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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.
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WARNINGS AND SAFETY PRECAUTIONS
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WARNINGS AND SAFETY PRECAUTIONS
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GENERAL INTRODUCTION
GENERAL INSTRUCTIONS
Thank you for purchasing the Napoleon® 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 instruc-
tions 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 Napoleon® 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.
CAUTION: It is important to select and use only pellets that are dry and free of dirt or any impurities such as high salt content. 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 estab-
lished 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 af-
fected 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% depending on
fuel quality may occur.
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7
DIMENSIONS
Figures 1a-b
NPS40
NPI40 with NI800 Flashing Shown
Figures 2a-c
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DIMENSIONS CONTINUED
NPI40 with AK9 Adapter and CISK Flashing Shown
Figures 3a-c
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DIMENSIONS CONTINUED
NPI40 with AK8 Adapter and GICSK Flashing Shown
Figures 4a-c
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SPECIFICATIONS
EPA COMPLIANCE
This heater is EPA exempt from Phase II requirements, but has
been tested for emissions using EPA test methods by Warnock
Hersey.
Electrical Rating
115 Volts, 3.6 Amps, 60Hz
Watts During Start-Up Se-
quence
400 (approximately)
Watts During Operation
180 (approximately)
NPS40 Width
NPS40 Height
NPS40 Depth
Weight
22 3/8"
30 1/2"
26 5/8"
210 Pounds
3"
Exhaust Collar
Intake Collar
NPS40 Hopper Cap.
NPI40 Hopper Cap.
EPA
2"
55 Pounds
45 Pounds
Exempt
Burn Rate**
BTU/h**
1.0 to 5.0 (Pounds Per Hour)
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.
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 OPTIONS
installation of this pellet heater and notify your insurance company
before proceeding with installation.
NPS40:
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 minimizing any smell
inside the home.
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 Vent-
ing".
HEATER PLACEMENT
See the section "Outside Air" for this option.
NPI40:
Have an authorized Napoleon® dealer install the heater. If you
install the heater yourself, have your dealer review your installation
plans and/or installation.
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 Instal-
lation.
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 Require-
ments"
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
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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).
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.
Figure 5
WARNING: DO NOT INSTALL IN
A SLEEPING ROOM.
CAUTION: THE STRUCTURAL
INTEGRITY OF THE MANUFAC-
TURED HOME FLOOR, WALL,
AND CEILING ROOF MUST BE
MAINTAINED.
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 cer-
tain 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 convection
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: Napoleon® strongly suggests using outside air for all resi-
dential 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 chim-
ney 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.
MOBILE HOME
Installation into a manufactured home or mobile home should be
installed in accordance with the Manufactured Home Construc-
tion and Safety Standard, Title 24 CFR, Part 3280, in the United
States or the Mobile Home Standard, CAN/CSA Z240 MH Series,
in Canada.
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GENERAL VENTING
PELLET VENT MUST MAINTAIN A MINIMUM 3" CLEARANCE
VENTING THE PELLET HEATER
TO ANY COMBUSTIBLE (install vent at clearances specified by
the vent manufacturer).
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).
DO NOT CONNECT THE PELLET VENT TO A VENT OR CHIM-
NEY SERVING ANY OTHER APPLIANCE OR HEATER.
DO NOT INSTALL A FLUE DAMPER IN THE EXHAUST VENT-
ING SYSTEM OF THIS UNIT.
PELLET VENT TERMINATION
The vent termination must have an approved cap (to prevent water
from entering) or a 45° downturn.
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" diameter vent if vent or liner
height is over 15' or if installation is over 4,000' above sea level.
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.
INSTALLING THE PELLET VENT
The vent must have a support bracket every 5' when on the exte-
rior wall.
Depending on pellet quality, vent configuration and air settings,
black soot may occur on the terminal wall.
To achieve optimum performance, keep vent runs as short as pos-
sible, especially on horizontal installations.
MAXIMUM VENTING:
ALCOVE INSTALLATION (NPS40 ONLY)
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 recom-
mended 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
outage.
Horizontal sections must
have a 1/4" rise every 12"
of travel if longer than 3'.
The pellet vent connec-
tions 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 con-
nections to permit easier
access when
Figure 7
Minimum Alcove Dimensions
servicing.
Figure 6
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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.
**
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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.
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VENTING INSTALLATION EXAMPLES
HORIZONTAL EXHAUST THROUGH WALL
INSTALLATION
Figure 13
THROUGH WALL WITH VERTICAL RISE AND HORIZONTAL TERMINATION INSTALLATION
Figure 14
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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)
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HEARTH MOUNT INSTALLATION
NPI40 INSTALLATION
Vertical Cap
Storm Collar
MINIMUM CLEARANCES TO COMBUSTIBLES
Side wall to unit
8"
10"
8"
Chimney Cap
Maximum mantel depth
Mantel to top of unit
Top facing to unit
Side facing to unit
Floor protection*
6 3/8"
6"
6"*
Pellet
Liner
Flue Cover
Figure 18
Pellet
Vent
Clean-o
tee
* Floor Protection: Minimum 6" in front of door and to either side.
MINIMUM MANTEL CLEARANCES
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.
Figure 19
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 mea-
surements. 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.
REAR TO TOP VENT CONVERSION INSTRUCTIONS
NOTE: The insert is factory shipped in a rear vent configuration.
1. To vent exit vertically, remove the two screws holding the
exhaust cover. NOTE: Be
careful not to damage the
Figure 20
gasket.
Exhaust Cover
2. Remove the two
screws holding the
exhaust tube (NOTE: Be
careful not to damage the
gasket).
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.
3. Attach the exhaust tube
and gasket in the vertical
position.
4. Attach the exhaust
cover and gasket over the
horizontal exit.
6. Position the stove in it's final location.
7. Pull the excess length of liner out through the top of the chim-
ney. Trim the excess liner, install the cap and cap the chimney.
Exhaust Tube
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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”
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INSTALLATION INTO A MASONRY FIREPLACE
Figure 22
PRIOR TO INSTALLATION
Stand-offs (See Dimensions on page 7) may be removed to fit the
insert into the fireplace.
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 combus-
tible 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, creo-
sote deposits, blockage or other signs of deterioration. If neces-
sary, have any repair work done by a qualified professional 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 accom-
modate 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 mea-
surements. 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 chim-
ney. Trim the excess length and cap the vent.
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INSTALLATION INTO A FACTORY BUILT (METAL) FIREPLACE
Figure 23
PRIOR TO INSTALLATION
Stand-offs (See Dimensions on page 7) may be removed to fit the
insert into the fireplace.
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 together 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 fire-
place, 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 fire-
place 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.
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. 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 chim-
ney. Trim the excess length and cap the vent. Cover the A vent
chimney to weatherproof.
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21
Figure 24b
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 24a
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22
MINIMUM ENCLOSURE CLEARANCES
Figure 25
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23
NPI40 FINISHING
7. Slide the assembled
FLASHING INSTALLATION
trim down over the
flashing. (FIGURE 31)
FIGURE 31
1. Secure the
Right Flashing
to the right
FIGURE 26
8. Affix the logo to the
bottom left hand corner
of the left flashing.
side of the
TRIM
ASSEMBLY
unit using two
of the #8 x
1/2" screws.
NOTE: Feed
the Air
Control Rod
into the Air
Control Slot
on the Right
Flashing
before securing.
(FIGURE 26)
CONTROL
PANEL
AIR
CONTROL
ROD
RIGHT
FLASHING
TRIVET NPI40
AIR
CONTROL
SLOT
BURN
RATE LABEL
The trivet for the NPI40 is attached by two set screws on the inside
of the hopper lid.
2. Twist spring handle
(supplied with the heater)
onto the air control rod until
it hits the stop.
Figure 32
3. Remove the two control
panel securing screws,
discard the screws and
shipping bracket. (FIGURE
27)
SHIPPING
BRACKET
CONTROL
PANEL
SECURING FIGURE 27
SECURING
SCREWS
4. Secure the control panel
to the Right Flashing using
the two #8 x 3/8"
SCREWS
screws. (FIGURE
FIGURE 28
20) Secure the Left
Flashing with the
remaining #8 x 1/2"
screws. (FIGURE
INSTALL VIEWING DOOR NPS40 AND NPI40
26)
The main viewing door has been boxed separate
from the heater, but MUST be installed
before burning the heater.
Figure 33
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)
FIGURE 29
(Insert
Illustrated)
TOP
FLASHING
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)
1. Open both side panels, exposing the bushing on the left and
the latches on the right.
FIGURE 30
2. Align the pins on the door to the bushing on the left side of
the heater. Lower into place until both bushings touch.
3. Engage the latch hooks into the door frame. Snap the rear
W415-0616 / B / 02.18.08
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24
OPERATING INSTRUCTIONS
The pellet heater can be operated with or without the ring in place
Pellet Feed Dial
over the burn pot. With the ring in place, a more efficient burn will
occur, however more finer fly ash will be experienced. It may be
necessary to clean the burn pot of ash more frequently.
This switch controls
the amount of heat
output. The switch
has a scale (dial) from
1 through 5. At setting
5 the pellet feed rate
is the greatest.
Pellet Feed
Dial
CAUTION: 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).
Auger Cycle
Light
Start switch
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.
Blower Dial
Figure 34
Press "START" switch, turn the pellet feed dial to high to fill the au-
ger full of pellets and pull the air control rod all the way out allow-
ing 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 fill-
ing the burn pot and continue with the start-up instructions below.
SHUT-DOWN
START-UP
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.
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.
LIGHTING HEATER MANUALLY
Your heater can be lit manually without using the automatic igniter
by following the procedure below.
If no ignition is apparent and pellets are building up in the burn pot,
remove pellets from the burn pot before restarting.
CAUTION: Heater may be hot.
1. Press the start switch
2. Turn feed dial to "Optimum"
CAUTION: Heater may be hot.
3. Place a "handful" of pellets into the burn pot.
4. Cover with a small amount of approved
(non-volatile) fire starter gel.
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 possible. Once the room
has come up to temperature, the control may be set to a comfort-
able level.
5. Light fire starter with a match and close the
viewing door.
CAUTION: 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.
NOTE: The convection blower may cycle to high automatically
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.
PROPER PELLET LOADING
Before loading pellets into the hopper first transfer the pellets
from it's original plastic bag to a metal bucket.
WARNING: IT IS NOT RECOMMENDED TO BURN THE UNIT
ON LOW OR HIGH. THE MOST EFFICIENT SETTING IS 4
(OPTIMUM).
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.
NOTE: The flashing amber light corresponds to the auger 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.
DO NOT load pellets into the hopper if they have been exposed to
moisture. Moisture can cause pellets to swell and cause block-
age in the feed system. Thoroughly dry pellets before placing into
hopper.
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GENERAL MAINTENANCE NPS40 AND NPI40
DAILY (WHENEVER USING THE HEATER)
OPEN MAIN VIEWING DOOR
INSPECT THE BURN POT
When burning, the flames should be bright orange with embers
jumping from the burn pot.
!
WARNING
The front of the heater becomes very hot during opera-
tion. Let the heater cool completely before conducting
service.
1. Open the side doors on either side of the heater.
Figure 35
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 Napo-
leon 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
2. On the right side of the heater are two latches. Release
the latches by pulling the rear handle forward and dis-
engaging the hook from the door frame. Swing open the
viewing door.
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 40
Figure 36
!
WARNING
DISPOSAL OF ASHES
This rod becomes very hot during operation. Wait till heat-
er has cooled completely or you MUST wear heat resistant
gloves when cleaning or handling this heater.
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.
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.
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DAILY (WHENEVER USING THE HEATER)
CONTINUED
BI-WEEKLY (OR EVERY 10 BAGS OF
PELLETS)
MAKE SURE PELLETS ARE NOT PILING UP
VACUUM FIREBOX
The more frequently you clean out the fly ash, the more efficient
your heater will burn.
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 or-
ange/black, turn the heater off and check for build up of pellets.
!
WARNING
The fire box becomes very hot during operation. Let the
heater cool completely before conducting service.
The most likely causes are:
1. Feed rate has been set to maximum for an
extended period of time. Turn feed rate to
optimum.
1. Open the viewing door. See Figure 35 and 36
2. The door, glass, or ash pan is open or has an air
leak.
2. Lift the burn pot out and set aside on a non-combustible
surface. See Figure 39. Remove the right and left
louvres by lifting the louvres up and out of the firebox
3. The burn pot requires cleaning.
4. The exhaust system requires cleaning.
5. The heater requires adjustment.
setting them on a non-combustible surface.
Figure 41
6. Poor pellet quality
Figure 38
LOUVRES
CLEANING THE BURN POT
!
WARNING
AIR HOUSING
FIREBOX
Make certain the heater has fully cooled (approximately 25
minutes) before opening the door and conducting service.
Figure 39
To clean the
burn pot, open
the door and
knock away any
debris on the
burn pot. If se-
verely clogged,
remove the burn
pot to gain bet-
ter access.
3. Vacuum out the firebox, louvres, air housing and burn pot of all
fly ash.
If removing
the burn pot
set aside on a
non-combustible
surface. See
Figure 39. Once
removed, discard all material that has accumulated in the burn pot.
Make certain that all openings
are clear of any build up of
ash from the ledge below the
burn pot.
Figure 42
LOCATING NOTCH
Re-install the burn pot ensur-
ing it sits level in the heater.
Also must ensure the ignitor
IGNITOR
4. Replace the louvres and burn pot, latch the viewing door closed
and the burn pot locating notch
and close both side doors.
line up when reinstalling the
burn pot.
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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
CLEAN THE VERTICAL EXHAUST DUCT
NPS40:
If the PRPP40 or the brick kit NP841KT is in place, remove that
accessory first.
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 prevent exces-
sive build-up.
Figure 43
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.
Figure 44
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 vent-
ing system. The exhaust venting system should be inspected at
least once every year to determine if cleaning is necessary.
Insert a vacuum into the exhaust port holes and remove as much
fly ash as possible from behind the left and right exhaust mani-
folds. 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 venting 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 46.
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SEMI-ANNUALLY (OR EVERY TWO TONS OF PELLET)
Inspect the door gasket to make sure it is fully attached. Heater
CLEAN THE EXHAUST BLOWER
gasket cement can be used to re-attach if necessary. If the door
gasket is worn or flattened, replace.
NOTE: Do not attempt this maintenance without a replacement
exhaust blower motor mounting gasket.
Check the door to make sure it latches correctly. The latch should
engage with a slight amount of resistance, yet not be too difficult.
1. Remove the six nuts holding the exhaust blower
motor in place.
If the glass is cracked, replace.
CLEAN THE VENT
Nuts
Figure 45
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.
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.
6. Place the new exhaust
blower mounting gasket
around the screw holes
being very careful not to
tear it.
Figure 46
Figure 47
Vent system should be cleaned using chimney sweep brushes. We
recommend this be done by a qualified chimney sweep.
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.
CHECK ALL SEALS
Check for air leaks around the door, glass, and ash pan and re-
place 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.
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NORMAL OPERATING SOUNDS
Figure 48
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WIRING DIAGRAM
Figure 49
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31
REPLACEMENTS
Contact your dealer for questions concerning prices and availability of replacement parts. Normally all parts can be or-
dered through your Napoleon® 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 Napoleon® 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
#
1
2
3
4
5
6
7*
8
9
PART NO. DESCRIPTION
RIGHT LOUVRE ASSEMBLY
LEFT LOUVRE ASSEMBLY
AIR CONTROL
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
AUGER MOTOR
CONVECTION BLOWER
COMBUSTION BLOWER
COMBUSTION BLOWER MOUNTING GASKET
COMBUSTION BLOWER MOTOR MOUNTING GASKET
CONVECTION BLOWER GASKET
PRESSURE FITTING TAP
AUGER SCREW
DOOR LATCH
POWER CONTROL
AUGER CONTROL
AMBER LIGHT
NPS40 COMPONENTS
57 W010-1508
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
WELDED TOP ASSEMBLY
SIDE DOOR ASSEMBLY
HOPPER DOOR ASSEMBLY
ASH PAN ASSEMBLY
PEDESTAL SIDE DOOR ASSEMBLY
PEDESTAL BASE
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
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
NYLON BUSHING
SCREW SET
HARNESS WIRE
NAPOLEON® LOGO
CONTROL DOOR
BOTTOM OI PANEL
COMMON ACCESSORIES
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
IGNITOR HOUSING
CONTROL PANEL LATCH
EXHAUST TUBE
PORCELAIN REFLECTIVE RADIANT PANELS
OUTSIDE AIR KIT - 5 FT (2" DIA.)
BRICK, REFRACTORY
DECORATIVE LOG SET
IGNITOR
SMALL BLACK WIRE HANDLE
CONTROL HOUSING
AIR CONTROL SPACER
MOTOR BRACKET
COMBUSTION AIR TUBE ASSEMBLY
ACCENT BAR (2)
CAST, BURN POT
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
NPS40 ACCESSORIES
77* NPHE-40
HOPPER EXTENSION (INCREASES HOPPER
CAPACITY FROM 55 LBS TO 100 LBS PELLETS)
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)
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COMMON REPLACEMENTS PARTS
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33
NPS40 REPLACEMENTS PARTS
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NPI40 REPLACEMENTS PARTS
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35
COMMON ACCESSORY PARTS
NPI40 ACCESSORY PARTS
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36
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
The heater will not
start
- 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.
- 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.
The exhaust blower - Remove the left side access panel and check all connections against the wiring
is not operating
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.
- 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 - Push the burn pot back against the ignitor tube making sure the ignitor lines up to the
light the pellets hole in the burn pot.
however everything - Make certain the air control rod is pushed in to start up position.
else in the heater
operates
- 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.
The auger motor
is not functioning
normally
- Make certain the exhaust blower is operating
- 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 / B / 02.18.08
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37
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 / B / 02.18.08
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38
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.
W415-0616 / B / 02.18.08
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39
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 / B / 02.18.08
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40
NOTES
W415-0616 / B / 02.18.08
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