Jøtul GI 450 DV Katahdin User manual

1
Installation and
Operation Instructions
Jøtul GI 450 DV Katahdin
Direct Vent Gas Fireplace Insert
– QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE
GAZ:
• 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 fournisseur
de gaz,appelez le service des incendies.
– L’installatione l’entretien doivent être
assurés par un installateur ou un service
d’entretien qualifié ou par le fournisseur
de gaz.
– 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.
– Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
– WHAT TO DO IF YOU SMELL GAS
• 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 a
neighbor’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, a
carbon monoxide (CO) detector shall be
installed in the same room as the
appliance.
WARNING: If the information in these
instructions is not followed exactly, a fire
or explosion may result causing property
damage, personal injury or loss of life.
AVERTISSEMENT: Assurez-vous de bien
suivreles instructions données dans cette
notice pour réduire auninimum le risque
d’incendie ou d’explosion ou pour éviter tout
dommage matériel, toute blessure ou la mort.
CAUTION:THESE INSTRUCTIONS MUST
REMAIN WITH THE HOMEOWNER.
ATTENTION : CES INSTRUCTIONS DOIVENT
DEMUERER AVEC LE PROPRIÉTERE D’UNE
MAISON.

2

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
Appendix / Leg Levelers ............................................ 26
Lighting Instructions ...................................
BACK COVER
Jøtul GI 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 of
Middleton, 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
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.
THIS PRODUCT MUST BE INSTALLED
BY A LICENSED PLUMBER OR
GAS-FITTER WHEN INSTALLED IN THE
COMMONWEALTH OF MASSACHUSETTS.
450

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 NANA
NANA
NATT
TT
TUU
UU
URR
RR
RALAL
ALAL
AL
GG
GG
GAA
AA
AS ONS ON
S ONS ON
S ONLL
LL
LYY
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 requirement
that is requested by the local authority having jurisdic-
tion, 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 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
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 servic-
ing the appliance must be replaced prior to operating
the appliance.

6
Minimum Fireplace Requirements
This appliance has been specifically designed to be
installed into a solid fuel-burning prefabricated fire-
place OR a code-approved solid fuel-burning masonry
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 firmaximum fir
maximum firmaximum fir
maximum fireplaceplac
eplaceplac
eplace openinge opening
e openinge opening
e opening
22
22
27 17 1
7 17 1
7 1//
//
/2”2”
2”2”
2” high x 39”high x 39”
high x 39”high x 39”
high x 39” widewide
widewide
wide..
..
.
The overall Standard Surround dimensions are
28” high X 40” wide.
Standard Surround with 2” Riser Bar:
Will cover a maximum firmaximum fir
maximum firmaximum fir
maximum fireplaceplac
eplaceplac
eplace openinge opening
e openinge opening
e opening
29 129 1
29 129 1
29 1//
//
/2”2”
2”2”
2” high x 39”high x 39”
high x 39”high x 39”
high x 39” widewide
widewide
wide
The overall Standard Surround dimensions with
the Riser Bar are 30” high X 40” wide.
OptionalOptional
OptionalOptional
Optional WW
WW
Wide Surride Surr
ide Surride Surr
ide Surround (mustound (must
ound (mustound (must
ound (must be used with Stan-be used with Stan-
be used with Stan-be used with Stan-
be used with Stan-
dardar
dardar
dard Surrd Surr
d Surrd Surr
d Surroundound
oundound
ound):):
):):
):
Will cover a maximum firmaximum fir
maximum firmaximum fir
maximum fireplaceplac
eplaceplac
eplace openinge opening
e openinge opening
e opening
31 131 1
31 131 1
31 1//
//
/2”2”
2”2”
2” high X 4high X 4
high X 4high X 4
high X 47”7”
7”7”
7” widewide
widewide
wide..
..
.
The overall Wide Surround dimensions are
32” high X 47 5/8” wide.
NONO
NONO
NOTT
TT
TE:E:
E:E:
E: A pair oA pair o
A pair oA pair o
A pair of Lf L
f Lf L
f Leg Eeg E
eg Eeg E
eg Extensions is included withxtensions is included with
xtensions is included withxtensions is included with
xtensions is included with
thethe
thethe
the WW
WW
Wide Surride Surr
ide Surride Surr
ide Surround found f
ound found f
ound for installaor installa
or installaor installa
or installationstions
tionstions
tions thatha
thatha
thatt
tt
tincludeinclude
includeinclude
include
the 2”the 2”
the 2”the 2”
the 2” Riser BarRiser Bar
Riser BarRiser Bar
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 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 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.
TT
TT
THH
HH
HIS APPLIANCIS APPLIANC
IS APPLIANCIS APPLIANC
IS APPLIANCE ME M
E ME M
E MUSUS
USUS
UST NOT NO
T NOT NO
T NOT BT B
T BT B
T BE CE C
E CE C
E CONON
ONON
ONNN
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NECEC
ECEC
ECTT
TT
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EDED
ED TT
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TOO
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O
A CA C
A CA C
A CHH
HH
HIMNIMN
IMNIMN
IMNEE
EE
EY OR FLY OR FL
Y OR FLY OR FL
Y OR FLUU
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E SERVIVI
VIVI
VING ANNG AN
NG ANNG AN
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Y OY O
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HER APPLI-ER APPLI-
ER APPLI-ER APPLI-
ER APPLI-
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ANCANC
ANCE OF ANE OF AN
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E OF ANY KIY KI
Y KIY KI
Y KINN
NN
NDD
DD
D..
..
.
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 clearances.
This appliance 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.
SEE THE APPENDIX ON PAGE 26 FOR DETAILS
CONCERNING USE OF THE LEG LEVELER BRACKETS
TO ADJUST THE HEIGHT OF THE UNIT.
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 ominimum o
minimum ominimum o
minimum of 6’f 6’
f 6’f 6’
f 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 termina-
tion 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 10'10'
10'10'
10', and the
maximum height shall be no more than 35'35'
35'35'
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.
•HORHOR
HORHOR
HORIZIZ
IZIZ
IZONON
ONON
ONTT
TT
TAL RUAL RU
AL RUAL RU
AL RUNS arNS ar
NS arNS ar
NS are note not
e note not
e not permitted anpermitted an
permitted anpermitted an
permitted anywherywher
ywherywher
ywhere ine in
e ine in
e in
the vthe v
the vthe v
the venen
enen
enting sting s
ting sting s
ting syy
yy
ystem.stem.
stem.stem.
stem.
• Venting liners CANNOT be less than 3” in diameter or
greater than 3” in diameter.
• Any unused 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 adjacent
walls is specified by building codes. A general guide
to follow is the Gas Vent Rule below.
VERVER
VERVER
VERY IMPY IMP
Y IMPY IMP
Y IMPOROR
OROR
ORTT
TT
TANAN
ANAN
ANTT
TT
T
If the intake flex
does notdoes not
does notdoes not
does not extend the full length
of the chimney and connect to the unit and the
termination cap - A META MET
A META MET
A METAL BAL B
AL BAL B
AL BLL
LL
LOO
OO
OCC
CC
CK OFF PLK OFF PL
K OFF PLK OFF PL
K OFF PLAA
AA
ATT
TT
TE ME M
E ME M
E MUSUS
USUS
USTT
TT
T
BB
BB
BE CE C
E CE C
E CONSONS
ONSONS
ONSTT
TT
TRUCRUC
RUCRUC
RUCTT
TT
TED ANED AN
ED ANED AN
ED AND ID I
D ID I
D INSNS
NSNS
NSTT
TT
TALLED ABALLED AB
ALLED ABALLED AB
ALLED ABOO
OO
OVEVE
VEVE
VE TT
TT
THH
HH
HEE
EE
E
UU
UU
UNN
NN
NII
II
IT BT B
T BT B
T BELEL
ELEL
ELOO
OO
OWW
WW
W TT
TT
THH
HH
HE ENE EN
E ENE EN
E END OFD OF
D OFD OF
D OF TT
TT
THH
HH
HE IE I
E IE I
E INN
NN
NTT
TT
TAKE DUCAKE DUC
AKE DUCAKE DUC
AKE DUCTT
TT
T
(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.
CC
CC
CANADANAD
ANADANAD
ANADA NOA NO
A NOA NO
A NOTT
TT
TE:E:
E:E:
E: Both InBoth In
Both InBoth In
Both Intaktak
taktak
take and Ee and E
e and Ee and E
e and Exhaustxhaust
xhaustxhaust
xhaust ducduc
ducduc
ductsts
tsts
ts
mustmust
mustmust
must ee
ee
extendxtend
xtendxtend
xtend the full length othe full length o
the full length othe full length o
the full length off
ff
f the chimnethe chimne
the chimnethe chimne
the chimney and bey and be
y and bey and be
y and be
cc
cc
conneconnec
onneconnec
onnectedted
tedted
ted tt
tt
to botho both
o botho both
o both the unitthe unit
the unitthe unit
the unit andand
andand
and thethe
thethe
the terminatermina
terminatermina
terminationtion
tiontion
tion
kitkit
kitkit
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
1.1.
1.1.
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 CIn C
In CIn C
In Canada,anada,
anada,anada,
anada, bothboth
bothboth
both
liners mustliners must
liners mustliners must
liners must ee
ee
extendxtend
xtendxtend
xtend the full length othe full length o
the full length othe full length o
the full length off
ff
f the chimnethe chimne
the chimnethe chimne
the chimneyy
yy
y
and be cand be c
and be cand be c
and be conneconnec
onneconnec
onnectedted
tedted
ted tt
tt
to botho both
o botho both
o both the unitthe unit
the unitthe unit
the unit andand
andand
and thethe
thethe
the termi-termi-
termi-termi-
termi-
nana
nana
nation kittion kit
tion kittion kit
tion kit..
..
.
2.2.
2.2.
2. Cut the appropriate lengths of flex duct for both the
intake and exhaust. Label both ends of the Exhaust
duct.
3.3.
3.3.
3. Follow the manufacturer’s instructions to attach the
ends of the duct(s) to the chimney termination kit as
appropriate.
44
44
4..
..
. Drop the liners down the chimney from the top and
rest the termination kit atop the chimney.
55
55
5..
..
. Seal the chimney termination kit to the top of the
chimney flue with high temperature sealant.
6.6.
6.6.
6. Secure the appropriate direct vent cap to the termi-
nation kit.
77
77
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.
8.8.
8.8.
8. If the Intake duct is not attached to the chimney
termination kit:
A.A.
A.A.
A. Install a minimum 6 foot length flex duct for the
up the flue.
BB
BB
B..
..
. A METAL block-off plate must be constructed and
installed in the damper area to cc
cc
completely seal oompletely seal o
ompletely seal oompletely seal o
ompletely seal off
ff
fff
ff
f
the flue from the room. Cut holes in the plate for
both the Intake and Exhaust liners.
C.C.
C.C.
C. A direct vent cap is required to allow fresh air into
the chimney flue and ultimately into the intake duct
to the insert.
9.9.
9.9.
9. Compress the ducts so that they are hanging above
the height of the fireplace opening and are out of
the way.
1010
1010
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.
11.11.
11.11.
11. Secure the ducts to the collars with sheet metal
screws or hose clamps. No silicone or sealant is
required.
12.12.
12.12.
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. WW
WW
Warning:arning:
arning:arning:
arning: FF
FF
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ailurailur
ailuree
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e tt
tt
to positiono position
o positiono position
o position the parthe par
the parthe par
the parts in acts in ac
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dance withe with
e withe with
e with thisthis
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this
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am or fam or f
am or failurailur
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ailuree
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o use only paro use only par
o use only parts specifically apprts specifically appr
ts specifically apprts specifically appr
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ed withed with
ed with
this appliancthis applianc
this appliancthis applianc
this appliance mae ma
e mae ma
e may ry r
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esult in prin pr
in prin pr
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operty damagty damag
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ty damage or personale or personal
e or personale or personal
e or personal
injurinjur
injurinjur
injuryy
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.
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 TOTHE FIRE-
BOX. 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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2
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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
WW
WW
Warning:arning:
arning:arning:
arning:
FF
FF
Failurailur
ailurailur
ailuree
ee
e tt
tt
to positiono position
o positiono position
o position thethe
thethe
the
parpar
parpar
parts in acts in ac
ts in acts in ac
ts in accc
cc
coror
oror
ordancdanc
dancdanc
dance withe with
e withe with
e with
this diagrthis diagr
this diagrthis diagr
this diagram or fam or f
am or fam or f
am or failurailur
ailurailur
ailuree
ee
e
tt
tt
to use only paro use only par
o use only paro use only par
o use only partsts
tsts
ts
specifically apprspecifically appr
specifically apprspecifically appr
specifically approo
oo
ovv
vv
veded
eded
ed
withwith
withwith
with this appliancthis applianc
this appliancthis applianc
this appliance mae ma
e mae ma
e mayy
yy
y
rr
rr
resultesult
esultesult
esult in prin pr
in prin pr
in properoper
operoper
opertyty
tyty
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damage or personaldamage or personal
damage or personaldamage or personal
damage or personal
injurinjur
injurinjur
injuryy
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.

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-combustibles.
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 cc
cc
combustibleombustible
ombustibleombustible
ombustible.
Always maintain the proper clearances to allow for
the proper flow of ventilation air around the insert.
Fireplace Clearances
MeasurMeasur
MeasurMeasur
Measure cleare clear
e cleare clear
e clearancanc
ancanc
ances fres fr
es fres fr
es fromom
omom
om the cthe c
the cthe c
the cenen
enen
enter and finishedter and finished
ter and finishedter and finished
ter and finished
floor ofloor o
floor ofloor o
floor off
ff
f the firthe fir
the firthe fir
the fireplaceplac
eplaceplac
eplace openinge opening
e openinge opening
e opening..
..
.
A = 40”A = 40”
A = 40”A = 40”
A = 40” (1016 mm)(1016 mm)
(1016 mm)(1016 mm)
(1016 mm) tt
tt
to a Sideo a Side
o a Sideo a Side
o a Side WW
WW
Wall,all,
all,all,
all, (any combustible
surface that extends more than 1 1/2” from the
fireplace face)
B = 22”B = 22”
B = 22”B = 22”
B = 22” (55(55
(55(55
(559mm)9mm)
9mm)9mm)
9mm) tt
tt
to Sideo Side
o Sideo Side
o Side TT
TT
Trimrim
rimrim
rim 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 SideSide
SideSide
Side WW
WW
Wallall
allall
all
clearclear
clearclear
clearancanc
ancanc
ancee
ee
e applies.
CC
CC
C = 36”36”
36”36”
36” (86(86
(86(86
(867mm)7mm)
7mm)7mm)
7mm) tt
tt
too
oo
o TT
TT
Topop
opop
op TT
TT
Trimrim
rimrim
rim that extends 1 1/2” or less
from the fireplace face.
D = 38”D = 38”
D = 38”D = 38”
D = 38” (915mm)(915mm)
(915mm)(915mm)
(915mm) tt
tt
to a Mano a Man
o a Mano a Man
o a Manteltel
teltel
tel 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 HearFlush Hear
Flush HearFlush Hear
Flush Hearth:th:
th:th:
th: 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.
RR
RR
Raised Hearaised Hear
aised Hearaised Hear
aised Hearth:th:
th:th:
th: 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”
NONO
NONO
NOTT
TT
TE:E:
E:E:
E: USE OFUSE OF
USE OFUSE OF
USE OF TT
TT
THH
HH
HE 2”E 2”
E 2”E 2”
E 2” RR
RR
RISER BISER B
ISER BISER B
ISER BARAR
ARAR
AR DOES NODOES NO
DOES NODOES NO
DOES NOTT
TT
TEFFECEFFEC
EFFECEFFEC
EFFECTT
TT
T
TT
TT
THH
HH
HE HE H
E HE H
E HEE
EE
EARAR
ARAR
ARTT
TT
TH RH R
H RH R
H REQUEQU
EQUEQU
EQUII
II
IRR
RR
REMENEMEN
EMENEMEN
EMENTT
TT
TS LISS LIS
S LISS LIS
S LISTT
TT
TED ABED AB
ED ABED AB
ED ABOO
OO
OVE.VE.
VE.VE.
VE.
Figure 6. Flush
hearth dimensions
Figure 7. Raised
hearth dimensions
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18”
32”
6”
Figure 5. Fireplace clearances to combustible materials.
B
A
C
D
Leg Leveler Brackets
See the Appendix on page 26 for information on the
proper use of the Leg Leveler Brackets to raise the insert.
ClearClear
ClearClear
Clearancanc
ancanc
ancee
ee
e tt
tt
to Co C
o Co C
o Combustiblesombustibles
ombustiblesombustibles
ombustibles
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 clear-
ance to mantel and trim be increased by 1”:
C = Hearth to Upper Trim - 37”
D = Hearth to Mantel - 39”