FMI CCAT36 Series Owner's Operation And Installation Manual

CATALYTIC FIREPLACE OWNER’S

PFS

USC

OPERATION AND INSTALLATION MANUAL

®

FMI CATALYTIC FIREPLACE CCAT36 SERIES

36" WOOD BURNING FIREPLACE

These models meet the EPA Wood Burning Fireplace
Program Phase 2 emission level. NOTE: To ensure proper

replace operation, the catalyst should be replaced at a
minimum of 3 years and a maximum of 5 years.

SAVE THIS BOOK

This book is valuable. In addition to instructing you
on how to install and maintain your appliance, it also
contains information that will enable you to obtain re­placement parts or accessory items when needed. Keep
it with your other important papers.

This replace is approved for use as a wood burning re-

place or for use with a vented gas log approved to ANS
Z21.60 and Z21.84 standards or for use with a vent-free gas
log heater approved to ANS Z21.11.2 standard. A FMI PROD-

UCTS, LLC hood must be installed when using a vent-free
log heater (see Accessories, page 21).

This wood burning replace complies with UL127­CAN/ULC-S610-M87 standard as a FACTORY BUILT
APPLIANCE.

FOR CANADA: The authority having jurisdiction (such
as the municipal building department, re department,
etc.) should be contacted before installation to deter­mine the need to obtain a permit.

INSTALLER: Leave this manual with the appliance.

CONSUMER: Retain this manual for future reference.

For more information, visit www.fmiproducts.com

Safety .................................................................. 2

TABLE OF CONTENTS

Specications ...................................................... 3

Fireplace Installation............................................ 4

Venting Installation .............................................. 6

PureFire Installation........................................... 13

Optional Gas Line Installation............................ 13

Operation and Maintenance .............................. 14

SAFETY

HearthCAT™Emissions Control System ........... 16

Parts .................................................................. 18

Replacement Parts ............................................ 20

Technical Service............................................... 20

Accessories ....................................................... 21

Notes ................................................................. 23

WARNING: Improper instal-

lation, adjustment, alteration,

service or maintenance can

cause injury, property damage or

loss of life. Refer to this manual
for assistance or additional in-

formation. Consult a qualied
installer or local distributor.

IMPORTANT: Check local codes
before installing this replace.

Before beginning installation of this replace,
read these instructions through completely.

• This FMI PRODUCTS, LLC replace and
its components are safe when installed
according to this installation manual.
Unless you use FMI PRODUCTS, LLC
components, which have been designed
and tested for the replace system, you
may cause a re hazard.

• The FMI PRODUCTS, LLC warranty will
be voided by and FMI PRODUCTS, LLC
disclaims any responsibility for the following
actions.

a. Modification of the fireplace, com-

ponents, doors, air inlet system and
damper control.

b. Use of any component part not manufac-

tured or approved by FMI PRODUCTS,
LLC in combination with a FMI PROD-

UCTS, LLC replace system.
Proper installation is the most important step
in ensuring safe and continuous operation of
replace. Consult the local building codes as
to the particular requirements concerned with
the installation of all factory built replaces.

WARNING: Do not install a

replace insert in this box unless

the manufacturer's instructions

with the insert specically state
this replace has been tested for

use with this insert.

FOR YOUR SAFETY

• Do not store or use gasoline
or any other ammable vapors
or liquids in the vicinity of this
or any other appliance.

• Due to high temperatures, the
appliance should be located
out of trafc and away from

furniture and draperies.

• Do not place clothing or other
ammable materials on or near

the appliance.

• Never leave children unat­tended when a re is burning
in the replace.

WARNING: Use solid wood

or processed solid fuel re logs
only. When processed wood
fuel re logs are used, do not
poke or stir the logs while they
are burning. Use only re logs
that have been evaluated for
the application in replace and
refer to re log warnings and
caution markings on packaging

prior to use.

This replace is not intended to
be used as a substitute for a fur-

nace to heat an entire home. Use

for supplemental heat only.

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125183-01B2

SPECIFICATIONS

GAS LINE

0" TO

TOP

SPACERS

0.75"
AIR
SPACE
BACK
AND
SIDES

OUTSIDE
AIR (LEFT
SIDE ONLY)

0" TO
BOTTOM

21"

1" AIRSPACE
TO COMBUSTIBLE
MATERIAL

HEARTH

EXTENSION
8" EACH
SIDE

52" X 16"

29"

ELECTRICAL
OUTLET

NO COMBUSTIBLE
MATERIAL ON FACE

8.717"

11.217"

COMBUSTIBLE
WALL BOARD

11.435"

NOT LESS
THAN 12" TO
PERPENDICULAR
SIDEWALL

12.5"

RIGHT SIDE

7.092"

LEFT SIDE

8.717"

14.437"

22"

KNOCK
OUTS

9.125"

3.5"

AIR KIT
KNOCK OUT

GAS LINE
KNOCK
OUTS

9.125"

3.5"

14.25"

32.5"

ROUND TOP TERMINATION

SQUARE CHASE-TOP

TERMINATION

41.250"

0.625"

37"

41"

1"

21"

33.813"

8"

35"

1"

125183-01B 3

41"

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2.313"

FIREPLACE INSTALLATION

SELECTING LOCATION

To determine safest and most efcient location
for replace, you must take into consideration
the following guidelines:

1. Location must allow for proper clearances
(see Figures 1 and 2).

2. Consider a location where replace will
not be affected by drafts, air conditioning
ducts, windows or doors.

3. A location that avoids cutting of joists or
roof rafters will make installation easier.

4. An outside air kit is available with this
replace (see Optional Outside Air Kit on
page 7).

MINIMUM CLEARANCE TO
COMBUSTIBLES

Back and sides of replace 3/4" minimum*
Floor** 0" minimum
Perpendicular wall to opening 14" minimum
Top spacers 0" minimum
Mantel clearances see Mantels, page 6
Chimney outer pipe surface 1" minimum

* Not required at nailing anges
** See step 2 of Framing

WARNING: Do not pack re­quired air spaces with insulation
or other materials.

Minimum/Maximum Chimney Height

Minimum height of chimney, measured from
base of replace to ue gas outlet of termina­tion, is 14.5 feet for straight ue or a ue with
one elbow set. Maximum distance between
elbows is 2 feet. For systems with two elbow
sets, minimum height is 22 feet. Maximum
height of any system is 50 feet. This measure­ment includes replace, chimney sections and
height of termination assembly at level of ue
gas outlet (see Figure 19, page 12).

FRAMING

1. Frame opening for replace using dimen­sions shown in Figures 1 and 2.

2. If replace is to be installed directly on
carpeting, tile (other than ceramic) or any
combustible material other than wood
ooring, replace must be installed upon
a metal or wood panel extending full width
and depth of replace.

3. Set replace directly in front of this open­ing and slide unit back until nailing anges
touch side framing.

4. Check level of replace and shim with
sheet metal if necessary.

5. Before securing fireplace to prepared
framing, ember protector must be placed
between hearth extension (not included)
and under bottom front edge of replace
to protect against glowing embers falling
through. If replace is to be installed on
a raised platform, a Z-type ember protec­tor (not included) must be fabricated to
t your required platform height. Ember
protector should extend under replace a
minimum of 1 1/2". Ember protector should
be made of galvanized sheet metal (28
gauge minimum) to prevent corrosion.

6. Using screws or nails, secure replace to
framing through anges located on sides
of replace.

41.75"

41.75"

21.875"

Figure 1 - Framing Dimensions

Maintain 3/4"
Clearance at

Sides and

17.3"

Back of

24.4"

52.2"

3/4" Clearance Not

Required at Nailing Flanges

73.8"

Fireplace

Figure 2 - Corner Installation

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125183-01B4

FIREPLACE INSTALLATION

HEARTH EXTENSION

A hearth extension projecting a minimum of
16" in front of and a minimum of 8" beyond
each side of replace opening is required to
protect combustible oor construction in front
of replace. Fabricate a hearth extension
using a material which meets the following
specications: a layer of noncombustible,
inorganic material having a thermal conductiv­ity of K=0.84 BTU IN/FT, HR. F (or less) at 1"
thick. For example, if material selected has
a K factor of 0.25, such as glass ber, the
following formula would apply:

0.25 x 1.0" = 0.30" thickness required

0.84
Thermal conductivity "K" of materials can be

obtained from manufacturer or supplier of
noncombustible material. If hearth extension
is to be covered, use noncombustible mate­rial such as tile, slate, brick, concrete, metal,
glass, marble, stone, etc. Provide a means
to prevent hearth extension from shifting and
seal gap between replace frame and hearth
extension with a noncombustible material
(see Figure 3).

WARNING: Hearth extension

is to be installed only as shown

in Figure 3.

Fireplace Front

Ember Protector

Seal Gap

NO

Do Not Block Louver

Extension

Fireplace Front
Elevated

Ember Protector

Hearth Extension, Circulating Modes

Fireplace Front

Ember Protector

Fireplace Front
Raised Hearth

Ember Protector

Fireplace Front
Elevated

Seal Gap

Seal Gap

Extension

Seal Gap

Hearth

Hearth

Ember Protector

Hearth Extension, Noncirculating Models

Figure 3 - Hearth Extension

125183-01B 5

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FIREPLACE INSTALLATION

Ref.

Continued

MANTELS

A mantel may be installed if desired (see
Figures 4 and 5). Woodwork such as wood
trims, mantels or any other combustible
material projecting from front face, must not
be placed within 9" of replace opening and
within 6" of top louver opening. Combustible
materials above 9" and projecting more than

1 1/2" from replace must not be placed less

than 12" from top opening of replace (NFPA
STD 211, Sec. 7-3.3.3).

6"

Ref.

12" Min.

12 1/4" Ref.

33°

3" Nom.

11/2" Max.

Combustible
Material

Safe
Zone for
Projection of
Combustible
Materials

12 1/4" Ref.

6"

33°

3" Nom.

12"

Min.

9"

Min.

Fireplace Opening

Figure 4 - Mantel Clearances to

Combustible Material (with Louver)

6"

Min.

Top of

Louvered

Opening

1

1
Max.

/2"

Combustible
Material

Safe Zone For
Projection of
Combustible
Materials

*Note: Drawing

Not To Scale

Upper Section

of Circulating

Fireplace

VENTING INSTALLATION

OPTIONAL OUTSIDE AIR KIT
(MODEL AK4/AK4F)

Installation of an outside air kit should be
performed during rough framing of replace
due to the nature of it's location. Outside com­bustion air is accessed through a vented crawl
space (AK4F) or through a sidewall (AK4).
See Figure 23 on page 15 for instruction of
operating air kit.

CAUTION: Combustion air

inlet ducts shall not terminate
in attic space.

9" Min.

Fireplace Opening

Figure 5 - Mantel Clearances to

Combustible Material (without Louver)

Upper

Section of

Fireplace

The maximum height for the
air vent can not exceed 3 feet
below the ue gas outlet of the

termination.

CHIMNEY PIPE

FMI PRODUCTS, LLC chimney system
consists of 12", 18", 24", 36" and 48" snap­lock, double-wall pipe segments, planned
for maximum adaptability to individual site
requirements. Actual lengths gained after t­ting overlaps must be taken into consideration
(lineal gain) and are given in lineal gain chart
(see Figure 7, page 7). Lineal gain is actual
measurable length of a part after two or more
parts are connected. For Canada, use chim­ney parts designated "HT".

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125183-01B6

VENTING INSTALLATION

Continued

Secure to Collars with Metal Tape, Screws
or Straps (Min. of 1/4" x 20" in size)

Air Inlet
Location
Must Allow
For Bushes
or Snow

12 3/8"

Galvanized
Outer Pipe

8" Stainless
Inner Pipe

Hemmed
End

Air Inlet

Vented Crawl Space
(Check Local Codes
Before Installing in a
Vented Crawl Space)

Figure 6 - Outside Air Kit

Eyebrow

Vent Hood

Required for
Wall Installation

WARNING: The opening in

collar around chimney at top of
replace must not be obstructed.
Never use blown insulation to ll
chimney enclosure.

ASSEMBLY AND INSTALLATION OF
DOUBLE WALL CHIMNEY SYSTEM

Each double wall chimney section consists of
a galvanized outer pipe, a stainless steel in­ner ue pipe and a wire spacer. Pipe sections
must be assembled independently as chimney
is installed. When connecting chimney directly
to replace, inner ue pipe section must be
installed rst with lanced side up. Outer pipe
section can then be installed over ue pipe
section with hemmed end up. Press down
on each pipe section until lances securely
engage hem on replace starter. The wire
will assure proper spacing between inner and
outer pipe sections.

Note: For Canada, use chimney parts desig­nated HT.

PART NO. DESCRIPTION GAIN

36" Fireplace 37 1/2"

12-8DM

12-8HT

18-8DM

18-8HT

24-8DM

24-8HT

36-8DM

36-8HT

48-8DM

48-8HT

RT-8DM Round Termination 6 7/8"*

RTL-8DM Round Termination 7 3/4"*

RTT-8DM

RTTL-8DM

ET-8DM Square Chase-Top 12"*

ETO-8DM

ETL-8DM

ETLO-8DM

* The lineal gain for the terminations is
measured to the ue gas outlet height.

LINEAL GAIN

Pipe Section 10 5/8"

Pipe Section 16 5/8"

Pipe Section 23 5/8"

Pipe Section 34 5/8"

Pipe Section 46 5/8"

Round Termination

with Slip Section

Round Termination

with Slip Section

Square Chase-Top

with Mesh

Square Chase-Top

with Slip Section

Square Chase-Top

with Mesh & Slip

Section

Figure 7 - Lineal Gain

6 7/8" to
23 1/8"*
8 1/2" to
21 1/2"*

12"*

7" to 15"*

12" to

25 1/2"*

Opening in collar around

chimney at top of replace must
not be obstructed. Never use
blown insulation to ll chimney

enclosure.

125183-01B 7

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VENTING INSTALLATION

Continued

Continue to assemble chimney sections as
outlined, making sure that both inner and
outer pipe sections are locked together. When
installing double wall snap-lock chimney to­gether, it is important to assure joint between
chimney sections is locked. Check by pulling
chimney upward after locking. Chimney will
not come apart if properly locked. It is not
necessary to add screws to keep chimney to­gether (exception - see Figure 10, page 9).

USING ELBOW OFFSETS (30E-8DM)

1. To achieve desired offset, you may install
combinations of 12", 18", 24", 36" and 48"
length of double wall pipe (see offset chart
and Figure 8).

Note: For systems with 2 elbow sets, mini-

mum height is 22 feet. Maximum height
for any system is 50 feet.

2. Chimney weight above offset rests on
return elbow. Straps must be securely
nailed to rafters or joists (see Figure 9,
details A and B on page 9).

3. Maximum length of pipe between supports
(return elbow or 12S-8DM) is 6' of angle
run. Maximum of two 6' angle run sections
per chimney system (see Figure 8).

4. All pipe connections between offset and
return must be secured with two screws
on outer pipe only (see Figure 10, page

9). Do not penetrate inner stainless.

Offset
Elbow

Return
Elbow

6' Max.

6' Max.

Return
Elbow

Offset
Elbow

Return
Elbow

Offset

Offset
Elbow

A

Elbow

Figure 8 - Typical Offset Installation

6' Max.

B C

6' Max.

Offset
Elbow

Return
Elbow

Ceiling
Support Pipe
12S-8DM

Return
Elbow

6' Max.

6' Max.

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125183-01B8