Page 1
INSTALLER: THESE INSTRUCTIONS MUST BE CONVEYED TO AND REMAIN WITH THE HOMEOWNER.
CERTIFIED UNDER CANADIAN AND AMERICAN NATIONAL STANDARDS, CSA 2.33, ANSI Z21.88 FOR VENTED GAS FIREPLACE HEATERS
GAS-FIRED DIRECT VENT INSERT
INSTALLATION AND OPERATION INSTRUCTIONS FOR:
VENTED GAS FIREPLACE
1
NATURAL GAS MODELS
PROPANE GAS MODELS GDI-30P
/
GDI-30N
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 neighbour'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.
Wolf Steel Ltd., 24 Napoleon Rd., Barrie, ON L4M 4Y8 Canada • (705)721-1212 • fax(705)722-6031
www.napoleonfireplaces.com • ask@napoleon.on.ca
W415-0384 / D / 09.13.05
Page 2
2
TABLE of CONTENTS
Pg 2-4 INTRODUCTION
Warranty
General Instructions
General Information
Care of Glass & Plated Parts
5-6 INSTALLATION
Insert Vent Connection
Chimney Connection
Gas Pipe Installation
Wall Switch / Thermostat
7-8 FINISHING
Log Placement
Door Operation
Mantle Clearances
PLEASE RETAIN THIS MANUAL FOR FUTURE REFERENCE
Pg 8-9 OPERATION / MAINTENANCE
Operating Instructions
Maintenance
10 BLOWER REPLACEMENT
10 ADJUSTMENTS
Pilot Burner Adjustment
Venturi Adjustments
11-12 REPLACEMENTS
Ordering Replacement Parts
Replacement Parts
Terminal Kits
Accessories
13-14 TROUBLE SHOOTING GUIDE
15 SERVICE HISTORY
WARNING
• The fireplace insert is a vented gas-fired heater. Do not burn wood or other materials in this fireplace insert.
• Adults and especially children should be alerted to the hazards of high surface temperatures and should stay
away to avoid burns or clothing ignition. Keep young children and animals away when the fireplace insert is
hot.
• Due to high temperatures, the fireplace insert 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 insert.
• Any safety screen or guard removed for servicing must be replaced prior to operating the fireplace insert.
• It is imperative that the control compartments, burners and circulating blower and its passageway in the fire
place insert and venting system are kept clean. The fireplace insert 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 insert area must be kept clear and free from
combustible materials, gasoline and other flammable vapours and liquids.
• Under no circumstances should this fireplace insert be modified.
• This fireplace insert must not be connected to a chimney flue pipe serving a separate solid fuel burning
appliance.
• Do not use this fireplace insert if any part has been under water. Immediately call a qualified service technician
to inspect the fireplace insert and to replace any part of the control system and any gas control which has been
under water.
• Do not operate the fireplace insert with the glass door opened, 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 insert glass door.
• This fireplace uses and requires a fast acting thermocouple. Replace only with a fast acting thermocouple sup
plied by Wolf Steel Ltd.
NOTE: changes, other than editorial, are denoted by a vertical line in the margin.
W415-0384 / D / 09.13.05
Page 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
3
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
warranted against defects for as long as you own the fireplace. This covers: combustionwarranted against defects for as long as you own the fireplace. This covers: combustion
warranted against defects for as long as you own the fireplace. This covers: combustion
warranted against defects for as long as you own the fireplace. This covers: combustionwarranted against defects for as long as you own the fireplace. This covers: combustion
chamber, heat exchanger, stainless steel burner, phazer™ logs and embers, ceramic glasschamber, heat exchanger, stainless steel burner, phazer™ logs and embers, ceramic glass
chamber, heat exchanger, stainless steel burner, phazer™ logs and embers, ceramic glass
chamber, heat exchanger, stainless steel burner, phazer™ logs and embers, ceramic glasschamber, heat exchanger, stainless steel burner, phazer™ logs and embers, ceramic glass
(thermal breakage only), gold plated parts against tarnishing, porcelainized enamelled com-(thermal breakage only), gold plated parts against tarnishing, porcelainized enamelled com-
(thermal breakage only), gold plated parts against tarnishing, porcelainized enamelled com-
(thermal breakage only), gold plated parts against tarnishing, porcelainized enamelled com-(thermal breakage only), gold plated parts against tarnishing, porcelainized enamelled components and aluminum extrusion trims.ponents and aluminum extrusion trims.
ponents and aluminum extrusion trims.
ponents and aluminum extrusion trims.ponents and aluminum 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
of the limited warranty.of the limited warranty.
of the limited warranty.
of the limited warranty.of 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 costswork, however, requires the prior approval of an authorized company official. Labour costs
work, however, requires the prior approval of an authorized company official. Labour costs
work, however, requires the prior approval of an authorized company official. Labour costswork, however, requires the prior approval of an authorized company official. Labour costs
to the account of to the account of
to the account of
to the account of to the account of
work must be done through an authorized work must be done through an authorized
work must be done through an authorized
work must be done through an authorized work must be done through an authorized
NAPOLEONNAPOLEON
NAPOLEON
NAPOLEONNAPOLEON
NAPOLEONNAPOLEON
NAPOLEON
NAPOLEONNAPOLEON
will provide replacement parts free of charge during the first yearwill provide replacement parts free of charge during the first year
will provide replacement parts free of charge during the first year
will provide replacement parts free of charge during the first yearwill provide replacement parts free of charge during the first year
are based on a predetermined rate schedule and any repair are based on a predetermined rate schedule and any repair
are based on a predetermined rate schedule and any repair
are based on a predetermined rate schedule and any repair are based on a predetermined rate schedule and any repair
NAPOLEONNAPOLEON
NAPOLEON
NAPOLEONNAPOLEON
NAPOLEONNAPOLEON
NAPOLEON
NAPOLEONNAPOLEON
dealer. dealer.
dealer.
dealer. dealer.
gas fireplace are gas fireplace are
gas fireplace are
gas fireplace are gas fireplace are
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 SPECIFICATIONS AND DESIGNS ARE SUBJECT TO CHANGE WITHOUT PRIOR NOTICE DUE TO ON-GOING PRODUCT IMPROVEMENTS. NAPOLEON® IS A REGISTERED
TRADEMARK OF WOLF STEEL LTD. PATENTS U.S. 5.303.693.801 - CAN. 2.073.411, 2.082.915 & DES 417,497(12.07.1999). © WOLF STEEL LTD.
W415-0384 / D / 09.13.05
Page 4
4
GENERAL INSTRUCTIONS
THIS GAS FIREPLACE INSERT SHOULD BE INSTALLED
AND SERVICED BY A QUALIFIED INSTALLER to con-
form 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.
• A carbon monoxide detector is required in all rooms containing
gas fired appliances.
• 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 CAN1B149 Installation Code in Canada or to the National Fuel
Gas Code, ANSI Z223.1, and NFPA 54 in the United
States. Mobile home installation must conform with local
codes or in the absence of local codes, install to the
current standard for gas equipped mobile housing CAN/
CSA Z240 MH Series in Canada or ANSI Z223.1 and NFPA
54 in the United States.
Purge all gas lines with the glass door of the fireplace
insert opened. Assure that a continuous gas flow is at
the burner before closing the door.
Under extreme vent configurations, allow several minutes (5-15) for the flame to stabilize after ignition.
Objects placed in front of the fireplace must be kept a
minimum of 48" away from the front face of the unit.
The fireplace insert 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 insert 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 fireplace insert.
The fireplace insert 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 recepta-
GENERAL INFORMATION
cle. The grounding prong must not be removed from the
cord plug.
FOR YOUR SATISFACTION, THIS FIREPLACE INSERT
HAS BEEN TEST-FIRED TO ASSURE ITS OPERATION
AND QUALITY!
Minimum inlet gas supply pressure is 4.5 inches water
column for natural gas and 11 inches water column for
propane. 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. When the fireplace is installed at elevations above 4,500ft, and in the absence 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.
Expansion / contraction noises during heating up and cooling down cycles are normal and to be expected.
Maximum input is 24,500 BTU/hr for natural gas and propane. Maximum output for natural gas and propane is
20,825 BTU/hr at an efficiency of 85% with the fan on. The
maximum A.F.U.E. (annual fuel utilization efficiency) rating
is 82%. This fireplace insert is not approved for closet or
recessed installations. It is approved for bathroom, bedroom and bed-sitting room installations and is suitable for
mobile homes. The natural gas model is suitable for installation in a mobile home that is permanently positioned
on its site and fuelled with natural gas.
This insert must be recessed into a vented noncombustible wood-burning fireplace (prefabricated or masonry)
only. The minimum fireplace opening size in which the
heater is to be installed is:
HEIGHT 21.75" WIDTH 28" DEPTH 18"
The minimum allowable chimney flue size is 6" round.
The minimum distance, from the bottom of a combustible
mantle projecting 3" maximum from the wall to the top of
the louvre opening, is 12". A non-combustible hearth must
CARE OF GLASS, AND PLATED PARTS
protrude a minimum of 18" from the unit unless the insert
is elevated a minimum of 12" above the combustible flooring.
Do not use abrasive cleaners to clean these 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
W415-0384 / D / 09.13.05
Page 5
INSTALLATION
5
WHEN HOT! If the glass is not kept clean permanent
discolouration and / or blemishes may result.
Provide adequate ventilation air.
Provide adequate accessibility clearance for
servicing and operating the fireplace insert.
Never obstruct the front opening of the fireplace insert.
Objects placed in front of the fireplace must
be kept a minimum of 48" away from the
front face of the unit.
FIGURE 1 a-c
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.
W415-0384 / D / 09.13.05
Page 6
6
INSERT VENT CONNECTION
Move the insert close to its final position inside the woodburning fireplace. This unit is equipped with 4 levelling
screws located in the four inside corners beneath the log
support. Level using the levelling screws to eliminate rocking or excessive noise when the fan is in operation. Once
the unit is level, move it partially into place within the fireplace to allow for all connections to be made. It is not prac-
tical to level the insert once it has been installed. Determine the required depth prior to installing the unit and adjust the four levelling screws accordingly.
CHIMNEY CONNECTION
Chimney installation must conform to both national and
local code requirements. The chimney must be lined with
one 2" or 3" diameter liner for intake and one 3" diameter
liner for exhaust. The minimum and maximum vent
lengths are 10 and 35 feet respectively. Recommended
Napoleon kits come in 3 lengths:
1-2" & 1-3" DOUBLE PLY ALUMINUM LINER-INLET AND EXHAUST &
2-3" TO 2" REDUCER:
GDI-2320KT VENT KIT 20FT
GDI-2325KT VENT KIT 25FT
GDI-2335KT VENT KIT 35FT
2-3" DOUBLE PLY ALUMINUM LINER-INLET AND EXHAUST:
GDI-320KT VENT KIT 20FT
GDI-325KT VENT KIT 25 FT
GDI-335KT VENT KIT 35 FT
While the liners must be continuous from the fireplace to
the chimney cap, to achieve the needed length, they may
be coupled, using an approved coupler.
We recommend that exhaust vents that pass through
unheated spaces, such as a garage or attic, be
wrapped in a protective sleeve to minimize condensation and reverse flow symptoms. See Trouble Shooting
for details.
This unit is approved for use with a 2" liner for air intake
and a 3" liner for exhaust. For best performance, however, it is recommended to use two 3" liners.
If a 2" liner is used for the intake, it may be necessary to
adjust the primary air shutter.
1. OUTSIDE: Slip the
one end of a liner a minimum of 2" over the
sleeve of the air terminal.
Secure using 3 screws.
Then seal the joint and
screw heads with high
temperature sealant. Repeat with the other liner.
FIGURE 2
3. INSIDE: Remove the securing screw from the front of the
vent mounting plate. Pull the vent mounting plate only, back
into the track, to the front stop. Start the slider back into
position. Re-secure the screw. The insert may now be
pushed into its final position inside the woodburning fireplace, and the screw tightened until the slider has been
pulled tight to the front stop.
4. Route the flex liners through the slider. Attach and secure
the liners to the vent mounting plate using the same procedure as before, ensuring that the marked exhaust liner is
attached to the exhaust collar.
FIGURE 3
GAS INSTALLATION
Install suitable supply piping connection to a flex connector
(as per local gas codes).
FIGURE 4
WALL SWITCH / THERMOSTAT
NOTE: We recommend that the other end of the exhaust
liner be marked to eliminate the exhaust liner being connected to the intake collar at the unit.
2. Gently stretch the liners to the required lengths and in-
sert into the chimney. Trim and fit the flashing plate to suit
the chimney termination. Place the air terminal onto the top
of the chimney. Make weather tight by sealing with caulking
(not supplied). Fasten to the chimney with screws and plugs
(not supplied).
W415-0384 / D / 09.13.05
For ease of accessibility, an optional remote wall switch
or millivolt thermostat may be installed in a convenient
location. Route 2-strand solid core millivolt wire from
the gas fireplace insert to the wall switch / millivolt thermostat. The recommended maximum lead length depends on the wire size: WIRE SIZE MAX. LENGTH
14gauge 100 feet
16gauge 60 feet
18gauge 40 feet
Do not connect either the wall switch, thermostat or gas valve to electricity (110 VOLTS).
Page 7
FINISHING
LOG PLACEMENT
PHAZERTM logs and glowing embers exclusive to Napoleon Fire-
places, provide a unique and realistic glowing effect that is
different in every installation. Take the time to carefully position the glowing embers for a maximum glowing effect.
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.
FIGURE 5a-d
7
3. Place the bottom of the left crossover log (#4) against
the left firebox side and pulled forward to the grate.
The top of the log should rest in the pocket on the back log.
4. Position the notch located on the end of the center log
(#5) against the middle grate post with the other end of the
log resting in the pocket of the left crossover log.
1. Place the back log (#1)
onto the log support tray and
behind the tabs. The tabs
maintain an air space between the log and the burner
to facilitate combustion air
flow. Ensure that the back
of the log rests against the
bracket on the back wall of the firebox.
2. Move the two small logs (#2 & #3) into position, lining
up the studs located on the burner with the holes on the
bottom of the logs. Ensure that the small logs sit flat on the
burner.
TABS
5. Place the bottom of the right crossover log (#6) against
the right firebox side and pulled forward to the grate. The
top of the log should rest in the pocket provided on the
center log (#5).
OPTIONAL CHARCOAL EMBERS
Randomly place the charcoal embers along the front and
sides of the log support tray in a realistic manner. Fine
dust found in the bottom of the bag should not be used.
GLOWING EMBERS
Tear the embers into pieces and place along the front row
of ports covering all of the burner area in front of the small
logs (#2 & #3). Care should be taken to shred the embers
into thin, small irregular pieces as only the exposed edges
of the fibre hairs will glow. The ember material will only
glow when exposed to direct flame; however, care
should be taken to not block the burner ports.
Blocked burner ports can cause an incorrect flame pattern,
carbon deposits and delayed ignition. PHAZERTM logs glow
when exposed to direct flame. Use only certified "glowing
embers" and PHAZERTM logs available from your Napoleon dealer.
W415-0384 / D / 09.13.05
Page 8
8
DOOR OPERATION
The upper louvres must be removed to allow the door to be
opened or closed. Release the top and bottom door latches,
located at the right side of the door.
FIGURE 6
DOOR LATCH
MANTLE CLEARANCE
This can vary according to the mantle depth. Use the graph
to help evaluate the clearance needed.
FIGURE 7
H
M
E
A
I
N
G
T
OPERATION / MAINTENANCE
OPERATING INSTRUCTIONS
Purge all gas lines with the glass door open. Assure
that a continuous gas flow is at the burner before closing the door. Allow several minutes (5-15) for the flame
to stabilize after ignition.
Do not operate the main burner of the insert with the door opened.
H
L
T
E
MANTLE WIDTH
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 "burn-in" of paints and lubricants
used in the manufacturing process and will not occur
again. Simply open a window to sufficiently ventilate
the room. 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.
PURGE THE GAS LINE WITH THE GLASS DOOR OPEN.
W415-0384 / D / 09.13.05
Page 9
9
FOR YOUR SAFETY READ BEFORE LIGHTING:
A. This fireplace is equipped with a pilot which must be lit
by hand. While following these instructions exactly.
B. Before operating 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 turn the gas control knob. Never
use tools. If the knob will not 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 fireplace and replace any part of the control system
and any gas control which has been under water.
LIGHTING INSTRUCTIONS
When lighting and re-lighting, the gas knob cannot be turned
from pilot to off unless the knob is depressed slightly.
1. Stop! Read the above safety information on this label.
2. Turn off all electric power to the fireplace.
3. Turn the gas knob clockwise to off.
4. Wait five (5) minutes to clear out any gas. If you smell gas
including near the floor. Stop! Follow "B" in the above safety
information on this label. If you don't smell gas go the next step.
5. Find pilot located in front of back log.
6. Turn gas knob counter-clockwise to pilot.
WHAT TO DO IF YOU SMELL GAS:
• Turn off all gas to the fireplace.
• Open windows.
• Do not try to light any appliance.
• Do not touch any electric switch; do not use any phone in
your building.
• 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.
L
O
F
O
I
F
H
N
O
P
T
L
I
O
FLAME
P
I
L
O
T
ADJUSTMENT
KNOB
PILOT
ON/OFF
KNOB
7. Depress slightly and hold gas knob while lighting the pilot
with the push button ignitor. Keep knob depressed for one
minute, then release. If pilot does not continue to burn, repeat steps 3 through 7.
8. With pilot lit, depress and turn gas knob counter-clockwise to on.
9. If equipped with flame adjustment valve, push and turn
knob to high.
10. If equipped with remote on-off switch/thermostat, main
burner may not come on when you turn valve to on. Remote
switch must be in the on position to ignite burner.
11. Turn on all electric power to the fireplace.
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 UNPLUG ELECTRICAL
POWER BEFORE SERVICING THE FIREPLACE
INSERT!
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 exposing both assemblies.
2. Push in gas control knob slightly and turn clockwise to
off. Do not force.
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.
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 thermocouple 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 5-10 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.
Remove the pilot screw cap. Adjust the pilot screw to provide properly sized flame. Turn in a clockwise direction to
reduce the gas flow. Replace the pilot screw cap.
Natural gas has the air shutter set at
1
/4" opening; pro-
pane has the air shutter set at 3/8" opening. Closing the air
W415-0384 / D / 09.13.05
Page 10
10
BLOWER REPLACEMENT INSTALLATION
b
l
a
c
k
d
e
r
1. Turn off the electrical power and the gas
w
h
i
t
e
supply to the fireplace
insert.
2. Open the glass door
and remove the logs
FIGURE 8
and fibre bricks, if installed.
FIGURE 9
BLOWER ACCESS COVER
3. Remove the blower access cover held on with 4 screws.
FIGURE 10
BLOWER ACCESS COVER REMOVED
MOUNTING
PLATE
4. Remove the blower mounting plate with the blower
attached.
NOTE: Check the blower gasket for damage. Replace if
FIGURE 11
THERMODISC / BRACKET ASSEMBLY
damaged.
5. Disconnect the two blower wires. Remove the blower
from the mounting plate and replace.
For thermodisc replacement: Remove the mounting
bracket secured to the underside of the burner base. Remove the thermodisc from the bracket and replace.
6. Reconnect the two wires. Re-install the blower gasket.
Reattach the blower mounting plate and blower access
cover. Replace the logs. Close the fire viewing door.
7. Turn the gas supply and electricity back on.
Because the blower is thermally activated, when turned on,
it will automatically start approximately 5-15 minutes after
lighting the fireplace insert and will run for approximately
30-45 minutes after the fireplace insert has been turned
off. Use of the fan increases the output of heat.
Drywall dust will penetrate into the blower bearings causing irreparable 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.
ADJUSTMENTS
PILOT BURNER ADJUSTMENT VENTURI ADJUSTMENT
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.
L
O
F
O
F
N
O
P
L
T
I
O
P
I
L
O
T
PILOT SCREW
I
H
FIGURE 13
FIGURE 12
W415-0384 / D / 09.13.05
The flame may not appear yellow immediately; allow 15 to
30 minutes for the final flame colour to be established.
FIGURE 14
Air shutter adjustment must only be done by a qualified
gas installer!
Page 11
REPLACEMENTS
11
Contact your dealer for questions concerning prices and
availability of replacement parts. Normally all parts can be
ordered through your Napoleon dealer or distributor.
FOR WARRANTY REPLACEMENT PART S , A PHOTOCOPY OF THE
ORIGINAL
INVOICE WILL BE REQUIRED TO HONOUR THE CLAIM.
REPLACEMENT PARTS
# PART # DESCRIPTION
1 GZ552 REPLACEMENT BLOWER
2 W725-0035 NATURAL GAS VALVE
2 W725-0026 PROPANE GAS VALVE
3 W455-0019 #43 NATURAL GAS BURNER ORIFICE
3 W455-0003 #54 PROPANE GAS BURNER ORIFICE
4 W357-0001 PIEZO IGNITER
5 W680-0004 THERMOPILE
6 W680-0005 THERMOCOUPLE
7 W010-0801 NATURAL GAS PILOT ASSEMBLY
7 W010-0800 PROPANE GAS PILOT ASSEMBLY
8 W690-0002 THERMAL SENSING SWITCH
9 W660-0009 BURNER ON/OFF SWITCH
10 W135-0183 REAR LOG (#1)
11 W135-0184 LEFT MIDDLE LOG (#2)
12 W135-0185 RIGHT MIDDLE LOG (#3)
13 W135-0186 LEFT CROSSOVER LOG (#4)
14 W135-0187 MIDDLE CROSSOVER LOG (#5)
15 W135-0188 RIGHT CROSSOVER LOG (#6)
16 GL-639 LOG SET
17 W361-0016 GLOWING EMBERS
18 W010-1046 BURNER ASSEMBLY
19 W455-0070 NATURAL GAS PILOT INJECTOR
19 W455-0068 PROPANE GAS PILOT INJECTOR
20 W385-0245 NAPOLEON LOGO
21 W562-0008 GLASS GASKET
22 KB-35 VARIABLE SPEED SWITCH
23 W010-1095 GLASS
24 W010-1042 DOOR, GLASS & GASKET ASSEMBLY
W/ GASKET
TERMINAL KITS
25 GDI-223 TERMINAL
VENT KITS
1-2" & 1-3" DOUBLE PLY ALUMINUM LINER-INLET AND EXHAUST &
2-3" TO 2" REDUCER:
26 GDI-2320KT VENT KIT 20FT
26 GDI-2325KT VENT KIT 25FT
26 GDI-2335KT VENT KIT 35FT
2-3" DOUBLE PLY ALUMINUM LINER-INLET AND EXHAUST:
27 GDI-320KT VENT KIT 20FT
27 GDI-325KT VENT KIT 25 FT
27 GDI-335KT VENT KIT 35 FT
When ordering replacement parts always give the following information:
ODEL & SERIAL NUMBER OF FIREPLACE
1. M
2. INSTALLATION DATE OF FIREPLACE
3. PART NUMBER
4. DESCRIPTION OF PART
5. FINISH
ACCESSORIES:
# PART NO. DESCRIPTION
28 GI-1LK BLACK UPPER & LOWER LOUVRES
28 GI-1LPB BLACK UPPER & POLISHED BRASS LOWER LOUVRES
28 GI-1LAB BLACK UPPER & ANTIQUE BRASS LOWER LOUVRES
28 GI-1LSS BLACK UPPER & BRUSHED STAINLESS STEEL
28 GI-1LG GOLD PLATED UPPER & LOWER LOUVRES
29 GI-OIK BLACK UPPER & LOWER INSET W/ POLISHED
29 GI-OIG GOLD PLATED UPPER & LOWER INSET
30 GI30B-KT BAY FRONT COMPLETE WITH PULL SCREEN
31 GIB-1LK BLACK LOUVRES
31 GIB-1LPB POLISHED BRASS LOWER LOUVRES
31 GIB-1LAB ANTIQUE BRASS LOWER LOUVRES
31 GIB-1LSS BRUSHED STAINLESS STEEL LOWER LOUVRES
31 GIB-1LG GOLD PLATED LOWER LOUVRES
32 GIB-1OIK BLACK LOWER INSET
32 GIB-1OIG GOLD PLATED LOWER INSETS
33 GI-900K6 6" BLACK WITH MARQUIS TRIM
33 GI-900B6 6" POLISHED BRASS WITH MARQUIS TRIM
33 GI-900AB6 6" ANIQUE BRASS WITH MARQUIS TRIM
33 GI-900SS6 6" BRUSHED STAINLESS STEEL BLACK TRIM
34 GI-909S6 6" PORCELAIN ALMOND WITH MARQUIS TRIM
34 GI-909K6 6" PORCELAIN BLACK WITH MARQUIS TRIM
34 GI-909F6 6" PORCELAIN GREEN WITH MARQUIS TRIM
35 GI-900K9 9" BLACK WITH MARQUIS TRIM
35 GI-900B9 9" POLISHED BRASS WITH MARQUIS TRIM
35 GI-900AB9 9" ANTIQUE BRASS WITH MARQUIS TRIM
35 GI-900SS9 9" BRUSHED STAINLESS STEEL WITH BLACK TRIM
36 GI-909S9 9" POCELAIN ALMOND WITH MARQUIS TRIM
36 GI-909K9 9" PORCELAIN BLACK WITH MARQUIS TRIM
36 GI-909F9 9" PORCELAIN GREEN WITH MARQUIS TRIM
37 CISK CAST SURROUND PAINTED BLACK
37 CISKK CAST SURROUND PORCELAIN ENAMEL BLACK
37 CISKN CAST SURROUND PORCELAIN ENAMEL
37 CISKB CAST SURROUND PORCELAIN ENAMEL
37 CISKF CAST SURROUND PORCELAIN ENAMEL
38 W690-0001 MILLIVOLT THERMOSTAT
39 W660-0011B REMOTE CONTROL - ADVANTAGE PLUS
40 GD-660 REMOTE WALL SWITCH WITH 20" WIRE
41 W660-0026 TIMER, BATTERY OPERATED
42 ANI-K ANDIRONS - BLACK
42 ANI-G ANDIRONS - GOLD PLATED
43 GI-798KT DECORATIVE BRICK PANELS
44 GI-910K 6" BEVELLED FLASHING - BLACK
45 GI-942K TRIM FOR BEVELLED FLASHING - BLACK
45 GI-942B TRIM FOR BEVELLED FLASHING - POLISHED BRASS
46 GI-RB RISER BOX - PAINTED BLACK
47* W175-0218 CONVERSION KIT - LP-NG
47* W175-0216 CONVERSION KIT - NG-LP
LOWER LOUVRES
BRASS LOWER DOOR TRIM
MAJOLICA BROWN
MAJOLICA BLUE
MAJOLICA GREEN
W415-0384 / D / 09.13.05
Page 12
12
W415-0384 / D / 09.13.05
* WARNING: This is a fast acting thermocouple. It is an integral safety component. Replace only with
a fast acting thermocouple supplied by Wolf Steel Ltd.
Page 13
TROUBLE SHOOTING GUIDE
B
EFORE ATTEMPTING TO TROUBLESHOOT, PURGE YOUR UNIT AND INITIALLY LIGHT THE PILOT AND THE MAIN BURNER WITH THE GLASS DOOR OPEN
SYMPTOM PROBLEM TEST SOLUTION
13
.
Pilot will not light.
Pilot goes out when
the gas knob is released.
No spark at pilot burner
Spark gap is incorrect
No gas at the pilot burner
Out of propane gas.
System is not correctly purged.
Out of propane gas
Pilot flame is not large enough
Pilot flame is not engulfing the
thermocouple.
Thermocouple shorting.
Faultly thermocouple.
Faulty valve.
- check if pilot can be lit by a match
- check that the wire is connected to the push button ignitor.
- check if the push button ignitor needs tightening.
- replace the push button ignitor.
- spark gap should be 0.150" to 0.175" (5/32" to 11/64" approx.)
from the electrode tip and the pilot burner.
- check that the manual valve is turned on.
- check the pilot orifice for blockage.
- replace the valve.
- call the gas distributor.
- fill the tank.
- purge the gas line with the glass door open.
- fill the tank.
- turn up the pilot flame.
- turn up pilot flame.
- replace pilot assembly.
- loosen and tighten thermocouple.
- clean thermocouple and valve connection.
- replace thermocouple.
- replace valve.
- replace.
- replace.
Pilot burning; no gas
to main burner; gas
knob is on 'HI'; wall
switch / thermostat is
on.
Pilot goes out while
standing; Main burner
is in 'OFF' position.
Main burner goes out;
pilot stays on.
Main burner orifice is plugged.
Faulty thermopile.
Faulty themostat or switch.
Faulty valve.
Gas piping is undersized.
Pilot flame is not large enough
or not engulfing the thermopile.
Thermopile shorting
Remote wall switch wire is too
long, too much resistance in
the system
Faulty thermostat or switch
- remove stoppage in orifice.
- replace.
- connect a jumper wire across the wall switch terminals; if
main burner lights, replace thermostat.
- disconnect the switch wires & connect a jumper wire across
terminals 1 & 3; if the main burner lights, check the wires for
defects and / or replace wires.
- replace.
- turn on all gas appliances and see if pilot flame flutters,
diminishes or extinguishes, especially when main burner ignites. Monitor supply pressure.
- check if supply piping size is to code. Correct all undersized
piping.
- turn up pilot flame.
- replace pilot assembly.
- clean thermopile and thermopile connection to valve.
- shorten wire to correct length or wire gauge.
- replace
W415-0384 / D / 09.13.05
Page 14
14
SYMPTOM PROBLEM TEST SOLUTION
Main burner goes out;
pilot goes out.
Exhaust fumes
smelled in room,
headaches.
Carbon is being deposited on glass,
logs or combustion
chamber surfaces.
REFER TO "MAIN BURNER GOES OUT; PILOT STAYS ON"
Vent re-circulating
Thermocouple shorting or
faulty.
Vent is reversing
Fireplace is spilling.
Air shutter has become
blocked
Flame is impinging on the
logs or combustion chamber.
- check joint seals and installation.
- loosen and tighten thermocouple
- clean thermocouple and valve connection.
- replace thermocouple.
- replace valve.
- check all venting and insert seals.
- check that door is properly sealed. If the insert is allowed to
burn with the door open when purging the unit, exhaust products
may reverse the venting action. Let the unit cool down to correct
the reversed venting action.
- check all seals.
- 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 vent liners are free of holes and well sealed at
all joints.
Main burner flame is
a blue, lazy, transparent flame.
White / grey film
forms.
Flames are very
aggressive.
Blockage in vent. - remove blockage. In really cold conditions, ice buildup may
occur on the terminal and should be removed as required.
Incorrect installation.
Sulphur from fuel is being deposited on glass, logs or combustion chamber surfaces.
Door is ajar -ensure door seal is tight.
- vent liners are reversed. Refer to Figures 2 & 3.
- check all venting and insert seals.
- 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.
W415-0384 / D / 09.13.05
Page 15
15
Service Performed Special ConcernsDealer Name
Name
Service Technician
Wolf Steel Fireplace Service History
This fireplace must be serviced annually depending on usage.
Date
W415-0384 / D / 09.13.05
Page 16
16
NOTES
W415-0384 / D / 09.13.05
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