OWNER’S OPERATION AND INSTALLATION MANUAL INDOOR WOOD BURNING (V)GCAT42/50(H)A SERIES INDOOR/OUTDOOR WOOD BURNING (V)JCAT42/50(H,S) SERIES FIREPLACES WITH INSULATION PFS C ® US These models meet the EPA Wood Burning Fireplace Program Phase 2 emission level. NOTE: To ensure proper fireplace 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 fireplace is approved for use as a wood burning fireplace or for use with a vented gas log approved to ANS Z21.60 and Z21.84 standards. This wood burning fireplace complies with UL127-CAN/ ULC-S610-M87 standard as a FACTORY BUILT FIREPLACE. FOR CANADA: The authority having jurisdiction (such as the municipal building department, fire 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 WARNING: Improper installation, adjustment, alteration, service or maintenance can cause injury, property damage or loss of life. Refer to this manual for assistance or additional information. Consult a qualified installer or local distributor. TABLE OF CONTENTS Safety................................................................... 2 Specifications....................................................... 3 Fireplace Installation............................................ 5 Venting Installation............................................... 7 Refractory Panel Installation.............................. 12 Optional Gas Line Installation............................ 13 PureFire Installation........................................... 14 Glass Door Installation....................................... 15 Operation and Maintenance Guidelines............. 16 PureFire Emissions Control System................... 17 Technical Service............................................... 19 Replacement Parts............................................. 19 Parts .................................................................. 20 Accessories........................................................ 24 IMPORTANT: Check local codes before installing this fireplace. FOR YOUR SAFETY • Do not store or use gasoline or any other flammable vapors or liquids in the vicinity of this or any other appliance. • Due to high temperatures, the appliance should be located out of traffic and away from furniture and draperies. • Do not place clothing or other flammable materials on or near the appliance. • Never leave children unattended when a fire is burning in the fireplace. SAFETY Before beginning the installation of the fireplace, read these instructions through completely. • This FMI PRODUCTS, LLC fireplace 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 fireplace system, you may cause a fire 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, components, doors, air inlet system and damper control. b. Use of any component part not manufactured or approved by FMI PRODUCTS, LLC in combination with a FMI PRODUCTS, LLC fireplace system. Proper installation is the most important step in ensuring safe and continuous operation of the fireplace. Consult the local building codes as to the particular requirements concerned with the installation of all factory built fireplaces. WARNING: Do not install a fireplace insert in this box unless the manufacturer's instructions with the insert specifically state this fireplace has been tested for use with this insert. 2 WARNING: Use solid wood or processed solid fuel firelogs only. When processed wood fuel fire logs are used, do not poke or stir the logs while they are burning. Use only fire logs that have been evaluated for the application in fireplace and refer to fire log warnings and caution markings on packaging prior to use. This fireplace is not intended to be used as a substitute for a furnace to heat an entire home. Use for supplemental heat only. www.fmiproducts.com 125655-01C SPECIFICATIONS 42" MODELS 2" CHIMNEY AIRSPACE CLEARANCE TO COMBUSTIBLE MATERIAL NO COMBUSTIBLE MATERIAL ON FACE COMBUSTIBLE WALL BOARD 11/2" AIR SPACE BACK AND SIDES OUTSIDE AIR MINIMUM 18" TO PERPENDICULAR SIDEWALL GAS LINE KNOCKOUTS HEARTH EXTENSION 66" X 20" 0" TO BOTTOM 12" EACH SIDE 30 1/2" 22 3/4" 15 3/4" 25 1/8" 23 1/2" 29" 17 5/8" 42" 42" HEARTH 4 3/8" 5/8" OUTSIDE AIR ACCESS 11" 67" 58" 61" 49" GAS LINE ACCESS 30" 10 1/2" 9 1/2" 3 1/2" 7" 1" 42" 51 1/8" 4 1/2" 81/2" 13" 17" Figure 1 - 42" Models (V)GCAT42(H)A AND (V)JCAT42(H,S) Series 125655-01C www.fmiproducts.com 3 SPECIFICATIONS Continued 50" MODELS 2" CHIMNEY AIRSPACE CLEARANCE TO COMBUSTIBLE MATERIAL NO COMBUSTIBLE MATERIAL ON FACE COMBUSTIBLE WALL BOARD 11/2" AIR SPACE BACK AND SIDES OUTSIDE AIR MINIMUM 18" TO PERPENDICULAR SIDEWALL GAS LINE KNOCKOUTS 0" TO BOTTOM HEARTH EXTENSION 74" X 20" 12" EACH SIDE 38 1/2" 24" 19 1/4" 33 1/8" 23 1/4" 28 1/2" 17 5/8" 50" 50" HEARTH 4 /8" 3 OUTSIDE AIR ACCESS 11" 67" 61" GAS LINE ACCESS 58" 49" 30" 10 1/2" 7" 1" 50" 59" 4 1/2" 9 1/2" 3 1/2" 8 1/2" 13" 17" Figure 2 - 50" Models (V)GCAT50(H)A AND (V)JCAT50(H,S) Series 4 www.fmiproducts.com 125655-01C FIREPLACE INSTALLATION SELECTING LOCATION To determine the safest and most efficient location for the fireplace, you must take into consideration the following guidelines: 1. The location must allow for proper clearances (see Figures 5 and 6). 2. Consider a location where fireplace 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 fireplace (see Optional Outside Air Kit on page 7). MINIMUM CLEARANCE TO COMBUSTIBLES Back and sides of fireplace 1 1/2" min.* Front of fireplace 48" min. Floor** 0" min. Perpendicular wall to opening 18" min. Top spacers 0" min. Mantel clearances see Mantels, page 7 Chimney outer pipe surface 2" min. * Not required at nailing flanges ** See step 2 of Framing WARNING: Do not pack required air spaces with insulation or other materials. Minimum/Maximum Chimney Height for Residential Installation Minimum height of chimney, measured from base of fireplace to flue gas outlet of termination, is 16 feet for straight flue or a flue with one elbow set. Maximum distance between elbows is 6 feet. For systems with two elbow sets, minimum height is 22 feet. Maximum height of any system is 50 feet. This measurement includes fireplace, chimney sections and height of termination assembly at level of the flue gas outlet (see Figure 16, page 10). Minimum/Maximum Chimney Height for Outdoor Installation Minimum height of chimney, measured from base of fireplace to flue gas outlet of termination, is 9.5 feet (minimum of 4 feet of chimney pipe sections required for outdoor installation). FRAMING 1. Frame opening for fireplace using dimensions shown in Figures 3 and 4. 2. If fireplace is to be installed directly on carpeting, tile (other than ceramic) or any combustible material other than wood flooring, fireplace must be installed upon a metal or wood panel extending full width and depth of fireplace. 3. Set fireplace directly in front of this opening and slide unit back until nailing flanges touch side framing. 4. Check level of the fireplace and shim with sheet metal if necessary. 5. Before securing fireplace to prepared framing, ember protector (provided) must be placed between hearth extension (not supplied) and under bottom front edge of fireplace to protect against glowing embers falling through. If fireplace is to be installed on a raised platform, a Z-type ember protector (not supplied) must be fabricated to fit your required platform height. Ember protector should extend under fireplace 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 fireplace to framing through flanges located on sides of fireplace. 67.125" 58.125" 45.25" (36" Models) 51.25" (42" Models) 59" (50" Models) 30.125" 28.250" (36" Models) Figure 3 - Framing Dimensions Maintain 1 1/2" Clearance at Sides and Back of Fireplace 61" (36" Models) 65" (42" Models) 71" (50" Models) 1 1/2" Clearance Not Required at Nailing Flanges 86.5" (36" Models) 92" (42" Models) 100" (50" Models) Figure 4 - Corner Installation 125655-01C www.fmiproducts.com 5 FIREPLACE INSTALLATION Continued A hearth extension projecting a minimum of 20" in front of and a minimum of 12" beyond each side of fireplace opening is required to protect combustible floor construction in front of fireplace. Fabricate a hearth extension using a material which meets the following specifications: 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 the material selected has a K factor of 0.25, such as glass fiber, 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 fireplace frame and hearth extension with a noncombustible material (see Figure 5). WARNING: Hearth extension is to be installed only as shown in Figure 4. Fireplace Front Seal Gap A mantel may be installed if desired (see Figure 6). Woodwork such as wood trims, mantels or any other combustible material projecting from front face must not be placed within 18" of fireplace opening. Combustible materials above 18" and projecting more than 1 1/2" from fireplace must not be placed less than 21" from the top opening of the fireplace (NFPA STD 211, Sec. 7-3.3.3). Mantels or any other combustible material also may come up to side edge of black metal face of fireplace as long as projections from front face fall within limit shown in Figure 6. 12 1/4" Ref. 6" Ref. 33° Upper Section of Fireplace Fireplace Opening Top View of Fireplace FIREBOX 11.5" SAFE ZONE 33° Fireplace Front Raised Hearth Fireplace Front Elevated Safe Zone for Projection of Combustible Materials 11/2" Max. Ember Protector Ember Protector Combustible Material 3" Nom. 18" Min. HEARTH EXTENSION MANTELS 21" Min. Note: For outdoor installations, fireplace enclosure must allow for adequate drainage and fresh air ventilation. It is recommended that a sealed, corrosion resistant catch pan with provision for drainage be installed under fireplace within fireplace enclosure. 18" Min. to Perpendicular Side Wall Hearth Extension Seal Gap 3" Max. 4.5" Combustible Material Must Not Overlap Front Face Figure 6 - Mantel Clearances to Combustible Material Ember Protector Figure 5 - Hearth Extension 6 www.fmiproducts.com 125655-01C VENTING INSTALLATION OPTIONAL OUTSIDE AIR KIT (MODEL AK4/AK4F) The installation of an outside air kit should be performed during the rough framing of the fireplace due to the nature of it's location. Outside combustion air is accessed through a vented crawl space (AK4F) or through a sidewall (AK4). CAUTION: Combustion air inlet ducts shall not terminate in attic space. The maximum height for the air vent can not exceed 3 feet below the flue gas outlet of the termination. 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 WARNING: The opening in the collar around the chimney at the top of the fireplace must not be obstructed. Never use blown insulation to fill the chimney enclosure. PART NO. LINEAL GAIN DESCRIPTION GAIN Georgian Fireplace 66 1/2" 12-12DM Pipe Section 10 5/8" 12-12HT 18-12DM Pipe Section 16 5/8" 18-12HT 24-12DM Pipe Section 23 5/8" 24-12HT 36-12DM Pipe Section 34 5/8" 36-12HT 48-12DM Pipe Section 46 5/8" 48-12HT RLT-12D Round Termination 7 3/4"* RLT-12HT Square Chase-Top STL-12D 7" to 15"* with Slip Section * The lineal gain for the terminations is measured to the flue gas outlet height. 15" Galvanized Outer Pipe Air Inlet Eyebrow Vent Hood Vented Crawl Space Required for (Check Local Codes Wall Installation Before Installing in a Vented Crawl Space) Figure 7 - Outside Air Kit CHIMNEY PIPE The 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 fitting overlaps must be taken into consideration (lineal gain) and are given in the lineal gain chart (see Figure 8). Lineal Gain is the actual measurable length of a part after two or more parts are connected. For Canada, use chimney parts designated "HT". 125655-01C 12 3/8" Stainless Inner Pipe Hemmed End Figure 8 - Lineal Gain ASSEMBLY AND INSTALLATION OF DOUBLE WALL CHIMNEY SYSTEM Each double wall chimney section consists of a galvanized outer pipe, a stainless steel inner flue pipe and a wire spacer. The pipe sections must be assembled independently as the chimney is installed. When connecting chimney directly to the fireplace, the inner flue pipe section must be installed first with the lanced side up. The outer pipe section can then be installed over 5 the flue pipe section with the hemmed end up. Press down on each pipe section until the lances securely engage the hem on the fireplace starter. The wire will assure the proper spacing between the inner and outer pipe sections. www.fmiproducts.com 7 VENTING INSTALLATION Continued Continue to assemble chimney sections as outlined above, making sure that both the inner and outer pipe sections are locked together. When installing double wall snap-lock chimney together, it is important to assure the joint between the chimney sections is locked. Check by pulling chimney upward after locking. The chimney will not come apart OFFSET A 4 3/8" 9 3/4" 12 3/4" 15" 18" 21 1/4" 23 3/4" 27 3/4" 30" 33" 36" 38 1/4" 41 1/4" 45" 46 3/4" 51" 53 1/4" 56 1/4" 59 1/4" 61 3/4" 64 3/4" 68 1/4" 70" 74 1/4" 76 3/4" 79 3/4" RISE B 16 3/8" 25 1/2" 30 3/4" 34 3/4" 40" 46 1/4" 49 1/4" 56 3/4" 60 3/4" 66" 71" 75" 80 1/4" 86 3/4" 89 1/2" 97" 101" 106 1/4" 111 1/2" 115 1/2" 120 3/4" 127" 130" 137 1/2" 141 1/2" 146 3/4" 12" 1 1 CHIMNEY LENGTH 18" 24" 36" 48" ELBOW SET ONLY 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 1 2 1 1 1 2 1 2 2 4 1 1 1 1 if properly locked. It is not necessary to add screws to keep the chimney together (exception, see Figure 9). USING ELBOW OFFSETS (30E-12DM) 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 9). 2. Chimney weight above offset rests on return elbow. Straps must be securely nailed to rafters or joists (see Figure 10, details A and B). 3. Maximum length of pipe between supports (return elbow or 12S-12DM) is 6' of angle run. Maximum of two 6' angle run sections per chimney system (see Figure 11, page 9). 4. All pipe connections between the offset and return must be secured with two screws on the outer pipe only (see Figure 9). Do not penetrate the inner stainless. See Detail A 1 1 2 1 2 2 1 2 1 1 2" Min. Straps Straps Detail B Angle Firestop Straps OFFSET CHART (22-50 FT. SYSTEM HEIGHT) See Detail B Straps Detail A Return Elbow Screws Figure 10 - Ceiling Support Pipe 12S-12DM B A Figure 9 - Elbow Offset 8 www.fmiproducts.com 125655-01C VENTING INSTALLATION Continued Return Elbow Offset Elbow Return Elbow Offset Elbow 6' Max. Return Elbow 6' Max. Ceiling Support Pipe 12S-12DM Return Elbow 6' Max. Offset Elbow Offset Elbow A Return Elbow Offset 6' Max. Elbow B 6' Max. 6' Max. C Figure 11 - Typical Offset Terminations FIRESTOP SPACERS (FS-10) Firestop spacers are required at each point where the chimney penetrates a floor space. Their purpose is to establish and maintain the required clearance between the chimney and the combustible materials. When the pipe passes through a framed opening into a living space above, the firestop must be placed onto the ceiling from below as shown in Figure 12. They also provide complete separation from one floor space to another or attic space as required by most codes. When the double wall pipe passes through a framed opening into an attic space, the firestop must be placed into an attic floor as shown in Figure 13. Existing Ceiling Frame Firestop Spacer Screws or Staples (Min. of 8) Figure 12 - Firestop Spacer with Living Space Above Ceiling 125655-01C Firestop Spacer Screws or Staples (Min. of 8) Existing Ceiling Frame Figure 13 - Firestop Spacer with Attic Space Above Ceiling PENETRATING ROOF To maintain a 2" clearance to the pipe on a roof with a pitch, a rectangular opening must be cut. 1. Determine center point through which pipe will penetrate roof. 2. Determine center point of roof. Pitch is distance the roof drops over a given span, usually 12". A 6/12 pitch means that roof drops 6" for each 12" measured horizontally down from roof rafters. 3. Use roof opening chart (Figure 14, page 10) to determine correct opening length and flashing required. 4. Remove shingles around opening measured. Cut out this section. www.fmiproducts.com 9 VENTING INSTALLATION Continued 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. Installing Flashing on a Metal Roof When installing the flashing on a metal roof, it is required that putty tape be used between the flashing and the roof. The flashing must be secured to the roof using #8 x 3/4" screws and then sealed with roof coating to prevent leakage through the screw holes. A roof coating must also be applied around the perimeter of the flashing to provide a proper seal. Storm Collar 19.5" Min. 30" Min. 2" Min. 2" Min. 2" Min. Flashing Cone Nail Only Outer Perimeter of Flashing Overlap Shingles Top and Sides Only Opening "A" Pitch Slope Flat 0-6/12 6/12-12/12 0° 26.6° 45.0° Opening Used Flashing "A" Max. Model No. 19.5" V6F-10DM 22' V6F-10DM 27" V12F-10DM Figure 14 - Roof Opening Measurements FLASHING INSTALLATION (V6F-10DM OR V12F-10DM) Determine the flashing to be used with the roof opening chart. Slide flashing over pipe until base is flat against roof. Replace as many shingles as needed to cover exposed area and flashing base. Secure in position by nailing through shingles (see Figure 15). DO NOT NAIL THROUGH FLASHING CONE. Underlap Shingles at Bottom Figure 15 - Flashing Installation Storm Collar Installation (SC2-1) Place storm collar over pipe and slide down until it is snug against the open edge of the flashing (see Figure 16). Apply waterproof caulk around the perimeter of the collar to provide a proper seal. Chimney Pipe Waterproof Caulk Storm Collar Flashing Figure 16 - Storm Collar 10 www.fmiproducts.com 125655-01C VENTING INSTALLATION Continued Terminations/Spark Arrestor The fireplace system must be terminated with the listed round top or chase terminations. In any case, refer to the installation instructions supplied with the termination. CAUTION: Do not seal openings on the rooftop flashing. Follow the installation instructions provided with the termination being used. Stainless Inner Flue Pipe Secure Termination to Outer Pipe with 3 Screws 24" Min. 24" Min. RTL-12D Level of Flue Gas Outlet Waterproof Caulking Storm Collar Flashing Overlap Shingles (Top and Sides of Flashing Base) 18" Min. Typ. Figure 18 - Multiple Chase Installation 10 FOOT RULE All flue gas outlet chimney terminations must extend a minimum of 3 feet in height above the highest point where it passes through the roof and must be at least 2 feet above the highest point of the roof that is within a horizontal distance of 10 feet (see Figure 19). Level of Flue Gas Outlet 10' 10' 2' Min. Underlap Shingles 3' Min. 2' Min. 3' Min. Figure 17 - Termination CHASE INSTALLATIONS Figure 19 - 18 Foot Rule Instructions for chase installations are included with the 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 18). Note: If a decorative shroud is to be installed, contact the manufacturer for specifications. 125655-01C FINISHING FIREPLACE Combustible materials, such as wallboard, gypsum board, sheet rock, drywall, plywood, etc. may make direct contact with sides and top around the fireplace face. It is important that combustible materials do not overlap the face itself. Brick, glass, tile or other noncombustible materials may overlap the front face provided they do not obstruct essential openings like louvered slots or any other opening. When overlapping with a noncombustible facing material, use only noncombustible mortar or adhesive. www.fmiproducts.com 11 REFRACTORY PANEL INSTALLATION IMPORTANT: Installation of brick should be done after the fireplace is placed in a permanent location. 1. Remove grate, screen assemblies and all hardware components out of the firebox. The bottom panel is pre-installed in the firebox. Make sure the bottom refractory panels is centered in the firebox and flush with the front of the fireplace. 2. Place cardboard on top of bottom refractory panel as a protection to prevent shipping and scratching during installation of the other panels. 3. Position "Z" shaped grate retaining brackets on top of the notched area toward the rear of the bottom refractory. They should be positioned a distance apart as shown in Figure 20. 4. Install rear refractory panel. This panel has a top and bottom. To determine which is which, match up the pattern on the rear panel with the left and right sides before LEFT BRICK PANEL Figure 20 - Installing Grate Retainers installing the rear panel. Make sure panel is center before continuing. 5. Install the right and left refractory panels with the gas line knockouts orientated down toward the bottom refractory. Align the left and right panels with the rear panel so the grout lines line up. 6. Install the upper corner brackets and tighten set screws (Figure 21). 7. Install grate by placing rear legs into slots in the grate retainers (Figure 21). UPPER CORNER BRACKET (2x) REAR BRICK PANEL GRATE GRATE RETAINER BRACKET (2x) RIGHT BRICK PANEL BOTTOM BRICK PANEL ASH PANEL Figure 21 - Installing Refractory Panels 12 www.fmiproducts.com 125655-01C REFRACTORY PANEL INSTALLATION Continued WARNING: Risk of fire! Replace grate with FMI PRODUCTS, LLC grate only (see Parts, page 20). This grate has been designed to keep the operation of your fireplace safe and efficient. 3. Mount flat end of screen rod with #10 x 5/8" to center of smoke shelf. 4. Install other screen rod in same manner. Rating Plate Hole for Screen Rod Leading Bricks INSTALLING SCREEN 1. Slide round end of screen rod into rings at top of screen. Attach one push-on nut to end of rod before attaching last ring of screen. 2. Insert the round end screen rod into hole on the left and right side of smoke shelf (Figure 22). Figure 22 - Installing Fireplace Screen OPTIONAL GAS LINE INSTALLATION Gas line hook up should be done by your Outside of Side Fireplace Firebrick supplier or a qualified service person. Finished Note: Before you proceed, make sure your Side Gas Line Remove gas supply is turned off. Conduit Knockout Use only a 1/2" black iron pipe and appropri1/2" Dowel Insulation ate fittings. 1. Remove knockout indentation on refracGas tory or firebrick wall located above refracConduit tory hearth floor. Knockout indentation Brick with Cover Access must be firmly tapped with any solid object Hole such as a 1/2" dowel until it is released. Figure 23 - Gas Line Access Remove fragmented portions of refractory Side (see Figure 23). Outside of Firebrick 2. Remove gas line cover plate located on Fireplace Finished either side of fireplace and pull out insulaIncoming Side tion from gas line conduit sleeve. Save 1/2" Black Gas Line insulation for reuse. Replace screws. Iron Pipe Conduit 3. Run a 1/2" black iron gas line into fireplace through the rear at gas line conduit sleeve (if using a raised platform, add height). Provide Seal sufficient gas line into fireplace chamber for Opening fitting connection (see Figure 24). Repack with Provide Enough Note: Secure incoming gas line to wood Insulation Refractory Threaded framing to provide rigidity for threaded end. Cement End for Fitting 4. Repack insulation around gas line and into Connection sleeve opening. Seal any gaps between Figure 24 Gas Line Installation gas line and refractory knockout hole with refractory cement or commercial furnace cement, Install the gas appliance or cap-off gas line if desired. 125655-01C www.fmiproducts.com 13 OPTIONAL GAS LINE INSTALLATION Continued CAUTION: All gas piping and connections must be tested for leaks after the installation is completed. After ensuring that the 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. WARNING: Do not operate an unvented gas log set in this fireplace with the chimney removed. 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 install a decorative gas appliance (vented gas log), the 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. 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 fireplace. WARNING: If the fireplace has been used for wood burning, the firebox and chimney must be cleaned of soot, creosote and ashes be a qualified chimney cleaner. Creosote will ignite if heavily heated. WARNING: When using a decorative vented gas log, the damper must be removed or permanently locked in the fully open position and the glass doors must be in the fully open position. PUREFIRE HOOD INSTALLATION 1. The PureFire hood supplied with this fireplace is packaged in a separate box and placed in the firebox during shipping. 2. Remove hood from box. Locate brackets (quantity 2) and screws (quantity 4) for hood installation in the hardware bag. 3. Using screws provided, secure the bracket to the inner dome of the fireplace as shown in Figure 25. The left and right bracket are different. The edge that is straight will be closer to the fireplace opening. 4. Lift hood up into the fireplace and place it on the retaining brackets (Figure 25). The rear of the hood will touching the rear of the fireplace. 14 Figure 25 - Installing PureFire Hood www.fmiproducts.com 125655-01C AIR DEFLECTOR AND GLASS DOOR INSTALLATION INSTALLING AIR DEFLECTORS (42'' MODELS ONLY) Slide air deflector in between the front side face and side brick panel (see Figure 27). The notched end of the deflector sits on bottom hearth. Air deflector does not require any fastening. The front side faces and side brick panels will hold the deflector in place (see Figure 27). IMPORTANT: Install glass door frame before installing glass door. INSTALLING DOOR FRAMES 1. Remove screws from smoke shelf (see Figure 26). 2. Mount top door frame and secure with screws removed in step 1. 3. Remove center ash refractory by pulling ring handle (see Figure 27). 4. Remove ash box. 5. Remove three screws located at front of firebox (see Figure 27). 6. Align bottom rail mounting holes with holes at front of firebox and secure with screws removed in step 5. 7. Place ash box in place. Replace center ash refractory. INSTALLING GLASS DOORS Spring clips have been installed but some adjustments may be needed. If doors do not close properly or do not appear straight, see Door Adjustment. 1. With bi-fold doors completely folded, insert bottom pivot pin into pivot hole located near bottom corner of front face opening and swing door to vertical position making sure top pins slide into door track. Door is installed when top door pin snaps into spring clip. 2. Repeat step 1 for remaining door. If you find doors do not close properly or do not appear level or straight, proceed with section on door adjustment, Fold Door and Slide Top Pins Into Track Spring Clip Insert Pin into Spring Clip Insert Bottom Pivot Pin into Hole Pivot Hole Top Door Frame Smoke Shelf Figure 28 - Installing Bi-Fold Doors DOOR ADJUSTMENT Figure 26 - Installing Top Door Frame Air Deflector Remove doors and slightly loosen lower pivot clips and upper spring clips. Replace doors and fully close them. Use 1/8" shims (any material) to level doors. Once proper setting is achieved, carefully open doors enough so that you can access spring clips with a Phillips screwdriver. Tighten screws. See Figure 29. Bottom Door Rail Spring Clip Ash Box Center Brick Ring Screws Handle Figure 27 - Installing Bottom Door Frame and Air Deflectors 125655-01C Figure 29 - Adjusting Bi-Fold Doors www.fmiproducts.com 15 OPERATION AND MAINTENANCE GUIDELINES GLASS DOORS Glass doors are optional with the fireplace. When fireplace is in operation, doors must be fully opened or fully closed position only or a fire hazard may be created (see Figure 30). A fireplace equipped with glass doors operates much differently than a fireplace with an open front. A fireplace with glass doors has a limited amount of air for combustion. Excessive heat within the fireplace can result if too large a fire is built or if combustion air gate is not completely open. The following tips should be followed to assure that both the fireplace and glass door retain their beauty and function properly. Both the flue damper and glass doors must be fully opened before starting fire. This will provide sufficient combustion air and maintain safe temperatures in firebox. IMPORTANT: The glass must be allowed to warm slowly and evenly. The tempered glass will withstand a gradual temperature rise to 550° F, which is more than a normal fire 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 fire and should not be burned in this fireplace. Always keep the fire well back from the doors and never allow flames to contact the glass. 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 flame out of the fireplace opening creating risks of both fire and smoke. Doors Fully Closed Fireplace Front Doors Fully Opened Fireplace Front Figure 30 - Bi-Fold Glass Doors OUTSIDE AIR AND DAMPER HANDLE OPERATION The damper handle, which opens and closes the damper blade, is located in the upper front face of the fireplace. Pushing the handle forward and up through the keyway slot will free damper blade to automatically open. Pushing the handle forward and down will lock damper blade closed (see Figure 31). Damper Weight To Close Damper Damper Weight 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 the fire and smoke. To Open Damper Figure 31 - Operating Damper Handle 16 www.fmiproducts.com 125655-01C PUREFIRE EMISSION CONTROL SYSTEM This fireplace is equipped with a PureFire Emission Control System. The Catalytic Hood system reduces particulates emissions in a wood burning fireplace to meet the EPA Wood-Burning Fireplace Program Phase 2 emission level. The EPA qualifying label, shown on page 18, will be affixed to the catalyst. Before lighting the first fire, remove and maintain this label in a safe place if needed for permits or building inspection. Prior to beginning installation, contact your local building official to determine the need to obtain a permit. For proper operation, catalyst must be replace every 3 to 5 years. FUELING GUIDELINES The fireplace grate must always be secured to the retaining brackets provided. The position of the grate must be centered against the back wall of the firebox. 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 artificial logs, colored newspaper or petroleum based fire 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 inefficient operation. The catalyst is designed to function at optimum efficiency when the fireplace is burning clean, dry, cord wood as fireplace 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, flammable liquids, naptha, household garbage, material treated with petroleum products, leaves, paper products, cardboard or salt driftwood. 125655-01C Refer to your FMI PRODUCTS, LLC Homeowner's Guide included with your fireplace for proper fire 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 fireplace equipped with the catalyst will significantly 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. 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 flame from the fire will clean the combustor. Only a certified technician should remove the unit. To ensure proper fireplace operation, the PureFire System should be replaced every 3 to 5 years (see Parts on page 20). NOTE: Chimney smoke may be visible during the first 8 to 10 minutes of fireplace operation when the fire is first getting started and the final 8 to 10 minutes of operation while the fire 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. www.fmiproducts.com 17 PUREFIRE EMISSION CONTROL SYSTEM Continued WARRANTY 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 Higher Emissions Lower Emissions 12.0 0 Better Worse 4.4 5.1 EPA PHASE 2 EMISSIONS LEVEL THIS MODEL Fireplaces with lower emissions produce less smoke when installed and operated properly. MANUFACTURER: FMI Products, LLC MODEL NO: GCAT50 & VGCAT50 PARTICLE EMISSIONS: 4.4 GRAMS/KG OF WOOD BURNED For proper operation, catalyst must be replaced every 3 to 5 years. * 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. 125574-02 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 fireplace 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 efficiently for three years of fireplace operation. ONLY recommended fuels should be burned. Follow the fueling directions in manufacturers operation manual. For warranty purposes, proof of fireplace 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. 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. FIREPLACE SMOKE EMISSIONS RANGE Higher Emissions Lower Emissions 12.0 0 Better Better Worse Worse 5.1 EPA PHASE 2 EMISSIONS LEVEL 4.4 THIS MODEL Fireplaces with lower emissions produce less smoke when installed and operated properly. MANUFACTURER: FMI Products, LLC MODEL NAME: GCAT42 42” Woodburning Fireplace VGCAT42 42” Woodburning Fireplace PARTICLE EMISSIONS: 4.4 GRAMS/KG OF WOOD BURNED For more information go to www.epa.gov/burnwise 18 125574-07 *EPA has determined, based on testing by an accredited independent laboratory and a certification of conformity by a nation ally recognized certification body, that this model qualifies at the Phase 2 emissions level for U.S. EPA’s Voluntary Fireplace Program. www.fmiproducts.com 125655-01C 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 fireplace ready. You can also visit our web site at www.fmiproducts.com. REPLACEMENT PARTS If this product is missing a part or has a broken component, please do not return it to the store. Call FMI PRODUCTS, LLC at 1-866-328-4537 to answer questions and replace parts under warranty. Note: Use only original replacement parts. This will protect your warranty coverage for parts replaced under warranty. 125655-01C When calling or writing, please have your model and serial numbers of your fireplace ready. Model and serial number information are in the fireplace's rating plate located on the fireplace smoke shelf. www.fmiproducts.com 19 PARTS MODELS (V)GCAT42/50(H)A SERIES AND (V)JCAT42/50(H,S) SERIES 8 10 7 27 6 9 28 5 26 11 12 20 21 14 4 13 22 16/17 15 1 2 19 29 30 24 3 23 20 18 25 www.fmiproducts.com 125655-01C PARTS 125655-01C www.fmiproducts.com • • • • • • • • • • • • • • • • • • • • • • (V)J CAT 50 • • • • • • • • (V)J CAT 42 DESCRIPTION Face Assembly • Firebox Bottom Assembly • Firebox Bottom • Firebox Surround • Outer Dome Assembly • Insulation Pan Support • Insulation Pan • Top Insulation • Fireplace Top Assembly, 42" • Fireplace Top Assembly, 50" Standoff • Fireplace Surround Assembly • Clearance Spacer • Fireplace Handle Bracket • Outside Air Cover Plate • Gas Conduit Cover • Conduit One • Conduit Two • Heat Shield Support • Ash Box Assembly • Inner Dome Assembly • Smoke Shield • Damper Control Bracket • Screen 42" • Screen 50" Screen 42" Stainless Screen 50" Stainless Screen Rod 42'' • Screen Rod 50" Screen Rod 42" Stainless Screen Rod 50" Stainless Grate 42'' • Grate 50" Grate 42" Stainless Grate 50" Stainless Hood Retaining Bracket - Right Hood Retaining Bracket - Right • Hood Retaining Bracket - Left Hood Retaining Bracket - Left • PureFire Catalytic Hood Adj. • PureFire Catalytic Hood CAT50 Air Deflector Left • Air Deflector Right • PARTS AVAILABLE NOT SHOWN 106539-02 Grate Retainer • 106539-04 Grate Retainer Stainless 114913-01 Rear Refractory Spacers • ** Not a field replaceable part. (V)G CAT 50 KEY NO. PART NO. 1 ** 2 ** 3 ** 4 ** 5 ** 6 ** 7 ** 8 ** 9 110285-02 110825-01 10 23490SA 11 ** 12 109720-02 13 117891-01 14 20042 15 21171 16 109752-01 17 109752-02 18 ** 19 123298-02 20 ** 21 ** 22 ** 23 109457-02 109457-01 117556-02 117556-01 24 1110106-03 110146-02 111568-02 117568-01 25 109496-05 109496-04 117544-05 117544-04 26 125864-01 125864-03 27 125864-02 125864-04 28 125582-01 125363-02 29 126198-01 30 126198-02 (V)G CAT 42 This list contains replaceable parts used in your firebox. When ordering parts, follow the instructions listed under Replacement Parts on page 19 of this manual. • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • QTY. 1 1 1 1 1 1 1 1 1 1 4 1 6 4 2 4 2 2 1 1 1 1 1 2 2 2 2 2 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 2 2 6 21 PARTS MODELS (V)GCAT50(H)A SERIES AND (V)JCAT50(H,S)A SERIES Picture may vary from actual 6 2 4 6 3 5 1 22 www.fmiproducts.com 125655-01C PARTS KEY NO. 1 2 3 4 5 6 PART NO. DESCRIPTION 111426-02 111426-01 111428-02 111428-01 125832-02 125832-01 125835-02 125835-01 125838-02 125838-01 125841-02 125841-01 125833-02 125833-01 125836-02 125836-01 125839-02 125839-01 125842-02 125842-01 125831-02 125831-01 125834-02 125834-01 125837-02 125837-01 125840-02 125840-01 111425-02 111425-01 114430-02 111430-01 110822-01 125655-01C G42 A, J 42S G42 HA, J42H G50 A, J 50S G50 HA, J50H VG4 2A, VJ4 2S VG4 2HA , VJ 42H VG5 0A, VJ5 0 VG5 S 0HA , VJ 50H This list contains replaceable parts used in your firebox. When ordering parts, follow the instructions listed under Replacement Parts on page 19 of this manual. Hearth 42" Red Hearth 42" Natural White Hearth 50" Red Hearth 50" Natural White Right Stacked 42" Red Right Stacked 42" Natural White Right Herringbone 42" Red Right Herringbone 42" Natural White Right Stacked 50" Red Right Stacked 50" Natural White Right Herringbone 50" Red Right Herringbone 50" Natural White Left Stacked 42" Red Left Stacked 42" Natural White Left Herringbone 42" Red Left Herringbone 42" Natural White Left Stacked 50" Red Left Stacked 50" Natural White Left Herringbone 50" Red Left Herringbone 50" Natural White Rear Stacked 42" Red Rear Stacked 42" Natural White Rear Herringbone 42" Red Rear Herringbone 42" Natural White Rear Stacked 50" Red Rear Stacked 50" Natural White Rear Herringbone 50" Red Rear Herringbone 50" Natural White Ash Panel 42" Red Ash Panel 42" Natural White Ash Panel 50" Red Ash Panel 50" Natural White Corner Refractory Bracket • QTY. • • • • • • • • • • • • • • • • • • • • • • • • • • • • www.fmiproducts.com • • 1 • • • • • • • • • • • • • • • 1 1 1 1 1 1 1 1 • • 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 23 ACCESSORIES EMBER PROTECTOR 20093 BI-FOLD GLASS DOORS BDG42 - 42'' Black BDG42P - 42'' Platinum BDG42B - 42'' Brushed Brass BD50 - 50" Black BD50P - 50" Platinum BD50B - 50" Brushed Brass OPTIONAL OUTSIDE AIR KIT FOR FLOOR INSTALLATION - AK4F DOUBLE WALL PIPE - 12-12DM, 18-12DM, 24-12DM, 36-12DM, 48-12DM, 12-12HT, 18-12HT, 24-12HT, 3612HT and 48-12HT 24 30° OFFSET AND RETURN 30E-12DM and 30E-12HT www.fmiproducts.com 125655-01C ACCESSORIES Continued STORM COLLAR - SC2-1 OPTIONAL OUTSIDE AIR KIT FOR SIDEWALL INSTALLATION - AK4 FIRESTOP SPACER - FS-10 ROOF FLASHING V6F-10DM - 0 to 6/12 Pitch V12F-10DM - 6/12 to 12/12 Pitch ROUND TOP TERMINATIONS RLT-12D AND RLT-12HT SQUARE CHASE-TOP TERMINATION - STL-12D AND STL-12DMP BLACK 125655-01C www.fmiproducts.com 25 NOTES _____________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ _____________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ _____________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ 26 www.fmiproducts.com 125655-01C NOTES _____________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ _____________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ _____________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ 125655-01C www.fmiproducts.com 27 2701 S. Harbor Blvd. Santa Ana, CA 92704 1-866-328-4537 www.fmiproducts.com 125655-01 Rev. C 09/13
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