Jøtul GI 450 DV Katahdin

Direct Vent Gas Fireplace Insert

Installation andOperation Instructions

CAUTION: THESE INSTRUCTIONS MUST
REMAIN WITH THE HOMEOWNER.
WARNING: If the information in these
instructions is not followed exactly, a fireor explosion may result causing property
damage, personal injury or loss of life.

ATTENTION : CES INSTRUCTIONS DOIVENTDEMUERER AVEC LE PROPRIÉTERE D’UNE
MAISON.
AVERTISSEMENT: Assurez-vous de bien
suivreles instructions données dans cettenotice pour réduire auninimum le risqued’incendie ou d’explosion ou pour éviter tout
dommage matériel, toute blessure ou la mort.

– Do not store or use gasoline or otherflammable vapors and liquids in thevicinity of this or any other appliance.

– Ne pas entreposer ni utiliser d’essence ni
d’autres vapeurs ou liquides inflammables
dans le voisinage de cet appareil ou de tout
autre appareil.

– WHAT TO DO IF YOU SMELL GAS– QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE
GAZ:• Do not try to light any appliance.
• Do not touch any electrical switch; do
not use any phone in your building.
• Immediately call you gas supplier from aneighbor’s phone. Follow the gas
supplier’s instruction.
• If you cannot reach your gas supplier,call the fire department.
– Installation and service must be
performed by a qualfied installer, service
agency or the gas supplier.
– In the Commonwealth of Massachusetts, acarbon monoxide (CO) detector shall be
installed in the same room as theappliance.

• Ne pas tenter d’allumer l’appareil.
• Ne touchez à aucum interrupteur. Ne pas
vous servir des téléphones se trouvant
dans le bâtiment où vous trouvez.
• Appelez immédiatement votre
fournisseur de gaz depuis un voisin. Suivez
les instructions du fournisseur.
• Si vou ne pouvez rejoindre le fournisseurde gaz, appelez le service des incendies.
– L’installatione l’entretien doivent êtreassurés par un installateur ou un service
d’entretien qualifié ou par le fournisseurde gaz.

12

Jøtul GI 450 DV Katahdin
Direct Vent Gas Fireplace Insert
Manufactured and Distributed by:
Jøtul AS
Fredrikstad, Norway
Jøtul North America
Gorham, Maine 04038 U.S.A.

Test Standards
This appliance complies with U.S.
and Canadian National Safety
standards and is tested and listed
by Intertek Testing Services ofMiddleton, Wisconsin to:
ANSI Z21.88-2005,ANSI Z21.88a / CSA 2.33a - 2007,
CAN/CGA 2.17 -M91, and CSA P.4-01.2.
New York City Dept. of Buildings MEA No. 312-00-E

THIS PRODUCT MUST BE INSTALLEDBY A LICENSED PLUMBER OR
GAS-FITTER WHEN INSTALLED IN THE
COMMONWEALTH OF MASSACHUSETTS.

Table of Contents:
Specifications ................................................................ 4
General Information .................................................... 5
Minimum Fireplace Dimensions .............................. 6
Installation Requirements ......................................... 6
Masonry Fireplace Installation ................................. 8
Prefabricated (Factory-built) Installation ............... 9
Clearance Requirements ........................................... 10
Hearth Requirements ................................................ 10
Gas Conversion .............................................................. 11
Gas Connection ............................................................ 12
Gas Pressure .................................................................. 13High Altitude Adjustment ........................................ 14
Flame Adjustment ....................................................... 15
Logset Installation ....................................................... 15
Blower Operation ....................................................... 16
Wall Thermostat .......................................................... 17
Remote Control ............................................................ 17
Surround Panel Installation ...................................... 18
Checking the System ................................................. 19
Fireplace Operation .................................................... 20
Maintenance ................................................................ 20
Service Log ..................................................................... 21
Illustrated Parts Diagram ......................................... 22
Replacement Parts ..................................................... 23
Antique Brick Panel Kit .............................................. 24
Appendix / Leg Levelers ............................................ 26
Lighting Instructions ................................... BACK COVER

THIS OWNER’S MANUAL PROVIDESINFORMATION TO ENSURE SAFE INSTALLATIONAND EFFICIENT, DEPENDABLE OPERATION OF
YOUR FIREPLACE INSERT. PLEASE READ THESE
INSTRUCTIONS IN THEIR ENTIRETY AND MAKE
THEM AVAILABLE TO ANYONE USING ORSERVICING THIS GAS INSERT.
DO NOT ATTEMPT TO ALTER OR MODIFY THE
CONSTRUCTION OF THIS APPLIANCE OR ITSCOMPONENTS. ANY MODIFICATION OR
ALTERATION WILL VOID THE WARRANTY,CERTIFICATION AND LISTING OF THISAPPLIANCE.

3

GI 450 DV
KatahdinSpecifications

20 1/2”

6 1/4”

15 3/8”MEASUREMENTS INCLUDE
THE FRONT GRILL ASSEMBLIESAND ARE NOT TO SCALE.

31 1/4”32 9/32”
14 5/8 ”

29 1/4”20 ”
13 1/4”16 9/16”

20 13/16”

15”

15 3/8”31 1/4”34 11/16”

Input Rates
Natural gas
33,000 BTU/hr. maximum input
26,000 BTU/hr. minimum input
Propane33,000 BTU/hr. maximum input
26,000 BTU/hr. minimum input
TU RALTHIS APPLIANCE IS SHIPPED TO USE NA
NATONLLY . FOR USE WITH PROPANE , INSTALLGAS ONPROPANE CONVERSION KIT #154903,
INCLUDED WITH THIS APPLIANCE.

4

Suggested Tool List for
Installation 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

General Requirements
 THIS HEATER MUST BE INSTALLED AND MAINTAINED BY
A QUALIFIED SERVICE AGENCY.

 The installation and repair of this appliance must be
done by a qualified service person. Failure to properly
install and maintain this heater could result in an
unsafe or hazardous installation, which may result in afire, explosion, property damage, personal injury or lossof life.

 This appliance should be inspected before use and at
least annually. More frequent cleaning may be required due to excessive lint from carpeting, bedding
material, etc. It is imperative that control compartments, burners and circulating air passageways of theappliance be kept clean.

 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 et toutecommande qui ont ete plonges dans l’eau.

 Do not operate this appliance with the glass front
removed, cracked or broken. Replacement of the glass
should be done by a licensed or qualified service
person. Only remove glass for routine service. Always
handle glass carefully.

 Pour utilisation avec les portes en verre cerifiers aved
l’appareil seulemend ou Ne pas utiliser avec des portes
on verre.

 S’assurer que le bruleur et le compartiment descommandes sont propres. Voir les instructions
d’installation et d’utilisation qui accompagnent
l’appareil.

 The installation must conform to local codes. Your local
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 burning
appliance. Always consult your local building inspector
or authority having jurisdiction to determine whatregulations apply in your area.

 Your local officials have final authority in determining if
a proposed installation is acceptable. Any requirementthat is requested by the local authority having jurisdiction, that is not specifically addressed in THIS manual,defaults to local code. In the absence of local codes, theinstallation requirements must comply with thecurrent National codes. In the U.S., these requirements
are established in the National Fuel Code, ANSI
Z223.1.(NFPA 54). In Canada, the codes have been
established in CAN/CGA B149 Fuel Installation Code.

 Installer l’appareil selon les codes ou reglements

Safety Notices
Your fireplace insert will reach high surface temperatures during normal operation. Please note the following safety considerations.

 Due to the high operating temperatures this appliance 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 away
to 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 be
placed ON or NEAR the Katahdin gas insert.

 Surveiller les enfants. Garder les vetements, lesmeubles, l’essence ou autres liquides a vapeur
inflammables loin de l’appareil.

 NEVER store or use gasoline or any other flammablelocaux, ou, en l’absence de tels reglements, selon les
Codes d’installation CAN/CGA-B149.

vapors or liquids in the vicinity of the Katahdin gas
insert.

 DO NOT OPERATE THIS INSERT IF ANY PART HAS BEEN

 Never burn any other materials in your Katahdin gas

UNDER WATER.

 Immediately call a qualified service technician toinspect the heater and to replace any part of thecontrol system and any gas control which has been
under water.

insert, it is strictly designed for use with natural gas
or propane fuel ONLY.

 Any safety screen, glass or guard removed for servicing the appliance must be replaced prior to operating
the appliance.

5

Minimum Fireplace Requirements
This appliance has been specifically designed to beinstalled into a solid fuel-burning prefabricated fireplace OR a code-approved solid fuel-burning masonry
fireplace with a tile flue liner.

SEE PAGE 19 FOR SURROUND AND RISER BARINSTALLATION INSTRUCTIONS.
SEE THE APPENDIX ON PAGE 26 FOR DETAILSCONCERNING USE OF THE LEG LEVELER BRACKETS
TO ADJUST THE HEIGHT OF THE UNIT.

Figure 1.

A

D

B
C
E

Minimum Fireplace Dimensions
A - 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 Opening
Standard Surround:e openingeplacWill cover a maximum fir
fireplac
eplace2 7 11//2” high x 39” wide
wide..
The overall Standard Surround dimensions are
28” high X 40” wide.
Standard Surround with 2” Riser Bar:eplac
e opening
Will cover a maximum fir
fireplac
eplace29 11//2” high x 39” wide
The overall Standard Surround dimensions with
the Riser Bar are 30” high X 40” wide.
Optional Wide Surround (must be used with StanSurroundd Surround):
dardSurroundound):
dareplac
e opening
Will cover a maximum fir
fireplac
eplace7” wide47”
wide..
31 11//2” high X 4
The overall Wide Surround dimensions are32” high X 47 5/8” wide.
NO
TE: A pair oeg EExtensions
xtensions is included withNOT
off LLegound ffor
or installa
tions tha
Surroundinstallations
thatt include
the Wide Surrthe 2” Riser Bar
Bar..

6

Do not modify or alter the construction of the gas
insert or any of its components to enable it to fit into a
fireplace. Any modification of the insert is potentially
Do not modify or alter the construction of the gas
insert or any of its components to enable it to fit into a
fireplace. Any modification of the insert is potentially
dangerous and will void the warranty, certifications
and approvals.

Installation Requirements
Prior to installation, the existing chimney exhaust
flue must be thoroughly cleaned and completely
inspected by a qualified chimney sweep or fireplace
service technician.
Do not install this appliance into a damaged
chimney, unless effective repairs can be made prior to
installation. If you are unsure of the condition of yourfireplace and chimney, contact a professional fireplace
service technician or your local Jøtul Authorized Dealer
to assist you in determining the condition of yourfireplace and chimney.
TH IS APPLIANC
EM
US
T NO
TB
EC
ON
N EC
TED TOAPPLIANCE
MUS
UST
NOT
BE
CON
ONN
ECT
UE SERVING AN
YO
T H ER APPLIAC
H IMN
EY OR FL
FLU
SERVI
VING
ANY
OT
CH
IMNE
ANC
E OF AN
Y KI
N D.
KIN
ANCE
ANY
All venting components must be installed inaccordance with the terms of their listing andmanufacturer’s instructions. Refer to the pipe
manufacturer’s instructions for proper pipe clearances.
This appliance is specifically designed to operateusing 3” Type B vent pipe components or a Listed
Flexible gas liner.

Vent Guidelines

Vent Installation Procedure• All vent components must be installed in accordancewith the terms of their listing and manufacturer’s
instructions.

The GI 450 DV Katahdin gas insert must be vented
through dual 3” flexible gas aluminum liners listed foruse with gas appliances.

• The minimum height of termination cap from the
top of the unit shall be no less than 10'
10', and the
maximum height shall be no more than 35'
35'. Seefigures 2 and 4.

This co-linear installation includes a pair of 3” flex
ducts that run from the insert up through the existing
chimney.

• Steep roofs, nearby trees, or predominantly windy
conditions can promote weak draft or occasional
downdrafts. In such cases, increasing the height ofthe vent or installation of high wind termination
caps may alleviate the condition.
IZON
TAL RUNS are not permitted an
ywher
e in
• HOR
HORIZ
IZON
ONT
RUNS
are
anywherywherethe vven
en
ting
s
y
stem.
enting sy• Venting liners CANNOT be less than 3” in diameter orgreater than 3” in diameter.
• Any unused flue or masonry enclosure can be used asa 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 any
living space.
• Installation of any components not manufactured orapproved by Jøtul or failure to meet all clearance
requirements will void all warranties and could result inproperty damage, bodily injury, or loss of life.
• Never modify any venting component, or use any
damaged venting product.
• THE GAS APPLIANCE AND VENT SYSTEM MUST BE
VENTED DIRECTLY TO THE OUTSIDE OF THE BUILDING, AND NEVER ATTACHED TO A CHIMNEY SERVINGA SOLID FUEL OR GAS BURNING APPLIANCE.
• The minimum vent height above the roof or adjacentwalls is specified by building codes. A general guideto follow is the Gas Vent Rule below.

Flat to 6/12

The other 3” liner will be attached to the intake
port on the back of the unit and will provide fresh air
for combustion to the unit. This liner must extend aminimum o
off 6’ off the back of the unit and extend
through 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 termination cap. See figures 2 and 4.
VER
Y IMP
OR
TAN
T
VERY
IMPOR
ORT
ANT
If the intake flex does not extend the full lengthof the chimney and connect to the unit and the
AL B
ATE M
US
T
termination cap - A METMETALBLL OC K OFF PL
PLA
MUS
UST
TALLED AB
OVE TH E
BE C
ONS
TRUC
T ED AND IINS
NS
NST
ABO
CONS
ONST
RUCT
AND
EL
OW T H E EN
D OF T H E IIN
N TAKE DUC
T
U N IT B
BEL
ELO
END
DUCT
(normally at the 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 will
be attached to the correct collar on the insert and on
the chimney termination kit.
CANAD
A NO
T E: Both In
take and EExhaust
xhaust duc
ts
ANADA
NOT
Intak
take
ducts
y and bextend the full length ooff the chimne
chimneymust eextend
connected t o both the unit and the termina
tion
onnected
termination
kit
kit..

VERY IMPORTANT NOTICE:GAS VENT RULE
ROOF SLOPE

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 run
the full length of the chimney and be directly connected to the chimney termination cap. See figure 2.

Minimum Height
From Roof
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

THE USE OF AN EXISTING CHIMNEY AS AN
AIR INTAKE IS NOT COVERED UNDER THE
ANSI Z21.88-1999-CSA 2.33-M99 TESTMETHODS AND RESULTING ITS/WHIPRODUCT CERTIFICATION. THE CODEAUTHORITY HAVING JURISDICTION MUST
BE CONSULTED PRIOR TO PROCEEDING
WITH THIS INSTALLATION METHOD.

7

Venting through a Masonry Fireplace

Fig. 2. Venting through fireplace chimney.

1. Measure height of the chimney to fireplace opening.
Determine if both the intake and exhaust will beanada, both
extended to the top of the chimney. In C
Canada,liners must eextend
xtend the full length oyoff the chimne
chimneyand be cconnec
onnec
ted t o both the unit and the termionnectednation kit
nationkit..
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.

Listed Direct Vent
Termination Cap
Required
Intake Air
Inlet

Direct venttermination kit
required

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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 the termination kit.
7. Inside the fireplace, fully extend the duct and trim
any excess so that the ends hang approximately 15”
from the floor of the fireplace.
8. If the Intake duct is not attached to the chimney
termination kit:

Lined Masonry
Chimney Flue

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 o
offf
the flue from the room. Cut holes in the plate forboth the Intake and Exhaust liners.

Maintain the proper
clearance to mantel
and trim

C. A direct vent cap is required to allow fresh air into
the chimney flue and ultimately into the intake duct
to the insert.
9. Compress the ducts so that they are hanging above
the height of the fireplace opening and are out of
the way.
10
10.. Position the insert without surround panels halfway inside the fireplace and attach duct you labelled
Exhaust 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.

Required metal
block-off plate toseal flue chamber if
intake flex does notextend the fulllength of the flue.

GI 450 DV
KATAHDINGAS INSERT

12. Once the gas line is installed, carefully push the unit
inside the fireplace.
See page 13 for gas line gas line connection.
See page 19 for surround panel installation.

8

Warning: FFailur
ailur
e t o position the parts in acdanc
e with thisailureparts
acccorordancdance
diagr
am or ffailur
ailur
e t o use only par
ts specifically appr
oved withailureparts
diagramappro
this appliance may rresult
esult in proper
ty damage or personal
properopertydamageappliance
may
injur
y.
injuryPrefabricated Fireplace Installation
A factory-built fireplace will require modification prior
to installation of the insert.

Modification
1. 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” liners
must be able to pass through the damper area.
3. Remove any firescreen or door assembly. This is
usually accomplished with removal of a support rod
on the inside of the fireplace frame.
4. Remove the metal ashlip, if appropriate, to allow theinsert to sit flat within the fireplace. Be sure to
reinstall any screws removed.
IMPORTANT:BEFORE STARTING THIS INSTALLATION, MAKE SURE THAT A
GAS LINE CAN BE INSTALLED OR IS INSTALLED TO THE FIREBOX. THIS SHOULD ONLY BE DONE BY A QUALIFIED OR
LICENSED PLUMBER OR GAS FITTER.

Installation
Follow the same installation procedural steps detailedon the preceding page for masonry fireplaces.

VERY IMPORTANT NOTICE:
THE USE OF AN EXISTING CHIMNEY AS AN
AIR INTAKE IS NOT COVERED UNDER THE
ANSI Z21.88-1999-CSA 2.33-M99 TESTMETHODS AND RESULTING ITS/WHIPRODUCT CERTIFICATION. THE CODEAUTHORITY HAVING JURISDICTION MUST
BE CONSULTED PRIOR TO PROCEEDING
WITH THIS INSTALLATION METHOD.

Dual 3” Listed Liners

Figure 4. Venting through prefabricatedfireplace chimney.
Listed Direct Vent
Termination Cap
Required

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Top sealing
1234
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anchor plate
1234
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required
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Intake air for
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combustion
1234
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Listed flexible
1234
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gas liners
1234
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Max. Height: 35 ft.
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Min. Height: 10 ft.
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Factory-built
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chimney pipe
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Maintain the proper 1234
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clearance to mantel 1234
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and trim
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Intake flex must
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extend minimum 6’
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into the chimney pipe
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Metal block off
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plate must be
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installed if the1234561234
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intake duct
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does not extend
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to the chimney
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termination.
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CollarExhaustCollarWarning:ailure t o position the
FFailur
ailureparts in acdanc
e withparts
acccorordancdance
this diagr
am or ffailur
ailurediagramailureto use only parts
parts
specifically appr
oved
appro
with this appliance mayappliancemay
result in proper
typroperopertydamage or personal
injur
y.
injuryGI 450 DV
KATAHDIN

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Figure 3. Duct collar locations.

9Clearance Requirements

Hearth Requirements

The following clearances and hearth specifications are
the minimum requirements for installing the GI 450
Katahdin Insert into a solid fuel-burning fireplace. See
figs. 5 through 8.

Flush Hearth: requires a non-combustible hearth in front
Hearth:of the fireplace that extends a minimum of 18” (457mm)
and is a minimum of 32” (813mm) wide.

A combustible surface is anything that can burn (i.e.
sheet rock, wallpaper, wood, fabrics etc.). These surfaces
are not limited to those that are visible and also include
materials that are behind non-combustibles.
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, “firerated” sheet rock is considered combustible
ombustible.
Always maintain the proper clearances to allow for
the proper flow of ventilation air around the insert.

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18”

Figure 6. Flushhearth dimensions

32”

Raised Hear
th: A raised hearth that is at least 6” highHearth:requires a non-combustible hearth in front of the fireplace that extends a minimum of 12” (305mm) from thefireplace face and is a minimum of 32” (813mm) wide.

Fireplace Clearances
Measure clearanc
es fr
om the ccenen
ter and finished
Measureclearanc
ances
from
enter
floor oeplac
e opening
eplaceopening..
off the fir
fireplac
A = 40” (1016 mm) t o a Side Wall, (any combustible
surface that extends more than 1 1/2” from thefireplace face)

Figure 7. Raisedhearth dimensions

B = 22” (559mm) t o Side Trim that extends 1 1/2” or less
(559mm)from the fireplace face. If the side trim extends morethan 1 1/2” from the fireplace opening then Side Wall
clear
anc
e applies.
clearanc
ance
C = 36” (867mm) to Top Trim that extends 1 1/2” or less
(867mm)from the fireplace face.

12”6”

D = 38” (915mm) t o a Man
tel that extends no more
Mantelthan 14 1/2” from the fireplace face.
NOTE: MANTEL AND TOP TRIM CLEARANCES ARENOT AFFECTED BY THE USE OF THE 2” RISER BAR.

Hearth must be minimum 6” high toextend only 12” in frontNO
T E: USE OF TH E 2” R
ISER BAR DOES NO
T EFFEC
T
NOT
RISER
BAR
NOT
EFFECT
TH E HEAR
TH R
EQU
T S LISTED AB
OVE.
HE
ART
REQU
EQUII R EMEN
EMENT
LIST
ABO

Leg Leveler Brackets
See the Appendix on page 26 for information on theproper use of the Leg Leveler Brackets to raise the insert.
D
C

A

B

Figure 5. Fireplace clearances to combustible materials.

10

ombustibles
Clear
anc
e to C
Clearanc
ance
Combustibles
When raising the firebox up to 2”, mantel and hearth
clearance remain unchanged from those specified above.
Raising the firebox higher than 2” will require that the clearance to mantel and trim be increased by 1”:
C = Hearth to Upper Trim - 37”
D = Hearth to Mantel - 39”

Gas Conversion
The GI 450 Katahdin gas insert is shipped from thefactory equipped to use NATURAL GAS. A conversion kit
is included with the insert for installation to permit use
of Propane fuel. The kit contains all the necessarycomponents needed to ensure safe operation, including
labeling that must be affixed to the insert.
WARNING:THE CONVERSION KIT IS TO BE INSTALLED BY AN AUTHORIZED JØTUL SERVICE TECHNICIAN IN ACCORDANCE WITH
THE MANUFACTURER’S INSTRUCTION AND ALL CODESAND REQUIREMENTS OF THE AUTHORITY HAVING JURISDICTION. FAILURE TO FOLLOW THESE INSTRUCTIONSCOULD RESULT IN SERIOUS INJURY OR PROPERTY DAMAGE. THE QUALIFIED AGENCY PERFORMING THIS WORKASSUMES RESPONSIBILITY FOR THIS CONVERSION.
IN CANADA:THE CONVERSION SHALL BE CARRIED OUT IN ACCORDANCE WITH THE REQUIREMENTS OF THE PROVINCIAL
AUTHORITIES HAVING JURISDICTION AND IN ACCORDANCE WITH THE REQUIREMENTS OF THE CAN1-B149.1
AND .2 INSTALLATION CODE.
CET EQUIPEMENT DE CONVERSION SERA INSTALLE PAR
UNE AGENCE QUALIFIEE DE SERVICE CONFORMEMENTAUX INSTRUCTIONS DU FABRICANT ET TOUTES EXIGENCESET CODES APPLICABLES DE L’AUTORISES AVOIR LAJURIDICTION. SI L’INFORMATION DANS CETTE INSTRUCTION N’EST PAS SUIVIE EXACTEMENT, UN FEY, EXPLOSIONOU PRODUCTION DE PROTOXYDE DE CARBONE PEUTRESULTER BLESSURE PERSONNELLE DE VIE. L’AGENCEQUALIFIEE DE SERVICE EST ESPONSABLE DE L’INSTALLATION
N’EST PAS PROPRE ET COMPLETE JUSQU’A L’OPERATION DE
L’APPAREIL CONVERTI EST CHEQUE SUIVANT LES CRITERESETABLIS DANS LES INSTRUCTIONS DE PROPRIETAIREPROVISIONNEES AVEC L’EQUIPEMENT.

IMP
OR
TAN
T:
IMPOR
ORT
ANT
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 Procedure
1. 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 lift
slightly. Remove the glass panel by lifting the glass
frame 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 using
care 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 forward sothat screen and tube are easily removed. Lift out.
6. Change the main burner orifice. Using a ½” open
end wrench or deep well socket remove the burner
orifice and replace with the appropriate orifice,supplied in the kit.
7. Adjust the air shutter on the burner tube to allow for
the proper mixing of air and gas. See Figure 8.
The correct settings: Natural - 1/4” open
Propane - 1/4” open

Figure 8.

Air Shutter

Burner Tube

Tools Requir
ed:
Requirequired:1/4” Nut driver, 7/16” and 1/2” open end wrench or deep
well socket, 4mm allen wrench, Torx t20 or slottedscrewdriver.
Kit C
on
ten
ts:
Con
onten
tents:
1 regulator tower labeled for propane
3 regulator tower screws
1 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.

NOTE: AIR SHUTTER SHOULD NEVER BE
LESS THAN 1/8” OPEN.
8. To change the pilot orifice: FROM WITHIN THE
FIREBOX, PULL THE PILOT HOOD OFF THE PILOTASSEMBLY. Using a 4mm allen wrench threadout the pilot orifice (counter clockwise). Replacewith the appropriate orifice:Tighten orifice into the base of the pilot assembly. Be
sure the orifice is threaded tightly into the base. See
fig. 9.
9. Replace pilot hood onto pilot assembly.

1110. Replace the burner tube, BE SURE TO SLIDE TUBE TO
THE LEFT COMPLETELY COVERING ORIFICE.

BE SURE TO REMOVE THE
BLACK RUBBER GASKETFROM THE VALVE.
Pilot Hood
Figure 10.
Regulator Assembly.
Pilot
Pilot
orifice

Orificescrewsinto baseGas Supply Connection
Figure 9. Pilot Assembly.
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 screws
from the front of the valve regulator. See fig. 10.
13. Remove the regulator tower and gasket.
A SKET
BE SU
RE TO REMOVE TH E B
B B ER G
SUR
REM
EMO
BLL A C K RU
RUBGA
OM TH E VAL
VE. See fig. 10.
ALVE.
FRO
FR
14. Install the new variable regulator tower with theoughly tighten new regulanew rubber gasket. Thor
Thoroughly
tor to valve body.
15. Install the identification labels to the insert so thatthey can be seen by any person that may be servicing
the insert. APPLY LABEL B TO THE RATING PLATE IN
THE SPACEPROVIDED.
16. Reassemble the insert, apply gas to the system andcheck for gas leaks including all insert lines before
and after the valve.
N EVER USE AN OPEN FL
H EC
K FFOROR G
AS
A ME TO C
FLA
CH
ECK
GA
LE
AK
S.
LEAK
AKS
IMP
OR
TAN
T
IMPOR
ORT
ANT
Correct gas pressure is essential for efficient and safe
operation of the Katahdin gas insert. It is importantthat the correct gas pressure be established at the timeof the installation. For more details, see the Gas Pressure section of this manual on page 14.
ALWAYS REFER TO THE LIGHTING INSTRUCTIONS ON THE
BACK COVER OF THIS MANUAL WHEN LIGHTING YOURKATAHDIN.

12

The gas supply line connection is made to the valve on
the left side of the unit facing the front. The gas supply
line should be a minimum of 3/8" in diameter, or theappropriate size to provide sufficient gas pressure to thevalve 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 are notpermitted use of the 3/8” iron is recommended. See fig.
12.
The use of Flexible Gas Appliance Connectors is
acceptable in many areas in the U.S., however, Canadian
methods 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 THE
NATIONAL FUEL GAS CODE ANSI Z223.1/NFPA 54 OR
CAN-B149.
All codes require: a gas shut-off valve (gas cock) .union,
to be installed in the supply line, and in the same room as
the appliance. This allows for the disconnection of theinsert for servicing and maintenance. See fig. 12.

T-handle gas cocks are required in
Massachusetts in compliance withcode 248CMR.

Figure 11. Valve inlet centerline.

Gas Pressures
Correct gas pressure is essential for efficient and safe
operation of the Katahdin gas insert. It is important thatthe correct pressure is established at the time of theinstallation.
Proper gas pressure provides a consistent flow ofgas to the appliance and is instrumental in checking for
gas leaks.The gas control valve on the insert is equippedwith pressure test points for gauge connections. The
gauge connections are located on the front of the valve
under the On/Off/Pilot knob. See fig. 13.

GAS LINE
CONNECTION

I N / E for inlet or supply pressure (the amount of gas
coming to the valve.)OU
T / A for manifold pressure (the amount of gas that
OUT
manifoldis coming out of the valve to the burner.)

1 1/4”
7 3/16”
Secure all joints tightly using appropriate tools andsealing compounds (for propane units, be sure to use
compounds that are propane resistant). Turn on gas
supply and test for gas leaks using a soapy water
solution. 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 page 23of 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 gas
odor is detected, immediately turn gas control knob
to the OFF position.
Tighten or reconnect the leaking joint and retest for any
gas leaks.

E

A

Figure 13. Pressure test points.
The appliance must be isolated from the gas supply
line by closing its individual manual gas shut-off valve(gas cock) during any pressure testing of the gas supply
piping system that is equal to or exceeds pressuresof 1/2 psig (3.5kPa).

NECESSARY INLET GAS PRESSURES (inches
water column)
MIN
MAX
NATURAL GAS
5.0 WC
13.5 WCPROPANE

11.0 WC

13.5 WC

NECESSARY MANIFOLD PRESSURES(inches water column)
MIN
MAX
NATURAL GAS
2.2 WC
3.5 WCPROPANE

6.5 WC

10.0 WC

ALWAYS TEST PRESSURE WITH VALVE CONTROLKNOB SET ON HIGH.
Figure 12. Gas connection components.

13Sympt
oms o
orr
ec
as pr
essur
e include:
ymptoms
off inc
incorrorrec
ectt ggas
pressur
essureInsuf
ficien
as pr
essur
e:
Insufficien
ficientt ggaspressur
essure:• Small pilot flame which can result in insufficient
millivolts.
• Little variation in flame picture between HI and LO
settings.
• Insufficient gas to support more than one appliancecausing nuisance outages or gas surges.

HIGH ALTITUDE INSTALLATIONS:
2000 ft. to 4500 ft. installations (or 610m - 1370m)
See Table 1.
For high altitude installations consult the local gas
distributor or the authority having jurisdiction forproper rating methods. If the installer must convert theunit to adjust for varying altitudes, the information label
must be completed by the installer and affixed to theappliance at the time of the conversion. See fig. 14.

Excessiv
eg
as pr
essur
e:
essivegas
pressur
essure:• Permanent damage to valve causing complete
appliance shut down.
• Too large a pilot flame resulting in over heating of
the power generator causing shut down.
• Sooting due to impingement and/or incorrect fuel to
air mix.

Derating procedure
1. 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.

High Altitude Adjustment

4 . Remove the orifice and replace with the appropriate
one from the high altitude kit.

When 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). Higher
altitudes affect the atmospheric pressure and heatvalue of gaseous fuels. The lower oxygen content in the
air and the lower gas viscosity require the use of adifferent orifice to achieve efficient, clean combustion
at the burner tube.

5 . Be sure to attach the high altitude conversion sticker
provided 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 APPEARANCE section of this manual for more details.

In the U
.S
U.S
.S..
THE DERATING KIT MUST BE INSTALLED BY AN AUTHORIZED SERVICE TECHNICIAN IN ACCORDANCE WITH THE
MANUFACTURER’S INSTRUCTIONS AND ALL CODES AND
REQUIREMENTS OF THE AUTHORITY HAVING JURISDICTION. THE INFORMATION STICKER MUST BE FILLED OUT
BY THE INSTALLER AND ADHERED TO THE APPLIANCE AT
THE TIME OF THE CONVERSION. THE QUALIFIED SERVICEAGENCY PERFORMING THIS WORK ASSUMES RESPONSIBILITY FOR THIS DERATING.
In C
anada
CanadaThis unit has been tested for installation at high altitudes in accordance with Canadian test standard CAN/
CGA-2.17.THE DERATING SHALL BE CARRIED OUT INACCORDANCE WITH THE REQUIREMENTS OF THE
PROVINCIAL AUTHORITIES HAVING JURISDICTION AND
IN ACCORDANCE WITH THE REQUIREMENTS OF THE
CAN1-B-149.1 AND .2 INSTALLATION CODE.

GAS TYPEORIFICESIZE

ELEVATION

JØTULPART NO.

NATURALGAS#31

0 - 2000’(0 - 619m)

045026PROPANE#51

0 - 2000’(0 - 619m)

045027

NATURALGAS#32

2001’- 4500’(611 - 1170m)

045024

PROPANE#52

2001’- 4500’(611 - 1170m)

045025

Table 1. High Altitude Orifice Chart.

THIS APPLIANCE HAS BEEN CONVERTED FOR USE
AT AN ALTITUDE OF ______________________
Orifice Size: _______ Manifold Press: ________
Input, BTU/Hr: ________ Fuel Type: _________
Date of Conversion: ______ / _______ / ______
Figure 14. High Altitude Conversion Notice Label

14

Flame Adjustment / Air Shutter
THE KATAHDIN GAS INSERT IS SHIPPED FROM THE
FACTORY EQUIPPED FOR USE WITH NATURAL GAS.
WHEN USING PROPANE, IT WILL BE NECESSARY TO
ADJUST THE AIR SHUTTER ON THE BURNER TUBE TO
ACHIEVE THE PROPER GAS TO AIR MIX. See fig. 15.
WARNING:AIR SHUTTER ADJUSTMENTS SHOULD ONLY BE
PERFORMED BY A QUALIFIED PROFESSIONALSERVICE TECHNICIAN.
The air shutter adjustment can also help achieve
the desired flame appearance. Generally, flame appearance is a matter of preference, however most consumers enjoy the warm, yellowish flame.
Closing the Air Shutter - Insufficient combustion
air will result in very long yellow flames that canpromote soot. Sooting produces black deposits on thelogs, on the inside walls of the appliance, and potentially on the exterior termination cap.
Sooting is caused by incomplete combustion in the
flames and lack of combustion air entering the air
shutter opening.
Opening the air shutter - will generate a flamethat is blue and transparent, or an “anemic” flame. This
flame is generally more efficient, but not very attractive.
Jøtul recommends the following settings for the
Katahdin gas insert:Pr
opane: 11//4” open
Propane: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 air
shutter 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 Set
NO
TE: Install the optional An
tique Brick P
anels
NOT
Antique
Panelsbef
ore installing the LLog
og Set
Set..
befor
ore
The Katahdin is equipped with a three piece log set
packaged in bubble wrap inside the firebox. The log set
must be removed from the packaging and arranged in
the 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.

Natur
al Gas: 11//4” open
Natur
tural
Figure 16. Log identification.
Figure 15.

Air Shutter

Burner Tube

Cross-over Log
Pin

NOTE: AIR SHUTTER SHOULD NEVER BE
LESS THAN 1/8” OPEN.
REMEMBER: Run the insert for a minimum of 15 to
20 minutes for an accurate representation of the flame
appearance. This should be done before and between
any air shutter adjustments.

Rear Log
Pin

Front Log

15

Blower Operation
The GI 450 DV Katahdin is equipped with a 125 cfm heatactivated blower. A ten foot power cord is installed in
the rear of the valve compartment under the firebox.
Open the Lower Grill and fully unwrap the power
cord. The cord can exit either the right or left side of thewer ccororde to pull all slack out o
off the popow
ord
insert. Be sur
sure
on
to pr
even
tac
om o
ebo
x.
ontac
pre
entt ccon
tactt with the bottbottomoff the fir
fireboebox
The is equipped with a three-prong (grounding)plug for protection against shock hazard and should be
plugged directly into a properly grounded three-prongEM
OVE T H E GR
OU
T CU
T OR RN DGROU
receptacle. DO NO
NOT
CUT
REM
EMO
OUN
I NG PRONG FROM T H E PL
UG.
PRONG
FRO
PLUG.
Figure 17. Completed log set assembly.
4. Place the front log on the single log pin so that the left
end of the log rests on the log support and the andiron holder- directly above the air shutter.
5. Place the cross-over log on the two remaining pinstop right to the rear log, bottom left on the front log.
See fig. 17.
6. Install the embers: the insert is shipped with a package of ember stones. Spread them evenly across theburner tube screen. It is best to equally space theseembers for optimum flame appearance. NOTE: YOU
DO NOT NEED TO USE ALL OF THE EMBER STONES.
7. Replace the andiron set, center in the firebox over the
andiron support.
THE CERAMIC FIBER LOGS AND EMBER STONES CANIRRITATE YOUR SKIN. IF THIS HAPPENS, GENTLY WASH
HANDS WITH WARM, SOAPY WATER.

The blower must be electrically grounded in accordance with local codes or, in the absence of local codes,
with the current NFPA 70- National Electrical Code or
CSA C22.1-Canadian Code.
The blower is controlled by a heat activated switch(snapstat) that will function only if the blower control
switch is in the AUTO setting. Once the firebox heats
after the burner has been operating for a short time, theblower will start on either the HI or LOW speed. In AUTO
mode, the blower will continue to operate after theburner is turned off, until the snapstat cools. See fig. 18.
If blower operation is not desired, place the control
switch in the OFF position to bypass the snapstat
function.
NOTE:
ALWAYS UNPLUG THE BLOWER WHENSERVICING THE APPLIANCE.

HI

LO
MAN
OFF
BLOWER

Figure 18. Blower Controls

16

AUTO

Optional Remote Control#129706

POWER
SUPPLYBKThe optional Jøtul remote can be installed on the
Katahdin gas insert. Using the wires supplied withthe remote, it is best to wire the remote directly to
the gas control valve of the insert.

GN
WH
BK

MANUAL

GY

OFF

BU

AUTO

SWITCHBK

SNAPSTATBK

BLOWERBK

RHEOSTAT

Figure 19. Blower Wiring Diagram - GI 450 Katahdin

Wall Thermostat

Connect one receiver lead to the terminal labelled TH. Connect the other receiver lead to theterminal labeled TH/TP. DO NOT DISCONNECT ANYOTHER WIRES FROM THE VALVE, AND DO NOT OVER
TIGHTEN TERMINAL SCREWS.
Jøtul rrececommends the use oecommends
off the optional
Remote R
ec
eiv
er Hea
Rec
eceiv
eiver
Heatt Shield (# 129
1297708) to protect
the receiver under the firebox. The best location for
the receiver is just below the air intake port toward
the back of the unit.

0 milliv
olt DC tw
o-wir
e cir
cuit
Use only a 75
750
millivolt
two-wiro-wirecircuitthermostatt . The thermostat should be placed in thethermosta
same room as the heater, typically 5’ off the floor. Avoid
drafty areas or any area that may affect the accuracy of
the thermostat.
The thermostat should be connected to the
Katahdin 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 overtighten
the connections. IT IS NOT NECESSARY TO DISCONNECTANY OTHER WIRES. See Figure 20.
For the thermostat to function, the ON/OFF/T-STAT
switch must be in the T-STAT position, and the pilot lightmust be running, as it is the power source for thethermostat.
At the thermostat, the two wires should be connected to the two connections screws on the thermostat base plate per the manufacturer’s instructions.

THERMOPILE

ROCKERSWITCH
ON

TH

OFF

TP

STAT

TH
TP
VALVE

OPTIONAL
THERMOSTATorREMOTECONTROLAir
IntakePort

Place Receiver HereFigure 21. Remote Receiver position.

CAUTION:LABEL ALL WIRES PRIOR TO DISCONNECTION WHENSERVICING THE CONTROLS. WIRING ERRORS CAN CAUSEIMPROPER AND DANGEROUS OPERATION. ALWAYS VERIFYPROPER OPERATION AFTER SERVICING THE APPLIANCE.
ATTENTION:
AU MOMENT DE L’ENTRETIENDES COMMANDES,ETIQUETEZ TOUS LES FILS AVANT LE DEBRANCHEMENT.
DES ERREURS DE CABLAGE PEUVENT ENTRAIUN FONCTIONNEMENT INADEQUAT ET DAGEREUX.

TERMINAL
BLOCK

Figure 20. Wiring diagram / GI450 DV Katahdin

17Surround Panel Installation
Complete the venting and gas line installation before
installation of the surround and riser bar.

Stabilizer
Bracket

6 mm nuts

All Surround Panel fasteners are already installed in
the appropriate locations. Simply remove and use themto attach the panels together in the same locations. A
10 mm wrench will be required.

Figure 22A. Mountthe stabilizer bar
using the two
6mm nuts
installed on the
top of the unit.

R ISER B
AR: The 2” riser bar is used in conjunction withBAR:
the standard surround, and is only needed in the eventthat the fireplace opening is between 27 1/2” and 29 1/
2” high. The riser bar can be used in any installation if
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 riser
bar to fill the space below the bottom grill assembly.
Exception: in raise fireplace installations the riser bar
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 leg
is 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 AND
RISER BAR IT MAY BE NECESSARY TO UTILIZE THE
STAB
AR THAT IS SHIPPED WITH THE UNIT.
ABII LIZER BBARTHIS STABILIZER ATTACHES TO THE OUTSIDE OF THE
FIREBOX AND WILL BRACE THE UNIT AGAINST THE
FIREPLACE LINTEL PREVENTING THE UNIT FROMLEANING FORWARD. See figs. 22 and 22A.

Stabilizer
Bracket for use
with raised
fireplaces

Mounting bolts
for stabilizer
bracket1234561234
12345
1234561234
12345
1234561234
12345
1234561234
12345
1234561234
12345
1234561234
12345
1234561234
12345
1234561234
12345
123456123456123456Fireplace123456123456 Lintel
123456123456123456123456

4. Lay the four surround panels on the floor backside
up. Using two bolts and washers attach the rightand left upper sections (breastplates) together. See
fig. 23.
5. Attach the left and right leg sections to the breastplate 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 tabs
are 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 of
the insert with the mounting tabs on the surround.
See fig. 25.

Figure 23

Use set screw to adjust alignment

Figure 23. Attach Surround Breastplates

Bottom Grill
Assembly2” RiserBar
Raised Fireplace

Figure 22. Installing the Stabilizer Bar.

18

Figure 24.
Attach Breastplates to Legs

8. Slide the surround down into the mounting holes.
Be sure all four mounting tabs engage securely withthe adjacent bracket holes. See fig. 26.
9. Secure the two sections of the riser bar together
with a washer and bolt and slide the assembled
riser 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. See figure 27.
10. Gently and slowly push the unit and surround backinto the fireplace. This is best done by pushing thefront outside edges of the glass frame. Reminder
eminder:
Be sure to inspect the gas line and blower cord to
make sure they are not crushed when the unit is in
its final location.

Checking the System
1. PURGING THE GAS LINE: When lighting the appliancefor the first time it will take a few moments to clear
the gas line of air. Once this purge is complete, theappliance will operate as described in the lighting
instructions located on the insert’s rating plate andback cover of this manual. All subsequent lightingsof the insert will not require such purging of the gas
line.
2. PILOT FLAME: The pilot flame should be steady, notlifting or floating. The flame should be blue in color
around the pilot hood,, with traces of yellow toward
the outer edges. It is imperative that the pilot flame
engulf the top 3/8” of the thermopile (power generator) and the top 1/8” of the quick drop out thermocouple. The pilot flame should project out of thepilot hood 1” at all three ports. See Figure 28.

1/8
(3mm)
Min.

Pilot Hood
Ignitor

Thermocouple
Leg
Panel

1
(25mm)

3/8
(8mm)
Min.

Thermopile

Leg
Panel

Mounting Tabs
point downward

Riser Bar Attachment

Figure 28. Correct Pilot flame appearance.

Figure 25. Surround mounting tab locations.

Engage tabs
with theseholes in thebrackets

Figure 26. Surround engagement with firebox.

3. BURNER ADJUSTMENT: The burner is equipped with avariable gas control valve. This valve provides easy
adjustment of the flame height appearance and heat
output. To adjust the flame between the HI and LO
setting, rotate the HI/LO knob, located in the centerof the valve face. Flame height will adjust approximately 1.0” to 1.5” between the HI and LO settings.
NO SMOKE OR SOOT SHOULD BE PRESENT. CHECK LOG
PLACEMENT IF ANY SOOT OR SMOKE IS APPARENT. IF
SOOT OR SMOKE PERSIST, THE AIR SHUTTER MAY
REQUIRE ADJUSTMENT.
CAUTION:
DO NOT ATTEMPT TO ALTER THE FLAME APPEARANCE BY
POSITIONING THE GAS VALVE IN ANY OTHER POSITIONOTHER THAN THE FULL “ON” POSITION.

Stabilizer Bar attaches
to top of unit

Mounting
Tabs

Pilot assembly

Riser Bar
attaches toleg sections of
the surroundFigure 27. Riser Bar installation.

Figure 29. Pilot assembly location.

19

7. Clean the glass only when necessary. Wipe surface
with 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 THE GLASS. NEVER
CLEAN THE GLASS WHEN IT IS HOT.

Maintenance
Figure 30. Normal flame pattern.

The Katahdin gas insert and its venting system should
be inspected before use and at least annually by aqualified service technician.

Fireplace Operation

IMPORTANT:ALWAYS TURN OFF THE GAS SUPPLY TO THE INSERT AND
UNPLUG THE FORCED AIR BLOWER BEFORE ANYSERVICE WORK IS PERFORMED ON THE INSERT.

1. This appliance is equipped with an On/Off/T-statrocker switch to control burner functions. Use the Tstat position for use with an optional wall-mounted
thermostat. Separate switches are provided for themultifunction forced air blower kit.
2. When lit for the first time, the Katahdin will emit anodor for several hours. This odor is the burn-off byproducts of external paints and lubricants used in
the manufacturing process. Open a nearby window
to provide fresh air and alleviate this temporary
condition.
3. Condensation may occur on the glass upon eachlighting of the appliance. This “fog” will disappear as
the appliance temperature increases.
4. Keep the controls and the area under the appliancefree of debris; vacuum this area frequently. Always
keep the appliance area clear and free from combustible materials, gasoline and other flammable liquids.
ALWAYS be sure the insert is cold and NO hot embers
or sparks are present before using a vacuum cleaner.
5. Remember, this appliance has a continuous burning
pilot flame. Exercise caution when using productswith combustible vapors.
6. CAUTION: DO NOT OPERATE THIS APPLIANCE WITH
THE GLASS REMOVED, CRACKED OR BROKEN.
REPLACEMENT OF THE GLASS SHOULD BE DONE BY A
LICENSED OR QUALIFIED SERVICE PERSON. USE ONLYREPLACEMENT GLASS PROVIDED BY YOUR AUTHORIZED JØTUL DEALER. NEVER USE ANY SUBSTITUTE
MATERIALS.
WARNING:OBSERVE CAUTION NEAR THE GLASS. THE GLASS PANEL
MAY SHATTER UNEXPECTEDLY IF STRUCK WITH ANOBJECT. ALWAYS HANDLE THE GLASS PANEL WITH CARE.

20

General cleaning: The firebox should be vacuumed out
annually to remove any surface build up. Be sure to
vacuum or wipe off the pilot assembly and burner
orifice 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 gasket
be inspected at least annually. Examine the rope
gasket 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 of
the firebox.
3. Swing the bottom of the glass frame out and lift
slightly.
4. Remove the glass panel by lifting the glass frame overthe brackets at the upper grill assembly. NOTE: IT ISNOT 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 glass
frame and secure with metal tabs. Do not overtighten tabs as this could break the glass.
ALWAYS USE JØTUL AUTHORIZED PARTS.
SUBSTITUTE ANY OTHER PARTS.

NEVERAlways replace any damaged or broken parts on the
Katahdin with JØTUL AUTHORIZED PARTS ONLY. These
are available through your Authorized Jøtul dealer.
Never use any substitute parts on your Katahdin gas
insert.
The Katahdin and its venting system should be
inspected annually or semi-annually by a qualified
service person or agency.
With proper care and maintenance, your appliancewill provide you with years of enjoyment. If you experience any problem or inconsistency with your Jøtul
Katahdin gas insert, contact your Jøtul Authorized
Dealer for assistance.
To expedite the proper service for your appliancethe following information will help your dealer determine what you will need for parts and service.

RETAIN THIS MANUAL FOR REFERENCE AND MAKE IT
AVAILABLE TO ANYONE USING OR SERVICING THE
INSERT.

SERVICE LOG:
First Year
Name of Technician________________________
Company Name____________________________
Date of service_____________________________
Work Performed____________________________________________________________________________________________________________________SERVICE LOG:
Second Year
Name of Technician________________________

MODEL NAME: Jøtul GI 450 DV Katahdin Gas Insert

Company Name____________________________SERIAL NUMBER:_________________________________

Date of service_____________________________DATE OF PURCHASE:______________________________

Work Performed________________________________________________________________________AUTHORIZED DEALER_________________________________________________________________________NAME OF INSTALLER:_____________________________TYPE OF FUEL:___________________________________
FUEL CONVERSION:

NO _______

YES______NOTES:_________________________________________SERVICE LOG:
Third Year
Name of Technician_______________________________________________________________________

Company Name___________________________________________________________________________

Date of service____________________________________________________________________________

Work Performed__________________________________________________________________________________________________________________________________________________________________________________________________________________

21

Figure 31. Illustrated Parts Breakdown - GI 450 DV Katahdin / Rev. 23/02/09

22

1

The part list on page
23 includes many
parts not shown inthis illustration.

33

11

10

32

13

8

31

30

23

6

10

12

9

29

28

14

27

15

16

19

20

21

25

7

5

26

24

4

18

34

3

17

22

16

14

2

Jøtul GI 450 D
VK
atahdinDVKa

GI 450 DV Katahdin Parts List
1

2
3
4
5
6

7

8
9
10
11
12
13

14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33

Glass Assembly, Complete .......................... 154902
Glass Panel ...................................................... 129662
Glass Frame ................................................ 12961792
Glass Panel w/ gasket .................................. 154986
Glass Gasket - 8ft. ......................................... 129124
Glass Latch ...................................................... 129135
Andiron - Blue Black ................................ 10393827
Andiron Holder ......................................... 12968292
Burner Kit ......................................................... 154994
Burner Tube ..................................................... 129660
Burner Tube Holder .................................. 12968392
Log Set .............................................................. 155379
Front Log .......................................................... 220626
Rear Log ............................................................ 220627
Cross-over Log ................................................ 220628
Upper Grill, left - Matte Black .............. 10394492
Blue-Black .................. 10394427
Jøtul Iron .................... 10394485
Upper Grill, right- Matte Black ............. 10394592
Blue-Black .................. 10394527
Jøtul Iron ..................... 10394585
Bottom Grill Assembly Hinge .................... 901043
Bottom Pan ..................................................... 220532
Burn Plate, left ........................................... 10395027
Burn Plate, right ........................................ 10393927
Log Support ..................................................... 129621
Air Deflector - rear wall ............................... 129676
Bottom Grill left - Matte Black ............. 10394692
Blue-Black ................. 10394627
Jøtul Iron ................... 10394685
Bottom Grill right - Matte Black .......... 10394792
Blue-Black ................. 10394727
Jøtul Iron ................... 10394685
Surround Hanger - left ............................ 12969792
Surround Hanger - right ......................... 12962392
Firebox .............................................................. 222510
Top Grill Mount - left ............................... 12963292
Top Grill Mount - right ............................ 12963192
Glass Frame Hanger ................................ 12966192
Heat Exchanger Gasket ............................... 129673
Heat Exchanger .............................................. 129624
Top Shroud ................................................. 12964192
Air Intake Manifold ....................................... 129618
3" Intake/Exhaust Gasket ........................... 129677
3" Intake/Exhaust Collar ............................. 129622
Relief Door .................................................. 12969692
Relief Door Guide ..................................... 12949992
Relief Door Gasket ......................................... 129673
Blower Shroud ........................................... 12963092
Blower, Rplcmt / Variable Speed ............... 222072
Blower Switch Box , Complete - MB ........ 156849
Blower Switch Box , Complete - JI ........... 156850
Blower Snapstat (140-120 deg F) ............. 220637
Snapstat Bracket ........................................... 220608
Blower Control Switch ................................. 220703
Exhaust Baffle ................................................ 220712

34

Spud Plate Assembly, NG ............................... 154901
Spud Gasket ....................................................... 129669
Valve - NG ........................................................ 3902159
Valve - LP .......................................................... 3902160
Pilot Gasket ........................................................ 129116
Pilot Assembly ( NG - Poptop) ....................... 129471
Pilot Orifice NG #51 ......................................... 129472
Pilot Orifice LP #30 ........................................... 129473
Orifice Holder .................................................... 129668
Nut - Orifice Holder ......................................... 129152
Brass Elbow 3/8 NTP to 5/16 ........................ 129129
Main Gas Line, w/ nut & ferrels ................... 154372
Main Burner Orifice NG #31 ......................... 045026
Main Burner Orifice LPG #51 ........................ 045027
Ignitor Button ................................................. 3902573
On/Off Extention Knob ................................... 129729
High/low Extention Knob .............................. 129730
Terminal Block ................................................... 129154
Thermocouple - Standard .............................. 129766
Thermopile ...................................................... 3094527
Electrode w/ wire ............................................. 129765
On/Off/Tstat Switch ........................................ 129153
Embers ................................................................. 129123
24" Supply Flex .................................................. 129707
7" Supply Nipple ............................................... 129728
Stabilizer Bracket .............................................. 129714
Leg Leveler Bracket, Right (2) ........................ 222440
Leg Leveler Bracket, Left (2) ........................... 222730

HARDWARE
1/4" hex head sheet metal screws ........................ 117917
M8 X 40 leveling bolt (4) .......................................... 118047
M6 X 12 bolt (Surround, Grills) .............................. 117130
M6 X 10 set screw (Breast Plate) ........................... 117720
M5 X 10 bolt (Hinge bolts) ...................................... 117970
M6 washer ................................................................... 120024
M6 flange nut ............................................................. 117968
Star washer .................................................................. 117958
Hanger Tab ................................................................... 129680

ACCESSORIES
Fuel Conversion Kit - to Propane .......................... 154903
Fuel Conversion Kit - to Natural Gas ................... 154928
Remote Control Kit .................................................... 129706
Remote Receiver Heat Shield .................................. 129708
Antique Brick Panel Kit ............................................. 155367
Wide Surround Kit - Matte Black .......................... 155323
Blue Black ............................ 155324
Jøtul Iron ............................. 155354
SURROUND PARTSBlue Black

Jøtul Iron

1 Breast Plate, Left .............. 10394092

Matte Black10394027

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

ALWAYS USE REPLACEMENTS PARTSPROVIDED BY AN AUTHORIZED JØTUL DEALER ONLY.

23

Antique Brick Panel Kit#155367
CAUTION!
THE BRICK PANELS AND LOG PARTS ARE EXTREMELY FRAGILE. USE BOTH HANDS TO SUPPORTEACH PIECE AS YOU HANDLE THEM.

Tools Requir
ed: 10 mm socket wrench
Requirequired:
Safety glasses and gloves
Kit C
on
ten
ts
Con
onten
tents
Left Side
Panel,
220620Installation Instructions
1. Remove the Glass Frame. Disengage the two compression latches located in the control compartment
and lift the frame off of the tabs at the top of thefirebox.

Upper Rear Panel, 220622

Lower Rear
Panel, 220621

Figure 32. Brick Panel Identification

2. Remove the Andirons and Logset.
These parts are not fastened. Simply lift them out of
the firebox.
3. Remove the Cast Iron Side Panels.
Use a 10mm socket wrench to remove the retainer
brackets located at the rear corner of each panel. Thesepanels will not be reinstalled, however, you must replace
the two 6 mm bolts to plug the holes.
4. Install the Right Side Panel.
Position the panel bottom first against the firebox
wall and slide it forward against the firebox front.
5. Install the Lower Rear Panel.
Orient the panel so that the beveled edge is on top
and 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 up
enough 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 the
top of the other rear panel. The side panels will hold it
in place.

Figure 33. Install the Right Side Panel.

r

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 firebox
and pull the latches forward to engage with the slots in theframe bottom.

Figure 34. Install Lower Rear Panel.

24

Right Side
Panel,
220619Figure 35. Install Left Side Panel.

Figure 36. Install Upper Rear Panel.

25Appendix
Leveler Bolts and Brackets
This feature enables greater installation
flexibility beyond eliminating problems causedby irregularities in the hearth floor.
The leveling bolts may be extended fromthe mounting brackets no more than 1/2”.
The firebox may be further raised, in 1/2”
increments, up to 2 1/2” more (max. 3” total) by
adjusting the height of the leveling bolt
mounting brackets.

Clearance to Combustibles
When raising the firebox up to 2”, mantel andhearth clearance remain unchanged fromthose specified in the Operation Manual.

Leveling
Bolt
Mounting
Brackets

1/2 max
Figure 37. The leveling bolts should not be
extended further than 1/2”.

Raising the firebox higher than 2” will
require that the clearance to mantel and trim
be increased by 1”:
Hearth to Upper Trim - 37”
Hearth to Mantel - 39”

Stabilizer Bar
In some instances, raising the height of theunit may require installing the insert with theincluded Stabilizer Bar. See page 18 of thismanual for further details.

3 max.

Figure 38. The bolt mounting brackets
may be extended up to 2 1/2”. With
maximum extension of both bolts andbrackets, the firebox may be raised a totalof 3”.

26

LIGHTING INSTRUCTIONSFOR YOUR SAFETY, READ BEFORE LIGHTING.
WARNING:IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTYDAMAGE, PERSONAL INJURY, OR LOSS OF LIFE.

A. This appliance has a pilot which must be lit
by hand. When lighting the pilot, follow these
instructions exactly.
B. B EFOR
E LIGHT I NG, smell all around the
EFOR
ORE
LIGHT
appliance area for gas. Be sure to smell next
to the floor because some gas is heavier than
air and will settle to the floor.
W HA
T TO DO IIFF YOU SSMELLAS:
MELL G
HATGA• 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 aneighbor’s phone.

• If your gas supplier cannot be reached, call thefire department.
C. Use only your hand to push in or turn the gas
control knob. Never use tools. If the knob will notpush in or turn by hand, do not try to repair it.
Call a qualified technician. Force or attempted
repair may result in a fire or explosion.
D. Do not use this appliance if any part has been
under water. Immediately call a qualified service
technician to inspect the appliance and to
replace any part of the control system and any
gas control which has been under water.

LIGHTING INSTRUCTIONS
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).

ON
OFF

Control
Knob

PILOT

4. Confirm that the gas supply line shut-off valve is open.

Control Valve
5. Push in gas control knob slightly and turn clockwise
to “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 information
above on this page. If you do not smell gas, go to thenext step.

7. Push in gas control knob slightly and turn counterclockwise
to “PILOT”.
8. Push in control knob all the way and hold in.
Immediately light the pilot by triggering the spark
ignitor (push the red button repeatedly) until pilot
lights. Continue to hold the control knob in forabout one minute after
the pilot lights. Releaseknob and it should springback. The pilot should
remain lit. If it goes out,
repeat Steps 5 through 8.
• If knob does not
return when released,
Pilot Assemblystop and immediately
call your service technician or gas supplier.
• If pilot will not stay lit after several tries, turn thecontrol knob to OFF and call your service technician or gas supplier.
9. Turn gas control knob counterclockwise

to “ON”.

10
10..Turn the stove ON/OFF switch to “ON”, or set thermostat (if used) to desired temperature.

TO TURN OFF GAS TO THE APPLIANCE:
1. Turn ON/OFF switch to” OFF”. The pilot will remain lit fornormal service.
2. For complete shutdown, turn ON/OFF switch to “OFF”.

3. Access the lower controls.
4. Depress gas control knob slightly and turn clockwise
to “OFF”. Do not force.

27

February, 2009
129710-G

This appliance must be installed in conformance with local and national building regulations. Before
beginning 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 in
specification, 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 les
specifications, couleurs etequipement sans avis prelable.

Jøtul ASA
P.O. Box 1411
N-1602 Fredrikstad
NorwayJøtul North America
55 Hutcherson Drive
Gorham, Maine 04038-2534

28