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Green Mountain 40 (Model 8640)

Manual: 6400-41404

R: 1/6/23

Green Mountain 40

(Model 8640)

Woodstove

OWNER'S MANUAL

Installation And

Operating Instructions

PFS Report F17-183

SAVE THIS OWNER’S MANUAL

FOR FUTURE REFERENCE

PLEASE READ THIS ENTIRE OWNER’S MANUAL BEFORE YOU INSTALL AND USE YOUR

NEW GREEN MOUNTAIN 40 WOOD STOVE.

Ce manuel est disponible en français sur hearthstonetech.com

If this room heater is not properly installed, a house fire may result.

To reduce the risk of fire, follow the installation instructions.

Failure to follow these instructions can result in property damage, bodily injury, or even death.

Conforms to UL Std. 1482-2022

Certified to ULC Std. S627-2021

CONTACT LOCAL AUTHORITIES WITH JURISDICTION (BUILDING DEPARTMENT or FIRE

OFFICIALS), ABOUT PERMITS REQUIRED, RESTRICTIONS AND INSTALLATION

INSPECTION IN YOUR AREA.

WARNING: This product can expose you to

chemicals including glass wool fiber and carbon

monoxide which are known to the State of California to

cause cancer, birth defects or other reproductive harm.

For more information go to www.P65Warnings.ca.gov

California Prop 65

We recommend that our products be installed

and serviced by professionals who are

certified in the U.S. by NFI (National Fireplace

Institute), or by W.E.T.T. (Wood Energy

Technology Transfer) in Canada.

www.nficertified.org

www.wettinc.ca

Hearthstone Quality Home Heating Products, Inc ® Green Mountain 40 (Model 8640)

2

NOTES ON STOVE OPERATION AND EFFICIENCY

Rating:

You have purchased a Hearthstone Green Mountain 40 tested to EPA Method 28R 40 CFR Part 60 where applicable. This

stove is certified to comply with the U.S. Environmental Protection Agency 2020 particulate emissions standard using crib

wood. It is certified at 1.07 gr/hr. emission rate and under specific test conditions has been shown to deliver heat at rates

ranging from 14,000 to 24,000 Btu (output).

This wood heater has a manufacturer-set minimum allowable low burn rate that must not be altered. It is against federal

regulations to alter this setting or otherwise operate this wood heater in a manner inconsistent with operating instructions in

this manual.

Please refer to the Warranty section of this manual for registration instructions. In case of warranty claims, please contact

the point of original sale or the nearest authorized Hearthstone dealer. Our dealer network processes all warranty claims.

Authorized Hearthstone dealers can be located at www.hearthstonestoves.com.

This heater is designed to burn natural wood only. Higher efficiencies and lower emissions generally result when burning

air-dried seasoned hardwoods, as compared to softwoods or to green or freshly cut hardwoods. DO NOT BURN: Garbage,

lawn clippings, material containing rubber (including tires), materials containing plastic, waste petroleum products paints or

paint thinners, asphalt products, materials containing asbestos, construction or demolition debris, railroad ties, pressure

treated wood, manure or animal remains, salt water driftwood or other previously salt water saturated materials, unseasoned

wood, paper products, cardboard, plywood or particleboard. This prohibition against burning these materials does not

prohibit the use of fire starters made from paper, cardboard, sawdust, wax and similar substances for the purpose of starting

a fire in an affected wood heater. Burning these materials may result in a release toxic fumes or render the heater ineffective

and cause smoke.

Following the maintenance guidelines set forth in this manual will help insure the efficient use of your wood heater and

minimize visible emissions. Having your stove inspected by a trained professional on a regular basis will greatly increase the

potential for recognizing potential impacts to efficiency.

Proper draft is important to the efficient operation of your heater. Refer to the Normal Operation section of this manual for

information regarding adequate draft. Both excessive and sub-minimum draft can affect the efficiency of your wood heater.

Excessive draft can lead to over-consumption of fuel, lower overall heating capacity of the stove and potential over firing.

Low draft can result in inefficient burns, low heat output, expulsion of smoke into the living area when stove doors are

opened and an increased potential for build-up of flammable materials in the flue.

Efficiency:

Efficiency was measured and weighted using EPA Method 28R and CSA B415-10 methodology. A weighted average was

used to calculate the overall efficiency across all of the 4 burn rate categories using the higher heating value (HHV). The

weighted average efficiency is 79% (HHV).

To maximize the efficiency of your wood stove, make sure it is sized properly for the space you plan to heat. An oversized

stove will often be forced to burn at a lower and dirtier burn rate. Consult with your dealer for sizing and correctly placing the

stove in your home. An incorrectly placed stove can greatly reduce efficiency. Maximizing the efficiency of your stove will

heat your house quickly, burn cleaner and use less wood.

Refer to the Choosing Firewood section of this manual for appropriate fuel selection. Seasoned firewood is typically at or

near 20% moisture content. This can be measured with any number of hand-held moisture meters available through your

local hearth shop. Follow instructions included in the meter you purchase to measure fuel wood moisture content. Burn only

dry, seasoned wood as using wet wood will greatly reduce your efficiency.

CO Emissions:

The Green Mountain 40 has the following CO emission rates by burn level: Category 1 (low) –40.7 g/hr., Category 2 (med.

low) –16.3 g/hr., Category 3 (med. high) – 8.6 g/hr. and Category 4 – 60.1 g/hr. Wet wood or unapproved fuel described

above can greatly affect the emissions of a wood burning stove.

Smoke/Fire/CO Detectors:

It is highly recommended that smoke and CO detectors be installed throughout the heated space when a wood burning

heater is installed. Be certain to install these devices not only in the area where the wood appliance is located, but also in

bedrooms, hallways leading to other areas of the house and all common areas of the heated space. Check the batteries in

these devices and assure operation by performing whatever test operations are recommended by the manufacturer.

Hearthstone Quality Home Heating Products, Inc ® Green Mountain 40 (Model 8640)

3

TABLE OF CONTENTS

INTRODUCTION ..................................................................................................................... 4

CODES ................................................................................................................................................................... 5

SAFETY INFORMATION ............................................................................................................................................ 5

PERIODIC CHECKLIST ............................................................................................................................................. 6

EMERGENCY PROCEDURES .................................................................................................................................... 6

SPECIFICATIONS .................................................................................................................. 7

INSTALLATION ...................................................................................................................... 8

UNPACKING ............................................................................................................................................................ 8

PACK LIST .............................................................................................................................................................. 8

INSTALLING YOUR STOVE ....................................................................................................................................... 8

HEARTH REQUIREMENTS & FLOOR PROTECTION...................................................................................................... 9

COMBUSTIBLE SURFACE REQUIRED CLEARANCES ................................................................................................. 10

CHIMNEY CONNECTOR SYSTEMS AND CLEARANCES FROM COMBUSTIBLE WALLS .................................................... 12

OUTSIDE AIR SUPPLY ........................................................................................................................................... 13

VENTING COMPONENTS & CONFIGURATION REQUIREMENTS ................................................................................... 14

INSTALLING IN A MOBILE HOME ............................................................................................................................. 18

OPERATION ......................................................................................................................... 19

CONTROLS AND FEATURES ................................................................................................................................... 19

BUILDING A FIRE .................................................................................................................................................. 21

BREAKING IN YOUR WOOD STOVE ........................................................................................................................ 21

NORMAL OPERATION ............................................................................................................................................ 22

CATALYTIC COMBUSTOR OPERATION .................................................................................................................... 23

MAINTENANCE .................................................................................................................... 25

CATALYTIC COMBUSTOR INSPECTION AND REPLACEMENT PROCEDURES ................................................................ 25

INSPECTING THE CATALYSTS ................................................................................................................................. 25

REPLACING THE CATALYSTS .................................................................................................................................. 26

REPLACING THE BAFFLE ........................................................................................................................................ 26

REPLACING THE REFRACTORY STONE AND SECONDARY RISER ASSEMBLY ................................................................ 26

GLASS REPLACEMENT PROCEDURES .................................................................................................................... 26

CREOSOTE FORMATION & REMOVAL ..................................................................................................................... 29

GASKETS ............................................................................................................................................................. 29

GLASS ................................................................................................................................................................. 29

TROUBLESHOOTING .......................................................................................................... 30

TROUBLESHOOTING GUIDE ................................................................................................................................... 31

REPLACEMENT PARTS & OPTIONAL ACCESSORIES ................................................................................................. 33

SAFETY LABEL ................................................................................................................... 34

WARRANTY .......................................................................................................................... 35

Hearthstone Quality Home Heating Products, Inc ® Green Mountain 40 (Model 8640)

4

INTRODUCTION

Thank you for purchasing a Green Mountain 40

woodstove from Hearthstone Quality Home Heating

Products. This stove will provide years of comfortable

heat. This stove combines the warmth and comfort of

soapstone and cast iron with the efficiency of

advanced catalytic technology. The Green Mountain

40 blends modern technology with the unique beauty

and qualities of cast iron. We trust that you will

appreciate the quality of this handcrafted product.

Your Green Mountain 40 woodstove burns very

efficiently, and produces a large amount of heat.

However, you should not consider your Green

Mountain 40 the primary heat source for your home.

The Green Mountain 40’s large glass window allows

you to enjoy the fire from a variety of locations in the

room.

Please read this manual in its entirety. Its purpose is

to familiarize you with your stove's safe installation,

proper break-in, operation and maintenance. It

contains extremely important information so keep it

handy and refer to it often.

A qualified heating technician may need this owner’s

manual as a reference when installing this stove in

your home. There are national, state, and local

building codes that direct the technician on how to

install your stove. These codes stipulate the

dimension of stovepipe and clearances to walls,

ceilings, hearth, and other combustible surfaces. The

codes exist to reduce the risk of fire. Failure to follow

these instructions can result in fire, property damage,

bodily injury, and even death.

Install the stove in a safe, open area, away from traffic

flow, doors, and hallways. If possible, try to install the

stove near an existing chimney and chimney

connector. It is extremely important to install this

stove with the proper clearance from combustible

surfaces. You can purchase specific connector pipe

and special wall coverings as specified by this manual

and the NFPA 211 code to protect combustible

surfaces. As a general rule, keep furniture, drapes,

curtains, wood, paper, and other combustibles at

least 36 inches (92 cm) away from the stove. Never

install the stove in or near a storage location for

gasoline, kerosene, charcoal lighter fluid or any other

flammable liquids.

Install the stove in your central living area to allow

heat to radiate naturally to distant rooms. Do not

install your stove in a poorly insulated area. This is

inefficient and would likely result in higher fuel usage.

 SAFETY NOTICE:

AN IMPROPERLY INSTALLED STOVE CAN

RESULT IN A HOUSE FIRE. FOR YOUR SAFETY,

CAREFULLY FOLLOW THE INSTALLATION

DIRECTIONS. CONTACT LOCAL BUILDING OR

FIRE OFFICIALS ABOUT RESTRICTIONS AND

INSTALLATION INSPECTION IN YOUR AREA.

The safety of your stove will depend on many factors,

some of which include: distance to combustible

objects, correct venting, and adequate chimney

maintenance. Should you have any questions, do not

hesitate to contact your dealer for additional

information.

Contact your dealer for any necessary warranty

service.

This Green Mountain 40 Model 8640 stove is

warranted by:

Hearthstone Quality Home Heating Products, Inc®

317 Stafford Ave.

Morrisville, Vermont 05661, USA

www.Hearthstonestoves.com

Hearthstone Quality Home Heating Products, Inc ® Green Mountain 40 (Model 8640)

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CODES

When you install your Green Mountain 40 woodstove,

it is imperative that you adhere to all Federal and local

codes. Obtain these codes from either of the following

sources:

American National Standards Institute, Inc. (ANSI)

1430 Broadway

New York, NY 10018

www.ansi.org

National Fire Protection Association, Inc. (NFPA)

Battery March Park

Quincy, MA 02269

www.nfpa.org

If you are installing your Green Mountain 40 in a

mobile or manufactured home, follow the guidelines

described in the Manufactured Home Construction

and Safety Standard, Title 24 CFR, Part 3280 (United

States).

SAFETY INFORMATION

Read and understand this Owner's Manual

thoroughly before installing and using this stove.

Make sure to install your stove:

 According to the manufacturer's

recommendations

 In accordance with all applicable codes

 With the proper sized chimney

When using your stove, follow these safety

precautions:

 Never modify this stove in any way.

 Never burn kiln dried, painted or treated wood in

this stove.

 DO NOT BURN GARBAGE. Never burn garbage

or trash, colored or glossy paper, solvents,

plywood, artificial logs, cardboard, or driftwood, in

this stove.

 Never burn coal in this stove.

 DO NOT BURN FLAMMABLE FLUIDS.

 DO NOT USE CHEMICALS OR FLUIDS TO

START THE FIRE. Never use gasoline,

kerosene, charcoal lighter fluid, or other

flammable fluids to start or invigorate the fire.

These fuels will cause dangerous burning

conditions in the stove. Keep all such materials

away from the stove.

 Never use a wood grate or other device to

elevate the fire.

 Never allow logs in the firebox to hit the glass

when the door is closed.

 Never slam the door or use the door to force

wood in to the stove.

 Never over-fire your stove. (See page 24)

 Never put articles of clothing or candles on a hot

stove.

 Never connect the stove to a flue used by another

appliance.

 Never connect to or use in conjunction with any

air distribution ductwork unless specifically

approved for such installations

Other safety guidelines:

 Keep all combustible items such as furniture,

drapes, clothing, and other items, at least 36"

(0.92 m) from the stove (See page 9)

 Install a smoke detector, preferably in an area

away from your wood stove.

 Keep a fire extinguisher handy. We recommend

the type rated "A B C."

 Dispose of ashes properly. (See page 23)

 Keep children and pets away from the stove when

it is burning; they could be seriously injured by

touching a hot stove.

 Clean your chimney system as needed. (See

page 29)

 Outside combustion air may be required if:

1. This solid-fuel-fired appliance does not

draw steadily, smoke rollout occurs, fuel

burns poorly, or back-drafts occur whether

or not there is combustion present.

2. Existing fuel-fired equipment in the house,

such as fireplaces or other heating

appliances, smell, do not operate properly,

suffer smoke roll-out when opened, or

back-draft whether or not there is

combustion present.

3. Opening a window slightly on a calm

(windless) day alleviates any of the above

symptoms.

4. The house is equipped with a well-sealed

vapor barrier and tight fitting windows

and/or has any powered devices that

exhaust house air.

Hearthstone Quality Home Heating Products, Inc ® Green Mountain 40 (Model 8640)

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5. There is excessive condensation on

windows in the winter.

6. A ventilation system is installed in the

house.

If these or other indications suggest that infiltration air

is inadequate, additional combustion air should be

provided from the outdoors. Outside combustion air

can be provided to the appliance by using the optional

outside air kit #96-53400

PERIODIC CHECKLIST

Perform each of these tasks at the specified

intervals.

At the End of Every Week:

 Empty ashes from the firebox, sooner if the

firebox is full.

At the Beginning of Every Other Month:

 Depending upon your use of the stove, visually

inspect the chimney connector and chimney for

creosote. (see page 29)

 Check door seals using the "dollar bill test." -

When the stove is cool, shut the door on a dollar

bill. If the bill pulls out without any resistance,

then your stove’s door is not sealing properly. To

tighten the seal, adjust the door latch

mechanism or change the door gasket. (Refer to

page 30.)

 Inspect the face of the catalytic combustor for fly

ash and soot. Use a soft-bristled brush to

remove if present. It is recommended to visually

inspect the catalytic combustor at least 3 times

during the heating season, or every 2-3 months.

At the End of Every Season:

 Dismantle the chimney connector and clean it

thoroughly. Replace any pieces that show signs

of rust or deterioration.

 Inspect and, if necessary, clean your chimney.

 Clean out the inside of the stove thoroughly.

 Check and clean the catalytic combustor, if

necessary

 Inspect all door gasket material and replace if

worn, frayed, cracked or extremely hard.

EMERGENCY PROCEDURES

If you have a stovepipe or chimney fire, follow these

instructions:

1. If the fire is too threatening, leave the area and

call the fire department immediately! If not,

perform the next three steps.

2. Close the primary air control.

3. Close the stovepipe damper (if present).

4. Close the bypass damper

5. Keep the stove front door closed!

 WARNING: DO NOT ATTEMPT TO PUT OUT A

STOVEPIPE OR CHIMNEY FIRE BY THROWING

WATER ONTO THE STOVE, STOVEPIPE, OR

CHIMNEY. THE EXTREMELY HIGH

TEMPERATURE OF SUCH FIRES CAN CAUSE

INSTANTANEOUS STEAM AND SERIOUS BODILY

HARM.

Once the chimney fire expires, leave the primary air

control and bypass handle closed and let the fire in

the stove die out completely. Inspect the stove,

stovepipe, and chimney thoroughly for any sign of

damage before firing the stove again. You must

correct any damage before using your stove again.

Establish a routine for the fuel, wood burner and

firing technique. Check daily for creosote build-up

until experience shows how often you need to clean

to be safe. Be aware that the hotter the fire the less

creosote is deposited, and weekly cleaning may be

necessary in mild weather even though monthly

cleaning may be enough in the coldest months.

Contact your local municipal or provincial fire

authority for information on how to handle a chimney

fire. Have a clearly understood plan to handle a

chimney fire.

Hearthstone Quality Home Heating Products, Inc ® Green Mountain 40 (Model 8640)

7

SPECIFICATIONS

Maximum Heat Output:

40,000 BTUs per hour of cordwood (based on

independent laboratory test results).

Floor Size of Heated Area:

Up to a maximum of 1,400 square feet. Factors

unique to your home can reduce the square

footage the stove will heat. Home insulation

value, number and efficiency of windows, floor

plan, stove placement, quality of the fuel and

other conditions may limit the heating ability of

the stove.

Firebox Capacity:

1.32 cubic feet.

Maximum Log Length: Up To 16” (40.6cm).

Emissions: 1.07 g/hr.

Burn Time: Up to 16+ hrs. (Heat Life™: Up to 20

hours) Note: The amount and weight of wood

contained per cubic foot of firebox volume can

vary from 10 to 25 lbs. per cubic foot depending

on type of wood, moisture content, packing

density and other factors.

Stove Dimensions:

Height: 30 3/8” (77.2cm)

Width: 23 1/4" (59.1cm)

Depth: 19 3/8" (49.2cm)

Weight: 350 lbs. (159 kg)

Connector Size: 6" (152 mm) diameter

Metal Chimney: 6" (152 mm) inside diameter

Masonry Chimney: 6” (152 mm) inside diameter

(round flue), 8” x 8” (203 x 203 mm) (square

flue)

Crate Dimensions: H-40” W-29” L-36” or

102x74x 92cm

Optional Equipment:

Outside Air Kit 96-53400

Blower Kit 96-57400

Figure 1 – Green Mountain 40 Dimensions

Hearthstone Quality Home Heating Products, Inc ® Green Mountain 40 (Model 8640)

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INSTALLATION

UNPACKING

Hearthstone packages your Green Mountain 40

woodstove with the greatest care so that it ships

safely. Under certain circumstances, however,

damage may occur during transit and handling. When

you receive the Green Mountain 40, carefully unpack

and inspect the stove and all accompanying parts.

Ensure that all parts are included inside the stove. If

any parts are damaged or missing, please contact

your authorized Hearthstone dealer immediately.

Be sure to remove the packaging material in the flue

collar and above the baffle before installing the

chimney.

PACK LIST

Green Mountain 40 Model 8640 Woodstove

Owner’s Manual

The label is attached by a cable to the bottom of the

stove. Take care when lifting the stove not to

damage the label or cable. After final positioning of

the stove, the label may be stored in the holding clip

on the bottom shield of the stove.

Figure 2 - Label Location

INSTALLING YOUR STOVE

Choose a place to install your Green Mountain 40

woodstove. Consider the location of your stove for

optimum heating efficiency. In general, it is better to

place your stove in a main living area, rather than in

a basement or other confined space.

Inspect this location to make sure that the stove and

stovepipes will have the required clearance from

combustible materials that are near the stove.

Combustibles include walls, floor, ceiling, and

chimney chase. You must carefully consider the

clearances to all of these combustibles before

actually connecting your stove.

If the floor is made of combustible material, then a

non-combustible floor protector is required between

the floor and the stove. An example of a non-

combustible floor protector is a hearth constructed

with a continuous layer of tile, brick, slate, glass or

another non-combustible facing. There is no R-value

requirement.

If you use a rear connector pipe, ensure it is listed with

Underwriter’s Laboratories. Check the listing of your

pipe with UL for the correct clearances.

The diagrams in this manual represent typical

installations, but are specific to the Simpson Dura-

Vent DVL brand.

The Green Mountain 40 is to be installed as a

freestanding room heater with the clearances in the

included installation instructions. The Stove is not to

be installed in any factory-built fireplace.

Clearances to NFPA Code 211 Protected Surfaces

You can reduce the clearances to combustible

surfaces by using any National Fire Protection

Agency (NFPA) approved wall protection system with

additional approval of the regulatory authority having

jurisdiction in your area. Please refer to NFPA Code

211 for specifications and complete details. You can

obtain this information directly from the NFPA.

National Fire Protection Agency

Batterymarch Park

Quincy, MA 02269

1-800-344-3555

1-617-770-3000

www.nfpa.org

Hearthstone Quality Home Heating Products, Inc ® Green Mountain 40 (Model 8640)

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HEARTH REQUIREMENTS & FLOOR PROTECTION

Ensure you protect combustible flooring with a covering of noncombustible material. The Green Mountain 40 does

not require an insulated hearth pad. The minimum floor protection must be met under the stove and extend beyond

the stove as follows:

The minimum floor protection for US installations is 33in x 31-1/2in.

The minimum floor protection for installations in Canada is 43in x 40in.

Figure 3 – Hearth Dimensions

Installing the stove in a room with Luxury Vinyl Plank (LVP) or Luxury Vinyl Tile (LVT) flooring requires extra

consideration from the stove to the LVP or LVT flooring. Some LVP and LVT flooring begins to warp at 110°

Fahrenheit. Each installation and flooring specification is different. Consult the flooring manufacturer for

maximum temperature recommendations. Additional shielding to prevent warping may be necessary depending

on the flooring used.

Hearthstone Quality Home Heating Products, Inc ® Green Mountain 40 (Model 8640)

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COMBUSTIBLE SURFACE REQUIRED CLEARANCES

Note: Dimensions shown in the following figures are from the body of the stove unless otherwise indicated.

It is very important to follow minimum clearances for chimney connectors to combustibles such as walls and

ceilings when installing the stove near combustible surfaces.

Figure 4 – Clearance to Combustibles

Alcove Clearances (inches) Unprotected Surfaces

Protected Surfaces (NFPA-211)

Minimum alcove width 51.25” – 131cm See NFPA-

211

Min. Alcove ceiling from floor with single wall connector 56” – 142.3cm See NFPA-211

Min. Alcove ceiling from floor with double wall connector

56” – 142.3cm See NFPA-211

FOR BLOWER KIT, USE KIT #96-57400

Parallel

Corner Corner

Clearances A B C D E

F

Single wall Connector – Inc. Rear Heat Shield 14”-36cm

13.75”-35cm

18”-45cm

25.5”-65cm 7”-18cm

17.25”-44cm

Single Wall Connector – With Blower Kit Shield 14”-36cm

13.75”-35cm

18”-45cm

25.5”-65cm

7”-18cm

17.25”-44cm

Double Wall Connector – Inc. Rear Heat Shield 14”-36cm

9.75”-25cm 14”-36cm

25.5”-65cm

7”-18cm

17.25”-44cm

Double Wall Connector – With Blower Kit Shield 14”-36cm

9.75”-25cm 14”-36cm

25.5”-65cm

7”-18cm

17.25”-44cm

Single Wall Connector – No Rear Heat Shield 14”-36cm

16”-41cm

21”- 54cm

25.5”-65cm 14”-36cm

25.5”-65cm

Alcove W/Single Wall Conn – Inc. Rear Heat Shield

14”-36cm

13.75”-35cm

18”-46cm 25.5”-65cm

See NFPA-

211

Alcove W/Single Wall Conn – With Blower Kit Shield

14”-36cm

13.75”-35cm

18”-46cm 25.5”-65cm

See NFPA-

211

Alcove W/Dbl Wall Conn – Inc. Rear Heat Shield 14”-36cm 9.75”-25cm

14”-46cm 25.5”-65cm

See NFPA-

211

Alcove W/Dbl Wall Conn – With Blower Kit Shield 14”-36cm 9.75”-25cm

14”-46cm 25.5”-65cm

See NFPA-

211

Hearthstone Quality Home Heating Products, Inc ® Green Mountain 40 (Model 8640)

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Figure 5 Chimney Connector Clearances

Single Wall Pipe

Double Wall Pipe

Through the wall top flue exit

With Blower

Kit Shield

**

Inc. Rear Heat

Shield

With Blower Kit

Shield**

Inc. Rear Heat

Shield

A

13.75”

(

35

cm)

13.75” (35cm) 9.75” (25 cm) 9.75” (25 cm)

B

1

8

” (

46

cm)

1

8

”

(

46

cm)

1

4

” (

36

cm)

1

4

” (

36

cm)

*For double wall pipe clearance to ceiling,

refer to pipe manufacturer specifications.

** FOR BLOWER KIT, USE KIT #96-57400

See Parallel Clearance to Combustibles for

clearances to the sides of the stove.

Hearthstone Quality Home Heating Products, Inc ® Green Mountain 40 (Model 8640)

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CHIMNEY CONNECTOR SYSTEMS AND

CLEARANCES FROM COMBUSTIBLE WALLS

FOR RESIDENTIAL HEATING APPLIANCES

A. Minimum 3.5in thick brick masonry all framed

into combustible wall with a minimum of 12in.

brick separation from clay liner to combustibles.

The fire clay liner shall run from outer surface of

brick wall to, but not beyond, the inner surface

of chimney flue liner and shall be firmly

cemented in place.

B. Solid-insulated, listed factory-built chimney

length of the same inside diameter as the

chimney connector and having 1in. or more of

insulation with a minimum 9in. air space

between the outer wall of the chimney length

and combustibles.

C. Sheet steel chimney connector, minimum 24

gauge in thickness, with a ventilated thimble,

minimum 24 gauge in thickness, having two 1in.

air channels, separated from combustibles by a

minimum of 6in of glass fiber insulation.

Opening shall be covered, and thimble

supported with a sheet steel support, minimum

24 gauge in thickness.

D. Solid insulated, listed factory-built chimney

length with an inside diameter 2in. larger than

the chimney connector and having 1in. or more

of insulation, serving as a pass-through for a

single wall sheet steel chimney connector of

minimum 24 gauge thickness, with a minimum

2in. air space between the outer wall of

chimney section and combustibles. Minimum

length of chimney section shall be 12in.

chimney section spaced 1in. away from

connector using sheet steel support plates on

both ends of chimney section. Opening shall be

covered, and chimney section supported on

both sides with sheet steel supports securely

fastened to wall surfaces of minimum 24-gauge

thickness. Fasteners used to secure chimney

section shall not penetrate chimney flue liner.

Hearthstone Quality Home Heating Products, Inc ® Green Mountain 40 (Model 8640)

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Figure 6 Trim and Mantle Clearances

OUTSIDE AIR SUPPLY

(Optional Kit #96-53400)

You can connect an outside air source directly to this

stove using an optional outside air kit. The advantage

of providing outside air directly to the stove is that the

air used by the stove for combustion is taken from

outside the residence rather than from within the

room where the stove is located.

The outside air kit for this stove allows for the direct

connection of the stove's air intake to a minimum 3"

(76 mm) diameter duct (supplied by others)* which

leads to the outside of the house. When considering

placement of the duct from the outside of the house

to the hearth, keep in mind the need to avoid

structural members of the house. The outside air kit

attaches to the underside of the stove. Refer to the

instructions provided with the kit for installation.

*An adaptor for 4” duct is available if needed. KIT #90-

53308

When using an outside air kit in Canada, the stove

must be attached to your home’s floor. Use the

shipping clips that came with the stove and fasteners

long enough to attach securely to the subfloor. (The

clips and fastener heads may be painted to minimize

visibility).

Figure 7 – Outside Air Kit Detail

The International Residential Code (IRC) does not

allow the outside air duct to terminate higher than the

appliance. Some building officials restrict vertical rise

in the duct’s termination. Hearthstone recommends

the termination be at the same level, or lower than the

air intake on the stove. When using an outside air kit

in Canada, a damper allowing 100% closure shall be

installed.

Locate the termination of the duct on the outside wall

of the home in such a manner to avoid the possibility

of obstruction by snow, leaves or other material.

Screen the termination using ¼” x ¼” mesh rodent

screen and cover it with a rain/wind proof hood (flex

pipe, outside termination, mesh, and hood supplied

by others) Contact your dealer for availability.

Hearthstone Quality Home Heating Products, Inc ® Green Mountain 40 (Model 8640)

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VENTING COMPONENTS &

CONFIGURATION REQUIREMENTS

 DO NOT CONNECT THIS UNIT TO A CHIMNEY

FLUE USED BY ANOTHER APPLIANCE

 Single wall connector that is at least 24 MSG or

25 MSG blued steel stovepipe.

 Double wall connector (Rear pipe) which is used

with a listed, factory-built “Type HT" chimney or

with a masonry chimney to reduce clearances, is

available from several manufacturers, your dealer

can help you choose. Some air insulated

connector pipe models recommended are

Simpson Dura Vent DVL and Metalbestos DS.

Security, GSW and Ameritec also have

acceptable Rear connector pipe.

 When used in a mobile home, a spark arrester is

required. (See page 18)

 The chimney connector cannot pass through a

floor or ceiling, nor any attic or roof space, closet

or similar concealed space. Where venting

requires passage through a wall or partition of

combustible construction, the installation must

conform to NFPA Code 211 or CAN/CSA - B365.

 Be sure to follow the manufacturer’s instructions

to maintain an effective vapor barrier at the

location where the chimney of other component

penetrates the exterior of the structure

 It is very important to follow minimum clearances

for chimney connectors to combustibles such as

walls and ceilings when installing the stove.

Typical chimney connector clearances are

outlined below. The single wall clearances are

generic; the double wall clearances shown are

specifically for Simpson DuraVent DVL and may

vary with other brands. Check the

specifications from the manufacturer of your

connector.

COMPONENTS OF A VENTING SYSTEM

The complete venting system consists of several

components: chimney connector, wall thimble, wall

pass-through, chimney, and liner. It is absolutely

necessary that you install all of these components

and maintain the clearances to combustibles

discussed earlier to ensure a safe stove installation.

To protect against the possibility of a house fire, you

must properly install and constantly maintain the

venting system in good condition. Be sure to inspect

the chimney and chimney connector and keep it clean.

Upon inspection, immediately replace rusted,

cracked, or broken components. Failure to follow

these instructions and specified components or using

make-shift compromises can result in fire, property

damage, bodily injury, and even death.

 The chimney connector is the stovepipe from the

woodstove to the chimney. The chimney

connector stovepipe is 6" (152 mm) diameter, 24

MSG or 25 MSG blued steel connector pipe. Do

not use aluminum or galvanized steel pipe - they

cannot withstand the extreme temperatures of a

wood fire.

 The thimble is a manufactured (or site-

constructed) device installed in combustible walls

through which the chimney connector passes to

the chimney. It keeps the walls from igniting. You

must use a wall thimble when installing a chimney

connector through a combustible wall to the

chimney.

 A wall pass-through (or chimney support

package) also keeps the walls from igniting. You

must use one when connecting through a wall or

ceiling to a prefabricated chimney.

 Only install this stove to a lined masonry chimney

or an approved high temperature prefabricated

residential type building heating appliance

chimney. Do not connect this stove to a chimney

serving another appliance; you will compromise

the safe operation of both the wood stove and the

connected appliance.

 A liner is the UL 1777 or ULC S635 (for factory

built fireplace or masonry) chimney.

You must connect your stove to a chimney

comparable to those recommended in this manual.

Do not use stovepipe as a chimney. Use stovepipe for

freestanding installations only to connect the stove to

a proper chimney.

 WARNING: DO NOT CONNECT THIS APPLIANCE

TO ANY AIR DISTRIBUTION DUCT OR SYSTEM.

INSTALLING A VENTING SYSTEM

Attach stovepipe sections to the flue collar and to

each other with the crimped end toward the stove. If

creosote builds up, this allows the creosote to run into

the stove and not on the outside of the stovepipe or

onto the stove.

Hearthstone Quality Home Heating Products, Inc ® Green Mountain 40 (Model 8640)

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Secure all joints, including attaching the stovepipe to

the stove's flue collar, with three sheet metal screws.

Install #10 x 1/2" (3 mm x 13 mm) sheet metal screws

into the holes pre-drilled in the flue collar.

Disregarding the screws can cause joints to separate

from the vibrations that result from a creosote

chimney fire.

You can simplify connecting stovepipe by using

additional accessories such as telescoping pipes,

slip-connectors or clean-out tees. These accessories

ease the periodic inspection of your chimney, as well

as allow you to dismantle the stovepipe easily

(without moving the stove).

Install the stove as close as practical to the chimney,

while maintaining all proper clearances. Install

stovepipe that is as short and as straight as possible.

Horizontal runs of stovepipe must always rise away

from the stove at a minimum of 1/4" per foot

(21mm/m).

We do not recommend long runs of stovepipe to

increase heat dispersal. Longer lengths of stovepipe,

or more connecting elbows, than necessary increase

the chances of draft resistance and the accumulation

of creosote buildup.

In general, you do not need to install a stovepipe

damper with the Green Mountain 40. Some

installations, however, could benefit from a stovepipe

damper, such as a tall chimney which can create a

higher than normal draft. In such cases, a damper can

help regulate the draft. The Green Mountain 40

requires a draft between 0.06" and 0.1" WC. For

drafts above 0.1" WC, install a stovepipe damper.

Check the draft at stove installation time.

Remember, the NFPA recommends minimum

clearances for chimney connectors to combustibles

such as walls and ceilings. Once the stove is installed

at safe distances from these combustible surfaces, it

is also important to maintain these connector

clearances for the remainder of the installation.

CONNECTING THE STOVE TO A CHIMNEY

You can install your Green Mountain 40 to a

prefabricated metal chimney, or to a masonry

chimney.

This room heater must be connected to (1) a listed

Type HT (2100° F) chimney per UL 103 or ULC S629,

or (2) a code-approved masonry chimney with a flue

liner. The chimney size should not be less than the

flue collar, or more than three times greater than the

cross-sectional area of the flue collar.

We recommend installing a cleanout tee where

possible to simplify chimney cleaning and

maintenance.

Connecting to a Prefabricated Metal Chimney

There are two ways to install a prefabricated metal

chimney:

 An interior installation where the chimney passes

inside the residence through the ceiling and roof.

 An exterior installation where the chimney passes

through the wall behind the stove then up the

outside of the residence.

Whenever possible, choose an interior chimney. An

interior chimney heats up quickly and retains its heat;

this promotes a better draft and discourages the

formation of creosote. An exterior chimney does not

benefit from the warmth of the building, so it typically

operates at lower flue temperatures than an interior

chimney and may experience increased creosote

accumulation.

When connecting the Green Mountain 40 to a

prefabricated metal chimney, you must follow,

precisely, the manufacturer's installation instructions.

Use only Type HT (2100° F), prefabricated metal

chimneys listed per UL 103 or ULC S629 standards.

Ensure the size of the prefabricated chimney’s flue is

appropriate for the Green Mountain 40. The Green

Mountain 40 requires a 6" (152 mm) inside diameter

flue for new installations. A 6” diameter flue provides

adequate draft and performance. You can use an 8"

(203 mm) diameter existing flue with a reducer. An

oversized flue contributes to creosote accumulation.

(In this case, bigger is NOT better.)

When purchasing a prefabricated chimney to install

with your stove, Ensure you also purchase from the

same manufacturer the wall pass-through (or ceiling

support package), "T" section package, fire-stops

(when needed), insulation shield, roof flashing,

chimney cap, and any other required accessories.

Follow the manufacturer’s instructions when installing

the chimney and accessories. In addition, ensure you

maintain all manufacturers’ recommendations for the

proper clearances to the chimney.

Connection to a Masonry Chimney

Consider two primary elements when connecting your

stove to a masonry chimney: the chimney itself and

the thimble where the stovepipe connects to the

chimney. Use only code approved masonry

chimneys containing a proper flue liner.

Hearthstone Quality Home Heating Products, Inc ® Green Mountain 40 (Model 8640)

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Before connecting to a masonry chimney, hire a

professional to examine the chimney for cracks, loose

mortar, and other signs of deterioration and blockage.

If the chimney needs repair, complete them before

installing and using your stove. Do not install your

stove until the chimney is safe for use.

Ensure the chimney’s cleanout is complete and

working properly. To avoid a loss of draft, the cleanout

door must close completely and provide a tight seal.

If the cleanout door leaks, the chimney will cool, your

stove will perform poorly, and creosote can form.

Ensure the size of the chimney’s flue is appropriate

for this stove and that it is not too large. Use a

masonry chimney with a maximum 6” Diameter or 8"

x 8" (203 mm x 203 mm) tile size for best results. An

oversized flue contributes to the accumulation of

creosote.

Use the following checklist to ensure that your

masonry chimney meets these minimum

requirements:

MASONRY CHIMNEY WALL CONSTRUCTION:

 Mortared brick or modular block at least 4" (102

mm) thick – must use liner

 A mortared rubble or stone wall – must use liner

FLUE LINER OPTIONS:

 Tile - minimum wall thickness of 5/8" (16 mm),

installed with refractory mortar, and with at least

1" (25 mm) air space around the liner

 Stainless steel - UL listed 6” diameter, insulated

or wrapped liner, or the space around the liner

filled with vermiculite or suitable material (these

 keep the liner warmer for better performance)

 Ensure any equivalent flue liner is a listed

chimney liner system meeting type HT

requirements or other approved material.

INTERIOR CHIMNEY REQUIREMENTS:

 Must have at least 2" (51 mm) clearance to

combustible materials

 Must install fire stops at the spaces where the

chimney passes through floors and/or ceiling

 Any insulation material must be at least 2" (51

mm) from the chimney

EXTERIOR CHIMNEY REQUIREMENTS:

 At least 1" (25 mm) clearance to combustible

materials

CHIMNEY HEIGHT REQUIREMENTS (SEE FIGURE 9):

 At least 3 feet (0.9 m) higher than the highest

part of the roof opening through which it passes.

 At least 2 feet (0.6 m) higher than any part of the

roof within 10 feet (3 m) measured horizontally

from the top of the chimney.

The recommended minimum chimney height for top

of stove installation is 16 feet (4.9 m) off the floor or

13 feet 7 1/4 inches (4.2 m) from the top of the

stove. For rear exit connection, the recommended

minimum chimney height is 19 feet (5.8m) off the

floor or 16 feet 7 1/4 inches (5.1m) from the top of

the stove. The recommended maximum chimney

height is 30 feet (9m). The Green Mountain 40

requires a draft between -0.06” and -0.15” water

column. Ensure your chimney is long enough to

provide the minimum draft, and use a damper if your

installation has a required chimney height that

provides too much draft.

Figure 8 Chimney Height Requirements

Hearthstone Quality Home Heating Products, Inc ® Green Mountain 40 (Model 8640)

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Figure 9 - Typical Chimney Configurations

Hearthstone Quality Home Heating Products, Inc ® Green Mountain 40 (Model 8640)

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INSTALLING IN A MOBILE HOME

Follow these special requirements for installing your

stove in a mobile home.

 Install the stove in accordance with 24 CFR,

Part 3280 (HUD)

 An outside air kit must be used in all mobile

home installations. See page 12 for details.

 Permanently attach the stove to your mobile

home’s floor. Use the shipping clips that came

with the stove and fasteners long enough to

attach securely to the subfloor. (The clips and

fastener heads may be painted to minimize

visibility).

Figure 10 - Lock Down Detail

 Install a Mobile Home Chimney & Connector

Kit*.

Each kit must include:

Stainless spark arrester cap, storm collar,

Adjustable vented flashing – 0/12 – 6/12,

Two 24” chimney pipes, 24” support box

with built-in starter section and trim.

* Install a Mobile Home Chimney and Connector Kit

conforming to US/UL103 or CAN/ULC-S629, Standard for

Factory-Built Chimneys.

 WARNING: DO NOT INSTALL IN A SLEEPING

ROOM IN A MOBILE HOME.

 CAUTION: MAINTAIN THE STRUCTURAL

INTEGRITY OF THE MOBILE HOME WALLS,

FLOOR, CEILING, AND ROOF WHEN INSTALLING

AND USING YOUR STOVE.

 FAILURE TO FOLLOW THESE INSTRUCTIONS

AND SPECIFIED COMPONENTS OR USING

MAKE-SHIFT COMPROMISES CAN RESULT IN

FIRE, PROPERTY DAMAGE, BODILY INJURY,

AND EVEN DEATH.

 Burning any fuel other than wood in this unit

could generate dangerous levels of carbon

monoxide within the living space.

 THE FRONT DOOR MUST REMAIN CLOSED WHEN

IN OPERATION EXCEPT FOR START UP AND

LOADING. Leaving the door open during use could

cause any smoke or fire detectors in the home to

be set off or a fire could escape the firebox and

start the room on fire.

 If this unit is installed in a mobile home, care must

be taken to ensure adequate air is available. If not

enough air is available it could starve the room of

all the oxygen. (See page 27 for more details)

Figure 11 – Mobile Home Chimney Installation

 CAUTION: REMOVE THE CHIMNEY WHEN

TRANSPORTING THE MOBILE HOME!

 Be sure to follow the manufacturer’s instructions

to maintain an effective vapor barrier at the

location where the chimney of other component

penetrates the exterior of the structure

Hearthstone Quality Home Heating Products, Inc ® Green Mountain 40 (Model 8640)

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OPERATION

Once your Green Mountain 40 is installed, you are

ready to light a fire.

Every installation, season’s firewood, and operator’s

technique varies. Learn how to use your stove most

efficiently for your installation. We can give you the

basic principles, but only you can ensure maximizing

the potential of your stove while also operating it

safely.

 WARNING: HOT WHILE IN OPERATION! KEEP

CHILDREN, PETS, CLOTHING AND FURNITURE

AWAY. CONTACT MAY CAUSE SKIN BURNS.

Read this entire chapter before lighting your first fire.

It explains the controls and features of your wood

stove, how to choose firewood, and how to use your

stove on a daily basis.

CONTROLS AND FEATURES

Before lighting any fires, become familiar with the

location and operation of your stove's controls and

features and learn how to use them (See Figure 10).

For your own safety, do not modify these features in

any way. We recommend you use fireplace gloves

when the stove is in operation and hot.

Figure 12 - Controls & Features

FRONT DOOR HANDLE: The firebox door allows

you to load wood into your stove; a wood handle

operates the door. To open the door, pull up on the

handle and swing the door away from the stove. To

latch the door, push the door tightly towards the

firebox then continue to push the handle in and down

until it latches shut. Gently pull on the door handle to

make sure it is properly latched.

PRIMARY AIR CONTROL: The primary air control

lever is located under the ash lip. The primary air

control allows you to regulate the amount of air

entering the firebox. Generally, the more air allowed

into the firebox, the faster the rate of burn and the

higher the heat output; conversely, less air creates a

slower burn, with lower heat output. For maximum

airflow, pull the lever out as far as possible; move the

lever inwards as far as possible for minimum airflow

(does not close completely).

Figure 13 – Air Control

BYPASS HANDLE: The bypass handle controls the

bypass door inside the stove. When the handle is

pointed towards the front of the stove, the bypass

door is open, and when the handle is pointed

towards the rear of the stove, the bypass door is

closed. The bypass door directs the flow of

combustion products through or around the catalytic

combustor. When the bypass handle is open,

combustion products are directed around the

catalytic combustor. The bypass handle should be

open when first staring a fire until the catalytic

combustor heats up to activation temperature, and

whenever opening the front door to load the stove.

When the bypass handle is closed, combustion

products are directed through the catalytic

combustor. The bypass handle should be closed

once the catalytic combustor heats up to activation

temperature, and remain closed whenever the stove

is burning and in the active temperature range.

Figure 14 – Bypass Closed

Hearthstone Quality Home Heating Products, Inc ® Green Mountain 40 (Model 8640)

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Figure 15 – Bypass Open

CATALYST THERMOMETER: The catalyst

thermometer monitors the downstream temperature

of the catalysts, and indicates when the stove is in

the active range for the catalysts. When the stove is

in the “active” range, the bypass handle should be

closed. When the stove is in the “Inactive” range, the

bypass handle should be opened until the stove

heats up. If the thermometer is in the “Too Hot”

range, keep the door closed, fully close the air

control, and allow the stove to cool down until the

thermometer falls into the “Active” Range. Once the

catalyst thermometer has reached the active range,

heat generated from burning smoke keeps the

catalysts warm and active as long as fuel remains in

the stove. The Green Mountain 40 typically operates

in the 800 ⁰F to 1300 ⁰F range.

Figure 16 – Catalyst Thermometer

CHOOSING FIREWOOD

Burn only natural firewood (known as cordwood) in

the Green Mountain 40 Model 8640 Wood Heater.

This stove is not designed to burn other fuels.

 CAUTION: DO NOT USE CHEMICALS OR

FLAMMABLE FLUIDS TO START THE FIRE. DO

NOT USE CHARCOAL, PELLETS, COAL,

ARTIFICIAL LOGS OR ANY OTHER MATERIALS AS

FUEL; THEY ARE NOT SAFE. DO NOT BURN

GARBAGE OR FLAMMABLE FLUIDS.

 THE USE OF UNAUTHORIZED FUEL SUCH AS

COAL COULD PRODUCE HIGH LEVELS OF

CARBON DIOXIDE IN THE LIVING SPACE. AT HIGH

LEVELS CARBON DIOXIDE COULD RESULT IN

PERSONAL INJURY OR DEATH.

The quality of your firewood directly affects heat

output, duration of burn and performance of your

stove. Softwoods generally burn hotter and faster,

while hardwoods burn longer and produce better

coals. Density and moisture content are two critical

factors to consider when purchasing wood.

The following is a list of some wood species and their

relative BTU (British Thermal Unit) content. The

higher the BTU content, the longer the burn. Firewood

with higher BTUs is generally ideal for a wood stove.

Burn untreated wood only. Other materials such as

wood preservatives, metal foils, coal, plastic,

garbage, sulphur, or oil may damage the catalysts.

Wood Heat Value: Sorted By Btu Content

Common Name Lb/ cord MBTU/ cord

High

Osage Orange (Hedge) 4,728 32.9

Hickory, Shagbark 4,327 27.7

Hop Hornbeam (Ironwood) 4,267 27.3

Beech, Blue (Ironwood) 3,890 26.8

Birch, Black 3,890 26.8

Locust, Black 3,890 26.8

Hickory, Bitternut 3,832 26.7

Locust, Honey 3,832 26.7

Apple 4,100 26.5

Mulberry 3,712 25.8

Oak, White 4,012 25.7

Medium High

Beech, European 3,757 24

Maple, Sugar 3,757 24

Oak, Red 3,757 24

Ash, White 3,689 23.6

Birch, Yellow 3,689 23.6

Hearthstone Quality Home Heating Products, Inc ® Green Mountain 40 (Model 8640)

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Medium

Juniper, Rocky Mtn 3,150 21.8

Elm, Red 3,112 21.6

Coffee tree, Kentucky 3.112 21.6

Hackberry 3,247 20.8

Tamarack 3,247 20.8

Birch, Gray 3,179 20.3

Birch, White (Paper) 3,179 20.3

Walnut, Black 3,192 20.2

Cherry 3,120 20

Ash, Green 2,880 19.9

Cherry, Black 2,880 19.9

Elm, American 3,052 19.5

Elm, White 3,052 19.5

Sycamore 2,808 19.5

Ash, Black 2,992 19.1

Maple, Red 2,924 18.7

Fir, Douglas 2,900 18.1

Medium Low

Boxelder 2,797 17.9

Alder, Red 2,710 17.2

Pine, Jack 2,669 17.1

Pine, Norway (Red Pine) 2,669 17.1

Pine, Pitch 2,669 17.1

Catalpa 2,360 16.4

Hemlock 2,482 15.9

Spruce, Black 2,482 15.9

Pine, Ponderosa 2,380 15.2

Low

Aspen, American 2,290 14.7

Butternut (Walnut, White) 2,100 14.5

Spruce 2,100 14.5

Willow 2,100 14.5

Fir, Balsam 2,236 14.3

Pine, White (Eastern,

Western)

2,236 14.3

Fir, Concolor (White) 2,104 14.1

Basswood (Linden) 2,108 13.8

Buckeye, Ohio 1,984 13.8

Cottonwood 2,108 13.5

Cedar, White 1,913 12.2

Moisture content also plays a key role in the

performance of your stove. Wood freshly cut from a

living tree (green wood) contains a great deal of

moisture. As you might expect, green wood burns

poorly. You must season green wood before using it

in your wood stove. To season green wood properly,

split, stack, and allow it to air dry for a period of one

year. Green wood may provide less than 2000 Btu per

pound, whereas dry wood can provide up to 7000 Btu

per pound.

Stack the firewood on skids or blocks to keep it off the

ground, cover only the top of the stack. Plastic or

tarps that cover the sides of the woodpile trap

moisture and prevent the wood from drying. As for

stacking, an old Vermonter said, "The spaces

between the logs should be large enough for a mouse

to get through, but not for the cat that's chasing it."

 CAUTION: DO NOT STORE FIREWOOD WITHIN

THE STOVE'S SPECIFIED CLEARANCES TO

COMBUSTIBLE MATERIALS.

BUILDING A FIRE

Once you understand the controls of your wood stove

and have the appropriate firewood, you are ready to

start a fire.

 WARNING: NEVER USE GASOLINE, GASOLINE-

TYPE LANTERN FUEL, KEROSENE, CHARCOAL

LIGHTER FLUID, 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.

BREAKING IN YOUR WOOD STOVE

It is imperative that your stove is "broken in" gradually.

Soapstone must be "seasoned"; over-firing a new

stove may cause soapstone to crack or may damage

other stove parts. Natural moisture in the freshly

quarried soapstone must be driven out slowly to

minimize the “shock” to the stone of its first exposure

to high firebox temperatures. In addition, the

asbestos-free furnace cement must be cured slowly

to ensure adequate sealing and bonding.

When you light your first fires, the woodstove will emit

some smoke and fumes. This is normal “off-gassing”

of the paints and oils used when manufacturing the

woodstove. If you find it necessary, open a few

windows to vent your room. The smoke and fumes

will usually subside after 10 to 20 minutes of

operation. The odor and smoke will end once the

stove is “cured”.

The first few fires of the season may produce other

odors from impurities that exist in the area

immediately surrounding the stove. Some potential

impurities are cleaning solvents, paint solvents,

cigarette smoke, and soot from scented candles, pet

hair, dust, adhesives, a new carpet, and new textiles.

Hearthstone Quality Home Heating Products, Inc ® Green Mountain 40 (Model 8640)

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These odors will dissipate over time. You can

alleviate these odors by opening a few windows or

otherwise creating additional ventilation around your

stove. If any odor persists, contact your dealer or an

authorized service technician.

If you adhere to the operating procedures in this

manual, the steel, cast iron, and soapstone

components of your stove will give you many years of

trouble-free use. With use, the color of the soapstone

may change and small fractures may appear on the

surface. These changes do not affect the function of

the stove. If a panel breaks completely, it must be

replaced

Avoid the following conditions that can cause the

glass, soapstone, steel or cast iron pieces to break:

 Do not throw wood into the stove.

 Do not use the door as a lever to force wood into

the stove.

 Do not load wood encrusted with ice into a

burning stove - the thermal shock can cause

damage.

 Do not use a manufactured log grate or otherwise

support the fuel. Burn the fire directly on the floor

of the firebox.

BUILDING A BREAK IN FIRE

1) Open the bypass handle. Open the front door and

place five or six double sheets of tightly twisted

newspaper in the center of the firebox. Arrange

kindling in a crisscross pattern over the

newspaper. Kindling should be approximately

ten pieces, 1/2" (13 mm) in diameter and 10" to

16" (254 mm to 457 mm) long.

2) Fully open the primary air control by pulling the

control handle towards you, away from the

firebox.

3) Light the paper under the kindling. Leave the

door slightly ajar momentarily until the kindling

has started to burn and draft begins to pull.

4) Close the door and allow the fire to burn. Keep

the door closed while the stove is in use.

5) KEEP A WATCHFUL EYE ON YOUR STOVE to

maintain a steady, low-heat fire. Your first fire

should make the stove warm but not hot to the

touch. Visible steam, or boiling moisture and

hissing indicate the soapstone is too hot. At most,

a few small chunks of wood should be added to

the fire to reach safe break-in temperatures.

6) Once the stove is warm but not hot to the touch,

close the primary air control by pushing it fully

inward toward the stove to allow the fire to die out

completely.

7) Let the stove return to room temperature.

Your first fire and first fire each season thereafter

should be built and maintained as outlined above.

Your patience will be rewarded by a properly

seasoned stove.

 NOTE: The cool flue gas temperatures

present during the break-in procedure may

cause rapid creosote build-up. The door

glass may also get dirty. A good hot fire will

clean it. We recommend a visual inspection

(and cleaning if necessary) of your stovepipe

and chimney once the break-in procedure is

completed.

NORMAL OPERATION

BUILDING A FIRE FOR EVERYDAY USE

1) Open the bypass handle. Open the front door and

place five or six double sheets of tightly twisted

newspaper in the center of the firebox. Arrange

kindling in a tee-pee configuration over the

newspaper. Use approximately 10 pieces of

kindling, 1/2" (13 mm) in diameter and 10" to 16"

(254 mm to 406 mm) long.

2) Fully open the primary air control by pulling the

lever completely out, away from the firebox.

3) Light the paper under the kindling. Leave the front

door slightly ajar momentarily until the kindling

begins to burn and draft begins to pull.

4) Close the door and allow the fire to burn.

5) Once the kindling is burning, open the front door

and add logs, small at first, to build the fire up.

Ensure you keep the logs away from the glass in

front in order for the air-wash system to work

properly. Keep the front door closed while the

stove is in use.

CAUTION: DO NOT BUILD THE FIRE TOO CLOSE

TO THE GLASS. KEEPING THE FIRE TOWARDS

THE CENTER OF THE FIRE BOX WILL KEEP

COALS FROM BUILDING UP AGAINST THE GLASS

DURING RELOADING.

6) Once the fire is burning well, and the catalyst

thermometer indicates that the stove is in the

active range, close the bypass handle. Now the

combustion products are passing through the

catalytic combustor, and your stove will be

burning at its optimal efficiency.

Hearthstone Quality Home Heating Products, Inc ® Green Mountain 40 (Model 8640)

23

7) After closing the bypass door, allow the stove to

run on a high setting for around 20 minutes to

ensure the catalytic combustor stays in the active

range. This will also allow the fire to burn off any

residue on the door glass from any previous low-

burn fires

8) Use the primary air control to regulate the desired

rate of burn. Pull the handle towards you for a

higher burn rate, and push the handle towards the

stove for a lower burn rate. The air control does

not close completely.

Note: Always remember to open the bypass handle

before opening the front door. When opening the front

door to reload or re-arrange logs, it is advisable to

open the door just a crack, pause for a moment then

open the door completely. This procedure allows the

firebox to clear of smoke before the door is open fully.

In addition, reloading on a bed of hot, red coals

reduces smoking time and brings fresh fuel up to a

high temperature rapidly. During the refueling and

rekindling of a cool fire, or a fire that has burned down

to the charcoal phase, operate the stove at a medium

to high firing rate for about 10 minutes to ensure that

the catalysts reach approximately 600 °F. Once the

catalysts reach operating temperature, the bypass

handle can be closed. When reloading the stove, try

to keep an open path behind the Lower Primary Air

Opening (LPAO). It is helpful to leave a small valley

in the coal bed behind the LPAO to insure faster re-

lighting.

CATALYTIC COMBUSTOR OPERATION

The Green Mountain 40 uses a catalytic combustor to

ensure highly clean and efficient burns. The catalytic

combustor is made from a stainless steel corrugation

that is coated with a catalytic material. The catalytic

combustor becomes active around 500 ⁰F (260⁰C),

helping to burn up smoke and any remaining particles

that were not fully burned in the firebox. During the

startup of a cold stove, a medium to high firing rate

must be maintained for about 20 minutes. This

ensures that the stove, catalysts, and fuel are all

stabilized and at proper operating temperatures.

Even though it is possible to have gas temperatures

reach 500 °F (260⁰C) within 2 to 3 minutes after a fire

is started, if the fire is allowed to die down

immediately, it may go out or the combustor may stop

working. Once the stove and catalytic combustor heat

up, heat generated from burning smoke keeps the

catalysts warm and active as long as fuel remains in

the stove. You stove will burn the cleanest and most

efficiently when the catalysts are in the active range.

There should be little to no visible smoke from your

chimney when the catalysts are in the active zone and

fully functional.

BURN RATE

This wood heater has a manufacturer-set

minimum low burn rate that must not be altered.

It is against federal regulations to alter this

setting or otherwise operate this wood heater in

a manner inconsistent with operating

instructions in this manual

LOW BURN: Move the air control lever all the way

inward toward the stove. (See figure 13). This closes

the air shutter to its minimum opening. A low burn rate

over extended periods is not advisable as it can

promote the accumulation of creosote. Inspect the

venting system frequently if using low burn rates

consistently.

MEDIUM LOW BURN: With the primary air control in

the low position, pull the air control forward (a little

less than 1/4”). A medium-low burn rate is the typical

setting and is preferable if the stove is unattended. At

this burn rate, a little goes a long way.

MEDIUM HIGH BURN: With the primary air control in

the low position, pull the air control forward (a little

less than 3/8”)

HIGH BURN: Completely open the primary air control

by moving it all the way outward toward the operator.

Fully load the firebox with wood on a bed of hot coals

or on an actively flaming fire. To minimize creosote

accumulation, run the stove on high once or twice

daily for 35 to 45 minutes to fully heat the stovepipe

and chimney.

CAUTION: Do not burn fuel other than cordwood in

your stove.

Figure 17 – Air Control Position

Hearthstone Quality Home Heating Products, Inc ® Green Mountain 40 (Model 8640)

24

OVER-FIRE CAUTION

Over-firing means the stove is operating at

temperatures above normal temperatures reached

during High Burns outlined in the BURN RATE

section. Carefully avoid over-firing, as it will damage

the stove. Symptoms of chronic over-firing can

include warped components, short burn times, a

roaring sound in the stove or stovepipe, and

discoloration of the stovepipe. A properly installed

stove using fuel and following operating procedures

as outlined in this manual should not over-fire.

Excessive draft, inappropriate fuel, and operator error

can cause over-firing. Correct an over-fire situation as

follows:

 EXCESSIVE DRAFT: Contact your local dealer

to have a draft reading taken. Any draft in excess

of 0.1 WC requires a damper in the stovepipe.

Some installations may require more than one

damper.

 INAPPROPRIATE FUEL: Do not burn coal; kiln

dried lumber, wax logs, compressed wood, highly

volatile fuels or combustibles, or anything other

than natural cordwood.

 OPERATOR ERROR: Ensure all the gaskets are

in good condition. Replace worn out or

compressed gaskets. Only burn the stove with

the firing and ash doors in the closed position.

If you suspect your stove is over-firing, discontinue

use and contact your dealer immediately. Damage

caused by over-firing is not covered by your

warranty. Results of over-firing can include warped

or burned out internal parts, cracked refractory

panels, discolored or warped external parts, and

damaged finish.

 ANY SIGNS OF OVER-FIRING WILL VOID YOUR

WARRANTY!

 THE FRONT DOOR MUST REMAIN CLOSED WHEN

IN OPERATION

REMOVAL AND DISPOSAL OF ASHES

You can leave a thin layer of ashes in the firebox if

preferred. Allow fire to die down or go out completely.

It is important to prevent ashes from building up

around the front door opening or they will spill out, or

they can pack into the gasket channel and prevent

proper sealing. To remove ashes, use a fireplace

shovel. Avoid removing large live coals by pushing

them to the side and removing only the finer ash with

a shovel.

Disposal of ashes - Ashes should be placed directly

into a metal container with a tight fitting lid. Do not

place any other items or trash into the metal

container. Do not pour water into the container.

Replace the container’s lid and allow the ashes to

cool. Never place the ash disposal container on a

combustible surface or vinyl flooring, as the container

could be hot!

Pending disposal, place the closed ash container on

a noncombustible floor or on the ground outside, well

away from all combustible materials, liquid fuels, or

vehicles. Retain ashes in the closed container until all

coals thoroughly cool.

If the ashes are disposed of by burial in soil or

otherwise locally dispersed, they should be retained

in the closed container until all cinders have

thoroughly cooled.

NEVER place ashes in wooden or plastic containers,

in trashcans with other trash, or in paper or plastic

bags, no matter how long the fire has been out.

Coals within a bed of ashes can remain hot for

several days once removed from the firebox.

Hearthstone Quality Home Heating Products, Inc ® Green Mountain 40 (Model 8640)

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MAINTENANCE

CATALYTIC COMBUSTOR INSPECTION AND

REPLACEMENT PROCEDURES

 WARNING: THIS WOOD HEATER CONTAINS A

CATALYTIC COMBUSTOR, WHICH NEEDS

PERIODIC INSPECTION AND REPLACEMENT FOR

PROPER OPERATION. IT IS AGAINST FEDERAL

REGULATIONS TO OPERATE THIS WOOD

HEATER IN A MANNER INCONSISTENT WITH

OPERATING INSTRUCTIONS IN THIS MANUAL, OR

IF THE CATALYTIC ELEMENT IS DEACTIVATED

OR REMOVED

It is important to periodically monitor the operation of

the catalytic combustor to ensure that it is

functioning properly and to determine when it needs

to be replaced. A non-functioning combustor will

result in a loss of heating efficiency, and an increase

in creosote and emissions. Following is a list of

items that should be checked on a periodic basis

-Combustors should be visually inspected at least

three times during the heating season to determine if

physical degradation has occurred. Actual removal of

the combustor is not recommended unless more

detailed inspection is warranted because of

decreased performance. If any of these conditions

exists, refer to Catalyst Troubleshooting section of

this owner’s manual.

-This catalytic (or hybrid) heater is equipped with a

thermometer to monitor catalyst operation. Properly

functioning combustors typically maintain

temperatures in excess of 500 °F, and often reach

temperatures in excess of 1,000 °F. If catalyst

temperatures are not in excess of 500 °F, refer to the

Catalyst Troubleshooting section of this owner’s

manual.

-You can get an indication of whether the catalysts

are working by comparing the amount of smoke

leaving the chimney when the smoke is going through

the combustor and catalysts light-off has been

achieved, to the amount of smoke leaving the

chimney when the smoke is not routed through the

combustor (bypass mode).

1. Light stove in accordance with operator’s

instructions

2. With smoke routed through the catalysts, go

outside and observe the emissions leaving the

chimney.

3. Engage the bypass mechanism and again

observe the emissions leaving the chimney.

Significantly more smoke will be seen when the

exhaust is not routed through the combustor

(bypass mode)

INSPECTING THE CATALYSTS AND

REMOVING/REPLACING THE BAFFLE

1. Allow the stove and ashes to fully cool.

2. Remove the metal baffle protector by sliding it

to the left or right, and then rotating it towards

you.

3. Lift up on the right side baffle, and gently pull

the left side baffle down and out of the stove

CAUTION - Do not force the baffle pieces. Gently

adjust the baffle orientation until each side can

be removed freely from the stove.

Figure 19 - Removing/Replacing the Baffle for

Inspection

4. Use a small vacuum nozzle or soft bristled

brush to remove any accumulated ash or

soot on the face of the catalyst.

5. Inspect the catalyst for any unusual warping,

corrosion, or plugged openings.

Figure 18 - Removing/Replacing the Baffle for Inspection

Hearthstone Quality Home Heating Products, Inc ® Green Mountain 40 (Model 8640)

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Figure 19 – Catalyst Access Door

4. Use a small vacuum nozzle or soft bristled

brush to remove any accumulated ash or

stoot on the face of the catalysts.

5. Inspect the catalysts for any unusual

warping, corrosion, or plugged openings.

6. If any unusual conditions are found, remove

the catalyst blocks – See replacing the

catalysts.

7. Replace the baffles and baffle protector.

Installation is the opposite of removal.

8. Ensure that the baffle pieces are pushed

together at the center joint.

REMOVING OR REPLACING THE CATALYSTS

Refer to the Catalytic combustor warranty on page

35 for catalyst replacement information. DO NOT

OPERATE UNIT WHITOUT CATALYSTS. Only

remove the catalysts if required. In general, the less

you handle the catalysts, the better. If any unusual

conditions are found, remove the catalyst blocks

1. Allow the stove and ashes to fully cool.

2. Loosen, but do not remove the screws

securing the rear heatshield. (If stove is so

equipped).

3. Remove the heat shield by sliding the screw

heads through the slots in the heatshield.

4. Remove the 2 bolts securing the cast iron

catalyst access cover, and remove the cover.

5. Inspect the catalysts for visible damage or fly

ash. If fly ash exists, gently brush the

catalysts off with a narrow soft-bristle brush,

or vacuum with a crevice tool.

6. If fly ash exists, or if there are suspected

catalyst performance issues, fully remove the

catalysts by gently pulling upwards from the

ribs in the cast iron, and then pulling

outwards through the catalyst access

opening.

7. Remove any remaining gasket material from

the opening and from the catalysts.

8. Inspect the catalysts for any fly ash or

clogging, and remove with a soft bristled

brush or vacuum crevice tool. If extra

cleaning is needed, follow the guidelines

below:

-You may use compressed air under 35

psi, air only, no chemicals.

-You may soak the catalysts in a hot water

mix (not boiling), 4 parts water, 1 part

vinegar. Rinse with cold water until

vinegar smell is mostly gone.

-No metal tools such as gun cleaners

should be used.

-No detergents or chemicals.

Figure 18 (cont.) - Removing/Replacing the Baffle for Inspection

Hearthstone Quality Home Heating Products, Inc ® Green Mountain 40 (Model 8640)

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9. Some warping or bowing of the catalysts over

time is acceptable, as long as the catalyst

gasket continues to seal. Measure the

catalysts in the middle section – if the

dimensions are outside the range shown in

Figure 19, replace the catalysts.

10. Depending on the generation of your stove,

re-gasketing the catalyst may not be

necessary. If there was gasket material on

the catalyst when you removed them, they

will need to be re-gasketed during the

installation. Beginning at one corner, re-install

fiberglass gasket material on the catalysts.

11. Beginning at one corner, re-install fiberglass

gasket material on the catalysts.

12. Wrap the gasket tape around the catalysts so it is

reasonably tight. Double layer the material on

three sides of the individual catalyst cartridges as

shown in the following picture.

13. Once the gasket is installed on the catalysts,

gently push the catalysts into the catalyst

opening until the catalysts hit against the

back wall of the cavity. Take care to ensure

the gasket is not damaged and position the

two cartridges so that the single layer gasket

edges touch one another in the center.

14. Replace catalyst access door.

15. Heat the stove slowly during your next fire to

allow the gasket to fully expand and seal the

catalysts.

Figure 20 - Acceptable Catalytic Distortion

Hearthstone Quality Home Heating Products, Inc ® Green Mountain 40 (Model 8640)

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REPLACING THE REFRACTORY STONE AND

SECONDARY RISER ASSEMBLY

1. Allow the stove and ashes to fully cool.

2. Open the front door of the stove and fully

clean any ash in the firebox

3. Remove the baffle following the instructions

in “Inspecting the Catalysts and

Removing/Replacing the baffle.

4. Remove the side stones one at a time by

tipping them towards the inside of the

firebox from the top.

5. With side stones and baffle removed, the

secondary riser assembly and rear stones

can be lifted up and out of the stove.

6. Installation is the reverse of disassembly.

Make sure that the secondary riser tube is

seated in the pocket at the rear of the

bottom casting.

GLASS REPLACEMENT PROCEDURES

 WARNING: DO NOT OPERATE THIS APPLIANCE

WITH THE GLASS PANEL REMOVED, CRACKED,

OR BROKEN. DO NOT SUBJECT THE DOOR TO

ABUSE, SUCH AS STRIKING OR SLAMMING SHUT.

ONLY A QUALIFIED SERVICE PERSON SHOULD

REPLACE THE GLASS PANEL.

1. Follow the instructions included with the

replacement glass kit.

2. Remove the door.

3. Remove the screws from the glass clips (use

penetrating oil if necessary) – Set aside for

reinstallation.

4. Carefully lift the damaged glass off the door and

discard.

5. Remove any remaining glass and old gasket

material.

6. Clean the screw holes and place a small amount

of anti-seize compound in each one.

7. Install a new glass gasket in the glass gasket

groove.

8. Place the new glass onto the door.

9. Important! Center the glass and ensure that the

edges of the glass are parallel with the edges of

the opening.

10. Check glass position again (centered, and

parallel), then screw the glass retainer clips with

the glass pads back on the door using a

crisscross pattern. Tighten the screws no more

than 1/8

th

of a turn after they seat. The glass will

break at this point if not positioned correctly.

11. Apply a light film of anti-seize lubricant on the

door’s hinge pins if needed.

12. Install the door.

13. After 5 or 6 fires, check the glass retainer

screws, and retighten if necessary.

Required Glass Kit: Part Number: 96-58405. Use

only 4mm x 329mm x 395mm Ceramic, or

Neoceram glass. Contact your Hearthstone dealer.

Figure 21 - Removing Riser and Rear Stones

Hearthstone Quality Home Heating Products, Inc ® Green Mountain 40 (Model 8640)

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CREOSOTE FORMATION & REMOVAL

When wood burns slowly at low temperatures, it may

produce tar and other organic vapors, which

combine with expelled moisture to form creosote.

These creosote vapors condense in the relatively

cool chimney flue of a slow-burning fire. As a result,

creosote residue accumulates on the flue lining.

When ignited, this creosote makes an extremely hot

fire, which may damage the chimney or even destroy

the house. When burning wood, inspect the chimney

connector and chimney at least once every two

months during the heating season to determine if

there is a creosote buildup.

If a creosote build-up occurs, inspect the stovepipe

connector and chimney more often, at least monthly

during the heating season to monitor the

accumulation. If a creosote residue greater that 1/4"

(6 mm) accumulates, remove it to reduce the risk of a

chimney fire.

PREVENTION

Burn the stove with the primary air control fully open

for 35 - 45 minutes daily to burn out creosote deposits

from within the stove and the venting system.

After reloading with wood, burn the stove with the

primary air control fully open for 15 to 20 minutes.

This manner of operation ensures early engagement

of the secondary combustion system that minimizes

creosote buildup in the chimney.

If your glass always remains dirty, your operating

temperatures are too low or your wood is wet;

therefore, there is a higher risk of creosote buildup.

Inspect the venting system at the stove connection

and at the chimney top. Cooler surfaces tend to build

creosote deposits faster, so it is important to check

the chimney at the top (where it is coolest) as well as

from the bottom near the stove.

CLEANING

Remove accumulated creosote with a cleaning brush

specifically designed for the type of chimney in use.

We recommend you use a certified chimney sweep to

perform this service. Contact your dealer for the name

of a certified chimney sweep in your area (your dealer

may be a certified sweep!).

We recommend that before each heating season you

have the entire system professionally inspected,

cleaned and repaired, if necessary.

Figure 22 - Front Door Assembly

Hearthstone Quality Home Heating Products, Inc ® Green Mountain 40 (Model 8640)

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GASKETS

Replace door gasket material every two to three

seasons, or whenever it becomes deteriorated or

loose, depending on stove use. If the door seal leaks,

a new gasket will ensure a tight seal and improve

stove performance.

We recommend you only use Hearthstone

replacement gaskets when you need to replace your

door gasket. Contact your dealer for a gasket kit that

includes instructions, and the gasket for your stove.

GLASS

The glass used in our stoves is actually not plain

glass, but a tough, clear ceramic material capable of

operating at temperatures up to 2300° F. Do not

operate the stove with a broken door glass. Do not

abuse the front door by striking or slamming.

When necessary, clean the glass. For the inside

surface of the glass, we recommend using a damp

paper towel dipped in gray ash. Rub the inside of the

glass with a circular motion. When all the deposits are

removed, clean up with window cleaner or with

commercial stove glass cleaners, which are available

from your local dealer. Use this type of cleaner for the

outside surface as well. Never attempt to clean the

glass while the fire is burning or while the glass is hot.

Remove deposits by following the instructions

provided with the cleaner. Wipe the cleaner off with a

soft cloth, or black & white newsprint.

Important: scratching or etching the glass will

weaken the integrity of the glass. Do not use a

razor blade, steel wool, or any other abrasive

material to clean the glass. Use a cleaner

specifically manufactured for woodstoves only.

The front door glass is a ceramic, thermal shock-

resistant glass, made specifically for use in

woodstoves. Do not use any replacement glass other

than the ceramic glass manufactured and supplied for

use in this woodstove. Replacement glass is available

through your local dealer.

Replace the door glass immediately if broken or

chipped. Contact your local dealer for replacement

glass. The glass kit includes instructions and

everything needed for the repair. If you replace the

glass yourself, wear work gloves and safety glasses.

Required Glass Kit: PN: 96-58405.

Hearthstone Quality Home Heating Products, Inc ® Green Mountain 40 (Model 8640)

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TROUBLESHOOTING

COMMON ISSUES

Virtually all woodstove operators experience basic

common problems at one time or another. Most are

correctable and generally require only a minor

adjustment of the stove, installation, or operating

technique. In cases where weather conditions

dramatically affect stove performance, the problems

are typically temporary and solve themselves once

the weather changes.

If you question whether your stove is producing

adequate heat, the best way to troubleshoot the

problem is to monitor the temperature of the stack no

more than 12 inches (30 cm) above the flue collar. A

400° F (200° C) stovepipe confirms the stove is

supplying sufficient heat. Keep in mind that your

house itself will regulate room/house temperatures.

How well the walls, floors and ceilings are insulated,

the number and size of windows, the tightness of

outside doors, and the construction or style of your

house (vaulted ceilings or other open spaces which

collect large percentages of heat, ceiling fans, etc.) all

are determining factors of room temperature.

Your stove's performance is also dependent on its

installation. One common cause of poor performance

is an oversized chimney flue. Oversized chimney

flues result in decreased draft, which prevents the

smoke from rising out the chimney. Oversized flues

are also more difficult to heat effectively, especially

when burning a high efficiency stove. Cool flue

temperatures inhibit the establishment of a strong

draft (and encourage the accumulation of creosote).

The lack of a strong draft will cause the fire to die

down and may even force smoke to pour into the

room.

If your chimney is the proper size and a strong draft

is not easily established, there is the possibility that

the chimney is too cold. Again, hot chimneys promote

stronger drafts. Opening a window briefly in the room

while lighting the stove may help.

Other draft guidelines are as follows:

An "AIRTIGHT" HOUSE: The air supply (infiltration)

to the interior of the house may be inadequate if your

home is super-insulated or especially well sealed.

This phenomenon of air starvation within the

building is exacerbated if exhaust fans, such as

clothes dryers, bathroom fans or cook stove exhaust

fans, are in operation within the home. Outfitting your

stove with the optional outside air adaptor connected

to an air duct, which leads to the outside of the

building, can correct this problem.

Tall Trees or Buildings: These obstructions, when

located close to the top of the chimney can cause

chronic or occasional downdrafts. When selecting a

site for a new chimney, consider the placement of

other objects near the proposed chimney location.

Wind Velocity: Generally, the stronger and steadier

a wind, the stronger (better) the draft. However,

"gusty" wind conditions can cause erratic downdrafts.

For consistent problems, consider a high wind cap,

such as the Vacu-Stack.

Barometric Pressure: Chimney drafts are typically

sluggish on balmy, wet or muggy days (low

barometric pressure). This is a weather-related

phenomenon, which generally is self-correcting as

the weather changes.

Briskness of Fire: The hotter the fire in your stove,

the hotter your chimney and, therefore, the stronger

the draft.

Breaks in the Venting System: An unsealed clean-

out door at the bottom of the chimney, leaky stovepipe

joints, a poor stovepipe-to-thimble connection,

missing caps, or a leaky chimney all can cause

inadequate draft.

Seasonal Factors: Early fall and late spring are

generally difficult seasons in which to establish proper

drafts. The colder the outside air is relative to room

temperature, the stronger the draft.

OPERATING THE STOVE

As outlined above, there are days when a good draft

is just not easy to establish. The causes are usually

seasonal factors or a cold chimney. Try starting the

fire by using small kindling and fuel to obtain a quick,

hot fire. Tend the fire frequently with small fuel until

the chimney is hot and the draft is well established.

Sometimes, partially opening a first floor window

briefly will help quickly get draft established.

Hearthstone Quality Home Heating Products, Inc ® Green Mountain 40 (Model 8640)

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TROUBLESHOOTING GUIDE

PROBLEM POSSIBLE CAUSE SOLUTIONS

STOVE

SMOKES

Operating Technique Fully open the primary air control one minute before opening

doors, and ensure the bypass is open before opening door.

Cold Chimney or reverse

draft

Preheat the chimney when first starting a fire. Briefly open a

window in the room containing the stove.

Blocked Chimney Examine the chimney and stovepipe for blockage or creosote

accumulations.

Oversized Chimney Reline the chimney to the appropriate diameter

Undersized Chimney Install a draft inducer or replace the chimney.

Chimney Too Short Lengthen the chimney.

Air Infiltration Into The

Chimney

Seal chimney connections and openings. Check clean-out

doors.

Bypass not closed Ensure that the bypass door is closed when the catalysts are in

the active range.

Catalysts not functioning Inspect catalysts for damage, ash build-up, or plugging. Brush

catalysts with a soft-bristled brush, or vacuum lightly. Replace if

required. Follow instructions to ensure catalyst light-off.

Not burning proper fuel Ensure cordwood is seasoned and dry.

More Than One

Appliance Connected to

the Flue

Disconnect all other appliances and seal openings.

BACK-PUFFING

OR GAS

EXPLOSIONS

Operating Technique Fully open the primary air control one minute before opening the

door and keep it fully open for a few minutes after reloading.

Ensure the bypass door is open before opening the door

Extra Low Burn Rate Burn the stove at a higher burn rate.

Chimney Down-draft Install a chimney cap.

Excessive Ash Build-up Empty the ash pan more frequently. Increase efficiency of

burns, and avoid using poor quality or green wood.

UNCONTROLL-

ED OR SHORT

BURN

Unsealed or Open Door

Close the door tightly or replace the gaskets.

Air leakage around glass gasket – replace gasket

Excessive Draft Check the installation. Operate at LOW BURN. Install stovepipe

damper. Draft in excess of 0.1 wc should be corrected with a

stovepipe damper(s)

Extra Long Chimney Shorten the chimney. Install stovepipe damper(s).

Oversized Chimney Reline the chimney to the proper diameter.

High Winds or Hilltop

Location:

Install a chimney cap.

INSUFFICIENT

HEAT

Poor Quality, low Btu

content, or Green Wood

Use only air-dried wood, preferably dried at least one year. Use

a wood with a high Btu content if available.

Low Burn Rate Operate the stove at a higher burn rate.

Cold Exterior Chimney Reline or insulate the chimney.

Leaky Stovepipe or

Chimney

Check the installation. Replace with a pre-fabricated insulated

chimney system or a properly sized masonry chimney.

Too Much Heat Loss

From House

Add insulation, use energy efficient windows, or caulk windows,

and seal openings in home.

Excessive Ash Build-up Empty the ash pan more frequently. Increase efficiency of

burns, and avoid using poor quality or green wood.

BLISTERING

OF FINISH

Operating Technique Do not over-fire the stove. Monitor stove temperatures. Use

seasoned wood only.

Excessive Draft Check the DRAFT. A damper may be required. Operate the

stove at a LOW BURN range.

Hearthstone Quality Home Heating Products, Inc ® Green Mountain 40 (Model 8640)

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ADDITIONAL CATALYST TROUBLESHOOTING GUIDE

PROBLEM POSSIBLE CAUSE SOLUTIONS

FLY ASH BUILD

UP ON

CATALYSTS

Catalysts have not

maintained light-off

temperature

Brush cold combustor with soft-bristled brush or vacuum lightly.

Follow instructions in the manual for a proper catalyst light-off

Burning materials that

cause a lot of char and

fly-ash

Don’t burn cardboard, gift wrap paper, or garbage. Burn only

dry, seasoned wood, per the owner’s manual.

Bypass closed too soon Follow instructions in the manual for a proper catalyst light-off

CATALYSTS

PLUGGING OR

MASKING

(SOOT/CRESO-

TE)

Burning wet, pitchy

woods, or burning large

loads of small diameter

wood with the combustor

in the operating position

without catalyst light off

occurring

Burn dry seasoned wood. Follow instructions in the manual for a

proper catalyst light-off, and ensure catalyst light-off as occurred

before closing bypass damper. It may be possible to burn the

soot or creosote off by building a hot fire, and allowing the stove

to run until the catalysts are well within the operating range

before closing the bypass. Continue to run the stove at a high

temperature for one hour, while ensuring the catalysts stay in

the upper operating range, but not too hot.

WARPING OR

BOWING OF

THE

CATALYSTS

Excessive catalyst

temperatures for long

periods of time.

Ensure that the catalysts remain in the operating zone, and

does not get to hot. Reduce air control settings for a lower burn

rate to ensure catalyst temperatures do not exceed the

operating range.

Hearthstone Quality Home Heating Products, Inc ® Green Mountain 40 (Model 8640)

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REPLACEMENT PARTS & OPTIONAL ACCESSORIES

Refer to the Illustrated Parts list for further detail about stove components, available online at

www.hearthstonestoves.com.

PART #

DESCRIPTION

REPLACEMENT PARTS

5640-002 BOTTOM HEAT SHIELD

5640-008 HINGE PIN

5640-009 HINGE BLOCK

5640-010 SECONDARY AIR RISER ASSEMBLY

5640-012 TIE ROD

5640-014 BAFFLE GUARD

5640-018 BYPASS ROD RETAINER

5640-020 LATCH STRIKER PLATE

5640-022 DOOR LATCH

5640-024 REAR SHIELD (INCLUDED)

7200-520 CATALYST THERMOMETER

REPLACEMENT KITS AND ACCESSORIES

96-53400 OUTSIDE AIR KIT

96-58400 GASKET KIT

96-58405 GLASS KIT

96-71400 HANDLE KIT

96-73400 FRONT DOOR LATCH KIT

96-75400 CATALYST REPLACEMENT KIT

96-76400 BAFFLE KIT

96-57400 BLOWER KIT

Hearthstone Quality Home Heating Products, Inc ® Green Mountain 40 (Model 8640)

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SAFETY LABEL

Hearthstone Quality Home Heating Products, Inc ® Green Mountain 40 (Model 8640)

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LIMITED WARRANTY

These warranties give you specific legal rights. You may also have other rights, which vary from State to

State.

Hearthstone Quality Home Heating Products, Inc. (Hearthstone) warrants to the original retail purchaser only (the

“Original Purchaser”) the new appliance manufactured by Hearthstone, purchased by the Original Purchaser and

installed by an authorized Hearthstone dealer or their designated representative against any of the occurrences

listed in this document that result from defects in material or workmanship. This warranty is not transferrable. All

obligations of Hearthstone under this document commence on the date of the Original Invoice (the “Purchase

Date”). The term “Limited Lifetime” is defined as 10 years from the beginning of warranty coverage.

Hearthstone appliances are designed to be operated only with the fuels listed in your owner’s manual.

Catalytic combustor LIMITED LIFETIME WARRANTY: The catalytic combustors are covered directly by the

combustor manufacturer, Applied Ceramics. Included with your stove you will find the LIMITED LIFETIME

WARRANTY for the catalysts, as well as a warranty card.

Catalyst Model Number: ACI-6M2 Catalyst Manufacturer: APPLIED CERAMICS

APPLIED CERAMICS warrants to the consumer who purchases a FIRECAT STEEL COMBUSTOR as a

component in an EPA certified solid fuel appliance, to replace at no charge to the consumer the FIRECAT STEEL

COMBUSTOR that ceases to function with two (2) years from the date of purchase by the original consumer,

provided that the following conditions are met:

(1) A copy of the original bill of sale that includes place and date of purchase must be submitted with the

warranty claim.

(2) The original FIRECAT STEEL COMBUSTOR must be returned to APPLIED CERAMICS

(3) The FIRECAT STEEL COMBUSTOR must not have been mechanically abused, nor must the wrong

fuels have been used in the appliance.

If after two years the FIRECAT STEEL COMBUSTOR fails to function, the prorated warranty will allow

replacement at the following special price schedule:

Year 3 $130.00

Year 4 $140.00

Year 5 $150.00

Year 6 $160.00

Year 7 and after at current retail price

Conditions 1, 2, and 3 also apply to the Prorated portion of the warranty. Any EPA certified solid fuel appliance

will receive one replacement catalyst for each defective catalyst returned during the three year period. The

consumer will be responsible for any removal, any servicing, and return of any items required for filing the warranty

claim. This warranty is APPLIED CERAMIC’S exclusive warranty, and APPLIED CERAMICS, disclaims any other

express or implied warranty for the FIRECAT STEEL COMBUSTOR, including any warranty or merchantability

fitness for a particular use.

Ensure the catalyst is well wrapped and padded for shipment in bubble wrap, or similar material. Ship the catalyst

with padding inside of a cardboard box.

All warranty claims must include $12.50 for postage and handling within the continental U.S. Alaska and Canada

claims must include $35.00.

Hearthstone Quality Home Heating Products, Inc ® Green Mountain 40 (Model 8640)

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Please allow 2-3 weeks for delivery. Order online @ www.firecatcombustors.com

Please read and understand the full warranty. Please return the completed warranty card promptly to Applied

Ceramics. The warranty card, and any warranty claims can be shipped to:

Applied Ceramics

55555 Pleasantdale Road

Doraville, GA, 30340

Stove components Limited Warranty

Warranty

Period

Wood Gas Pellet Covered Components

Limited Lifetime

X X X Stone

X X X Cast iron not listed elsewhere

X Clean burning air supply system*

5 Year X X X Door handles and latches

X X X Steel Components and Firebox

X Burner and logs

3 Year X Burn Pot and Baffles

2 Year X X X Appliance Electrical and Gas

Components

X X Refractory, Vermiculite Panels, Baffles

1 Year X X X Enamel finish against peeling or fading

X X X Accessories

X X X Glass

X Ash Grate

X X X All components not listed elsewhere

Any parts repaired or replaced during the limited warranty period will be warranted under the terms of the limited

warranty for a period not to exceed the remaining term of the original limited warranty or one year, whichever is

longer.

Parts: Hearthstone will replace through an authorized dealer, defective parts covered by the foregoing warranty

at no charge.

Labor: Within the first (1st) year after the Purchase Date, Hearthstone will pay for warranty labor performed by an

authorized Dealer at Hearthstone’s published labor rates in effect at the time the labor is performed only if the

appliance is installed by an authorized dealer or their designated representative. Otherwise or thereafter, the

Original Purchaser is responsible for the cost of labor.

Shipping cost for parts: Within the first ninety (90) days after the Purchase Date, Hearthstone will pay for the

shipping of appliance parts covered by any of the foregoing warranties to and from Hearthstone or an authorized

Dealer, as the case may be. Thereafter, the Original Purchaser is responsible for all shipping costs related to

shipping appliance parts to and from Hearthstone or an authorized Dealer, as the case may be.

Shipping cost for the appliance: Within the first (1st) year after the Purchase Date, if the Original Purchaser is

instructed to return the appliance to Hearthstone or an authorized Dealer for repair, Hearthstone will pay fifty

percent (50%) and the Original Purchaser will pay fifty percent (50%) of the shipping costs related to shipping the

appliance to and from Hearthstone or an authorized Dealer, as the case may be. Thereafter, the Original

Purchaser is responsible for one hundred percent (100%) of all of the shipping costs related to shipping the

appliance to and from Hearthstone or an authorized Dealer, as the case may be. Notwithstanding any other

provision of this document, in no event will Hearthstone pay for any Dealer fees or other fees for pick up or delivery

of the appliance returned for repair; the Original Purchaser shall be responsible for any such fees.

EXCLUSIONS & CONDITIONS

The warranties contained in this document do not cover, nor is Hearthstone responsible for:

Hearthstone Quality Home Heating Products, Inc ® Green Mountain 40 (Model 8640)

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1. Damages resulting from:

a. Failure to install, operate, or maintain the appliance in accordance with the owner’s manual, operating

instructions, installation instructions, or safety rating label provided with the appliance.

b. Over-firing the appliance. Over-firing can be identified by, but not limited to, warped cast iron or steel,

rust colored cast iron, bubbling, cracking and discoloration of steel or enamel finishes.

c. Failure to install the appliance in accordance with all national or local building codes.

d. Shipping or improper handling.

e. Improper operation, abuse, misuse, continued operation with damaged, corroded, or failed components,

accident, or improper/incorrect service or repairs.

f. Environmental conditions, inadequate ventilation, negative pressure, or improper drafting caused by

tightly sealed constructions, insufficient make-up air supply, or air handling devices such as exhaust

fans, forced air furnaces, or other such causes.

g. Damage caused by direct exposure to water.

h. Use of fuels other than those specified in the owner’s manual.

I. Installation or use of components not supplied with the appliance, or any other components not

expressly authorized and approved by Hearthstone.

J. Modifications of the appliance not expressly authorized and approved by Hearthstone in writing

K. Interruptions or fluctuations of electrical power supplied to the appliance.

2. All stones are warranted against cracking or breakage due to thermal stress, excluding surface and hairline

cracks and scratches that do not affect the operation, or safety of the appliance.

3. Repair or replacement of wear parts. Such parts that are subject to normal wear and tear during the

warranty period such as paint, gaskets, baffles, refractory materials, ash grates, and glass.

4. Damage resulting from installation, modification, alteration, repair or service of the appliance by any party

other than an authorized Hearthstone dealer (a “Dealer”) or their designated representative, or Hearthstone.

5. Damage due to water or condensation due to installation of the appliance in a high moisture area.

6. Damage due to installation of the appliance in an atmosphere contaminated by damaging chemicals,

including but not limited to chlorine, fluorine or salts.

7. Scratches on glass, enameled surfaces or stones due to mechanical abrasion.

8. Noise caused by expansion or contraction caused by the heating and cooling of the appliance.

9. Odors caused by the heating of the appliance, or surrounding materials

10. Consequential damage caused by leaking of condensate during startup

11. A defect in any part of the appliance if the Original Purchaser fails to comply with Hearthstone’s or a

Dealer’s request to ship the part or the appliance to Hearthstone or a Dealer, as the case may be.

12. Replacement stones and enameled parts are taken from current stock, and may not match originals in color,

grain, or pattern. Hearthstone will supply replacement parts for discontinued parts in finishes or colors as

available, or at their discretion.

13. Hearthstone’s obligation under this warranty does not extend to the appliance’s ability to heat the desired

space. Information is provided to assist the customer and the dealer in selecting the appropriate appliance

for the application. Consideration must be given to appliance location and configuration, environmental

conditions, insulation and air tightness of the structure.

THE WARRANTIES CONTAINED IN THIS DOCUMENT ARE EXCLUSIVE AND ARE GIVEN BY

HEARTHSTONE AND ACCEPTED BY THE ORIGINAL PURCHASER IN LIEU OF ALL OTHER EXPRESS

WARRANTIES AND ANY OBLIGATIONS, LIABILITIES, RIGHTS, CLAIMS, OR REMEDIES IN CONTRACT OR

TORT, WHETHER OR NOT ARISING FROM HEARTHSTONE’S NEGLIGENCE, ACTUAL OR IMPUTED. ALL

IMPLIED WARRANTIES, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A

PARTICULAR PURPOSE, ARE GIVEN ONLY TO THE EXTENT REQUIRED BY FEDERAL OR STATE LAW.

EXCEPT AS OTHERWISE REQUIRED BY STATE LAW, UPON THE EXPIRATION OF THE EXPRESS LIMITED

WARRANTIES CONTAINED HEREIN, NO IMPLIED WARRANTIES, INCLUDING THE IMPLIED WARRANTIES

OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, SHALL APPLY TO THE SUBJECT

APPLIANCE. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY

LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU.

THE WARRANTIES CONTAINED IN THIS DOCUMENT EXTEND ONLY TO THE ORIGINAL PURCHASER OF

THE APPLIANCE WARRANTED HEREUNDER. THEY ARE NOT TRANSFERRABLE AND DO NOT EXTEND

TO ANY SUBSEQUENT OWNERS.

Hearthstone Quality Home Heating Products, Inc ® Green Mountain 40 (Model 8640)

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UNDER NO CIRCUMSTANCES SHALL HEARTHSTONE BE LIABLE TO THE ORIGINAL PURCHASER OR

ANY OTHER PERSON FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, INCLUDING BUT NOT

LIMITED TO DAMAGE TO PROPERTY OR PERSONAL INJURIES, WHETHER ARISING OUT OF LOSS OF

USE, BREACH OF WARRANTY, TORT, OR OTHERWISE, EVEN IF HEARTHSTONE HAS BEEN APPRAISED

OF THE POSSIBILITY OF SUCH DAMAGES. SOME STATES DO NOT ALLOW THE EXCLUSION OR

LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION OR

EXCLUSION MAY NOT APPLY TO YOU.

QUALIFYING FOR WARRANTY COVERAGE

To obtain performance of any obligation under this document, the Original Purchaser must, within the applicable

warranty time period, contact their original Hearthstone dealer, or the current responsible local Hearthstone dealer,

for instructions regarding the return of defective parts for repair, the return of the appliance for repair, or to

schedule a Dealer service call. The Original Purchaser should refer to the Dealer Network search engine

contained on Hearthstone’s Web site (www.hearthstonestoves.com) if the original dealer is not available, to find

a Hearthstone dealer nearest to the Original Purchaser’s location.

REMEDY

The remedy for any breach of the foregoing warranties will consist of repair or replacement, at Hearthstone’s

option, of any covered defect in the appliance. When the Original Purchaser contacts a Hearthstone Dealer, the

Dealer on behalf of Hearthstone, as the case may be, will instruct the Original Purchaser to either return the

defective part, or the entire appliance (if requested), to the Dealer or Hearthstone or allow a Dealer to make a

service call at the place where the appliance is located. Hearthstone may require that a digital picture be provided

to support the claim. Notwithstanding any other provision of this document, the Original Purchaser shall pay for

any fees and service charges related to a Dealer’s service call or the shipping charges associated with the return.

WARRANTY REGISTRATION

The Original Purchaser can complete their warranty registration on our website at www.hearthstonestoves.com,

or send a completed and signed Warranty Registration Form, which is enclosed in the appliance document packet,

to the following address:

Hearthstone Quality Home Heating Products, Inc.

Warranty Department

317 Stafford Avenue

Morrisville, VT 05661

NOTE: SENDING IN THE SIGNED WARRANTY REGISTRATION FORM IS NOT REQUIRED AS A CONDITION OF

WARRANTY COVERAGE OR HEARTHSTONE’S PERFORMANCE.