Jøtul GI 450 DV Katahdin User manual

1
WARNING:
IF THE INFORMATION IN THESE INSTRUC-
TIONS ARE NOT FOLLOWED EXACTLY, A FIRE
OR EXPLOSION MAY RESULT CAUSING PROP-
ERTY DAMAGE, PERSONAL INJURY OR LOSS
OF LIFE.
FOR YOUR SAFETY:
DO NOT STORE OR USE GASOLINE OR OTHER
FLAMMABLE VAPORS AND LIQUIDS IN THE
VICINITY 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 FROM
A 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 POUR
REDUIRE AU MINIMUM LE RISQUE D’INCENDIE
OU POUR EVITER TOUT DOMMAGE MATERIEL,
TOUTE BLESSURE OU MORTALIT’E.
NE PAS ENTREPOSER NI UTILISER D’ESSENCE
NI OU LIQUIDES INFLAMMABLES DANS LE
VOISINAGE DE CET APPAREIL OU DE TOUT
AUTRE APPAREIL.
L’INSTALLATION LE SERVICE DOIVENT
ETRE EXECUTES PAR UN INSTALLATEUR
QUALIFIE, AGENCE DE SERVICE OU LE
FOURNISSEUR DE GAZ.
QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE
GAZ.
• NE PAS TENTER D’ALLUMER L’APPAREIL
• NE TOUCHEZ A AUCUM NTERRUPTEUR.
• NE PAS VOUS SERVIR DES TELEPHONES SE
TROUVANT DANS LE BATIMENT OU VOUS
VOUS TROUVEZ.
• APPELEZ IMMEDIATEMENT VOTRE
FOURNISSEUR DE GAZ CHEZ UN VOISIN.
SUIVEZ LES INSTRUCTIONS DU FOURNISSEUR.
• SI VOUS NE POUVEZ REJOINDRE LE
FOURNISSEUR DE GAZ, APPELEZ LE SERVICE
DES INCENDIES.
Installation
and
Operation
Instructions
GI 450 DV Katahdin
Gas 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 PROVIDES
INFORMATION TO ENSURE SAFE INSTALLATION
AND EFFICIENT, DEPENDABLE OPERATION OF
YOUR FIREPLACE INSERT. PLEASE READ THESE
INSTRUCTIONS IN THEIR ENTIRETY AND MAKE
THEM AVAILABLE TO ANYONE USING OR
SERVICING THIS GAS INSERT.
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 ................................................................ 13
High 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
Lighting Instructions ...................................
BACK COVER
Jøtul GI 450 Katahdin
Direct Vent Gas Fireplace Insert
Manufactured and Distributed by:
Jøtul A.S.A.
Fredrikstad, Norway
Jøtul North America
Portland, Maine
Test Standards
This appliance complies with
National Safety standards and is
tested and listed by Intertek
Testing Services of Middleton,
Wisconsin to ANSI Z21.88-
2002•CSA 2.33-M02 and
CAN/CGA 2.17--M91, CSA P.4.-01.2
for Canada.
MEA No. 312-00-E
DO NOT ATTEMPT TO ALTER OR MODIFY THE
CONSTRUCTION OF THIS APPLIANCE OR ITS
COMPONENTS. ANY MODIFICATION OR
ALTERATION WILL VOID THE WARRANTY,
CERTIFICATION AND LISTING OF THIS
APPLIANCE.
www.nficertified.org
To ensure your confidence, we recommend
that whenever possible, our products be
installed and serviced by professionals who
are certified by the National Fireplace
Institute (NFI) or, in Canada, by Wood Energy
Technical Training (WETT).
We at Jøtul North America are dedicated to
manufacturing the finest quality hearth
products you can be assured will give you
many years of safe, dependable service.
THIS PRODUCT MUST BE INSTALLED
BY A LICENSED PLUMBER OR
GAS-FITTER WHEN INSTALLED IN THE
COMMONWEALTH OF MASSACHUSETTS.

4
GI 450 DV
Katahdin
Specifications
31 1/4”
MEASUREMENTS INCLUDE
THE FRONT GRILL ASSEMBLIES
AND 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 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
15 3/8”
Input Rates
Natural gas
33,000 BTU/hr. maximum input
26,000 BTU/hr. minimum input
Propane
33,000 BTU/hr. maximum input
26,000 BTU/hr. minimum input
THIS APPLIANCE IS SHIPPED TO
USE NN
NN
NAA
AA
ATURAL GAS ONLTURAL GAS ONL
TURAL GAS ONLTURAL GAS ONL
TURAL GAS ONLYY
YY
Y. FOR USE
WITH PROPANE , INSTALL PROPANE
CONVERSION KIT #154903,
INCLUDED WITH THIS APPLIANCE.

5
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 a
fire, explosion, property damage, personal injury or loss
of life.
This appliance should be inspected before use and at
least annually. More frequent cleaning may be re-
quired due to excessive lint from carpeting, bedding
material, etc. It is imperative that control compart-
ments, burners and circulating air passageways of the
appliance be kept clean.
S’assurer que le bruleur et le compartiment des
commandes 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 is
required 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 what
regulations apply in your area.
Your local officials have final authority in determining
if a proposed installation is acceptable. Any require-
ment that 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, the installation requirements must comply with
the current National codes. In the U.S., these require-
ments 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
locaux, ou, en l’absence de tels reglements, selon les
Codes d’installation CAN/CGA-B149.
DO NOT OPERATE THIS INSERT IF ANY PART HAS BEEN
UNDER WATER.
Immediately call a qualified service technician to
inspect the heater and to replace any part of the
control system and any gas control which has been
under water.
Ne pas se servir de cet appareil s’il a ete’ plonge dans
l’eau, completement ou en partie. Appeler un
technicien qualifie pour inspecter l’appareil et
remplacer toute partie du syste’me de controle et
toute commande 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.
Safety Notices
Your 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 from
furniture and draperies.
Children and adults should be alerted to the hazards
of high surface temperatures and should stay away
to avoid burns or clothing ignition.
Young children should be supervised while they are
in 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, les
meubles, l’essence ou autres liquides a vapeur
inflammables loin de l’appareil.
NEVER store or use gasoline or any other flammable
vapors or liquids in the vicinity of the Katahdin gas
insert.
Never burn any other materials in your Katahdin gas
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.

6
Minimum Fireplace Requirements
The GI 450 DV Katahdin has been specifically designed
to be installed into a solid fuel-burning prefabricated
fireplace OR a code-approved solid fuel-burning ma-
sonry fireplace with a tile flue liner.
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:
Will cover a maximum fireplace opening
27 1/2” high x 39” wide.
The overall Standard Surround dimensions are
28” high X 40” wide.
Standard Surround with 2” Riser Bar:
Will cover a maximum fireplace opening
29 1/2” 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 Standard
Surround):
Will cover a maximum fireplace opening
31 1/2” high X 47” wide.
The overall Wide Surround dimensions are
32” high X 48” wide.
NOTE: A pair of Leg Extensions is included with the
Wide Surround for installations that include the 2”
Riser Bar.
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 poten-
tially 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 your
fireplace and chimney, contact a professional fireplace
service technician or your local Jøtul Authorized
Dealer to assist you in determining the condition of
your fireplace and chimney.
THIS APPLIANCE MUST NOT BE CONNECTED TO A
CHIMNEY OR FLUE SERVING ANY OTHER APPLIANCE OF
ANY KIND.
All venting components must be installed in
accordance with the terms of their listing and
manufacturer’s instructions. Refer to the pipe
manufacturer’s instructions for proper pipe clear-
ances.
The Katahdin is specifically designed to operate
using 3”Type B vent pipe components or a Listed
Flexible gas liner.
B
E
D
C
A
SEE PAGE 19 FOR SURROUND AND RISER BAR
INSTALLATION INSTRUCTIONS.
Figure 1.

7
Vent Installation Procedure
The GI 450 DV Katahdin gas insert must be vented
through dual 3” flexible gas aluminum liners listed for
use with gas appliances.
This co-linear installation includes a pair of 3” flex
ducts that run from the insert up through the existing
chimney.
One duct is attached to the exhaust port on the
back of the unit and will carry the exhaust gases to
the outside of the house. This exhaust liner must run
the 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 intake
port on the back of the unit and will provide fresh air
for combustion to the unit. This liner must extend a
minimum of 6’ off the back of the unit and extend
through the damper area of the fireplace and into the
tile liner of the chimney. This liner can also extend the
full 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’s
instructions.
• The minimum height of termination cap from the
top of the unit shall be no less than 10', and the
maximum height shall be no more than 35'. See
figures 2 and 4.
• Steep roofs, nearby trees, or predominantly windy
conditions can promote weak draft or occasional
downdrafts. In such cases, increasing the height of
the vent or installation of high wind termination
caps may alleviate the condition.
•HORIZONTAL RUNS are not permitted anywhere in
the venting system.
• Venting liners CANNOT be less than 3” in diameter
or greater than 3” in diameter.
•Anyunused flue or masonry enclosure can be used
as a passageway for venting PROVIDED the flue is
relined using 3” Listed Flexible Gas Liner.
• The remaining space around the liner in a masonry
or zero-clearance flue CANNOT be used to vent any
other appliance.
• Listed Flexible Gas Liners may not be exposed to any
living space.
• Installation of any components not manufactured or
approved by Jøtul or failure to meet all clearance
requirements will void all warranties and could result
in property 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 BUILD-
ING, AND NEVER ATTACHED TO A CHIMNEY SERVING
A SOLID FUEL OR GAS BURNING APPLIANCE.
• The minimum vent height above the roof or adja-
cent walls is specified by building codes. A general
guide to follow is the Gas Vent Rule below.
VERY IMPORTANT
If the intake flex does not extend the full length
of the chimney and connect to the unit and the
termination cap - A METAL BLOCK OFF PLATE MUST
BE CONSTRUCTED AND INSTALLED ABOVE THE UNIT
BELOW THE END OF THE INTAKE DUCT (normally at
the damper area). See figure 2.
To avoid cross venting the insert, label the duct to
be used for the exhaust conduit at both the top and
bottom ends. This ensures that the exhaust duct will
be attached to the correct collar on the insert and on
the chimney termination kit.
CANADA NOTE: Both Intake and Exhaust ducts
must extend the full length of the chimney and be
connected to both the unit and the termination kit.
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 TEST
METHODS AND RESULTING ITS/WHI
PRODUCT CERTIFICATION. THE CODE
AUTHORITY HAVING JURISDICTION MUST
BE 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 Height
From Roof
ROOF SLOPE

8
Venting through a Masonry Fireplace
1. Measure height of the chimney to fireplace opening.
Determine if both the intake and exhaust will be
extended to the top of the chimney. In Canada, both
liners must extend the full length of the chimney
and be connected to both the unit and the termina-
tion kit.
2. Cut the appropriate lengths of flex duct for both the
intake and exhaust. Label both ends of the Exhaust
duct.
3. Follow the manufacturer’s instructions to attach the
ends of the duct(s) to the chimney termination kit as
appropriate.
4. Drop the liners down the chimney from the top and
rest the termination kit atop the chimney.
5. Seal the chimney termination kit to the top of the
chimney 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:
A. Install a minimum 6 foot length flex duct for the
up the flue.
B. A METAL block-off plate must be constructed and
installed in the damper area to completely seal off
the flue from the room. Cut holes in the plate for
both the Intake and Exhaust liners.
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. Position the insert without surround panels half-
way inside the fireplace and attach duct you labelled
Exhaust to the Exhaust collar on the insert. Both
Intake and Exhaust collars are labelled.
11. Secure the ducts to the collars with sheet metal
screws or hose clamps. No silicone or sealant is
required.
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. Warning: Failure to position the parts in accordance with this
diagram or failure to use only parts specifically approved with this
appliance may result in property damage or personal injury.
Fig. 2. Venting through fireplace chimney.
Required metal
block-off plate to
seal flue chamber if
intake flex does not
extend the full
length of the flue.
Maintain the proper
clearance to mantel
and trim
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Direct vent
termination kit
required
GI 450 DV
KATAHDIN
GAS INSERT
Lined Masonry
Chimney Flue
Intake Air
Inlet
Listed Direct Vent
Termination Cap
Required

9
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 attached
to the unit with brackets which can be cut or pried off.
2. Remove the damper assembly. This includes the
damper 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 the
insert 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 detailed
on the preceding page for masonry fireplaces.
Figure 3. Duct collar locations.
Exhaust
Collar
Air Inlet
Collar
Dual 3” Listed Liners
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 TEST
METHODS AND RESULTING ITS/WHI
PRODUCT CERTIFICATION. THE CODE
AUTHORITY HAVING JURISDICTION MUST
BE CONSULTED PRIOR TO PROCEEDING
WITH THIS INSTALLATION METHOD.
Figure 4. Venting through prefabricated
fireplace chimney.
Metal block off
plate must be
installed if the
intake duct
does not extend
to the chimney
termination.
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Intake air for
combustion
Intake flex must
extend minimum 6’
into the chimney pipe
GI 450 DV
KATAHDIN
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Listed Direct Vent
Termination Cap
Required
Top sealing
anchor plate
required
Listed flexible
gas liners
Max. Height: 35 ft.
Min. Height: 10 ft.
Factory-built
chimney pipe
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Maintain the proper
clearance to mantel
and trim
Warning:
Failure to position the
parts in accordance with
this diagram or failure to
use only parts specifically
approved with this
appliance may result in
property damage or
personal injury.

10
Clearance 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.
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-combus-
tibles.
If you are not sure of the combustible nature of a
material, 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 for
the proper flow of ventilation air around the insert.
Fireplace Clearances
Measure clearances from the center and finished floor
of the fireplace opening.
A = 40” (1016 mm) to a Side Wall, (any combustible
surface that extends more than 1 1/2” from the
fireplace face)
B = 22” (559mm) to Side Trim that extends 1 1/2” or
less from the fireplace face. If the side trim extends
more than 1 1/2” from the fireplace opening then Side
Wall clearance applies.
C= 36” (867mm) to Top Trim that extends 1 1/2” or less
from the fireplace face.
D = 38” (915mm) to a Mantel that extends no more
than 14 1/2” from the fireplace face.
NOTE: MANTEL AND TOP TRIM CLEARANCES ARE
NOT AFFECTED BY THE USE OF THE 2” RISER BAR.
Hearth Requirements
Flush Hearth: requires a non-combustible hearth in front
of 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” high
requires a non-combustible hearth in front of the fire-
place that extends a minimum of 12” (305mm) from the
fireplace face and is a minimum of 32” (813mm) wide.
Hearth must be minimum 6” high to
extend only 12” in front
12”
NOTE: USE OF THE 2” RISER BAR DOES NOT EFFECT THE
HEARTH REQUIREMENTS LISTED ABOVE.
Figure 5. Fireplace clearances to combustible materials.
Figure 6. Flush
hearth dimensions
Figure 7. Raised
hearth dimensions
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