspect the gasket. If thewindow gasket is in goodcondition,youcanleaveitinplace.Ifyoureplaceit,useonlyPartNo.1203556.Besurethechannelaroundthewindowopeningisclean,andfreeofdust.

4. Install the glass. Lay the glass on the inner gasketwith the coated sidedown (toward theoutsideof thedoor).Tightenthescrewssnugly,butlooseenoughtoallow for a little movement of the glass when the stove is in operation.Overtightening can crack the glassimmediatelyorcauseittocrackifitisunabletoexpandwhen hot.

Check the Operation of the Primary Air Shutter:Theprimaryairshutterisvisiblefromthebackofthestove.The shutter must open and close freely when you move the thermostatlever.Ifitdoesnot,checkforanyobstruction,orforaboundorstretchedchainneedingadjustment.(Figure43)Onacoldstovetheshuttershouldbeopennomorethan1/8" (3mm)when theprimaryair control lever ispushedcompletely to the left (closed), as seen from thebackofthe stove. When the lever is pushed completely to the right (open), the shutter should be open to an angle ofapproximately70°fromthestoveback.The ball chain shouldmeasure 8-1/2" (216mm) fromconnection to the thermostat coil to connection on the primary airflap.If setting is incorrect, the thermostat coilmaybebent orbroken.CallyourVermontCastingsDealerforassistance.

INTREPID II

ST524Intrepid IIprimary air shutter11/22/00 djt

Thermostat Lever

PrimaryAirShutter

Figure 43-Theprimaryairshuttermustmovefreely.


ST531Door Pawl11/00

Pawl

SmallLockingNut

LargeLockingNut

Set Screw

StrikerScrew

HandleStub

Figure 44 - Turnthedoorlatchstrikerscrewinorouttotightenorloosen the door latch.

ST532damper adj11/00

Thermostat Cover

D-plate

DamperActuatorRod Handle

Damper

LockingNutAllenHeadAdjustmentScrew

Figure 45-Tightenthedamperadjustmentscrewforasnugseal.

The Catalytic Combustion SystemInspection and Cleaning:Thiswoodheaterincludesacatalyticcombustor,whichneedsperiodicinspectionandreplacementforproperoperation.IntheUnitedStates,itisagainstthelawtooperatethiswoodheater in a manner inconsistent with the operating instructions inthismanual,orifthecatalyticelementisdeactivatedorremoved.Under normal operating conditions the catalytic element shouldremainactivefortwotosixyears(dependingontheamountofwoodburned).However,itisimportanttomonitorthe combustor periodically to ensure that it is functioning properly as well as to determine when it needs to be replaced.Aprobethermostat,passingthroughthebackofthestoveintothecatalyticcombustionchamber,automatically regulatesthe catalytic combustion air supply. Deterioration of the probe may result in decreased catalytic combustor performance.Apoorly-functioningcatalyticcombustionsystemwillresultinalossofheatingefficiency,andanincreaseincreosoteand emissions.The combustor should be visually inspected in place for flyashaccumulationandphysicaldamagethreetimesperyear. Do not remove the combustor unless a more detailed inspection is warranted because of diminished performance asoutlinedbelow,ortoinspecttheprobethermostat.Therefractorypackagethathousesthecatalyticcombustorshouldbeinspectedannuallyforabuildupofflayash,andcleanedifnecessary.Thismaybedoneduringexaminationof the combustor.Theprobethermostatshouldbeinspectedannually,ormoreoften if decreased catalytic combustion performance is not due to a defective combustor.

Thefrontdoorsofthestoveshouldclosesecurelyandtightly,when the handle is in the closed position. When the latch is properlyadjustedthereshouldbeaslightresistanceasthedoors are moved to the completely closed position.Tighten the Damper Handle as Needed:The damper handle is attached to the damper rod with a set screwbearingagainstaflatspotontherod.Checkthesetscrew periodically for tightness; tighten as needed.Damper Adjustment:Whenthestovedamperisclosed,thepressureoftherodagainst the damper plate assures a good seal between the damperandthedamperhousing.Adjustmentmaybeneededafter a period of time to retain adequate pressure.Tomakethisadjustment,startwiththedamperintheclosedand lockedposition. (Figure45)Loosen the7/16" lockingnutinthecenterofthedamper.Usea1/8"AllenwrenchtoturntheAllenscrewafullturnclockwise.Testthedamperforsnugness,andcontinueadjustingtheAllenscrewasneeded.Tighten the 7/16" locking nutwhen the damper operatessmoothlybutfirmly.

How to Adjust the Door Latch:Overtime,thegasketingaroundthedoorswillcompress,andthelatchmayneedadjustment.Toadjustthelatch,loosenthesmalllockingnut,extendthestrikerscrewoneturnwhilekeeping the striker screw from turning. (Figure 44)Keepmakingadjustmentsalittleatatimeuntilthesettingisright.


INTREPID II

ST533remove catalyst11/00

RefractoryChamber

RefractoryAccessPanel

Upper Firebackwith Throat Hood

CatalyticBlock

ExhaustPockets

Clamps

Figure 46-Removingthecatalyticelement.

1. Removetheandirons.2. Reachinsidethestovewithapairofpliersandturnthe

twoclampsthatholdthefireback90°.Turntheleftclampclockwise,andtherightclampcounterclockwise.

3. Grasp the fireback by its vertical ribs and remove it,together with the attached throat hood. Pull the left side outfirst.

4. Carefullycleantheleftandrightexhaustpocketsoftherefractory package.Use a shop vacuum, ideally onewithaveryfinefilter,andbecarefultoavoiddamagingthe refractory material. This material can stand high temperatures,butitissomewhatbrittlephysically.

5. Carefullyremovetherefractoryaccesspanelinfrontofthe catalytic element.

6. Gently slide the catalytic element out of the refractorychamber. Check the element and the bottom of thechamberforabuildupofflyash.

7. If thecatalyticelement is clogged, take it outdoors forcleaning.Blowgently through thehoneycomb.A largeamountofflyashmaycomeoutoftheelement.

8. Inspecttheelement.Althoughsmallhairlinecrackswillnotaffectperformance,theelementshouldbelargelyintact.Iftheelementisbrokeninpiecesorhaslargesectionsmissing, replace it.Call your dealer for a replacementelement.

9. Usea flashlight andamirror, inserted into oneof theexhaustpocketsoftherefractorychamber,toinspecttheprobe.Theendoftheprobeshouldextendabout1"intothecombustionchamber,andshouldnotshowanysignsof deterioration.

Usethestoveinyourusualmannerfortwoweeks,inspectingthe chimney and the chimney connector frequently.Ifcreosotedoesnotbuildupasquicklyasbefore,itislikelythattheperformancechangewascausedbyflyashdepositson the catalytic element.However,monitor the chimneysystemforafewweekstoensurethatproperperformancecontinues.If you continue to finda significant creosotebuildupor ifyoucontinuetoseeexcessivesmokefromthechimney,thecatalytic element will need to be replaced. Call your dealer for information about a replacement. NOTE: Use only replacement catalyst supplied by an authorizedVermontCastingsdealer.

When to Suspect a Combustion System Problem:ThebestwaytoevaluatetheperformanceofyourIntrepidII’scombustionsystemistowatchtheamountofsmokeleavingthechimney-bothwhenthecombustorhasachieved“light-off”andwhenithasnot.Followthisprocedure:With a fire going and the combustor activated,with thedamper closed to send smoke through the combustor asdescribed intheOperationSection,gooutsideandwatchthesmokeleavingthechimney.Then,openthestovedamperandagainwatchthesmokeleaving the chimney.Youshouldseesignificantlymoresmokeafterthesecondstep,whenthestovedamperisopenandsmokedoesnotgothroughthecombustor.However,donotconfusesmokewith steam form wet wood; steam disappears rapidly in the air,smokedoesnot.Ifthistestindicatesaproblem,considerotherpossiblefactorsaswell,suchasthetimeofyearorachangeinthequalityofyourfuel.Inspringandfall,draftisweakerthanitisduringcolderwinterweather,andfirescanburnsluggishly.Small,hotfiresareagoodsolutionundertheseconditions.“Green”(insufficientlyseasoned)woodwillburnmorepoorlythan properly seasoned fuel. You may have to run your stove hotter(withmoreprimaryair)toachievegoodperformanceif you are burning green or wet wood.Also,consideranychangesinyourburningroutine.Once you have ruled out any other possible causes fordeclineinperformance,youmayinspectthecombustorandprobe.Wearadustmask,safetyglasses,andgloves.RefertoFigure46asaguide.


1. Removetheexistinggasketbygraspinganendandpullingfirmly.

2. Use a wire brush or a screwdriver to clean the channel of anyremainingcementorbitsofgasket.Removestubborndeposits of cement with a cold chisel if necessary.

3. Determine the correct length of the appropriate-sizedgasketbylayingitoutinthechannel.Allowanextra1-2"(25-50mm)andmarkthespottobecut.

4. Removethegasketfromthechannel,placeitonawoodcuttingsurface,andcutitatthemarkedspotwithautilityknife.Twist the ends slightly to keep the gasket fromunraveling.

5. Layanunbroken1/8"(3mm)beadofgasketcementinthenewly-cleanedchannel.Startingatoneend,pressthegasketintothechannel.Ensureagoodjointwherethegasketmeetsbeforetrimminganyexcess.Donotoverlapthegasketendsorleaveendswithraggededges.

6. Pressthegasketedpartfirmlyagainstitsnormalmatingsurfacetoseatthegasketevenlyinitschannel.

7. Fordoors,replacethedoorsandclosethemonapieceofwaxedpapertokeepthecementfrommigratingontothestovefront,ortapotherpartswiththerubbermallet(orhammer/blockofwood).

8. Cleanexcesscementfromaroundthechannel.Letthecementthatholdsthenewgasketdrythoroughly.

Adjust the Door if Necessary:Thedoorlatchordampermechanismmayneedadjustmentafter you have regasketed them. Initially, itmay requireloosening to accommodate the new gasket; after a fewweeks,itmayneedtighteningtocompensateforcompressionofthenewgasket.Permanent Gaskets:Othergasketssealbetweennon-movingparts,butthesearenotsubjecttothesamewearanddeteriorationasgasketsonmovingparts.Itisunlikelythatyouwilleverneedtoreplacethesegasketsunlesstheinvolvedpartsaredisassembledandthenputbacktogether.Ifthisisthecase,thejobshouldbedoneonlybyaqualifiedservicetechnician.Thediameterof thegasket that seals thesenon-movingparts is 5/16",andtheareassealedarethefluecollartothestoveback;andthelowerfirebacktothesides.Theglasspanelsuseaspecialdie-cutflatgasket;referto"GlassReplacement"forinformation on these.

Replace Refractory Package:RefertoFigure46.1. Removeandirons.2. Reachinsidethestovewithpairofpliersandturnthe

twoclampsthatholdthefireback90°.Turntheletclampclockwise and the right clamp counterclockwise. Thebolts thathold theseclampsare tapped into thebackaswellascappedbychromeacornnutsintheback.

3. Grasptheupperfirebackbyitsverticalribsandremoveit, togetherwith theattachedthroathood.Pull the leftsideoutfirst.

4. Carefullyremovetherefractoryaccesspanelinfrontofthecatalyticblock.

5. Gently slide the catalytic block out of the refractorychamber.

6. Removethedamperhousing.Itisheldinplacebytwoweld screws and two chrome acorn nuts in the backof the stove. Loosen the chrome acorn nuts and rotate thetabstoreleasethedamperhousing.Youmayfinditnecessary to remove or loosen the thermostat cover to access the one of acorn nuts installed behind the cover.

7. Removetherearairtubeinthebackofthestovewhichis held in place with two phillips screws.

8. Takeout thesecondaryprobeby removing theupperphillips screw and sliding the probe out of the hole.

9. Liftthedamagedrefractorychamberupandoutofthefirebox.

10.Reversetheprocedureforinstallingthenewrefractorychamber.

ReplacetheStoveGasketsasNeededTheIntrepidusesfiberglassropegasketstomakeatightsealbetweensomeparts.Withuse,particularlyonthosepartsthat move, gaskets can become brittle and compressed,and can begin to lose their effectiveness. These will need periodic replacement.Thesizesofreplaceablegasketarelistedbelow,alongwiththeir applications.

Thereisaflat,die-cutgasketbetweeneachglasspanelanditsdoor."GlassReplacement"forinformationonreplacingtheglasspaneloritsgasket.Ifyouneedtochangeagasket,firstobtainanappropriatereplacementfromyourVermontCastings,Dealer.Waituntilthefireisoutandthestovehascooled.Besuretofollowthestandardsafetyprocedureforworkingwithdustymaterials:Wearsafetygogglesandadustmask.The procedure for replacing the gaskets is the same,regardlessofthegasketlocation.

Gasket Diameter And the Parts it Seals5/16"WireGasket The griddle to the stove top5/16" Thedampertotheupperfireback;

the front doors to the stove front; and the door halves to each other.


Annual Maintenance:Performa thorough cleaning, inspection and repair eachspring,attheendoftheheatingseason.• Thoroughly clean the chimney and chimney connector.• Inspect the chimney for damage and deterioration.

Replaceweaksectionsofprefabricatedchimney.Haveamasonmakerepairstoamasonrychimney.

• Inspectthechimneyconnectorandreplaceanydamagedsections.

• Checkgasketingforwearorcompression,andreplaceifnecessary.A‘papertest’willguideyouonthis.Closeandlockthedoorordamperonaslipofpaperandthentrytopullthepaperout.Ifthepaperpullsoutwithlittleornoresistance,thegasketisnotsnugenoughatthatspot.Ifadjustingthedamperorlatchdoesnotresultinasealthatmakesithardtopullthepaperout,replacethegasketing.

• Inspectandclean the catalytic block, andvacuumouttheashat thebottomof thebackplateafter removingthelowerfireback.Lightlycleantherefractoryassemblythat houses the element. Be careful not to damage the refractorymaterial,whichisveryfragile.

• Inspectthesecondaryprobethermometer.• Checkdooranddamperhandlesfortightness.Adjustif

needed.• Checkheatshieldscrews.Tightenasnecessary.• Clean dust from the inner sides of bottom, rear and

connector heat shields.• Removeashesfromtheashpanandreplacewithmoisture

absorbingmaterial(suchascatlitter)tokeepthestoveinteriordry.Closethestovedoortokeepcatsfromusingthe litter.

• Touchupthepaintonblackstoves.

The Chimney SystemCreosote:Your Intrepid II is designed to reduce creosote buildupsignificantly. However, regular chimney inspection andmaintenancemuststillbeperformed.Forsafety,goodstoveperformance, and to protect your chimney and chimneyconnector,inspectthechimneyandchimneyconnectorona regular schedule. Clean the system if necessary. Failure tokeepthechimneyandconnectorsystemcleancanresultinaseriouschimneyfire.Whenwoodisburnedslowly,itproducestar,organicvaporsand moisture that combine to form creosote. The creosote vaporscondense in the relativelycoolchimneyflue.Asaresult,creosoteresidueaccumulatesonthefluelining.Whenignited,thiscreosotemakesanextremelyhotfirewithintheflue system that can damage the chimney and overheatadjacentcombustiblematerial.If you do have a chimney fire, act promptly to:

• Close the damper and thermostat lever.• Get everyone out of the house.• Call the Fire department.

Youshouldinspectthesystemeverytwoweeksduringtheheating season as part of a regular maintenance schedule. Toinspectthechimney,letthestovecoolcompletely.Then,usingamirrorandastronglight,sightupthroughthefluecollarintothechimneyflue.Ifitisnotpossibletoinspectthefluesysteminthisfashionthestovemustbedisconnectedto provide better viewing access.Ifasignificantlayerofcreosotehasaccumulated-1/8"(3mm)ormore-removeittoreducetheriskofachimneyfire.Cleanthechimneyusingabrushthesamesizeandshapeastheflueliner.Flexiblefiberglassrodsareusedtorunthebrushupanddown the liner, causinganydeposits to fallto the bottom of the chimney where they can be removed through the clean out door.The chimney connector should be cleaned by disconnecting thesections,takingthemoutside,andremovinganydepositswithastiffwirebrush.Reinstalltheconnectorsectionsaftercleaning,beingsuretosecuretheindividualsectionswithsheet metal screws.Ifyoucannotinspectorcleanthechimneyyourself,contactyour local VermontCastings authorized dealer or hire aprofessional chimney sweep.


Appendix: Catalytic CombustorMasking and PoisoningWhile the catalyst itself does not enter into the combustion process, it is possible for certain elements, such as leadandsulfur,toattachtotheactivesitesonthesurfaceofthehoneycomb.Thoughthecatalystisstillthere,itiscovered,ormasked,bythecontaminant,andcannotfunction.Toavoidthis situation, it is important not to burn anything in yourIntrepidIIthatisasourceofthesecontaminants.Particularlyavoidpaintedortreatedwood,coal,householdtrash,coloredpapers,metalfoils,orplastics.Chemicalchimneycleanersmay also contain harmful elements. The safest approach is toburnonlyuntreated,naturalwood.Flame Impingement:Thecatalyticelementisnotdesignedforexposuretodirectflame.IfyoucontinuallyoverfireyourIntrepidII,thechemistryofthecatalystcoatingmaybealtered,inhibitingthecombustionprocess.Aglowingstovepartatthebackofthefireboxisasignofover-firing.Thermaldegradationoftheceramicbasemayalsooccur,causing the element to disintegrate. Stay within the recommendedguidelinesoftheOperationsection.Mechanical Damage:If theelement ismishandled,damagemayoccur.Alwaystreattheelementcarefully.Rememberthecatalystismadeofaceramicmaterial;treatitasyouwouldfinechina.Hairlinecrackswillnotaffecttheperformanceofthecatalyst,aslongas the steel sleeve holds the element in the proper position.Peeling:Peeling of the surface coat may occur if the catalytic element isfrequentlysubjectedtoexcessivetemperatures.Followtheoperating instructions carefully to avoid this type of damage.Every Vermont Castings product is equipped with either a Corning “Long-Life”® or a Technical Glass Products “Honeycomb”®.Theproductsareequivalent.Ifforanyreasonyoumustshipyourcatalyticelement,rememberitsfragilenature.Placetheelementinaplasticbag,andpackageitwithagenerousamountofshockabsorbingmaterial.

Inanychemicalreaction,includingthecombustionprocess,there are certain conditions which must be met before the reactioncantakeplace.Forexample,areactionmayrequirea certain temperature, or a certain concentration of thereactants(thecombustiongasesandoxygen),oracertainamountoftime.Catalysts,thoughnotchangedthemselvesduringthereaction,havetheabilitytoactatamolecularleveltochangetheserequirements.IntheIntrepidII’ssecondarycombustion chamber the catalyst reduces the temperature at whichsecondarycombustioncanstartfromthe1000-1200°F(540-650°C)rangetothe500-600°F(260-315°C)range,increasingefficiency,andreducingcreosoteandemissions.The catalytic reaction, though advantageous, does havesome limitations of its own. Primary among these it that the reactants(thegases)comeintoclosephysicalcontactwiththe catalyst itself.Toensurethenecessarycontact,thecatalyticelementinyourIntrepidIIiscomposedofaceramicbaseintheshapeofahoneycomb.Oneachofthehoneycomb’smanysurfacesacoatingofthecatalyst(usuallyanoblemetalsuchasplatinumorpalladium)isapplied.Thelargesurfaceareaexposedinthisconfigurationensuresthatthecombustiongaseshavethe greatest opportunity to come in contact with the catalyst.Loss of catalytic activity will be apparent in several ways. First youmaynoticean increase in fuelconsumption.Second,there will be a visible increase in the rate at which creosote builds up in your chimney connector system. You may also notice a heavy discharge of smoke from the chimney.Anumber of catalytic problems which can cause loss of activity are described below:Blockage:Whilethehoneycombpatternensuresgoodcontact,italsoincreasestheresistancetoflowof thecombustiongases,and,becauseofthemanysurfaces,providesmoreplacesforcreosoteandflyashtodeposit.Itisimportanttofollowtheoperatinginstructionsinordertominimizethesedeposits,andtoperiodicallyinspectyourcatalystforsignsofblockage.


Service Parts

Beginning Manufacturing Date: N/A Ending Manufacturing Date: Active

Intrepid II

Part number list on following page. 03/18

0001990 (Classic Black) 0001999 (Ebony) (Ending Manufacturing Date: 2013)0001997 (Biscuit) 0001997T (Biscuit w/Transition Doors) (End Manufacturing Date: March 2017 )0001987 (Majolica Brown) 0001987T (Majolica Brown w/Transition Doors)(End Manufacturing Date: March 2017)0001991 (Bordeaux) 0001991T (Bordeaux w/Transition Doors) (End Manufacturing Date: March 2017 )0001990T (Classic Black w/Transition Doors)

45

46

47 48

49

50

57

52

53

54

60a

57

59

68

65646362

44

55

56

66

6761

58a

51

72

58b

60b

74

71

71

70

70

69

69

76

76

7575

12

3 4

5 6

7

8

9

10

12

13

16 17

18

20

9

21

222526

24

23

21

36

37

38

39

40

41

15

11

12

9

42

77

78

43

43

2728

29 30

31

32

33

35

34

22a

73


Service Parts


Intrepid II

IMPORTANT: THIS IS DATED INFORMATION. Parts must be ordered from a dealer or distributor. Hearth and Home Technologies does not sell directly to consumers. Provide model number and serial number when requesting service parts from your dealer or distributor.

Stocked at Depot

ITEM DESCRIPTION COMMENTS PART NUMBER1 Secondary Air Cover 1306762

2 Flue Collar

Classic Black 1306561Biscuit 30003181Bordeaux 30006713Majolica Brown 30004825

3 Back Panel 13086624 Damper Rod 16025235 Damper Clip 1306725 Y6 Damper 1306701 Y7 Damper Housing 1306702 Y8 Throat Hood 1306763 Y9 Weld Screw Pkg of 10 1201583-1010 Upper Fireback 1306703 Y11 Firebrick Clamp 1306724 Y12 Hex Bolt, 3/8”-16x1-1/2” Pkg of 10 1201456-1013 Lower Fireback 130670415 Rear Air Tube 130865816 Thermostat Cover 130671117 Damper Handle Assembly 5004265 Y18 Friction Spring Pkg of 10 1201846-1020 Thermostat Clip 160140821 Ball Chain Fitting (Qty 2 req) Pkg of 10 1201972-1022 Ball Chain 120196022 Thermostat Assembly 500550623 Primary Air Flap 130671024 Air Flap Pin 160155125 Clip, Glass 1601394 Y26 Pan Head Bolt, #10-24x3/8” Pkg of 10 1200983-1027 Pan Head Bolt, #10-24x1/4” Pkg of 10 1200980-1028 Secondary Probe Assembly 1601489A Y29 Secondary Air Link 160148630 Phillips Bolt, 1/4”-20x5/8” Pkg of 10 1200896-1031 Shim Ring 120198632 Secondary Air Flap 160149033 Refractory Chamber w/Access Panel 1602527 Y34 Ceramic Catalyst 3000115335 Refractory Access Panel 1602516 Y

Additional service part numbers appear on following page.


Service Parts


Intrepid II


Stocked at Depot

ITEM DESCRIPTION COMMENTS PART NUMBER36 Andiron 1306717A Y37 Left Insert 130865138 Grate 130865239 Right Insert 130865040 Ashpan Only 1400951K41 Ashpan Front Only 130649342 Ashpan Handle 3000097343 Damper Tab Pkg of 10 1601488-1044 Griddle 1306356A Y

45 Right Griddle Quad Pre 2010 1301832A YPost 2010 30005119

46 Leftt Griddle Quad Pre 2010 1301807APost 2010 30005118

47 Top

Classic Black 1308657ABiscuit 30003180Bordeaux 30006712Majolica Brown 30004824

48 Right Side


49 Bottom


50 Left Side


51 Single Leg


52 Tie Rod 160164053 Hex Bolt, Leg, 3/8”-16x1” 120143254 Right Air Manifold 130865455 Left Air Manifold 1308653



Service Parts


Intrepid II


Stocked at Depot

ITEM DESCRIPTION COMMENTS PART NUMBER56 Handle Holder 1600600

57 Front


58a Left Door Shell Enamel


58b Left Transition Door Enamel


59 Left Glass Panel 1401157 Y

60a Right Door Shell Enamel


60b Right Transition Door Enamel


61 Right Glass Panel 1401156 Y62 Handle Botl, 1/4”-20x3-Z Pkg of 10 1201310-1063 Handle Wood 1600664 Y64 Handle Insert 30002714 Y65 Front Door Handle 3000271966 Griddle Handle Assembly 30002775 Y67 Gasket, Fiberglass 3/16” Round, Bulk 10 Ft 1-00-1186258229 Y68 Latch Assembly 3000236269 Glass Clips, Bottom 3000083270 Glass Clips, Side 3000083371 Glass Clips, Top 3000083472 Nut, Jam Pkg of 10 1203290-1073 Ash Pan Assembly 500352274 Griddle Gasket 10 Ft 1-00-1203668 Y75 Door Gasket 15 Ft 1-00-1203588 Y



Service Parts


Intrepid II


Stocked at Depot

ITEM DESCRIPTION COMMENTS PART NUMBER76 Door Pins 160053577 Temperature Probe 3000727578 Bracket, Temperature Probe 30007279

Bottom Heat Shield Assembly 30004020C-Clip 1204015Wing Screw 1201621Glass Clip Screws Pkg of 10 1200998-10Flue Collar Gasket 15 Ft 1-00-30002422

40 Vermont Castings • Intrepid II Installation & Operating Manual_R49 • 04/18 3-90-20009664021-645J • 08-03-171

Hearth & Home TechnologiesLIMITED LIFETIME WARRANTY

Hearth & Home Technologies, on behalf of its hearth brands (“HHT”), extends the following warranty for HHT gas, wood, pellet and electric hearth appliances that are purchased from an HHT authorized dealer.

WARRANTY COVERAGE:HHT warrants to the original owner of the HHT appliance at the site of installation, and to any transferee taking ownership of the appliance at the site of installation within two years following the date of original purchase, that the HHT appliance will be free from defects in materials and workmanship at the time of manufacture. After installation, if covered components manufactured by HHT are found to be defective in materials or workmanship during the applicable warranty period, HHT will, at its option, repair or replace the covered components. HHT, at its own discretion, may fully discharge all of its obligations under such warranties by replacing the product itself or refunding the verified purchase price of the product itself. The maximum amount recoverable under this warranty is limited to the purchase price of the product. This warranty is subject to conditions, exclusions and limitations as described below.

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

Parts Labor Gas Pellet Wood Electric Venting Components Covered

X X Igniters, auger motors, electronic components, and glass

X X X Factory-installed blowers

X Molded refractory panels

X Ignition Modules

X Firepots, burnpots, mechanical feeders/auger assemblies

X Vent Free burners, Vent Free ceramic fiber logs, Aluminized Burners

X X Castings and Baffles

6 years 3 years X Catalyst - limitations listed

7 years 3 years X X Manifold tubes, HHT chimney and termination

10 years 1 year X Burners, logs and refractory

Limited Lifetime 3 years X X X

Firebox and heat exchanger, Grate and Stainless Steel Burners, FlexBurn® System (engine, inner

cover,access cover and fireback)

X X X X X All replacement parts beyond warranty period

Warranty Period HHT Manufactured Appliances and Venting

All parts and material except as covered by Conditions, Exclusions, and Limitations listedX X X

2 years

3 years

1 Year

90 Days

5 years 1 year

xX

41 Vermont Castings • Intrepid II Installation & Operating Manual_R49 • 04/18 3-90-20009664021-645J • 08-03-172

WARRANTY CONDITIONS:• This warranty only covers HHT appliances that are purchased through an HHT authorized dealer or distributor. A list of HHT

authorized dealers is available on the HHT branded websites.

• This warranty is only valid while the HHT appliance remains at the site of original installation.

• This warranty is only valid in the country in which the HHT authorized dealer or distributor that sold the appliance resides.

• Contact your installing dealer for warranty service. If the installing dealer or distributor is unable to provide necessary parts, contact the nearest HHT authorized dealer or supplier. Additional service fees may apply if you are seeking warranty service from a dealer other than the dealer from whom you originally purchased the product.

• Check with your dealer in advance for any costs to you when arranging a warranty call. Travel and shipping charges for parts are not covered by this warranty.

• Limited Catalyst Warranty

o For wood burning products containing a catalyst, the catalyst will be warranted for a six-year period as follows: if the original catalyst or a replacement catalyst proves defective or ceases to maintain 70% of its particulate emission reduction activity (as measured by an approved testing procedure) within 36 months from the purchase date, the catalyst will be replaced for free.

o From 37 to 72 months a pro-rated credit will be allowed against a replacement catalyst and labor credit necessary to install the replacement catalyst. The proration rate is as follows:

Amount of Time Since Purchase Credit Towards Replacement Cost0 - 36 Months 100%

37 - 48 Months 30%49 - 60 Months 20%61 - 72 Months 10%

o 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 name, address, and telephone number of the location where the product is installed, proof of original purchase date, date of failure, and any relevant information regarding the failure of the catalyst.

WARRANTY EXCLUSIONS:This warranty does not cover the following:

• Changes in surface finishes as a result of normal use. As a heating appliance, some changes in color of interior and exterior surface finishes may occur. This is not a flaw and is not covered under warranty.

• Damage to printed, plated, or enameled surfaces caused by fingerprints, accidents, misuse, scratches, melted items, or other external sources and residues left on the plated surfaces from the use of abrasive cleaners or polishes.

• Repair or replacement of parts that are subject to normal wear and tear during the warranty period are not covered. These parts include: paint, wood and pellet gaskets, firebricks, grates, flame guides, batteries and the discoloration of glass.

• Minor expansion, contraction, or movement of certain parts causing noise. These conditions are normal and complaints related to this noise are not covered by this warranty.

• Damages resulting from: (1) failure to install, operate, or maintain the appliance in accordance with the installation instructions, operating instructions, and listing agent identification label furnished with the appliance; (2) failure to install the appliance in accordance with local building codes; (3) shipping or improper handling; (4) improper operation, abuse, misuse, continued operation with damaged, corroded or failed components, accident, or improperly/incorrectly performed repairs (5) environmental conditions, inadequate ventilation, negative pressure, or drafting caused by tightly sealed constructions, insufficient make-up air supply, or handling devices such as exhaust fans or forced air furnaces or other such causes; (6) use of fuels other than those specified in the operation instructions; (7) installation or use of components not supplied with the appliance or any other components not expressly authorized and approved by HHT; (8) modification of the appliance not expressly authorized and approved by HHT in writing; and/or (9) interruptions or fluctuations of electrical power supply to the appliance.

• Non-HHT venting components, hearth connections or other accessories used in conjunction with the appliance.

• Any part of a pre-existing fireplace system in which an insert or a decorative gas appliance is installed.

• HHT’s obligation under this warranty does not extend to the appliance’s capability to heat the desired space. Information is provided to assist the consumer and the dealer in selecting the proper appliance for the application. Consideration must be given to the appliance location and configuration, environmental conditions, insulation and air tightness of the structure.


352MountainHouseRoad•Halifax,Pa17032www.vermontcastings.com

4021-645J • 08-03-173

This warranty is void if:• The appliance has been over-fired, operated in atmospheres contaminated by chlorine, fluorine, or other damaging chemicals.

Over-firing can be identified by, but not limited to, warped plates or tubes, deformation/warping of interior cast iron structure or components, rust colored cast iron, bubbling, cracking and discoloration of steel or enamel finishes.

• The appliance is subjected to prolonged periods of dampness or condensation.

• There is any damage to the appliance or other components due to water or weather damage which is the result of, but not limited to, improper chimney or venting installation.

LIMITATIONS OF LIABILITY• The owner’s exclusive remedy and HHT’s sole obligation under this warranty, under any other warranty, express or implied, or in

contract, tort or otherwise, shall be limited to replacement, repair, or refund, as specified above. In no event will HHT be liable for any incidental or consequential damages caused by defects in the appliance. Some states do not allow exclusions or limitation of incidental or consequential damages, so these limitations may not apply to you. This warranty gives you specific rights; you may also have other rights, which vary from state to state. EXCEPT TO THE EXTENT PROVIDED BY LAW, HHT MAKES NO EXPRESS WARRANTIES OTHER THAN THE WARRANTY SPECIFIED HEREIN. THE DURATION OF ANY IMPLIED WARRANTY IS LIMITED TO DURATION OF THE EXPRESSED WARRANTY SPECIFIED ABOVE.

Documents

Installation & Operating Manualdownloads.hearthnhome.com/installManuals/20000966_Intrepid_38.pdfThe French language version of this manual is available online: La version ... Installation