FMI CCAT36 Series Owner's Operation And Installation Manual

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Page 1

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

Page 2

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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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"

21"

33.813"

35"

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41"

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2.313"

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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"

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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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

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

Extension

Seal Gap

Hearth

Ember Protector

Hearth Extension, Noncirculating Models

Figure 3 - Hearth Extension

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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).

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.

33°

3" Nom.

12"

Min.

Fireplace Opening

Figure 4 - Mantel Clearances to

Combustible Material (with Louver)

Min.

Top of

Louvered

Opening

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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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.

Return Elbow

Offset Elbow

Return Elbow

Offset

Offset Elbow

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.

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VENTING INSTALLATION

Continued

Ceiling Support Pipe 12S-8DM

2" Min.

See Detail A

See Detail B

Straps

Detail A

Return Elbow

OFFSET RISE CHIMNEY LENGTH

A B 48" 36" 24" 18" 12"

4 3/8" 16 3/8" ELBOW SET ONLY 9 3/4" 25 1/2" 1

12 3/4" 30 3/4" 1

15" 34 3/4" 1 18" 40" 1 1

21 1/4" 46 1/4" 1 23 3/4" 49 1/4" 1 1

27 3/4" 56 3/4" 1

30" 60 3/4" 1 1 33" 66" 1 1 36" 71" 1 1

38 1/4" 75" 2 41 1/4" 80 1/4" 1 1 1

45" 86 3/4" 2

46 3/4" 89 1/2" 1 1 1

51" 97" 1 1

53 1/4" 101" 2 1 56 1/4" 106 1/4" 2 59 1/4" 111 1/2" 1 1 1 61 3/4" 115 1/2" 2 1 64 3/4" 120 3/4" 2 1 68 1/4" 127" 1 2

70" 130" 2 1 1 74 1/4" 137 1/2" 1 2 1 76 3/4" 141 1/2" 1 2 1 79 3/4" 146 3/4" 4

OFFSET CHART (22-50 FT. SYSTEM HEIGHT)

Straps

Detail B

Angle

Firestop

Figure 9 - Ceiling Support Pipe 12S-8DM

Figure 10 - Elbow Offset

Straps

Screws

125183-01B 9

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VENTING INSTALLATION

Continued

FIRESTOP SPACERS (3600FS-8DM-1)

Firestop spacers are required at each point where chimney penetrates a floor space. Their purpose is to establish and maintain required clearance between chimney and combustible materials. When pipe passes through a framed opening into a living space above, restop must be placed onto ceiling from below as shown in Figure 11.

They also provide complete separation from one oor space to another or attic space as required by most codes. When double wall pipe passes through a framed opening into an attic space, restop must be placed into an attic oor as shown in Figure 12.

If area above is a living space, install

restop below framed hole.

Figure 11 - Firestop Spacer with Living

Space Above Ceiling

If area above is an attic or insulated area,

install restop above framed hole.

Figure 12 - Firestop Spacer with Attic

Space Above Ceiling

PENETRATING ROOF

To maintain a 1" clearance to pipe on a roof with a pitch, a rectangular opening must be cut.

1. Determine center point where pipe will penetrate roof.

2. Determine center point of roof. Pitch is the distance the roof drops over a given span, usually 12". A 6/12 pitch means that the roof drops 6" for each 12" measure horizontally down from roof rafters.

3. Use roof opening chart (Figure 13) to determine correct opening length and ashing required.

4. Remove shingles around opening measured. Cut out this section.

5. Add next sections of pipe until end penetrates roof line. Check to see that proper clearances are maintained. Extend chimney by adding sections of double wall pipe until pipe is minimum of 30" above highest point of roof cutout. Termination and chimney must extend a minimum of 36" above highest point where it passes through roof.

Minimum Measurements

14 3/8"

(36.5 cm)

Pitch Slope Opening

Flat 0° 15" V6F-8DM

0-6/12 26.6° 16 1/8" V6F-8DM

6/12- 12/12 45.0° 20 3/8" V12F-8DM

1" (2.5 cm)

"A" Max.

30"

(76.2 cm)

(2.5 cm)

Opening "A"

Used Flashing

Model No.

Figure 13 - Roof Opening Measurements

FLASHING INSTALLATION (V6F-8DM OR V12F-8DM)

Determine ashing to be used with roof opening chart. Slide ashing over pipe until base is at against roof. Replace as many shingles as needed to cover exposed area and ashing base. Secure in position by nailing through shingles (see Figure 14, page 11). DO NOT NAIL THROUGH FLASHING CONE.

Installing Flashing on a Metal Roof

When installing ashing on a metal roof, it is required that putty tape be used between ashing and roof. Flashing must be secured to roof using #8 x 3/4" screws and then sealed with roof coating to prevent leakage through screw holes. A roof coating must also be applied around perimeter of ashing to provide a proper seal.

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VENTING INSTALLATION

Continued

Storm Collar

Flashing Cone

Nail Only Outer Perimeter of Flashing

Underlap Shingles at Bottom

Figure 14 - Flashing Installation

Storm Collar Installation (SC1 or SC2)

Place storm collar over pipe and slide down until it is snug against open edge of ashing (see Figure 15). Use SC1 for all round terminations and SC2 for all terminations with slip sections. Apply waterproof caulk around perimeter of collar to provide a proper seal.

Chimney Pipe

Storm Collar

Figure 15 - Storm Collar

Terminations/Spark Arrestor

Fireplace system must be terminated with listed round top or chase terminations. In any case, refer to installation instructions supplied with termination. Terminations approved for this replace are RT-8DM and RTL-8DM that can be used for ashing or chase and ET-8DM, ETO-8DM, ETL-8DM and ETLO-8DM for chase style termination only. Figure 16 shows an RTL-8DM round top termination.

Overlap Shingles Top and Sides Only

Waterproof Caulk

Flashing

Terminations with 16" slip pipe sections are available. RTT-8DM and RTTL-8DM are approved for flashing installations. When needed, these adjustable terminations may be used in combination with pipe assembly to achieve correct chimney height.

Note: In rare instance there is a problem with side driven rain or wind or chimney is not drafting properly, an ADS-8DM (Anti-Draft Shield) can be used with round terminations.

Attach Bracket Tabs to Outer Pipe (3 Places) Secure with Screws

Overlap Shingles Top and Sides

Figure 16 - Termination

RTL-8DM

Level of Flue Gas Outlet

Caulk

Collar

Flashing

Underlap Shingles Bottom Only

CHASE INSTALLATIONS

Instructions for chase installations are included with chase style termination chosen. In a multiple chase installation, be sure to provide adequate distance between terminations to prevent smoke spillage from one termination to another. We suggest that terminations be separated at least 24", center to center and stacked at a vertical height difference of 18" (see Figure 17).

Note: If a decorative shroud is to be installed,

contact manufacturer for specications.

CAUTION: Do not seal open-

ings on the rooftop ashing. Fol-

18" MIN. TYP.

low the installation instructions provided with the termination

being used.

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24" MIN.

Figure 17 - Multiple Chase Installation

Page 12

VENTING INSTALLATION

Continued

10 FOOT RULE

All ue gas outlet chimney terminations must extend a minimum of 3 feet in height above highest point where it passes through roof and must be at least 2 feet above highest point of the roof that is within a horizontal distance of 10 feet (see Figure 18).

10'

2' Min.

Level of Flue Gas Outlet

10'

3' Min.

FINISHING THE FIREPLACE

Combustible materials, such as wallboard, gypsum board, sheet rock, drywall, plywood, etc. may make direct contact with sides and top around the replace face. It is important that combustible materials do not overlap face itself. Brick, glass, tile or other noncombustible materials may overlap front face provided they do not obstruct essential openings such as louvered slots. When overlapping with a noncombustible facing material, use only noncombustible mortar or adhesive.

Figure 18 - 10 Foot Rule

EFFECTIVE HEIGHT OF TERMINATION CAP

14.5 FT. MINIMUM HEIGHT

2' Min.

EFFECTIVE HEIGHT OF TERMINATION CAP

14.5 FT. MINIMUM HEIGHT

UP TO 6FT. MAX.

3' Min.

EFFECTIVE HEIGHT OF TERMINATION CAP

MAX. HEIGHT 50 FT. (ANY SYSTEM)

UP TO 6FT. MAX.

30E-8DM

EFFECTIVE HEIGHT OF TERMINATION CAP

MIN. HEIGHT OF 22 FT. (WITH 2 ELBOW SETS) MAX. HEIGHT 50 FT.

30E-8DM

Figure 19 - Typical Residential Installations

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Page 13

PUREFIRE HOOD INSTALLATION

1. The PureFire hood supplied with this replace is packaged in a separate box and placed in the rebox during shipping.

2. Remove hood from box.

3. Lift the hood up into the replace at an angle with the rear facing up. Set the front section of the hood on the refractory brackets. Then tilt the rear toward the back of the replace so the hood is resting on refractory brackets (see Figure 20). The rear of the hood will be touching the rear of the replace.

OPTIONAL GAS LINE INSTALLATION

Gas line hook up should be done by your supplier or a qualied service person.

Note: Before you proceed, make sure your gas supply is turned off.

Use only a 1/2" black iron pipe and appropriate ttings.

1. Remove knockout indentation on refractory or rebrick wall located above refractory hearth oor. Knockout indentation must be rmly tapped with any solid object, such as a 1/2" dowel, until it is released. Remove fragmented portions of refractory (see Figure 21).

Outside of Fireplace

Gas Line Conduit

Insulation

Gas Conduit Cover

Figure 21 - Gas Line Knockout

2. Remove gas line cover plate located on either side of replace and pull out insulation from gas line conduit sleeve. Save insulation for reuse.

Side Firebrick Finished Side

1/2" Dowel

Refractory Knockout Plug

Refractory Retainer

Figure 20 - Installing PureFire Hood

3. Run a 1/2" black iron gas line into replace through rear at gas line conduit sleeve (if using a raised platform, add height). Provide sufcient gas line into replace chamber for tting connection (see Figure 22).

Outside of Fireplace

Gas Line Conduit

Repack Insulation

Figure 22 - Gas Line Installation

Note: Secure incoming gas line to wood

framing to provide rigidity for threaded end.

4. Repack insulation around gas line and into sleeve opening. Seal any gaps between gas line and refractory knockout hole with refractory cement or commercial furnace cement. Install gas appliance or cap off gas line if desired.

Incoming 1/2" Black Iron Pipe

Seal Opening with Refractory Cement

Provide Enough Threaded End for Fitting Connection

Hood

Side Firebrick Finished Side

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Page 14

OPTIONAL GAS LINE INSTALLATION

Continued

CAUTION: All gas piping and

connections must be tested for leaks after installation is com-

pleted. After ensuring that gas

valve is on, apply soap and water

solution to all connections and

joints. Bubbles forming show a leak. Correct all leaks at once. DO NOT USE AN OPEN FLAME FOR LEAK TESTING AND DO NOT OPERATE ANY APPLIANCE IF A LEAK IS DETECTED. LEAK TESTING SHOULD BE DONE BY A QUALIFIED SERVICE

PERSON.

Note: A FMI PRODUCTS, LLC hood must be installed when using an unvented gas log set (see Accessories on page 21).

WARNING: Do not operate

an unvented gas log set in this

replace with chimney removed.

If you install a decorative gas appliance (vented gas log), decorative gas appliance must comply with the Standard for Decorative

Gas Appliance for Installation in Solid Fuel Burning Fireplaces, ANS Z21.60 or Z21.84

and shall also be installed in accordance with

the National Fuel Gas Code, ANSI 7223NFPA 54 latest edition.

WARNING: To avoid the risk

of damaging the replace materials and increasing the risk of spreading a re, do not use the replace to cook or warm food.

WARNING: If the replace has been used for wood burning, rebox and chimney must be cleaned of soot, creosote and ashes be a qualied chimney

cleaner. Creosote will ignite if

heavily heated.

WARNING: When using a dec-

orative vented gas log, damper must be removed or permanently locked in fully open position and glass doors must be in fully open

position.

OPERATION AND MAINTENANCE

GLASS DOORS

Glass doors are optional with this replace. When replace is in operation, doors must be fully opened or fully closed position only or a re hazard may be created (see Figure 23, page 15).

A replace equipped with glass doors operates much differently than a replace with an open front. A replace with glass doors has a limited amount of air for combustion. Excessive heat within replace can result if too large a re is built or if combustion air gate is not completely open.

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The following tips should be used to assure that both fireplace and glass door retain their beauty and function properly. Both ue damper and glass doors must be fully opened before starting a re. This will provide sufcient combustion air and maintain safe temperatures in rebox.

IMPORTANT: Glass must be allowed to warm slowly and evenly. Tempered glass will withstand a gradual temperature rise to 550° F, which is more than a normal re will generate. Such materials as pitch/wax laden logs, very dry mill end lumber and large amounts of paper or cardboard boxes can create an excessively hot re and should not be burned in this replace. Always keep re back from doors and never allow ames to contact glass.

125183-01B14

Page 15

OPERATION AND MAINTENANCE

Continued

WARNING: Fireplaces

equipped with glass doors

should be operated only with doors fully opened or doors fully closed. Doors, if left partly open, may draw gas and ame out of the replace opening creating risks of both re and smoke.

Doors Fully Closed

Fireplace Front

Doors Fully Opened

Fireplace Front

Figure 23 - Glass Doors

Cleaning Glass

Clean glass with any commercial glass cleaner or soap and water. Do not use any abrasive material to clean glass. Do not clean glass with any cool water if glass is still hot from re and smoke.

A gas line or gas log lighter may be installed for the purpose of installing a vented or ventfree decorative gas appliance incorporating an automatic shutoff device and complying with the Standard for Decorative Gas Appliances

for Installation in Vented Fireplaces, ANSI Z21.60 or American Gas Association draft requirements for Gas Fired Log Lighters for Wood Burning Fireplaces, Draft NO. 4 dated

August, 1993. If you wish to install an unvented (vent-free)

gas log set, only unvented gas log sets which have been found to comply with the standard for unvented room heaters, ANSI Z21.11.2 are to be installed in this replace.

OUTSIDE AIR AND DAMPER

HANDLE OPERATION

Damper handle, which opens and closes damper blade, is located in upper front face of replace. Pushing handle into left of keyway slot will free damper blade to automatically open. Pushing handle into right will lock damper blade closed (see Figure 24).

Outside air kit handle is located at left hand side of fireplace (see Figure 24). Pulling handle out will free outside air door to open. Pushing handle in will lock door closed.

WARNING: Risk of re! Replace grate with FMI PRODUCTS, LLC model 125186-01 only. This grate has been designed to keep the operation of your replace safe and efcient.

For further operating guidelines, instructions and warranty information, please refer to your homeowner's guide or contact your authorized dealer.

Damper

Handle

OPEN

Outside Air Kit Handle

Figure 24 - Damper and Air Kit Handle

Handle

Retainer

Keyway Slot

125183-01B 15

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Page 16

PUREFIRE EMISSION CONTROL SYSTEM

This replace is equipped with a PureFire Emission Control System. The Catalytic Hood system reduces particulates emissions in a wood burning replace to meet the EPA Wood-Burning Fireplace Program Phase 2 emission level.

The EPA qualifying label, shown below, will be afxed to the catalyst. Before lighting the rst re, remove and maintain this label in a safe place if needed for permits or building inspection. Prior to beginning installation, contact your local building ofcial to determine the need to obtain a permit. For proper operation, catalyst must be replace every 3 to 5 years.

FUELING GUIDELINES

The replace grate must always be secured to the retaining brackets provided. The position of the grate must be centered against the back wall of the rebox.

Burn only dry, seasoned (cured) wood with less than 20% moisture. Avoid the use of treated, painted and laminated wood. Never burn garbage or other foreign materials. Do not use articial logs, colored newspaper or petroleum based re starters. Avoid wood with high salt content. All of these materials may contain compounds which can shorten the life of the catalyst. Wet or unseasoned wood may lower catalytic temperatures and result in inefcient operation.

The catalyst is designed to function at optimum efciency when the replace is burning clean, dry, cord wood as replace fuel. A simple visual inspection of the chimney during the wood burning process will determine catalyst performance.

The fuel load should always be placed on the back of the grate. Use clean dry wood, seasoned cord wood is the best choice. Never burn trash, plastics, gasoline, rubber, industrial solvents, ammable liquids, naptha, household garbage, material treated with petroleum products, leaves, paper products, cardboard or salt driftwood.

Refer to your FMI PRODUCTS, LLC Home-

owner's Guide included with your replace for proper re building technique and ash removal procedures. These fueling guidelines must be followed in order to achieve maximum emissions performance from the PureFire System.

OPERATION

The proper use of a wood burning replace equipped with the catalyst will signicantly reduce the emissions that it produces. Simple fuel considerations with regard to moisture content, size, and quality of fuel will help control the production of wood smoke and improve the performance of the catalyst and fireplace efficiency. With proper care, the catalyst will provide years of fuel savings and lowered emissions. By following some simple guidelines, you will ensure maximum performance and longevity.

PHASE 2 QUALIFIED

U.S. Environmental Protection Agency

Wood-burning Fireplace Program

Phase 2 Qualified models are cleaner and pollute less than those models that have not met this emissions level. Exposure to smoke has been associated with respiratory illness and other health problems. Models that have lower smoke emissions may reduce your risk.

For more information go to www.epa.gov/burnwise

FIREPLACE

SMOKE EMISSIONS RANGE

Lower Emissions

Better

5.1

4.8

Fireplaces with lower emissions produce less smoke when installed and operated properly.

MANUFACTURER: FMI Products, LLC

MODEL NO: CCAT36 36" Woodburning Fireplace

PARTICLE EMISSIONS: 4.8 GRAMS/KG OF WOOD BURNED

* EPA has determined, based on testing by an accredited independent laboratory and a certification of conformity by a nationally recognized certification body, that this model qualifies at the Phase 2 emissions level for U.S. EPA's Voluntary Fireplace Program.

THIS MODEL

For proper operation, catalyst must be replaced every 3 to 5 years.

Higher Emissions

EPA PHASE 2 EMISSIONS LEVEL

Worse

12.0

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125183-01B16

Page 17

PUREFIRE EMISSION CONTROL SYSTEM

Continued

The smoke that is usually seen coming out of a chimney is essentially a combination of unburned fuel (carbon and hydrogen) and moisture in the form of water vapor. The catalyst is a technology that provides secondary combustion for the wood burning process.

MAINTENANCE

The PureFire System is a maintenance free technology. Do not attempt to remove or clean the combustor. The direct ame from the re will clean the combustor. Only a certified technician should remove the unit. To ensure proper replace operation, the PureFire System should be replaced every 3 to 5 years (see Parts on page 17).

NOTE: Chimney smoke may be visible during the rst 8 to 10 minutes of replace operation when the re is rst getting started and the nal 8 to 10 minutes of operation while the re is dissipating. Under normal operating conditions, you should see little or no smoke coming out of the chimney. If continuous smoke is visible, make sure only dry seasoned wood is being burned. If visible smoke continues, the combustor has ceased to function or there is thermal crumbling. Call FMI PRODUCTS, LLC at 1-866-328-4537 for replacement parts.

WARRANTY

FMI PRODUCTS, LLC warranty obligations for the PureFire Emissions Control System are limited to the terms set forth below.

FMI PRODUCTS, LLC warrants to the consumer who purchases a new solid fuel burning replace containing a PureFire Emissions Control System as a new component, to replace the catalyst at no charge should it cease to function within three years from the date of purchase. The PureFire Catalytic Component is designed to perform efciently for three years of replace operation. ONLY recommended fuels should be burned. Follow the fueling directions in manufacturers operation manual. For warranty purposes, proof of replace purchases is required. Labor for removal and/or installation of the catalytic component is not the responsibility of the manufacturer.

Neither FMI PRODUCTS, LLC nor the dealer who sells the PureFire Emissions Control System is responsible for indirect, incidental, special, punitive or consequential damages arising out of the improper use of this product or the continued use of this product beyond the required replacement period.

125183-01B 17

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Page 18

PARTS

WOOD BURNING FIREPLACE MODELS (V)CCAT36, (V)CCAT36I, (V)CCAT36H, (V)CCAT36L, (V)CCAT36LI, (V)CCAT36LH

36/37

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40/41

38/39

125183-01B18

Page 19

PARTS

WOOD BURNING FIREPLACE MODELS (V)CCAT36, (V)CCAT36I, (V)CCAT36H, (V)CCAT36L, (V)CCAT36LI, (V)CCAT36LH

This list contains replaceable parts used in your replace. When ordering parts, see Replacement Parts on page 21 of this manual.

KEY NO. PART NO. DESCRIPTION (V)CCAT36(I,H) (V)CCAT36L(I,H) QTY.

1 106638-01 Insulation Pan • • 1 2 ** Fireplace Top • • 1 3 106641-01 Fireplace Surround • • 1 4 106642-01 Air Rod Retainer • • 1 5 106643-01 Damper Rod Retainer • • 1 6 ** Firebox Bottom • • 1 7 ** Firebox Surround • • 1 8 ** Air Separator • • 1 9 See Page 17 Left Refractory • • 1 10 See Page 17 Right Refractory • • 1 11 See Page 17 Rear Refractory • • 1 12 See Page 17 Bottom Rear Refractory • • 1 13 See Page 17 Bottom Front Refractory • • 1 14 ** Firebox Support Leg • • 4 15 106687-01 Damper Can Collar • • 1

16 106691-01 Screen Rod • • 2 17 ** Firebox Top Assembly • • 1 18 ** Air Kit Door Assembly • • 1 19 ** Face Weldment • • 1 20 125562-01 Smoke Deector • • 1 21 ** Fireplace Top Insulation • • 1 22 ** Access Panel • • 1 23 107854-01 Right Refractory Bracket • • 1 24 107854-02 Left Refractory Bracket • • 1 25 125186-01 Grate • • 1 26 11418 Push-On Nut • • 2 27 12105 Screen • • 2 28 ** Collar Insulation • • 1 29 20023 Chimney Starter Collar • • 1 30 20027 Refractory Retainer • • 2 31 23534 Grate Retainer • • 2 32 20088 Door Stop • • 1 33 20090 Spring Clip • • 2 34 20280 Top Standoff • • 4 35 21171 Conduit Plate Cover • • 4 36 21379 Gas Conduit • • 2 37 21380 Gas Conduit • • 2 38 106650-01 Bottom Louver Panel • 1 39 106651-01 Bottom Smooth Panel • 1 40 106684-01 Top Louver Panel • 1 41 106651-01 Top Smooth Panel • 1 42 124994-01 PureFire Catalytic Hood • • 1

** Not a eld replaceable part

125183-01B 19

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Page 20

REPLACEMENT PARTS

HERRINGBONE BRICK

LINER

VCCAT36H/VCCAT36LH Left - 108164-01 Right - 108165-01

Rear - 108166-01

Bottom Rear - 108167-01

Bottom Front - 108168-01

CCAT36H/CCAT36LH Left - 108164-02 Right - 108165-02

Rear - 108166-02

Bottom Rear - 108167-02

Bottom Front - 108168-02

TECHNICAL SERVICE

You may have further questions about installation, operation, or troubleshooting. If so, contact FMI PRODUCTS, LLC at 1-866-328-4537. When calling please have your model and serial numbers of your heater ready.

STANDARD BRICK LINER

VCCAT36(I)/VCCAT36L(I) Left - 106658-01 Right - 106659-01

Rear - 106660-01 Bottom Rear 106661-01 Bottom Front 106662-01

CCAT36(I)/CCAT36L(I) Left - 106658-02 Right - 106659-02

Rear - 106660-02 Bottom Rear - 106661-02 Front Rear - 106662-02

EMBER PROTECTOR

20093

You can also visit our web site at www.fmiproducts.com.

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125183-01B20

Page 21

DOUBLE WALL PIPE

12-8DM 12-8HT 18-8DM 18-8-HT 24-8DM 24-8HT 36-8DM 36-8HT 48-8DM 48-8HT

ROOF FLASHING

0 TO 6/12 PITCH - V6F-8DM 6/12 TO 12/12 PITCH - V12F-8DM

FIRESTOP SPACER

3600FS-8DM-1

ACCESSORIES

ANTI-DRAFT SHIELD

(Round Top Termination Only)

ADS-8DM

30° OFFSET AND RETURN

30E-8DM

ROUND TOP TERMINATIONS

RT-8DM, RTL-8DM

ROUND TOP TERMINATIONS WITH

SLIP SECTION

RTT-8DM, RTTL-8DM

STORM COLLAR

SC1-1 For RT-8DM and RTL-8DM SC2-1 For RTT-8DM and RTTL-8DM

SQUARE CHASE-TOP

TERMINATION

ET-8DM, ETO-8DM

ANTI-DRAFT SHIELD

(Round Top Termination Only)

ADS-8DM

125183-01B 21

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ECONO-TOP TERMINATION WITH

SLIP SECTION

ETL-8DM, ETLO-8DM

Page 22

ACCESSORIES

Continued

OUTSIDE AIR KIT FOR SIDE WALL INSTALLATION - AK4

OUTSIDE AIR KIT FOR FLOOR INSTALLATION

AK4F

BI-FOLD GLASS DOOR

BD36 - Black

BD36B - Brushed Brass BD36P - Platinum

ADJUSTABLE HOOD

Antique Brass Finish - GA6053 Black Painted Finish - GA6050

Required when installing a vent-free gas log in this replace.

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125183-01B22

Page 23

NOTES

_____________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________

125183-01B 23

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Page 24

2701 S. Harbor Blvd.

Santa Ana, CA 92704

1-866-328-4537

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125183-01

Rev. B 12/10

FMI CCAT36 Series Owner's Operation And Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual