Napoleon Grills GDI-44P User's Manual
Contents
1. 1 FIGURE17 Support and backwall ma 3 Remove the blower access door held on with D 10 screws Replace the blower access door gasket ue SWITCH Q when changing the blower SHOWN WITH LOG SUPPORT AND BACK WALL REMOVED IGURE 18b BLOWER THROUGH ACCESS DOOR 4 Disconnect the two blower wires Remove the blower bracket secured with one wing nut and lock washer For thermodisc replacement Remove the Z shaped mounting bracket secured to the firebox wall behind the left side control door Remove the thermodisc from the bracket and replace Figure 19 W415 0314 C 01 15 04 able to be positioned entirely onto the pad 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 BLOWER WIRES A THERMODISC BRACKET ASSEMBLY FIGURE 19 5 Replace the blower using the existing bracket Slide the vibration reducing pad A into the clip C and up against the threaded stud B at the other end The blower must be FIGURE 20 Slide the blower into the clip C Secure to the threaded stud using the existing lock washer and wing nut Ensure that the blower does not touch the fireplace base or the firebo2. 12 tre is out of alignment open each side and loosen the two screws at either side trim hinge Slide the trim up or down to adjust and re tighten screws There is also a very slight in out ad justment that can be made Note Since the side pan els open and close to ac cess the controls a gap is necessary at the mitre joint The top trim piece has an adjustable securing bracket which enables the trim to be secured to the firebox shell s FIGURE 13 W415 0314 C 01 15 04 8 LOG PLACEMENT PHAZER logs exclusive to Napoleon Fireplaces pro vide a unique and realistic glowing effect that is different in every installation Use only certified PHAZER logs avail able from your Napoleon Wolf Steel Ltd dealer POSITIONING THE LOGS IMPROPERLY WILL CAUSE FLAME IMPINGEMENT AND CARBONING Position the logs as shown All logs are numbered ee j a 0 es en L T A LOCATING PIN The rear log should be centred on the log support and rest against the rear wall CENTRE SUPPORT LOCATING PIN Log 3 rests against the far left grate post and onto the locating pin on the centre support Log 2 rests against the far right grate post and over the locating pin on the centre support and against the tip of log 3 NOTE Skewering log 2 onto the locating pin may be necessary Log 6 has a leg that fits into an indentation on the top of log 3 Log 4
3. and turn gas knob counter clock wise to on 10 If equipped with flame adjustment valve push and turn knob to high 11 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 12 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 2 Push in gas control knob slightly and turn clockwise to performed REAR BURNER CONROL The purpose of the rear burner is to increase heat output or BTUs of the unit and will only operate when the main burner is functioning To turn the rear burner on simply depress the burner control knob located in the valve compartment at the left hand side below the piezo igni tor and rotate the knob counter clockwise to high In order to achieve maximum turn down rate the rear burner must be turned off rear burner control knob off Do not force MAINTENANCE TURN OFF THE GAS AND UNPLUG ELECTRICAL POWER BEFORE SERVICING THE FIREPLACE INSERT CAUTION Label all wires prior to disconnection when serv icing controls Wiring errors can cause improper and dan gerous 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 per son The fireplace area must be kept clear and free of com bustible materials
4. fireplace is installed at el evations above 4 500ft and in the absence of specific rec ommendations 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 cool ing down cycles are normal and to be expected Maximum input is 40 000 BTU hr for natural gas and pro pane In order to achieve maximum turn down rate the rear burner must be turned off See Operating Instructions in the owner s manual for more information Maximum output for natural gas and propane is 27 600 BTU hr at an efficiency of 69 with the fan on 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 noncombus tible wood burning fireplace prefabricated or masonry only The minimum fireplace opening size in which the heater is to be installed is HEIGHT 21 inches WIDTH32inches DEPTH 16 inches The minimum allowable chimney flue size is 7 round The minimum distance from the bottom of a combustible mantle projecting 3 maximum from the wall to the top of the aluminium trim is 12 A hearth must protrude a mini mu
5. ney W415 0314 C 01 15 04 2 Gently stretch the liners to the required lengths and in sert into the chimney Place the terminal onto the top of the chimney cap and fit the flashing plate to suit Make weather tight by sealing with caulking not supplied and fasten to the chimney with screws and plugs not supplied 3 NOTE f there is not enough ceiling height between the fireplace and the insert to allow the flexliner connection on the top of the unit to be made proceed to step 4 If there is enough ceiling height connect the 3 stainless steel flexliner to the exhaust collar closest to the top front on the unit See figure 1c Connect the intake flexliner to the remaining rear collar Secure and seal BACK WALL Role 4 Both the log support and the back wall must be removed in order to gain access to the vent connection assembly Both the back wall and log support are detached by remov ing the 12 perimeter screws of the back wall and the 3 screws located at the back of the log support Remove the vent connection assembly NOTE The vent connection assembly collars are not spe cific until the stainless steel flexliner has been attached to one side This now designates the side as exhaust The exhaust collar must be positioned closest to the front open ing of the insert SEE FIGURE 1c Secure and seal the flexliners 5 To reinstall the vent connection assembly reach in
6. rests in the indentations on the tops of logs 2 and 1 W415 0314 C 01 15 04 Logs 5 and 7 fit onto the indentations of the lower logs GLOWING EMBERS Tear the embers into pieces and place along the front row of ports covering all of the burner area in front of logs 2 amp 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 PHAZER logs glow when exposed to direct flame Use only certified glowing embers and PHAZER logs available from your Napo leon dealer DOOR INSTALLATION Place the door into the two lower door brackets and secure C C 3 U U WU f ne Ie FIGURE 15 LOWER DOOR BRACKETS MANTLE CLEARANCE This can vary according to the mantle depth Use the graph to help evaluate the clearance needed 6 MANTLE a Le f ca 14 cao He gt FIGURE16 NI TG LH ET 5 a G MANTLE WIDTH OPERATION MAINTENANCE Purge all gas lines with the glass door open Assure that a continuous gas flow is at the burner before clos ing the
7. 100 DOOR FRAME 24 WO010 0889 DOOR c w GLASS 25 W290 0063 BLOWER ACCESS GASKET 26 W430 0011 MAGNETIC CLOSURE 27 W660 0009 ON OFF SWITCH 28 W690 0002 THERMODISC 29 W380 0002 VARIABLE SPEED SWITCH KNOB 30 W660 0019 VARIABLE SPEED SWITCH 31 W450 0023 PAL NUT 32 W730 0024 3 STAINLESS FLEXLINER X 3 33 W175 0204 3 COUPLER 34 W010 0888 VENT CONNECTION ASSEMBLY 35 W290 0076 VENT CONNECTION ASSEMBLY GASKET TERMINAL KITS 35 GDI 223 TERMINAL KIT VENT KITS 1 2 amp 1 3 DOUBLE PLY ALUMINUM LINER INLET AND EXHAUST amp 2 3 TO 2 REDUCER 36 GDI 2320KT VENT KIT 20FT 36 GDI 2325KT VENT KIT 25FT 36 GDI 2335KT VENT KIT 35FT 2 3 DOUBLE PLY ALUMINUM LINER INLET AND EXHAUST 37 GDI 3820KT VENT KIT 20FT 37 GDI 325KT VENT KIT 25 FT 37 GDI 335KT VENT KIT 35 FT W415 0314 C 01 15 04 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 W415 0314 C 01 15 04 13 14 TROUBLE SHOOTING GUIDE BEFORE ATTEMPTING TO TROUBLESHOOT PURGE YOUR UNIT AND INITIALLY LIGHT THE PILOT AND THE MAIN BURNER WITH THE GLASS DOOR REMOVED SYMPTOM Pilot will not light PILOT BUANEH THERMOPILE Fae et ae THERMOCOUPLE PROBLEM TEST SOLUTION No spark at pilot burner 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 i
8. 2 3 DOUBLE PLY ALUMINUM LINER INLET AND EXHAUST GDI 320KT GDI 325KT GDI 335KT VENT KIT 20FT VENT KIT 25 FT 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 aluminium coupler provided installation is sealed amp secured We recommend that exhaust vents that pass through unheated spaces such as a garage or attic be wrapped in a protective sleeve to minimize condensa tion and reverse flow symptoms This unit is approved for use witha 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 is necessary to adjust the primary air shutter See Air Shutter Settings 1 OUTSIDE Slip the FIGURE 2 one end of a liner a 3 TERMINAL minimum of 2 over the inaia collar of the air terminal ALS FLASHING Secure using 3 screws gt x g foe Then seal the joint and S lt Sse screw heads with high pee A LOVERLAP temperature sealant wy Repeat with the other liner EXHAUST N SEALANT to the exhaust collar of the INTAKE s HI TEMP terminal ae ALUMINU NOTE Connect the supplied 3 FLEXLINER of stainless steel flexliner to the COUPLER exhaust liner already attached to STAINLES the terminal using the coupler STEEL also supplied Secure and seal FLEXLINER before dropping down the chim FIGURE3
9. ART 5 FINISH ACCESSORIES 38 W690 0001 MILLIVOLT THERMOSTAT H PART DESCRIPTION 39 W660 0010B REMOTE CONTROL ADVANTAGE EE W725 0099 RET SHAW VALVE NG 39 W660 0011B REMOTE CONTROL ADVANTAGE PLUS 1 ATEO aoe eer 40 GD660 REMOTE WALL SWITCH c w 20FT WIRE Sue BURNER TUBE 41 GI 794KT DECORATIVE BRICK PANELS cM AOU BURMER PAN 42 W175 0202 NATURAL GAS TO PROPANE CONVERSION KIT E 14o FRONT BURNER OMPICE NG 43 GDIBP3 3 SIDED BACKER PLATE c w ACCENT TRIM A A oroar TE FRONT BURNER ARITI ESLP 44 GDIBP4 4 SIDED BACKER PLATE c w ACCENT TRIM A A AP REAR BURNER ORIFICE NG 45 GDITRM3 ALUMINIUM EXTRUSION matte BLACK a Aa oo eee ee 45 GDITRM3 K ALUMINIUM EXTRUSION POLISHED BLACK 3 i oe oe 45 GDITRM3 B ALUMINIUM EXTRUSION POLISHED BRASS Ss i prince Be asl ellececial ag 46 GDITRM4 ALUMINIUM EXTRUSION MATTE BLACK ee ee ee 46 GDITRM4 K ALUMINIUM EXTRUSION POLISHED BLACK So eee ee ewe 46 GDITRM4 B ALUMINIUM EXTRUSION POLISHED BRASS Z ee TEIE RMOCOL PLE 47 GDIUT UPPER DOOR TRIM Bpass woe Oe 47 GDIUT G UPPER DOOR TRIM coup 9 W573 0008 HIGH TEMPERATURE SEALANT a Wotescace BECTRICIOR IT 107 WS ial PEA tel 49 GDIBP3D BACKER PLATE 3 SIDED DELUXE 11 GL 635 LOG SET COMPLETE 12 W135 0030 LOG 1 13 W135 0160 LOG 2 14 W135 0161 LOG 3 15 W135 0033 LOG 4 16 W135 0034 LOG 5 17 W135 0035 LOG 6 18 W135 0036 LOG 7 19 W361 0016 GLOWING EMBERS 20 GZ552 BLOWER 21 W385 0245 NAPOLEON LOGO 22 W010 0890 GLASS c w GASKET 23 W225 0
10. INSTALLER THESE INSTRUCTIONS MUST BE CONVEYED TO AND REMAIN WITH THE HOMEOWNER CERTIFIED UNDER CANADIAN AND AMERICAN NATIONAL STANDARDS CSA 2 33 ANSI 221 88 FOR VENTED GAS FIREPLACE HEATERS NAPOLEON QUALITY FIREPLACES GAS FIRED DIRECT VENT INSERT INSTALLATION AND OPERATION INSTRUCTIONS FOR VENTED GAS FIREPLACE NATURAL GAS MODELS GDI 44N PROPANE GAS MODELS GDI 44P CERTIFIED FOR CANADA AND UNITED STATES USING ANSI CSA METHODS 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 e Do not try to light any appliance e Immediately call your gas supplier e Do not touch any electrical switch from a neighbour s phone Follow the e Do not use any phone in your gas supplier s instructions building 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 Warnock Hersey Hearth Patio amp Barbecue Association 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 0314 C 01 15 04 2 TABLE of CONTENTS Pg 2 4 I
11. MITATIONS 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 char
12. NTRODUCTION Pg 9 10 OPERATION MAINTENANCE Warranty Operating Instructions General Instructions Rear Burner Control General Information Maintenance Care of Glass amp Plated Parts 4 0 REPLACEMENT BLOWER 5 7 INSTALLATION Insert Vent Connection Chimney Connection cil Gas Pipe Installation vee Aiea aut Wall Switch Thermostat enh ei eiene 7 8 FINISHING 12 13 REPLACEMENTS Ordering Replacement Parts Replacement Parts 11 ADJUSTMENTS Pilot Burner Adjustment Trim Extrusion Installation a ecomen Terminal Kits Ember Placement Accessories Door Installation Mantle Clearances 14 15 TROUBLE SHOOTING GUIDE 16 SERVICE HISTORY PLEASE RETAIN THIS MANUAL FOR FUTURE REFERENCE WARNING e The fireplace insert is a vented gas fired heater Do not burn wood or other materials in this fireplace insert e 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 insert e Due to high temperatures the fireplace insert should be located out of traffic and away from furniture and draperies e Clothing or other flammable material should not be placed on or near the fireplace insert e Any safety screen or guard removed for servicing must be replaced prior to operating the fireplace insert e It is imperative that the control compartments burners and circulating blower and its passageway in
13. best performance however it is recommended to use two 3 liners Air shutter settings will differ depending on the liner sys tem used Use the charts below to determine the correct air shutter setting 3 3 LINER SYSTEM FRONT REAR naf mne ne 3 46 7 16 AIR SHUTTER SETTING 2 3 LINER SYSTEM FRONT REAR Mal 5ye AIR SHUTTER SETTING 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 estab lished Air shutter adjustment must only be done by a qualified gas installer FIGURE 25 BU VEN TURI W415 0314 C 01 15 04 12 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 FOR WARRANTY REPLACEMENT PARTS A PHOTOCOPY OF THE ORIGINAL INVOICE WILL BE REQUIRED TO HONOUR THE CLAIM REPLACEMENT PARTS When ordering replacement parts always give the follow ing information 1 MopeL amp SERIAL NUMBER OF FIREPLACE 2 INSTALLATION DATE OF FIREPLACE 3 PART NUMBER 4 DESCRIPTION OF P
14. but these parts are not to be applied so as to have an air tight seal 4 SIDED BACKER PLATE 42 34 52 1 8 O 4 SIDED BACKER PLATE FRONT VIEW W415 0314 C 01 15 04 s INSERT VENT CONNECTION Move the insert close to its final position inside the wood burning fireplace This unit is equipped with 6 levelling screws located as follows two are on either side of the circulation blower on the rear panel four are located front and back on either side beneath the log support Level using four of the levelling screws See Figure 1a Levelling the unit will 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 practical to level the insert once it has been installed Determine the required depth prior to in Stalling the unit and adjust the four levelling screws accord ingly 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 amp 1 3 DOUBLE PLY ALUMINUM LINER INLET AND EXHAUST amp 2 3 TO 2 REDUCER GDI 2320KT VENT KIT 20FT GDI 2325KT VENT KIT 25FT GDI 2335KT VENT KIT 35FT
15. dividual 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 test ing 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 ELEC TRICAL 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 cle The grounding prong must not be removed from the cord plug W415 0314 C 01 15 04 GENERAL INFORMATION 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
16. door Allow several minutes 5 15 for the flame to stabilize after ignition Do not operate the main burner of the in sert with the door removed 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 at tempted 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 When lit for the first time the fireplace will emit a slight odour for a few hours This is a normal temporary condi tion 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 ro
17. duct 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 STEELLTD PATENTS U S 5 303 693 801 CAN 2 073 411 2 082 915 amp DES 417 497 12 07 1999 WOLF STEELLTD W415 0314 C 01 15 04 4 GENERAL INSTRUCTIONS THIS GAS FIREPLACE INSERT SHOULD BE INSTALLED AND SERVICED BY A QUALIFIED INSTALLER to con form with local codes Installation practices va
18. estrictor vent kit W0O10 0898 W415 0314 C 01 15 04 15 16 Special Concerns Service Performed Wolf Steel Fireplace Service History Service Technician This fireplace must be serviced annually depending on usage Dealer Name Date W415 0314 C 01 15 04
19. 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 W415 0314 C 01 15 04 9 10 MAINTENANCE CONTINUED 2 Keep the control compartment logs burner air shutter opening and the area surrounding the logs clean by vacu uming 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 REPLACEMENT BLOWER INSTALLATION 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 approxi mately 30 minutes after the fireplace has been turned off Use of the fan increases the output of heat Air drawn in through the lower slot is driven up the back of the firebox and exhausted as hot air through the upper slot 1 Turn off the electrical power and the gas supply to the fireplace insert 2 Remove the fire viewing door Remove the logs log BLOWER
20. ge 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 pro
21. gnitor needs tightening replace the push button ignitor Spark gap is incorrect spark gap should be 0 150 to 0 175 5 32 to 11 64 approx from the electrode tip and the pilot burner No gas at the pilot burner check that the manual valve is turned on check the pilot orifice for blockage replace the valve call the gas distributor Out of propane gas fill the tank Pilot goes out when System is not correctly purged Purge the gas line with the glass door open the gas knob is re Out of propane gas fill the tank leased Pilot flame is not large enough turn up the pilot flame Pilot flame is not engulfing the turn up pilot flame thermocouple replace pilot assembly Thermocouple shorting loosen and tighten thermocouple clean thermocouple and valve connection replace thermocouple replace valve Faultly thermocouple replace Faulty valve replace Pilot burning no gas Main burner orifice is plugged remove stoppage in orifice Man burner gas Faulty thermopile replace knob is on Hl wal TT TT a aeee switch thermostat is au ty themostat or switch connect a jumper wire across the wall switch terminals if On main burner lights replace thermostat disconnect the switch wires amp connect a jumper wire across terminals 1 amp 3 if the main burner lights check the wires for defects and or replace wires Faulty valve replace Pilot goes
22. he 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 ofthe 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 1 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 in sulation 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 be fore 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 ob structed by the backer plates aluminium trim etc
23. m of 12 from the unit CARE OF GLASS AND PLATED PARTS 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 Na poleon Wolf Steel Ltd dealer DO NOT SUBSTITUTE MA TERIALS Clean the glass after the first 10 hours of opera tion 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 INSTALLATION Provide adequate ventilation air Provide adequate accessibility clearance for servicing and operating the fireplace insert Never obstruct the front opening of the fire place insert Objects placed tn front of the fireplace must be kept a minimum of 48 away from the front face of the unit FIGURE 1 a c 3 SIDED BACKER PLATE ALUMINUM TRIM 33 14 52 a 3 SIDED BACKER PLATE FRONT VIEW 43 T a GDI 44 TOP VIEW Clean out ashes from the inside of the wood burning fire place Make sure that the chimney and wood burning fire place 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 in sert 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 t
24. n be aware of this precaution Any circulation air opening may be covered with mate rial but not sealed ALUMINIUM EXTRUSION TRIM KIT INSTALLATION The insert can be equipped I with either a 3 or 4 sided trim kit to finish off the fire place opening Slide the trim assembly over the key holes 2 per side and drop into place If installing the optional 3 or 4 sided i backer plate GDIBP3 or tf GDIBP4 it must be hung i prior to the trim kit installa tion using the same key i a holes FIGURE Li bi _ h The insert may now be pushed into its final position inside the wood burning fire place Secure the insert to the fireplace using perforated strapping attached to the two securing holes on either side of the unit as shown We rec ommend that the trim be in stalled before the unit is placed into its final position SECURING HOLES WALL SWITCH THERMOSTAT 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 ther mostat The recommended maximum lead length de pends on the wire size WIRE SIZE MAX LENGTH 14gauge 100 feet 16gauge 60 feet 18gauge 40 feet Do not connect either the wall switch thermo stat or gas valve to electricity 110 VOLTS FIGURE 10 To adjust the trim If the mi FIGURE
25. n room headaches Carbon is being de Air shutter has become ensure air shutter opening is free of lint or other obstruc posited on glass blocked tions logs or combustion chamber surfaces Flame is impinging on the check that the logs are correctly positioned logs or combustion chamber 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 Air shutter is not set to specifi check and adjust air shutter to correspond with the fuel type cations and air intake size Main burner flame is Blockage in vent remove blockage In really cold conditions ice buildup may a blue lazy transpar occur on the terminal and should be removed as required ent flame Incorrect installation vent liners are reversed Refer to Figure 2 check all venting and insert seals White grey film Sulphur from fuel is being de clean the glass with a recommended gas fireplace glass forms posited on glass logs or com cleaner DO NOT CLEAN GLASS WHEN HOT bustion chamber surfaces If deposits are not cleaned off regularly the glass may be come permanently marked Flames are very Door is ajar ensure door seal is tight aggressive Venting action is too great restrict vent exit with r
26. om PURGE THE GAS LINE WITH THE GLASS DOOR OPEN WHAT TO DO IF YOU SMELL GAS e Turn off all gas to the fireplace e Open windows e Do not try to light any appliance e Do not touch any electric switch do not use any phone in your building e Immediately call your gas supplier from a neighbour s phone Follow the gas supplier s instructions e f you cannot reach your gas supplier call the fire depart ment N 1 ERMOPIL THE r C a FLAME ADJUSTMENT ON OFF KNOB KNOB 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 If fireplace is equipped with flame adjustment valve turn clockwise to off 6 Find pilot located in front of back log 7 Turn gas knob counter clockwise to pilot 8 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 re peat steps 3 through 7 9 With pilot lit depress
27. out while standing Main burner is in OFF position Gas piping is undersized turn on all gas appliances and see if pilot flame flutters diminishes or extinguishes especially when main burner ig nites Monitor supply pressure check if supply piping size is to code Correct all undersized piping Main burner goes out pilot stays on W415 0314 C 01 15 04 Pilot flame is not large enough turn up pilot flame or not engulfing the thermopile replace pilot assembly Thermopile shorting clean thermopile and thermopile connection to valve Remote wall switch one too shorten wire to correct length or wire gauge long too much resistance in the system Faulty thermostat or switch replace SYMPTOM PROBLEM TEST SOLUTION Main burner goes out REFER TO MAIN BURNER GOES OUT PILOT STAYS ON pilot goes out Vent re circulating check joint seals and installation Thermocouple shorting or loosen and tighten thermocouple faulty clean thermocouple and valve connection replace thermocouple replace valve Vent is reversing check all venting and insert seals check that door is properly sealed If the insert is allowed to burn with the door off when purging the unit exhaust products may escape through the air intake pipe and reverse the venting action Let the unit cool down to correct the reversed venting action Exhaust fumes Fireplace is spilling check all seals smelled i
28. re 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 NAPOLEON gas fireplace are warranted 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 breakage only gold plated parts against tarnishing porcelainized enamelled com ponents and aluminum extrusion trims Electrical 110V and millivolt components and wearable parts such as blowers gas valves thermal switch switches wiring remote controls ignitor gasketing and pilot assembly are covered and NAPOLEON will provide replacement parts free of charge during the first year of the limited warranty Labour 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 to the account of NAPOLEON are based on a predetermined rate schedule and any repair work must be done through an authorized NAPOLEON dealer CONDITIONS AND LI
29. ry from re gion to region and it is important to know the specifics that apply to your area for example in Massachusetts State e The fireplace damper must be removed or welded in the open position prior to installation of a fireplace insert or gas log e The appliance off valve must be a T handle gas cock e The flexible connector must not be longer than 36 inches e The appliance is not approved for installation in a bedroom or bathroom unless the unit is a direct vent sealed combustion product e 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 CAN1 B149 Installation Code in Canada or to the National Fuel Gas Code ANSI 2223 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 2223 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 min utes 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 in
30. 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 e Under no circumstances should this fireplace insert be modified e This fireplace insert must not be connected to a chimney flue pipe serving a separate solid fuel burning appli ance e 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 e 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 e Do not strike or slam shut the fireplace insert glass door e This fireplace uses and requires a fast acting thermocouple Replace only with a fast acting thermocouple supplied by Wolf Steel Ltd NOTE changes other than editorial are denoted by a vertical line in the margin W415 0314 C 01 15 04 NAPOLEON gas fireplaces are manufactured under the strict Standard of the world recognized ISO 9001 2000 Quality Assurance Certificate NAPOLEON products a
31. through the in sert and manoeuvre the vent con nection assembly through the opening in the firebox top Take care not to damage the gasket Secure the assembly using the four studs and 14 20 hex nuts FIGURE6 VENT CONNECTION ASSEMBLY 6 Reinstall the back wall followed by the log support us ing the perimeter screws removed in step 4 GAS INSTALLATION Install suitable supply piping connection to the flex con nector supplied oe local gas codes COSC penecar yg T O PITTING 7 HCUREs T VALVE Tp asss In order to close off the fireplace opening or if the opening is larger than the 3 or 4 sided aluminium extrusion trim kits it is recommended to reduce the opening using a noncombustible material such as ceramic tile marble etc or the GDIBP3 or GDIBP4 backer plate kits The GDIBP3 backer plate is able to fit an opening of 52 x 33 The GDIBP4 backer plate is able to fit an opening of 52 x 4234 The outside edge of the backer plate is finished off with gold trim included in each kit A GDIBP3D 3 sided deluxe backer plate complete with marquis trim may also be used to complete the installation This kit is able to fit an open ing of 57 x 33 Detailed installation instructions are in cluded with each kit If this unit is being installed into an existing wood burning zero clearance fireplace the
32. x 6 Reconnect the two wires Holding the replacement gas ket in place re attach the blower access door Replace the backwall logs and log support Reinstall the fire viewing door 7 Turn the gas supply and electricity back on FIGURE 21 Drywall dust will penetrate into the blower bearings caus ing 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 Remove the pilot screw cap Adjust the pilot screw to pro vide properly sized flame Turn in a clockwise direction to reduce the gas flow Replace the pilot screw cap PILOT lt rm BURNER THERMOPILE THERMOCOUPLE M EAN S deh V lt i cow h KGT OW a mf z3 zz DIL SC FLAME MUST ENVELOP UPPER 3 8 TO 1 2 OF THERMOCOUPLE amp L THERMOPILE o FIGURE 23 TE ISI FIGURE 22 VENT RESTRICTION Some vent configurations may display a very active flame If this appearance is not desirable the vent exit may be restricted using the restrictor plate shown in FIGURE 24 W010 0898 FIGURE 24 VENTURI ADJUSTMENT This unit is approved for use with a 2 liner for air intake and a 3 liner for exhaust For
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