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User Manual - Discount Stove & Fireplace

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1. BE dE 66 6 6 6 6 ae 5 as Mounting Brackets 8 5 l 1 6 ki 9 6 amp 8 9 68 6 m 9 m Figure 57 Overlay mounting brackets 139712_ROO GI 635 IPI Sept 2015 29 139712 800 GI 635 IPI Sept 2015 WARNING READ AND UNDERSTAND ALL OPERATING INSTRUCTIONS BEFORE ATTEMPTING 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 WARNING SEVERE INJURY THIS APPLIANCE CAN BE SET TO OPERATE THERMOSTATICALLY BE AWARE THAT THE APPLIANCE MAY BE VERY HOT EVEN WHEN THE BURNER IS NOT APPARENTLY OPERATING KEEP CHILDREN AWAY FROM THE APPLIANCE WARNING OBSERVE CAUTION NEAR THE GLASS PANEL THE GLASS MAY SHATTER IF STRUCK BY AN OBJECT ALWAYS HANDLE THE GLASS PANEL WITH CARE REMOVE GLASS ONLY FOR SERVICE Figure 58 Right side Control Compartment components cover plate is removed fi Red Initialization s 0 Button s 0 Battery Box Proflame 2 Integrated Fireplace Control El
2. Figure 61 Burner Control Switch Figure 62 Correct Pilot Flame Pattern Blower Function Two heat activated 95 cfm blowers assist in moving heat into the living environment Power is supplied through the same circuit used by the other fireplace components The blowers 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 Electrical Code Proflame 2 Remote Control Features Overview The Proflame 2 Integrated Fireplace Control IFC module incorporates electronic remote control of the J tul GI 635 functions Together with the hand held transmitter the IFC controls front and rear burner operation both manually and thermostatically It will also control flame modulation blower functions and accent lighting The system utilizes an IPI system Intermittent Pilot Ignition and may also be switched to keep the pilot lit continuously if desired CPI Continuous Pilot Ignition Power is provided to the IFC by 120V house current and is backed up by a 6V battery pack four 1 5v AA for operation during a power failure Remote Control Transmitter The hand held remote transmitter has all controls available on its face for reliable ease of use It gives room temperature readout set temperature readout all function abilities as well as childproof lockout an
3. 3 Engage the surround panel inner flanges between the hanger brackets and the firebox shroud 4 Tighten the screws securely Right Hanger Bracket 28 Hidden Hanger Bracket Installation The Hidden Overlay Hanger Brackets are used for installations that do not require the standard Backer Plate They provide a means of attachment for the Front Cast Iron Overlay assembly Left Bracket 225765 Right Bracket 225766 Upper Bracket 225767 M6 x 8 phillips truss head screws 10 1 Attach each bracket using the 10 M6 x 8 phillips head screws provided as shown in fig 56 NOTE Do not recess the unit into the fireplace beyond the Upper Bracket Mantle clearance data is unavailable for a recessed installation Front Cast Iron Overlay Assembly The cast iron Overlay is shipped fully assembled including the integrated Safety Barrier Screen e Remove and discard the four plastic joint shims from the front of the Brown Majolica frame assembly The Matte Black assembly does not ship with joint shims Installation The overlay frame is heavy assistance may be helpful Handle the enameled assembly carefully to avoid inadvertent damage Simply engage the side mounting brackets with the steel support tabs on either the Hanger Brackets or Backer Plate whichever is appropriate
4. Figure 59 Front Burner Air Shutter Cable location Left side Compartment Figure 60 Correct flame picture Adjusting Air Supply Settings On first firing push each Air Shutter cable in to fully open the air shutters Place the Mode Control to ON and operate both burners set on HIGH for a minimum of 15 20 minutes to allow the insert components to come up to stable operating temperature The burners are very sensitive to air supply volume Make air adjustments in 1 8 1 4 increments waiting a few minutes to observe the flame pattern changes before making subsequent adjustments Repeat the process until a satisfactory 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 termination cap Very blue transparent or weak anemic flames are indications of too much air which although efficient are not very attractive Generally Propane will require a more open air shutter setting than will Natural Gas 31 139712 00 GI 635 IPI Sept 2015 Fireplace Operation Burner Switch e OFF The Burner will not operate gt ON Power is available for all Burner functions Pilot Modes Continuous Pilot Ignition CPI This permits the pilot to continue burning even when there is no call for heat This feature allows the
5. elevation to the baseline clearance data specified above j 1 j Y JE aan co OO E Figure 6 Baseline Mantel and Trim clearance requirements 139712 00 GI 635 IPI Sept 2015 Vent Guidelines e All vent components must be installed in accordance with the terms of their listing and manufacturer s instructions See the Appendix on page 44 for a listing of approved vent manufacturers e 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 7 and 8 e 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 e HORIZONTAL RUNS are not permitted anywhere in the venting system e Venting liners CANNOT be less than 3 in diameter nor greater than 3 in diameter e 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 e The remaining space around the liner in a masonry or factory built flue CANNOT be used to vent any other appliance e Listed Flexible Gas Liners may not be exposed to any living space e Install
6. DS Figure 4 Hearth Trim and Wall clearances A Hearth Protection Width e Unit flush or raised Min 4 1 8 10 5 cm from fireplace opening B Hearth Protection Depth e Unit flush with hearth 12 30 5 cm Unit raised minimum 6 off floor 0 C Side Trim Clearance e Upto 6 15 2c m depth from fireplace center line 21 53 3 cm D Side Room Wall Clearance e From the fireplace center line 24 61 cm E Top Trim Clearance from hearth 37 94cm F Mantel Clearance from hearth See fig 6 139712_ROO GI 635 IPI Sept 2015 N wo OO OD seUou UOIJRA9 7 10014 09e de114 NOTE Raised Hearth Forward hearth protection may be reduced by two inches 5 08 cm for every inch of fireplace floor elevation Fig 5 D T T T i 12 11 10 9 8 7 6 5 4 3 2 1 Hearth Extension Forward Inches 1 Figure 5 Hearth reduction slope Mantel and Ceiling Clearances Measure clearances from the finished floor of the fireplace A 2 opening See fig 6 3 A 4 104 cm 1 i E B 40 102 cm i C 39 99cm D 38 97 cm 2 D gt gt E 37 94 cm A L E B D Minimum Ceiling Height from fireplace floor 55 1 4 140 3 cm NOTE For raised hearths add the fireplace
7. gt SUPPORT BRACKET 21 139712 800 GI 635 IPI Sept 2015 Install Optional Reflective Glass Panels 157803 Kit Contents Left Side Panel 225768 Center Panel 225769 e Right Side Panel 225770 Tools Required Spade Screwdriver Safety Gloves CAUTION THE PANELS ARE VERY FRAGILE WHILE MANEUVERING THE PANELS INTO POSITION BE CAREFUL TO AVOID STRIKING CORNERS AND EDGES ON THE FIREBOX PARTS Carefully unpack the panels and set out on carpet or other protective surface The panels will be installed with the textured surface against the firebox walls 1 An Air Shutter cable is located on the floor of each side compartment Engage the end of the Latch Tool with the cable eye and push each fully in This action retracts the shutters and allows the Burner assembly to be disengaged from the firebox See figs 16 and 58 2 Grasp the Burner assembly at the two large ports as shown in fig 28 Lift it straight up then tilt it back to disengage it from the injectors and pull it out of the firebox 3 Remove the two Panel Retainer Brackets from the top of the firebox Set them aside for later reinstallation Fig 29 4 Lift the Center Panel up over the rear lip of the log retainer and set it on the shelf provided Fig 30 5 Bend the tabs at each end of the retainer shelf to lock the glass in place Fig 31 6 Place the front bottom corner of the Side Panel into the firebox while simultaneously g
8. 3 8 NPT x 3 8 Flare Fitting 1 2 x 3 8 Flare Shut off Valve 3 8 Flex Tubing SD 3 8 Nipple 2 3 8 Union N K 3 8 Close Nipple 3 8 Shut off 1 2 x 3 8 Valve Reducer Figure 10 External gas connection components Gas Pressure Test Correct gas pressure is essential for efficient and safe operation of the gas insert It is important that the correct pressure is established at the time of the installation The appliance must be isolated from the gas supply line by closing its internal manual gas shut off valve gas cock during any pressure testing of the gas supply piping system that is equal to or exceeds pressures of 1 2 psig 3 5kPa 1 Use the Glass Frame Latch Tool to open and close the internal gas cock located on the supply line in the valve compartment See fig 11a 2 Connect a manometer to the Inlet and Manifold test connection points located on the face of the Control Valve See fig 12 Adjust the pressure to the appropriate specifications indicated in the chart below INLET or supply pressure the amount of gas coming to the valve Indicated by the arrow embossed on the valve OUT for manifold pressure the amount of gas that is coming out of the valve to the burner REQUIRED INLET GAS PRESSURES inches water column MIN MAX NATURAL GAS 4 0 WC 7 0 WC PROPANE 12 0 WC 14 0 WC REQUIRED MANIFOLD PRESSURES inches water column MIN MAX
9. Figure 37 1 Rear Log 225771 2 Left Lower Log 225772 3 Chunk Burner Log 225773 4 Right Lower Log 225774 5 Right Front Cross Log 225775 6 Right Upper Cross Log 225777 7 Left Upper Cross Log 225776 Figure 35 1 Log Engage the two pegs located on rear burner skirt with the holes in the underside of the log 24 139712_ROO GI 635 IPI Sept 2015 Figure 39 3 Log Two rounded notches in the bottom of Figure 42 4 Log The ceramic stub in the base of the log the log align with matching nubs in the right side of sets into the back of the slot in right side of the burner the burner base base Push the log all the way to the rear ae BA a 264 fa 25 139712 00 GI 635 IPI Sept 2015 Figure 45 5 Log The notch A at the upper end mates with the stub A protruding from Log 4 The flat pad B at the lower end rests on the matching flat B in the burner base 139712_ROO GI 635 IPI Sept 2015 Figure 50 6 Log Engage the underside hole with the right peg on Log 1 Rest the forward end of the log in Figure 53 Use tweezers to pinch small tufts of Rock the shallow groove on top of Log 5 Wool very sparsely around the burner base Figure 54 DO NOT BLOCK ANY PORTING HOLES KEEP FIBERS AWAY FROM THE PILOT CARRY OVER PORTS ee Figure 51 7 Log Engage the underside holes with the pins in Log 1 and Log 2 Figure 52 27 139712 00 GI 635 IPI Sept 2015
10. 1 If there is not one already present on each floor level where there are bedroom s a carbon monoxide detector and alarm shall be placed in the living area outside the bedroom s The carbon monoxide detector shall comply with NFPA 720 2005 Edition A carbon monoxide detector shall a Be located in the room that houses the appliance or equipment b Be either hard wired or battery powered or both and c Shall comply with NFPA 720 2005 Edition AProduct approved vent terminal must be used and if applicable a Product approved air intake must be used Installation shall be in strict compliance with the manufacturer s instructions A copy of the installation instructions must remain with the appliance or equipment at the completion of the installation NATIONAL We recommend that FIREPLACE our gas products be INSTITUTE installed and serviced by NFI professionals who are certified in the U S by the National Fireplace Institute NFI as NFI CERTIFIED Gas Specialists www nficertified org Canad ENER UIDE Gas Fireplace Energy Efficiency Rating 66 44 67 85 Natural Gas Propane ENEACHOICE ORG Based on CSA P4 1 02 Model No J tul GI 635 DV IPI Table of Contents Installation amp Service Tools uu 2 Unpacking the Fireplace 3 Specifications General Information Safety Information 00 ec ececseeseeneeees 6 Installation st 7 Fireplace Require
11. If your gas supplier cannot be reached call the fire department 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 REMOTE CONTROL KEYS ON OFF Press once hear tone backlight is ON NOTE This appliance is equipped with an Press again hear tone backlight is OFF ignition device which automatically lights the THERMOSTAT Press for 3 choices pilot Do not try to light the pilot by hand ON Manual thermostat control OFF Manual burner control T stat is OFF Smart automatic burner modulation STOP Read the safety information above Set the Burner Switch to the OFF position BURNER SWITCH Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP Follow B in the safety information above UP DOWN Press UP arrow or If you do not smell gas go to the next step PNR adjust thermostat ame fan and lamp This appliance is intended to be operated by remote control Set the Burner Switch to ON to enable remote communication With the Remote Transmitter OFF press the Mode button 2 then toggle UP DOWN to CPI mode The pilot will light MODE Press to cycle between CPI and IPI operation Press the Power bu
12. Secure the appropriate DIRECT VENT CAP to the termination kit vI Inside the fireplace fully extend the flex duct and cut off any excess so that the liners extend approximately 15 from the floor of the fireplace If the intake flex is NOT attached to the chimney termination kit See VENT NOTICE on page 12 A It is necessary to install a minimum 6 foot length of flex pipe into the flue for the intake air B A METAL damper block off plate must be constructed and installed in the damper area to completely seal off the flue from the room Cut holes for both the intake and exhaust liners in the block off plate C A direct vent cap is still required to allow fresh air into the chimney flue and ultimately into the intake flex and insert N ioe D Attach the Fireplace Conversion Notice to the back of the fireplace if appropriate g Surround panels 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 139712_ROO GI 635 IPI Sept 2015 Vent Connection Wear Safety Gloves 1 Remove the Lock Screw from the Vent Adaptor Panel and to detach the panel from the firebox Retain the screw for reinstallation Attach the ends of the flex liners to the appropriate collars on the Vent Pa
13. 24 12 225527 Valve Heat Shield 2 129464 Compression Nut 5 16 13 118214 Screw 8 x 1 4 Taptite SLHWH SZPL 3 129463 Compression Sleeve 5 16 14 225792 Valve NG 50 TD Proflame w Stepper Motor 4 129152 Jam Nut Orifice Holder Assembly 15 157821 Fuel Conversion Kit Motorized LP 50 TD 5 220643 Orifice Holder Straight 16 157822 Fuel Conversion Kit Motorized NG 50 TD 6 220976 Orifice 47 NG 17 222941 Elbow Brass Street 90 3 8 NTP 221185 Orifice 1 20 mm LP 18 223214 Nipple Iron 3 8 NTP x1 5 Long 7 225663 Retainer Orifice Holder 19 129129 Elbow 90 Brass 3 8 NTP to 5 16 Dia Compression 8 117917 Screw 8 x 1 2 HWH SMA Black Oxide 20 220044 Adaptor Brass 3 8 NPT to 5 16 Dia Compression 9 225762 Orifice 2 25 mm NG 21 222923 Proflame Splitflow Solenoid Valve 129804 Orifice 1 40 mm LP 22 222407 Valve Straight 3 8 FIP x 3 8 FIP 10 129707 Flex Tube w Connectors 3 8 OD x 36 23 225498 Valve Handle 1 225526 Valve Bracket 24 223215 Adaptor Straight Brass 3 8 NTP x 3 8 Flare 25 129390 Flex Tube Main Gas 5 16 OD x 14 40 139712_ROO GI 635 IPI Sept 2015 Figure 88 Internal firebox components No Part Number Description 1 225490 Baffle 2 225693 Side Panel Retainer 3 225511 Rear Log Support 4 225681 Pilot Assembly Integrated Dual Fuel 5 157831 Right Cable Assembly 6 157744 Burner Assembly 7 225648 P
14. Derating procedure 1 Install the appropriate orifice as specified in the High Altitude Chart Table 1 above 2 Follow the burner removal procedure detailed on page 16 3 Use a 1 2 deep well socket or open end wrench to remove the orifice and replace with the appropriate one from the high altitude adjustment kit 4 Attach the high altitude conversion sticker provided to the rating plate on the appliance See figure 17 5 Follow the burner installation procedure detailed on page 16 5 It may be necessary to adjust the air shutters See the Flame Picture Air Shutter Adjustment on the page 31 for more details 18 GAS ORIFICE SIZE ELEVATION J TUL PART NO NATURAL GAS 2 20mm L 1 95 mm R 2001 4500 611 1170 m 225762 Left 225840 Right PROPANE 1 35 mm L 1 15 mm R 2001 4500 611 1170 m Table 1 High Altitude Orifice Chart 223792 Left 220048 Right THIS APPLIANCE HAS BEEN CONVERTED FOR USE AT AN ALTITUDE OF Orifice Size Input BTU Hr Date of Conversion Manifold Press Fuel Type Figure 17 High Altitude Conversion Notice Label Final Positioning 1 Blower Power Cord Extend the blower power cord out forward of the fireplace routing it to the nearest power source The cord can extend approximately 8 feet 2 44 cm to the right or 5 feet 154 cm to the left A compatible 10 foot extension cord is available from your
15. NOTE COMPLETE FUEL CONVERSION HIGH ALTITUDE ADJUSTMENT AND BRICK OR GLASS PANEL INSTALLATION BEFORE ASSEMBLING BACKER PLATES Figure 55 Backer Plate installation Standard Backer Plate Installation The standard Backer plates each incorporate hanger brackets to which the Front Cast Iron Overlay Assembly will be attached Tools Required e phillips screwdriver e safety glasses and gloves Procedure 1 Loosely attach the Backer Plate to the insert firebox using the ten M6 x 8 phillip head screws as shown in Fig 55 Tighten the screws in an alternating pattern Three or Four Sided Trimmable Backer Plate Installation Tools Required ze iie e zip wheel or other sheet metal cutting tool cae Left e phillips screwdriver e safety glasses and gloves Upper Bracket ie Trimmable Backer Plates include Hanger Bracket Kit 157802 which must be installed in order to attach the Cast Iron Overlay assembly An assistant will be helpful in aligning the backer panel Eu Firebox Shroud with the hanger brackets and firebox Procedure 1 Scribe and trim the 22 ga sheet steel surround panel as appropriate for the fireplace face anner Flange 2 Very loosely attach the three Hidden Surround Hanger 2 7 Figure 56 Brackets to the insert firebox using the ten M6 x 8 Trimmable Surround phillips head screws as shown in Fig 56 installation
16. amp 11 Figure 83 Low Battery See page 37 Maintenance CAUTION THE IGNITION SYSTEM OF THIS APPLIANCE CARRIES LIVE VOLTAGE ALWAYS TURN OFF THE GAS SUPPLY TO THE INSERT AND DISCONNECT THE POWER SOURCE BEFORE ANY SERVICE WORK IS PERFORMED INCLUDING BATTERY REPLACEMENT With proper care and maintenance your appliance will provide you with years of enjoyment If you experience any problem with your fireplace insert contact your J tul 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 General Cleaning e Vacuum the controls area under the firebox at least monthly or more frequently if pet hair is in the environment 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 e The firebox should be vacuumed annually Inspect the pilot assembly for corrosion and have any damaged components replaced by a qualified service technician Remove any debris from burner ports particularly the pilot carry over ports See fig 54 page 27 Use a brush attachment to vacuum the log set Gasket Inspection e Inspect the glass gasket annually Examine the gasket for si
17. clear and free from combustible materials or flammable liquids 10 This appliance can be operated with a continuously burning pilot flame Exercise caution when using household products containing combustible vapors CAUTION DO NOT OPERATE THIS APPLIANCE WITH THE GLASS PANEL REMOVED CRACKED OR BROKEN REPLACEMENT OF THE GLASS SHOULD BE DONE BY A LICENSED OR QUALIFIED SERVICE PERSON USE ONLY REPLACEMENT GLASS PROVIDED BY YOUR AUTHORIZED J TUL DEALER NEVER SUBSTITUTE ANY OTHER TYPE OF GLASS Flame Picture Air Shutter Adjustment WARNING AIR SHUTTER ADJUSTMENTS SHOULD ONLY BE PERFORMED BY A QUALIFIED PROFESSIONAL SERVICE TECHNICIAN The volume of air supplied to the front and rear burners is regulated by individual air shutters which are controlled in turn by cables located at the each side of the firebox The left cable controls the Rear Burner and the right cable controls the Front Burner Push the cable in to increase air volume Pull the cable out to decrease air volume The air shutter adjustment allows you to achieve the desired flame appearance Generally flame appearance is a matter of personal preference however most people enjoy warm yellowish flames of medium proportions The simple air shutter adjustment feature allows you to dial in the burners to acquire a flame picture sweet spot that combines efficient combustion with pleasing aesthetics 139712_ROO GI 635 IPI Sept 2015
18. dealer J tul PN 223253 2 Backer Plate Options Follow the procedures for installation of the various backer plates detailed on pages 28 29 139712_ROO GI 635 IPI Sept 2015 This page is intentionally blank 19 139712_ROO_GI 635 IPI Sept 2015 Install Optional Brick Panels Figure 18 Remove burner assembly 157686 Traditional Red Tools Required Rear Panel 225793 Flat Head Screwdriver Left Side Panel 225794 Right Side Panel 225795 157798 Brownstone Rear Panel 225514 e Left Side Panel 225517 Right Side Panel 225516 CAUTION THE PANELS ARE VERY FRAGILE HANDLE GINGERLY BEING CAREFUL TO AVOID DAMAGING THE EDGES OR CORNERS FROM CONTACT WITH OTHER PARTS OF THE FIREPLACE An Air Shutter cable is located on the floor of each side compartment Engage the end of the Latch Tool with the cable eye and push each fully in This action retracts the shutters and allows the Burner assembly to be disengaged from the firebox See figs 16 and 58 REMOVE THE BURNER Push each air shutter cable all the way in to fully open the air shutters Grasp the burner assembly as shown in fig 18 Pull the assembly straight up then tilt the front up and pull forward and out to disengage the burner from the firebox You may need to shake the assembly from side to side to help disengage the air shutters from the burner injectors INSTALL THE REAR BRICK PANEL Locate the small arrow embossed into the right side ed
19. liquids in the vicinity of the fireplace Never burn any solid materials wood cardboard paper coal etc in this gas fireplace Use with natural gas or propane fuel ONLY Do not slam or strike the glass panel This appliance is NOT for use with aftermarket glass doors This appliance is approved for use only with the surround panel options listed on page 4 of this manual Wear gloves and safety glasses while installing or performing maintenance procedures on this appliance This fireplace insert is specifically designed for use with 3 Type B vent pipe components or Listed flexible gas liners A Electrical Hazards Be aware of electrical wiring locations when cutting holes in walls and ceilings for termination The blower must be electrically grounded in accordance with local codes or in the absence of local codes with the current ANSI NFPA 70 National Electrical Code or CSA C22 1 Canadian Electrical Code The Blower is supplied with a three prong grounding plug for protection against shock hazard and should be plugged directly into a properly grounded three prong receptacle DO NOT CUT OR REMOVE THE GROUNDING PRONG FROMTHE PLUG Always disconnect the power supply when performing any service on the fireplace including battery replacement Power Requirement This appliance requires 120 VAC power to operate the blowers accent lamps and electronic ignition Fou
20. 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 5 Do not operate this fireplace if any part of it 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 139712_ROO GI 635 IPI Sept 2015 6 Do not operate the fireplace with the glass front removed cracked scratched 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 7 Notify your insurance company before proceeding with installation of this fireplace Your fireplace insert has a unique serial number stamped on the rating plate which is located in the right side compartment Please record the serial number in the space below You may also wish to attach your purchase receipt to this page for future reference MODEL NAME J tul GI 635 DV IPI Gas Fireplace Insert SERIAL NUMBER DATE OF PURCHASE AUTHORIZED DEALER ADDRESS PHONE INSTALLER FUEL TYPE FUEL CONVERSION NO NOTES 139712 800 GI 635 IPI Sept 2015 Safety Information Due to the high operating temperatures this appliance sh
21. temperature and icon At the same time the Receiver will deactivate the call for heat and the burner will shut down Fig 68 A single 0660 from the Receiver will confirm reception of the command Remote Burner Control There are six flame levels available With the system ON and the burner flame level at maximum press the Down Arrow Key once to reduce the flame height by one step Each time the Down Key is pressed the flame will step down until the burner is finally turned off Fig 69 The Up Arrow Key will increase the flame height each time it is pressed If the Up Arrow Key is pressed while the system is on but the flame is off the flame will come on in the High position as in figs 70 72 A single beep will confirm reception of the command The Front and Rear Burners are activated by using the Mode Key to index to the Split Flow icon Press the Up Arrow Key to turn it ON Fig 73 Press the Down Arrow Key to turn it OFF A single beep will confirm reception of the command 139712_ROO GI 635 IPI Sept 2015 6 IF Figure 66 IPI is the default position T al Figure 68 Burner shut down LA Figure 70 Flame Level 1 KL 1 iii ms Figure 72 Flame Level 6 E is Figure 65 Room temperature readings b il a CPi Figure 67 CPI ON ama ama or
22. Burner il Switch gt A 0 SS di Rear Burner Air Shutter Cable Operation Initial System Check and General Operation This appliance is designed to be operated with use of the Remote Control System Run the following procedure to test basic burner function before completing the installation into the fireplace 1 Battery Installation If you have not already done so install four 1 5v AA batteries into the IFC Back up battery box attached by hook and loop tape in the right side compartment Fig 58 Install three 1 5v AAA batteries into the Remote Transmitter The transmitter and receiver have already been synchronized at the factory If synchronization is lost follow instructions on page 34 2 Connect the appliance to 120VAC house current 3 Initial System Purge When lighting the appliance for the first time or after a long period of disuse it will take a few moments to clear the gas line of air Once this purge is complete the appliance will operate as described in the lighting instructions located on the rating plate and back cover of this manual 4 With the transmitter OFF dark display press the Mode 552 button and then press the UP DOWN button to toggle between IPI and CPI modes Select CPI mode The pilot will light PILOT ADJUSTMENT Each flame should be steady not lifting or floating The flames should be blue in color at the pilot hood with traces of yellow toward t
23. CK BY AN OBJECT ALWAYS HANDLE THE GLASS PANEL WITH CARE ATTENTION e FOR INSTALLATION OR MAINTENANCE CLOSE THE SUPPLY GAS COCK SET BURNER SWITCH OFF AND DISCONNECT POWER FROM THE FIREPLACE IN CASE OF REMOTE CONTROL MALFUNCTION TURN OFF THE IFC MODULE USING THE MAIN ON OFF SWITCH 33 139712 00 GI 635 IPI Sept 2015 Remote Control Functions Pilot Mode Control The IPI CPI functionality will be fully controlled by the remote transmitter See Pilot Mode page 35 Set the insert burner switch to ON to enable the remote control burner operation OFF Turns off burner functionality Switch to OFF when the fireplace will not be used for an extended period of time The accent lamp and blower functionality will continue to be available with the remote set to OFF Remote Transmitter The Transmitter features a simple button layout and informative display screen See figs 63 64 LCD DISPLAY graphically indicates temperature settings and status of the Thermostat Burner Fan and Accent Lamp ON OFF Key controls Burner Fan and Lamp functions THERMOSTAT Key Used to set either Manual or Thermostatic Control and index through thermostatic functions UP DOWN Arrow Key Selects thermostat temperature range fan speed and flame height MODE Key used to select the component to be controlled CPI IPI Burner Blowers and Accent Lamp The included Wall Mount Bracket can
24. JOTUL WARNING FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury death or property damage 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 e Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions e If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier J tul GI 63 5 DV PI In the Commonwealth of Massachusetts 1 1 a carbon monoxide CO detector shall Direct Vent Fireplace Insert be installed in the same room as the appliance This appliance may be installed in an aftermarket l n st a at O n a n d permanently located manufactured home or mobile home where not prohibited by local codes O p e rat i 0 n l n st r u ct O n S This appliance is only for use with the types of gas indicated on the rating plate A conversion kit is supplied with the appliance A DANGER HOT GLASS WILL CAUSE BURNS DO NOT TOUCH GLASS UNTIL COOLED NEVER ALLOW CHILDREN TO TOUCH GLASS 6 US Intertek A barrier designed to reduce the burn hazard from the glass view
25. NATURAL GAS 1 1 WC 3 8 WC PROPANE 2 9 WC 11 0 WC ALWAYS TEST PRESSURE WITH THE VALVE REGULATOR ADJUSTED TO THE HIGHEST SETTING Figure 11 Insert the Latch Tool into the receiver hole in the gas cock Figure 11a Pull the tool forward toward you to open the gas cock Push it back to close the gas 139712_ROO GI 635 IPI Sept 2015 Figure 12 Pressure test points Inlet Manifold Pilot Adjustment Y Symptoms of incorrect gas pressure include Insufficient gas pressure e 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 e Permanent damage to valve causing complete appliance shut down Too large a pilot flame resulting in overheating of the flame sensor and consequent shut down Sooting due to impingement and or incorrect fuel to air mix WARNING DO NOT ALLOW THE INLET GAS PRESSURE TO EXCEED 14 0 WC OR 1 2 PSIG AS SERIOUS DAMAGE TO THE VALVE MAY RESULT 15 139712_ROO_GI 635 IPI Sept 2015 Fuel Conversion NOTE IN ORDER TO ACCESS THE STEPPER MOTOR COMPONENTS COMPLETE THE FUEL CONVERSION PROCEDURE BEFORE PLACING THE INSERT WITHIN THE FIREPLACE The J tul GI 635 DV IPI is shipped from the factory equipped to
26. NTS ANY MODIFICATION OR ALTERATION WILL VOID THE WARRANTY CERTIFICATION AND LISTING OF THIS APPLIANCE IMPORTANT SAVE THESE INSTRUCTIONS 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 N 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 pet hair dander etc It is imperative that control compartments burners and circulating air passageways of the appliance be kept clean This appliance may be installed in an aftermarket permanently located manufactured mobile home where not prohibited by local codes This appliance is only for use with the type s of gas indicated on the rating plate This appliance is not convertible for use with other gases unless a certified kit is used w 4 The installation must conform to local codes Your local J tul authorized 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 In the absence of
27. TUL shall not be liable or otherwise responsible for any error or omission by a person installing or servicing a J tul Gas Stove or Fireplace Insert If you believe your J tul Gas Stove or Fireplace Insert is defective you should contact your nearest authorized J tul dealer who will process a warranty claim IN ORDER TO QUALIFY FOR WARRANTY COVERAGE JOTUL 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 J tul North America Inc 55 Hutcherson Drive Gorham Maine 04038 USA 45 139712 ROO G 1 635 IPI Sept 2015 46 139712_ROO GI 635 IPI Sept 2015 LIGHTING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE LIGHTING WARNING IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE PERSONAL INJURY OR LOSS OF LIFE A This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand B BEFORE LIGHTING smell all around the 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 WHAT TO DO IF YOU SMELL GAS 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 outside of the house
28. USE ONLY JOTUL PN 157834 DO NOT USE ANY OTHER TYPE OF GLASS REPLACEMENT OF THE GLASS SHOULD BE DONE BYA LICENSED OR QUALIFIED SERVICE PERSON USE ONLY REPLACEMENT GLASS PROVIDED BY YOUR AUTHORIZED J TUL DEALER NEVER SUBSTITUTE ANY OTHER COMPONENTS 38 139712_ROO GI 635 IPI Sept 2015 J tul GI 635 DV IPI Replacement Parts ONLY USE REPLACEMENT PARTS PROVIDED BY AN AUTHORIZED J TUL DEALER Figure 86 Controls components right side compartment No Part Number Description 1 225797 Controls Skid Plate 2 225694 Latch Handle 3 157265 Replacement IPI Battery Box 4 118257 Hook and Loop Tape Velcro 5 120517 Rocker Switch SPST Black Plain 6 225495 IFC Bracket 7 117999 Screw 8 x 3 8 SLSMA Type B Zinc 8 225497 IFC Heat Shield 9 157634 Replacement Proflame 2 Board w labels 10 18055 Kepnut M4 Ext Tooth Lockwasher Ext Wire Harness Proflame 2 Split Flow 225682 12 157492 Replacement Power Cord 18 AWG 10 ft 13 157495 Replacement Multifunction Remote Transmitter 14 223951BKP Replacement Remote Wall Bracket Blk PC 5 117951 Wire Strain Relief Heyco 7P 2 Lg 39 139712 800 GI 635 IPI Sept 2015 Figure 87 Valve Train components left side compartment No Part Number Description No Part Number Description 1 225676 Flex Tube Main Gas 5 16 OD x
29. a IE la Figure 69 Burner OFF amas or ap 4 Figure 71 Flame Level 5 aT O0 Figure 73 Split Flame 35 139712_ROO_GI 635 IPI Sept 2015 Room Thermostat Transmitter Operation The Remote Control can operate as a room thermostat The thermostat can be set to a desired temperature to control the comfort level in a room To activate this function press the Thermostat Key The display will indicate that the room thermostat is ON and the current Set Temperature is now displayed Fig 74 To adjust the Set Temperature press the Up or Down Arrow Keys until the desired Set Temperature is displayed Fig 75 SMART Thermostat Function This function adjusts the flame intensity according to the difference in the Set Point temperature and the actual room temperature As the room temperature gets closer to the Set Point the Smart Function will modulate flame intensity down To activate this function press the Thermostat Key until the word SMART appears to the right of the thermometer bulb icon Fig 76 E To adjust the temperature press the Up or Down Arrow Keys until the desired Set Temperature is displayed Fig 77 Fan Control The fan speed can be adjusted through six settings To activate this function press the Mode Key to index to the Fan Control icon See fig 78 The fan will not function at all if it is not first set to ON Use
30. ase retain your dated sales receipt in your records as proof of purchase EXCLUSIONS AND LIMITATIONS NOTICE This warranty is void if installation or service is performed by someone other than an authorized installer service agency or gas supplier or if installation is not in conformance with the installation and operating instructions contained in this owner s manual or local and or national fire and building regulations A listing of local authorized installers service agencies and gas suppliers can be obtained from the National Fireplace Institute at http www nficertified org This warranty does not cover the following 1 Repair or replacement of parts that are subject to normal wear and tear during the warranty period or to parts that may require replacement in connection with normal maintenance These parts include gaskets and glass except to the extent such parts suffer damage from thermal stress 139712_ROO GI 635 IPI Sept 2015 2 Damage due to incorrect installations not in conformance with the installation instructions contained in this owner s manual or local and or national fire and building regulations 3 Damage due to service performed by an installer service agency or gas supplier unless otherwise agreed to in writing by JOTUL 4 Labor or other costs associated with the repair of gas controls plumbing burners log set or sheet metal firebox beyond the warranty period 5 Damage caused by unauthorized mod
31. ation of any components not manufactured or approved by J tul or failure to meet all clearance requirements will void all warranties and could result in property damage bodily injury or loss of life e Never modify any venting component or use any damaged venting product e THE GAS APPLIANCE AND VENT SYSTEM MUST BE VENTED DIRECTLY TO THE OUTSIDE OF THE BUILDING AND NEVER ATTACHED TO A CHIMNEY SERVING A SOLID FUEL OR GAS BURNING APPLIANCE e 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 GAS VENT RULE ROOF SLOPE Minimum Height From Roof Flat to 6 12 10 0 3M Over 7 12 to 9 12 2 0 0 6M DR Over 10 12 to 12 12 40 Over 13 12 to 16 12 Over 17 12 to 21 12 10 Vent Installation Procedure This appliance must be vented through the chimney by a pair of 3 inch flexible aluminum liners listed for use with gas appliances One duct is attached to the exhaust port on the top 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 connected to the chimney termination cap See figure 7 and 8 The other 3 inch liner will be attached to the air intake port and will provide fresh air for combustion to the unit This liner must extend a minimum of 6 feet through the damper area of the fireplace and into the tile liner
32. aust is on the right Secure the ducts to the appropriate collars on the Vent Adaptor with sheet metal screws or duct clamps No sealant is required See Vent Connection instructions on page 13 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 139712_ROO GI 635 IPI Sept 2015 IMPORTANT NOTICE INSTALLATION OF A HIGH WIND TERMINATION CAP IS RECOMMENDED FOR ALL IPI APPLIANCES TO HELP INCREASE PERFORMANCE We Recommend e ICC EXCEL DIRECT Use TM CT3 with TM CTS Cap Shield M amp G Duravent Use Wind Screen 46DVA VWG Exhaust Listed Standard or High Wind Termination Cap Sealed Chimney Cap Anchor Plate Listed Flexible Gas Liners Max Height 35 ft Min Height 10 ft i In the U S the Air V Intake pipe must extend through the damper and into the first chimney flue Maintain proper clearance to Mantel and Trim See pages 8 9 The flue must be per manently sealed from the living area if the Air Intake pipe does not connect directly to a Direct Vent Termina tion at the top of the chimney Figure 7 Masonry Fireplace Venting Configuration IN CANADA Air intake must connect to chimney cap 11 139712_ROO_GI 635 IPI Sept 2015 1 1 1 IMPORTANT NOTICE Pre
33. be used for convenient Transmitter storage away from curious children Transmission A JEA oC Thermostat Q F ON OFF SMART LE orr DRE i on CF O sur amp amp Set Point Temperature Level State Burner Modulation 6 7 nea Split Valve Fan Modulation ae Lamp Modulation Figure 64 Remote transmitter display data 34 Child Safety Lock out Low Battery Alarm IFC Transmitter Mode Synchronization 1 Set the Burner Switch to OFF located in the right side compartment 2 Install three AAA batteries into the Transmitter 3 Press the red initialization button on the left top corner of the IFC board just behind the switch plate fig 58 page 30 The board will beep three times and a yellow LED indicates a 10 second synchronization time limit 4 Within the 10 second time frame push the ON button on the Transmitter The IFC will beep three or four times to indicate that it has acknowledged the transmitter command and sets to the particular code of that Transmitter 5 After initialization the burner switch must be placed in the ON position and Remote Mode placed in CPI The remote can then be used to control the burner To return to full Manual functionality hold the red initialization button down until it beeps three or four times and the yellow LED illuminates Within 10 seconds push the button again until it
34. burn Natural gas Propane Fuel Conversion Kit 157821 is included with this appliance Use Fuel Conversion Kit 157822 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 J TUL 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 LP Conversion Kit Tools required e 1 2 amp 13 mm open end wrench or deep well socket Torx T20 driver e 1 4 nut driver e 7 16 open end wrench LP Conversion Kit Contents e 1Regulator Motor labeled for the appropriate fuel 2 Regulator Torx screws e 1 Left Injector 1 40 mm e 1 Right Injector 1 20 mm e Label A to be completed and applied to the base of the valve compartment e Label B apply to the rating plate in the space indicated on the plate e Small valve label apply to valve body e Conversion instructions SIT Proflame 880 Valve BTU hr Rating Specificati
35. burner to function properly under a variety of adverse conditions For example it can be difficult to establish positive draft through a very long vent system particularly in very cold weather In such cases the entire system will benefit as the heat generated by a continuous pilot flame will help establish a positive draft CPI mode will also reduce glass condensation upon start up Exercise caution when operating with a continuous pilot DO NOT USE CLEANING PRODUCTS HAVING COMBUSTIBLE VAPORS AROUND THE OPERATING FIREPLACE e Intermittent Pilot Ignition IPI This feature allows the pilot flame to go out when there is no call for heat Ideal for use with thermostatic or manual remote control the Integrated Fireplace Control module ignites the pilot flame only when there is a call for heat A battery back up permits continued functionality in the event of a power failure Flame Picture 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 TO ALLOW MORE AIR TO SUPPORT EFFICIENT COMBUSTION See Adjusting Air Supply Settings on page 31 Accent Lamp The Accent Lamp is controlled by the hand held remote transmitter See figs 80 81 page 36 Heat generated from the accent lamp can assist in maintaining draft in very long vent runs and thereby help ensure consistent IPI start up performance 32 J TUL
36. d low battery indicator Icons appear on the screen indicating which mode of operation you are controlling The four button controls are easy to learn and simple to operate The transmitter is powered by 3 1 5V AAA batteries Remote Control Receiver The receiver is integrated with the IFC board which is located within the valve compartment Integrated Fireplace Control IFC The IFC is the electrical heart of the system It provides power to all components and converts to 6 5v DC in the event of power failure The IFC also sends power to the fan system and the accent light however when no line power is available these features will not operate The battery back up only allows continued remote control of burner functions Sit 886 Modulating Valve This valve has the ability to be stepped down in six increments between high and low It can be done manually or by setting the remote control to the Smart thermostat modulation mode Automatic modulation means that as the room temperature approaches the limit set for shut down the valve gradually decreases or steps down the fire intensity Conversely as room temperature cools the valve gradually increases flame intensity The overall result is more comfortable even heating that minimizes temperature peaks and valleys 139712_ROO GI 635 IPI Sept 2015 Pilot Assembly The pilot assembly consists of a pilot hood electrode and a flame sensor The electrode sends a spark to th
37. e pilot hood which ignites the gas The sensor is then engulfed by the pilot flame flame rectification occurs and the pilot remains lit Intermittent Pilot Flame Rectification Process When there is a call for heat the pilot will automatically make four attempts to light the burner before locking out On the first attempt the pilot will spark for up to sixty 60 seconds If rectification occurs within that time the burner will light If rectification does not occur the pilot will extinguish If the main burner ignites and rectification is lost the system will extinguish the burner and immediately ignite the pilot and relight the burner The system will attempt to light the main burner three 3 more times On the fourth attempt the system will again light the pilot and then sit idle with only the pilot burning for sixty 60 seconds in order to establish draft to support combustion air flow If rectification still does not occur with the main burner lit the system will lock out A lock out condition is cleared by cancelling the call for heat i e switching the burner off or adjusting the thermostat Under certain conditions wherein draft is unstable or weak it is advisable to run the system in Continuous Pilot mode CPI The continuous pilot will generate enough heat to maintain the draft strength required for rectification to occur WARNING OBSERVE CAUTION NEAR THE GLASS PANEL THE GLASS MAY SHATTER IF STRU
38. ed Brick Panel Kit Brownstone Brick Panel Kit Reflective Glass Panel Kit Cast Iron Overlay Matte 8 36 eeesesesesssesees Cast Iron Overlay Brown Majolica Enamel Fuel Conversion Kit NG to LP included Fuel Conversion Kit LP to NG High Altitude Adjustment Kit LP High Altitude Adjustment Kit NG Hidden Hanger Bracket Kit Required if no Backer Plate is used Backer Plate Options All Backer Plates include Hanger Brackets for the Cast Iron Overlay Three sided Backer Plate Natural Gas 1 10 WC 0 27kPa 3 8 WC 0 95 kPa 40 W x 28 1 4 H 157799 Propane 2 9 WC 0 72kPa 11 0 WC 2 74 kPa 42 W x31 157800 46 W 34 H 157801 Orifice Sizes Three sided Trimmable Backer Plate Altitude o 2000 ft 0 610 m NG LP 47 3 4 W 38 H 157826 Rear Left 225mm 140mm Front Right 47 1 20 MM Altitude 2000 4500 ft 610 1370 m Rear Left 220MM 1 35 Mmm Front Right 1 95 mm 1 15 MM NG LP Steady State Efficiency 70 38 72 28 A F U E Efficiency 70 30 72 40 CSA P4 1 02 Fireplace Efficiency 66 44 67 85 Electronic Ignition IPI or Continuous Pilot CPI 4 122 mm Four sided Timmable Backer Plate 47 3 4 W 38 63 H 157827 General Information THIS HEATER MUST BE INSTALLED AND MAINTAINED BY A QUALIFIED SERVICE AGENCY DO NOT ATTEMPT TO ALTER OR MODIFY THE CONSTRUCTION OF THIS APPLIANCE OR ITS COMPONE
39. eplace Conversion Notice Plate e Rock Wool Remote Transmitter e Transmitter Wall Bracket e Four 1 5v AA IFC Back up Batteries e Three 1 5v AAA Remote Transmitter Batteries e Safety Screen Barrier Guidelines Detach the firebox from the pallet with removal of the attachment bracket screws at each side of the firebox base Remove the Latch Tool from the shipping pallet Use it to disengage the two spring latches from the glass frame as shown in fig 1 Engage the tool prong with the latch receiver hole and pull the latch hook forward and up to detach it from the glass frame slot Pivot the top of the frame forward to disengage it from the bottom corners of the firebox Set the glass frame out of the way 5 The Log Set is inside the firebox Remove and set it out of the way until you are ready to install it 6 PRE INSTALLATION FIT UP Leveling bolts are located at each corner of the firebox base to allow a maximum 1 2 adjustment to correct hearth irregularities Before assembly locate the firebox in its final position within the fireplace and adjust the leveling bolts as necessary to level and plumb the unit Front bolts are accessible in each side compartment through the fireplace front Tip the firebox forward to adjust the rear bolts out of the base Pull the unit back out of the fireplace and read the installation requirements in this manual before proceeding with assembly and installation The remote c
40. fabricated Fireplace Installation INSTALLATION OF A HIGH WIND TERMINATION CAP IS RECOMMENDED FOR ALL IPI APPLIANCES TO HELP IMPORTANT INCREASE PERFORMANCE BEFORE STARTING THIS INSTALLATION MAKE SURE THAT We Recommend A GAS LINE CAN BE INSTALLED OR IS INSTALLED TO THE ICC EXCEL DIRECT Use TM CT3 with TM CTS Cap Shield FIREBOX THIS SHOULD ONLY BE DONE BY A QUALIFIED OR LICENSED PLUMBER OR GAS FITTER A factory built fireplace will require modification prior to installation of the insert M amp G Duravent Use Wind Screen 46DVA VWG Exhaust Modification Gas 1 Remove any refractory glass doors screen rails screen EE PE mesh fuel grates and other components attached to Standard or High wind the firebox Smoke shelves shields and baffles may Termination Cap Intake Air be removed if attached by mechanical fasteners gt nm Do not cut out any sheet metal parts of the fireplace DO NOT PLOCK OFF b any UP P DOUBLE OR TRIPLE WALL 1 into which the insert will be installed CHIMNEY AIR FLOW Storm Collar If the factory built fireplace has no gas access Listed Flexible hole s provided an access hole of 11 2 37 5 mm Gas Liners or less may be drilled trough the lower sides or Max Height 4o ft j Min Height 10 ft bottom of the firebox in 3 proper workmanship es like manner This access hole must be sealed with noncombustible
41. ge of the panel Orient the panel with the arrow pointing up Fig 19 N w Engage the panel behind the upper retainer rail and seat the bottom behind the lower retainer rail on the burner skirt shelf Figs 20 21 4 INSTALL THE SIDE BRICK PANELS Tilt each panel orienting the lower front corner down as shown in fig 22 Carefully roll the panel into position flat against the firebox side BE CAREFUL TO AVOID PINCHING THE CORNERS OF THE PANELS AGAINST ADJACENT FIREBOX COMPONENTS The fibrous ceramic material can be easily chipped Locate the panel retainer bracket at the top of the firebox and use the screwdriver to bend it down Press the brackets down fully against each panel Fig 23 REPLACE THE BURNER Be certain both Air Shutter adjuster trays Fig 24A are positioned all the way forward toward the front to allow engagement with the air shutters on the bottom of the burner Fig 24 vi Tilt the burner assembly down toward the back to engage with the burner Injectors and air shutter adjustment trays The steel burner base should slide under the pilot assembly and the front support brackets should fully engage with the adjacent floor studs Figs 25 26 Properly seated the burner should be level with and just below the front face of the firebox See Fig 27 20 139712_ROO GI 635 IPI Sept 2015 Figure 22 Install side panels 7 Se ee Figure 25 Engage burner bracket with floor stud
42. gns of deterioration or stiffness and confirm that the gasket maintains a positive seal This is important to prevent combustion gases escaping into the room Replace the gasket if necessary Refer to the replacement parts list on page 43 139712_ROO GI 635 IPI Sept 2015 Accent Lamp Replacement 1 Remove the cast iron overlay assembly backer plate and glass frame 2 Remove the lamp shade and bulb receptacle three screws See fig 92 pg 43 Replace with 222943 130V 50W light bulb 3 Handle the new bulb with gloves Skin oils will cause the bulb to fail prematurely If you touch the bulb with your bare skin wipe it clean with a soft cloth 4 Replace components previously removed Battery Replacement 1 Disconnect electrical power from the appliance 2 Remove the cast iron overlay 3 The battery box is attached to the right side controls compartment by hook and loop tape Pull the box out of the compartment and detach the cover plate Install four AA batteries noting the polarity indicated on the box 4 Replace the battery box and restore AC power to the fireplace CAUTION ALWAYS DISCONNECT ELECTRICAL POWER WHEN SERVICING THIS APPLIANCE LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING THE CONTROLS WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION ALWAYS VERIFY PROPER OPERATION AFTER SERVICING THE APPLIANCE 37 139712 800 GI 635 IPI Sept 2015 Glass Care Moisture condensation
43. he outer edges It is important that the pilot flame fully engulf the top 1 4 of the flame rectifier sensor Both pilot flames should project one inch out of the pilot hood See Fig 62 page 32 The pilot flames may be adjusted if necessary using the adjustment screw located on the gas valve body Fig 12 page 15 Adjustments should be made only by a qualified gas technician 5 Set the Burner switch to ON then press the remote Power button once to turn on the burner Press the UP button repeatedly to cycle to the HI setting See pages 33 36 for detailed Remote Control function instructions 6 For the first few hours of operation it is common to detect some odor as the metal and manufacturing materials cure under heat This condition is temporary and can be alleviated by allowing fresh air to circulate through the area 7 Condensation will develop on the glass upon each lighting of the appliance This fog will dissipate as the glass heats Using CPI mode will minimize condensate 8 IMPORTANT It will be necessary to clean the glass after the first few fires A white powdery residue will be evident which results from the burner media curing Use a non abrasive household glass cleaner or warm water IF THE GLASS IS NOT CLEANED THIS RESIDUE CAN CAUSE THE GLASS TO BECOME PERMANENTLY ETCHED DO NOT USE AMMONIA BASED CLEANERS g Keep the control compartments free of dust and debris Always keep the appliance area
44. ification use or repair 6 Damage to enameled surfaces caused by improper operation or misuse including use that is not in conformance with the operating instructions contained in this owner s manual Such damage can typically be identified by bubbling cracking or discoloration of the enamel finish 7 Costs incurred by travel time and or loss of service 8 Damage incurred while the Jotul Gas Stove or Fireplace Insert is in transit IN NO EVENT SHALL J TUL ITS PARENT COMPANY SHAREHOLDERS AFFILIATES OFFICERS EMPLOYEES AGENTS OR REPRESENTATIVES BE LIABLE OR RESPONSIBLE TO YOU FOR ANY SPECIAL INDIRECT INCIDENTAL CONSEQUENTIAL PUNITIVE OR OTHER SIMILAR DAMAGES INCLUDING BUT NOT LIMITED TO LOST PROFITS LOST SALES INJURY TO PERSON OR PROPERTY OR DAMAGES TO A STRUCTURE OR ITS CONTENTS ARISING UNDER ANY THEORY OF LAW WHATSOEVER ALL IMPLIED WARRANTIES INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FORA PARTICULAR PURPOSE OR OTHERWISE ARE LIMITED IN DURATION TO THE LENGTH OF THIS WRITTEN WARRANTY EXCEPT AS EXPRESSLY SET FORTH HEREIN JOTUL MAKES NO ORAL WRITTEN OR OTHER WARRANTY WITH RESPECT TO JOTUL GAS STOVES OR FIREPLACE INSERTS Some states do not allow the exclusion or limitation of incidental or consequential damages or limitations on the length of implied warranties Therefore the above exclusions or limitations may not apply to you This warranty gives you specific legal rights and you may have
45. ilot Bracket 8 157830 Left Cable Assembly 9 117917 Screw 8 1 2 HWH SMA 10 8 Hex Nut M6 Serrated Flange 225525 Pilot Grommet Silicone 12 18279 Screw 10 32 x 1 4 Pan Head B 225640 Air Shutter Tray Handle 41 139712 800 GI 635 IPI Sept 2015 Figure 89 Cast Iron Overlay and Safety Screen Assembly No Part Number 1 10467492 Top Breast Plate MB 10467247 Top Breast Plate BRM 2 10467592 Left Surround Leg MB 10467547 Left Surround Leg BRM 3 10467692 Right Surround Leg MB 10467647 Right Surround Leg BRM 4 10467792 Plinth MB 10467747 Plinth BRM 5 225783 Hanging Bracket 2 6 225785 Adjustable Screen Retainer 3 225856 Adjustable Screen Retainer Enamel 3 7 225786 Top Corner Bracket 2 225851 Top Corner Bracket Enamel 8 225784 Top Screen Retainer 9 117978 Screw M6 x10 Button Head 29 10 225787 Bottom Corner Bracket 2 225852 Bottom Corner Bracket Enamel 2 225788 Bottom Shade 12 225782 Bulkhead Screen Adjustor 13 225672 Safety Screen Frame 42 139712_ROO GI 635 IPI Sept 2015 Figure 90 Blower Assembly Figure 91 Glass components No Part Number Description No Part Number Description 1 117917 Screw HWH SMA 8 x 1 2 SL BIk Oxide 1 129124 Gasket Fiber Gla
46. ing area is provided with this INSTALLER Leave this manual with the appliance appliance and shall be installed for the protection of children and other at risk individuals CONSUMER Retain this manual for future reference 139712_ROO_GI 635 IPI Sept 2015 THIS OWNER S MANUAL PROVIDES INFORMATION 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 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 HEATER MUST BE INSTALLED AND MAINTAINED BY A QUALIFIED SERVICE AGENCY Suggested Tools for Installation and Service External regulator for Propane only Piping which complies with local code Manual shut off valve T Handle required in Massachusetts Sediment trap if required by code Tee joint e Work Gloves Pipe wrench Safety glasses Pipe sealant e Torx T 20 screwdriver 10 mm open end wrench Tin snips 1 2 7 16 open end wrench Phillips head screwdriver Flat head screwdriver 1 4 nut driver Installation Requirements for the Commonwealth of Massachusetts THIS PRODUCT MUST BE INSTALLED BY A LICENSED MASTER OR JOURNEYMAN PLUMBER OR GAS FITTER WHEN INSTALLED IN THE COMMONWEALTH OF MASSACHUSETTS
47. insulation after the gas supply has ee been installed combustible materials 2 Remove the damper assembly This includes the s 0 blade handi d link 1 in accordance with the amper blade handle and any linkage Two 3 liners fireplace manufacturer s must be able to pass through the damper area listing es 3 Remove any fire screen or door assembly This is A A metal block off Factory Dull usually accomplished with removal of a support rod oe ed Class Listed PRE 2 plate is require on the inside of the fireplace frame slot e 4 Remove the metal ash lip if appropriate to allow the living area if the insert to sit flat within the fireplace Be sure to theAirintake pipe A does not connect reinstall any screws removed directly to a 5 Attach the fireplace conversion notice to the back of termination cap the factory built fireplace within wood framed chase Hearth protection must be maintained in accordance VENT NOTICE with the fireplace manufacturer s If the intake flex does not extend the full length listin 1 A 5 of the chimney and connect to the unit and the Lo termination cap A METAL BLOCK OFF PLATE MUST BELOW THE END OF THE INTAKE DUCT normally at the damper area See fig 8 BE CONSTRUCTED AND INSTALLED ABOVE THE UNIT y Y Y W Figure 8 Venting
48. ions du pr sent manuel J tul vise sans cesse am liorer ses produits C est pourquoi elle se r serve le droit de modifier les sp cifications couleurs et accessoires sans pr vis qui peuvent diff r d une publication l autre JOTUL Jotul North America 55 Hutcherson Drive Gorham Maine 04038 2634 J tul ASA P O Box 1411 N 1602 Fredrikstad Norway www jotul us
49. ireplace must be in good working order Chimney cleanouts must be accessible and fit properly If you are unsure of the condition of your fireplace and chimney contact a professional fireplace technician or your local authorized J tul dealer for professional assistance DO NOT REMOVE BRICKS OR MORTAR FROM THE FIREPLACE OR CHIMNEY STRUCTURE However masonry or steel may be removed from the smoke shelf and adjacent damper frame area to accommodate installation of a chimney liner provided that their removal will not weaken the structure of the fireplace or chimney and will not reduce protection for combustible materials If the fireplace has been modified to accommodate installation use anchors or masonry nails to attach the metal Fireplace Conversion Notice Plate to the back wall of the masonry fireplace firebox where it will be readily seen should the insert be removed 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 clearances 139712_ROO_GI 635 IPI Sept 2015 Minimum Fireplace Requirements This appliance is approved for installation into a solid fuel burning factory built fireplace or a code approved solid fuel burning masonry fireplace with a tile flue liner An acceptable fireplace cavity
50. is a normal occurrence with gas appliances and particulate accumulation may appear on the inside surface to the glass Use a dampened soft cloth to clean the glass and polish with 3 dry soft towel Specially formulated ceramic glass cleaner may also be used DO NOT CLEAN GLASS WHEN IT IS HOT DO NOT USE ABRASIVE OR AMMONIA BASED CLEANING SOLUTIONS TAKE CARE TO NOT SCRATCH THE GLASS SURFACE Glass Replacement To remove the glass panel or glass gasket 1 Use the Latch Tool to release the two glass frame latches on top of the firebox 2 Swing the bottom of the glass frame out and lift up to disengage it from the firebox 3 Lay the assembly on a flat surface and use a flat blade screwdriver or pliers to pry up the four 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 ALWAYS USE J TUL AUTHORIZED PARTS NEVER SUBSTITUTE ANY OTHER PARTS T 6 55 Figure 85 Glass Replacement Bend tabs to secure panel WARNING re p P OBSERVE CAUTION NEAR THE GLASS THE GLASS PANEL MAY SHATTER IF STRUCK WITH AN OBJECT ALWAYS HANDLE THE GLASS PANEL WITH CARE WARNING INSPECT THE GLASS SURFACE FOR SCRATCHES AS THESE CAN WEAKEN THE PANEL TENSILE STRENGTH REPLACE THE PANEL IF ANY SCRATCHES ARE EVIDENT
51. ments esses 8 Hearth 706606 ssesesseeseeeees 8 Ele rances sssisissnshns instants 9 Vent Guidelines 10 Masonry Fireplaces oo sess 11 Prefabricated Fireplaces 12 Vent Connection cccsccccscscscecessesseseeees 13 Fireplace Assembly 14 Gas Connection Gas Pressure Test Fuel 60 50 High Altitude Adjustment 18 Final 05 18 Brick Panel Kits 20 Reflective Glass Panel Kit ceseseeees 22 Log Set Installation oes 24 Backer Plate Installation 28 Trimmable Backer Plate Installation 28 Hidden Hanger Bracket c esses 29 Front Cast Iron Overlay oo cscs 29 Operation 30 Initial System Check Fireplace Operation Remote Control 6 33 Maintenance 37 General and Annual Cleaning 37 Accent Lamp Bulb Replacement 37 Battery Replacement ou sees 37 Glass Care and Replacement 38 Illustrated Part 27630000 0 39 Appendix A Wiring Diagram Approved Vent Manufacturers 44 Warranty Statement 0 eens 45 Lighting Instructions 0 0 eee 47 139712_ROO GI 635 IPI Sept 2015 Unpacking the Gas Insert 1 Thoroughly inspect the appliance for shipping damage and immediately contact the dealer if any is found A Miscellaneous Hardware Kit is packed within the firebox crate with this manual Confirm these contents Fuel Conversion Kit LP e Fir
52. must have the minimum dimensions specified in fig 3 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 will void the warranty certifications and approvals of the unit and could be dangerous B 1 Minimum Fireplace Dimensions A Inside Height 24 61 cm B Inside Width 23 1 2 59 7 cm at 16 1 2 of depth C Inside Depth 16 1 2 42 cm Figure 3 D Opening Height 24 61 cm E Opening Width 33 3 4 85 7 cm Maximum Fireplace Opening Cast lron Overlay Will cover a maximum fireplace opening 25 3 8 high x 34 1 2 wide NOTE If a Backer Plate will not be used Backerless Overlay Hanger Kit 157802 must be installed on the insert firebox in order to attach the Overlay assembly Backer Plate Options The Backer Plate functions to neatly cover the fireplace opening between the insert shell and the fireplace walls Standard Backer Plates are fabricated of 12 gauge aluminized steel finished in high temperature Matte Black powder coating Trimmable Backer Plates are fabricated of 22 ga aluminized steel finished in Matte Black paint Choose a
53. n overall size that is at least 1 inch larger than your fireplace opening 157799 3 Sided Backer Plate 28 1 4 H x 40 W 157800 3 Sided Backer Plate 31 H x 42 W 157801 3 Sided Backer Plate 34 H 46 W 157826 3 Sided Trimmable Backer Plate 38 H x 47 3 4 W 157827 4 Sided Trimmable Backer Plate 38 63 H x 47 3 4 W Intended for flush faced fireplace installations Clearance Requirements The following clearances and hearth specifications are the minimum requirements for installing this appliance into a solid fuel burning fireplace See figs 4 6 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 combustible Always maintain the proper clearances to allow for the flow of ventilation air around the insert Hearth Requirements Hearth protection in front of the GI 635 DV IPI must be composed of masonry material extending at least 4 1 8 10 5 cm to each side of the fireplace opening and 12 30 5 cm forward from the fireplace facing material
54. nel and secure each with screws or duct clamps Sealant is unnecessary See Fig 9 Position the firebox under the vent collar panel and use the Latch Tool to engage the panel with the associated pins on the firebox Vent Manifold Fig 9 Reinstall the Lock Screw to secure the adaptor panel to the firebox Push the insert firebox fully into the final position Do not install the Backer Plate or Overlay Frame until all other assembly and system checks are completed Dual 3 Listed Vent Liners Air Intake A Lock Screw wee Figure 9 Vent connection 13 139712_ROO_GI 635 IPI Sept 2015 Fireplace Assembly Before beginning final assembly push the insert into the fireplace and adjust the leveling bolts located at each corner as appropriate to achieve a level and plumb installation Complete the assembly procedures in this order 1 Gas Connection and Leak Test Gas Pressure Test Fuel Conversion High Altitude Adjustment Brick Panel or Reflective Glass Panel Kits Log Set Air Shutter Adjustment 2 3 4 5 6 7 NOTE IN ORDER EASE ACCESS TO COMPONENTS COMPLETE PROCEDURES 1 4 ABOVE BEFORE PLACING THE INSERT WITHIN THE FIREPLACE Gas Supply Connection 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 the appropriate size to provide sufficient gas pressure
55. not overtighen Be certain the pilot hood directs flame to the flame sensor 7 REINSTALL THE BURNER ASSEMBLY Be certain both Air Shutter Adjuster trays on the firebox floor are positioned fully forward toward yourself Move the burner shutters on the bottom of the burner to the fully closed position Drop the burner into the firebox while engaging it with the Air Shutter Adjustors The two front support brackets should engage with the pins in the firebox floor See also figs 24 27 on page 21 BE CERTAIN THE BURNER IS LEVEL AND SECURELY SEATED ON THE FIREBOX FLOOR Properly located it should not be able to move in any direction and the front lip of the burner should be just below the firebox Figure 14 Fuel Conversion Components Pilot Assembly 139712_ROO GI 635 IPI Sept 2015 LA 8 lt o 6 sy 9 a Front Burner oi Injector Rear Burner Injector Rear Burner Air Shutter Cable Y 2 0 Front Burner Air Shutter Cable 1 Air Shutter 4 pi Adjustor Trays lt a Pilot Head Pilot Orifice Lever Figure 15 Pilot Conversion to Propane 8 CHANGE THE VARIABLE REGULATOR TOWER on the gas 1 O 1 12 control valve See fig 16 e Remove the heat shield from
56. of the chimney This liner can also extend the full length of the chimney and connect to the termination cap See NOTICE below See also figures 7 and 8 NOTICE 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 7 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 NOTICE THE USE OF AN EXISTING CHIMNEY AS AN AIR INTAKE IS NOT COVERED UNDER THE ANSI Z21 88 2014 CSA 2 33 Mo4 TEST METHODS AND RESULTING ITS WHI PRODUCT CERTIFICATION THE CODE AUTHORITY HAVING JURISDICTION MUST BE CONSULTED PRIOR TO PROCEEDING WITH THIS INSTALLATION METHOD Venting through a Masonry Fireplace N Ww uw N o0 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 termination kit Cut the appro
57. olume of air per cubic foot Higher altitudes affect the atmospheric pressure and heat value of gaseous fuels The lower oxygen content in the air and the lower gas viscosity require the use of a different orifice to achieve efficient clean combustion at the burner tube In the U 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 APPLIED TO THE APPLIANCE AT THE TIME OF THE CONVERSION THE QUALIFIED SERVICE AGENCY PERFORMING THIS WORK ASSUMES RESPONSIBILITY FOR THIS DE RATING In Canada This 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 IN ACCORDANCE 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 High Altitude Installations 2000 ft to 4500 ft installations or 610 m 1370 m See Table 1 For high altitude installations consult the local gas distributor or the authority having jurisdiction for proper rating methods If the installer must convert the unit to adjust for varying altitudes the information label must be completed by the installer and applied to the appliance at the time of the conversion See fig 17
58. ons NG LP 10 000 8 700 40 000 40 000 38 000 38 000 Min Input Rate o 2000 ft Max Input Rate o 2000 ft Max Input Rate up to 4500 ft 16 Fuel Conversion Procedure 1 Turn off the gas supply and electrical power to the appliance 2 Use the Latch Tool to remove the glass frame See fig 1 3 RETRACT THE AIR SHUTTERS Two Air Shutter cables are located in each side compartment and push them fully in This action retracts the shutters and allows the burner to be disengaged from the firebox See figs 16 and 58 4 REMOVE THE BURNER Grasp the burner assembly at the two large ports as shown in fig 13 Lift it straight up then tilt it back to disengage it from the injectors and pull it out of the firebox It may be necessary to shake the burner to disengage the air shutters from the burner injectors 5 Figure 13 Remove burner assembly 5 CHANGE THE BURNER INJECTORS Use a 1 2 open end wrench or deep well socket to remove the burner injectors from the brass elbows at the rear of the firebox See fig 14 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 15 LP push lever to the Right to expose the red indicator NG push lever to the Left Retighten the pilot base nut but do
59. ontrol IFC and hand held Transmitter have been synchronized at the factory before the batteries are removed for shipping Reinstall the batteries in each unit before operating the fireplace See battery box location in fig 58 page 30 Figure 1 Pull each Spring Latch out and down to disengage it from the Glass Frame 139712 800 GI 635 IPI Sept 2015 J tul GI 635 DV IPI Direct Vent oly JOTUL Gas Fireplace Insert Manufactured and Distributed by J tul North America Gorham Maine USA 6 US Jotul AS Intertek Fredrikstad Norway Test Standards This appliance complies with National Safety standards and is tested and listed by Intertek Testing Services NA Inc of Middleton Wisconsin In addition the J tul GI 635 DV IPI gas fireplace insert has been tested and listed as a direct vent gas fireplace heater and listed to ANSI z21 88 2014 CSA 2 33 2014 Standard for Vented Gas Fireplace Heaters CAN CGA 2 17 91 Standard for Gas Fired Appliances for use at High Altitudes and CSA P 4 01 2 Standard for Measuring Annual Fireplace Efficiency Specifications Input Rates Natural Gas 40 000 BTU hr maximum input 10 000 BTU hr minimum input Propane 40 000 BTU hr maximum input 8 700 BTU hr minimum input Inlet Pressure MIN MAX Natural Gas 4 0 WC 1 00 kPa 7 0 WC 1 74 kPa Propane 12 0WC 3 00 kPa 14 0 WC 3 48 kPa Manifold Pressure MIN i MAX Accessories Traditional R
60. orm Use parts of one manufacturer only DO NOT MIX VENT COMPONENTS FROM DIFFERENT MANUFACTURERS IN THE SAME SYSTEM 44 J tul GI 635 DV IPI Fireplace Insert Limited Lifetime Warranty Effective January 1 2013 This warranty policy applies to gas products identified by Jotul trade names as set forth below A LIMITED FIVE YEAR WARRANTY Cast Iron Steel Doors Surround Components Firebox J tul North America Inc J TUL warrants to the original retail purchaser that those components of the J tul Gas Stove or Fireplace Insert specified above will be free of defects in material and workmanship for a period of five 5 years from the date of purchase This warranty is subject to the terms exclusions and limitations set forth in the following text B LIMITED TWO YEAR WARRANTY Burner Burner Treatments Firebox Panels J TUL warrants to the original retail purchaser that those components of the J tul Stove or Fireplace Insert specified above will be free of defects in material and workmanship for a period of two 2 years from the date of purchase This warranty is subject to the terms exclusions and limitations set forth in the following text C LIMITED TWO YEAR WARRANTY Enamel Finish J TUL warrants to the original retail purchaser the enamel finish on cast iron components of the J tul Stove or Fireplace Insert specified above against peeling or fading for a period of two 2 years from the date of purcha
61. other rights which vary from state to state J TUL reserves the right to discontinue modify or change the materials used to produce the Jotul Scan or Atra Gas Stove or Fireplace JOTUL shall have the right to replace any defective component with substitute components determined by J TUL to be of substantially equal quality and price The dollar value of J TUL liability for breach of this warranty shall be limited exclusively to the cost of furnishing a replacement component J TUL shall not in any event be liable for the cost of labor expended by others in connection with any defective component Any costs or expenses beyond those expressly assumed by JOTUL under the terms of this warranty shall be the sole responsibility of the owner s of the Jotul Gas Stove or Fireplace Insert No dealer distributor or other person is authorized to modify augment or extend this limited warranty on behalf of JOTUL NO MODIFICATION OR CHANGE TO THIS WARRANTY WILL BE EFFECTIVE UNLESS IT IS MADE IN A WRITTEN DOCUMENT MANUALLY SIGNED BY AN AUTHORIZED OFFICER OF J TUL An authorized installer may have been provided with certain information related particularly to the J tul Gas Stove or Fireplace Insert however no authorized installer or other person who may service the appliance is an agent of JOTUL No inference should be made that JOTUL has tested certified or otherwise pronounced any person as qualified to install or service the appliance JO
62. ould be located out of traffic and away from furniture draperies etc Maintain proper clearance to combustible mantels and fireplace trim 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 appliance Toddlers young children and others may be susceptible to accidental contact burns A physical barrier such as a child guard is recommended to be used if there are at risk individuals in the house To restrict access to a fireplace or stove install an adjustable safety gate to keep toddlers young children and other at risk individuals out of the room and away from hot surfaces A safety barrier is provided with this appliance designed to reduce the risk of burns from the hot viewing glass and shall be installed for the protection of children and other at risk individuals If the barrier becomes damaged the barrier shall be replaced only with the J tul barrier part number 225672 Any safety screen glass panel guard or barrier removed for servicing an appliance must be replaced prior to operating the appliance Clothing or other flammable materials should not be placed on or near the fireplace Never allow anyone to use the fireplace if they are unfamiliar with its operation NEVER store or use gasoline or any other flammable vapors or
63. priate lengths of flex duct for both the intake and exhaust Label both ends of the Exhaust duct to ease identification inside the house Follow the manufacturer s instructions to attach the ends of the duct s to the chimney termination kit as appropriate Drop the liners down the chimney from the top and rest the termination kit atop the chimney Seal the chimney termination kit to the top of the chimney flue with high temperature sealant Secure the appropriate direct vent cap to the termination kit Inside the fireplace fully extend the duct and trim any excess so that the ends hang approximately 15 from the floor of the fireplace If the Intake duct is not attached to the chimney termination kit A Install a length of flex duct that extends at least into the first flue tile B The fireplace chimney flue must be permanently sealed off from the room C Adirect vent cap is required to allow fresh air into the chimney flue and ultimately into the intake duct to the insert D Attach the Fireplace Conversion Notice to the back of the fireplace if appropriate 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 Exh
64. r AA batteries provide back up power to operate the burner in case of a power outage The Blowers and Accent Lamp will not function with loss of power Leg Leveling Note This appliance is equipped with four leveling bolts that can be 139712_ROO GI 635 IPI Sept 2015 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 23 2 Gas Inlet p 7 597 I 23 2 6 600 mm 8 34 2 222 mm Ti Re 16 3 B Dy p 416 mm 51 mm Figure 2 Firebox dimensions 3 76 mm Cast Iron Overla Glass Viewing Area 25 27 19 651mm 705mm X 495mm T1 3434 883 mm Installation Requirements This insert can be installed in most solid fuel burning fireplaces of either masonry construction or a prefabricated factory built fireplace Prior to any installation the existing chimney flue must be thoroughly cleaned and inspected by a qualified chimney sweep or fireplace service person Do not install this appliance into a chimney that is damaged or contains combustible construction materials Any repairs must be made prior to installing the insert The chimney and f
65. se This warranty is subject to the terms exclusions and limitations set forth below D LIMITED ONE YEAR WARRANTY Gas amp Electrical Components controls plumbing valve blower J TUL warrants to the original retail purchaser that those components of the J tul Gas Stove or Fireplace Insert specified above will be free of defects in material and workmanship for a period of one 1 year from the date of purchase This warranty is subject to the terms exclusions and limitations set forth in the following text J TUL will repair or replace including parts amp labor at its option any of the above components determined by JOTUL to be covered by this warranty You must at your own expense arrange to deliver or ship the component to an authorized J tul dealer and arrange for pickup or delivery of the component after repairs have been made If upon inspection J TUL determines that the component is covered by this warranty the repair or replacement will be made as set forth above This warranty is not transferable and is extended only to and is solely for the benefit of the original retail purchaser of the Jotul Gas Stove or Fireplace Insert This paragraph sets forth the sole remedy available under this warranty in the event of any defect in the J tul Gas Stove or Fireplace Insert The warranty period for any replaced component will be the remaining unexpired portion of the warranty period for the original component Ple
66. signals the acknowledgement NOTE In Manual functionality there is no control over the blower lamp or pilot modes The pilot automatically defaults to CPI mode Figure 63 Blue LCD Screen Remote transmitter function keys ON OFF Key THERMOSTAT Key UP DOWN Key MODE Key oom Temperature 6 CPI Mode AUX Not Applicable Remote Transmitter Controls Temperature Indication Display With the transmitter in the OFF position press the Thermostat Key and the Mode Key at the same time The display screen will show the current room temperature cycling between Fahrenheit and Celsius indicators each time the keys are pressed simultaneously See fig 65 Pilot Mode With the transmitter in the OFF position press the transmitter Mode key IPI is the default mode Fig 66 Press the Up arrow to index to the CPI icon and activate the Continuous Pilot Ignition mode Fig 67 Pressing the Down Arrow Key will return to Intermittent Pilot Ignition A single beep will confirm reception of the command Turn on the Burner E Press the ON OFF Key on the Transmitter The display will show all the active icons At the same time the Receiver will activate the Pilot Ignitor First the pilot will ignite followed shortly by the burner A single beep from the Receiver will confirm reception of the command Turn off the Burner E Press the ON OFF Key The display will show only the room
67. ss w Graphite 25 x 1 25 8 5 ft 2 225494 Blower Bracket Left and Right 2 157834 Glass Panel w Gasket 3 225479 Blower 60 mm Crossflow Left 3 22548292 Glass Frame Matte Black 4 225478 Blower 60 mm Crossflow Right 4 157739 Replacement Frame w Glass Assembly inc 1 2 3 5 157832 Blower Wire Harness Figure 92 Lamp Assembly No Part Number Description 1 225491 Light Fixture Matte Black 2 117917 Screw HWH SMA 8 x 1 2 SL Blk Oxide 3 222974 Glass Ceramic Light Fixture 4 222977 Gasket Light Fixture 5 17967 Screw Pan Head SMA 7 3 8 6 157601 Replacement Holder Harness Connector 7 222943 Light Bulb 130V 50 Watt 43 139712 00 GI 635 IPI Sept 2015 Appendix Proflame 2 Stepper Regulator Figure 93 GI 635 DV IPI Proflame 2 Wiring Diagram as S Spark H IPI Pilot HMG i HL Battery Pack Four 1 5v AA Main Burner Switch jo op Main Power Cord iual Blowers Optional Accent D Lamp A D SEN y p a 4 Approved Vent Manufacturers This appliance is approved for use with vent systems from the following manufacturers e M amp G DuraVent Inc Direct Vent Pro Series e American Metal Products Amerivent e Security Chimneys International Ltd Secure Vent e Selkirk Metalbestos Direct Temp e Metal Fab Inc Direct Vent e Industrial Chimney Corp ExcelDirect e Bernard Delsin Mfg Pro F
68. the Up Down Arrow Keys to turn ON OFF or adjust the fan speed Fig 79 A single beep will confirm reception of the command After a 5 minute interval the fan will power up to its highest speed and then modulate down to the established fan speed setting The fan will continue to operate for 12 minutes after the burner is turned off Manual speed control is not available when the SMART Thermostat is ON Accent Lamp Control With the Remote ON press the Mode Key to index to the Lamp icon Figs 80 81 E Pressing the Up Arrow Key will turn the Lamp ON Press the arrow keys to adjust the brightness E Pressing the Down Arrow Key will turn the Lamp OFF Child Safety Lock This function will lockout the Transmitter to prevent unsupervised operation To activate the Lock press the Mode key and UP Key at the same time Fig 82 To de activate the Lock press the Mode Key and UP Key at the same time 36 E EE Set Figure 74 Thermostat ON g7 N 2 E Figure 76 Smart Mode T Gti Figure 78 Fan Mode OFF Figure 80 Lamp Control D ka Figure 82 Lock ON ef Room Temperature la 8 Figure 75 Change Set Temperature JE Ba Figure 77 Smart Set Temp gt Figure 79 Fan Speed Figure 81 Lamp ON
69. the valve compartment to access the Regulator Tower e Disconnect the IFC lead from the regulator lead e Remove the original regulator tower with removal of two Torx mounting screws Install the new regulator tower from the kit using the screws previously removed Tighten screws securely Reconnect the Regulator lead to the IFC lead 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 e Label A Apply to the right side compartment adjacent to the Rating Plate e Label B Apply to the Rating Plate e Small valve sticker Apply to valve body 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 Pressure Test Conduct a pressure test of the valve following the guidelines on page 14 of this manual Burner Confirmation Follow Steps 1 5 under Initial System Check on page 30 before final assembly of accessory log set and surround components D T Remove Heat Shield Regulator Lead to IFC Lead Regulator Tower Front Burner Air Shutter Cable Figure 16 Replace the Regulator Tower 17 139712_ROO_GI 635 IPI Sept 2015 High Altitude Adjustment When installing this appliance at altitude above 2000 feet it is necessary to compensate for the thinner air less v
70. through prefabricated fireplace chimney 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 IMPORTANT NOTICE THE USE OF AN EXISTING CHIMNEY AS AN AIR INTAKE IS NOT COVERED 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 12 Prefabricated Fireplace Vent Procedure 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 N Cut the appropriate lengths of flex for both the intake and exhaust If the intake flex will be attached to the chimney termination kit Attach the appropriate ends of the flex to the chimney termination kit CAUTION AVOID CROSS VENTING THE FLEX PIPE Label the end of the exhaust pipe to ease identification inside the house Ww 4 Drop the liners down the chimney from the top and rest the termination kit atop the chimney Seal the chimney termination kit to the top of the chimney pipe with high temperature sealant 6
71. to the valve regardless of the input setting See fig 10 11 The GI 635 DV IPI is shipped a 36 length of flexible gas 3 8 gas line J tul recommends the use of the flexible gas line for ease of installation and service However for those areas where flexible gas lines are not permitted use of a 3 8 iron nipple and union is recommended See fig 10 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 LOCAL CODE OR IN THE ABSENCE OF LOCAL CODE MUST COMPLY WITH THE MOST RECENT EDITION OF THE NATIONAL FUEL GAS CODE ANSI Z223 1 NFPA 54 OR CAN B149 An integrated gas cock is built into the fuel supply line just upstream of the valve This feature conforms to building codes requiring a shut off valve be located within the same room as the appliance The gas cock allows for the disconnection of the insert for servicing and maintenance See figs 1 11a Secure all joints tightly using appropriate tools and sealing 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 or electronic gas sensor Never use an open flame to check for leaks Tighten or reconnect the leaking joint and retest for any gas leaks 14 INSTALLATION OF A T HANDLE GAS COCK IS REQUIRED IN MASSACHUSETTS IN COMPLIANCE WITH CODE 248 CMR
72. tton to light the burner If the appliance will not operate follow the instructions below To Turn Off Gas To Appliance and call your service technician or gas supplier g See the Owner s Manual for more detailed remote control instructions Pilot Light Assembly TO TURN OFF GAS TO THE APPLIANCE 1 Set the Remote thermostat to the lowest setting 2 Set the Burner Switch to the OFF position 3 Disconnect electric power to the appliance if service is to be performed CAU TION Do not operate this appliance with the ATTENTION Ne pas utiliser l appareil si la vitre glass removed cracked or broken Replacement of the glass est retir e fissur e ou cass e Confiez le remplacement de la panel shall be done by a licensed or qualified service person vitre un technicien d entretien qualifie 47 00 2LLGEL 51050 6 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 J tul maintains a policy of continuous product development Consequently products may differ in specification color or type of accessories from those illustrated or described in various publications Ce appareil doit tre installe conform ment aux codes et r glements locaux et nationaaux du batiment Avant de commencer l istallation il est important de lire et comprendre les instruct
73. uiding the rear corner onto the side of the log shelf Rotate the panel inward and to the side until it is flush with the wall Fig 32 Repeat on the opposite side 7 Replace the Panel Retainers in the opposite orientation from which they were removed Bend the retainer if necessary to lock the panels in place See fig 33 8 Follow the procedure in Step 5 page 20 to reinstall the burner assembly 22 ect NG a Figure 28 Remove burner assembly Oa Figure 29 Remove retainer brackets Figure 30 Cut away view of Center Panel installation M e ee rer N M E CA Figure 32 Install the Side Panels aaa mer Figure 33 Replace retainer brackets opposite from original orientation 139712_ROO GI 635 IPI Sept 2015 23 139712 00 GI 635 IPI Sept 2015 Figure 36 2 Log The flat pads on the underside of the log Install the Log Set rest on the flat landings in the burner base NOTE Install the optional Brick Panels before installing the Log Set Install the log set in the order presented here Fig 53 shows the final arrangement Figure 34

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