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I spent a ton of money on this fireplace . Its definately not the cheapest unit out there . While it does burn great and looks fine, it operates far from what is advertised.
First and foremost, the airwash system that is supposed to keep the glass clean does not work. Also, they say that you can operate the fireplace with the doors open and it will not bring smoke back into the room . These are the two features that sold me on this unit.
We have brought this forward to our retailer and the Napolean rep has apparantley been avoiding us like the plaque.
I have had the NZ6000 for 1 year now and am experiencing the same thing with the air wash. The most creosite collect s on the top corners. Napoleon has also given me the run-around. Try using very dry wood and make sure you get the box heated nicely prior to putting it on low. I also run mine for 15 to 20 minutes with the doors open to let the fire get going fiercely, prior to closing the doors. Then I leave it on high for another 10 mintues and then lower the setting. This will help in keeping the glass cleaner not clean. I also have a problem with the doors not aligning in the center. The left one bows out in the center and the right has the welded middle bar angled inward which leaves some play on the door when completely shut. This causes air to seep into the firebox from the room. I can hear the air hissing.
Regarding the smoke, make sure that you put the lever on high for a few seconds and then open the doors slightly, wait a few second to let the air stablize and then slowly open the doors, without breathing :). Unfortunately this is the only thing that you can do other than opening the baffle which will let the hot air escape and unfortunately cause some smoke to seep in when you close it, because it will cause the air to move around the firebox erratically. Sometimes when I load the firebox I only open the right hand side door which helps with the smoke if the fire is not lit nicely. ususally if the fire is going good i don't get smoke in the room if I am careful in opening the doors.