Napoleon GI 3600-N User Manual

INSTALLER: THESE INSTRUCTIONS MUST BE CONVEYED TO AND REMAIN WITH THE HOMEOWNER.

Wolf Steel Ltd., 24 Napoleon Rd., Barrie, ON L4M 4Y8 Canada • [phone] • fax[phone]

www.napoleonfireplaces.com • [e-mail]

CERTIFIED UNDER CANADIAN AND AMERICAN NATIONAL STANDARDS, CSA 2.22, AND ANSI Z21.50 RESPECTIVELY FOR VENTED GAS FIREPLACES.

GAS - INSERTS

INSTALLATION AND OPERATION INSTRUCTIONS FOR

GAS-FIRED VENTED FIREPLACE

1

NATURAL GAS MODEL
PROPANE GAS MODEL

CERTIFIED FOR CANADA AND UNITED STATES USING ANSI / CSA METHODS

GI 3600 - N

GI 3600 - P

WARNING: If the information in these instructions is not followed exactly, a fire or

explosion may result causing property damage, personal injury or death.

FOR YOUR SAFETY

Do not store or use gasoline or other flammable vapours and liquids in the vicinity of

this or any other appliance.

WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any appliance.

• Do not touch any electrical switch.

• Do not use any phone in your building.

• Immediately call your gas supplier from
a neighbor's phone. Follow the gas
supplier's instructions.

• 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.

W415-0061 / B / 01.11.05

2

TABLE of CONTENTS

PG 2-5 INTRODUCTION

Warranty
General Instructions
General Information
Care of Glass, & Plated Parts

5 INSTALLATION
6-7 FINISHING

Brick panels
Log Placement/Charcoal Embers
Louvre Installation
Logo Placement

7 OPERATION / MAINTENANCE

Spill Switch
Venting Action Check

PLEASE RETAIN THIS MANUAL FOR FUTURE REFERENCE

8

OPERATION / MAINTENANCE

Operating Instructions
Maintenance

CONT'D

9 BLOWER SYSTEM

Blower Replacement Instructions

9 ADJUSTMENTS

Pilot Burner Adjustment
Venturi Adjustments

10-11 REPLACEMENTS

Ordering Replacement Parts
Replacement Parts
Accessories / Options

12-13 TROUBLE SHOOTING GUIDE
14 SERVICE HISTORY

WARNING

• Do not burn wood or other materials in this fireplace.

• Adults and especially children should be alerted to the hazards of high surface temperatures and should
stay away to avoid burns or clothing ignition. Supervise young children when they are in the same room as
the fireplace.

• Due to high temperatures, the fireplace should be located out of traffic and away from furniture and draper­ies.

• Clothing or other flammable material should not be placed on or near the fireplace.

• Any safety screen or guard removed for servicing must be replaced prior to operating the fireplace.

• It is imperative that the control compartments, burners and circulating blower and its passageway in the
fireplace and venting system are kept clean. The fireplace and its venting system should be inspected
before use and at least annually by a qualified service person. More frequent cleaning may be required due
to excessive lint from carpeting, bedding material, etc. The fireplace area must be kept clear and free from
combustible materials, gasoline and other flammable vapours and liquids.

• Under no circumstances should this fireplace be modified.

• This fireplace must not be connected to a chimney flue pipe serving a separate solid fuel burning appliance.

• Do not use this fireplace if any part has been under water. Immediately call a qualified service technician to
inspect the fireplace and to replace any part of the control system and any gas control which has been
under water.

• Do not operate the fireplace with the glass door removed, cracked or broken. Replacement of the glass
should be done by a licensed or qualified service person.

• Do not strike or slam shut the fireplace glass door.

W415-0061 / B / 01.11.05

3

NAPOLEON gas fireplaces are manufactured under the strict Standard of the world recognized

ISO 9001 : 2000 Quality Assurance Certificate.
NAPOLEON products are designed with superior components and materials, assembled by trained craftsmen who
take great pride in their work. The burner and valve assembly are leak and test-fired at a quality test station. The
complete fireplace is thoroughly inspected by a qualified technician before packaging to ensure that you, the cus­tomer, receives the quality product that you expect from NAPOLEON.

NAPOLEON GAS FIREPLACE PRESIDENT'S LIFETIME LIMITED WARRANTY

The following materials and workmanship in your new The following materials and workmanship in your new

The following materials and workmanship in your new

The following materials and workmanship in your new The following materials and workmanship in your new

ranted against defects for as long as you own the fireplace. This covers: combustion chamber,ranted against defects for as long as you own the fireplace. This covers: combustion chamber,

ranted against defects for as long as you own the fireplace. This covers: combustion chamber,

ranted against defects for as long as you own the fireplace. This covers: combustion chamber,ranted against defects for as long as you own the fireplace. This covers: combustion chamber,
heat exchanger, stainless steel burner, phazer™ logs and embers, ceramic glass (thermal break-heat exchanger, stainless steel burner, phazer™ logs and embers, ceramic glass (thermal break-

heat exchanger, stainless steel burner, phazer™ logs and embers, ceramic glass (thermal break-

heat exchanger, stainless steel burner, phazer™ logs and embers, ceramic glass (thermal break-heat exchanger, stainless steel burner, phazer™ logs and embers, ceramic glass (thermal break­age only), gold plated parts against tarnishing, porcelainized enamelled components and alumi-age only), gold plated parts against tarnishing, porcelainized enamelled components and alumi-

age only), gold plated parts against tarnishing, porcelainized enamelled components and alumi-

age only), gold plated parts against tarnishing, porcelainized enamelled components and alumi-age only), gold plated parts against tarnishing, porcelainized enamelled components and alumi­num extrusion trims.num extrusion trims.

num extrusion trims.

num extrusion trims.num extrusion trims.

Electrical (110V and millivolt) components and wearable parts such as blowers, gas valves,Electrical (110V and millivolt) components and wearable parts such as blowers, gas valves,

Electrical (110V and millivolt) components and wearable parts such as blowers, gas valves,

Electrical (110V and millivolt) components and wearable parts such as blowers, gas valves,Electrical (110V and millivolt) components and wearable parts such as blowers, gas valves,

thermal switch, switches, wiring, remote controls, ignitor, gasketing, and pilot assembly arethermal switch, switches, wiring, remote controls, ignitor, gasketing, and pilot assembly are

thermal switch, switches, wiring, remote controls, ignitor, gasketing, and pilot assembly are

thermal switch, switches, wiring, remote controls, ignitor, gasketing, and pilot assembly arethermal switch, switches, wiring, remote controls, ignitor, gasketing, and pilot assembly are
covered and covered and

covered and

covered and covered and
the limited warranty.the limited warranty.

the limited warranty.

the limited warranty.the limited warranty.

Labour related to warranty repair is covered free of charge during the first year. RepairLabour related to warranty repair is covered free of charge during the first year. Repair

Labour related to warranty repair is covered free of charge during the first year. Repair

Labour related to warranty repair is covered free of charge during the first year. RepairLabour related to warranty repair is covered free of charge during the first year. Repair

work, however, requires the prior approval of an authorized company official. Labour costs towork, however, requires the prior approval of an authorized company official. Labour costs to

work, however, requires the prior approval of an authorized company official. Labour costs to

work, however, requires the prior approval of an authorized company official. Labour costs towork, however, requires the prior approval of an authorized company official. Labour costs to
the account of the account of

the account of

the account of the account of
must be done through an authorized must be done through an authorized

must be done through an authorized

must be done through an authorized must be done through an authorized

NAPOLEONNAPOLEON

NAPOLEON

NAPOLEONNAPOLEON

NAPOLEONNAPOLEON

NAPOLEON

NAPOLEONNAPOLEON

will provide replacement parts free of charge during the first year ofwill provide replacement parts free of charge during the first year of

will provide replacement parts free of charge during the first year of

will provide replacement parts free of charge during the first year ofwill provide replacement parts free of charge during the first year of

are based on a predetermined rate schedule and any repair work are based on a predetermined rate schedule and any repair work

are based on a predetermined rate schedule and any repair work

are based on a predetermined rate schedule and any repair work are based on a predetermined rate schedule and any repair work

NAPOLEONNAPOLEON

NAPOLEON

NAPOLEONNAPOLEON

dealer. dealer.

dealer.

dealer. dealer.

NAPOLEONNAPOLEON

NAPOLEON

NAPOLEONNAPOLEON

gas fireplace are war- gas fireplace are war-

gas fireplace are war-

gas fireplace are war- gas fireplace are war-

CONDITIONS AND LIMITATIONS

NAPOLEON warrants its products against manufacturing defects to the original purchaser only -- i.e., the individual or legal entity (registered customer) whose name appears on the

warranty registration card filed with NAPOLEON -- provided that the purchase was made through an authorized NAPOLEON dealer and is subject to the following conditions and limitations:

This factory warranty is nontransferable and may not be extended whatsoever by any of our representatives.
The gas fireplace must be installed by a licenced, authorized service technician or contractor. Installation must be done in accordance with the installation instructions included with the

product and all local and national building and fire codes.

This limited warranty does not cover damages caused by misuse, lack of maintenance, accident, alterations, abuse or neglect and parts installed from other manufacturers will nullify

this warranty.

This limited warranty further does not cover any scratches, dents, corrosion or discolouring caused by excessive heat, abrasive and chemical cleaners nor chipping on porcelain enamel

parts, mechanical breakage of PHAZER™ logs and embers, nor any venting components used in the installation of the fireplace.

NAPOLEON warrants its stainless steel burners against defects in workmanship and material for life, subject to the following conditions: During the first 10 years NAPOLEON will replace

or repair the defective parts at our option free of charge. From 10 years to life, NAPOLEON will provide replacement burners at 50% of the current retail price.

In the first year only, this warranty extends to the repair or replacement of warranted parts which are defective in material or workmanship provided that the product has been operated

in accordance with the operation instructions and under normal conditions.

After the first year, with respect to this President's Limited Lifetime Warranty, NAPOLEON may , at its discretion, fully discharge all obligations with respect to this warranty by refunding

to the original warranted purchaser the wholesale price of any warranted but defective part(s).

After the first year, NAPOLEON will not be responsible for installation, labour or any other costs or expenses related to the reinstallation of a warranted part, and such expenses are not

covered by this warranty.

Notwithstanding any provisions contained in this President's Limited Lifetime Warranty , NAPOLEON’S responsibility under this warranty is defined as above and it shall not in any event

extend to any incidental, consequential or indirect damages.

This warranty defines the obligations and liability of NAPOLEON with respect to the NAPOLEON gas fireplace and any other warranties expressed or implied with respect to this product,

its components or accessories are excluded.

NAPOLEON neither assumes, nor authorizes any third party to assume, on its behalf, any other liabilities with respect to the sale of this product. NAPOLEON will not be responsible
for: over-firing, downdrafts, spillage caused by environmental conditions such as rooftops, buildings, nearby trees, hills, mountains, inadequate vents or ventilation, excessive venting
configurations, insufficient makeup air, or negative air pressures which may or may not be caused by mechanical systems such as exhaust fans, furnaces, clothes dryers, etc.

Any damages to fireplace, combustion chamber, heat exchanger, brass trim or other component due to water, weather damage, long periods of dampness, condensation, damaging
chemicals or cleaners will not be the responsibility of NAPOLEON.

The bill of sale or copy will be required together with a serial number and a model number when making any warranty claims from your authorized dealer. The warranty registration card
must be returned within fourteen days to register the warranty.

NAPOLEON reserves the right to have its representative inspect any product or part thereof prior to honouring any warranty claim.

ALL SPECIFICA TIONS AND DESIGNS ARE SUBJECT T O CHANGE WITHOUT PRIOR NOTICE DUE T O ON-GOING PRODUCT IMPROVEMENTS. NAPOLEON® IS A REGISTERED
TRADEMARK OF WOLF STEEL L TD. PA TENTS U.S. 5.303.693.801 - CAN. 2.073.41 1, 2.082.915. © WOLF STEEL L TD.

W415-0061 / B / 01.11.05

4

GENERAL INSTRUCTIONS

THIS GAS FIREPLACE SHOULD BE INSTALLED AND
SERVICED BY A QUALIFIED INSTALLER to conform with

local codes. Installation practices vary from region to re­gion and it is important to know the specifics that apply to
your area,

for example: in Massachusetts State:

• The fireplace damper must be removed or welded in the open
position prior to installation of a fireplace insert or gas log.

• The appliance off valve must be a “T” handle gas cock.

• The flexible connector must not be longer than 36 inches.

• The appliance is not approved for installation in a bedroom or
bathroom unless the unit is a direct vent sealed combustion
product.

• WARNING: This product must be installed by a licensed
plumber or gas fitter when installed within the commonwealth

of Massachusetts.

In absence of local codes, install to the current National
Fuel Gas Code, ANSI Z223.1, or the current CAN/CGA
B149, Installation Codes.

Purge all gas lines with the glass door of the
fireplace removed. Assure that a continuous gas
flow is at the burner before installing the door.
Under extreme vent configurations, allow several
minutes (5-15) for the flame to stabilize after igni­tion.
Altitudes greater than 4000ft. require a minimum
vent run of 12ft.

The fireplace and its individual shutoff valve must be dis­connected from the gas supply piping system during any
pressure testing of that system at test pressures in excess
of 1/2 psig (3.5 kPa). The fireplace must be isolated from
the gas supply piping system by closing its individual
manual shutoff valve during any pressure testing of the
gas supply piping system at test pressures equal to or
less than 1/2 psig (3.5 kPa).
A 1/8 inch NPT plug, accessible for test gauge connection,
must be installed immediately upstream of the gas supply
connection to the stove.
This fireplace must be connected to any accepted lined
chimney system listed to ULC-S635M (in Canada) or UL­1777 (in USA). The venting connection must be in compli­ance with the vent manufacturers installation instructions.
The draft hood must be installed so it is in the same atmo­spheric pressure zone as the combustion air inlet to the
fireplace.

Provide adequate ventilation and combustion air. Pro­vide adequate accessibility clearance for servicing and
operating the fireplace. Never obstruct the front open­ing of the fireplace.

This insert must be recessed into a vented noncombus­tible woodburning fireplace (prefabricated or masonry) only .
The minimum fireplace size in which the heater is to be
installed is:

HEIGHT 17½ inches WIDTH 25½ inches DEPTH 16½ inches

The minimum distance, from the bottom of a combustible
mantle projecting 6" maximum from the wall to the top of
the unit, is 8".

The fireplace, when installed, must be electrically con­nected and grounded in accordance with local codes. In
the absence of local codes, use the current CSA C22.1
CANADIAN ELECTRICAL CODE in Canada or the ANSI/
NFPA 70 NATIONAL ELECTRICAL CODE in the United
States. The blower power cord must be connected into a
properly grounded receptacle. The grounding prong must
not be removed from the cord plug.

GENERAL INFORMATION

FOR YOUR SA TISF ACTION, THIS FIREPLACE HAS BEEN
TEST-FIRED TO ASSURE ITS OPERATION AND QUAL­ITY! Maximum input is 24,000 BTU/hr for natural gas and

22,000 BTU/hr for propane. When the fireplace is installed
at elevations above 4,500ft, and in the absense of specific
recommendations from the local authority having jurisdic­tion, the certified high altitude input rating shall be reduced
at the rate of 4% for each additional 1,000ft. Maximum out­put for natural gas is 15,900 BTU/hr and 16,000 BTU/hr for
propane.
Minimum inlet gas supply pressure is 4.5 inches water
column for natural gas and 11 inches water column for
propane. This fireplace is certified for bedroom and
bedsitting room installation. Maximum inlet gas pressure
is 7 inches water column for natural gas and 13 inches
water column for propane. Manifold pressure under flow
conditions is 3.5 inches water column for natural gas and
10 inches water column for propane.

No external electricity (110 volts or 24 volts) is required
for the gas system operation.

Expansion / contraction noises during heating up and cool­ing down cycles are normal and to be expected. Change in
flame appearance from "HI" to "LO" is more evident in natu­ral gas than in propane.

CARE OF GLASS AND PLATED

Do not use abrasive cleaners to clean plated parts. Buff
lightly with a clean dry cloth. The glass is 3/16" ceramic
glass available from your Napoleon / Wolf Steel Ltd. dealer.
Do not substitute materials. Clean the glass after the first
10 hours of operation with a recommended gas fireplace
glass cleaner. Thereafter clean as required.
Do not clean glass when hot! If the glass is not kept clean
permanent discolouration and / or blemishes may result.

W415-0061 / B / 01.11.05

FIGURE 1

5

INSTALLATION

Clean out ashes from the inside of the wood-burning fire­place. Make sure that the chimney and wood-burning fire­place are in a clean and sound condition and constructed
of non-combustible materials. If necessary have any repair
work done by a qualified person before installing the in­sert. Remove the existing fireplace damper or lock into an
open position.
Using screws, attach the fireplace warning tag (W385-0199)
to the inside of the firebox of the fireplace into which the
insert is being installed.

WARNING: THIS FIREPLACE HAS BEEN CONVERTED FOR USE WITH A GAS
FIREPLACE INSERT ONLY AND CANNOT BE USED FOR BURNING WOOD OR SOLID
FUELS UNLESS ALL ORIGINAL PARTS HAVE BEEN REPLACED AND THE FIREPLACE
IS RE-APPROVED BY THE AUTHORITY HAVING JURISDICTION.

ATTENTION: CE FOYER A ETE CONVERTI AFIN D'ETRE UTILISE SEULEMENT COMME
FOYER ENCASTRE AU GAZ ET NE PEUT ETRE UTILSE POUR BRULER DU BOIS OU
TOUT AUTRE COMBUSTIBLE SOLIDE, SANS QUE TOUTES LES PIECES
ORIGINALES AIENT ETE REMPLACEES ET QUE LE FOYER SOIT APPROUVE DE
NOUVEAU PAR LES AUTORITES AYANT JURIDICTION.

W385-0199

The sheet-metal parts of the fireplace, in which the gas
fireplace insert is to be installed, must not be cut.

If the wood-burning factory-built fireplace has no gas
access hole(s) provided, an access hole of 1½ inch or
less may be drilled through the lower sides or bottom
of the fireplace in a proper workman like manner. This
access hole must be plugged with non-combustible in­sulation after the gas supply line has been installed.

Ensure that existing chimney cleanouts fit properly.
The refractory, glass doors, screen rails, screen mesh

and log grates may be removed from the fireplace be­fore installing the gas fireplace insert.

Smoke shelves, shields and baffles may be removed if
attached by mechanical fasteners.

The ventilation openings in the fireplace may be ob­structed by the backer plates, aluminium trim etc. but
these parts are not to be applied so as to have an air­tight seal.

Line the chimney with a 3" or 4" diameter approved liner.
With a 4" liner, an increaser must be connected between
the dilution draft hood and the liner. Chimney installation
must conform to both national and local code requirements.
The liner must be continuous from the fireplace to the
chimney cap.

FIGURE 2

Remove the securing screw from the front of the dilution
plate. Push the dilution draft hood out of the securing clips
and attach the liner using 3 screws equally spaced. Pack
insulation around the liner at the damper area to prevent
air flow from entering the chimney. Move the insert into the
centre of the woodburning fireplace making sure that the
dilution draft hood inserts back into its securing clips. Level
using the four leveling screws located front and back on
either side of the fireplace base. Leveling the insert will
eliminate rocking or excessive noise when the fan is in
operation. Replace the securing screw to the front of the
dilution plate.

FIGURE 3

Install rigid black pipe, a flex connector, if local codes per­mit, or 1/2" type L, copper tubing with a 3/8" to 1/2" adapter

and a shut off valve to the fireplace. Seal and tighten se­curely. The adapter will be required between the gas valve
and the copper tubing or flex connector. Do not kink flex-
ible connector! Check for gas leaks by brushing on a
soap and water solution. Do not use open flame!

W415-0061 / B / 01.11.05

6

An on/off switch has been included and can be located at
the right side trim. For ease of accessibility, this switch
may be replaced with a wall switch or substituted with a
millivolt thermostat that may be installed in a convenient
location on any wall. Route a 2 strand solid core millivolt
wire through the electrical hole located at the bottom right
side of the unit. The recommended maximum lead length
depends on wire size:

WIRE SIZE MAX. LENGTH

14gauge 100 feet
16gauge 60 feet
18gauge 40 feet

Attach the two leads to terminals 1 and 3 located on the
gas valve.

FIGURE 4

1

2

3

Do not connect the gas valve to electricity (110 volts or

24 volts).

The insert can be equipped with a flashing kit to close off
most fireplace openings. Mount the flashing inside the unit's
outer shell using 4 securing screws. The flashing and trim
are available in many finishes to accent any room decor.
Objects placed in front of the fireplace should be kept a
minimum of 48" away from the front face.

FIGURE 5

W415-0061 / B / 01.11.05

FINISHING

7

FIBRE FIREBRICK PANELS

To give your insert that authentic masonry fireplace look,
optional fibre firebrick panels are available at your Napo­leon / Wolf Steel Ltd. dealer . Complete inst allation and main­tenance instructions are included with the kit.

LOG PLACEMENT

TM

PHAZER

leon Fireplaces, provide a unique and realistic glowing ef­fect that is different in every installation. Take the time to
carefully position the charcoal embers for a maximum glow­ing effect.

as close as possible to the burner ports without
blocking/covering them. The left and right spacing between
the log ends and the burner ports should be equal.

YOU MA Y FIND IT EASIER TO PLACE SOME CHARCOAL

logs and charcoal embers, exclusive to Napo-

1. Place the front log onto the main burner, pushing it

EMBERS BENEA TH THE FRONT LOG NOW.

CHARCOAL EMBERS

Randomly place the embers beneath the front log, cover­ing all of the burner area beneath the hollowed out section
of the log. Place the remaining embers along the front.
Keep ember dust away from burner ports to avoid plug­ging them.

Fine dust found in bottom of bag not to be used.

PHAZERTM logs and charcoal embers glow when exposed

to direct flame. Use only certified PHAZERTM logs and char­coal embers available from your Napoleon / Wolf Steel Ltd.
dealer.

FIGURE 7

FLUSH LOUVRE KIT, GI-1L

FIGURE 6

2. Place the back log onto the step located at the
back of the combustion chamber. The notch situated at the
lower right of the back log should be centered evenly above
the pilot assembly.

3. While supporting the back log, to prevent it from
falling forward, set the three smaller logs into the pockets
and grooves of the front and back logs, respectively.
Log colours may vary . During the initial use of the fireplace,
the colours will become more uniform as colour pigments
burn in during the heat activated curing process.

POSITIONING THE LOGS IMPROP-

ERLY WILL CAUSE FLAME IMPINGE-

MENT AND CARBONING.

SIDE VIEW

UPPER

LOUVRE

LOUVRE

CLIP

LOWER LOUVRES

Secure the lower louvre
assembly to the insert,
using the 4 screws sup­plied.

UPPER LOUVRES

Insert the back edge of
the upper louvre into the
upper louvre clips.

FIGURE 8

W415-0061 / B / 01.11.05

13/8"

8

LOGO PLACEMENT

Remove the backing of the logo supplied and place on the
glass viewing area, as indicated.

LOGO

11/8"

FIGURE 9

OPERATION / MAINTENANCE

SPILL SWITCH VENTING ACTION CHECK

This is a thermally activated switch, attached to the back of
the unit and extending up into the dilution draft hood, which
senses the change in temperature and shuts down the
gas valve in the event of a severe downdraft of air or a
blocked or disconnected vent.
It acts as a safety shut-off to prevent a build up of carbon
monoxide or an explosion of unburnt gases during start
up. If the flue is blocked or has no "draw", the spill switch
will automatically shut off the supply of gas within about 5­10 minutes.

TAMPERING WITH THE SWITCH CAN RESULT IN CAR­BON MONOXIDE (CO) POISONING AND POSSIBLE
DEATH.

A CHECK FOR CORRECT VENTING ACTION MUST BE
MADE BEFORE THE INSTALLED INSER T IS LEFT WITH
THE CUSTOMER.

Test after installing the unit into a vented non-combustible
fireplace in the following manner:

1. Close all doors and windows in the room; start exhaust
fans in the home; turn fireplace blower off.

2. Set controls to "high" and light the unit.

3. Wait 5 minutes. Light a match and hold it to the spill tube

opening.

4. Venting action is satisfactory if smoke is drawn into the
spill tube. Venting action is unsatisfactory if the flame and
smoke are not drawn into the tube.

5. If venting action is unsatisfactory , turn the unit of f, wait 10
minutes and try again. If the smoke or flame is still not
drawn into the spill tube, turn the unit off and check for vent
blockage or restriction. If necessary, consult with a quali­fied air quality specialist.

FIGURE 10

When lit for the first time, the fireplace will emit a slight
odour for a few hours. This is a normal temporary condi­tion caused by the curing of the logs and the "burn-in" of
internal paints and lubricants used in the manufacturing
process and will not occur again. Simply open a window
to sufficiently ventilate the room.

W415-0061 / B / 01.11.05

After extended periods of non-operation such as follow­ing a vacation or a warm weather season, the fireplace
may emit a slight odour for a few hours. This is caused
by dust particles in the heat exchanger burning off. Open
a window to sufficiently ventilate the room.

FOR YOUR SAFETY READ BEFORE LIGHTING:

A This fireplace has a pilot which must be lit by hand

while following these instructions exactly.

B Before lighting, smell all around the fireplace area for

gas and next to the floor because some gas is heavier
than air and will settle on the floor.

C Use only your hand to push in or turn the gas control

knob. Never use tools. If the knob will not push in or

WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone
in your building.

LIGHTING INSTRUCTIONS

1.Stop! Read all the safety information above. When light-

ing and re-lighting, the gas knob cannot be turned from
"pilot" to "off" unless the knob is depressed.

2.Turn off all electrical power to the stove.

3.Turn the gas knob

4.Wait 5 minutes for any gas in the combustion chamber

to escape. Continue to the next step if you do NOT smell
any gas. If you smell gas, STOP! and follow the instruc­tions in "What to do if You Smell Gas" listed above.

5.If the unit is equipped with a flame adjustment valve,

turn

6.Locate the pilot situated in front of the rear log.

7.Turn the gas knob counter-clockwise to "pilot"

position.

clockwise to off.

clockwise to off.

turn by hand, do not try to repair it. Call a qualified ser­vice technician. Force or attempted repair may result in
a fire or explosion.

D Do not use this fireplace if any part has been under

water. Immediately call a qualified service technician
to inspect the unit and replace any part of the control
system and any gas control touched by water.

• Immediately call your gas supplier from a neighbour's
phone. Follow the gas supplier's instructions.

• If you cannot reach your gas supplier, call the fire de­partment.

8.Depress and hold the gas knob while lighting the pilot
with the push button ignitor. Keep the knob fully depressed
for one (1) minute, then release. If the pilot does not con­tinue to burn, repeat steps 3 through 7.

9.With the pilot lit, turn the gas knob counter-clock­wise

10.If your insert is equipped with a flame adjustment valve,
push and turn the knob to "high".

11.If your insert is equipped with a remote "on-off" switch,
the main burner may not come on when you turn the gas
valve to "on" or "high". The remote switch must be in the

"on" position as well to ignite the main burner.

12.Turn on all electrical power to the insert.

to "on" position.

9

TO TURN OFF GAS

1.Turn off all electrical power to the unit if service is to be
performed.

MAINTENANCE

TURN OFF THE GAS AND ELECTRICAL POWER

BEFORE SERVICING THE FIREPLACE.

CAUTION: Label all wires prior to disconnection when ser­vicing controls. Wiring errors can cause improper and dan­gerous operation. Verify proper operation after servicing.
This insert and its venting system should be inspected
before use and at least annually by a qualified service per­son. The fireplace area must be kept clear and free of com­bustible materials, gasoline or other flammable vapours
and liquids. The flow of combustion and ventilation air must
not be obstructed.

1. In order to properly clean the burner and pilot assembly,
remove the logs to expose both assemblies.

2. Keep the control compartment, logs, burner, air shutter
opening and the area surrounding the logs clean by vacu­uming or brushing, at least once a year.

2.Push in gas control knob slightly and turn clock-
wise to off. DO NOT FORCE.

3. Check to see that all burner ports are burning. Clean out

any of the ports which may not be burning or are not burn­ing properly.

4. Check to see that the pilot flame is large enough to

engulf the thermopile on one leg and reaches toward the
burner on the other leg.

5. Replace the cleaned logs.

6. Check to see that the main burner ignites completely on

all openings when the gas knob for the burner is turned
on. A 5 to 10 second total light-up period is satisfactory. If
ignition takes longer, consult your Napoleon dealer / dis­tributor.

7. Check that the door gasketing is not broken or missing.

Replace if necessary.

W415-0061 / B / 01.11.05

10

BLOWER SYSTEM

The Napoleon gas fireplace insert comes standard with a
blower, a heat sensor, variable on/off speed control and a
power cord. Because the blower is thermally activated,
when turned on, it will automatically start approximately 15
minutes after lighting the fireplace and will run for approxi­mately 30 minutes after the fireplace has been turned off.
Use of the fan increases the output of heat. Air, drawn in
through the lower louvre access door, is driven up the back
of the firebox, and exhausted as hot air between the upper
louvres.

FIGURE 11

Drywall dust will penetrate into blower bearings causing
irrepairable damage and must be prevented from coming
into contact with the blower or its compartment.
Any damage resulting from this condition is not covered
by the warranty policy.

BLOWER REPLACEMENT INSTRUCTIONS

• Turn off the gas and electric power to the unit.

• Remove the upper glass bracket. Loosen the lower glass
bracket and remove the glass.

• Remove the logs.

• Remove the burner assembly.

• Remove the eight screws holding the access door in
place on the control assembly (located at the back of the
burner support).

• Remove the four screws holding the blower duct and
slide it forward from beneath the burner support.

• Disconnect the electrical connectors at the blower.

• Remove the blower.

FIGURE 12

ADJUSTMENTS

PILOT BURNER ADJUSTMENT VENTURI ADJUSTMENT

1. Remove the pilot adjustment cap.

2. Adjust the pilot screw to provide properly sized flame.

3. Replace the adjustment cap.

PILOT SCREW

FIGURE 12

FIGURE 13

Natural gas models have air shutters set at 1/16 (.063")
inch open. Propane gas models have air shutters set at 3/
16 (.188) inch open. Closing the air shutter will cause a
more yellow flame, but can lead to carboning. Opening the
air shutter will cause a more blue flame, but can cause
flame lifting from the burner ports. The flame may not ap­pear yellow immediately; allow 15 to 30 minutes for the
final flame colour to be established.

AIR SHUTTER ADJUSTMENT MUST ONL Y BE DONE BY A

QUALIFIED GAS INST ALLER!

FIGURE 14

W415-0061 / B / 01.11.05

REPLACEMENTS

Contact your dealer for questions concerning prices and
availability of replacement parts. Normally all parts can be
ordered through your Napoleon dealer or distributor.

FORFOR

WARRANTYWARRANTY

FOR

WARRANTY

FORFOR

WARRANTYWARRANTY

ORIGINALORIGINAL

THETHE

ORIGINAL

THE

ORIGINALORIGINAL

THETHE

* IDENTIFIES ITEMS WHICH ARE NOT ILLUSTRATED. FOR

FURTHER
DEALER

.

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REPL

REPLREPL

INVOICEINVOICE

INVOICE

INVOICEINVOICE

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A

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CLAIMCLAIM

CLAIM

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PHOPHO

PHO

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INFORMATION, CONTACT YOUR NAPOLEON

REPLACEMENT PARTS ACCESSORIES

11

When ordering replacement parts always give the follow­ing information:

1. MODEL & SERIAL NUMBER OF FIREPLACE

2. INSTALLATION DATE OF FIREPLACE

3. PART NUMBER

4. DESCRIPTION OF PART

5. FINISH

# PART # DESCRIPTION

1 GL-610 LOG SET ASSEMBLY C/W CHARCOAL EMBERS
2 W135-0007 BACK LOG
3 W135-0052 FRONT LOG
4 W135-0015 RIGHT LOG
5 W135-0016 LEFT LOG
6 W135-0009 CENTER LOG
7* W550-0001 CHARCOAL EMBERS
8* W385-0245 NAPOLEON LOGO
9 W725-0036 NATURAL GAS VALVE - REMOTE RBT SHAW
9 W725-0037 PROPANE GAS VALVE - REMOTE RBT SHAW
10 W100-0058 PROPANE GAS PILOT ASSEMBL Y
10 W100-0057 NATURAL GAS PILOT ASSEMBLY
11 W455-0025 #18 NATURAL GAS PILOT INJECTOR
11 W455-0084 #10 PROP ANE GAS PILOT INJECTOR
12 W357-0001 PIEZO IGNITER - CHANNEL
13 W680-0004 THERMOPILE
14 W010-0364 BURNER ASSEMBLY
15 W455-0017 #42 DMS NATURAL GAS BURNER ORIFICE
15 W455-0003 #54 DMS PROPANE GAS BURNER ORIFICE
16 W010-0440 DOOR GLASS W/ TOP GASKET
17* W562-0012 GLASS GASKET (2 PC - SIDE)
18* W562-0011 GLASS GASKET (TOP)
19* W690-0002 THERMAL SENSING SWITCH
20 GZ-552 REPLACEMENT BLOWER
21 KB35 VARIABLE SPEED SWITCH C/W KNOB
22* W080-0062 UPPER GLASS BRACKET
23* W080-0079 LOWER GLASS BRACKET
24* W660-0009 BURNER ON/OFF SWITCH
25* W660-0006 SPILL SWITCH

# PART # DESCRIPTION

FOR OPENINGS SMALLER THAN 27" X 42":

26 GI-900B6 DELUXE 6" FLASHING KIT - POLISHED BRASS
26 GI-900AB6 DELUXE 6" FLASHING KIT - ANTIQUE BRASS
26 GI-900K6 DELUXE 6" FLASHING KIT - BLACK
26 GI-900SS6 DELUXE 6" FLASHING KIT - STAINLESS STEEL
26 GI-909S6 DELUXE 6" PORCELAIN FLASHING KIT - ALMOND
26 GI-909K6 DELUXE 6" PORCELAIN FLASHING KIT - BLACK
26 GI-909F6 DELUXE 6" PORCELAIN FLASHING KIT - GREEN

FOR OPENINGS SMALLER THAN 30" X 48":

26 GI-900B9 DELUXE 9" FLASHING KIT - POLISHED BRASS
26 GI-900AB9 DELUXE 9" FLASHING KIT - ANTIQUE BRASS
26 GI-900K9 DELUXE 9" FLASHING KIT - BLACK
26 GI-900SS9 DELUXE 9" FLASHING KIT - STAINLESS STEEL
26 GI-909S9 DELUXE 9" PORCELAIN FLASHING KIT - ALMOND
26 GI-909K9 DELUXE 9" PORCELAIN FLASHING KIT - BLACK
26 GI-909F9 DELUXE 9" PORCELAIN FLASHING KIT - GREEN

FOR OPENINGS SMALLER THAT 28" X 47":

27 GI-93K BASIC FLASHING KIT - BLACK
27 GI-93PB BASIC FLASHING KIT - POLISHED BRASS
28* GI-92PB 2" TRIM FOR GI-93K

FOR OPENINGS SMALLER THAN 26" X 42":

27 GI-63K BASIC FLASHING KIT ­27 GI-63PB BASIC FLASHING KIT - POLISHED BRASS
27 GI-63AB BASIC FLASHING KIT - ANTIQUE BRASS
28* GI-2PB 2" TRIM FOR GI-63K

PER-TRM GOLD ACRYLIC TRIM
29* W470-0002 ENAMEL TOUCH UP AND BRUSH (
30* W690-0001 MILLIVOLT THERMOST AT
31* W660-0011 HANDHELD REMOTE WITH DIGITAL READOUT / THERMOST A TIC
32* GD660 WALL SWITCH & 20FT WIRE
33 GI-777KT DECORATIVE BRICK PANELS
34 GI-787KT DECORATIVE BRICK PANEL FOR BAY DOOR
35 GIBS BAY SCREEN
36 GIBG BAY GLASS
37 GI360B-KT BAY DOOR ASSEMBLY
38 GI-LB36G BAY WINDOW LOUVRES - GOLD
38 GI-LB36PB BAY WINDOW LOUVRES - POLISHED BRASS
38 GI-LB36AB BAY WINDOW LOUVRES - ANTIQUE BRASS
38 GI-LB36K BAY WINDOW LOUVRES - BLACK
38 GI-LB36SS BAY WINDOW LOUVRES - STAINLESS STEEL
39 GI-1LG GOLD PLATED LOUVRES UPPER & LOWER
39 GI-1LK FLUSH LOUVRES & DOOR TRIM - BLACK
39 GI-1LPB FLUSH LOUVRES & DOOR TRIM - POLISHED BRASS
39 GI-1LAB FLUSH LOUVRES & DOOR TRIM - ANTIQUE BRASS
39 GI-1LSS FLUSH LOUVRES & DOOR TRIM - STAINLESS STEEL
40* W175-0172 NG T O L P CONVERSION KIT
40* W175-0191 LP T O N G CONVERSION KIT

BLACK

SPECIFY COLOUR)

W415-0061 / B / 01.11.05

12

W415-0061 / B / 01.11.05

TROUBLE SHOOTING GUIDE

B

EFORE ATTEMPTING TO TROUBLESHOOT, PURGE YOUR UNIT AND INITIALLY LIGHT THE PILOT AND THE MAIN BURNER WITH THE GLASS DOOR REMOVED

SYMPTOM PROBLEM TEST SOLUTION

13

.

Pilot goes out when
the gas knob is re­leased.

Pilot will not light. - check that the wire is connected to the push button ignitor.

System is not correctly purged.
Out of propane gas.

Pilot flame is not large enough
Pilot flame is not engulfing the

thermopile.
Thermopile shorting.

Faulty thermopile.
Faulty valve. - replace.

No spark at pilot burner

Spark gap is incorrect

No gas at the pilot burner

Out of propane gas

- purge the gas line with the glass door removed.

- fill the tank.

- turn up the pilot flame.

- gently twist the pilot head to improve the flame pattern
around the thermopile.

- clean thermopile and valve connection.

- check that thermopile insulation is not frayed and ground­ing out on the housing or the burner support.

- replace thermopile.

- replace valve.

- replace.

- check if the push button ignitor needs tightening.

- replace pilot assembly if the wire insulation is broken or
frayed.

- replace pilot assembly if the ceramic insulator is cracked
or broken.

- replace the push button ignitor.

- spark gap should be 1/16" to 1/8" from the electrode tip
and the pilot burner. Light the pilot with a match and adjust
the electrode tip to the required spark gap and proper loca­tion.

- check that the manual valve is turned on.

- check the pilot orifice for blockage.

- replace the valve.

- call the gas distributor.

- fill the tank.

Pilot goes out while
standing; Main
burner is in 'OFF' po­sition.

Pilot burning; no gas
to main burner; gas
knob is on; wall
switch is on.

Main burner flame is
a blue, lazy, transpar­ent flame.

Gas piping is undersized.

Wall switch is defective

Wall switch wiring is defective.

Main burner orifice is plugged.

Remote gas valve operator is
defective.

Insufficient secondary air.

Downdraft or blockage in chim­ney.

- turn on all gas appliances and see if pilot flame flutters,
diminishes or extinguishes, especially when main burners
ignite. Monitor supply pressure.

- check if supply piping size is to code. Correct all under­sized piping.

- connect a jumper wire across the wall switch terminals; if
the main burner lights, replace the wall switch.

- disconnect the switch wires from the valve & connect a
jumper wire across terminals 1 and 3; if the main burner
lights, check the wires for defects and/or replace wires.

- remove stoppage in orifice.

- connect a jumper wire across terminals 1 and 3; if main
burner does not light, replace gas valve.

- increase fresh air supply (open door, window, add make-up
air supply)

- remove blockage.

- check that chimney is installed to building codes (3ft above
highest roof line or 2ft higher than any portion of a building
within a horizontal radius of 10ft of the chimney.)

W415-0061 / B / 01.11.05

14

SYMPTOM PROBLEM TEST SOLUTION

Main burner goes out;
pilot goes out.

Main burner goes out;
pilot stays on.

Carbon is being de­posited on glass,
logs or combustion
chamber surfaces.

Refer to "Main burner goes out; pilot stays on"
Chimney down-drafting

Chimney is blocked

Liner disconnected from insert.

Faulty spill switch.

Pilot flame is not large enough
or not engulfing the thermopile.

Thermopile shorting.

Air shutter has become blocked

Flame is impinging on the logs
or combustion chamber.

- wait ten minutes. Shut off all exhaust fans in the house (ie:
kitchen and bathrooms), furnace, and clothes dryer. Open
windows and/or doors. Start fireplace and monitor its opera­tion.
Close doors and windows and start appliances as before;
room is in negative pressure; increase fresh air supply.

- check for chimney blockage.

- re-attach liner.

- replace.

- turn on pilot flame. Gently twist the pilot head to improve
the flame pattern aroung the thermopile.

- clean thermopile and thermopile connection to valve.

- ensure air shutter opening is free of lint or other obstruc­tions.

- check that the logs are correctly positioned.

- open air shutter to increase the primary air.

- check the input rate: check the manifold pressure and orifice
size as specified by the rating plate values.

- check that the door gasketing is not broken or missing and
that the seal is tight.

- check that both 4" and 7" vent liners are free of holes and well
sealed at all joints.

- check that minimum rise per foor has been adhered to for
any horizontal venting.

Remote wall switch
is in off position;
main burner comes
on when gas knob is
turned to "ON" posi­tion.

Exhaust fumes
smelled in room,
headaches.

Carbon is being de­posited on glass, logs
or combustion cham­ber surfaces.

White / grey film
forms.

Wall switch is mounted upside
down.

Remote wall switch is grounding.

Remote wall switch wire is
grounding.

Faulty valve.
Fireplace is spilling.

Flame is impinging on the logs
or combustion chamber.

Sulphur from fuel is being depos­ited on glass, logs or combus­tion chamber surfaces.

- reverse.

- replace.

- check for ground (short); repair ground or replace wire.

- replace.

- check for chimney blockage.

- check that chimney is installed to building code.

- room is in negative pressure; increase fresh air supply.

- check that the logs are correctly positioned.

- open air shutter to increase the primary air.

- check the input rate: check the manifold pressure and
orifice size as specified by the rating plate values.

- clean the glass with a recommended gas fireplace glass
cleaner. DO NOT CLEAN GLASS WHEN HOT.
If deposits are not cleaned off regularly, the glass may be­come permanently marked.

W415-0061 / B / 01.11.05

15

Wolf Steel Fireplace Service History

Service Performed Special ConcernsDealer Name

Name

Service Technician

This fireplace must be serviced annually depending on usage.

Date

W415-0061 / B / 01.11.05

16

NOTES

W415-0061 / B / 01.11.05