Vermont Casting WinterWarm Fireplace Insert or System manual

Homeowner ’ s Installation and Operating Manual SAFETY NOTICE: IF THIS APPLIANCE IS NOT PROPERL Y INST ALLED, OPERA TED AND MAIN- T AINED, A HOUSE FIRE MA Y RESUL T . TO REDUCE THE RISK OF FIRE, FOLLOW THE INST ALLA TION INSTRUCTIONS. F AILURE TO FOLLOW INSTRUCTIONS MA Y RESUL T IN PROPERTY DAMAGE, BODIL Y INJURY OR EVEN DEA TH. CONT ACT LOCAL BU[...]

2 W interW arm Fireplace Inser t or System 2000941 Introduction Thank you for purchasing a V ermont Castings’ WinterW arm, an efficient fireplace carefully engineered to bring you the latest in wood combustion principles and modern foundry technology . The WinterW arm masonry Fireplace Insert turns a traditional masonry fireplace into a powerf[...]

3 W interW arm Fireplace Inser t or System 2000941 Specifications Range of heat output* ............. 10,300 - 30,000 BTU/hr Maximum heat output** .......................... 50,000 BTU/hr Area heated*** ................ Up to 1500 sq. ft. (140sq. m) Size of wood splits ....................... 20-24” (508-610 mm) Fuel Capacity ...................[...]

4 W interW arm Fireplace Inser t or System 2000941 Section I Operation Y our WinterW arm’s Controls and What They Do Three controls regulate the performance of your Win- terW arm: A primary air control supplies oxygen for the fire, a damper directs air flow within the fireplace, and a variable-speed fan control, or rheostat, regulates the warm[...]

5 W interW arm Fireplace Inser t or System 2000941 The Fans T wo fans deliver a steady stream of warm air . Heated air from your WinterW arm is forced into the room by two internal fans. The control for the fans is below the brass primary air control knob, just above the upper left corner of the door . (Fig. 5) “Off” is to the far left. “High[...]

6 W interW arm Fireplace Inser t or System 2000941 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. WinterW arm Control Settings Burn Rate Primary Air Control Low From far right to 1/3[...]

7 W interW arm Fireplace Inser t or System 2000941 FP1074 Winter W ar m  damper settings 3/27/01 djt Open Closed Damper Control Lever FP1074 Fig. 10 When the damper is closed, the front door automati- cally locks to prevent opening while a fire is burning. 1. Open the stove damper , and open the primary air control fully . 2. Lay some cru[...]

8 W interW arm Fireplace Inser t or System 2000941 NOTE: If the charcoal bed is relatively thick and your fuel is well-seasoned, it is possible to add fresh fuel (smaller pieces first), close the door and damper , and reset the air control within five minutes. Special T actics for Cold-Climate Heating The WinterW arm is capable of producing up to[...]

9 W interW arm Fireplace Inser t or System 2000941 • Before replacing the ash pan, clear away any ash that has spilled over the sides and back of the pan. • Replace the ash pan and close the ash door and front door . Empty the ash pan regularly , typically every one to three days. The frequency will vary depending on how you operate your Winter[...]

10 W interW arm Fireplace Inser t or System 2000941 Adjust the Door Latch Periodically The front door of the WinterW arm should close securely to prevent accidental opening and should close tightly to prevent air from leaking into the fire chamber . The door handle will be positioned vertically when the door is closed. Over a period of time, the g[...]

1 1 W interW arm Fireplace Inser t or System 2000941 Replacing the Door Gaskets Remove the door by lifting it straight up off its hinge pins. Lay it face down on a padded surface. Follow steps 1-4 as described above. FP1077 Winter W ar m door gask ets 3/28/01 djt #1 Gasket #2 Gasket #3 Gasket Fig. 10 Location of door gaskets. FP1077 Replac[...]

12 W interW arm Fireplace Inser t or System 2000941 Adjust the Damper as Needed Examine your WinterW arm’s damper after the first 50 hours of use and adjust it if necessary . Thereafter , check the damper at least once a year and adjust as needed. Both fine and coarse adjustments to the damper are possible. Begin with the fine adjustment, whic[...]

13 W interW arm Fireplace Inser t or System 2000941 When to Suspect a Combustor Problem The best way to evaluate the performance of your WinterW arm’s combustor is to observe the amount of smoke leaving the chimney — both when the combus- tor has achieved “light-off” and when it has not. Follow this simple two-step procedure: • With a fi[...]

14 W interW arm Fireplace Inser t or System 2000941 • Check the combustor and the bottom of the refractory chamber for a build-up of fly ash, and remove any ash by taking the combustor outside and gently blowing air through the element. Do not brush the surface, as this could damage the element. Carefully vacuum ash from the refractory chamber .[...]

15 W interW arm Fireplace Inser t or System 2000941 Y ou should inspect the system every two weeks during the heating season as part of a regular maintenance schedule. T o inspect the chimney , let the WinterW arm cool completely . Then, using a strong light, sight up through the flue collar into the chimney flue. If it is not possible to inspect[...]

16 W interW arm Fireplace Inser t or System 2000941 2 4 1 3 2 1 LEFT F AN 1 1 6 8 3 1 4 2 1 2 RIGHT F AN 24 9 SH2 SH4 SH4 SH2 On Body Assembly Field Cover Wireway 13 21 17 17 21 8 13 2 4 1 3 2 1 PH2 PH4 RHEOST A T N G I H N H 15 Left Receptacle B A 1 10 5 7 12 20 16 3 1 4 2 1 2 PH4 P H2 N G I H N H Right Receptacle 19 23 14 22 18 On Front Assembly [...]

17 W interW arm Fireplace Inser t or System 2000941 Section III: Preparing a Masonry Chimney Installing the WinterW arm into a masonry fireplace is an effective way to add an efficient heater to your home. Requirements for the Existing Masonry Fireplace The WinterW arm Fireplace Insert is listed only for installation within a properly built mason[...]

18 W interW arm Fireplace Inser t or System 2000941 Clearance Requirements After confirming that your fireplace is the right size, check the clearances to combustibles. First mark with tape the exact center of your fireplace opening on the hearth. Measure the side clearance from this point. Measure the top trim and/or mantel clearances from the [...]

19 W interW arm Fireplace Inser t or System 2000941 NEW required thickness K of new material (per inch) K of listed material (per inch) thickness of listed material = x IWF291 MBUF 6/19/96 (K factor of alternate material) (0.84) X (7/16" [1 1mm]) = (Required thickness of alternate material) (5.0) (0.84) X (7/16" [1 1mm]) = 2.6" (65mm[...]

20 W interW arm Fireplace Inser t or System 2000941 FP1087 WW Fle x connector 3/30/01 djt Flex Connector 1/4” (6mm) Nut Pipe Support 1/4” (6mm) Nut Pipe Support Block-Off Plate 1/4” (6mm) Screw Starter Piece (Optional) 1/4” (6mm) Wing Nut 1/4” (6mm) W asher 1/4” (6mm) Bolt FP1087 Fig. 22 Components of the Flex Connector System.[...]

21 W interW arm Fireplace Inser t or System 2000941 3. Reverse the Flue Collar (If Necessary) The flue collar of the WinterW arm is reversible to allow for installation into fireplaces with different lintel depths and different damper orientations. It is shipped in the rear-most position (the deep lintel position), which ac- commodates lintel dep[...]

22 W interW arm Fireplace Inser t or System 2000941 Section IV : Installing the Fireplace System Cabinet The insulated metal cabinet included with the Win- terW arm Fireplace System enables the WinterW arm Fireplace Insert to be installed in minimum-clearance situations and where no masonry fireplace or chimney exists, such as in new home construc[...]

23 W interW arm Fireplace Inser t or System 2000941 FP1089 WinterW Arm trim sizes 3/28/01 djt 66" (1683mm) 66" (1683mm) 27" (686mm) 27" (686mm) 39 ¹⁄₂ " (1003mm) 93 ¹⁄₂ " (237cm) FP1091 Fig. 22 Minimum dimensions required for framing a corner installation of the chase. I B D E C B A C FP1093 WinterWarm [...]

24 W interW arm Fireplace Inser t or System 2000941 The listed chimneys and their manufacturers are: American Metal Products Ameri-T ec Model HS Condensation Engineering Corp. Model HS GSW Building Product Co. Model SC Metal Fab, Inc. Model TG Security Chimneys Ltd. Model ASHT Selkirk Metalbestos Model SSII Simpson Dura-V ent Model SDP In the Unite[...]

25 W interW arm Fireplace Inser t or System 2000941 Custom-made floor protectors may be used if they offer the same protection as the approved floor protector described in the preceding paragraph, which in testing was found to have a standard K value of 0.84. Custom- built floor protectors must have a K value equal to, or less than, 0.84, meanin[...]

26 W interW arm Fireplace Inser t or System 2000941 Electrical Requirements The WinterW arm Cabinet has a removable junction box located on the bottom front corner of the left side. This enables the wiring to be completed before the cabinet is installed if desired. The junction box houses two receptacles, one for the WinterW arm column fans and the[...]

27 W interW arm Fireplace Inser t or System 2000941 mented directly to the trim panels, or over noncom- bustible backing to shim it out relative to the finished wall surface. Be sure the height of the side pieces is between 29” (740 mm) and 33 ¹⁄₄ " (845 mm), and that the thickness of backing, adhesive, and stone combined is not more t[...]

28 W interW arm Fireplace Inser t or System 2000941 Prepare and Install WinterW arm Cabinet 1. Unpack the carton. 2. Install the flex connector . Install the flex connector and attached flue flange to the underside of the cabinet top using eight #10-1/2” hex head sheet metal screws. The connector should point forward with the long axis of the[...]

29 W interW arm Fireplace Inser t or System 2000941 6. Move the cabinet into the chase and fasten the trim panels to the chase framing. NOTE: The chase floor must be the same height as the hearth and must provide uninterrupted support. Push the cabinet carefully into the chase opening until the ends of the upper trim panel and the outer edges of t[...]

30 W interW arm Fireplace Inser t or System 2000941 Install the two air duct boxes in their framed openings. (Fig. 46) If desired, paint the inner surface of each air duct tube for about 6” (152mm) to eliminate reflected glare; attach this end to the air duct box flange. Cut and fit the air duct tubing between the air duct boxes and the top of[...]

31 W interW arm Fireplace Inser t or System 2000941 Use drywall screws to fasten the wall covering to the metal standoff and drywall stops at the cabinet. Drill pilot holes through the wall covering material and one thickness of the sheet metal with a #40 (.098”) drill bit. T ape and fill holes and/or seams and decorate your chase wall at this t[...]

32 W interW arm Fireplace Inser t or System 2000941 Section V : Completing the WinterW arm Installation Prepare and Install the WinterW arm Firechamber 1. Uncrate the WinterW arm Fire Chamber . Uncrate the WinterW arm Firechamber and place it mounted on its shipping pallet about 24” (610mm) in front of its final destination — a masonry firepl[...]

33 W interW arm Fireplace Inser t or System 2000941 • The outside air duct’s inlet must be lower than the primary air inlet of the firebox, to prevent air infiltration. • The air inlet must be covered by a wire mesh screen with openings not larger than 1/4” x 1/4” (6 x 6mm) to prevent rodents entering from the outside. a. With the Winte[...]

34 W interW arm Fireplace Inser t or System 2000941 Prepare and Install the WinterW arm Front Do not remove the WinterW arm Front from its ship- ping container until the directions indicate to do so. The installation of the front is much easier if you partially assemble some of the components before removing it from the container . Refer to the Fig[...]

35 W interW arm Fireplace Inser t or System 2000941 If you have installed the optional outside air kit, pass the control rod through the latticework at this time. (Fig. 53) Seat the front against the Fire Chamber assembly , and attach with the six 1/4-20 X 3/4” (19mm) hex head cap screws and washers that are provided. There are two for each side [...]

36 W interW arm Fireplace Inser t or System 2000941 10. Install and Adjust the Controls. The rods that operate the WinterW arm’s primary air , fan, and damper should be installed before mounting the column capitals and mantel. T wo of the rods are 1/4” (6mm) and are controls for the fan and the primary air . The third rod is 3/8” (9mm) and co[...]

37 W interW arm Fireplace Inser t or System 2000941 12. Move the Entire Unit the final few inches into the Cabinet. Move the WinterW arm the final few inches into the cabinet, making sure the surround panels are properly aligned. If you are using the CFM Corporation Flex Connector System, reach up into the flue collar area to grasp the Starter P[...]

38 W interW arm Fireplace Inser t or System 2000941 1 19 1 19 124 1 19 120 50 49 46 45 47 47 46 57 66 31 40 30 7 34 127 39 17 32 33 32 18 17 27 22 26 28 25 128 24 29 140 1 1 41 8 23 19a 21 19 104 57 96 98 97 102 99 88 13 88 56 99 101 81 103 105 36 90 92 94 93 89 94 67 68 69 65 140 125 59 6 3 59 12 5 54 36 12 1 1 1 1 1 13 1 12 75 105 14 106 54 7 34 [...]

39 W interW arm Fireplace Inser t or System 2000941 1. Bottom Only 1301 150 2. 5/16 Fiberglass Medium Density (sold by the foot) 1203588 3. 3/8-16 x 2” Hex Head Leveller Bolt 1201742 4. 1/4-20 x 5/8” Phillips Flat Head Screw 1200865 5. Left Fan Heat Shield 1301 151 6. Right Fan Heat Shield 1301 152 7. 1/4-20 x 1/2” Hex Head Cap Screw 1201338 [...]

40 W interW arm Fireplace Inser t or System 2000941 87. Door 1301257 88. Half Hinge, Door (No pin) Upper 1604280 89. Glass Cassette (Approx. 22” x 13”) 5002617 90. Gasket, 3/16 Fiberglass 4ND Black 1203556 91. Glass Retainer , Lower 1601403 92. Glass Retainer , Upper (2 required) 1601409 94. 10-24 x 3/8” Phillips Pan Head Screw 1200985 95. Br[...]

41 W interW arm Fireplace Inser t or System 2000941 Appendix:Approved Chimney Components 9201 9216 9206 9219 9214 9221/9221SS 9217/9217SS 9264 9266 9244 9946 9980A 9980B 9980C 9959 9284 9268/9268SS 9251 9249 9250 9281 9252 9262* 9260* Condensation Engineering Corp. Vitroliner HS-2100 Anchor/base plate W all band Elbows Chimney sections Starter Stor[...]

42 W interW arm Fireplace Inser t or System 2000941 Appendix: Catalytic Combustor In any chemical reaction, including the combustion process, there are certain conditions which must be met before the reaction can take place. For example, a reaction may require a certain temperature, or a certain concentration of the reactants (the combustion gases [...]

43 W interW arm Fireplace Inser t or System 2000941 W arranty Limited 3 Y ear W arranty CFM Corporation warrants that this woodburning stove will be free of defects in material and workmanship for a period of three years from the date you receive it, except that the catalyst, thermostat assembly , handles, glass door panels, cement, and gasketing s[...]

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