manual gi 450 katahdin 091104
TRANSCRIPT
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WARNING:IF THE INFORMATION IN THESE INSTRUC-TIONS ARE NOT FOLLOWED EXACTLY, A FIREOR EXPLOSION MAY RESULT CAUSING PROP-ERTY DAMAGE, PERSONAL INJURY OR LOSSOF LIFE.
FOR YOUR SAFETY:DO NOT STORE OR USE GASOLINE OR OTHERFLAMMABLE VAPORS AND LIQUIDS IN THEVICINITY OF THIS OR ANY OTHER APPLIANCE.
INSTALLATION:INSTALLATION AND SERVICE MUST BE PER-FORMED BY A QUALIFIED INSTALLER, SER-VICE AGENCY OR LICENSED GAS SUPPLIER.
WHAT TO DO IF YOU SMELL GAS:• DO NOT TRY TO LIGHT ANY APPLIANCE.• DO NOT TOUCH ANY ELECTRICAL SWITCHES.• DO NOT USE THE PHONE IN YOUR BUILDING.IMMEDIATELY CALL YOUR GAS SUPPLIER FROMA NEIGHBOR’S PHONE.• FOLLOW YOUR GAS SUPPLIER’S INSTRUCTIONS.• IF YOU CANNOT REACH YOUR GAS SUPPLIER,CALL THE FIRE DEPARTMENT.
AVERTISSEMENT:ASSUREZ-VOUS DE BIEN SUIVRE LES IN-STRUCTIONS DANS CETTE NOTICE POURREDUIRE AU MINIMUM LE RISQUE D’INCENDIEOU POUR EVITER TOUT DOMMAGE MATERIEL,TOUTE BLESSURE OU MORTALIT’E.
NE PAS ENTREPOSER NI UTILISER D’ESSENCENI OU LIQUIDES INFLAMMABLES DANS LEVOISINAGE DE CET APPAREIL OU DE TOUTAUTRE APPAREIL.
L’INSTALLATION LE SERVICE DOIVENTETRE EXECUTES PAR UN INSTALLATEURQUALIFIE, AGENCE DE SERVICE OU LEFOURNISSEUR DE GAZ.
QUE FAIRE SI VOUS SENTEZ UNE ODEUR DEGAZ.• NE PAS TENTER D’ALLUMER L’APPAREIL• NE TOUCHEZ A AUCUM NTERRUPTEUR.• NE PAS VOUS SERVIR DES TELEPHONES SETROUVANT DANS LE BATIMENT OU VOUSVOUS TROUVEZ.• APPELEZ IMMEDIATEMENT VOTREFOURNISSEUR DE GAZ CHEZ UN VOISIN.SUIVEZ LES INSTRUCTIONS DU FOURNISSEUR.• SI VOUS NE POUVEZ REJOINDRE LEFOURNISSEUR DE GAZ, APPELEZ LE SERVICEDES INCENDIES.
InstallationandOperationInstructions
GI 450 D
V Katah
dinG
as Fireplace Insert
2
Welcome to Jøtul...Congratulations on the purchase of your new
Jøtul GI 450 DV Katahdin Gas Fireplace Insert.
We at Jøtul are glad you’ve made the decision to
warm your hearth with a Jøtul product. Your new
fireplace exemplifies our experience gained over
150 years as the world’s largest manufacturer of
solid fuel burning appliances. We’ve been making
fine quality cast iron stoves and fireplaces
continuously since 1853.
The Jøtul GI 450 DV Katahdin Gas Fireplace Insert
combines advanced gas technology with the
warm, traditional elements of cast iron. With
proper care and use, your fireplace will provide
you with many years of safe, dependable and
satisfying service.
Please take a few minutes to familiarize yourself
with this manual and the features of your new
Jøtul fireplace.
3
THIS OWNER’S MANUAL PROVIDESINFORMATION TO ENSURE SAFE INSTALLATIONAND EFFICIENT, DEPENDABLE OPERATION OFYOUR FIREPLACE INSERT. PLEASE READ THESEINSTRUCTIONS IN THEIR ENTIRETY AND MAKETHEM AVAILABLE TO ANYONE USING ORSERVICING THIS GAS INSERT.
Table of Contents:Specifications ................................................................ 4General Information .................................................... 5Minimum Fireplace Dimensions .............................. 6Installation Requirements ......................................... 6Masonry Fireplace Installation ................................. 8Prefabricated (Factory-built) Installation .............. 9Clearance Requirements .......................................... 10Hearth Requirements ................................................ 10Gas Conversion ........................................................... 11Gas Connection........................................................... 12Gas Pressure ................................................................ 13High Altitude Adjustment ....................................... 14Flame Adjustment ..................................................... 15Logset Installation ..................................................... 15Blower Operation ....................................................... 16Wall Thermostat ......................................................... 17Remote Control ........................................................... 17Surround Panel Installation .................................... 18Checking the System ................................................. 19Fireplace Operation ................................................... 20Maintenance ............................................................... 20Service Log.................................................................... 21Illustrated Parts Diagram......................................... 22Replacement Parts ..................................................... 23Antique Brick Panel Kit ............................................. 24Lighting Instructions ................................... BACK COVER
Jøtul GI 450 KatahdinDirect Vent Gas Fireplace Insert
Manufactured and Distributed by:Jøtul A.S.A.
Fredrikstad, Norway
Jøtul North AmericaPortland, Maine
Test StandardsThis appliance complies withNational Safety standards and istested and listed by IntertekTesting Services of Middleton,Wisconsin to ANSI Z21.88-2002•CSA 2.33-M02 andCAN/CGA 2.17--M91, CSA P.4.-01.2for Canada.
MEA No. 312-00-E
DO NOT ATTEMPT TO ALTER OR MODIFY THECONSTRUCTION OF THIS APPLIANCE OR ITSCOMPONENTS. ANY MODIFICATION ORALTERATION WILL VOID THE WARRANTY,CERTIFICATION AND LISTING OF THISAPPLIANCE.
www.nficertified.org
To ensure your confidence, we recommendthat whenever possible, our products be
installed and serviced by professionals whoare certified by the National Fireplace
Institute (NFI) or, in Canada, by Wood EnergyTechnical Training (WETT).
We at Jøtul North America are dedicated tomanufacturing the finest quality hearth
products you can be assured will give youmany years of safe, dependable service.
THIS PRODUCT MUST BE INSTALLED BY A LICENSED PLUMBER OR
GAS-FITTER WHEN INSTALLED IN THECOMMONWEALTH OF MASSACHUSETTS.
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GI 450 DVKatahdinSpecifications
31 1/4”
MEASUREMENTS INCLUDETHE FRONT GRILL ASSEMBLIESAND ARE NOT TO SCALE.
6 1/4”
20 1/2”
32 9/32”
15 3/8”
31 1/4”
34 11/16”
20 13/16”13 1/4”
29 1/4”
20 ”
15”
16 9/16”
14 5/8 ”
Suggested Tool List forInstallation and Maintenance• External regulator (for LP only)• Piping which complies with local code• Manual shutoff valve• Sediment trap• Tee joint• Pipe wrench• Pipe sealant• 10mm open end wrench• 1/2”, 7/16” open end wrench• Phillips head screwdriver• Flat head screwdriver• 1/4” nut driver• Gloves• Safety glasses• Torx T20 screwdriver• Leak test solution
15 3/8”
Input RatesNatural gas33,000 BTU/hr. maximum input26,000 BTU/hr. minimum inputPropane33,000 BTU/hr. maximum input26,000 BTU/hr. minimum input
THIS APPLIANCE IS SHIPPED TOUSE NNNNNAAAAATURAL GAS ONLTURAL GAS ONLTURAL GAS ONLTURAL GAS ONLTURAL GAS ONLYYYYY. FOR USEWITH PROPANE , INSTALL PROPANE
CONVERSION KIT #154903,INCLUDED WITH THIS APPLIANCE.
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General RequirementsTHIS HEATER MUST BE INSTALLED AND MAINTAINED BYA QUALIFIED SERVICE AGENCY.
The installation and repair of this appliance must bedone by a qualified service person. Failure to properlyinstall and maintain this heater could result in anunsafe or hazardous installation, which may result in afire, explosion, property damage, personal injury or lossof life.
This appliance should be inspected before use and atleast annually. More frequent cleaning may be re-quired due to excessive lint from carpeting, beddingmaterial, etc. It is imperative that control compart-ments, burners and circulating air passageways of theappliance be kept clean.
S’assurer que le bruleur et le compartiment descommandes sont propres. Voir les instructionsd’installation et d’utilisation qui accompagnentl’appareil.
The installation must conform to local codes. Yourlocal Jøtul dealer can assist you in determining what isrequired in your area for a safe and legal installation.Some areas require a permit to install a gas burningappliance. Always consult your local building inspectoror authority having jurisdiction to determine whatregulations apply in your area.
Your local officials have final authority in determiningif a proposed installation is acceptable. Any require-ment that is requested by the local authority havingjurisdiction, that is not specifically addressed in THISmanual, defaults to local code. In the absence of localcodes, the installation requirements must comply withthe current National codes. In the U.S., these require-ments are established in the National Fuel Code, ANSIZ223.1.(NFPA 54). In Canada, the codes have beenestablished in CAN/CGA B149 Fuel Installation Code.
Installer l’appareil selon les codes ou reglementslocaux, ou, en l’absence de tels reglements, selon lesCodes d’installation CAN/CGA-B149.
DO NOT OPERATE THIS INSERT IF ANY PART HAS BEENUNDER WATER.
Immediately call a qualified service technician toinspect the heater and to replace any part of thecontrol system and any gas control which has beenunder water.
Ne pas se servir de cet appareil s’il a ete’ plonge dansl’eau, completement ou en partie. Appeler untechnicien qualifie pour inspecter l’appareil etremplacer toute partie du syste’me de controle ettoute commande qui ont ete plonges dans l’eau.
Do not operate this appliance with the glass frontremoved, cracked or broken. Replacement of the glassshould be done by a licensed or qualified serviceperson. Only remove glass for routine service. Alwayshandle glass carefully.
Pour utilisation avec les portes en verre cerifiers avedl’appareil seulemend ou Ne pas utiliser avec des porteson verre.
Safety NoticesYour fireplace insert will reach high surface tempera-tures during normal operation. Please note the follow-ing safety considerations.
Due to the high operating temperatures this appli-ance should be located out of traffic and away fromfurniture and draperies.
Children and adults should be alerted to the hazardsof high surface temperatures and should stay awayto avoid burns or clothing ignition.
Young children should be supervised while they arein the same room as the Katahdin gas insert.
Clothing or other flammable materials should not beplaced ON or NEAR the Katahdin gas insert.
Surveiller les enfants. Garder les vetements, lesmeubles, l’essence ou autres liquides a vapeurinflammables loin de l’appareil.
NEVER store or use gasoline or any other flammablevapors or liquids in the vicinity of the Katahdin gasinsert.
Never burn any other materials in your Katahdin gasinsert, it is strictly designed for use with natural gasor propane fuel ONLY.
Any safety screen, glass or guard removed forservicing the appliance must be replaced prior tooperating the appliance.
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Minimum Fireplace RequirementsThe GI 450 DV Katahdin has been specifically designedto be installed into a solid fuel-burning prefabricatedfireplace OR a code-approved solid fuel-burning ma-sonry fireplace with a tile flue liner.
Minimum Fireplace DimensionsA - Inside Height = 17” (431 mm )
B - Inside Width = 21” (533 mm)(at 15” of depth)
C - Inside Depth = 15”
D - Opening Height = 20”
E - Opening Width = 32 1/2”
Maximum Fireplace OpeningStandard Surround:
Will cover a maximum fireplace opening27 1/2” high x 39” wide.
The overall Standard Surround dimensions are28” high X 40” wide.
Standard Surround with 2” Riser Bar:Will cover a maximum fireplace opening29 1/2” high x 39” wide
The overall Standard Surround dimensions withthe Riser Bar are 30” high X 40” wide.
Optional Wide Surround (must be used with StandardSurround):
Will cover a maximum fireplace opening31 1/2” high X 47” wide.
The overall Wide Surround dimensions are32” high X 48” wide.
NOTE: A pair of Leg Extensions is included with theWide Surround for installations that include the 2”Riser Bar.
Do not modify or alter the construction of the gasinsert or any of its components to enable it to fit intoa fireplace. Any modification of the insert is poten-tially Do not modify or alter the construction of thegas insert or any of its components to enable it to fitinto a fireplace. Any modification of the insert ispotentially dangerous and will void the warranty,certifications and approvals.
Installation RequirementsPrior to installation, the existing chimney exhaust
flue must be thoroughly cleaned and completelyinspected by a qualified chimney sweep or fireplaceservice technician.
Do not install this appliance into a damagedchimney, unless effective repairs can be made prior toinstallation. If you are unsure of the condition of yourfireplace and chimney, contact a professional fireplaceservice technician or your local Jøtul AuthorizedDealer to assist you in determining the condition ofyour fireplace and chimney.
THIS APPLIANCE MUST NOT BE CONNECTED TO ACHIMNEY OR FLUE SERVING ANY OTHER APPLIANCE OFANY KIND.
All venting components must be installed inaccordance with the terms of their listing andmanufacturer’s instructions. Refer to the pipemanufacturer’s instructions for proper pipe clear-ances.
The Katahdin is specifically designed to operateusing 3” Type B vent pipe components or a ListedFlexible gas liner.
B
E
D
C
A
SEE PAGE 19 FOR SURROUND AND RISER BARINSTALLATION INSTRUCTIONS.
Figure 1.
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Vent Installation ProcedureThe GI 450 DV Katahdin gas insert must be ventedthrough dual 3” flexible gas aluminum liners listed foruse with gas appliances.
This co-linear installation includes a pair of 3” flexducts that run from the insert up through the existingchimney.
One duct is attached to the exhaust port on theback of the unit and will carry the exhaust gases tothe outside of the house. This exhaust liner must runthe full length of the chimney and be directly con-nected to the chimney termination cap. See figure 2.
The other 3” liner will be attached to the intakeport on the back of the unit and will provide fresh airfor combustion to the unit. This liner must extend aminimum of 6’ off the back of the unit and extendthrough the damper area of the fireplace and into thetile liner of the chimney. This liner can also extend thefull length of the chimney and connect to the termi-nation cap. See figures 2 and 4.
Vent Guidelines• All vent components must be installed in accordance
with the terms of their listing and manufacturer’sinstructions.
• The minimum height of termination cap from thetop of the unit shall be no less than 10', and themaximum height shall be no more than 35'. Seefigures 2 and 4.
• Steep roofs, nearby trees, or predominantly windyconditions can promote weak draft or occasionaldowndrafts. In such cases, increasing the height ofthe vent or installation of high wind terminationcaps may alleviate the condition.
• HORIZONTAL RUNS are not permitted anywhere inthe venting system.
• Venting liners CANNOT be less than 3” in diameteror greater than 3” in diameter.
• Any unused flue or masonry enclosure can be usedas a passageway for venting PROVIDED the flue isrelined using 3” Listed Flexible Gas Liner.
• The remaining space around the liner in a masonryor zero-clearance flue CANNOT be used to vent anyother appliance.
• Listed Flexible Gas Liners may not be exposed to anyliving space.
• Installation of any components not manufactured orapproved by Jøtul or failure to meet all clearancerequirements will void all warranties and could resultin property damage, bodily injury, or loss of life.
• Never modify any venting component, or use anydamaged venting product.
• THE GAS APPLIANCE AND VENT SYSTEM MUST BEVENTED DIRECTLY TO THE OUTSIDE OF THE BUILD-ING, AND NEVER ATTACHED TO A CHIMNEY SERVINGA SOLID FUEL OR GAS BURNING APPLIANCE.
• The minimum vent height above the roof or adja-cent walls is specified by building codes. A generalguide to follow is the Gas Vent Rule below.
VERY IMPORTANT
If the intake flex does not extend the full lengthof the chimney and connect to the unit and thetermination cap - A METAL BLOCK OFF PLATE MUSTBE CONSTRUCTED AND INSTALLED ABOVE THE UNITBELOW THE END OF THE INTAKE DUCT (normally atthe damper area). See figure 2.
To avoid cross venting the insert, label the duct tobe used for the exhaust conduit at both the top andbottom ends. This ensures that the exhaust duct willbe attached to the correct collar on the insert and onthe chimney termination kit.
CANADA NOTE: Both Intake and Exhaust ductsmust extend the full length of the chimney and beconnected to both the unit and the termination kit.
VERY IMPORTANT NOTICE:
THE USE OF AN EXISTING CHIMNEY AS ANAIR INTAKE IS NOT COVERED UNDER THE
ANSI Z21.88-1999-CSA 2.33-M99 TESTMETHODS AND RESULTING ITS/WHI
PRODUCT CERTIFICATION. THE CODEAUTHORITY HAVING JURISDICTION MUSTBE CONSULTED PRIOR TO PROCEEDING
WITH THIS INSTALLATION METHOD.
GAS VENT RULE
Flat to 6/12 1’0” 0.3M
Over 7/12 to 9/12 2’0” 0.6M
Over 10/12 to 12/12 4’0” 1.2M
Over 13/12 to 16/12 6’0” 1.8M
Over 17/12 to 21/12 8’0” 2.4M
Minimum HeightFrom RoofROOF SLOPE
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Venting through a Masonry Fireplace
1. Measure height of the chimney to fireplace opening.Determine if both the intake and exhaust will beextended to the top of the chimney. In Canada, bothliners must extend the full length of the chimneyand be connected to both the unit and the termina-tion kit.
2. Cut the appropriate lengths of flex duct for both theintake and exhaust. Label both ends of the Exhaustduct.
3. Follow the manufacturer’s instructions to attach theends of the duct(s) to the chimney termination kit asappropriate.
4. Drop the liners down the chimney from the top andrest the termination kit atop the chimney.
5. Seal the chimney termination kit to the top of thechimney flue with high temperature sealant.
6. Secure the appropriate direct vent cap to thetermination kit.
7. Inside the fireplace, fully extend the duct and trimany excess so that the ends hang approximately 15”from the floor of the fireplace.
8. If the Intake duct is not attached to the chimneytermination kit:
A. Install a minimum 6 foot length flex duct for theup the flue.
B. A METAL block-off plate must be constructed andinstalled in the damper area to completely seal offthe flue from the room. Cut holes in the plate forboth the Intake and Exhaust liners.
C. A direct vent cap is required to allow fresh air intothe chimney flue and ultimately into the intake ductto the insert.
9. Compress the ducts so that they are hanging abovethe height of the fireplace opening and are out ofthe way.
10. Position the insert without surround panels half-way inside the fireplace and attach duct you labelledExhaust to the Exhaust collar on the insert. BothIntake and Exhaust collars are labelled.
11. Secure the ducts to the collars with sheet metalscrews or hose clamps. No silicone or sealant isrequired.
12. Once the gas line is installed, carefully push theunit inside the fireplace.
See page 13 for gas line gas line connection.
See page 19 for surround panel installation. Warning: Failure to position the parts in accordance with thisdiagram or failure to use only parts specifically approved with thisappliance may result in property damage or personal injury.
Fig. 2. Venting through fireplace chimney.
Required metalblock-off plate toseal flue chamber ifintake flex does notextend the fulllength of the flue.
Maintain the properclearance to manteland trim
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Direct venttermination kitrequired
GI 450 DVKATAHDINGAS INSERT
Lined MasonryChimney Flue
Intake AirInlet
Listed Direct VentTermination CapRequired
9
Prefabricated Fireplace Installation
A factory-built fireplace will require modification priorto installation of the insert.
Modification1. Remove any fuel grate and other components if
attached. On most models, the firegrate is attachedto the unit with brackets which can be cut or pried off.
2. Remove the damper assembly. This includes thedamper blade, handle and any linkage. Two 3” linersmust be able to pass through the damper area.
3. Remove any firescreen or door assembly. This isusually accomplished with removal of a support rodon the inside of the fireplace frame.
4. Remove the metal ashlip, if appropriate, to allow theinsert to sit flat within the fireplace. Be sure toreinstall any screws removed.
IMPORTANT:BEFORE STARTING THIS INSTALLATION, MAKESURE THAT A GAS LINE CAN BE INSTALLEDOR IS INSTALLED TO THE FIREBOX. THISSHOULD ONLY BE DONE BY A QUALIFIED ORLICENSED PLUMBER OR GAS FITTER.
InstallationFollow the same installation procedural steps detailedon the preceding page for masonry fireplaces.
Figure 3. Duct collar locations.
ExhaustCollar
Air InletCollar
Dual 3” Listed Liners
VERY IMPORTANT NOTICE:
THE USE OF AN EXISTING CHIMNEY AS ANAIR INTAKE IS NOT COVERED UNDER THE
ANSI Z21.88-1999-CSA 2.33-M99 TESTMETHODS AND RESULTING ITS/WHI
PRODUCT CERTIFICATION. THE CODEAUTHORITY HAVING JURISDICTION MUSTBE CONSULTED PRIOR TO PROCEEDING
WITH THIS INSTALLATION METHOD.
Figure 4. Venting through prefabricatedfireplace chimney.
Metal block offplate must beinstalled if theintake ductdoes not extendto the chimneytermination.
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Intake air for combustion
Intake flex mustextend minimum 6’into the chimney pipe
GI 450 DVKATAHDIN
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Listed Direct VentTermination CapRequired
Top sealinganchor platerequired
Listed flexiblegas linersMax. Height: 35 ft.Min. Height: 10 ft.
Factory-builtchimney pipe
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Maintain the properclearance to manteland trim
Warning: Failure to position theparts in accordance withthis diagram or failure touse only parts specificallyapproved with thisappliance may result inproperty damage orpersonal injury.
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Clearance RequirementsThe following clearances and hearth specifications arethe minimum requirements for installing the GI 450Katahdin Insert into a solid fuel-burning fireplace. Seefigs. 5 through 8.
A combustible surface is anything that can burn(i.e. sheet rock, wallpaper, wood, fabrics etc.). Thesesurfaces are not limited to those that are visible andalso include materials that are behind non-combus-tibles.
If you are not sure of the combustible nature of amaterial, consult your local fire officials. Remember,“Fire Resistant” materials are considered combustible;they are difficult to ignite, but will burn. Also, “fire-rated” sheet rock is considered combustible.
Always maintain the proper clearances to allow forthe proper flow of ventilation air around the insert.
Fireplace ClearancesMeasure clearances from the center and finished floorof the fireplace opening.
A = 40” (1016 mm) to a Side Wall, (any combustiblesurface that extends more than 1 1/2” from thefireplace face)
B = 22” (559mm) to Side Trim that extends 1 1/2” orless from the fireplace face. If the side trim extendsmore than 1 1/2” from the fireplace opening then SideWall clearance applies.
C = 36” (867mm) to Top Trim that extends 1 1/2” or lessfrom the fireplace face.
D = 38” (915mm) to a Mantel that extends no morethan 14 1/2” from the fireplace face.
NOTE: MANTEL AND TOP TRIM CLEARANCES ARENOT AFFECTED BY THE USE OF THE 2” RISER BAR.
Hearth RequirementsFlush Hearth: requires a non-combustible hearth in frontof the fireplace that extends a minimum of 18” (457mm)and is a minimum of 32” (813mm) wide.
Raised Hearth: A raised hearth that is at least 6” highrequires a non-combustible hearth in front of the fire-place that extends a minimum of 12” (305mm) from thefireplace face and is a minimum of 32” (813mm) wide.
Hearth must be minimum 6” high toextend only 12” in front
12”
NOTE: USE OF THE 2” RISER BAR DOES NOT EFFECT THEHEARTH REQUIREMENTS LISTED ABOVE.
Figure 5. Fireplace clearances to combustible materials.
Figure 6. Flushhearth dimensions
Figure 7. Raisedhearth dimensions
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18”
32”
6”
BA
C
D
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Gas ConversionThe GI 450 Katahdin gas insert is shipped from thefactory equipped to use NATURAL GAS. A conversion kitis included with the insert for installation to permit useof Propane fuel. The kit contains all the necessarycomponents needed to ensure safe operation, includinglabeling that must be affixed to the insert.
WARNING:THE CONVERSION KIT IS TO BE INSTALLEDBY AN AUTHORIZED JØTUL SERVICE TECH-NICIAN IN ACCORDANCE WITH THEMANUFACTURER’S INSTRUCTION AND ALLCODES AND REQUIREMENTS OF THE AU-THORITY HAVING JURISDICTION. FAILURETO FOLLOW THESE INSTRUCTIONS COULDRESULT IN SERIOUS INJURY OR PROPERTYDAMAGE. THE QUALIFIED AGENCY PER-FORMING THIS WORK ASSUMES RESPONSI-BILITY FOR THIS CONVERSION.
IN CANADA:THE CONVERSION SHALL BE CARRIED OUTIN ACCORDANCE WITH THE REQUIREMENTSOF THE PROVINCIAL AUTHORITIES HAVINGJURISDICTION AND IN ACCORDANCE WITHTHE REQUIREMENTS OF THE CAN1-B149.1AND .2 INSTALLATION CODE.CET EQUIPEMENT DE CONVERSION SERAINSTALLE PAR UNE AGENCE QUALIFIEE DESERVICE CONFORMEMENT AUX INSTRUC-TIONS DU FABRICANT ET TOUTESEXIGENCES ET CODES APPLICABLES DEL’AUTORISES AVOIR LA JURIDICTION. SIL’INFORMATION DANS CETTE INSTRUCTIONN’EST PAS SUIVIE EXACTEMENT, UN FEY,EXPLOSION OU PRODUCTION DEPROTOXYDE DE CARBONE PEUT RESULTERBLESSURE PERSONNELLE DE VIE. L’AGENCEQUALIFIEE DE SERVICE EST ESPONSABLEDE L’INSTALLATION N’EST PAS PROPRE ETCOMPLETE JUSQU’A L’OPERATION DEL’APPAREIL CONVERTI EST CHEQUESUIVANT LES CRITERES ETABLIS DANS LESINSTRUCTIONS DE PROPRIETAIREPROVISIONNEES AVEC L’EQUIPEMENT.
Tools Required:
1/4” Nut driver, 7/16” and 1/2” open end wrench ordeep well socket, 4mm allen wrench, Torx t20 or slottedscrewdriver.
Kit Contents:
1 regulator tower labeled for propane3 regulator tower screws1 burner orifice (#31 NG #51 LPG)1 pilot orifice ( #30 for LPG, #51 for NG)Label A - applied to the base of the insert.Label B - to apply to the rating plate.
IMPORTANT:
Be sure to unplug the blower before proceeding withthis conversion. The gas supply must be turned off anddisconnected from the valve.
Conversion instructions are also included with theconversion kit.
Gas Conversion Procedure1. Open the bottom grill assembly, release the two
glass clips of the underside of the firebox.
2. Swing the bottom of the glass panel out and liftslightly. Remove the glass panel by lifting the glassframe over the brackets at the upper grill assembly.Note: it is NOT necessary to remove the Upper Grillassembly.
3. Lift out the andirons and remove the log set usingcare not to scratch or damage logs.
4. Remove burner tube: Lift the rear of the tube androtate slightly forward. Slide the tube to the right todisengage it from the burner orifice.
5. Once free of the orifice, continue to rotate forwardso that screen and tube are easily removed. Lift out.
6. Change the main burner orifice. Using a ½” openend wrench or deep well socket remove the burnerorifice and replace with the appropriate orifice,supplied in the kit.
7. Adjust the air shutter on the burner tube to allow forthe proper mixing of air and gas. See Figure 8.
The correct settings: Natural - 1/4” open
Propane - 1/4” open
8. To change the pilot orifice: FROM WITHIN THEFIREBOX, PULL THE PILOT HOOD OFF THE PILOTASSEMBLY. Using a 4mm allen wrench threadout the pilot orifice (counter clockwise). Replacewith the appropriate orifice:
#51or natural gas
#30 for propane
Tighten orifice into the base of the pilot assembly.
Burner Tube
Air Shutter
NOTE: AIR SHUTTER SHOULD NEVER BE
LESS THAN 1/8” OPEN.
Figure 8.
12
Be sure the orifice is threaded tightly into the base.See fig. 9.
9. Replace pilot hood onto pilot assembly.
10. Replace the burner tube, BE SURE TO SLIDE TUBE TOTHE LEFT COMPLETELY COVERING ORIFICE.
11. Open the bottom grill assembly to access the valve.
12. Change the variable regulator on the valve (Hi/Loknob). Using a Torx t-20 screwdriver or small flathead screwdriver, remove the three specialty screwsfrom the front of the valve regulator. See fig. 10.
13. Remove the regulator tower and gasket.
BE SURE TO REMOVE THE BLACK RUBBER GASKETFROM THE VALVE. See fig. 10.
14. Install the new variable regulator tower with thenew rubber gasket. Thoroughly tighten new regula-tor to valve body.
15. Install the identification labels to the insert so thatthey can be seen by any person that may be servicingthe insert. APPLY LABEL B TO THE RATING PLATE INTHE SPACEPROVIDED.
16. Reassemble the insert, apply gas to the system andcheck for gas leaks including all insert lines beforeand after the valve.
NEVER USE AN OPEN FLAME TO CHECK FOR GAS LEAKS.
IMPORTANT
Correct gas pressure is essential for efficient and safeoperation of the Katahdin gas insert. It is importantthat the correct gas pressure be established at the timeof the installation. For more details, see the GasPressure section of this manual on page 14.
ALWAYS REFER TO THE LIGHTING INSTRUCTIONS ON THEBACK COVER OF THIS MANUAL WHEN LIGHTING YOURKATAHDIN.
Gas Supply ConnectionThe gas supply line connection is made to the valve onthe left side of the unit facing the front. The gas supplyline should be a minimum of 3/8" in diameter, or theappropriate size to provide sufficient gas pressure tothe valve regardless of the input setting.
See fig. 11 and 12.
For your convience the GI 450 DV Katahdin isshipped with a short piece of 3/8” iron and a 24” lengthof flexible gas line. Jotul recommends the use of theflexible gas line for ease of installation and service.However, for those areas where flexible gas lines arenot permitted use of the 3/8” iron is recommended. Seefig. 12.
The use of Flexible Gas Appliance Connectors isacceptable in many areas in the U.S., however, Canadianmethods vary depending on local code.
ALL INSTALLATIONS MUST COMPLY WITH LOCALCODE OR IN THE ABSENCE OF LOCAL CODE, MUSTCOMPLY WITH THE MOST RECENT EDITION OF THENATIONAL FUEL GAS CODE ANSI Z223.1/NFPA 54 ORCAN-B149.
All codes require: a gas shut-off valve (gas cock).union, to be installed in the supply line, and in the sameroom as the appliance. This allows for the disconnectionof the insert for servicing and maintenance. See fig. 12.
T-handle gas cocks are required in Massachusettsin compliance with code 248CMR.
Pilot Hood
Pilotorificescrewsinto base
Figure 9. Pilot Assembly.
PilotOrifice
BE SURE TO REMOVETHE BLACK RUBBERGASKET FROM THE
VALVE.
Figure 10.Regulator Assembly.
13
Secure all joints tightly using appropriate tools andsealing compounds (for propane units, be sure to usecompounds that are propane resistant). Turn on gassupply and test for gas leaks using a soapy watersolution. Never use an open flame to check for leaks.
Leak Test:
· Mix a 50-50 solution of water and dish soap.
· Light appliance - See lighting instructions on page23 of this manual or on the rating plate.
· Brush or spray all joints and connections with thesoapy water solution.
· If bubbles appear at any connection or seam or a gasodor is detected, immediately turn gas control knobto the OFF position.
Tighten or reconnect the leaking joint and retest forany gas leaks.
Gas PressuresCorrect gas pressure is essential for efficient and safeoperation of the Katahdin gas insert. It is importantthat the correct pressure is established at the time ofthe installation.
Proper gas pressure provides a consistent flow ofgas to the appliance and is instrumental in checking forgas leaks.The gas control valve on the insert is equippedwith pressure test points for gauge connections. Thegauge connections are located on the front of the valveunder the On/Off/Pilot knob. See fig. 13.
IN / E for inlet or supply pressure (the amount of gascoming to the valve.)
OUT / A for manifold pressure (the amount of gas thatis coming out of the valve to the burner.)
The appliance must be isolated from the gas supplyline by closing its individual manual gas shut-off valve(gas cock) during any pressure testing of the gas supplypiping system that is equal to or exceeds pressuresof 1/2 psig (3.5kPa).
NECESSARY INLET GAS PRESSURES (incheswater column)
MIN MAXNATURAL GAS 5.0 WC 13.5 WC
PROPANE 11.0 WC 13.5 WC
NECESSARY MANIFOLD PRESSURES(inches water column)
MIN MAXNATURAL GAS 2.2 WC 3.5 WC
PROPANE 6.5 WC 10.0 WC
ALWAYS TEST PRESSURE WITH VALVE CONTROLKNOB SET ON HIGH.
Figure 12. Gas connection components.
GAS LINE
CONNECTION
Figure 11. Valve inlet centerline.
1 1/4”
7 3/16”
E AFigure 13. Pressure test points.
14
Symptoms of incorrect gas pressure include:
Insufficient gas pressure:
• Small pilot flame which can result in insufficientmillivolts.
• Little variation in flame picture between HI and LOsettings.
• Insufficient gas to support more than one appliancecausing nuisance outages or gas surges.
Excessive gas pressure:
• Permanent damage to valve causing completeappliance shut down.
• Too large a pilot flame resulting in over heating ofthe power generator causing shut down.
• Sooting due to impingement and/or incorrect fuel toair mix.
High Altitude AdjustmentWhen installing GI 450 Katahdin insert at high altitude(above 2000'), it is necessary to compensate for thethinner air (less volume of air per cubic foot). Higheraltitudes affect the atmospheric pressure and heatvalue of gaseous fuels. The lower oxygen content in theair and the lower gas viscosity require the use of adifferent orifice to achieve efficient, clean combustionat the burner tube.
In the U.S.
THE DERATING KIT MUST BE INSTALLED BY AN AUTHO-RIZED SERVICE TECHNICIAN IN ACCORDANCE WITH THEMANUFACTURER’S INSTRUCTIONS AND ALL CODES ANDREQUIREMENTS OF THE AUTHORITY HAVING JURISDIC-TION. THE INFORMATION STICKER MUST BE FILLED OUTBY THE INSTALLER AND ADHERED TO THE APPLIANCE ATTHE TIME OF THE CONVERSION. THE QUALIFIED SERVICEAGENCY PERFORMING THIS WORK ASSUMES RESPONSI-BILITY FOR THIS DERATING.
In Canada
This unit has been tested for installation at highaltitudes in accordance with Canadian test standardCAN/CGA-2.17.THE DERATING SHALL BE CARRIED OUTIN ACCORDANCE WITH THE REQUIREMENTS OF THEPROVINCIAL AUTHORITIES HAVING JURISDICTION ANDIN ACCORDANCE WITH THE REQUIREMENTS OF THECAN1-B-149.1 AND .2 INSTALLATION CODE.
HIGH ALTITUDE INSTALLATIONS:2000 ft. to 4500 ft. installations (or 610m - 1370m)See table 1.
For high altitude installations consult the local gasdistributor or the authority having jurisdiction forproper rating methods. If the installer must convert theunit to adjust for varying altitudes, the information labelmust be completed by the installer and affixed to theappliance at the time of the conversion. See fig. 14.
Derating procedure1. To derate this unit, install the appropriate orifice per
the High Altitude Chart.
2. Remove the two ¼” hex head screws that hold theburner tube/log support to the bottom of the insert.
3. Remove the burner tube/log support to expose themain burner orifice.
4. Remove the orifice and replace with the appropriateone from the high altitude kit.
5. .Be sure to attach the high altitude conversion stickerprovided with the kit to the rating plate on theappliance. See figure 14.
6. It may be necessary to adjust the air shutter on theburner tube. See the AIR SHUTTER/FLAME APPEAR-ANCE section of this manual for more details.
This sticker (shown below) is included in all highaltitude kits and must be adhered to the insertwhenever it is converted for high altitude installa-tions.
Figure 14. High Altitude Conversion Notice Label
Table 1. High Altitude Orifice Chart.
GASTYPE
NATURALGAS
NATURALGAS
PROPANE
PROPANE
#31
#51
#32
#52
0 - 2000’(0 - 619m)
2001’- 4500’(611 - 1170m)
0 - 2000’(0 - 619m)
2001’- 4500’(611 - 1170m)
JØTULPART NO.ELEVATIONORIFICE
SIZE
045026
045027
045024
045025
THIS APPLIANCE HAS BEEN CONVERTED FOR USE
AT AN ALTITUDE OF ______________________
Orifice Size: _______ Manifold Press: ________
Input, BTU/Hr: ________ Fuel Type: _________
Date of Conversion: ______ / _______ / ______
15
Flame Adjustment / Air Shutter
THE KATAHDIN GAS INSERT IS SHIPPED FROM THEFACTORY EQUIPPED FOR USE WITH NATURAL GAS.WHEN USING PROPANE, IT WILL BE NECESSARY TOADJUST THE AIR SHUTTER ON THE BURNER TUBE TOACHIEVE THE PROPER GAS TO AIR MIX. See fig. 15.
WARNING:AIR SHUTTER ADJUSTMENTS SHOULD ONLY BEPERFORMED BY A QUALIFIED PROFESSIONAL
SERVICE TECHNICIAN.
The air shutter adjustment can also help achievethe desired flame appearance. Generally, flameappearance is a matter of preference, however mostconsumers enjoy the warm, yellowish flame.
Closing the Air Shutter - Insufficient combustionair will result in very long yellow flames that canpromote soot. Sooting produces black deposits on thelogs, on the inside walls of the appliance, and poten-tially on the exterior termination cap.
Sooting is caused by incomplete combustion in theflames and lack of combustion air entering the airshutter opening.
Opening the air shutter - will generate a flame thatis blue and transparent, or an “anemic” flame. Thisflame is generally more efficient, but not very attrac-tive.
Jøtul recommends the following settings for theKatahdin gas insert:
Propane: 1/4” open
Natural Gas: 1/4” open
REMEMBER: Run the insert for a minimum of 15 to20 minutes for an accurate representation of the flameappearance. This should be done before and betweenany air shutter adjustments.
To adjust the air shutter
1. Remove the burner tube and using a phillips headscrewdriver loosen the screw at the air shutter andadjust accordingly.
2. Be sure to retighten the screw that holds the airshutter setting.
3. Reassemble the insert including glass assembly.Allow insert to burn 30 minutes on the HIGH setting,observing the flame continuously.
4. If the flame appears weak, slow, or sooty, repeat theprocess described above until the flame is as desired.
Installing the Log SetNOTE: Install the optional Antique Brick Panels beforeinstalling the Log Set.
The Katahdin is equipped with a three piece log setpackaged in bubble wrap inside the firebox. The log setmust be removed from the packaging and arranged inthe unit prior to start up of the gas insert. Protect yourhands by wearing gloves to prevent skin irritation fromthe ceramic fibers.
1. Unwrap each log and set on floor near unit.
2. Lift out andiron.
3. Place rear log over the rear log pins in the rear of thefirebox. The rear log should be installed with thetapered end of the log on the right.
Figure 16. Log identification.
Burner Tube
Air Shutter
NOTE: AIR SHUTTER SHOULD NEVER BE
LESS THAN 1/8” OPEN.
Figure 15.
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Blower OperationThe GI 450 DV Katahdin is equipped with a 125 cfmheat-activated blower. A ten foot power cord is in-stalled in the rear of the valve compartment under thefirebox.
Open the Lower Grill and fully unwrap the powercord. The cord can exit either the right or left side of theinsert. Be sure to pull all slack out of the power cord toprevent contact with the bottom of the firebox.
The is equipped with a three-prong (grounding)plug for protection against shock hazard and should beplugged directly into a properly grounded three-prongreceptacle. DO NOT CUT OR REMOVE THE GROUNDINGPRONG FROM THE PLUG.
The blower must be electrically grounded inaccordance with local codes or, in the absence of localcodes, with the current NFPA 70- National ElectricalCode or CSA C22.1-Canadian Code.
The blower is controlled by a heat activated switch(snapstat) that will function only if the blower controlswitch is in the AUTO setting. Once the firebox heatsafter the burner has been operating for a short time,the blower will start on either the HI or LOW speed. InAUTO mode, the blower will continue to operate afterthe burner is turned off, until the snapstat cools. See fig. 18.
If blower operation is not desired, place the controlswitch in the OFF position to bypass the snapstatfunction.
NOTE:ALWAYS UNPLUG THE BLOWER WHEN
SERVICING THE APPLIANCE.
Figure 18. Blower Controls
Figure 17. Completed log set assembly.
4. Place the front log on the single log pin so that theleft end of the log rests on the log support and theandiron holder- directly above the air shutter.
5. Place the cross-over log on the two remaining pins-top right to the rear log, bottom left on the front log.See fig. 17.
6. Install the embers: the insert is shipped with apackage of ember stones. Spread them evenly acrossthe burner tube screen. It is best to equally spacethese embers for optimum flame appearance. NOTE:YOU DO NOT NEED TO USE ALL OF THE EMBERSTONES.
7. Replace the andiron set, center in the firebox over theandiron support.
THE CERAMIC FIBER LOGS AND EMBER STONES CANIRRITATE YOUR SKIN. IF THIS HAPPENS, GENTLY WASHHANDS WITH WARM, SOAPY WATER.
17
Wall ThermostatWhen installing a wall mounted thermostat to the
Katahdin, it must be a 750 millivolt DC two-wire circuitthermostat. The thermostat should be placed in thesame room as the heater, typically 5’ off the floor. Avoiddrafty areas or any area that may affect the accuracy ofthe thermostat.
The thermostat should be connected to theKatahdin using a minimum of 16 gauge wire with amaximum length of 35 feet of wire.
Connect the two thermostat wire leads to the twolower terminals on the terminal block located to theright of the ON/OFF/TSTAT switch. Do not overtightenthe connections. IT IS NOT NECESSARY TO DISCONNECTANY OTHER WIRES. See Figure 20.
For the thermostat to function, the ON/OFF/T-STATswitch must be in the T-STAT position, and the pilotlight must be running, as it is the power source for thethermostat.
At the thermostat, the two wires should be con-nected to the two connections screws on the thermo-stat base plate per the manufacturer’s instructions.
Optional Remote Control#129706
CAUTION:LABEL ALL WIRES PRIOR TO DISCONNEC-TION WHEN SERVICING THE CONTROLS.WIRING ERRORS CAN CAUSE IMPROPER ANDDANGEROUS OPERATION. ALWAYS VERIFYPROPER OPERATION AFTER SERVICING THEAPPLIANCE.
ATTENTION:AU MOMENT DE L’ENTRETIENDESCOMMANDES, ETIQUETEZ TOUS LES FILSAVANT LE DEBRANCHEMENT. DES ERREURSDE CABLAGE PEUVENT ENTRAIUNFONCTIONNEMENT INADEQUAT ETDAGEREUX.
The optional Jøtul remote can be installed on theKatahdin gas insert. Using the wires supplied withthe remote, it is best to wire the remote directly tothe gas control valve of the insert.
Connect one receiver lead to the terminallabelled TH. Connect the other receiver lead to theterminal labeled TH/TP. DO NOT DISCONNECT ANYOTHER WIRES FROM THE VALVE, AND DO NOT OVERTIGHTEN TERMINAL SCREWS.
Jøtul recommends the use of the optionalRemote Receiver Heat Shield (# 129708) to protectthe receiver under the firebox. The best location forthe receiver is just below the air intake port towardthe back of the unit.
Figure 19. Blower Wiring Diagram - GI 450 Katahdin
Figure 20. Wiring diagram / GI450 DV Katahdin
Place Receiver Here
Figure 21. Remote Receiver position.
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Air IntakePort
18
Surround Panel InstallationComplete the venting and gas line installation beforeinstallation of the surround and riser bar.
RISER BAR: The 2” riser bar is used in conjunction withthe standard surround, and is only needed in the eventthat the fireplace opening is between 27 1/2” and 291/2” high. The riser bar can be used in any installationif desired. See fig. 22.
Start with the insert slightly pulled out of the fireplace.
1. If the riser bar is to be used the insert must be lifted2” off the floor of the fireplace to allow for the riserbar to fill the space below the bottom grill assembly.Exception: in raise fireplace installations the riserbar may extend toward the hearth. See fig. 22.
2. This can be done through the use of the four levelinglegs that are included with the unit. One leveling legis threaded through the floor in each corner of thefireplace.
3. Any other non-combustible material can be used tolift the unit the necessary 2” for the riser bar.
NOTE: DUE TO THE WEIGHT OF THE SURROUND ANDRISER BAR IT MAY BE NECESSARY TO UTILIZE THESTABILIZER BAR THAT IS SHIPPED WITH THE UNIT.THIS STABILIZER ATTACHES TO THE OUTSIDE OF THEFIREBOX AND WILL BRACE THE UNIT AGAINST THEFIREPLACE LINTEL PREVENTING THE UNIT FROMLEANING FORWARD. See figs. 22 and 22A.
4. Lay the four surround panels on the floor backsideup. Using two bolts and washers attach the rightand left upper sections (breastplates) together. Seefig. 23.
5. Attach the left and right leg sections to the breast-plate assembly using a bolt and washer on each side.See fig. 24.
6. Four mounting tabs are attached to the back of thesurround panels at the factory. Be sure all four tabsare in place and secure. See fig. 25.
7. Stand the assembled surround up and gently lift tothe unit. Align the mounting holes on the sides ofthe insert with the mounting tabs on the surround.See fig. 25.
Figure 22A.Mount thestabilizer barusing the two6mm nutsinstalled on thetop of the unit.
StabilizerBracket
12341234123412341234123412341234
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123456123456123456123456123456123456123456123456123456123456123456123456123456123456123456123456123456
2” RiserBar
Bottom GrillAssembly
StabilizerBracket foruse withraisedfireplaces
Raised Fireplace
Mountingbolts forstabilizerbracket
Fireplace Lintel
Figure 22. Installing the Stabilizer Bar.
6 mm nuts
Figure 24.Attach Breastplates to Legs
Figure 23
Use set screw to adjust alignment
Figure 23. Attach Surround Breastplates
19
3. BURNER ADJUSTMENT: The burner is equipped witha variable gas control valve. This valve provides easyadjustment of the flame height appearance and heatoutput. To adjust the flame between the HI and LOsetting, rotate the HI/LO knob, located in the centerof the valve face. Flame height will adjust approxi-mately 1.0” to 1.5” between the HI and LO settings.
NO SMOKE OR SOOT SHOULD BE PRESENT. CHECK LOGPLACEMENT IF ANY SOOT OR SMOKE IS APPARENT. IFSOOT OR SMOKE PERSIST, THE AIR SHUTTER MAYREQUIRE ADJUSTMENT.
CAUTION:DO NOT ATTEMPT TO ALTER THE FLAMEAPPEARANCE BY POSITIONING THE GASVALVE IN ANY OTHER POSITION OTHERTHAN THE FULL “ON” POSITION.
Checking the System1. PURGING THE GAS LINE: When lighting the appli-
ance for the first time it will take a few moments toclear the gas line of air. Once this purge is complete,the appliance will operate as described in thelighting instructions located on the insert’s ratingplate and back cover of this manual. All subsequentlightings of the insert will not require such purgingof the gas line.
2. PILOT FLAME: The pilot flame should be steady, notlifting or floating. The flame should be blue in coloraround the pilot hood, with traces of yellow towardthe outer edges. It is imperative that the pilot flameengulf the top 3/8” of the thermopile (power genera-tor) and the top 1/8” of the quick drop out thermo-couple. The pilot flame should project out of thepilot hood 1” at all three ports. See Figure 28.
8. Slide the surround down into the mounting holes.Be sure all four mounting tabs engage securelywith the adjacent bracket holes. See fig. 26.
9. Secure the two sections of the riser bar togetherwith a washer and bolt and slide the assembledriser bar under the bottom grill assembly on theunit. Attach the Riser Bar to each leg panel with abolt and washer as shown in fig. 25.
Note: the riser bar is not used for support of theinsert- if more space is needed for the riser bar,raise the unit using the front levelling legs. Seefigure 27.
10. Gently and slowly push the unit and surroundback into the fireplace. This is best done bypushing the front outside edges of the glass frame.Reminder: Be sure to inspect the gas line andblower cord to make sure they are not crushedwhen the unit is in its final location.
Figure 27. Riser Bar installation.
Riser Barattaches toleg sections ofthe surround
MountingTabs
Stabilizer Bar attachesto top of unit
Figure 25. Surround mounting tab locations.
Mounting Tabspoint
downward
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Ignitor
Thermopile
Pilot Hood
Figure 28. Correct Pilot flame appearance.
Pilot assembly
Figure 29. Pilot assembly location.
Riser Bar Attachment
Engage tabswith theseholes in thebrackets
Figure 26. Surround engagement with firebox.
LegPanel
LegPanel
20
Fireplace Operation1. The GI 450 DV Katahdin gas insert is equipped with
an On/Off/T-stat rocker switch to control burnerfunctions. Use the T-stat position for use with anoptional wall-mounted thermostat. Separateswitches are provided for the multifunction forcedair blower kit.
2. When lit for the first time, the Katahdin will emit anodor for several hours. This odor is the burn-off by-products of external paints and lubricants used inthe manufacturing process. Open a nearby windowto provide fresh air and alleviate this temporarycondition.
3. Condensation may occur on the glass upon eachlighting of the appliance. This “fog” will disappear asthe appliance temperature increases.
4. Keep the controls and the area under the appliancefree of debris; vacuum this area frequently. Alwayskeep the appliance area clear and free from combus-tible materials, gasoline and other flammableliquids. ALWAYS be sure the insert is cold and NO hotembers or sparks are present before using a vacuumcleaner.
5. Remember, this appliance has a continuous burningpilot flame. Exercise caution when using productswith combustible vapors.
6. CAUTION: DO NOT OPERATE THIS APPLIANCE WITHTHE GLASS REMOVED, CRACKED OR BROKEN. RE-PLACEMENT OF THE GLASS SHOULD BE DONE BY ALICENSED OR QUALIFIED SERVICE PERSON. USE ONLYREPLACEMENT GLASS PROVIDED BY YOUR AUTHO-RIZED JØTUL DEALER. NEVER USE ANY SUBSTITUTEMATERIALS.
WARNING:OBSERVE CAUTION NEAR THE DOOR. THE GLASSPANEL MAY SHATTER UNEXPECTEDLY IF STRUCKWITH AN OBJECT. ALWAYS HANDLE THE GLASSPANEL WITH CARE.
7. Clean the glass only when necessary. Wipe surfacewith a clean, dampened, soft cloth. Follow with a dry,soft towel as desired. Take care not to scratch theglass surface.
WARNING:DO NOT USE ABRASIVE CLEANERS ON THEGLASS. NEVER CLEAN THE GLASS WHEN ITIS HOT.
MaintenanceThe Katahdin gas insert and its venting system shouldbe inspected before use and at least annually by aqualified service technician.
IMPORTANT:ALWAYS TURN OFF THE GAS SUPPLY TO THE
INSERT AND UNPLUG THE FORCED AIR BLOWERBEFORE ANY SERVICE WORK IS PERFORMED ON
THE INSERT.
General cleaning: The firebox should be vacuumed outannually to remove any surface build up. Be sure tovacuum or wipe off the pilot assembly and burnerorifice and burner tube. Also, when vacuuming thelog set, be sure to handle it carefully as it is veryfragile.
Gasket inspection: It is important that the glass gasketbe inspected at least annually. Examine the ropegasket for signs of deterioration and make sure thegasket has a positive seal. This is important toprevent combustion gases from escaping into theroom. Replace the gasket if necessary, refer to thereplacement parts list on page 23.
To remove the glass panel or glass gasket:
1. Open the bottom grill assembly.
2. Release the glass clips on either side of the bottom ofthe firebox.
3. Swing the bottom of the glass frame out and liftslightly.
4. Remove the glass panel by lifting the glass frameover the brackets at the upper grill assembly.NOTE:IT IS NOT NECESSARY TO REMOVE THE UPPER GRILLASSEMBLY.
5. Lay the assembly on a flat surface and lift the metaltabs that secure the glass panel to the frame.
6. Install the new glass panel and gasket in the glassframe and secure with metal tabs. Do not overtighten tabs as this could break the glass.
ALWAYS USE JØTUL AUTHORIZED PARTS. NEVERSUBSTITUTE ANY OTHER PARTS.
Figure 30. Normal flame pattern.
21
Always replace any damaged or broken parts on theKatahdin with JØTUL AUTHORIZED PARTS ONLY. Theseare available through your Authorized Jøtul dealer.Never use any substitute parts on your Katahdin gasinsert.
The Katahdin and its venting system should beinspected annually or semi-annually by a qualifiedservice person or agency.
With proper care and maintenance, your appliancewill provide you with years of enjoyment. If youexperience any problem or inconsistency with yourJøtul Katahdin gas insert, contact your Jøtul AuthorizedDealer for assistance.
To expedite the proper service for your appliancethe following information will help your dealer deter-mine what you will need for parts and service.
RETAIN THIS MANUAL FOR REFERENCE AND MAKEIT AVAILABLE TO ANYONE USING OR SERVICING THEINSERT.
MODEL NAME: GI 450 DV Katahdin Gas Insert
SERIAL NUMBER:__________________________
DATE OF PURCHASE:_______________________
AUTHORIZED DEALER:_____________________
NAME OF INSTALLER:______________________
TYPE OF FUEL:_____________________________
WAS INSERT CONVERTED?__________________
NOTES:
SERVICE LOG:First Year
Name of Technician________________________
Company Name____________________________
Date of service_____________________________
Work Performed____________________________
____________________________________________
____________________________________________
SERVICE LOG:Second Year
Name of Technician________________________
Company Name____________________________
Date of service_____________________________
Work Performed____________________________
____________________________________________
____________________________________________
SERVICE LOG:Third Year
Name of Technician________________________
Company Name____________________________
Date of service_____________________________
Work Performed____________________________
____________________________________________
____________________________________________
22
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Figure 31. Illustrated Parts Breakdown - GI 450 DV Katahdin
23
34 Spud Plate Assembly, NG ............................... 154901Spud Gasket ....................................................... 129669Valve- NG ......................................................... 3902159Valve- LP ........................................................... 3902160Pilot Gasket ........................................................ 129116Pilot Assembly ( NG - Poptop) ....................... 129471Pilot Orifice NG #51 ......................................... 129472Pilot Orifice LP #30 ........................................... 129473Orifice Holder .................................................... 129668Nut - Orifice Holder ......................................... 129152Brass Elbow 3/8 NTP to 5/16 ........................ 129129Main Gas Line, w/ nut & ferrels ................... 154372Main Burner Orifice NG #31 ......................... 045026Main Burner Orifice LPG #51 ........................ 045027Ignitor Button ................................................. 3902573On/Off Extention Knob ................................... 129729High/low Extention Knob .............................. 129730Terminal Block ................................................... 129154Thermocouple - Standard .............................. 129766Thermopile ...................................................... 3094527Electrode w/ wire ............................................. 129765On/Off/Tstat Switch ........................................ 129153Embers ................................................................. 12912324" Supply Flex .................................................. 1297077" Supply Nipple ............................................... 129728Stabilizer Bracket .............................................. 129714
HARDWARE1/4" hex head sheet metal screws........................ 117917M8 X 60 leveling bolt ................................................ 117969M6 X 12 bolt (Surround, Grills) .............................. 117130M6 X 10 set screw (Breast Plate) ........................... 117720M5 X 10 bolt (Hinge bolts) ...................................... 117970M6 washer ................................................................... 120024M6 nut ................................................................................ 9930Star washer .................................................................. 117958Leg Levellers ................................................................. 117969Hanger Tab ................................................................... 129680
ACCESSORIESFuel Conversion Kit - to Propane .......................... 154903Fuel Conversion Kit - to Natural Gas ................... 154928Remote Control Kit .................................................... 129706Remote Receiver Heat Shield .................................. 129708Antique Brick Panel Kit ............................................. 155367Wide Surround Kit - Matte Black .......................... 155323
Blue Black ............................ 155324 Jøtul Iron ............................. 155354
1 Glass Assembly, Complete .......................... 154902Glass Panel ...................................................... 129662Glass Frame ................................................ 12961792Glass Panel w/ gasket .................................. 154986Glass Gasket - 8ft. ......................................... 129124Glass Latch ...................................................... 129135
2 Andiron - Blue Black ................................ 103938273 Andiron Holder ......................................... 129682924 Burner Kit ......................................................... 154994
Burner Tube ..................................................... 1296605 Burner Tube Holder .................................. 129683926 Log Set .............................................................. 155379
Front Log .......................................................... 220626Rear Log ............................................................ 220627Cross-over Log ................................................ 220628
7 Upper Grill, left - Matte Black .............. 10394492 Blue-Black .................. 10394427
Jøtul Iron .................... 10394485Upper Grill, right- Matte Black ............. 10394592
Blue-Black .................. 10394527 Jøtul Iron ..................... 10394585
8 Bottom Grill Assembly Hinge .................... 9010439 Bottom Pan ..................................................... 22053210 Burn Plate, left ........................................... 10395027
Burn Plate, right ........................................ 1039392711 Log Support ..................................................... 12962112 Air Deflector - rear wall ............................... 12967613 Bottom Grill left - Matte Black ............. 10394692
Blue-Black ................. 10394627 Jøtul Iron ................... 10394685
Bottom Grill right - Matte Black .......... 10394792 Blue-Black ................. 10394727
Jøtul Iron ................... 1039468514 Surround Hanger - left ............................ 12969792
Surround Hanger - right ......................... 1296239215 Firebox ......................................................... 1296149216 Top Grill Mount - left ............................... 12963292
Top Grill Mount - right ............................ 1296319217 Glass Frame Hanger ................................ 1296619218 Heat Exchanger Gasket ............................... 12967319 Heat Exchanger .............................................. 12962420 Top Shroud ................................................. 1296419221 Air Intake Manifold ....................................... 12961822 3" Intake/Exhaust Gasket ........................... 12967723 3" Intake/Exhaust Collar ............................. 12962224 Relief Door .................................................. 1296969225 Relief Door Guide ..................................... 1294999226 Relief Door Gasket ......................................... 12967327 Blower Shroud ........................................... 1296309228 Blower Assembly, Replacement ................ 155887
Blower Cord only ........................................... 12917729 Blower Switch Box, Matte Black .......... 22071692
Blower Switch Box, Jøtul Iron ............... 2207168530 Blower Snapstat (140-120 deg F) ............. 22063731 Snapstat Bracket ........................................... 22060832 Blower Control Switch, (2) .......................... 22070333 Exhaust Baffle ................................................ 220712
ALWAYS USE REPLACEMENTS PARTSPROVIDED BY AN AUTHORIZED JØTUL
DEALER ONLY.
GI 450 DV Katahdin Parts List
SURROUND PARTS Matte Black Blue Black Jøtul Iron
1 Breast Plate, Left .............. 10394092 10394027 10394085
2 Breast Plate, Right ........... 10394192 10394127 10394185
3 Leg, Left ............................. 10394292 10394227 10394285
4 Leg, Right .......................... 10394392 10394327 10394385
5 Riser Bar, Left ................... 10394492 10394427 10394485
6 Riser Bar, Right ................ 10394592 10394527 10394585
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CAUTION!THE BRICK PANELS AND LOG PARTS
ARE EXTREMELY FRAGILE. USE BOTHHANDS TO SUPPORT EACH PIECE AS
YOU HANDLE THEM.
Installation Instructions1. Remove the Glass Frame. Disengage the two com-
pression latches located in the control compartmentand lift the frame off of the tabs at the top of thefirebox.
2. Remove the Andirons and Logset.These parts are not fastened. Simply lift them out ofthe firebox.
3. Remove the Cast Iron Side Panels.Use a 10mm socket wrench to remove the retainerbrackets located at the rear corner of each panel. Thesepanels will not be reinstalled, however, you must replacethe two 6 mm bolts to plug the holes.
4. Install the Right Side Panel.Position the panel bottom first against the fireboxwall and slide it forward against the firebox front.
5. Install the Lower Rear Panel.Orient the panel so that the beveled edge is on topand the mortar joints align with those on the sidepanel. Engage the bottom edge with the cutout inthe side panel.
6. Install the Left Side Panel. Lift the lower panel upenough to allow the side panel to clear it. Be sure topush the side forward, up against the firebox front.
7. Install the Upper Rear Panel.This will be a snug fit. Set the panel up high and thencarefully lower it to seat its bottom edge against thetop of the other rear panel. The side panels will holdit in place.
8. Reinstall the Logset and Andirons.Refer to the Owner’s Manual if necessary.
9. Replace the Glass Frame.First engage the top of the frame with the retainer tabs atthe top of the firebox. Seat the frame against the fireboxand pull the latches forward to engage with the slots in theframe bottom.
Figure 33. Install the Right Side Panel.
Figure 34. Install Lower Rear Panel.
r
Kit Contents
Right SidePanel,220619
Tools Required: 10 mm socket wrenchSafety glasses and gloves
Left SidePanel,220620 Lower Rear
Panel, 220621
Upper Rear Panel, 220622
Antique Brick Panel Kit#155367
Figure 32. Brick Panel Identification
25
Figure 35. Install Left Side Panel.
Figure 36. Install Upper Rear Panel.
26
27
7. Push in gas control knob slightly and turn counter-clockwise to “PILOT”.
8. Push in control knob all the way and hold in.Immediately light the pilot by triggering the sparkignitor (push the red button repeatedly) until pilotlights. Continue to hold the control knob in forabout one minute afterthe pilot lights. Releaseknob and it should springback. The pilot shouldremain lit. If it goes out,repeat Steps 5 through 8.
• If knob does notreturn when released,stop and immediatelycall your service technician or gas supplier.
• If pilot will not stay lit after several tries, turnthe control knob to OFF and call your servicetechnician or gas supplier.
9. Turn gas control knob counterclockwise to “ON”.
10.Turn the stove ON/OFF switch to “ON”, or setthermostat (if used) to desired temperature.
3. Access the lower controls.
4. Depress gas control knob slightly and turn clock-wise to “OFF”. Do not force.
FOR YOUR SAFETY, READ BEFORE LIGHTING.
LIGHTING INSTRUCTIONS
TO TURN OFF GAS TO THE APPLIANCE:
LIGHTING INSTRUCTIONS
WARNING:IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY, A FIRE OR EXPLOSION MAY
RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY, OR LOSS OF LIFE.
A. This appliance has a pilot which must be litby hand. When lighting the pilot, followthese instructions exactly.
B. BEFORE LIGHTING, smell all around theappliance area for gas. Be sure to smell nextto the floor because some gas is heavier thanair and will settle to the floor.
WHAT TO DO IF YOU SMELL GAS:• Extinguish any open flame.• Open windows.• Do not light any appliance.• Do not touch any electrical switches.• Do not use any phone in your building.• Immediately call your gas supplier from a
neighbor’s phone.
• If your gas supplier cannot be reached, call thefire department.
C. Use only your hand to push in or turn the gascontrol knob. Never use tools. If the knob willnot push in or turn by hand, do not try to repairit. Call a qualified technician. Force or attemptedrepair may result in a fire or explosion.
D. Do not use this appliance if any part has beenunder water. Immediately call a qualified servicetechnician to inspect the appliance and toreplace any part of the control system and anygas control which has been under water.
1. STOP! Read the safety information above.
2. Access the lower controls.
3. Turn the stove ON/OFF switch to “OFF”, or set thethermostat to lowest setting (if used).
4. Confirm that the gas supply line shut-off valve is open.
5. Push in gas control knob slightly and turn clockwiseto “OFF”.
NOTE: Knob cannot be turned from “PILOT” to “OFF”unless the knob is pushed in slightly. Do not force.
6. Wait five (5) minutes to clear out any gas. If you thensmell gas, STOP! Follow “B” in the safety informationabove on this page. If you do not smell gas, go to thenext step.
1. Turn ON/OFF switch to” OFF”. The pilot will remain lit fornormal service.
2. For complete shutdown, turn ON/OFF switch to “OFF”.
Pilot AssemblyControl Valve
ControlKnob
OFFPILO
T ON
28
Jøtul ASAP.O. Box 1411N-1602 FredrikstadNorway
Jøtul North America400 Riverside StreetPortland, ME 04104
Novem
ber 2004
129710-C
This appliance must be installed in conformance with local and national building regulations. Beforebeginning the installation, it is important that the these instructions be carefully read and understood.Jøtul maintains a policy of continual product development. Consequently, products may differ inspecification, color or type of accessories from those illustrated or described in various publications.
Jøtul vise sans cesse a ameliorer ses produits. C’est pourquoi, il se reserve le droit de modifier lesspecifications, couleurs etequipement sans avis prelable.