owner's manual - wood stoves...burning wood stoves and fireplacesavailable today. as an owner...

1 Vermont Castings • Defiant Flexburn Installation & Operating Manual_R43 • 11/18 3-90-30005220

SAFETY NOTICE: IF THIS APPLIANCE IS NOT P R O P E R LY I N S TA L L E D , O P E R AT E D A N D 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.

Nous recommandons que nos appareils de chauffage au bois soient installés et entretenus apr des professionnels qui ont été accrédités aux É.-U. par le National Fireplace Institute® (NFI) comme étant des spécialistes du NFI en matière d’appareilsde chauffage au ois, ou qui sont accrédités au Canadadans le cadre du Programme de formation techniqueen énergie du bois (WETT)

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

Owner's ManualInstallation and Appliance Setup - Care and Operation

INSTALLER: Leave this manual with party responsible for use and operation.OWNER: Retain this manual for future reference.Call your dealer for questions on Installation, Operation, or Service.

0968Defiant cover11/00

For use in the United States and Canada

Defiant® FlexBurn® Non-Catalytic/Catalytic Wood Burning Stove

Model 1975

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!

Installationandserviceofthisapplianceshouldbeperformedbyqualifiedpersonnel.Hearth&HomeTechnologiesrecommendsHHTFactoryTrainedorNFIcertifiedprofessionals.


Congratulations on your choice of a Vermont Castings Defiant® stove. With this purchase you have made a commitmenttomakethehearthaplaceofwarmth,beautyandcomfortinyourhome.AtVermontCastings,wesharethatjoy and appreciation for the hearth. We assure you that your cast-ironVermontCastingsstovehasbeenmadewiththeutmost care and will provide you with many years of service. Asyoubecomeacquaintedwithyournewstove,youwillfindthatitsappearanceismatchedbyitsfunctionality,duetocastiron’s unique ability to absorb and radiate heat.Also,VermontCastingsproductsareamongthecleanest-burningwoodstovesandfireplacesavailabletoday.Asanowner of aVermontCastings stove, youmake a strongstatementforpollution-freeenergy.However,cleanburningdepends on both the manufacturer and the operator. Please read this manual carefully to understand how to properly operate and maintain your stove.AtVermontCastings,we are equally committed to yoursatisfaction as a customer. That is why we maintain an exclusivenetworkofthefinestdealersintheindustry.Ourdealers are chosen for their expertise and dedication tocustomerservice.Theyarefactory-trainedandknowledgeableabout every Vermont Castings product. Feel free to contact your Authorized Vermont Castings Dealer anytime you have a particular question about your stove or its performance.This manual contains valuable instructions on the installation andoperation of yourVermontCastingsDefiant®. It alsocontains useful information on maintenance. Please read the manual thoroughly and keep it as a reference.Thismanual describes the installation, operation, andmaintenanceoftheVermontCastingsDefiant® Model 1975 Non-Catalytic/Catalyticwoodburningheater.Thisheatermeets the U.S. Environmental Protection Agency’s emission limitsforwoodheaterssoldonorafterMay15,2015.TheDefiant® Model #1975 has been tested and is listed byOMNI-Test Laboratories ofPortland,Oregon.The teststandardsareANSI/UL-1482-2011andANSI/UL-737fortheUnitedStates,andULCS627-00forCanada.TheDefiant® is listed for burning wood only. Do not burn other fuels. The Defiant® is not approved for use in manufactured (mobile) homes. Please read this entire manual before you install and use your new stove. Failure to follow instructions may result in propertydamage,bodilyinjury,orevendeath.

Installation AccessoriesWarming Shelf

#0210 Classic Black #0217 Brown Majolica#0211 Biscuit #0219 Twilight#0218 Bordeaux

#3264 MobileHomeBracketKit#3180 OutsideAirAdapter#1907 Firescreen#1860 6"X12"OvalStarterPipe#1855 8"X11"OvalStarterPipe#3190 PipeHeatshieldFK26 FanKit#0180 RectangularCeilingKit#0181 RoundCeilingKitA line of porcelain enamel stove pipe is available in Biscuit, Bordeaux, Brown Majolica colors.

= Contains updated information

Product Specifications and Important Safety Information ApplianceCertification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 California safety information . . . . . . . . . . . . . . . . . . . . . . . . 3 BTU&EfficiencySpecifications . . . . . . . . . . . . . . . . . . . . . 3Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Installation OutsideAir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Types of Chimney to Use . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Chimney Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Chimney Connector Guidelines . . . . . . . . . . . . . . . . . . . . . 7 FireplaceInstallations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Floor Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Clearances to Combustibles . . . . . . . . . . . . . . . . . . . . . . 12Assembly Setting up your Stove . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 InstallBottomHeatShield . . . . . . . . . . . . . . . . . . . . . . . . 18 Adjust Leg Levelers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 InstallingCatalystTemperatureProbe . . . . . . . . . . . . . . . 19 AttachingDamperHandle . . . . . . . . . . . . . . . . . . . . . . . . 19 FanKitInstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Installing/RemovingCatalyst . . . . . . . . . . . . . . . . . . . . . 20Smoke Alarm / Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . 21Operation Air Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Damper Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 WoodBurningOperation . . . . . . . . . . . . . . . . . . . . . . . . . 23 Ash Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Draft Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30The Catalytic Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Service Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Table of Contents


MODEL: Defiant®,Model1975LABORATORY: OMNITestLaboratories,IncREPORT NO. 227-S-40-2

TYPE: SolidFuelRoomHeater/WoodBurning Type

STANDARD(s): UL1482-2011,UL737-2011,ULC-S627-00

ELECTRICAL RATING: 115VAC,60Hz

EPA Certification Number: 783Non-Catalytic InformationEPA Certified Emissions: 2.3g/hr*EPA Default Efficiency: 71.0%**Actual tested Efficiency: 66%***EPA BTU Output: 9,600-26,600****Peak BTU/Hour Output: 55,900Catalytic InformationEPA Certified Emissions: 1.1g/hr*EPA Default Efficiency: 80.0%**Actual tested Efficiency: 73.8%***EPA BTU Output: 11,400-34,100****Peak BTU/Hour Output: 55,500Other Important Information

Vent Size: 6Inch(152mm)8Inch(203mm)

Firebox Size: 3.2cu.ft.Max. Wood Length: 25"MaximumIdeal Wood Length: 20"(TopLoad)

Fuel Seasoned Cordwood (20%moisture)

Area Heated..............................1,300to2,800SquarefeetLoading .......................................................... Front and topChimney Connector: ......................................................... for6"fluecollar ...........................6"(152mm)diameter for8"ovalfluecollar ....................8"(203mm)diameterFlue Exit Position ............................................Top or RearPrimary Air ............Manuallyset,thermostaticallymaintainedSecondary Air ...................................Fixed,self-regulatingAsh Handling System........................ Removable ash panGlass Panels .............................High-temperatureceramicWeight ......................................................475lbs.(215kg.)

*An efficiency based on EPA historical data: 63% for non-catalytic stoves.**Maximum calculated efficiency using Douglas Fire dimensional lumber and data collected during EPA emissions 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 unit calculated using the maximum first hour burn rate from the High EPA Test and BTU content of seasoned cordwood (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.

! WARNINGThis product and the fuels used to operate this product (wood),andtheproductsofcombustionofsuchfuels,canexpose you to chemicals including carbon black,whichisknowntotheStateofCaliforniatocausecancer,andcarbonmonoxide,whichisknowtotheStateofCaliforniato cause birth defects or other reproductive harm. For moreinformationgoto:www.P65Warnings.ca.gov

Product Specifications and Important Safety Information

California safety information

Proposition 65 Warning:Fuelsusedingas,woodburningoroilfiredappliances,and theproductsofcombustionof such fuels, contain chemicals known to the StateofCalifornia to cause cancer, birth defects and otherreproductive harm.CaliforniaHealth&SafetyCodeSec.25249.6

Appliance Certification BTU & Efficiency Specifications


Dimensions

Figure 1-Defiant® 1975 dimensions.

Drawing Not to Scale

D E F I A N T

32-3/8”(822mm)

28-7/8”(733mm)

31-1/2”(800mm)

5-1/8”(130mm)

19”(483mm)

1693Defiant dimensions1/02

29-7/8” (759mm)

23-5/8”(600mm)

19”(483mm)

26”(660mm)

D E F I A N T

CL

28-7/8”(733mm)

Rear Venting

44-5/8”(1133mm)

23-3/4”(603mm)


InstallationSAFETY NOTICE: IF YOUR DEFIANT® IS NOT PROPERLY INSTALLED, A HOUSE FIRE MAY RESULT. TO REDUCE THE RISK OF FIRE, FOLLOW THE INSTALLATION INSTRUCTIONS. CONTACT LOCAL BUILDING OR FIRE OFFICIALS ABOUT RESTRICTIONS AND INSTALLATION INSPECTION REQUIREMENTS IN YOUR AREA.Beforeyoubeginaninstallation,besurethat:• Your stove and chimney connector will be far enough from

combustible material to meet all clearance requirements.• Thefloorprotector is largeenoughand is constructed

properly 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.The metal label permanently attached to the back of every Vermont Castings’ stove indicates that the stove has been tested to currentUL andULC standards, and gives thename of the testing laboratory. Clearance and installation information also is printed on the label. When the stove is installed according to the information both on the label and inthismanual,localauthoritiesusuallywillacceptthelabelas evidence that the installation meets codes and can be approved.However,codesvaryindifferentareas.Beforestartingtheinstallation,reviewyourplanswiththelocalbuildingauthor-ity. Your local dealer can provide any additional information needed.Foranyunresolvedinstallationissues,refertotheNationalFireProtectionAssociation’s publicationANSI/NFPA211Standard forChimneys,Fireplaces,Vents andSolidFuelBurningAppliances.ForCanada,theequivalentpublicationisCSACAN-B365InstallationCodeforSolidFuelBurningAppliances and Equipment. These standards are the basis for many national codes. They are nationally recognized and are accepted by most local authorities. Your local dealer or your localbuildingofficialmayhaveacopyoftheseregulations.IMPORTANT: Failure to follow these installation instruc-tions may result in a dangerous situation, including a chimney or house fire. Follow all instructions exactly, and do not allow makeshift compromises to endanger property and personal safety.

Outside AirAsourceofair(oxygen)isnecessaryinorderforcombustionto take place. Whatever combustion air is consumed by the firemustbereplaced.Airisreplacedviaairleakagearoundwindowsandunderdoors.Inhomesthathavetightlysealeddoorsandwindows,anoutsideairsourceisneeded.

Figure 2-Chimneyheightrequirementswith6"chimneyand/orchimney connector.

30

25

20

15

0 2000 4000 6000 8000 10000 12000

Hei

gh

t

Altitude

ST491Defiantchimney height 11/2/00 djt

Items Needed for Installation (not supplied)• Outside air adapter (available at your authorized

Vermont Castings dealer)• Phillips head screw driver • Silicone sealant• 3”FlexorRigidDuct• 3”OutsideAirTerminationCapwithScreen• HoseClamps• Drills and saws necessary for cutting holes through

thewallorflooringinyourhome.1. Usinga#2Phillipsscrewdriverattachtheflexadapterto

theapplianceusing4screws.Figure5.13&5.14.2. Floor&RearInstallation:Cuta3”(76mm)holeinoutside

wallorfloortoaccommodateoutsideairpiping.Use3”(76mm)aluminummetalflexor rigidpiping todirectlyconnect outside air to appliance intake. Use the supplied termination cap with a rodent screen. Seal between the wall(orfloor)andthepipewithsiliconetopreventmoisturepenetration.

Whenpoordraftiscausedbyalowinfiltrationrate,openingagroundfloorwindowonthewindwardsideofthehouseandnear the stove will usually alleviate the problem.A better solution is to install a permanent outside air supply tothestoveand/orroom.Infact,bringingairforcombustionfrom outside the home directly to the air inlet of the stove is required for new construction in some areas. Chimney HeightAltitudeaffectschimneyperformance.Whenusingan8"ovalto6"fluecollaradapterontheDefiant®,refertoFigure1forsuggested chimney heights at various altitudes. Chimney heightshouldbemeasuredfromthefluecollartothetopofthe chimney. The recommended minimum chimney height is16’(5m).


ST241chimney types12/13/99 djt

Aprefabricateddouble-wall insulated chimney

Atile-linedmasonry chimney

Figure 3-Approvedchimneytypes.

2' Min.

2' Min.

3'Min.

0 To 10'

3'Min.

0 To 10'

AC617RLTSKC8

2/11/98

Reference Point

Figure 4-The2’-3’10’ChimneyRule.

Masonry ChimneysAninspectionofthechimneymustconfirmthatithasalining.Do not use an unlined chimney. The chimney should have no cracks, loosemortar, other signs of deterioration, andblockage. Repair any defects before the chimney is used with your stove.Unusedopeningsinanexistingmasonrychimneymustbesealedwithmasonrytothethicknessofthechimneywall,andthechimneylinershouldberepaired.Openingssealedwith pie plates or wallpaper are a hazard and should be sealedwithmortarorrefractorycement. In theeventofachimneyfire,flamesandsmokemaybeforcedoutoftheseunused 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.A loose or leaky clean-out door canweakenchimneydraft,causingperformanceproblems.Prefabricated ChimneysA prefabricated metal chimney must be one tested and listedforusewithsolid-fuelburningappliancestotheHigh-Temperature(H.T.)ChimneyStandardUL-103-1985(2100°F)fortheUnitedStates,andHighTemperature(650°C)StandardULCS-629forCanada.DO NOT CONNECT THIS UNIT TO A CHIMNEY FLUE SERVING ANOTHER APPLIANCE.Chimney SizeADefiant®withan8"(203mm)fluecollar isapprovedforventingintoamasonrychimneywithanominalfluesizeof8"x8"(203x203mm)or8"x12"(203x305mm),andintoaroundfluewithnominalfluesizeof8"(203mm).ADefiant® witha6"(152mm)flueconnectorisapprovedforventingintoamasonrychimneywithanominalfluesizeof8"x8"(203x203mm),andintoaroundfluewithnominalflueof6"(152mm).NOTE: When installed with a 6" flue collar, the Defiant® may not be operated with the front doors open.Whateverthefluecollarsize,aDefiant® may be vented into largerchimneysaswell.However,chimneyswithlinerslargerthan8"x12"(203x305mm)mayexperiencerapidcoolingofsmokeandreductionindraft,especiallyifthechimneysare located outside the home. These large chimneys may needtobe insulatedorhavetheirfluesrelinedforproperstove performance. Accessories to help make the connection between stainless steelchimneylinersandyourDefiant® are available through your local dealer.

Thechimneymustextendat least3’(914mm)abovethehighestpointwhereitpassesthroughorneararoof,andatleast2’(610mm)higherthananypartofabuildingwithin10’(3m)horizontally.(Figure4)Forproperdraftandgoodperformance,anychimneyusedwithaDefiant®shouldextendatleast16’(5m)abovethefluecollarofthestove.

Types of Chimney to UseYoumustconnecttheDefiant®toacode-approvedmasonrychimneywithaflueliner,toarelinedmasonrychimneythatmeetslocalcodes,ortoaprefabricatedmetalchimneythatcomplieswiththerequirementsforTypeHTchimneysintheStandardforChimneys,Factory-Built,ResidentialTypeandBuildingHeatingAppliance,UL103.Figure3illustratesthetwo types. The chimney and chimney connector must be in good condition and kept clean.Ifyouuseanexistingmasonrychimney,itmustbeinspectedto ensure it is in a safe condition before the stove is installed. Yourlocalprofessionalchimneysweep,buildinginspector,orfiredepartmentofficialwillbeabletoinspectthechimneyorprovideareferraltosomeonewhocan.See"ChimneyandFireplacehazards",intheappendix,forparticulars.


Chimney Connector GuidelinesAchimneyconnector is thesingle-wallpipethatconnectsthe stove to the chimney. The chimney itself is the masonry orprefabricatedstructure thatenclosestheflue.Chimneyconnectors are used only to connect the stove to the chimney. Single-wall connectors should bemade of 24 gauge orheavier steel. Do not use galvanized connector; it cannot withstand the high temperatures that can be reached by smokeandexhaust gases, andmay release toxic fumesunderhighheat.Theconnectormaybe6"(152mm)or8"(203mm)indiameter.Ifpossible,donotpass thechimneyconnector throughacombustiblewallorceiling.Ifpassagethroughacombustiblewall is unavoidable, refer to the section onWall Pass-Throughs.Donotpasstheconnectorthroughanattic,aclosetor similar concealed space. The whole connector should be exposedandaccessibleforinspectionandcleaning.Inhorizontalrunsofunshieldedchimneyconnector,maintainadistanceof30"(762mm)fromtheceiling.Keepitasshortanddirect as possible,with nomore than two90° turns.Slope horizontal runs of connector upward 1/4" per foot(6mmpermeter)goingfromthestovetowardthechimney.Therecommendedmaximumlengthofahorizontalrunis3’(1m),andthetotallengthshouldbenolongerthan8’(2.4m).Incathedralceilinginstallations,extendtheprefabricatedchimneydownwardtowithin8’(2.4m)ofthestove.Thiswillhelpmaintainagooddraftbykeepingthesmokewarm,sothat it rises readily.Wearglovesandprotectiveeyewearwhendrilling,cuttingorjoining sections of chimney connector.Single-wall Chimney Connectors• Beginassemblyattheovalfluecollarofthestove.Insert

the crimpedendof theoval-to-roundadapter into thestove’sfluecollar,andkeepeachcrimpedendpointingtowardthestove.(Figure5)Usingtheholesinthefluecollarasguides,drill1/8"(3mm)holesinthebottomofthefirstsectionofchimneyconnectorandsecureittothefluecollarwiththree#10x1/2"sheetmetalscrews.Liftoffthegriddle,andshieldthestove’ssurfacebetweenthegriddleopeningandthefrontofthefluecollartoprotectthefinishwhenyoudrillthefronthole.

Flue Gas Direction

Toward Stove

Figure 5 - Chimney connector.

• Fasteneachjointbetweensectionsofchimneyconnector,includingtelescopingjoints,withatleastthree(3)sheetmetal screws.Thepre-drilledholes in the topof eachsection of chimney connector serve as guides when you drill1/8"(3mm)holesinthebottomofthenextsection.Furnacecementmaybeusedtosealtheoval-to-roundadaptertothefluecollar.

• Fastenthechimneyconnectortothechimney.Instructionsfor various installations follow. Figure 6 illustrates thegeneral layout of chimney connector parts.

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

NOTE: Special slip pipes and thimble sleeves that form telescoping joints between sections of chimney connector are available to simplify installations. They often eliminate the need to cut individual connector sections. Consult your local dealer about these special pieces.Securing the Single-wall Connector to a Prefabricated ChimneyFollow the installation instructions of the chimney manufacturer exactlyasyouinstallthechimney.Themanufacturerofthechimneywillsupplytheaccessoriestosupportthechimney,eitherfromtheroofofthehouse,attheceilingoftheroomwherethestoveisinstalled,orfromanexteriorwall.Special adapters are available from your local dealer to make the connection between the prefabricated chimney and the chimney connector. The top of such adapters attaches directly to the chimney or to the chimney’s ceiling support package,whilethebottomoftheadapterisscrewedtothechimney connector.Theseadaptersaredesignedsothetopendwillfitoutsidetheinnerwallofthechimney,andthebottomendwillfitinsidethefirstsectionofchimneyconnector.Securing the Single-wall Connector to a Masonry ChimneyBothfreestandingmasonrychimneysandfireplacemasonrychimneys may be used for your installation. Freestanding Installations Ifthechimneyconnectormustpassthroughacombustiblewall to reach thechimney, followtherecommendations intheWall Pass-Through section that follows. The openingthrough the chimney wall to the flue (the "breech")mustbelinedwitheitheraceramicormetalcylinder,calledthe"thimble,"whichiscementedsecurelyinplace.Mostchimneybreechesincorporatethimbles,butthefitmustbesnugandthe joint between the thimble and the chimney wall must be cementedfirmly.


Figure 8-Inthisinstallation,thechimneyconnectorattachestothechimneyabovethefireplaceopening.

ST244Plymouthfplc over mantel12/99

D E F I A N T

*

*

Check TheseClearances

Mantel

Seal ThisOff

ST243thinble connection

12/13/99 djt

Thimble Sleeve

Chimney Connector

Flue

Keepsleeveendflushwithfluetile

Figure 7-Thethimble,madeofeitherceramicormetal,mustbecemented securely in place.

ST492Defiantfreestanding installation11/00

Chimney

Elbow

Slip Pipe

Standard Connector

OvaltoRound Adapter

Flue Collar

Thimble

Flue Inner

Flue

Figure 6 -An exploded view of the chimney connection in afreestanding masonry installation.

Fireplace InstallationsThe chimney connector may be connected to the chimney abovethefireplaceopeningorthroughthefireplace.Above the FireplaceThe Defiant® may be connected to a chimney above a fireplaceopening.(Figure8)Insuchinstallations,thestoveispositionedonthehearthinfrontofthefireplaceandthechimney connector rises from the stove top and then angles ninety degrees back into the chimney. The chimney liner shouldextendtothepointatwhichthechimneyconnectorenters the chimney. If the chimney connector in your installation enters thechimneyaboveafireplace,followalltheguidelinesmentionedaboveforfreestandinginstallations.Inaddition,givespecialconsideration to the following points:

• Check the clearance between the stove and the chimney connector,andanycombustibletrimorthemantel.

• Check the clearance between the chimney connector andtheceiling.Theclearanceshouldbeatleast30"(762mm)with unshielded connectors.Consult theclearance charts for other installation options.

• Thefireplacedampermustbesealedtopreventroomairfromescapinguptheflue.However,itmustbepossibletore-openthedampertoinspectorcleanthechimney.

Toinstallathimblesleeve,slideitintothebreechuntilitisflushwiththeinnerfluewall.Donotextenditintotheactualfluepassage,asthiscouldinterferewiththedraft.Thethimblesleeveshouldprotrude1-2"(25-50mm)intotheroom. Use furnace cement and thin gasketing to seal the sleeve in place in the thimble. Secure the chimney connector to the outer end of the sleeve with sheet metal screws.Withoutathimble,asuitable lengthofchimneyconnectorcanbeextendedthroughthebreechtotheinnerfaceoftheflueliner,andcementedsecurelyinplace.Additionalpiecesof connector are then attached with sheet metal screws.

Aspecialpiececalledthe"thimblesleeve,"slightlysmallerindiameter thanstandardconnectorsandmost thimbles,will facilitate the removal of the chimney connector system for inspection and cleaning. (Figure 7) Thimble sleeves are available from your local dealer.


ST245fireplace flex connector12/99

FlexibleConnector

Mantel Shield

FireplaceAdapterKit"PositiveConnection"

Figure 9-Throughthefireplaceinstallation.

DEFIAN

ST493Brick pass thru11/00

Wall Stud

Chimney Connector

Floor Protection

12"ofNoncombustibleMaterial

Figure 10-Anapprovedwallpass-throughfortheUnitedStates.

Three other methods are also approved by the NFPA:

• Placing a section of chimney connector inside a ventilated thimble, which in turn is separated fromcombustiblesby6" (152mm)offiberglass insulatingmaterial.

• Placing a section of chimney connector inside a section of9"(230mm)diameter,solid-insulated,factory-builtchimney,with 2" (51mm) of air space between thechimney section and combustibles.

• Using a section of solid-insulated double-wall hightemperaturechimney,withaninsidediameterthesameas the chimney connector, at least one inchof solidinsulation,andaminimumof9" (229mm)airspacebetween the outer wall of the chimney section and combustibles.

In Canada, The Canadian Standards Association hasestablisheddifferentguidelinesforwallpass-throughs.Figure11showsonemethod,inwhichallcombustiblematerialinthewall iscutawaytoprovidetherequired18"(457mm)clearance for the connector. The resulting space must remain empty.Aflush-mountedsheetmetalcovermaybeusedononesideonly.Ifcoversmustbeusedonbothsides,eachcover must be mounted on noncombustible spacers at least 1"(25mm)clearofthewall.

Figure 10 shows oneNFPA recommendedmethod.Allcombustible material in the wall is cut away from the single-wallconnectortoprovidetherequired12"(305mm)clearance. Any material used to close up the opening must be noncombustible.

Wall Pass-ThroughsWheneverpossible,designyourinstallationsotheconnectordoes not pass through a combustible wall. If you areconsideringawallpass-throughinyourinstallation,checkwithyourbuildinginspectorbeforeyoubegin.Also,checkwith thechimneyconnectormanufacturer foranyspecificrequirements.Accessoriesareavailableforuseaswallpass-throughs.Ifusingoneofthese,makesureithasbeentestedandlistedforuseasawallpass-through.IntheUnitedStates,theNationalFireProtectionAssociation(NFPA) has established guidelines for passing chimney connectors through combustible walls. Many building code inspectors follow these guidelines when approving installations.

Through the FireplaceIfyourfireplaceopeningheightisatleast29"(737mm),youmayinstallaDefiant®throughtheopeningusinga"positiveconnection" kit, available from your local dealer. Positiveconnectionkitsensureatightfitbetweenthestovefluecollarandthechimneyflue.(Figure9)Fireplaceinstallations,whetherconnectedtotheflueaboveor through the fireplace opening, have special clearancerequirementstoadjacenttrimandthemantel.You’llfindtherequiredsafeclearancesforDefiant®fireplaceinstallationsonPage13.Floor protection requirements also apply to fireplace installations. This information is on Page 11.


DEFIAN

T

ST494steelwall pass thru11/00

18"(460mm)clearancebetweenpipeandsides/top/bottom of opening

Figure 11-Anapprovedwallpass-throughforCanada.

D

E

A

B

A

E

C

ST500Defiantfloor protection1/31/02 djt

E

F

E

F

U.S. Canada A. 44" 48" (1219mm) B. 46" 50" (1270mm) C. 12" 12" (305mm) 8"Connector 10" 10" (250mm) 6"Connector D. 6" 8" (203mm) E. 6" 8" (203mm) F. 16" 18" (460mm)

Figure 12-Requiredfloorprotectiondimensions.

Whenusingafirescreenwithdoorsopen,UL737,StandardforFireplaceStoves,thisunitwastestedusinga1"(25mm)non-combustiblehearthpadwithathermalconductivity,(k)=0.47BTU-in/hr-ft2-°F,resultingintherequirementofproviding a total thermal resistance (R) of 2.12. (Refer to "HowtoDetermineifalternateFloorProtectionMaterialsareAcceptable" section.)Thefloorprotectormaybecoveredwith a decorative noncombustible material if desired. Do notobstructthespaceundertheheater.An8"chimneyandchimney connector is required and the bypass damper must be in the fully open position.Important: All installations on a combustible floor require the use of the supplied bottom heat shield. Protection requirements vary somewhat between the Untied States and Canada as follows:In U. S. installationsthefloorprotectorisrequiredunderthestoveandmustextendatleast16"(notincludingtheashlip)fromthefrontofthestove("F",Figure12),andatleast6"fromthesidesandrear.("D"and"E",Figure12)In rear venting configurations, floor protectionmust alsoextendunderthechimneyconnectorand2"toeitherside.("C",Figure12)Forthe8"(203mm)connector,theprotectormustbeaminimumof12"(305mm)wide.Forthe6"(152mm)connector,theprotectormustbe10"(254mm)wide.The protector must be centered under the connector. Tomeettheserequirements,afloorprotectormustbeatleast44"wideand46"deep.In Canada:A noncombustible floor protector is requiredunderthestoveaswell.Thefloorprotectormustextend18"(457mm)tothefront("F",Figure12),and8"(203mm)fromthesidesandrear.("D"and"E",Figure12)Tomeettheserequirements,afloorprotectormustbeatleast46"(1168mm)wideand50"(1270mm)deep.

Your local dealer or your local building inspector can provide details for other approved methods of passing a chimney connectorthroughacombustiblewallinyourarea.InCanada,this type of installationmust conform toCAN/CSA-B365,Installation Code for Solid Fuel Burning Appliances andEquipment. NOTE:DonotventyourDefiant®intoafactory-built(zero-clearance)fireplace.Theseappliancesandtheirchimneysarespecificallydesignedasaunitforuseasfireplaces.Itmay void the listing or be hazardous to adapt them for any other use.DO NOT CONNECT THE DEFIANT® TO ANY AIR DISTRIBUTION DUCT OR SYSTEM.Floor ProtectionA tremendous amount of heat radiates from the bottom plate ofyourstove.Thefloorareadirectlyunderandaroundthestove will require protection from radiant heat as well as from straysparksorembersthatmayescapethefirebox.HeatprotectionisprovidedwiththeuseoftheBottomHeatShield supplied with the stove. Most installations will require the bottom heat shield to be attached.Onlywhen thestove isplacedonacompletelynoncombustible surface such as unpainted concrete over earth may it be used without the heat shield. With the bottom heat shield installed theDefiant® 1975 was tested using a 1⁄2" (13mm) non-combustible hearthmaterialwith a thermal conductivity, (k) = 0.47BTU - in/hr-ft2-°F,resultingintherequirementofprovidingatotalthermalresistance(R)of1.06.(Referto"HowtoDetermineif Alternate Floor ProtectionMaterials are Acceptable"section.)Thefloorprotectormaybecoveredwithadecorativenoncombustible material if desired. Do not obstruct the space under the heater.


How to Determine if Alternate Floor Protection Materials are AcceptableAllfloorprotectionmustbenoncombustible(i.e.metals,brick,stone,mineralfiberboards,etc.).Anyorganicmaterials(i.e.plastics,woodpaper products, etc.) are combustible andmust not beused.The floor protection specified includessomeformofthermaldesignationsuchasR-value(thermalresistance)ork-factor(thermalconductivity).Procedure:1.ConvertspecificationstoR-value:

i.R-valuegiven-noconversionneeded.ii.k-factorisgivenwitharequiredthickness(T)ininches:

iii.K-factorisgivenwitharequiredthickness(T)ininches:

iv.r-factorisgivenwitharequiredthickness(T)ininches:R=rxT

2. Determine theR-value of the proposedalternate floorprotector:i. Use the formula in Step 1 to convert values not

expressedasR.ii. Formultiple layers, addR-values of each layer to

determineoverallR-value.3. If theoverallR-valueof thesystemisgreater than the

R-valueof thespecifiedfloorprotector, thealternate isacceptable.

EXAMPLE:Thespecifiedfloorprotectorshouldbe1/2-inchthickmaterialwithk-factorof0.84.Theproposedalternateis4"brickwithanr-factorof0.2over1/8"mineralboardwithak-factorof0.29Stepa:UseformulaabovetoconvertspecificationtoR-value:

Step b: Calculate R of proposed system. 4"brickofr=0.2,therefore: Rbrick=0.2x4=0.8 1/8"mineralboardofk=0.29,therefore Rmineralboard=x0.125=0.431

Rtotal = Rbrick + Rmineralboard=0.8+0.431=1.231Stepc:CompareproposedsystemRtotalof1.231tospecified

Rof0.59.SinceproposedsystemRtotalisgreaterthanrequired,thesystemisacceptable.

Definitions:

R=xT1k

R=xT1Kx12

R=xT=x0.5=0.591k

10.84

10.29

r = = (ft2)(hr)(°F)

(Btu)(in)1k

(Btu)(ft)(ft2)(hr)(°F)

K=

k==Kx12(Btu)(in)

(ft2)(hr)(°F)R = (ft2)(hr)(°F)

Btu

Floor Protection for Fireplace InstallationDo not assume that your fireplace hearth is completelynoncombustible.Manyfireplacehearthsdonotsatisfythe"completelynoncombustible"requirementbecausethebrickorconcreteinfrontofthefireplaceopeningissupportedbyheavy wood framing. Because heat passes readily through brickorconcrete,itcaneasilypassthroughtothewood.Asaresult,suchfireplacehearthscanbeafirehazardandareconsideredacombustiblefloor.For all fireplace installations, follow the floor protectionguidelinesdescribedabove,includingtheneedforabottomshield.Keep inmindthatmanyraisedhearthswillextendless than the required clearance from the front of the heater. Insuchcases,sufficientfloorprotectionasdescribedabovemust be added in front of the hearth to satisfy the minimum floorprotectorrequirementfromthefrontofthestove:16"(410mm)intheUnitedStatesand18"(460mm)inCanada.Hearthrugsdonotsatisfytherequirementforfloorprotectionastheyarenotfireproof.Fireplace installations also have special clearance requirements to the side walls, side decorative trim andfireplacemantel.Refertotheinformationonfireplaceandmantel trim shields in this section.Keep the Stove a Safe Distance From Surrounding MaterialsBoth a stove and its chimney connector radiate heat in all directionswhenoperating,andnearbycombustiblematerialscan overheat dangerously if they are too close to the heat source. A safe installation requires that adequate clearance be maintained between the hot stove and its connector and nearby combustibles.Clearance is the distance between either your stove or chimneyconnector,andnearbywalls,floors,theceiling,andanyotherfixedcombustiblesurface.TheDefiant®hasspecificclearance requirements that have been established after careful research and testing. These clearance requirements must be strictly observed.Inaddition,keepfurnishingsandothercombustiblematerialsaway from thestove. Ingeneral, adistanceof 48" (1219mm) must be maintained between the stove and movable combustible items such as drying clothes, furniture,newspapers,firewood,etc.Keepingthoseclearanceareasempty assures that nearby surfaces and objects will not overheat.


Fireplace and Mantel Trim ShieldsAfireplaceinstallationrequiresspecialclearancebetweenthesideofthestoveandtherightandleftwalls,betweenthesideofthestoveandthedecorativesidetrimonthefireplaceface,andbetweenthetopofthestoveandthemantel.N o n c o m b u s t i b l e s h i e l d s installed1" (25mm)away fromthe combustible surface on noncombustible spacers, calledventilatedshields,maybeusedto reduce clearances.To protect a mantel from the heat of a stove in a fireplace installation,useacustom-madeventilated mantel shield that is at least 48" (1220mm) long,centered over the stove. (Figure 14) Ventilated shields for sidetrimmust extend the full lengthof the trim.Anunprotectedmantel("A",Figure15)cannotbemorethan9"(230mm)deepandmusthaveaminimumclearanceof41"(1041mm),measuredfromthestove’stopplate.Withaventilatedshield,thisclearancemaybereducedsafelyto29"(737mm).Unprotectedtoptrim(B)protruding3/4"(19mm)orlessfromthefaceofthefireplacemustbeaminimumof28"(711mm)fromthestove’stopsurface.Withaventilatedtrimshield,thisclearancemaybereducedsafelyto21"(533mm).

ST248wall shield construction12/14/99 djt

Stud Wall Framing

Wall Shield

Noncombus-tible Spacers and Fasteners

Drywall

Air Flow

Air Flow

Screen

Shield

Metal Spacer

Figure 13-Approvedwallshieldconstruction.

1" (25mm)

1/4" (6mm)

ST501mantel andtrim shield11/10/00 djt

Figure 14 - A custom-formed mantel shield.

Safe Ways to Reduce ClearancesClearance requirements are established to meet every installationpossibility,andtheyinvolvethecombinationofthese variables:

• When the stove pipe has no listed heat shield mounted on it.

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

Ingeneral,thegreatestclearanceisrequiredwhenyouplacea stove and its connector near a wall with no heat shield. Forexample,whentheDefiant® is installed parallel to the rear wallandnoconnectorshieldisused,itmustbeatleast15"(381mm)fromthewallbehinditandatleast21"(533mm)from walls on either side. These dimensions are measured from the top edge of the stove to the combustible wall.IftheDefiant®isinstalledinacornerandnoshieldisused,thecornersofthestovetopmustbeatleast5"(127mm)from nearby walls.Clearances may be reduced only by means approved by the regulatoryauthority,andinaccordancewiththeclearanceslistedinthismanual.RefertoPage14forapprovedclearancereductionspecifications.NOTE:Aminimumof67”(170cm)fromthetopofthestovetotheceilingisrequiredforallinstallationsoftheDefiant®.NOTE: Installation of the Defiant® is not permitted in alcoves.Wall ShieldsOne way to reduce clearances is with a wall shieldconstructedof24gaugeorheaviersheetmetal,orofanothernoncombustiblematerial such as 1/2" (13mm) insulationboard such as Durock® or Wonderboard®,orcommonbrick"laidonflat,"withthe31⁄2"(90mm)sidedown.Shieldsmustbespacedoutfromthecombustiblesurface1"(25mm)onnoncombustiblespacers,asinFigure13.Thespacers should not be directly behind the stove or chimney connector.Airmustbeabletoflowbetweenthewallandtheshield.Atleast50%ofthebottom1"(25mm)oftheshieldmustbeopen,andtheshieldmustbeopenatthetop.Metalscreeningacross the top will keep small stray objects from being trapped behindtheshield.(Figure13)Theshieldmustbeaminimumof48"(1219mm)tall,andmustextendatleast19"(483mm)higherthanthetopofthestove,whicheverishigher.Theshieldbehindthechimneyconnectormustbe30"(760mm)wide,centeredbehindthepipe; for installations that use an approved prefabricated chimneytopassthroughtheceiling,theshieldbehindthechimneyconnectormuststop1"(25mm)belowtheceiling.With8"connectionsandchimneys,becauseofpotentiallyhigher pipe temperatures, the shieldmust extend the fullheightof thewall (up to9’ (2.7m))andstop1" (25mm)below the ceiling.


Unprotected Protected A.Mantel 41"(1041mm) 29"(737mm) B.TopTrim 28"(711mm) 21"(533mm) C.SideTrim 14"(356mm) 14"(356mm) D.SideWall 21"(533mm) 11"(280mm)

Fireplace and Mantel Trim Clearances

Figure 15-Maintainclearancestocombustiblecomponentsofthemantelpiece.

ST253bEncoretrim clearances02/01 djt

A B

D

C C

Side Wall

Unprotectedsidetrim(C)thatprotrudes3/4"(19mm)orlessfromthefaceofafireplacemusthaveaminimumclearanceof14"(356mm),measuredfromthestove’stopsideedge.Ifthetrimextendsmorethan3/4"(19mm),itissubjecttothe requirements for wall clearance.The charts and sample installations that follow list all the clearancesrequiredforthevariousinstallationconfigurationsoftheDefiant®.


Theattachedrearshroudmustbeusedinallinstallations.Thefluecollarheatshieldmustbeusedinallverticalinstallations.1. Theconnectorpipeheatshieldmustextend36"(914mm)abovethefluecollar.2. WARNING:Ifstovehasbeeninstalledbasedontheclearancesdescribedaboveas"Topexitwithsinglewallordouble

wallconnectorpipe,"thenstovecannotbeoperatedas"Dooropenwithfirescreenanddamperopen"withoutmovingthe stove so the clearance meets those described for this type installation.

3. Usingalisteddoublewallovaltoroundconnector.4. Aminimumof67”(170cm)fromthetopofthestovetotheceilingisrequiredforallinstallationsoftheDefiant®.Aceilingheatshield,24" (610mm) indiameterandsuspended1" (25mm) from theceilingmustsurround thepipe ininstallations where the chimney penetrates the ceiling.

Defiant® Clearance Chart for 6" and 8" Connections ONLYStove Clearance

Unprotected SurfaceNo Connector Heat Shield

Protected Surfaces1

with Connector Heat Shield

Stove Installed Parallel to Wall Stove in Corner Stove Installed Parallel to Wall Stove in

CornerSide Rear2 Corners Side Rear2 Corners

(to rear shroud)

(to back edge of

cast)

(to rear shroud)

(to back edge of

cast)Topexitwithsinglewall connector pipe

(A)21"(521 mm)

(B)15"(381mm)

(C)21"(521 mm)

(D)5"(127 mm)

(E)5"(127 mm

(F)3"(76mm)

(G)9"(229 mm)

(D)5"(127 mm)

Dooropenwithfirescreen used and damper open (8"chimney only)2

(H)22"(559 mm)

(I)18"(457mm)

(J)24"(610mm)

N/A N/A N/A N/A N/A

TopExitwithDoublewall3 connector pipe

(P)21"(521 mm)

(Q)15"(381mm)

(R)21"(521 mm)

(S)5"(127 mm)

(T)5"(127 mm)

(U)3"(76mm)

(V)9"(229 mm)

(W)2"(51 mm)

RearExit(X)21"

(521 mm)(Y)10"

(254mm)(Z)16"

(407mm)N/A N/A N/A N/A N/A


Defiant® Clearance Diagramsfor use with either a 6" or 8" chimney connection

Unprotected SurfacesNo Connector Heat Shield

Protected Surfaceswith Connector Heat Shield

StoveInstalledParallel to Wall

Stove in CornerStoveInstalledParallel to Wall

Stove in Corner

E

F

D

D

D

ST855aDefiant 2n1ClearanceDiagrams

D

A

B

H

I

T

U

W

W

SP

SQ

XN/A N/A

Y

C G

N/AN/AN/A

J

RV

N/A

Z

Top Exit Installations, double-wall chimney connector, flue collar shield installed

Door open with fire screen, damper open, 8" chimney only, 1" floor protection

Top Exit Installations, single-wall connector

Rear Exit Installations


Double Wall ConnectorSide (A) Rear (B) Corner (C) Side (D) Rear (E) Corner (F)

36-1/2"(927mm) 21"(533mm) 16"(406mm) 20-1/2"(521mm) 9"(229mm) 16"(406mm)

Distance from the Center of the Flue Collar to the Wall

ST511Intrepid flue centerlineDiagrams11/16/00

*

A B C

*

D E F

*Thisdistance,fromthecenterofthefluecollartothefrontedgeofthehearth,isthesameforallinstallationsonthispage:34"(865mm)intheUnitedStatesand36"(914mm)inCanada.

Single Wall - No Connector Heat ShieldsUnprotected Surface Protected Surface

Parallel Installations Corner Installations Parallel Installations Corner

InstallationsSide (A) Rear (B) Corner (C) Side (D) Rear (E) Corner (F)

36-1/2"(927mm) 21"(533mm) 16"(406mm) 20-1/2"(521mm) 9"(229mm) 16"(406mm)

Doors Open - 8" ConnectorUnprotected Surfaces

Parallel Installations Corner Installations

Side (A) Rear (B) Corner (C)37-1/2(953mm) 18"(457mm)


48"(1220 mm)

48"(1220 mm)

48"(1220 mm)

ST498Defiant

Wall shield B 11/00

Figure 17 -Parallel installationwith rearwallpass-through, twowall shields. Reduced clearances to both rear and side walls. Wall shieldsmaymeet at corner if desired.Wall pass-throughmustcomply with codes.

Referto"SpecialInstallations."

Figure 16 -Parallel installation,verticalchimneyconnector, twowall shields. Reduced clearances for both rear and side walls. Wall shields may meet at corner if desired. Shielding for connector is centered behind connector.

48"(1220 mm)

48"(1220 mm)

48"(1220 mm)

48"(1220 mm)

ST499Defiant

Wall Shield C11/00

Figure 18-Cornerinstallation,verticalchimneyconnector,twowallshields. Reduced side clearances. Wall shield MUST meet at corner.

48"(1220 mm)

48"(1220 mm)

48"(1220 mm)

48"(1220 mm)

ST497Defiantwall shield A11/00


Remove the unit from the shipping brackets by removing (2) 1/4-20hexheadboltsfromeachshippingbracket,leavingbracketsattachedtotheskid.Figure19.(Savethe1/4-20hexhead bolts as they will be needed later to install heat shield.)NOTE:Whenmovingthestove,liftthestovetotakeweightoffthelegswheneverpossible.Draggingorslidingthestove,especially across rough surfaces can cause the legs to loosen or even break.Set Up Your StoveCastironstovesareheavy,anditwilltaketwotofourpeopletomoveyourDefiant® into position.Wipe the protective coating of oil from the griddle with a clean dry rag or a paper towel. Install the handle on the griddle. First, place the griddleupside down at the edge of a flat surface and assemble the handle. Figure20.With the handle pointing 45°fromitsfinalposition,tighten the nut as far as possible with the pliers. Move the handle to its final positionwhile stillholding the nut with the pliers.

Assembly

ST857abottom heat shield12/051/10

Figure 22-Attachthebottomheatshield.

BottomHeatShieldST516Attach griddle handle11/17/00 djt

Figure 20-Attachthegriddlehandle.

Install the Bottom Heat ShieldNOTE: TheBottomHeatShieldisrequiredinmostinstallations.RefertoFloorProtection,Page9,forfurtherdetails.1. Install(4)1/4-20x3/8"hexboltssuppliedinthemanual

bag into the four holes located under the stove (Figure 22).

2. Alignthebottomheatshieldkeyholestothefourhexboltspreviously installed into base. (Figure 22). The outside air cutout hole should be toward the rear of the stove.

3. Attachtheheatshieldsidesbypassingtheslotsovertheboltheads.Tightenthehexheadbolts.Figure22.

Storing the HandleUse the removable handle to open or close the doors. After usingit,removethehandlesoitwillnotgethot.Storethehandle in the handle holder installed behind the right front leg. (Figure 21)

CAUTION!Overtighteningcanstriptappedthreads.

Figure 19-Removeunitfromshippingbrackets.

1/4-20 Bolt

ST564handle holder12/13/00

ST564handle holder12/13/00

BottomHeatShield

DoorHandleHolder

Leg Bolt and Washer

Figure 21-Handleholderandheatshieldpositions.


ST540Assemblyhandle11/00

Figure 26-Assemblethefrontdoorhandle.

DEFIANT

ST539attachthermostathandle11/00

Figure 25-Attachthethermostathandle.

Figure 23-Installfluecollarheatshield.

ST1180flue collar heat shield

Sheet Metal Screws

Sheet Metal Screws

Flue Collar HeatShield

Assemble the Removable Insert HandleThe wooden removable insert handle opens and closes the frontdoors.Removeaftereachuse,andstoreitinthehandleholder behind the right front leg. Assemble the handle by passingthe3-3/8"screwthroughthewoodenshaftandintothebrightmetalnub.(Figure26)Tightencarefullyuntilsnug.

Attach the Damper Handle Usethe1/4"-20x3"screwtoattachthedamperhandletothe damper stub on the left side. Attach the Primary Air Thermostat Handle The primary air thermostat handle is the smaller of the two black handles. Secure the handle to the stub on the right sideofthestovewithan8-32x2"slotheadmachinescrew.(Figure 25)

Figure 24-InstalltheCatalystTemperatureProbe

1.4"

1.8"

Bracket mounting screw hole location

Fold bracket strap over catalyst probe shaft and secure with screw.

Insertcatalystprobethrough sheet metal and castironbackandtwist&pushthroughfiberpanel.

Remove hold plug from cast iron back.

Insertcatalystprobebracketwithself-drillingscrew.

Attach the Catalyst Temperature ProbeToinstallthecatalysttemperatureprobe,removetheholeplug from the cast iron wall behind the rear shield as shown (Figure24)use two#10sheetmetal screwsandbracketsupplied,securethebracketandprobetothebackofyourstove.(Figure24)

Flue collar heat shield must be installed.

WARNING!

Adjust the Leg Levelers Lift the stove slightly so there is no weight on the leg while making the adjustment.Reverse the Flue Collar (If necessary)Reversethefluecollarbyremovingthetwoscrewsthatattachit to the back of the stove. Be sure the gasket around the fluecollaropeningisinpositionwhenyouscrewthecollarback onto the stove.


Fan Kit Installation1. Attach the fan assembly at the bottom edge of the inner

backwithtwo(2)1/4-20x3/4"hexheadscrews.2. Attach snapstat to the mounting holes on the underside

ofthebottomwithtwo(2)1/4-20panheadscrews.3. Attach the rheostat holder (provided with the stove)

under the right front wing of the bottom heat shield with two(2)#10sheetmetalscrews.

4. Attachtherheostattoitsholderbyinsertingtherheostatcontrolshaftthroughtheholderhole.Installtheretainingring and rheostat knob onto the shaft.

5. Secure the rheostat cable to the underside of the bottom heat shield using the wire tie provided and the hole at the right rear edge of the heat shield.

6. Fanwill notoperateuntil stove reachesapproximately109°F.

Figure 27-Faninstallation(Kit#2767).

ST848fan install6/05

Rheostat Knob

Rheostat Snapstat Screws

HoleforWireTie to Secure Cable

Rheostat Holder

Installing or Removing Catalyst1. Remove the access cover by gently lifting up and pulling

outfromthebottomedge.(Figure28)2. Remove the inner cover by pulling it straight out. (Figure

29)3. Remove the catalyst by gently pulling it straight out.

(Figure 30) Place the catalyst where the catalyst’sceramic components will not be damaged.

ST1187remove access cover

Access Cover

Figure 28-Removeaccesscover.

ST1188remove inner cover

InnerCover

Figure 29-Removeinnercover.

ST1189remove catalyst

Remove Catalyst

Figure 30-Removecatalyst.


Smoke and CO DetectorsThe 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 TipsConvenientlylocatea"ClassA"fireextinguishertocontendwith small fires. Be sure the fire extinguisher works andis clearly visible. All occupants of the house should know whereitis,andhowitoperates.Haveheavystoveglovesavailablenear thestove.Havespecialsafetyaccessories(e.g.,ChildGuardScreen)availableforuseifsmallchildrenwill be in the home.Intheeventofastovepipeorchimneyfire….• Evacuate the house immediately• Notifythefiredepartment• If the fire isn't too threatening, closingdown the stove

tight,(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.


Operation

ST541Defiantfront viewcontrols11/00

GriddleHandleDoorHandle

Air Control Lever

AshDoorHandle

DoorHandleHolder

(Behind Leg)

Andiron

Damper Handle

Figure 31-TheDefiant®’s controls are conveniently located and easy to operate.

D E F I A N TD E F I A N T



ST541thermostatsettings11/00

LowHeatRange

Air Control Positions

MediumHeatRange

HighHeatRange

Figure 32-Thehandlealsomaybepositionedanywherebetweenthetwoextremesfordifferentheatlevels.

DEFIANTD E F I A N T DEFIANTD E F I A N T

ST543Damperpositions11/00

Damper Positions

Open(UpdraftMode) Closed(EfficientMode)

Figure 33-TheDefiant®’s damper operating positions.

A Damper Directs Air Flow Within the StoveThe damper handle on the left side of the stove operates thedampertodirectairflowwithinthestove.The damper is open when the handle points to the rear,enabling smoke to pass directly into the chimney. The damper mustbeopenwhenstartingorrevivingafire,andwheneverthe griddle or doors are opened.The damper is closed when the handle points forward. Smoke travels through the secondary combustion system where it can be further burned, before passing up thechimney.(Figure33)The damper should always be either fully open or fully closed. There are no intermediate positions. When closing the damper, be sure to pull firmly enough to snap the handle into the locked position.

A Single Air Control Regulates Heat Output and Burn TimeThe primary air control lever,ontherightsideofthestove,controlstheamountofincomingairforstarting,maintaining,andrevivingafire.Oncetheaircontrolismanuallyset,abi-metallicthermostatautomatically maintains the heat output at a constant level for a more even heat over the life of the burn.Moreairenteringthestovemakesthefireburnhotterandfaster,whilelessairprolongstheburnatalowerheatoutputlevel.(Figure32)Forthegreatestairsupplyandmaximumheatoutput(buttheshortestburntime),movethelevertowardthefrontofthestove.Forafirethatwilllastlongerwithlessheat,movethe lever toward the rear of the stove.

The Defiant® Controls:Two controls regulate the performance of the Defiant®: a primary air control suppliesoxygenforthefire,andadamper directsairflowwithinthestovetoactivateanddeactivatethecombustionsystem.(Figure31)Symbols cast into the stove are reminders of the correct directions for using the controls. The words ‘Left’ and ‘right’ in these directions are facing the stove.

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.

WARNING!


Conditioning Your StoveCast iron isextremelystrong,but itcanbebrokenwithasharp blow from a hammer or from the thermal shock of rapidandextremetemperaturechange.The cast plates expand and contract with changes intemperature. When you first begin using your Defiant®,minimize thermal stress by letting the plates adjust gradually duringthreeorfourinitialbreak-infiresfollowingSteps1-3below.Wood Burning OperationBurnonlysolidwoodintheDefiant®,andburnitdirectlyonthe grate. Do not elevate the fuel. Do not burn coal or other fuels.IntheUnitedStates,it isagainstthelawtooperatethis wood heater in a manner inconsistent with operating instructions in this manual.The bypass damper must be open when starting a fire or when refueling. Do not use chemicals or fluids to start the fire. Do not burn garbage. Never use flammable fluids such as gasoline, gasoline type lantern fuel, kerosene, charcoal lighter fluid, naptha, engine oil or similar liquids to start or "freshen up" a fire in this heater. Keep all such liquids well away from the heater while it is in use. 1. Openthestovebypassdamper,andopentheprimaryair

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

stove.Placesixoreightpiecesofdrykindlingsplittoafinger-widthsizeonthepaper.Onthekindling,laytwoorthree largersticksofsplitdrywoodapproximately1-2"(25-51mm)indiameter.(Figure34)

NOTE: Some chimneys must be "primed",orwarmedup,beforetheywilldrawsufficientlytostartafire.Tocorrectthissituation,rollupacouplepiecesofnewspaper,placethemontopofthekindlingandtowardthebackofthestove,lightthem,andclosethedoors.Thiswillencouragethesmoketoriserapidly,makingiteasiertoestablishagooddraft.Oncethedraftisestablished,openthefrontdoorandlighttherestof the fuel from the bottom. Do not light the main bed of fuel untilthechimneybeginsdrawing,andrepeattheprocedureas often as necessary if the initial attempt is unsuccessful.NOTE: Effectiveness of a "top-down"methodtostartafire.Smoke emissions when 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,placelargerpiecesofkindlingonthebottomofthekindling pile followed by smaller and smaller pieces as the pile isadded to.Veryfinelysplitpiecesshouldbeon thetop. Light the kindling pile with a match at the top and allow the kindling to burn downward into the larger pieces. This reduces smoke by slowly increasing the fire sizewithoutcreatinganair-starvedcondition.4. If your Defiant® has been broken-in previously using

Steps1-3,continuetobuildthefiregradually.Addlargerwood with a diameter of 3-4" (75-100 mm). Continueadding split logs of this size to the briskly-burning fireuntilthereisaglowingemberbed2-3"(51-75mm)deep.(Figure38)Agoodemberbed isnecessary forproperfunctioning of the combustion system.

5. Close the damper when the griddle temperature reaches 450°F(230°C)andsufficientemberbedisestablished.This will force the smoke into the secondary combustion chamber where the smoke and gases will ignite if the stove is sufficiently hot. Even though it is possible forthefiretogetquitehotwithinafewminutesafterafireisstarted,secondarycombustionmaystoporthefiremaygooutifthefirediesdownimmediatelyasaresultofthedamper being closed too early.

6. Adjusttheaircontrolforyourdesiredheatoutput.NOTE: Stove installations vary widely, and the operatingguidance given here is only a starting point. The "Draft Management" section in thismanualwill explain in detailhow the features of your installation may help or hinder good draft,andhowyoumayneedtovaryyourfiringtechniqueifyour installation doesn’t encourage a good draft.High-Efficiency Wood Burning with the Catalytic CombustorYour Defiant stove was shipped from the factory with aseparately packaged catalytic combustor. When operating the stove with the catalytic combustor, use the sameoperation instructions as outlined in the previous section.

ST263starting a fire12/99

Figure 34-Startthefirewithnewspaperanddrykindling.

3. Lightthenewspaperandclosethedoor.Graduallybuildupthefirebyaddingafew3-5"(80-120mm)diameterpiecesofsplitfirewood. If this is one of the first few "break-in" fires, let the fire burn brightly, and then let it die out.During the break-in fires, do not let thestove get hotter than 500°F. (260°C) asmeasured onanoptionalstove-topthermometer.Adjusttheaircontrolleverasnecessary tocontrol thefire.Someodor fromthestove’shotmetalandthepaintisnormalforthefirstfewfires.


Whilenotrequired,operatingyourstovewiththecatalyticcombustor installed creates optimum conditions for secondarycombustionandwillincreaseyourefficiencyupto 15%on low burn,making sure you get themost heatout of each load of wood. Refer back to the "Installing or Removing Catalyst" section of this manual.The catalytic element is a ceramic "honeycomb" coatedwith the catalytic material. The element sits at the bottom of the secondary combustion chamber. Smoke, gasesand particulates that are not fully combusted during the secondarycombustionprocesspass through thecatalyst,creatingatertiaryburn.Thisresultsinhigherefficiencyandlower emissions.The catalyst will initiate combustion of smoke and particulates at500°-600°F(260°-315°C),halfthetemperaturenormallyrequiredforunaidedsecondarycombustion.Ifyoufollowedthe startup operation steps in the previous section the stove willbesufficientlyhottoallowthecombustortowork.Oncethe combustor startsworking, heat generated by burningthe smoke will keep it working.Todeterminewhetherthecombustor isoperating,refertothe temperature probe which shows the operating range of the catalytic combustor. This is located on the back of the stove and is viewed from the top. NOTE: It will takeseveral minutes after closing the bypass damper for the temperatureprobetofullyadjusttothenewtemperature.Iftheprobeindicatorisbelowtheoperatecatalystrange,addfueloropenthebypassdampertoallowthefiretofurtherbuild before engaging the catalyst again. If theprobe indicator isabovetheoperatecatalystrange,the catalytic combustor is running too hot and may be damaged. Inmanycases,decreasing theprimaryaircanreduce the catalyst temperature and adding less wood with each loading can also help if overheating is persistent. Do not add wood to the stove if the probe reads above the operate catalyst range. Avoidusingafullloadofverydrywoodinthefirebox,suchasdryslabwoodorwoodwithbelow14%moisturecontent.This may result in continuous very high temperatures in the secondary combustion area and damage the combustor.Never kindle a fire with colored paper or paper that hascoloredinkoraglossysurface.Neverburntreatedwood,garbage, solvents or trash. All of these may poison thecatalyst and prevent it from operating properly. Never burn cardboard or loose paper except for kindling purposes.Neverburncoal;doingsocanproducesootorlargeflakesofcharorflyash thatcancoat thecombustorandcausesmoke to spill into the room. Coal smoke can also poison the catalyst so that it won’t operate properly. NOTE: The ceramic catalytic combustor is fragile and will crack if subjected to thermal shock. Thermal shock can occur when refueling with wet wood or closing the bypass damper too early after refueling. Hairline cracks will notaffect the performance of the combustor, but repeatedthermal shocks can result in cells falling out, somewhatreducing the effectiveness of the combustor.

Two Ways to Add FuelThe Defiant®’s griddle lifts for convenient top-loading oflogs,andistheeasiestwaytoaddfuel.(Figure35)However, the front doors open as well for adding anoccasionallogtoafire.Ifthestoveisequippedwith8"(203mm)stovepipe, the frontdoorsmaybeopened (orevenremoved) and the optionalDefiant® spark screen placedin the opening for open-fire viewing.TheDefiant® is notapproved for operation with the front doors open if equipped witha6"(152mm)chimneyconnectororchimney.

Defiant

ST521Intrepidloading11/00

Figure 35-Toploadingisthebestwaytoaddfuelduringregularuse.Frontloadingisusefulforkindlingafire.

Toopenthefrontdoors,insertthehandleintothedoorlatchstubandturnittotheleftandup.(Figure36)To close them, always close the left door first. Turn thehandle in the right door to the left and up (to the open position)andcloseit.Finally,pushonthedoorasyouturnthe handle to the right and down. The doors will draw in slightly,andthehandleshouldoffersomeresistanceasyouturn it to the closed position. Toreducetheriskofbreakingtheglass,avoidstrikingtheglass or slamming the doors.When you are not using the door handle, store it in theholder behind the right front leg of the stove.

ST544door open11/00

Clockwise to Open

Counterclockwise to Close

Figure 36-Toopenthefrontdoors,turnthehandleclockwise.

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


WARNING!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.

The Defiant® may be used as a fireplace with the front doors open or removed, BUT only when it is equipped with 8" (203 mm) stove pipe and only when the optional spark screen is secured correctly in the opening to protect against the possibility of sparks and embers leaving the stove. The test standard for your stove when it is operated in this mode is UL 737. 1" floor protection is also required. Refer to the "Floor Protection" section in this manual.Use only the Defiant® spark screen, Item #1907, with your Defiant®. Defiant® SPARK SCREENS ARE AVAILABLE FROM YOUR VERMONT CASTINGS DEALER.Refuel While the Embers Are Still HotWhenreloading,bestresultswillbeachievedifyoufirstde-ash the stove by stirring the fuel bed to allow ash to fall through the grate into the ash pan. Do not break the charcoal into very small pieces or pound or compress the charcoal bed. Check to make sure air holes at thebottomofthefirebackarenotblockedbyashorembers(blockage will reduce performance of the stove). Itisimportantthataircancirculatethroughthecharcoalbedduring the burn. Larger pieces of charcoal allow more air to circulateunderthewood,resultinginthefirerevivingmorequickly.(Figure37)

ST264aadd wood fire11/00

Figure 37-Addfullsizelogsaftertheemberbedis3"(75mm)deep.

1. Openthedamperandturntheprimaryaircontroltohigh.2. De-ash the stove as described above. Open the ash

door and check the level of ash in the ash pan. Empty the pan if necessary and replace it in the stove. Close the ash door.

3. Open the griddle top, load the wood (smaller piecesfirst),andclosethegriddletop.

4. Waitseveralminutesforthenewwoodtofullyigniteandfor the stove top surface temperature to reach 450°F(230°C).

5. Close the damper. And adjust the air control for the amount of heat your desire.

NOTE: If theremainingcharcoalbedisrelativelythick(2-3"/51-75mm)andifyourfueliswellseasoned,itispossibletoaddfreshfuel(smallerpiecesfirst),closethedooranddamper, and reset the primary air control for the desiredheatoutputwithinfiveminutes.

For best results when refueling, wear long-cuffed stovegloves to protect your hands and forearms. Add fuel while thestovestillhasplentyofglowingemberstore-kindlethefireand includesomesmallerpiecesofwood in thenewfuel load to help the stove regain its operating temperature quickly. Use this sequence as a guide to successful refueling:

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

Andirons Help Protect the GlassYour stove has andirons to keep logs away from the glass panels. The andirons are essential to maintain clear fireviewing, and should be left permanently in place. Sincethe andirons may slightly hinder refueling through the front doors,moststoveownerswillprefertheconvenienceoftoploading through the griddle. Do not place fuel between the andirons and the doors.Burn Only High-Quality WoodTheDefiant®isdesignedtoburnnaturalwoodonly;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. Burninganymaterialsnotallowedintheseinstructions,orover-firingthestove,mayvoidthewarranty.You’ll enjoy the best results when burning wood that has been adequately air-dried. The wood should be 20-24"(457-508mm) in length.Avoidburning "green"wood thathas not been properly seasoned. Do not burn construction materials; they often contain chemicals and metals that can damage the inside surfaces of the stove and pollute the air.Donotburnoceandriftwood;whenitburns,thesalt itcontains will attack the cast iron.


Thebesthardwoodfuels includeoak,maple,beech,ash,and hickory that has been split, stacked, and air-driedoutside under cover for at least one year. Ifhardwood isnotavailable,youcanburnsoftwoodsthatincludetamarack,yellowpine,whitepine,Easternredcedar,fir,andredwood.Theseshouldalsobeproperlydried.Storesplitwoodundercovertokeepitdry.Evenforshort-termstorage,besuretokeepwoodasafedistancefromtheheater and keep it out of the areas around the heater used for refueling and ash removal.Surface Thermometer is a Valuable Guide to OperationAn optional surface thermometer tells you when to adjust theaircontrol,andwhentorefuel.(Figure38)

ST523Intrepidtemp readings11/00

Figure 38-Taketemperaturereadingswithathermometerlocatedin the middle of the griddle.

For example, when the thermometer registers at least450°F(230°C)onthestovetopafterstart-upyouknowthestove is hot enough and it may be time to close the damper ifasufficientemberbedhasalsobeenestablished.Notethatthestovewillwarmupmuchsoonerthanthechimney,though;awarmchimneyisthekeytoeasy,effectivestoveoperation. Please review the "Draft Management" section of thismanualtoseehowthesize,type,andlocationofyourchimney will affect your stove operation. When thermometer readingsdropbelow350°F.(175°C) it’s timetoadjust theair control for a higher burn rate or to reload the stove. A temperaturereadingover650°F.(340°C)isasigntoreducethe air supply to slow the burn rate.Use the following temperature ranges as a guide:• Readingsinthe350°-500°F.(175°-260°C)rangeindicate

low to medium heat output.• 500°-600°F. (260°-315°C) readings indicate medium

heat output.• Readingsof600°-650°F.(315-340°C)indicatehighheat

output.OperatingyourDefiant®continuouslyatgriddletemperatureshigherthan650°F(340°C)maydamagethecastironorenamelfinish.

Use the Air Control Settings that Work Best for YouNo single air control setting will fit every situation. Eachinstallationwilldifferdependingon thequalityof the fuel,theamountofheatdesired,andhowlongyouwishthefireto burn; outdoor air temperature and pressure also affect draft.

The control setting also depends on your particular installation’s "draft", or the force that moves air from the stove up through the chimney. Draft is affected by such thingsasthelength,type,andlocationofthechimney,localgeography,nearbyobstructions,andotherfactors.Seethe"Draft Management" section of this manual for details on how the installation affects performance.Toomuchdraftmaycauseexcessive temperatures in theDefiant®,andcouldevendamagethestove.Ontheotherhand, too little draft can causebackpuffing into the roomand/orthe"plugging" of the chimney.Howdoyouknowifyourdraft isexcessivelyhighorlow?Symptoms of too much draft include an uncontrollable burnoraglowing-redstovepart.Signsofweakdraftaresmoke leaking into the room through the stove or chimney connector joints or low heat output.Insomenewerhomesthatarewell-insulatedandweather-tight, poor draftmay result froman insufficient air supplyinthehouse.Insuchinstances,anopenwindownearthestove on the windward side of the house can provide the combustion air supply needed. Another option for getting more combustion air to the stove is to duct air directly from outside to the stove. In someareas provisions for outside combustion air are required in all new construction.The Defiant® is equipped to deliver outside air forcombustion.Adapter#3108isrequiredforinstallationandany3"noncombustibleductwill need tosuppliedby theinstaller. When first using the stove, keep track of the air controlsettings.Youwillquicklyfindthataspecificsettingwillgiveyouafixedamountofheat. Itmaytakeaweekor twotodetermine the amount of heat and the length of burn you shouldexpectfromvarioussettings.Most installations do not require a large amount of combustion air, especially if adequate draft is available.Donotforanyreasonattempttoincreasethefiringofyourheater 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.


Defiant® Control Settings (RefertothefirstpageoftheOperationsection.)DO NOT OPERATE THE STOVE WITH THE ASH DOOR OPEN. OPERATION WITH THE ASH DOOR OPEN CAN CAUSE AN OVER-FIRING CONDITION TO OCCUR. OVER-FIRING THE STOVE IS DANGEROUS AND CAN RESULT IN PROPERTY DAMAGE, INJURY OR LOSS OF LIFE. Ash DisposalRoutineashremovalisimportantforeaseofmaintenance,and is important for the stove’s durability. Remove ash before it reaches the top of the ash pan. Check the level at leastonceaday.Every fewdays,clearanyashfromtheouteredgesofthefirebox.Mostoftheashwillfallthroughthe grate. Stir the ash with a shovel or poker so that it falls through the grate slots. IMPORTANT: Check the level of ash in the ash pan before reloadingthestove.Iftheashlevelisclosetothetopedgeofthepan,emptythepanaccordingtothisprocedure:• Openthedamper.• Open the griddle or front doors, and use a shovel or

pokertostirexcessashthroughtheashslotsinthegratedown into the ash pan.

• Close the griddle or doors, and unlatch the ash door.(Figure39)Itwillpivot,swingingtheashpanoutofthestove.

Figure 39- Turn the ashdoor handle clockwise to open andcounterclockwise to close.

ST545ashdoor11/00

Open

Close

• Removetheashpan,makingsuretokeepitlevel.• To keep the cover from sliding off and to keep ash from

fallingonthefloor,donottilttheashpanforward.• If the stove is in operation, close the ash door while

disposing of the ash. You may need to lift the latch end of the door slightly to align the latch with the mating part on the stove bottom.

• Properly dispose of the ash in a metal container with a tight-fitting lid.Store thecontaineroutdoorsaway fromall combustible material.

• Returntheashpanto itsoriginalposition in thestove,andcloseandlatchtheashdoor.(Figure41)

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

Empty theashpan regularly, typically every one to threedays. The frequency will vary depending on how you operateyourDefiant®:ashwillaccumulatefasterathigherheat outputs.Removed ash should be placed outdoors in a metal containerwithatight-fittinglid.Keeptheclosedcontainerofashonanoncombustiblefloororontheground,wellawayfrom all combustible materials, pending final disposal. Ifthe ash is disposed of by burial in soil or otherwise locally dispersed,itshouldbekeptintheclosedcontaineruntilallcinders have thoroughly cooled.• Slidethecoverontothepan,makingsureitissecurely

closed.(Figure40)

ST566remove ashpan7/05

Figure 40-Besurethecoverissecurelyattachedbeforeremovingthe ash pan.

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


Draft ManagementA stove is part of a system,which includes the chimney,theoperator,thefuel,andthehome.Theotherpartsofthesystem will affect how well the stove works. When there is agoodmatchbetweenalltheparts,thesystemworkswell.Wood stove or insert operation depends on natural (unforced)draft.Naturaldraftoccurswhen theexhaust ishotter (and therefore lighter) than the outdoor air at the top ofthechimney.Thebiggerthetemperaturedifference,thestronger the draft. As the hot gases rise through the chimney they provide suction or ‘draw’ that pulls air into the stove for combustion.Aslow,lazyfirewiththestove’sairinletsfullyopenindicatesaweakdraft.Abriskfire,supportedonlybyairenteringthestovethroughthenormalinlets,indicatesagooddraft. The stove’s air inlets are passive; they regulate how muchaircanenterthestove,buttheydon’tmoveairintoit.Depending on the features of your installation - steel ormasonrychimney,insideoroutsidethehouse,matchedtothestove’soutletoroversized-yoursystemmaywarmupquickly,oritmaytakeawhiletowarmupandoperatewell.Withan‘airtight’stove,onewhichrestrictstheamountofairgettingintothefirebox,thechimneymustkeepthestove’sexhaustwarmall theway to theoutdoors inorder for thestove to work well. Some chimneys do this better than others. Here’salistoffeaturesandtheireffects.Masonry ChimneyMasonry is a traditionalmaterial for chimneys, but it canperform poorly when it serves an ‘airtight’ stove. Masonry isaveryeffective‘heatsink’-itabsorbsalotofheat.Itcancool the chimney gases enough to diminish draft. The bigger thechimney,thelongerittakestowarmup.It’softenverydifficulttowarmupanoutdoormasonrychimney,especiallyanoversizedone,andkeepitwarmenoughtomaintainanadequate draft. Steel ChimneyMostfactory-madesteelchimneyshavealayerofinsulationaround the inner flue. This insulation keeps the chimneywarm.Theinsulationislessdensethanmasonry,soasteelchimney warms up more quickly than a masonry chimney. Steeldoesn’thavethegoodlooksofmasonry,butitperformsmuch better. Indoor/Outdoor LocationBecausethechimneymustkeepthesmokewarm,it’sbesttolocate it inside the house. This uses the house as insulation fortheflueandallowssomeheatreleaseintothehome.Anindoorchimneywon’tloseitsheattotheoutdoors,soittakesless heat from the stove to heat it up and keep it warm.

Chimney HeightThecommonwisdomtellsusthatatallerfluedrawsbetterthanashortone.Thisisn’tnecessarilyso.Ifachimneyistallenoughtomeetthesafetyrequirementsofthe2/3/10footrule,thenaddingmoreheightisn’ttherightanswertoadraftproblem.Infactitcouldmaketheproblemworsebyaddingmoremasstothechimneysystem,whichmustbewarmedup,adistancefromtheheatsource(thestove).Don’tmakeachimneytallerunlessyoumustinordertomeetthesafetyrules,or unless there’s some nearby feature causing a downdraft. Even then, there are downdraft-preventing chimney capsavailable,whichareprobablythesmarterchoice.Flue Sizing The inside size of a chimney for an ‘airtight’ stove should matchthesizeofthestove’sflueoutlet.Whenachimneyservesanairtightstove,moreisnotbetter;infact,itcanbeadisadvantage.Hotgasesloseheatfasterastheytravelslowerthroughachimney;ifweventastovewithasix-inchfluecollar(28squareincharea)intoa10x10"flue,thegasesslowtoone third their original speed. This allows the gases to cool morerapids,whichweakensdraftstrength.Ifanoversizedflueisalsooutsidethehouse,theheatitabsorbsgetstransferredtotheoutdoorairandtheflueusuallystayscool.It iscommonforamasonryflue,especiallyoneservingafireplace,tobeoversizedforthestove.Itcantakequiteawhiletowarmupsuchaflue,andtheresultscanbedisappointing.Thebestsolutiontoanoversizedflueisaninsulatedsteelchimneyliner,thesamediameterasthestoveorinsertsflueoutlet;thelinerkeepstheexhaustwarm,andtheresultisastrongerdraft.Annon-insulatedlinerisasecondchoice-thelinerkeepstheexhaustrestrictedtoitsoriginalsize,butthehot gases still must warm up the air around the liner. This makesthewarm-upprocesstakelonger.Pipe & Chimney LayoutEveryturntheexhaustmusttakeasittravelstothechimneytop will slow it down. The ideal pipe and chimney layout is to vent vertically into a completely straight and vertical chimney. Ifyouarestartingfromscratch,usethislayoutifpossible.Ifthestovepipemustelbowtoenterachimney,locatethethimble about midway between the stove top and the ceiling. This achieves several goals: it allows the gases to speed up beforetheymustturn,itleavessomepipeintheroomforheattransfer,anditgivesyoulong-termflexibilityforinstallinga different stove without relocating the thimble. Thereshouldbenomorethaneightfeetofsingle-wallstovepipe between the stove and a chimney; longer runs can cool theexhaustenoughtocausedraftandcreosoteproblems.Withprefabricatedchimney,bringitdowntosixtoeightfeetfromthestove.Withamasonrychimney,arrangethepipeso that it turns into the chimney within eight feet of the stove.


Back-puffingBack-puffingresultswhenthefireproducesvolatilegasesfasterthanthechimneydraftpullsthemoutofthefirebox.Thegasesbackupinthefireboxuntiltheyareconcentratedenoughandhotenoughtoignite.Ifyourstoveback-puffs,the stove needs to cool down. You should open the damper toletthesmokerisetothefluemorequickly,allowmoreairintothefirebox,avoidbigloadsoffirewoodandcheckthatthe wood moisture is not too low. Draft TestingAn easy way to test your chimney draft is to close the stove’s damper,waitafewminutestolettheairflowstabilize,thenseewhetheryoucanvarythestrengthofthefirebyswingingtheair control open and closed. Results are not always instant; 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. Negative PressureGood draft also depends on a supply of air to the stove; a chimney can’t pull in more air than is available to it. Sluggish draft results when a house is tight enough to prevent the readyflowofairtothestove,orbycompetitionbetweenthestoveandotherequipmentthatsendsindoorairoutside-especiallypower-drivenequipmentlikerangehoods,clothesdryers,etc.Ifthechimneydrawswellwithallotherequipmentturnedoff(orsealed,inthecaseoffireplacesand/orotherstoves),thenyousimplyneedtobecarefulwithtimingtheuseof theotherairconsumingequipment. Ifyouneed tocrackanearbywindowordoortoenablethechimneytoflowwell,itmaybeagoodideatoinstallanoutside-airintaketobring combustion air directly to the stove. An outside air kit is available to connect the stove directly to a source of outdoor combustion air.ConclusionWood-burning is an art rather than a science. Once thestoveandchimneysystemareinplace,youcanonlyvaryyourtechnique,mostlyyourtiming,toachievegoodresults.Ifyoukeeptrackofyourburninghabitsandrelatethemtotheireffectsonthestove’soperation,you’llberewardedwithgood performance and year of reliable heating.

Single VentingEach‘airtight’stoverequiresitsownflue.Ifanairtightstoveis vented to a flue that also serves an open fireplace, ora leakierstove, it’seasier for thechimneydraft topullairin through those channels and performance of the stove suffers.Imagineavacuumcleanerwithaholeinthehosetounderstandtheeffecthere.Insomecasestheotherappliancecanevencauseanegativedraftthroughthestove,andresultin a dangerous draft reversal.CreosoteCreosote is a by-product of slow wood-burning. It’s anorganictarthatcancondenseintheflueifitispresentintheexhaust,slow-moving,andcoolstolessthan290°F(130°C).Condensedcreosoteisvolatile,andcangeneratechimneyfiresifitgetshotenough.Allthefeaturesthataffectchimneydraftalsoaffectcreosotecondensation-sousewhatevercombination of installation features and operational steps that will encourage good draft and minimize creosote production.Becauselettingtheexhaustcooloffandslowdownisoneofthekeystocreosoteaccumulation,itmakessensetolineachimneytomatchthestove’soutletsize,forsafetyreasonsas well as performance. Canadian law requires a matching linertoserveanystoveorinsertventedthroughafireplacechimney;intheUS,theNationalFireProtectionAssociation(NFPA)recommendsachimneylineriftheflueismorethanthree times bigger (in square area) than the outlet on the stove or insert. Some localities enforce the NFPA guidelines as part of their building codes.FuelEven the best stove installation will not perform well with poorfuel.Thebestfuelishardwoodthathasair-dried12-18months.Softwoodburns,butnotaslongashardwood.‘Green’woodhasalotofmoistureinit;itwillburn,butsomeoftheheatpotentialisusedtoboiltheextramoisturefromthe wood. This reduces the amount of heat that reaches your home and can contribute to a creosote problem. There are moisturemetersavailableforfirewood;youcanalsojudgeyourwoodbyitsappearanceandweight.Ifyougetitgreen,lift a piece and get a sense of its weight; it can lose a third or more of its weight as it dries. Also look at the ends of a log; as it dries it shrinks and often cracks. The more weathered andcrackedapieceis,thedrieritis.Dry wood burns readily with a good chimney draft. But with modernstoves,woodcanbetoodryandtoovolatile.Smokeand combustible gases can ‘gas out’ from the wood quickly anddenselyenoughtooverloadthecombustionsystem.Ifyou hear a rumbling or roaring noise (like a propane torch) fromthestove,thatisasignthatthestoveisoverfiring.


Figure 43-Anexplodedviewoftheglassassembly.

ST547door install11/00

Retainer Clip

Glass Panel

Glass Gasket

Door Gasket

Retainer Clip

Left Door

Right Door (Back Side)

Replace Broken Glass ImmediatelyDo not operate your stove if the glass in the doors is damaged.Ifyouneedtoreplacetheglass,useonlythehightemperatureceramic glass supplied by Vermont Castings. Do not use substitutes. Removing the Glass1. Remove the right and left door assemblies by raising the

dooruntilthelowerhingepinclearsitshole;then,anglethe door bottom slightly outward and pull down to release the upper hinge pin. Place the doors face down on a padded work surface. Be especially careful with enameled doors.

2. Remove the screws that hold the glass retainer clips in place,andremovetheclips.

3.Carefullyliftthebrokenglasspanelfromthedoor.Installing the GlassCheck the gasket around the window; it should be soft and resilient so that the glass will seal properly against the door. Replace the gasket if it has hardened or if it is compressed.1. Center the glass on the gasket. 2. Secure the glass on both doors with the retainer clips.

Tightenallscrews.(Figure43)3. Replacethedoorsonthestove.4.Openandclosethedoorstocheckthattheyfitandwork

properly. Adjust as necessary.

MaintenanceKeep Your Stove Looking New and Working Its BestLetthefireinthestovegooutandallowthestovetocoolcompletely before beginning any maintenance procedure.Care of the Cast Iron SurfaceAn occasional dusting with a dry rag will keep the painted castironofyourDefiant®lookingnew.Thestove’spaintcanbetouchedupasneeded.First,masktheareas,suchasenameledparts,glass,orhandles,aroundthe spot to be painted. Clean the spot with a wire brush. Removethegriddleandsetitaside.Itisnormalforthegriddletodarkenafteruse.Youcancleanitwithafine-bristlewirebrush,orsteelwool.Then, touch up the stovewith Vermont Castings’ hightemperature stove paint. Apply the paint sparingly; two light coats of paint are better than a single heavy one.Care of the Porcelain Enamel SurfaceUse a dry or slightly damp rag or soft brush to remove spills orstains.Fordifficultjobsthatrequireacleaningagent,useonly a kitchen appliance cleaner or polish recommended for use on enamel surfaces.Ifporcelainenamelbecomeschippedorscratchedduringuse,apply"enamelepoxy"tothedamagedareaandallowtodry.Oncetheepoxyhasdried,sandtheareatoblendwithsurroundingareaandapplyappropriatecolortouch-uppaint.Allow to dry completely before operating stove. Cleaning the GlassMost of the carbon deposits on the glass will burn off during hotfires.However, the ash residue that accumulateson the glasssurface should be removed regularly to prevent etching. To cleantheglass,followthisprocedure:• Be sure the glass is completely cool.• Clean the glass with water or a cleaner made especially for

this purpose. Do not use abrasive cleaners. Use cleaning agents sparingly and be sure to keep them off the outer surfaces of the stove.

• Rinse the glass thoroughly.• Dry the glass completely.Adjusting Theromstat ControlThe thermostat control is adjusted at the factory and should not bemodified. In the unlikely event that adjustment isrequired,youwillneedaflatheadscrewdriverandapairofpliers. Locate the primary cover on the lower back portion of thestove(Figure42).Withpliers,bend the tabs to thestraightpositionandusetheflatheadscrewdrivertoprythebracketoutfarenoughtoremovethecover.Oncethecoverisoff,loosenthethumbscrewwiththeprimaryhandleintheclosed position. Adjust the steel cable by either pulling slack out of the cable or allowing more in. Tighten the thumb screw and test the primary control by turning the handle to the open positionandcheckingthepositionoftheflap.Thereshouldnotbeanydelaybetweenthehandleandtheflap.Alwaysensuretheflapwillclosecompletely.

Figure 42-PrimarycoverandBracket.

Bracket

Primary Cover

TabTab


ST554Damper adjustment11/00

Pressure Adjusting Screw

Allen Wrench

Lock Nut

Damper

Figure 44-AdjustthedamperwiththeAllenwrench.

Figure 45-Rotatepawland/orremoveflatwashertoadjustlatch.

ST1154door pawl

Roller

Lock Nut

Set Screw

Shoulder Screw

HandleStubFlat Washer

Replace the Stove Gaskets as NeededYourDefiant®usesfiberglassropegasketstomakeatightsealbetweensomeparts.Withuse,particularlyonmovingparts,gasketscanbecomebrittleandcompressedandcanbegin to lose their effectiveness. These will need periodic replacement.Thesizesofreplaceablegasketarelistedbelow,alongwiththeir applications.Gasket Diameter......And the Parts it Seals5/16"-Thegriddletothestovetop(wirereinforcedgasket)5/16" -Thedampertotheupperfireback7/16" - The front doors to the stove front; and the doors to each other.3/8" - The ash door to the front of the bottom panel3/16" - The outer glass panes to the doorIfyouneedtochangeagasket,firstobtainanappropriatereplacement from your Vermont Castings’ Authorized Dealer. Waituntilthefireisoutandthestovehascooled.Besuretofollow the standard safety procedure for working with dusty materials: wear safety goggles and a dust mask. Theprocedureforreplacinggasketsisthesame,regardlessof the gasket location. Follow these steps:1.Removetheexistinggasketbygraspinganendandpulling

firmly.(Figure46)2. Use a wire brush or the tip of a screwdriver to clean the

channel of any remaining cement or bits of gasket. Remove stubborn deposits of cement with a cold chisel if necessary. (Figure46)

Tighten the Damper Handle as NeededA handle on the left side of the stove controls the damper. The handle attaches to the damper rod with a set screw. Periodically check the set screw and tighten as necessary.How to Adjust the Door LatchesThe front door of the stove should close securely to prevent accidental opening and should close tightly to prevent air fromleakingintothefirechamber.Thedoorhandlewillbepositioned vertically when the door is closed.Over a period of time, the gasket around the doorwillcompress and the latch may need adjustment. To adjust the handle,followthisprocedure:1. Remove and retain the lock nutwith a 9/16"wrench.

(Figure45)2. Loosenthesetscrewwitha1/8"Allenwrench.3. Rotatethepawl180°.Replacethelocknut.Tightenthe

set screw.4. Additionaladjustmentcanbemadebyremovingtheflat

washer.Oranycombinationofwasher removaland/orpawl rotation.

Test the door seal. Close the door on a dollar bill and attempt to pull it free. If the bill is freedwith little resistance, thegasket isn’t snug enough at that spot. Continue to make small adjustments until the setting is right.Ifadditionaladjustingofthelatchdoesnotenablethedoortosealsufficientlyinonearea,try"adjusting"thegasketinthatarea. Pack more cement or a smaller diameter gasket into the channel beneath the gasket so the main gasket is raised and makescontactwiththedoorframe.Ifthisproceduredoesn’tsolvetheproblem,replacethegasket.Instructionsforgasketreplacement are given later in this section.

Adjust the Damper as NeededThe tension on the Defiant®’s damper is adjustable tocompensate for compression of the gasket that seals the dampertotheupperfireback.Toadjustthedamper:1. Remove the griddle. Loosen the lock nut at the center of

thedamper.(Figure44)2. Turn the pressure screw approximately one half turn

clockwise with an Allen wrench provided with your stove. 3. Tighten the locknut.Prevent thepressurescrew from

turningasyoutightenthenut.Re-testthedamper.


ST559Removegasket11/30/00 djt

Figure 46 - Remove gasket then clean channel with wire brush.

ST559Removegasket11/30/00 djt

CementStove Gasket

Figure 47-Layabeadofgasketcementthenpressgasketinplace.

All Gasketed Construction GasketsOthergasketsformsealsbetweenallothernon-movingparts,but these are not subject to the same wear and deterioration asgasketsonmovingparts.Itisunlikelythatyouwilleverneed to replace these gaskets unless the involved parts are disassembledandthenputbacktogether.Ifthisisthecase,thejobshouldbedoneonlybyaqualifiedservicetechnician.5/16"diametergasketsealsthefollowingparts:• Thelowerfirebacktothebackpanel• The left and right air plates (inner sides)• All connections between the stove plates.

The Chimney SystemCreosote Your Defiant® is designed to reduce creosote build-upsignificantly. However, regular chimney inspection andmaintenancemuststillbeperformed.Forsafety,goodstoveperformance, and to protect your chimney and chimneyconnector,inspectyourchimneyandchimneyconnectorona regular schedule. Clean the system if necessary. Failure to keep the chimney and connector system clean can result inaseriouschimneyfire.Whenwoodisburnedslowly,itproducestar,organicvaporsand moisture that combine to form creosote. The creosote vaporscondenseintherelativelycoolchimneyflueofaslow-burningfire.Asaresult,creosoteresidueaccumulatesonthefluelining.Whenignited,thiscreosotemakesanextremelyhotfirewithinthefluesystemthatcandamagethechimneyandoverheatadjacentcombustiblematerial.Ifasignificantlayerofcreosotehasaccumulated—1/8"(3mm)ormore—itshouldberemovedtoreducetheriskofachimneyfire.Youcanneverbetoosafe.Contactyourlocalfireauthorityforinformationonwhattodointheeventofachimneyfire,and have a clearly understood plan on how to handle one.Ifyoudoexperienceachimneyfire,actpromptlyto:

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

Inspect the system every twoweeks during the heatingseason as part of a regular maintenance schedule. To inspect thechimney, let thestovecool completely.Then,usingamirrorandastronglight,sightupthroughthefluecollarintothechimneyflue.Ifyoucannotinspectthefluesysteminthisfashion, thestovemustbedisconnectedtoprovidebetterviewing access. Clean the chimney using a brush the same size and shape astheflueliner.Flexiblefiberglassrodsareusedtorunthebrushupanddown the liner, causinganydeposits to fallto the bottom of the chimney where they can be removed throughtheclean-outdoor.

6.Startingatoneend,press thegasket into thechannel.(Figure47)Ensureagoodjointwherethegasketmeetsbeforetrimminganyexcess.Donotoverlapthegasketends or leave ends with ragged edges.

7.Pressthegasketedpartfirmlyagainstitsnormalmatingsurface to seat the gasket evenly in its channel. Close andlatchthedoortodothis,ortapotherpartswiththerubbermallet(orhammer/blockofwood).

8.Cleananyexcesscementfromaroundthechannel,thenlet the cement that holds the new gasket dry thoroughly.

9. The stove’s doors may need adjustment after you have regasketed them. Initially, itmay require loosening thelatchtoaccommodatethenewgasket;afterafewweeks,it may need tightening to compensate for compression of the new gasket. The directions for adjusting the latches areonPage30.

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 from unraveling.

5.Layanunbroken1/8"(3mm)beadofsiliconeinthenewly-cleanedchannel.(Figure47)


The Catalytic ElementThiswoodheatercontainsacatalyticcombustor,whichneedsperiodicinspectionandreplacementforproperoperation.Inthe United States it is against the law to operate this wood heater in a manner inconsistent with the operating instructions in this manual. Undernormaloperatingconditions,thecatalyticcombustorshouldremainactivefortwotosixyears(dependingontheamountofwoodburned).However,itisimportanttomonitorthe combustor periodically to ensure that it is functioning properly,aswellastodeterminewhenitneedstobereplaced.Anon-functioningcombustorwillresultinalossofheatingefficiency,andanincreaseincreosoteandemissions.Inspection and CleaningInspectthecombustorforflyashaccumulationandphysicaldamage two to three times per year. Clean the combustor as needed.The refractory package that houses the catalytic combustor shouldbe inspected for a buildupof fly ashand cleanedif necessary. Thismay be donewhen you examine thecombustor.

ST1162ash clean out

Clean out any ash build up

Remove these components

Figure 48 - Inspectandcleanoutashaccumulationbehind thecombustion system.

Annual Spring Cleaning:• Disassemble the chimney connector and take it outdoors

for inspection and cleaning. Replace weak sections of connector.

• Inspectthechimneyforsignsofdeterioration.Repairstoa masonry chimney should be made by a professional mason. Replace damaged sections of prefabricated chimney. Your local Vermont Castings dealer or a chimney sweep can help determine when replacement is necessary.

• Thoroughly clean the chimney.

Cleanthechimneyconnectorbydisconnectingthesections,takingthemoutside,andremovinganydepositswithastiffwirebrush.Reinstalltheconnectorsectionsaftercleaning,being sure to secure the joints between individual sections with sheet metal screws.Ifyoucannotinspectorcleanthechimneyyourself,contactyour local Vermont Castings dealer or a professional chimney sweep.

Maintenance Schedule The StoveDaily:• Clear any ash build-up fromaround the air holes and

combustionflowpathinthelowerfireback.

• Ashes should be removed before they reach the top of the ash pan. Check accumulation at least once a day.

• Keeptheareaaroundthestoveclearofanycombustiblematerialssuchaswood,furnitureorclothing.

Two Months: • Check door handle to be sure it is working properly.

Gasketing becomes compressed after a period of time. Adjust handle tightness if necessary.

• Check leg bolts and heat shield screws; tighten if necessary.

Annual Spring Cleaning:• Checkgasketingforwear,andreplaceifnecessary.• Remove ashes from the ash pan and replace with a

moisture absorbing material (such as kitty litter) to keep the interior of the stove dry.

• Cleanthedustfromtheinnersidesofbottom,rearorpipeheat shields if your stove is equipped with them. Clean surfacesarebetterheatreflectorsthandirtysurfaces.

• Touch up the black paint.

• Inspectforandremoveashbuild-upbehindthecombustionpackage. This should be done in conjunction with annual cleaningofthechimneyconnector.Inspectthepassagebehind the combustion package (a mirror will be helpful) and vacuumaway ash using a flexible vacuumhoseinsertedinthepassage.(Figure48)

The Chimney Connector

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

necessary.Two Months:• Inspectthechimneyandchimneyconnector.Payparticular

attentiontothehorizontalrunsofchimneyconnector,andthe elbows. Clean the system if necessary.


ST1180catalyst access

Catalyst

Access DoorInnerFireback

Figure 49-Inspectthecatalyticcombustor.

2.Inspecttheelementfordamageordegradation.Althoughsmall hairline crackswill not affect performance, theelement should be essentially intact. If the element isbroken inpiecesorhassectionsmissing, it shouldbereplaced. Call your local Vermont Castings Authorized Dealer for a replacement element.

3.Iftheelementisingoodconditionandclean,re-installitinthestoveandreplacetherefractoryinnerfirebackandaccess door.

Operate the stove in your usual manner for two weeks,inspecting the chimney and the chimney connector frequently during this period. If creosote does not build up as fast, it is likely that theperformance changewas caused by fly ash deposits onthecatalyticelement.However,continuetheinspectionsofthe chimney system for a few weeks to ensure that proper performance continues.If you continue to finda significant creosotebuildupor ifyou continue to see excessive smoke from the chimney,the catalytic element will need to be replaced. Contact your nearest Vermont Castings’ Authorized Dealer for information about a replacement element.NOTE: Use only the replacement catalyst supplied by a Vermont Castings dealer.

When to Suspect a Combustor ProblemThebestwaytoevaluatetheperformanceofyourDefiant®’s combustor is to observe the amount of smoke leaving the chimney—bothwhenthecombustorhas"lighted-off"andwhen it has not. Follow these steps: • Withafiregoingandthecombustorproperlyactivated,with

the damper closed to route smoke through it as described in the Operation Section, go outside and observe thesmoke leaving the chimney.

• Then,openthestovedamperandonceagaincheckthesmoke leaving the chimney.

Youshould seesignificantlymore smokewhen thestovedamper is open and exhaust does not pass through thecombustor.However,becarefulnottoconfusesmokewithsteam from wet wood. Steam dissipates in the air quickly; smoke does not. Ifthistestindicatesaproblem,considerotherpossiblefactorsaswell,suchastheweatherorachangeinthequalityofyourfuel.Inwarmweather,draftisweakerthanitisincolderwinterweather,andfirescanburnsluggishly.Small,hotfiresare a good solution under these conditions.Burning"green"(insufficientlyseasoned)woodwillresultinpoorer performance than burning properly seasoned fuel. Reloading with green wood can also thermal shock the catalyst,resultingincracking,ortheeventualfallout,oftheceramic honeycomb substrate. You may have to run your stove hotter (more air) to achieve acceptable performance using green or wet wood.NOTE: Burning wet wood increases the risk of thermally shocking the combustor,which can cause cracks in theceramic substrate and fallout of individual cells.Also,consideranychangesinyouroperatingroutine.Onceyouhaveruledoutanyotherpossiblecauses foradeclineinperformance,inspectandcleanthecombustorifnecessary. Be sure to protect any surface you use for setting the stove parts aside. Inspecting the CombustorRemoveaccessdoorandinnerfireback.Removethecatalyticcombustorbyliftingandslidingittowardsyou.(Figure49)Toassurealonglifeforthecombustor,itisrecommendedto service the combustor on a regular basis based on the amountofuse.Thisproceduretakesaboutfive(5)minutesand requires no tools except for a vacuum if cleaning isnecessary. Cleaning the Combustor1. Check the combustors honeycomb-like element for a

buildupofflyash.Ifanyisevident,takethecombustoroutside and clean it by blowing air gently through it. Do not push anything through the honeycomb; do not use compressed air to clear the passages. Such abrasion can scrape the thin coating of platinum (the catalyst) off the ceramicbase,shorteningthecatalyst’slifeandreducingits effectiveness.


Service Parts List

Service Parts

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

De ant Flexburn

Part number list on following page. 05/18

0001975 (Classic Black) 0001978 (Ebony) (Ending Manufacturing Date: 2013)0001976 (Biscuit) 0001976T (Biscuit w/Transition Doors) (End Manufacturing Date: March 2017 )0001977 (Majolica Brown) 0001977T (Majolica Brown w/Transition Doors)(End Manufacturing Date: March 2017)0001979 (Bordeaux) 0001979T (Bordeaux w/Transition Doors) (End Manufacturing Date: March 2017 )0001980 (Twilight) 0001980T (Twilight w/Transition Doors) (End Manufacturing Date: March 2017)0001975T (Classic Black w/Transition Doors)

9

80

21

20

17

1916

18

10 11

2

13a1415

13b

63

58

32

59

3

36

29

81

39

40

47

38

12

45

37

31

50

51

52

5570

69

64

68

62

74

72

61a

71 69

65

67a

74

72

62

30

60

56

34

56

56

20

2053

1

57

78

33

81

4783

24

79

8249

48

53

77

76

75a

8249

66

68

64

64

26

27

28

73

54

1

20

83a

83b

23

23

8

25

435

41

5

44

42

6

7 46

84

8687

85

88

89

90

13c

13

43

91

93

92

61b

67b

94

95

75


Service Parts


De ant Flexburn

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 Brick Support Bracket 300052792 Griddle Gasket 10 Ft 1-00-1203668 Y3 Back 30005242A4 Refractory, Right End 300052065 Refractory, Left End 300052076 Refractory Support 300052337 Gasket, Refractory Support 300052378 Back Insulation Board 300052699 Outer Back 3000524910 Griddle Quadrant, Left 3000239911 Griddle Quadrant, Right 30002401A12 Griddle 30005257A13 Complete Griddle Handle Assembly 30002775 Y13a Griddle Handle, Wood 1600661 Y13b Griddle Handle, CRS-BN1 3000271513c Nut, Hex 1/4-20 Pkg of 10 1203210-1014 Griddle Handle Bushing Pkg of 10 1201900-1015 Griddle Handle Bolt Pkg of 10 1201308-1016 Damper Gasket 15 Ft 1-00-1203588 Y17 Damper Ramp 130064318 Damper Housing 30002821A19 Damper 3000281620 Damper Tab Pkg of 10 1601488-1021 Damper Rod 160006523 Gasket, Back Refractory 10 Ft 1-00-3000527024 Rheostat Bracket 3000286325 Refractory, Engine - E/D 3000520226 Damper Handle Screw Pkg of 10 1201310-1027 Damper Handle 1600664 Y28 Damper Handle w/Screw Assembly 30002720A Y

29 Left Side

Classic Black 30002832ABiscuit 30002872Bordeaux 30006697Ebony 30002892Majolica Brown 30004834Twilight 30007126

30 Left Air Manifold 30002818Additional service part numbers appear on following page.


Service Parts


De ant Flexburn


Stocked at Depot

ITEM DESCRIPTION COMMENTS PART NUMBER31 Right Air Manifold 30005243

32 Right Side


33 Thermostat Handle Base 30002716 Y34 Washer Damper Rod Pkg of 10 30007257-1035 Firebrick Plate, S/S 3000521736 Inner Bottom 30005241

37 Top Ashdoor HingePre 0081391652 30002836APost 0081391652 1-00-30002836

38 Door Handle Bracket 3000284439 Bottom 30005240A

40 Ashlip


41 Gasket, Firebrick 3000520942 Refractory, Firebrick 3000520343 Retainer, Firebrick Refractory 3000524844 Refractory, Inner Cover 30005205 Y45 Andiron 30002827A Y46 Refractory, Access Cover 3000725247 Leg Leveler Pkg of 10 1201745-1048 Ashdoor Handle Shaft 3000530149 Pawl Assembly, 3/4 Short Adj. 30005157 Y49a Spring Washer Pkg of 10 63D0069-1050 Ashdoor 30002810A50a Ashdoor Gasket 15 Ft 1-00-120358951 Ashdoor Handle, Wood 1600663 Y

52Ashdoor Hinge Rod Pre 0081391652 30002826Hinge Hardware Post 0081391652 1-00-2826

53 Cotter Pin, Ashdoor ( Pkg of 10 ) Pre 0081391652 30001749-10Additional service part numbers appear on following page.


Service Parts


De ant Flexburn


Stocked at Depot

ITEM DESCRIPTION COMMENTS PART NUMBER

54 Ashdoor Bottom Hinge SupportPre 0081391652 1300642APost 0081391652 1-00-1300642

55 Ashpan Bracket 3000190856 Rear Side Bracket 3000284557 Thermostat Handle 1600660 Y58 Airwash Manifold, Front 30005244

59 Front


60 Flue Collar Gasket 1-00-30002422

61a

Left Door (Shell Enamel Parts)


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

Classic Black 30002854Biscuit 30002879Bordeaux 30006773

No longer available 30002899Majolica Brown 30004840Twilight 30007133

61b

Left Door (Transition Door Enamel)

Classic Black 30007091ABiscuit 30007093Bordeaux 30007097Majolica Brown 30007095Twilight 30007109

Left Door Sub Assembly (Transition Door Enamel)

Classic Black 30007175Biscuit 30007177Bordeaux 30007179Majolica Brown 30007181Twilight 30007183

62 Door Hinge Strip 1300645AAdditional service part numbers appear on following page.


Service Parts


De ant Flexburn


Stocked at Depot

ITEM DESCRIPTION COMMENTS PART NUMBER

63 Top


64 Glass Clip 3000171565 Glass Clip ( Right Door Only ) 3000171666 Front Door Handle and Shaft 30002717 Y

67a

Right Door (Shell Enamel Parts)


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

Classic Black 30002853Biscuit 30002878Bordeaux 30006772

No longer available 30002898Majolica Brown 30004839Twilight 30007134

67b

Right Door (Transition Door Enamel)

Classic Black 30007090ABiscuit 30007092Bordeaux 30007096Majolica Brown 30007094Twilight 30007108

Right Door Sub Assembly (Transition Door Enamel)

Classic Black 30007176Biscuit 30007178Bordeaux 30007180Majolica Brown 30007182Twilight 30007184

68 Door Gasket 15 Ft 1-00-7000910 Y69 Glass Gasket 10 Ft 1-00-1186258229 Y70 Left Door Glass 3000524771 Right Door Glass 3000524772 Lower Door Hinge Pin 30002727 Y73 Spacer ( For Damper Rod ) Pkg of 10 1201779-10

Additional service part numbers appear on following page.


Service Parts


De ant Flexburn


Stocked at Depot

ITEM DESCRIPTION COMMENTS PART NUMBER74 Upper Door Hinge Pin 30002727 Y75 Complete Handle Assembly 30004175K Y75a Handle Base Stub 30002714 Y76 Wood Handle 1600664 Y77 Handle Bolt Pkg of 10 1201310-1078 Thermostat Handle Botl Pkg of 10 1201243-1079 Ash Pan Assembly 30001690

80 Flue Collar


81 Leg

Classic Black 30002835ABiscuit 30002877Bordeaux 30006695Ebony 30002897Majolica Brown 30004843ATwilight 30007124

82 Jam Nut, Hex Head Pkg of 10 1203290-1083 Bottom Heat Shield 30005037

83a Bottom Heat Shield, Right Wing 3000503883b Bottom Heat Shield, Left Wing 3000503984 Grate Bottom 30005234A85 Thermostat Assembly 5005470 Y86 Thermostat Cable 5005471 Y87 Thermostat Friction Spring Pkg of 10 1201846-1088 Primary Air Valve Assembly 3000527589 Heat Plate Vertical Flue 3000526590 Catalyst, Ceramic 3000662391 Thermostat Handle Assembly 3000706792 Primary Air Cover 3000706993 Primary Air Base 3000707194 Temperature Probe 3000727495 Braket, Temperature Probe 30007278

4021-645J • 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

4021-645J • 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.

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.


352MountainHouseRoad•Halifax,Pa17032www.vermontcastings.com

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