Jøtul GI 545 DV MV Installation And Operation Instructions Manual Download Page 31

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139919 GI 545 DV and DV MV 5/19

129124

Gasket, Tadpole, .25 X 1.25, Self Adhesive

2 220042

Clip, U Type (

Tinnerman - Repairs only)

3 158135

Glass w/ Gasket, Replacement

4 22628592 Glass Frame - MB

5 22628392 Baffle, Firebox - MB

6 117968

Nut, M6 Serrated Flange plain

7 22628292 Air Intake Wall - MB

8 117917

Screw, HWH SMA #8 x 1/2 SL Blk Oxide

9 22630792 Burner Skirt - MB

10 226350

Orifice Cover, GI 545 DV

11 226351

Intake Air Diverter, GI 545 DV

12 158056

Burner Assembly, GI 545 DV

13 22633992 Hanging Bracket, Left - MB”

14 226281

Firebox Weldment

15 226416

Heat Shield, Remote Receiver

16 224910

Remote Control Kit

17 226284 Base

18 118047

Bolt, Leveling, M8 x 40

19 226367

Switch Box

20 138720

Decal, Blower Switch Box

21 158136

Rheostat & Wire Harness

22 220703

Switch, Rocker, SPDT, Center Off, Black

23 220637

Snapstat, 140-120 deg° F

24 222951

Bracket, Snapstat, Firebox Mounted,

25 225069

Snapstat Shield

26 225063

Snapstat Finger Guard

27 157969

Blower, Cross flow, 12” Cage -

Replacement

28 226311

Cover, Access Blower

29 12969992 Bracket, Control Panel

30 129154

Terminal Block, 2 Pole 77 series

31 117920

Screw, Pan Head Ph M4x8 M/S Zinc

32 117922

Nut, Hex M4 DIN 934 PLAIN

33 129698

Support, Control Panel

34 226413

Gasket, Spud Plate

No. Part No.

Description

No. Part No.

Description

35 226366

Spud Plate

36 129670

Gasket, Pilot Assembly

37 226428

Pilot Spacer, .940”

38 226417

Pilot Ass’y, NG/LP, 820 Valve, PSE

39 118218

Screw, HWH SMA 8 x 1.5”” SL Zinc

40 222280

Gasket, Drop In Orifice Holder

41 223231

Orifice Holder, Drop In Assembly

42 220018

(Natural Gas) Orifice, #37

42 220731

(Propane Gas) Orifice, #53

43 226352

Handle Air Shutter

44 220734

Gasket, 2.25in OD x .125

45 226380

Primary Air Handle

46 118016

Nut, Lock, M6

47 226286

Top Back Shroud

48 226412

Gasket, Vent Adaptor

49 225942

Latch, Glass Frame

50 226394

Delayed Ignition Latch Ass’y

51 129707

Flex Tube, 3/8”” OD x 36””, 3/8” F

52 223215 Adaptor, Straight, 3/8 NTP x 3/8

53 117920

Screw, Pan Head Ph M4x8 M/S Zinc

54 226348

Igniter Bracket, GI 545 DV

55 3902573

Piezo Ignitor Button

56 129729

Valve Extension knob - On/Off

57 129730

Regulator Extension knob - Hi/Lo

58 222263

Valve, NG, 50% TD, SIT 820

(DV Models)

226560

Valve, NG, 50% TD, SIT 821

(DV MV Models)

59 129612

Valve Bracket

60 117911

Screw, Pan Head Ph 10-32x3/8 M/S Zinc

61 226340

Hanging Bracket, Right

62 221930

Air Shutter

63 158137

Blower Control Assembly

64 158138

Power Cord Assembly

65 158117

Replacement Glass & Frame

66 225451

Embers, Small

Summary of Contents for GI 545 DV MV

Page 1: ...lier In the Commonwealth of Massachusetts a carbon monoxide CO detector shall be installed in the same room as the appliance WARNING FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury death or property damage Thisappliancemaybeinstalledinanaftermarket permanentlylocated manufacturedhomeor mobilehome wherenotprohibitedbylocalcodes Thisapplianceisonlyfo...

Page 2: ...is included with this appliance however an additional T Handle valve may be required in Massachusetts Sediment trap if required by code Tee joint Pipe wrench Pipe sealant 10 mm open end wrench 1 2 7 16 open end wrench Phillips head screwdriver Flat head screwdriver 1 4 nut driver Work Gloves Safety glasses Torx T 20 screwdriver Tin snips Glass Frame Latch Tool included with appliance Retain and st...

Page 3: ... shipping crate and fireplace for damage and immediately contact the dealer if any is found 2 The Log Set and optional Blower are shipped separately from the firebox Do not install these untill directed in these instructions A Miscellaneous Hardware Kit is packed within the firebox crate with this manual Confirm these contents Fuel Conversion Kit LP Fireplace Conversion Notice Plate Rock Wool Embe...

Page 4: ...udes Canadian energy performance verified Conforms to CAN CSA P 4 1 15 Energy Peformance Standard for Fireplace Efficiency by ETL Intertek Arlington Heights Illinois Four sided Trimmable Backer Plate Matte Black Paint 46 W x 34 H 116 8 x 86 4 cm 158110 5 625 14 3 cm Four sided Backer Plate Cast Iron or Steel Surround Overlay Three sided Overlay Backer Plate Matte Black Paint Overlay Backer Frame 4...

Page 5: ...placement of the glass should be done by a licensed or qualified service person Only remove glass for routine service Always handle glass carefully 7 Notify your insurance company before proceeding with installation of this fireplace 8 It is normal that burner ignition and extinction be accompanied by a muffled woof or thud noise Discontinue use and call a qualified service technician if these fun...

Page 6: ...iance n Clothing or other flammable materials should not be placed on or near the fireplace n Never allow anyone to use the fireplace if they are unfamiliar with its operation n NEVER store or use gasoline or any other flammable vapors or liquids in the vicinity of the fireplace n Never burn any solid materials wood cardboard paper coal etc in this gas fireplace Use with natural gas or propane fue...

Page 7: ...rom inside the firebox and the rear bolts are adjusted by tipping the firebox and unscrewing them from the base Also note that use of the leveling bolts will affect required minimum clearance to combustible top trim and mantle construction See the figures and tables on pages 8 and 9 DO NOT REMOVE BRICKS OR MORTAR FROM THE FIREPLACE OR CHIMNEY STRUCTURE However masonry or steel may be removed from ...

Page 8: ...acker Plate 46 W x 34 H 158110 4 Sided Trimmable Backer Plate 46 W x 34 H Trimmable plate is intended for flush faced fireplace installations Figure 5 3 Hearth Trim and Wall clearances 5 3 Hearth Protection Hearth protection in front of the GI 545 DV MV must be composed of masonry material extending at least 3 1 8 10 5 cm to each side of the fireplace opening and 12 30 5 cm forward from the firepl...

Page 9: ...Forward hearth protection may be reduced by two inches 5 08 cm for every inch of fireplace floor elevation Fig 5 4 5 4 Mantel and Ceiling Clearances Measure clearances from the finished floor of the fireplace opening See fig 5 5 Mantel Projection Clearance from Hearth A 12 30 5 cm 39 3 4 1010 cm B 10 25 4 cm 39 1 8 99 cm C 8 20 3 cm 38 1 2 97 8 cm D 6 15 2 cm 37 7 8 95 6 cm E 4 10 2 cm 37 1 4 94 6...

Page 10: ...ll vent components must be installed in accordance with the terms of their listing and manufacturer s instructions See the Appendix on page 32 for a listing of approved vent manufacturers The minimum height of termination cap from the top of the unit shall be no less than 10 ft 3 05 m and the maximum height shall be no more than 35 ft 10 67 m See figures 6 1 6 2 Steep roofs nearby trees or predomi...

Page 11: ... 9 Remove the Vent Adaptor from the unit by pushing it to the rear Connect both ducts to the appropriate collars 10 Position the insert without Backer Plate half way inside the fireplace and start the Vent Adaptor onto the top of the firebox As you face the front of the insert the Intake collar is on the left and the Exhaust is on the right 11 Secure the ducts to the appropriate collars on the Ven...

Page 12: ...UNDER THE ANSI Z21 88 1999 CSA 2 33 M04 TEST METHODS AND RESULTING ITS WHI PRODUCT CERTIFICATION THE CODE AUTHORITY HAVING JURISDICTION MUST BE CONSULTED PRIOR TO PROCEEDING WITH THIS INSTALLATION METHOD Figure 6 2 Venting through prefabricated fireplace chimney Listed Flexible Gas Liners Max Height 35 ft Min Height 10 ft Listed Direct Vent Standard or High wind Termination Cap Minimum UL 127 List...

Page 13: ... to the back of the fireplace if appropriate 9 Backer Plates or the Cast Iron Overlay panel must not block or seal any ventilation openings on the prefabricated fireplace WARNING FAILURE TO POSITION THE PARTS IN ACCORDANCE WITH THESE DIAGRAMS OR FAILURE TO USE ONLY PARTS SPECIFICALLY APPROVED WITH THIS APPLIANCE MAY RESULT IN PROPERTY DAMAGE OR PERSONAL INJURY 6 3 Vent Connection Wear Safety Glove...

Page 14: ...HUSETTS IN COMPLIANCE WITH CODE 248 CMR Figure 7 1 External gas connection components 7 Fireplace Assembly Before beginning final assembly push the insert partially into the fireplace and adjust the leveling bolts located at each corner as appropriate to achieve a level and plumb installation Complete assembly procedures 1 5 before placing the insert within the firepace 1 Gas Connection and Leak T...

Page 15: ...ct gas pressure include Insufficient gas pressure Small pilot flame which can result in poor pilot rectification and or frequent burner outages Little variation in flame picture between HI and LO regulator settings Insufficient gas to support more than one appliance causing nuisance outages or gas surges Excessive gas pressure Permanent damage to valve causing complete appliance shut down Too larg...

Page 16: ...he floor while pulling the assembly forward Remove it from the firebox and set it out of the way 4 CHANGE THE BURNER INJECTOR Use a 1 2 or 13 mm open end wrench or deep well socket to remove the original burner injector from the brass fitting at the rear of the firebox See fig 7 4 Install the injector from the conversion kit and tighten it securely 5 CHANGE THE INTEGRATED DUAL FUEL PILOT ORIFICE U...

Page 17: ... Fuel Conversion Components Air Shutter Handle Air Shutter Lock Nut A B Regulator Piezo Ignitor Valve Control Knob Burner Control Apply small label valve Remove black gasket Regulator Tower NATURAL GAS PROPANE Pilot Head Orifice Lever Figure 7 4 Burner and injector removal Pilot Assembly Shutter Hood Injector Burner Assembly ...

Page 18: ...all thermostat control 2 Light the pilot following the instructions found in this manual and on the appliance rating plate When the pilot is lit the burner will respond to calls for heat either thermostatically or by remote transmitter 7 4 2 Wall Thermostat Use only a 750 millivolt DC two wire circuit wall thermostat Follow the manufacturerer s installation instructions Use a minimum 16 gauge wire...

Page 19: ...GERPRINT STAINS SKIN OIL RESIDUE WILL BE DIFFICULT TO REMOVE FROM THE GLASS SURFACES IMPORTANT INSTALL EACH GLASS PANEL ORIENTED WITH THE TEXTURED SIDE FACING AGAINST THE FIREBOX WALLS 2 install the Rear Panel all kits The panel simply rests on the rear burner skirt flat against the back of the firebox The side panels will lock the rear panel in place as they are installed Fig 7 9 1 Open the Side ...

Page 20: ...V MVTraditional Log Set 158099 1 Left Rear Log 226418 2 Right Rear Log 226419 3 Left Burner Log 226420 4 Left Cross Log 226421 5 Right Burner Log 226422 6 Right Cross Log 226423 7 Left Small Log 226424 8 Right Small Log 226425 Fig 7 11 5 5 6 6 1 1 2 2 3 3 4 7 6 8 Figure 7 13 Engage Rear Log 2 with the 2 pins indIcated in fig 7 12 on Rear Log 1 and the burner skirt 2 Log 3 PINS Figure 7 14 Engage t...

Page 21: ...R CARRY OVER PORTS PILOT PORTS Figure 7 18 Engage holes in underside of Small Right Log 7 with the pins on log 6 and at the rear of the burner plate in fig 17 Figure 7 19 Engage the hole in Small Left Log 8 with the pin on Rear Log 1 oriented as shown above Spread Burner Embers in one even layer over the burner being careful avoid obstucting the pilot and burner carry over ports shown in Fig 7 20 ...

Page 22: ...bag to simulate glowing embers 5 5 6 6 1 1 2 2 3 3 4 Figure 7 21 Figure 7 22 Engage the Rear Log 1 with the two steel pegs located on rear burner skirt 3 Log 4 PINS 2 2 Log 3 PIN 1 Log 2 PINS Figure 7 26 Engage the underside of Right Top Log 5 with Pin 5 indicated in fig 7 25 as well as the matching seat on Log 1 5 5 GI 545 DV MV Beach Fire Log Set 158100 1 Rear Log 226487 2 Right Burner Log 22648...

Page 23: ...r Rock 3 underneath right side of log four in front of the left burner opening with the engraved number facing inward Figure 7 31 Place Right Burner Log Rock 4 underneath right side of log two in front of the burner s right most opening with engraved number facing inward Figure 7 33 Place Burner Embers in one even layer over steel burner be careful not to block pilot area Figure 7 32 Place left Sk...

Page 24: ...ure 7 35 Backer Plate hooks A engage slots B from behind The front Overlay engages with slots C from the front IMPORTANT DO NOT PLACE THE INSERT IN THE FINAL POSITION UNTIL THE BACKER PLATE IS INSTALLED THE FIREBOX MUST BE SET OUT OF THE FIREPLACE ENOUGH TO INSTALL THE BACKERPLATE COMPLETE THE GAS VENT CONNECTION AND FUEL CONVERSION BEFORE INSTALLING THE BACKER PLATE 7 8 Backer Plate Installation ...

Page 25: ...tabs back to allow air circulation behind the Overlay See detail WARNING See Fig 7 36 A MINIMUM 1 2 13 mm AIR SPACE MUST BE MAINTAINED BETWEEN THE FRONT OVERLAY ASSEMBLY AND THE BACKER PLATE OR FIREPLACE FACE THIS AIR SPACE IS AUTOMATICALLY MAINTAINED BY THE BACKER PLATE HOOKS WHICH ACT AS STAND OFFS IF A BACKER PLATE IS NOT USED THE AIR SPACE MUST BE CREATED BY BENDING BACK THE TWO STEEL TABS ON ...

Page 26: ... TO OPERATE THIS APPLIANCE DO NOT ALLOW ANYONE TO OPERATE THIS APPLIANCE WHO HAS NOT READ AND UNDERSTOOD THESE INSTRUCTIONS KEEP THE REMOTE CONTROL TRANSMITTER WHERE CHILDREN CANNOT REACH IT n During the first few hours of operation it is common to detect some smoke and odor resulting from the high temperature paint curing This condition is temporary and may be alleviated by opening windows and us...

Page 27: ...actory flame picture is achieved Insufficient combustion air will promote inefficient combustion resulting in very long yellow flames and soot Sooting produces black deposits on the logs on the firebox walls and potentially on the flue termination cap Very blue transparent or weak anemic flames are indications of too much air which although efficient are not very attractive Generally propane fuel ...

Page 28: ...eplace insert contact your Jøtul Authorized Dealer for assistance KEEP THIS MANUAL FOR REFERENCE AND MAKE IT AVAILABLE TO ANYONE USING OR SERVICING THE INSERT This appliance and venting system should be inspected before use and at least annually by a qualified service technician 9 1 General Cleaning Vacuum the controls area under the firebox at least monthly or more frequently if pet hair is in th...

Page 29: ...steel tabs that secure the glass panel at the corners of the frame 4 Install the new glass panel and gasket in the glass frame and secure with the steel tabs Do not over tighten the tabs as that could break the glass ALWAYSUSEJØTUL AUTHORIZEDPARTS NEVERSUBSTITUTE PARTS FROM OTHER SOURCES See fig 10 1 page 31 WARNING OBSERVE CAUTION NEAR THE GLASS THE GLASS PANEL MAY SHATTER IF STRUCK WITH AN OBJEC...

Page 30: ... DV MV 5 19 3 2 1 4 5 6 6 7 8 9 10 11 12 13 14 15 16 17 18 8 6 18 19 20 21 22 22 23 24 25 26 8 27 28 29 30 31 32 33 34 35 8 36 37 38 39 40 41 42 8 42 43 8 44 45 46 47 8 8 8 48 49 50 8 8 50 8 2 8 8 8 8 6 6 51 52 53 54 55 56 57 58 59 60 52 61 6 6 10 0 Illustrated Part List ...

Page 31: ...x8 M S Zinc 32 117922 Nut Hex M4 DIN 934 PLAIN 33 129698 Support Control Panel 34 226413 Gasket Spud Plate No Part No Description No Part No Description 35 226366 Spud Plate 36 129670 Gasket Pilot Assembly 37 226428 Pilot Spacer 940 38 226417 Pilot Ass y NG LP 820 Valve PSE 39 118218 Screw HWH SMA 8 x 1 5 SL Zinc 40 222280 Gasket Drop In Orifice Holder 41 223231 Orifice Holder Drop In Assembly 42 ...

Page 32: ...esident George Bush Hwy Suite 330 Richardson TX 75080 1139 800 992 8368 American Metal Products Amerivent 8601 Hacks Cross Rd Olive Branch MS 38654 800 423 4270 Security Chimneys International Limited 2125 Monterey Laval Québec Canada H7L 3T6 450 973 9999 Metal Fab Inc P O Box 1138 Wichita KS 67201 316 943 2351 Industrial Chimney Corp Excel Direct Vent 400 J F Kennedy St Jerome Quebec Canada J7Y 4...

Page 33: ...nearest authorized Jøtul dealer who will process a warranty claim IN ORDER TO QUALIFY FOR WARRANTY COVERAGE JØTUL MUST RECEIVE NOTICE OF A POSSIBLE DEFECT WITHIN SIXTY 60 DAYS OF THE DATE THE DEFECT IS FIRST DISCOVERED OR REASONABLY COULD HAVE BEEN DISCOVERED This warranty is given by Jøtul North America Inc 55 Hutcherson Drive Gorham Maine 04038 USA Effective January 1 2019 This warranty policy a...

Page 34: ...34 139919_GI 545 DV and DV MV 5 19 ...

Page 35: ...annot be reached call the fire department C Use only your hand to push in or turn the gas control knob Never use tools If the knob will not push 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 ...

Page 36: ...rial number in the space below You may also wish to attach your purchase receipt to this manual for future reference MODEL Jøtul GI 545 DV _____ Jøtul GI 545 DV MV _____ SERIAL NUMBER _____________________________________ DATE OF PURCHASE __________________________________ AUTHORIZED DEALER _________________________________ ADDRESS __________________________________________ PHONE _________________...

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Jøtul GI 545 DV MV, Installation And Operation Instructions Manual

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