W415-0616 / C / 06.04.08
$10.00
3
NAPOLEON ® Pellet Heaters 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 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 PELLET HEATERS PRESIDENT'S LIFETIME LIMITED
WARRANTY
The following materials and workmanship in your new NAPOLEON® Pellet Heater are warranted against
defects for as long as you own the heater. This covers: the pellet hopper, outer shell, ceramic glass (thermal
breakage only) and ash drawer.
The combustion chamber and heat exchanger are warranted against defects for a period of five years. All
other wearable parts and electrical components such as blowers, thermal switches and burn pot 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 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 non-transferable and may not be extended whatsoever by any of our representatives.
The Pellet Heater must be installed by an 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. Operating heater on high for extended periods
of time, is neglect. Parts installed from other manufacturers will nullify this warranty.
This limited warranty further does not cover any scratches, dents, corrosion or discoloring caused by excessive heat, abrasive and chemical cleaners nor chipping on porce-
lain enamel parts, nor any venting components used in the installation of the fireplace.
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 the 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 parts).
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 the 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® pellet heater 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 blowers, 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 regis-
tration card must be returned within fourteen days to register the warranty.
Regular cleaning of the fine ash generated during the operation of this heater is a necessary part of maintaining your pellet heater. Failure of any components, which is at-
tributed to poor maintenance, is not warrantable and will not be covered by this policy.
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 REGIS-
TERED TRADEMARK OF WOLF STEEL LTD. PATENTS U.S. 5.303.693.801 - CAN. 2.073.411, 2.082.915. © WOLF STEEL LTD.
W415-0616 / C / 06.04.08
4
WARNINGS AND SAFETY PRECAUTIONS
W415-0616 / C / 06.04.08
5
WARNINGS AND SAFETY PRECAUTIONS
W415-0616 / C / 06.04.08
6
GENERAL INTRODUCTION
GENERAL INSTRUCTIONS
Thank you for purchasing the Wolf Steel Ltd. Pellet Heater.
This heater is designed for use with Pelletized Wood Only.
Please read this entire manual before installation and use of this pellet fuel-burning room heater. Failure to follow
these instructions could result in property damage, bodily injury or even death.
Keep this manual handy for future reference.
This Pellet Heater, when installed, must be electrically grounded in accordance with the local codes, or 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.
This heater will not operate using natural draft or without a power source for the blower systems and fuel feed system.
PELLET QUALITY
Pellet quality is important, please read the following:
Your Wolf Steel Ltd. Pellet Heater has been designed to burn premium hard or soft wood pellets only. Do not use
any other type of fuel such as fire logs or fire starting pellet, as this will void the warranties stated in this manual.
The performance and heat output of the pellet heater is directly related to the quality and moisture of the pellets.
Store pellets in a cool dry area to prevent moisture absorption.
!
WARNING
It is important to select and use only pellets that are dry and free of dirt or any impurities such as high salt con-
tent. Dirty fuel will adversely affect the operation and performance of the unit and will void the warranty. The
Pellet Fuel Industries (P.F.I.) has established standards for wood pellet manufacturers. We recommend the use
of pellets that meet or exceed these standards. Ask your dealer for a recommended pellet type.
P.F.I. PELLET STANDARDS:
Fines (fine particles)
Bulk Density
Size
1% maximum through a 1/8" screen
40 pound per cubic foot minimum
1/4" to 5/16" diameter, 1/2" - 1 1/2" long maximum
1% maximum (Premium grade)
Ash Content
3% maximum (Standard grade)
8% maximum
Moisture Content
Heat Content
Approximately 8200 BTU per pound minimum
If the fuel does not comply to this standard the unit may not operate as designed.
We recommend the use of premium grade (1% ash content) for longer stove life and less frequent cleaning.
SPECIFICATIONS
HEATING SPECIFICATIONS
Approximate Maximum Heating Capacity (in square feet)*
Burn Rate (Pounds per Hour)**
800 to 2000 Sq. Feet
1.0 to 5.0
Maximum Burn Time on Low Burn**
Hopper Capacity
55 Hours (NPS40), 45 Hours (NPI40)
55 Pounds (NPS40), 45 Pounds (NPI40)
* Heating capacity will vary depending on the home's floor plan, degree of insulation, and the outside temperature. It is
also affected by the fuel size, quality, and moisture level.
** Small pellets will increase or decrease the stated burn rates and burn times. Differences of plus or minus 20% de-
pending on fuel quality may occur.
W415-0616 / C / 06.04.08
7
DIMENSIONS
Figures 1a-b
NPS40
NPI40 with NI800 Flashing Shown
Figures 2a-c
W415-0616 / C / 06.04.08
8
DIMENSIONS CONTINUED
NPI40 with AK9 Adapter and CISK Flashing Shown
Figures 3a-c
W415-0616 / C / 06.04.08
9
DIMENSIONS CONTINUED
NPI40 with AK8 Adapter and GICSK Flashing Shown
Figures 4a-c
W415-0616 / C / 06.04.08
10
SPECIFICATIONS
Electrical Rating
115 Volts, 3.6 Amps, 60Hz
400 (approximately)
Watts During Start-Up Sequence
Watts During Operation
180 (approximately)
NPS40 Width
NPS40 Height
NPS40 Depth
Weight
22 3/8"
30 1/2"
26 5/8"
210 Pounds
Exhaust Collar
Intake Collar
3"
2"
NPS40 Hopper Cap.
NPI40 Hopper Cap.
EPA
55 Pounds
45 Pounds
Exempt
Burn Rate**
1.0 to 5.0 (Pounds Per Hour)
BTU/h**
8500 to 42500
Minimum Fireplace Opening Size
Front: 22 1/2* W x 20 5/8 H x 14 1/4 D
Back: 20 3/8 W
* In order to install flashing flush to finished wall and centered within the opening the front opening of the fireplace or
enclosure must be 32 5/8" wide.
EPA COMPLIANCE
This heater is EPA exempt from Phase II requirements, but
has been tested for emissions using EPA test methods by
Warnock Hersey.
GENERAL INSTALLATION
PLANNING YOUR INSTALLATION
!
WARNING
Read this entire manual before you install and use this heater. failure to follow the instructions may result in
property damage, bodily injury, or even death.
Check with local building officials for any permits required for installation of this pellet heater and notify your insurance
company before proceeding with installation.
Before installing we recommend placing the heater outside and load 5 pounds of pellets inside the hopper. Plug the heater
in and let it run on HIGH until the pellets run out. This will cure the paint and burn off the oils on the steel, there by mini-
mizing any smell inside the home.
HEATER PLACEMENT
Have an authorized dealer install the heater. If you install the heater yourself, have your dealer review your installation
plans and/or installation.
Draw out a detailed plan of the installation including dimensions and verify the dimensions with the requirements listed in
this manual.
For built-in enclosures, when determining the location of the heater, locate the wall studs (for horizontal penetrations). You
may wish to adjust the heater position slightly to ensure the vent does not intersect with a framing member.
Heater must be positioned so that no combustibles are within, or can swing within (e.g. drapes, doors), 48" of the front of
the heater.
If the heater is placed in a location where the ceiling height is less than 7' above the base of the heater, the installation
must follow the requirements in the section "Alcove Installations Requirements"
W415-0616 / C / 06.04.08
11
INSTALLATION OPTIONS
NPS40:
To install in a Residential or Mobile Home see the section "Mobile Home Requirements".
For alcove installations see the section "Alcove Installation Requirements".
For horizontal vent or vertical vent see the section "General Venting".
See the section "Outside Air" for this option.
NPI40:
The insert can be adapted to vent out the rear or vertically.
To install as an insert into an existing masonry fireplace factory built fireplace or a built in combustible enclosure see Insert
Installation.
FLOOR PROTECTION REQUIREMENTS
NPS40:
The heater must be installed on a non-combustible floor protector extending the full depth of the heater and extending a
minimum 6" in front and on either side (minimum .018" thick - 26 gauge).
The floor protector must extend under and 2" beyond each side and rear of a "Tee" (if used).
NPI40:
In the case of the NPI40, the floor protector must have a R-value of 0.4 hr ft²°F
BTU
SAFETY FEATURES
HIGH LIMIT SWITCH:
Your heater is equipped with a high limit switch. In the event that the temperature of the heater approaches an unsafe
operating temperature, this switch will shut down the pellet feed, which will eventually shut down the unit. If this happens,
it is important to find out why the unit overheated. Contact your local dealer.
LOW LIMIT SWITCH:
This switch will automatically shut down the heater if the fire goes out.
BLOWER OVER-RIDE SWITCH:
Your heater is equipped with a convection blower that circulates hot air into your room. This switch will automatically turn
the blower on, when the temperature at the back of the fire box reaches a certain temperature. The blower can cycle from
your desired setting to maximum speed depending on the feed rate. When the heater cools back down, the blower will
return to the initial setting.
VACUUM SWITCH:
This switch will sense lack of air flow through the heater and shut down the pellet feed. This lack of flow could be caused
by a blocked vent.
POWER FAILURE:
In the event of a power failure, the heater will shut down. Once power is restored, the heater will re-start, unless the con-
vection air temperature has gone above the high limit switch setting. If this happens, contact your local dealer.
OUTSIDE AIR
Available from your Napoleon Dealer (114KT)
Outside air must not be drawn from an enclosed space (garage, unventilated crawl space).
NOTE: Wolf Steel Ltd. strongly suggests using outside air for all residential installations, especially for those that
are energy efficient, air-tight homes.
Outside air supply must not be over 15' long.
Outside air vents must be made with 1 3/4" diameter or larger metal or aluminum duct with a metal screen attached to the
end to keep out rodents (P.V.C. or other materials may not be used).
The outside air inlet must not be above or within 12" of the chimney termination, must have a rain cap or down-turned
elbow to prevent the water from entering and be located so that it will not become plugged by snow or other material.
Outside air is mandatory for a combustible built-in enclosure install for the NPI40.
W415-0616 / C / 06.04.08
12
MOBILE HOME
Installation into a manufactured home or mobile home should be installed in accordance with the Manufactured Home
Construction and Safety Standard, Title 24 CFR, Part 3280, in the United States or the Mobile Home Standard, CAN/CSA
Z240 MH Series, in Canada.
The heater must be grounded to the steel chassis of the mobile home (Some states do not
require this; check with your local building department).
Figure 5
!
WARNING
Do not install in a sleeping room.
The structural integrity of the manufactured home floor, wall, and ceiling roof
must be maintained.
GENERAL VENTING
PELLET VENT MUST MAINTAIN A MINIMUM 3" CLEARANCE TO ANY COMBUSTIBLE (install vent at clearances
specified by the vent manufacturer).
DO NOT CONNECT THE PELLET VENT TO A VENT OR CHIMNEY SERVING ANY OTHER APPLIANCE OR HEATER.
DO NOT INSTALL A FLUE DAMPER IN THE EXHAUST VENTING SYSTEM OF THIS UNIT.
TYPE OF VENT
Must be an approved 3" or 4" Diameter Type "L" or "PL" vent, vented to the outside or connect the vent to a factory built
type "A" chimney using an adaptor; and/or stainless steel chimney liner for masonry fireplace installations. Use 4" diam-
eter vent if vent or liner height is over 15' or if installation is over 4,000' above sea level.
INSTALLING THE PELLET VENT
The vent must have a support bracket every 5' when on the exterior wall.
To achieve optimum performance, keep vent runs as short as possible, especially
on horizontal installations.
MAXIMUM VENTING:
Maximum venting height is 33'. Maximum horizontal offset is 10'. Use no more than
180° of elbows (two 90' elbows, or two 45' elbows and one 90' elbow, etc), plus
termination.
VENT INSTALLATION:
Termination must exhaust above the air inlet elevation, and parallel or above the
exhaust output of the pellet appliance. It is recommended that at least 3' of vertical
pipe be installed to create some natural draft. This is to help prevent the possibility
of smoke or odour during the appliance shut down or in the event of a power out-
age.
Horizontal sections must have a 1/4" rise every 12" of travel if longer than 3'.
The pellet vent connections must be sealed with HI-Temp RTV Silicone and
screwed together with at least 3 3/8" long stainless steel screws.
Seal each vent section by injecting a liberal amount of 500°F
(260°C) RTV silicone sealant into the gap. We recommend sealing
the outside of the vent connections to permit easier access when
servicing.
Figure 6
W415-0616 / C / 06.04.08
13
VENTING THE PELLET HEATER
Use an approved wall thimble when passing the vent through walls and a ceiling support/fire stop spacer when passing
the vent through ceilings (maintain a 3" clearance to any combustibles).
PELLET VENT TERMINATION
The vent termination must have an approved cap (to prevent water from entering) or a 45° downturn.
If the termination is located on a windy side of the house, a shield is recommended to prevent soot from building up on the
side of the house.
Horizontal terminations must protrude 12" from the wall, vertical terminations require a minimum 24" above the highest
point that it penetrates through the roof.
Depending on pellet quality, vent configuration and air settings, black soot may occur on the terminal wall.
ALCOVE INSTALLATION (NPS40 ONLY)
Figure 7
Minimum Alcove Dimensions
W415-0616 / C / 06.04.08
14
MINIMUM AIR TERMINAL INSTALLATIONS
E
C
Figure 8
K
J
I
B
D
B
F
G
A
L
H
E
Illustration dimensions are to the center and the exhaust exit point of the vent.
CLEARANCE
Clearance above grade, veranda porch, deck or balcony.
(Including Vegetation and Mulch)
A
B
24 INCHES
Clearance beside or below any windows or doors that open.
Clearance above any window or door that opens.
48 INCHES
12 INCHES*
Vertical clearance to ventilated soffit located above the terminal within a horizontal
distance of 2 feet from the centerline of the terminal.
18 INCHES
0 INCHES
C
D
E
Clearance to an outside corner wall.
Clearance to an inside combustible corner wall or protruding combustible ob-
structions ( vent chase, etc.).
3 INCHES
9 INCHES
Clearance to a non-mechanical air supply inlet to the building or a combustion
air inlet to any other appliance.
F
Clearance to a mechanical air supply inlet.
G
H
I
3 FEET
7 FEET**
Clearance above a paved sidewalk or paved driveway located on public property.
Clearance under a veranda, porch, deck or balcony.
12INCHES**
24 INCHES
2 FEET
J
Clearance above the roof.
Clearance from an adjacent wall including neighbouring buildings.
K
Clearance to each side of center line extended above natural gas or porpane
meter/regulator assembly or mechanical vent.
3 FEET within a
height of 15 FEET
above the meter/
regulator assembly
L
*
Recommended to prevent condensation on windows and thermal breakage
This is a recommended distance. For additional requirements check local codes.
**
W415-0616 / C / 06.04.08
15
NPS40 INSTALLATION
MINIMUM CLEARANCE TO COMBUSTIBLES
STRAIGHT INSTALLATION
Through the Wall Installations
Interior Vertical Vents
Figure 10
Figure 9
CORNER INSTALLATION
Through the Wall Vents
Interior Vertical Vents
Figure 11
Figure 12
NOTE: If interior vertical pellet vent is used, the clearance to the back wall is determined by the upward-turning
elbow or "Tee". It will vary in depth depending on the brand of pellet vent used (it is approximately 5"). Before
placing the heater, connect the elbow or "Tee" and allow for the minimum 3" clearance to the combustible wall.
W415-0616 / C / 06.04.08
16
VENTING INSTALLATION EXAMPLES
HORIZONTAL EXHAUST THROUGH WALL INSTALLATION
Figure 13
THROUGH WALL WITH VERTICAL RISE AND HORIZONTAL
TERMINATION INSTALLATION
Figure 14
W415-0616 / C / 06.04.08
17
MINIMUM INSIDE VERTICAL CLEARANCES
Vertical Cap
Storm Collar
Roof Flashing
Vent must maintain 3”
Ceiling Support
clearance to combus-
tibles.
Figure 15
3”
2”
Floor Protection
Outside air (Recommended)
(Installation showing inlet of out-
side air in ventilated crawl space)
CLASS A CHIMNEY RETROFIT
Vertical Cap
Storm Collar
Roof Flashing
Vent must maintain 3”
clearance to combus-
tibles.
Class A Chimney
Ceiling Support
Figure 16
3”
2”
Floor Protection
Outside air (Recommended)
(Installation showing inlet of out-
side air in ventilated crawl space)
W415-0616 / C / 06.04.08
18
HEARTH MOUNT INSTALLATION
Vertical Cap
Storm Collar
Chimney Cap
Figure 17
Pellet
Liner
Flue Cover
Pellet
Vent
Clean-o
tee
6”
MIN
Bring outside air
to the stove
Outside Air
(Recommended)
PRIOR TO INSTALLATION
Clean all ashes out of the inside of the fireplace. Make sure that the chimney and fireplace are free of cracks, loose
mortar, cresote deposits, blockage or other signs of deterioration. If necessary, have any repair work done by a qualified
professional before installing the insert.
Do not remove bricks or mortar from the fireplace.
INSTALLATION INTO A MASONRY FIREPLACE
1. Remove the fireplace damper or fasten it permanently open.
2. Measure the throat of the fireplace and mark this shape on a piece of 24 gauge sheet metal (flue cover). Cut a hole
sized for the pellet liner to lie directly below the fireplace flue opening. Allow two inches of material for a flange on all
sides and cut to these measurements. Bend down the flanges. If you have never done this before, it might be a good
idea to make a cardboard pattern and test it first. fasten this flue cover in position as high as possible with two
masonry screws per side through the flanges into the fireplace.
3. If you plan on connecting outside air it is recommended to do so at this time.
4. Connect the pellet vent with a clean out tee to the back of the stove. Refer to manufacturer's installation instructions
and the "General Venting Section".
5. Run a liner down the chimney and connect to tee.
6. Position the stove in it's final location.
7. Pull the excess length of liner out through the top of the chimney. Trim the excess liner, install the cap and cap the
chimney.
W415-0616 / C / 06.04.08
19
NPI40 INSTALLATION
MINIMUM CLEARANCES TO COMBUSTIBLES
Side wall to unit
8"
Maximum mantel depth
Mantel to top of unit
Top facing to unit
Side facing to unit
Floor protection*
10"
8"
6 3/8"
6"
6"*
Figure 18
* Floor Protection: Minimum 6" in front of door and to either
side.
MINIMUM MANTEL CLEARANCES
Figure 19
REAR TO TOP VENT CONVERSION INSTRUCTIONS
NOTE: The insert is factory shipped in a rear vent configuration.
Figure 20
Exhaust Cover
1. To vent exit vertically, remove the two screws holding the exhaust cover.
NOTE: Be careful not to damage the gasket.
2. Remove the two screws holding the exhaust tube
NOTE: Be careful not to damage the gasket.
Exhaust Tube
3. Attach the exhaust tube and gasket in the vertical position.
4. Attach the exhaust cover and gasket over the horizontal exit.
W415-0616 / C / 06.04.08
20
NPI40 INSTALLATION OVERVIEW
Figure 21
See the section
“INSTALLATION - MINIMUM
MANTEL CLEARANCES”
Drywall
(or other
combustible
material)
See the section
“MINIMUM FRAM-
ING DIMENSIONS”
See the sections
“GENERAL VENTING”
and “INSTALLATION”
See the section
“MINIMUM
CLEARANCES TO
COMBUSTIBLES”
Side
Wall
See the section
“INSTALLATION
INTO A BUILT-IN
ENCLOSURE”
W415-0616 / C / 06.04.08
21
INSTALLATION INTO A MASONRY FIREPLACE
PRIOR TO INSTALLATION
Stand-offs (See Dimensions on page 7) may be removed to fit
the insert into the fireplace.
Figure 22
When installing the insert into a masonry fireplace, do not
remove any bricks or masonry. If necessary, the damper plate
may be removed from the smoke shelf, to accommodate the
chimney liner. Do not weaken the structure, or reduce the
protection for combustible materials to less then that required
by the National Building Code.
A non-combustible hearth must cover the flooring underneath,
as well as extend a minimum of six inches in front and to both
sides of the heater.
Clean all ashes out of the inside of the fireplace. Make sure
that the chimney and fireplace are free of cracks, loose mortar,
creosote deposits, blockage or other signs of deterioration. If
necessary, have any repair work done by a qualified profes-
sional before installing the insert.
Do not remove bricks or mortar from the fireplace.
Install floor protection if necessary.
INSTALLATION INTO A MASONRY FIREPLACE
HORIZONTAL VENT INSTALLATION
1. If you plan on connecting outside air it is recommended to
do so at this time.
2. A hole must be made in the back of the fireplace to accommodate
the pellet vent. Connect the pellet vent to the back of the stove and
position in place. Refer to manufacturer's installation instructions
and the "General Venting Section".
3. Connect the vent cap to vent.
VERTICAL LINER INSTALLATION
1. If you plan on connecting outside air it is recommend to
do so at this time.
2. Remove the fireplace damper or fasten it permanently
open.
3. Measure the throat of the fireplace and mark this shape on a piece of 24
gauge sheet metal (flue cover). Cut a hole sized for the pellet liner to lie directly below the fireplace flue opening. Allow
two inches of material for a flange on all sides and cut to these measurements. Bend down the flanges. If you have
never done this before, it might be a good idea to make a cardboard pattern and test it first. fasten this flue cover in
position as high as possible with two masonry screws per side through the flanges into the fireplace.
4. Convert the exhaust tube to a vertical application. See "Rear to Top Vent Conversion Instructions" section.
5. Run a liner down the chimney and connect to the exhaust tube. Refer to manufacturer's installation instructions and
the "General Venting Section".
6. Position the insert in it's final location.
7. Pull the excess length of liner out through the top of the chimney. Trim the excess length and cap the vent.
W415-0616 / C / 06.04.08
22
INSTALLATION INTO A FACTORY BUILT (METAL) FIREPLACE
PRIOR TO INSTALLATION
Stand-offs (See Dimensions on page 7) may be removed to fit the insert
into the fireplace.
Figure 23
When installing the insert into a factory built fireplace, you must not modify
any part that would alter the integrity in any way. Bolted or screwed to-
gether pieces (smoke shelf/deflectors) may be removed, but must be able
to be re-installed if the insert was removed.
External trim pieces, which do not affect the operation of the fireplace,
may be removed provided they are available to be re-installed in event the
insert is removed.
A warning label must be attached to the back wall of the fireplace stating
that "This fireplace has been altered to accommodate a fireplace insert and
must be re-inspected by a qualified person prior to re-use as a factory built
fireplace".
A non-combustible hearth must cover the flooring underneath, as well as
extend a minimum of six in front and to both sides of the heater.
Install floor protection if necessary.
INSTALLATION INTO A MASONRY FIREPLACE
LINER INSTALLATION
1. If you plan on connecting outside air it is recommended to do so
at this time. As illustrated connect the air vent to the back of the
insert, flex the vent up through the A vent chimney and bend the
vent 180°.
2. Remove the fireplace damper or fasten it permanently open.
3. Convert the exhaust tube to a vertical application. See "Rear to
Top Vent Conversion Instructions" section.
4. Run a liner down the chimney and connect to the exhaust tube.
Refer to manufacturer's installation instructions and the "General
Venting Section".
5. Install flashing. See "NPI Finishing - Flashing Installation" section.
6. Position the insert in it's final location.
7. Pull the excess length of liner out through the top of the chimney. Trim the excess length and cap the vent. Cover the
A vent chimney to weatherproof.
W415-0616 / C / 06.04.08
23
INSTALLATION INTO A COMBUSTIBLE BUILT-IN ENCLOSURE
MINIMUM FRAMING DIMENSIONS
When installing the insert as a "Built-in" heater, it is important to maintain the "Clearances to Combustibles" as illustrated
in Figure 24a-b.
A non-combustible heart must cover the flooring underneath, as well as, a minimum of six inches in front and to both sides
of the heater.
NOTE: The stand-offs located on the back of the insert must not be removed when installing the insert into a
built-in combustible enclosure.
1. Install floor protection.
2. Frame structure maintaining minimum clearances. Locate and frame openings for both the exhaust and outside air.
Outside air is mandatory for "Enclosure" installations.
3. Refer to the vent manufacturer's installation instructions and to "General Venting" section. Connect the vent.
4. Install flashing. See "NPI40 Finishing - Flashing Installation" section.
5. Consideration must be taken during installation that removal of the insert is necessary for inspection and annual
maintenance. Install the vent cap.
Figure 24b
Figure 24a
W415-0616 / C / 06.04.08
24
MINIMUM ENCLOSURE CLEARANCES
Figure 25
NPI40 FINISHING
FLASHING INSTALLATION
1. Secure the Right Flashing to the
right side of the unit using two of the
#8 x 1/2" screws.
FIGURE 26
NOTE: Feed the Air Control Rod into the
Air Control Slot on the Right Flashing
before securing. (FIGURE 26)
SHIPPING
BRACKET
SECURING
SCREWS
CONTROL
PANEL
SECURING
SCREWS
2. Twist spring handle (supplied with
the heater) onto the air control rod
until it hits the stop.
FIGURE 27
CONTROL
PANEL
AIR
CONTROL
ROD
3. Remove the two control panel
securing screws, discard the screws
and shipping bracket. (FIGURE 27)
RIGHT
FLASHING
AIR
CONTROL
SLOT
BURN
RATE LABEL
4. Secure the control panel to the Right
Flashing using the two #8 x 3/8" screws.
(FIGURE 20) Secure the Left Flashing
with the remaining #8 x 1/2" screws.
(FIGURE 26)
FIGURE 28
FIGURE 29
TOP
FLASHING
5. Align the holes in the top of the Right and
Left Flashing with those on the bottom lip
of the Top Flashing and secure from the
rear using the four #8-32 x 3/8" screws,
washers and nuts. (FIGURE 29)
6. The three pieces of trim are assembled in
the same manner as a picture frame. Place the
corner brackets (with screw loosened) into the trim
sections. Tighten the screw spreading the two
pieces apart. Attach the adjoining section. Repeat
with the opposite side. Tighten all screws firmly.
(FIGURE 30)
FIGURE 31
TRIM
ASSEMBLY
FIGURE 30
7. Slide the assembled trim down over the flashing.
(FIGURE 31)
8. Affix the logo to the bottom left hand corner of the left flashing.
W415-0616 / C / 06.04.08
25
TRIVET NPI40
The trivet for the NPI40 is attached by two set screws on the inside of the hopper
lid.
Figure 32
INSTALL VIEWING DOOR NPS40 AND NPI40
The main viewing door has been boxed separate from the heater, but MUST be installed before burning
the heater.
1. Open both side panels, exposing the bushing on the left and the latches on the right.
Figure 33
2. Align the pins on the door to the bushing on the left side of the heater.
Lower into place until both bushings touch.
(Insert
Illustrated)
3. Engage the latch hooks into the door frame. Snap the rear handle hook to
lock the latch closed.
LIGHTING HEATER MANUALLY
Your heater can be lit manually without using the automatic igniter by following the procedure below.
!
WARNING
Heater may be hot.
Other than placing a handful of pellets in the burn pot for lighting manually, never feed pellets through the
glass viewing door. An "OVERFIRE" condition could occur, if more pellets enter the firebox then what the feed
tube can deliver. Pellets must only be burned within the burn pot.
1. Press the start switch
2. Turn feed dial to "Optimum"
3. Place a "handful" of pellets into the burn pot.
4. Cover with a small amount of approved (non-volatile) fire starter gel.
5. Light fire starter with a match and close the viewing door.
PROPER PELLET LOADING
Before loading pellets into the hopper first transfer the pellets from it's original plastic bag to a metal bucket.
NOTE: If the pellets are kept in the plastic bag, the bag may come in contact with the heater causing the bag to
melt and the pellets to spill.
DO NOT load pellets into the hopper if they have been exposed to moisture. Moisture can cause pellets to swell and
cause blockage in the feed system. Thoroughly dry pellets before placing into hopper.
W415-0616 / C / 06.04.08
26
OPERATING INSTRUCTIONS
The pellet heater can be operated with or without the ring in place over the burn pot. With the ring in place, a more ef-
ficient burn will occur, however more finer fly ash will be experienced. It may be necessary to clean the burn pot of ash
more frequently.
!
WARNING
Never use gasoline, lantern fuel, lighter fluid to start or "freshen-up" a fire in this heater. Keep all such fluids
away from heater when in use.
Due to different installation set ups, length and size of venting and fuel quality, the low feed setting from the factory will not
always be correct. It may be necessary to experiment with feed rate vs air control. (For example, #2 may be your lowest
setting).
Always operate this heater with the door closed.
If this is the first time the heater has started or the heater has run out of pellets, the auger will need to be purged.
Press "START" switch, turn the pellet feed dial to high to fill the auger full of pellets and pull the air control rod all the way
out allowing air flow into the fire. If the heater does not reach the required temperature and turns off after 15 minutes,
press the start switch again. This time turn the pellet feed dial to low, to prevent over filling the burn pot and continue with
the start-up instructions below.
START-UP
1. Press "START" switch
2. Rotate the Pellet feed dial rate to optimum
3. Adjust the air control rod to the preferred setting (this position will vary depending on venting configuration and fuel
quality).
4. If the heater stops running after approximately 15 minutes, press "START" switch again.
If no ignition is apparent and pellets are building up in the burn pot, remove pellets from the burn pot before restarting.
Pellet Feed Dial
This switch controls
!
WARNING
the amount of heat
Pellet
output. The switch
has a scale (dial)
from 1 through 5. At
setting 5 the pellet
feed rate is the
greatest.
Heater may be hot
Feed
Dial
Blower Speed Dial
By adjusting the Blower Speed dial you will vary the rate of
airflow into the room by varying the speed of the convection
blower. When you first start the heater, it should be placed in the
"OFF" position in order to heat up the unit as quickly as pos-
sible. Once the room has come up to temperature, the control
may be set to a comfortable level.
Auger
Cycle
Light
Start
Switch
NOTE: The convection blower may cycle to high automati-
cally depending on the setting of the pellet feed rate and the
Blower Speed. This is a normal safety feature of the unit.
Once the heater has cooled down the blower will return to
the set speed.
Blower
Dial
Figure 34
NOTE: The flashing amber light corresponds to the au-
ger motor feeding the pellets. Wood pellets of different
quality may affect the performance of the heater. If the
heater has trouble operating at the ends of it's range,
adjust the feed rate accordingly.
!
WARNING
It is not recommended to burn the unit on low or
high. the most efficient setting is 4 (optimum).
SHUT-DOWN
To turn your heater off, simply turn the feed dial counter-clockwise until the dial clicks to the "OFF" position. This will stop
the feed of pellets. The blowers will continue to run to cool the heater. When cool enough, the heater will shut down. DO
NOT unplug unit while combustion blower is operating. This may lead to smoke escaping from the heater into the
room.
W415-0616 / C / 06.04.08
27
GENERAL MAINTENANCE NPS40 AND NPI40
DAILY (WHENEVER USING THE HEATER)
OPEN MAIN VIEWING DOOR
!
WARNING
The front of the heater becomes very hot during operation. Let the heater cool completely before conducting
service.
1. Open the side doors on either
side of the heater.
Figure 36
Figure 35
2. On the right side of the heater
are two latches. Release the
latches by pulling the rear
handle forward and
disengaging the hook from
the door frame. Swing open
the viewing door.
DISPOSAL OF ASHES
Ashes should be placed in a metal container with a tight fitting lid. The container should be placed on a non-combustible
floor, well away from combustible materials, pending final disposal. If ashes are disposed of by burial in soil or otherwise
locally dispersed, they should be retained in the closed container until all cinders are thoroughly cooled.
INSPECT THE BURN POT
When burning, the flames should be bright orange with embers jumping from the
burn pot.
Figure 37
CLEANING GLASS DOOR
If the glass is not kept clean, permanent discolouration and/or blemishes may result. If glass should ever crack, it must be
replaced using 5mm thick ceramic glass available from your Napoleon Dealer.
DO NOT SUBSTITUTE MATERIALS
DO NOT CLEAN GLASS WHEN HOT
DO NOT use abrasive cleaners to clean glass or plated parts.
DO NOT OPERATE THIS HEATER WITH THE GLASS DOOR OPEN
W415-0616 / C / 06.04.08
28
CLEANING THE HEAT EXCHANGE TUBES
!
WARNING
The front edge of the hopper lid becomes very hot, do not touch the area below the handle.
Figure 38
!
WARNING
This rod becomes very hot during operation. Wait till heater has cooled completely or you MUSt wear heat
resistant gloves when cleaning or handling this heater.
With the heater cool (or wearing heat resistant gloves), slide the heat exchange cleaner rod up and down several times to
prevent the build up of ash on the heat exchange tubes.
Keep the viewing door closed so the fly ash does not enter the room.
NOTE: More frequent cleaning may be required depending upon pellet quality.
MAKE SURE PELLETS ARE NOT PILING UP
If the pellets build up over the burn pot, turn the pellet feed switch to "OFF".
If the flames seem to be coming only from the sides, or are orange/black, turn the
heater off and check for build up of pellets.
The most likely causes are:
1. Feed rate has been set to maximum for an extended period of time. Turn feed
rate to optimum.
2. The door, glass, or ash pan is open or has an air leak.
3. The burn pot requires cleaning.
4. The exhaust system requires cleaning.
5. The heater requires adjustment.
Figure 39
6. Poor pellet quality
W415-0616 / C / 06.04.08
29
CLEANING THE BURN POT
!
WARNING
Make certain the heater has fully cooled (approximately 25 minutes) before opening the door and conducting service.
To clean the burn pot, open the door and knock away any debris on the burn
pot. If severely clogged, remove the burn pot to gain better access.
If removing the burn pot set aside on a non-combustible surface. See Figure
40. Once removed, discard all material that has accumulated in the burn pot.
Figure 40
Make certain that all openings are clear of any build up of ash from the ledge
below the burn pot.
Re-install the burn pot ensuring it sits level
in the heater. Also must ensure the ignitor
and the burn pot locating notch line up
when reinstalling the burn pot.
LOCATING NOTCH
IGNITOR
BI-WEEKLY (OR EVERY 10 BAGS OF PELLETS)
VACUUM FIREBOX
The more frequently you clean out the fly ash, the more efficient your heater will burn.
!
WARNING
The fire box becomes very hot during operation. Let the heater cool completely before conducting service.
1. Open the viewing door. See Figure 35 and 36
2. Lift the burn pot out and set aside on a non-combustible surface.
See Figure 40. Remove the right and left louvres by lifting the louvres up
and out of the firebox setting them on a non-combustible surface.
LOUVRES
AIR HOUSING
FIREBOX
Figure 41
W415-0616 / C / 06.04.08
30
3. Vacuum out the firebox,
louvres, air housing, burn pot
and the opening at the top of
the exhaust manifold of all fly
ash. See Figure 42 and 43.
4. Replace the louvres and burn
pot, latch the viewing door
closed and close both side
doors.
Exhaust Manifold
Opening
Figure 42
Figure 43
SEMI-ANNUALLY (OR EVERY TWO TONS OF PELLET)
NOTE: More frequent cleaning may be required depending on pellet quality.
!
WARNING
Disconnect the power cord prior to conducting service. The following section details extensive maintenance
procedures. We strongly suggest these items be carried out by a trained service technician, possibly by a service
agreement set up with your dealer.
NOTE: The heater becomes very hot during operation. Let the heater cool completely and disconnect the power
cord prior to conducting service.
VACUUM HOPPER
NPS40:
Run the heater until the pellets run out, then open the hopper and vacuum out the
entire hopper. The dust and any other debris near the bottom should be removed to
Figure 44
prevent excessive build-up.
Cleaning the Optional Plated Surfaces
Fingerprints or other marks left on plated surfaces may become etched in place if they
are not wiped clean prior to turning the heater on. Wipe the gold with a non-abrasive
cleaning solvent and a soft cloth (make sure the heater is cool). Other cleaners may
leave a film that may become etched into the finish.
SOOT AND FLY ASH FORMATION
The products of combustion will contain small particles of fly ash. The fly ash will collect in the exhaust venting system and
restrict the flow of the flue gases. Incomplete combustion occurs during startup, shutdown, or incorrect operation of the
room heater will lead to some soot formation which will collect in the exhaust venting system. The exhaust venting system
should be inspected at least once every year to determine if cleaning is necessary.
W415-0616 / C / 06.04.08
31
CLEAN THE VERTICAL EXHAUST DUCT
If the PRPP40 or the brick kit NP841KT is in place, remove that accessory
first.
Figure 45
1. Open side door, release the latch and pivot the viewing door wide open.
See Figure 35 and 36.
2. Remove the one screw on each exhaust port located on either side of
the fire box. Remove the exhaust port doors and set aside on a
non-combustible surface.
Insert a vacuum into the exhaust port holes and remove
as much fly ash as possible from behind the left and right
exhaust manifolds. Once clean, replace the exhaust port
doors and secure with the screws.
CLEAN EXHAUST HOUSING (INSERT ONLY)
To clean the exhaust blower and exhaust housing, the heater must be pulled out from the fireplace cavity. Remove the vent-
ing from the exhaust collar. If installed as a top vent, remove cover plate from the rear of the housing. If installed as a rear
vent, remove the cover plate from the top of the housing. Vacuum out the housing back to blower outlet. See Figure 47.
SEMI-ANNUALLY (OR EVERY TWO TONS OF PELLET)
CLEAN THE EXHAUST BLOWER
NOTE: Do not attempt this maintenance without a replacement exhaust
blower motor mounting gasket.
Nuts
1. Remove the six nuts holding the exhaust blower motor in place.
2. Pull the motor out being careful not to damage the wiring, unplug the two
wires that are connecting the motor and gently set aside. (The pieces of
gasket may be discarded.
Figure 46
3. Start by cleaning the exhaust tube by feeding a brush or rag through the
inside of the tube and out the exhaust blower housing.
4. Vacuum out the exhaust ports and the blower housing.
5. With a bristle brush vacuum, clean the blades of the motor.
Figure 47
6. Place the new exhaust blower mounting gasket around the screw holes being
very careful not to tear it.
7. Re-attach the wiring to the motor and place it back on to the
housing, taking care that the side of the motor does not tear the
gasket and then re-attach the nuts.
W415-0616 / C / 06.04.08
32
CHECK ALL SEALS
Check for air leaks around the door, glass, and ash pan and replace gaskets as required.
Air leaks into the firebox will decrease the heater's performance greatly, leading to excessive soot, inefficient burning, and
may even cause a malfunction.
Test the door seal by shutting the door on a piece of paper in various locations. If the paper can be easily slid out, air may
be leaking around the door seal. Carefully inspect the door gasket and door catch.
Inspect the door gasket to make sure it is fully attached. Heater gasket cement can be used to re-attach if necessary. If
the door gasket is worn or flattened, replace.
Check the door to make sure it latches correctly. The latch should engage with a slight amount of resistance, yet not be
too difficult.
If the glass is cracked, replace.
CLEAN THE VENT
Vent system should be cleaned using chimney sweep
brushes. We recommend this be done by a qualified chimney
sweep.
Figure 48
W415-0616 / C / 06.04.08
33
NORMAL OPERATING SOUNDS
Figure 49
W415-0616 / C / 06.04.08
34
WIRING DIAGRAM
Figure 51
W415-0616 / C / 06.04.08
35
REPLACEMENTS
Contact your dealer for questions concerning prices and availability of replacement parts. Normally all parts can be or-
dered through your Authorized dealer or distributor.
When ordering replacement parts always give the following in formation:
1. Model and Serial Number of the fireplace
2. Installation Date of the fireplace
3. Part Number
4. Description of part
5. Finish
For warranty replacement parts, a photocopy of the original invoice will be required.
* Identifies items which are not illustrated. For further information, contact your Authorized dealer.
#
PART NO. DESCRIPTION
COMMON COMPONENTS TO BOTH UNITS
52 W010-0219
53 W290-0122
54 W010-1673
55 W010-1685
56 W010-1567
EXHAUST COVER
EXHAUST GASKET
#
PART NO. DESCRIPTION
RIGHT LOUVRE ASSEMBLY
LEFT LOUVRE ASSEMBLY
AIR CONTROL
1
2
3
4
5
6
7*
8
9
W660-0052
W660-0053
W660-0054
W660-0055
W660-0056
W380-0020
W195-0004
W435-0009
W062-0021
LOW LIMIT SWITCH 140°F (80°C)
OVER-RIDE SWITCH 160°F (71°C)
IGNITION SWITCH 120°F (60°C)
HIGH LIMIT SWITCH 200°F (93°C)
VACUUM SWITCH
CONTROL KNOB
POWER CORD
NPS40 COMPONENTS
57 W010-1508
WELDED TOP ASSEMBLY
SIDE DOOR ASSEMBLY
HOPPER DOOR ASSEMBLY
ASH PAN ASSEMBLY
PEDESTAL SIDE DOOR ASSEMBLY
PEDESTAL BASE
58 W010-1527
59 W010-1529
60 W010-1667
61 W010-1668
62 W035-0191
63* W555-0059
64 W475-0482
65 W475-0484
66 W475-0485
67 W652-0040
AUGER MOTOR
CONVECTION BLOWER
COMBUSTION BLOWER
COMBUSTION BLOWER MOUNTING GASKET
COMBUSTION BLOWER MOTOR MOUNTING GASKET
CONVECTION BLOWER GASKET
PRESSURE FITTING TAP
AUGER SCREW
10 W062-0022
11 W290-0111
12 W290-0120
13 W290-0113
14* W255-0020
15 W570-0107
16 W390-0002
17 W190-0019
18 W190-0020
19 W405-0001
20 W660-0058
21 W660-0063
22 W660-0062
23 W555-0061
24 W105-0012
25 W570-0110
26* W750-0163
27* W385-0334
28 W010-1528
29 W475-0555
30 W720-0089
31 W390-0012
32 W010-1490
33 W357-0004
34* W325-0042
35 W350-0361
36 W615-0073
37 W080-0777
38 W010-1491
39 W030-0022
40 W135-0320
41 W135-0321
42 W430-0002
43* W290-0120
44 W290-0119
45 W460-0004
46* W615-0078
47 W300-0038
48 W300-0037
49* W562-0022
50 W290-0122
51 W010-1612
AIR CONTROL ROD
OUTER REAR PANEL
OUTER PANEL, RIGHT
OUTER PANEL, LEFT
PEDESTAL GASKET
DOOR LATCH
POWER CONTROL
AUGER CONTROL
AMBER LIGHT
NPI40 COMPONENTS
68 W010-1670
69 W010-1671
70 W555-0069
SIDE DOOR ASSEMBLY
WELDED HOPPER LID ASSEMBLY
AIR CONTROL ROD
POWER SWITCH
PELLET FEED SWITCH
VARIABLE SPEED W/O PAL NUT SWITCH
SCRAPER ROD
COMMON ACCESSORIES
NYLON BUSHING
SCREW SET
HARNESS WIRE
NAPOLEON® LOGO
CONTROL DOOR
71 W225-0195
71 W225-0195G
71 W225-0195SC DOOR FRAME, SATIN CHROME
72 GS200-G
72 GS200-SS
73 PRPP40
74* 114KT
75 NP841KT
76 NPL41
DOOR FRAME, BLACK
DOOR FRAME, GOLD
TRIVET
TRIVET
BOTTOM OI PANEL
IGNITOR HOUSING
CONTROL PANEL LATCH
EXHAUST TUBE
IGNITOR
PORCELAIN REFLECTIVE RADIANT PANELS
OUTSIDE AIR KIT - 5 FT (2" DIA.)
BRICK, REFRACTORY
DECORATIVE LOG SET
SMALL BLACK WIRE HANDLE
CONTROL HOUSING
AIR CONTROL SPACER
MOTOR BRACKET
NPS40 ACCESSORIES
77* NPHE-40
HOPPER EXTENSION (INCREASES HOPPER
CAPACITY FROM 55 LBS TO 100 LBS PELLETS)
COMBUSTION AIR TUBE ASSEMBLY
ACCENT BAR (2)
CAST, BURN POT
NPI40 ACCESSORIES
78 NI800
79* GICSK
80 AK8
81* CISK
81* CISKK
81* CISKN
81* CISKB
81* CISKF
82* AK9
8" BLACK FLASHING WITH BLACK TRIM
ARCHED CAST IRON SURROUND
ADAPTOR KIT (REQ'D FOR GICSK)
CAST IRON SURROUND KIT - BLACK
CAST IRON SURROUND KIT - ENAMEL BLACK
CAST IRON SURROUND KIT - MOJOLICA BROWN
CAST IRON SURROUND KIT - MOJOLICA BLUE
CAST IRON SURROUND KIT - MOJOLICA GREEN
ADAPTOR KIT (REQ'D FOR CISK)
CAST, RING
MAGNETIC DOOR CATCH ASSEMBLY (2)
MOTOR MOUNTING GASKET
IGNITION GASKET
RECEPTACLE
SPACER, LATCH
GLASS, FRONT
GLASS, SIDE
GLASS GASKET
EXHAUST GASKET
EXHAUST COLLAR
W415-0616 / C / 06.04.08
36
COMMON REPLACEMENTS PARTS
W415-0616 / C / 06.04.08
37
NPS40 REPLACEMENTS PARTS
W415-0616 / C / 06.04.08
38
NPI40 REPLACEMENTS PARTS
W415-0616 / C / 06.04.08
39
COMMON ACCESSORY PARTS
NPI40 ACCESSORY PARTS
W415-0616 / C / 06.04.08
40
TROUBLESHOOTING
*NOTE: All troubleshooting procedures should be carried out by qualified technicians or installers.
CAUTION: When checking connections, installing jumper wires (for test purposes only) or replacing
components, unplug heater from the receptacle to prevent electrical shock or dampage to the compo-
nent. NOTE: Many of the following tests will require that the side panels are removed from the stove
or the insert be removed from its cavity to access the components. Before troubleshooting always
confirm that all components are clean and free of ash build up.
SYMPTOM
TEST SOLUTION
- Make certain there is power to the outlet and that the heater is plugged in.
- With the heater unplugged, examine all connections. Make sure no exposed wires are
touching the heater (except the chassis ground wire) and that they are all firmly
connected.
The heater will
not start
- Check the manual reset hi limit switch
- Check the stability and placement of connections against the wiring diagrams in this
manual.
- Check that the burn pot is positioned properly.
- Push the "START" switch. If the heater fails to start, unplug the unit.
- Ensure that connections to the power control module are connected.
- Place a jumper wire between the red and white wires that attach to the start switch.
- Plug stove in, if stove starts replace switch.
- Replace the power control if this fails.
CAUTION: Check the ignitor resistance before installing a new start-up timer as it may
result in another failure to the new start-up timer due to a short in the ignitor. The proper
resistance through the ignitor should be 30Ω to 50Ω ( 3Ω).
Smoke in the
room
- Check all gasket seals.
- Vent connections all sealed.
- Unit has failed to reach 140°F within 15 minutes and the blower has shut off.
- Restart unit.
NOTE: A minimal amount of smoke is normal during the start up process.
- Remove the left side access panel and check all connections against the wiring
diagram. For the insert - remove from cavity.
- Apply 115V AC directly to the exhaust blower and if the motor does not run, replace the
blower.
The exhaust
blower is not
operating
- If the motor runs, have a dealer check the wire harness.
- See "The heater will not operate when hot" section
- Contact your local dealer or a certified technician for service.
The ignitor will
not light the
pellets however
everything else in
the heater oper-
ates
- Push the burn pot back against the ignitor tube making sure the ignitor lines up to the
hole in the burn pot.
- Make certain the air control rod is pushed in to start up position.
- Check all the electrical connections on the 120°F (49°C) temperature sensor located on
the exhaust channel.
- Place a jumper wire between the two leads on the 120°F (49°C) temperature sensor
and if the ignitor works, replace the sensor.
- If it still fails to light, replace the ignitor.
- Make certain the exhaust blower is operating
The auger motor
is not functioning
normally
- Check the condition of the vacuum hose (located on the left side of the heater). Should
not be cracked or torn.
- Check the manual reset button on the 200°F (93°C) temperature sensor. Before
re-setting the red button, check for the cause of the over-heating.
- Check that the auger set screw is tight and not slipping.
- If the auger still does not work, then apply 115V AC directly to the auger motor. If it still
does not work, replace it.
- Check the auger by bypassing the 200°F (93°) temperature sensor with a jumper wire.
If auger works, replace the sensor.
- Check the vacuum sensor by placing a jumper wire between the blue wire and the
black wire that are attached to the sensor. If the auger works, test to see if the exhaust
blower is producing enough vacuum (may require cleaning).
- If not, replace the vacuum sensor.
W415-0616 / C / 06.04.08
41
TROUBLESHOOTING CONTINUED
SYMPTOM
TEST SOLUTION
Feed rate dial has - Secure all connections to the power control module.
no effect on the
fire (timer control
only)
- Perform a resistance test to the potentiometer by placing the two test leads
from a multi meter into the leads of the potentiometer. The potentiometer should have a
range of 850 KΩ ( 10%).
Potentiometer Readings:
Full counter-clockwise (switched off) = open circuit, overload or infinite
resistance
Low fire .......... 900 KΩ to 1,050 KΩ
High fire ......... 56 KΩ to 62 KΩ
If the range is not close or does not vary then replace the potentiometer.
The convection
blower is not
functioning nor-
mally
- Using the wiring diagram, compare all the connections between the controller, switch,
and the convection blower.
- If the convection motor will not run, apply 115V AC to the motor directly. Replace the
blower controller if the motor runs. The convection blower has failed if the motor does
not run. Replace the blower.
- If the convection blower runs on high at all times (no control with the blower controller),
check the connections from the 160°F (71°C) sensor (located on the upper left side on
the rear of the fire wall) and convection blower controller to the blower. Disconnect one
of the wires from the sensor and if control of the convection blower returns to the
blower controller, replace the sensor.
- If the motor is still on high, re-connect the sensor and replace the convection blower
controller.
The heater will
General
not operate when - Check the hopper for fuel.
hot
- Incorrect air damper setting may cause excessive air to consume the fire too quickly
before the next drop of fuel. Therefore leaving the fuel completely unburned in the burn
pot and will cause the fuel to burn cold and very slowly. Fuel also may build up and
smother the fire.
NOTE: The unit may require a change to the vent system or installation of fresh air to
correct air to fuel ratio problems.
- Combustion blower failure may occur because it is not turning fast enough to generate
the proper vacuum in the fire box. Do a visual check to see if the motor is turning.
- Check vacuum levels in the exhaust channel by bypassing the vacuum switch, then
remove the vacuum hose from vacuum switch. When checking the vacuum exhaust
place the open end of the vacuum hose on the gauge (readings must be above 0.10"
W.C. on low fire). (NOTE: if the motor fails to reach a 0.10" W.C., then replace the
combustion blower).
- Poor quality fuel may not produce enough heat to keep the stove burning or
operational.
- If the exhaust temperature sensor fails try bypassing the sensor located on the exhaust
blower. If the stove operates properly, the unit may require cleaning or a new sensor.
Contact your local deal for service.
- Unplug the stove, open the left side panel and jump the two brown leads that are
attached to the 140°F (60°C) temperature sensor. If the stove operates replace the
140°F (60°C) sensor.
W415-0616 / C / 06.04.08
42
TROUBLESHOOTING CONTINUED
SYMPTOM
TEST SOLUTION
The 200°F (93°)
high limit tem-
perature sensor
has tripped
- Reset the sensor and determine whether it was the convection blower or 160°F (71°C)
temperature sensor failure. Bypass the 160°F (71°C) sensor. Does the convection
blower not come on high? If no than replace the blower.
The heater will
not turn off
- Disconnect one of the brown wires from the exhaust temperature sensor and if the unit
continues to operate, contact your local dealer for service.
- Compare the wiring diagram to the start control module and the connections to the
140°F (60°C) temperature sensor. Check the connections.
- Remove one of the brown wires from the 140°F (60°C) temperature sensor. The heater
should be shut down right away as long as the start button was not pressed within 15
minutes of this test. If the heater shuts down within 15 minutes, replace the 140°F
(60°C) sensor. If the heater does not shut down in 15 minutes, test the switch.
- The heater must be cold to test the switch. Pull the plug, then plug the heater back in. If
the heater fails to start, replace the switch.
The heater keeps - Due to different installation set ups, length and size of venting and fuel quality, the low
going out
feed setting from the factory will not always be correct. It may be necessary to
experiment with feed rate vs air control. (For example, #2 may be your lowest setting).
- If the heater goes out and leaves fresh unburned pellets or cigarette-like ashes in the
burn pot, the fire is going out before the heater shuts off.
- Check to see if the air control rod is in the correct position.
- Turn the feed rate up slightly (poor quality pellets will require slightly higher settings).
- Check to see if the heater needs a more complete cleaning as well as the burn pot,
venting, etc...
- Was there a power failure?
- Contact your local dealer for service
- If the heater goes out and there are no pellets in the liner, the auger is stopping.
- See "The auger motor will not function normally" and "The exhaust blower will not
function normally".
Excessive carbon - Check quality of pellets. Even pellets from the same manufacturer can vary in quality
build up in the
firebox, low heat
out put
since the materials they use to form pellets may also vary.
- Moisture content of pellets too high. Pellets must be stored in a dry place. Areas such
as a garage are too damp causing pellets to absorb moisture.
Unit is burning
dirty and lazy
- Check that all exhaust and intake pathways are clear of any obstructions.
- Burn pot is clean.
- Pellets are dry.
- Venting and terminal are clear of obstructions.
- Exhaust blower is operation and is clean.
W415-0616 / C / 06.04.08
43
SERVICE AND MAINTENANCE LOG
OWNERSHIP RECORDS
Dealer's Name:
Dealer's Address:
City:
State/Province:
Zip Code/Postal Code:
Date Installed:
Serial Number:
Notes:
Date of Purchase:
SERVICE DATE
SERVICE TECHNICIAN
SERVICE DESCRIPTION
W415-0616 / C / 06.04.08
44
NOTES
W415-0616 / C / 06.04.08
|