Jøtul GI 635 DV IPI User manual

Fuel Conversion
Instructions
Kit 157784 - NG to LP
Kit 157785- LP to NG
This conversion kit shall be installed
by a qualified service agency in
accordance with the manufacturer’s
instructions and all applicable
codes and requirements of the
authority having jurisdiction. If the
information in these instructions
is not followed exactly, a fire,
explosion, or production of carbon
monoxide may result causing
property damage, personal
injury or loss of life.The qualified
service agency is responsible for
the proper installation of this kit.
The installation is not proper and
complete until the operation of
the converted appliance is checked
as specified in the manufacturer’s
instructions supplied with the kit.
Cet équipement de conversion sera
installé par une agence qualifiée de
service conformément aux instruc-
tions du fabricant et toutes exigences
et codes applicables de l’autorisés
avoir la juridiction. Si l’information
dans cette Instruction n’est pas suivie
exactement, un feu, explosion ou pro-
duction de protoxyde de carbone peut
résulter le dommages causer de pro-
priété, pert ou blessure personnelle
de vie. L’agence qualifiée do service
est esponsable de l’installation pro-
pre de cet équipemetn. L’installation
n’est pas propre et complète jusqu’à
l’operation de l’appareil converi est
chéque suivant les critères établis
dans les instruction de propriétaire
provision nées avel l’équipement.
CAUTION: Before proceeding with
this conversion, the gas supply must
be shut off prior to disconnecting
the electrical power.
ATTENTION: Avant de procéder à cette
conversion, l’approvisionnement en
gaz doit être coupée avant de dé-
brancher l’alimentation électrique.
Jøtul GI 635 DV IPI Newcastle
Direct Vent Fireplace Insert
Jøtul North America, Inc. 55 Hutcherson Dr. Gorham, Maine 04038
June, 2016 1396717_R04
NOTE: IN ORDER TO ACCESS THE STEPPER
MOTOR COMPONENTS, COMPLETE THE FUEL
CONVERSION PROCEDURE BEFORE PLACING
THE INSERT WITHIN THE FIREPLACE.

2
Fuel Conversion Kit
Propane #157784 / Natural Gas #157785
SIT Proflame 2 Valve
Rating Specifications - BTU/hr NG LP
Min. Input Rate, 0 - 2000 ft. 40,000 40,000
Max. Input Rate, 0 - 2000 ft. 10,000 8,700
Tools required:
• Torx T20 or slotted screwdriver
• 10 mm or 7/16” open end wrench
• 1/2” open ended wrench or deep-well socket
Conversion Kit Contents:
• 1, Regulator Tower labeled for either LP or NG
• 2, Regulator Tower screws
• 2, Burner Orifices:
Propane - Left - 1.40 mm
- Right - 1.20 mm
Natural Gas - Left - 2.25 mm
- Right - #47
• Label A - to be completed and applied to
the back of the stove.
• Label B - apply to the stove’s Rating Plate
• Small valve label - apply to valve body
• Conversion instructions
• Fuel Conversion Label A - Valve Compartment
• Fuel Conversion Label B - Rating Plate Notice
• Small Regulator Tower Label
Fuel Conversion
The Jøtul GI 635 DV IPI is shipped from the factory
equipped to burn Natural gas. Propane Fuel
Conversion Kit 157784 is included with this appliance.
Use Fuel Conversion Kit 157785 to convert back
to Natural Gas. The kits contain all the necessary
components, including labels that must be applied 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 CODES AND REQUIREMENTS
OF THE AUTHORITY HAVING JURISDICTION. FAILURE
TO FOLLOW THESE INSTRUCTIONS COULD RESULT
IN SERIOUS INJURY OR PROPERTY DAMAGE. THE
QUALIFIED AGENCY PERFORMING THIS WORK
ASSUMES 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.
7.3.1 Fuel Conversion Procedure
1. Turn off the gas supply and electrical power to the
appliance.
2. REMOVE THE GLASS FRAME using the Latch Tool. See fig. 1.
3. RETRACT THE AIR SHUTTERS: Locate the Air Shutter cable
on the floor in each side compartment - push each fully in.
This action retracts the shutters and allows the burner to be
disengaged from the firebox. See figs. 2 and 4.
4. REMOVE THE BURNER:
Lift out the two steel support shelves, fig. 1, (A), located at
each side of the burner. Grasp the burner assembly at the
sides, lifting it straight up, then tilt it back to disengage
it from the injectors and front locator studs (B). Pull the
assembly up out of the firebox.
5. CHANGE THE BURNER INJECTORS: Use a 1/2”open end
wrench or deep-well socket to remove the burner injectors
from the brass fittings at the rear of the firebox. See fig.
2. Install the injectors from this conversion kit into the
appropriate left and right locations and tighten securely.
6. CHANGE THE INTEGRATED DUAL-FUEL PILOT ORIFICE:
Use the 7/16” wrench to just loosen the pilot head enough
to push in the orifice lever. See fig. 3.
LP : push lever to the Right to expose the red indicator.
NG: push lever to the Left.
Retighten the pilot base nut, but do not over-tighten. Be
certain the pilot hood directs flame to the flame sensor.
7. CHANGE THE VARIABLE REGULATOR TOWER on the gas
control valve. See fig. 4.
• Remove the heat shield and screw from the valve
compartment to access the Regulator Tower.
• Disconnect the IFC lead from the regulator lead.
• Remove the two Torx screws to remove the original
regulator tower, rubber diaphragm and spring.
• Install the new regulator tower from the kit using the
screws previously removed.Tighten screws securely.
Reconnect the Regulator lead to the IFC lead.
• Reinstall the Regulator Heat Shield and screw.
Figure 1. Burner removal and re-installation.
A
A
B
B

3
Figure 2. Fuel Conversion Components.
Figure 3. Pilot Conversion to Propane.
Figure 4. Replace the Regulator Tower.
Regulator Lead
to IFC Lead
Regulator
Tower
Remove
Heat
Shield and
screw
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


Air Shutter
Cable
Pilot Assembly
Front Burner
Injector
Rear Burner
Injector
Front Burner Air
Shutter Cable
Air Shutter
Adjustor Trays
Rear Burner Air
Shutter Cable
8. Apply the conversion notice labels included in the kit to the
appliance where they will be visible to any person who may
be servicing the unit.
• Label “A”: Apply to the right side compartment adjacent to
the Rating Plate.
• Label “B”: Apply to the Rating Plate.
• Small valve sticker: Apply to valve body.
9. REINSTALL THE BURNER ASSEMBLY. Tilt the back of the
burner down to engage the air shutters with the injectors.
Set the burner in place, engaging the front brackets at each
side with the studs in the firebox floor, fig. 1, (B).
Replace the steel side support shelves, fig. 1, (A).
Properly located, the burner should be level from side to
side and securely seated within the firebox.
10. GAS LEAK CHECK: Use an electronic gas detector or soap
solution to test for leaks at the pilot head and all gas line
joints.
NEVER USE AN OPEN FLAME TO CHECK FOR GAS LEAKS.
11. PRESSURE TEST: Conduct a pressure test of the valve
following the guidelines on the next page.
12. BURNER CONFIRMATION: Follow Steps 1 -5 under Initial
System Check on page 27 of the Installation Manual
before final assembly of accessory, log set, and surround
components.
NOTE: PREVENT
GLASS FRAME
DAMAGE.REMOVE
GLASS FRAME
BEFORE REMOVING
THE HEAT SHIELD.

4
Gas Pressure Check
Correct gas pressure is essential for efficient and safe
operation of the stove. It is important that the correct
pressure is established at the time of the installation.
Proper gas pressure provides a consistent flow of gas to the
appliance and is instrumental in checking for gas leaks.
Pressure Test: Attach a manometer to the appropriate
test point on the valve. See fig. 5. The gauge connections are
located on the front of the valve. Connections are identified
by:
E - for Inlet or Supply Pressure (the amount of gas
coming to the valve.)
A - for Manifold Pressure (the amount of gas that is
coming out of the valve to the burner.)
ALWAYS TEST PRESSURES WITH VALVE REGULATOR SET TO
HIGH.
INLET GAS PRESSURES
(inches water column)
MIN MAX
NATURAL GAS 5.0 7.0
PROPANE 12.0 14.0
The appliance and its appliance main gas valve must
be disconnected from the gas supply piping system dur-
ing any pressure testing on that system at test pressures
in excess of 1/2 psig (3.5 kPa).
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 less than 1/2 psig (3.5
kPa).
MANIFOLD PRESSURES
(inches water column)
MIN MAX
NATURAL GAS 1.1 3.8
PROPANE 2.9 11.0
Figure 6.
Insert the Latch Tool into the receiver hole in
the gas cock.
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



Pull the tool forward toward you to open the gas cock.
Push it back to close the gas cock.
Figure 5.
Pressure test points.
ManifoldInlet
Pilot
Adjustment
OUT
Figure 8. Correct flame picture.
Figure 7. Correct pilot flame pattern.
Pilot and Burner Flame Adjustment
Pilot flame can be adjusted at the valve screw (fig. 5) to
engulf the flame rectifier and extend over the burner
ignition ports (fig.7).
See the Operation Manual for detailed instructions
on adjustment of the front and rear burner air shut-
ters to achieve the ideal burner flame picture (fig. 8).
Flame Rectifier