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P90 Zero Clearance Direct Vent Gas Fireplace

Owners &

Installation Manual

MODELS: P90-NG1 Natural Gas P90-LP1 Propane

WARNING: If the information in these instructions are not followed exactly, a ﬁ re or explosion may result causing property damage, personal injury or loss of life.

FOR YOUR SAFETY Do not store or use gasoline or other ﬂ ammable vapours and liquids in the vicinity of this or any other appliance.

Installation and service must be performed by a qualiﬁ ed installer, service agency or the gas supplier.

Tested by:

918-525

FPI FIREPLACE PRODUCTS INTERNATIONAL LTD. 6988 Venture St., Delta, BC Canada, V4G 1H4

Installer: Please complete the details on the back cover

and leave this manual with the homeowner.

Homeowner: Please keep these instructions for future reference.

FOR YOUR SAFETY What to do if you smell gas:

 Do not try to light any appliance  Do not touch any electrical switch:

do not use any phone in your building.

 Immediately call your gas supplier

from a neighbour's phone. Follow the gas supplier's instructions.

 If you cannot reach your gas

supplier, call the ﬁ re department.

07/17/06

Page 2

To the New Owner:

Congratulations! You are the owner of a state-of-the-art Excalibur® Gas Fireplace by FPI FIREPLACE PRODUCTS INTERNATIONAL LTD. The P90 is a hand crafted appliance and has been designed to provide you with all the warmth and charm of a wood ﬁ replace at the ﬂ ick of a switch. The model P90 has been approved by Warnock Hersey for both safety and efﬁ ciency. As it also bears our own mark, it promises to provide you with economy, comfort and security for many trouble free years to follow. Please take a moment now to acquaint yourself with these instructions and the many features of your Excalibur® Fireplace.

INFORMATION FOR MOBILE/MANUFACTURED HOMES AFTER FIRST SALE

This Excalibur® product has been tested and listed by Warnock Hersey as a Direct Vent Wall Furnace to the following standards: VENTED GAS FIREPLACE HEATERS ANSI Z21.88b-2003/CSA 2.33b-2003 and GAS-FIRED APPLIANCES FOR USE AT HIGH ALTITUDES CAN/CGA 2.17M91.

This Direct Vent System Appliance must be installed in accordance with the manufacturer's installation instructions and the Manufactured Home Construction and Safety Standard, Title 24 CFR, Part 3280, or the current Standard of Fire Safety Criteria for Manufactured Home Installations, Sites, and Communities ANSI/NFPA 501A, and with CAN/CSA Z240-MH Mobile Home Standard in Canada.

This appliance installation must comply with the manufacturer's installation instructions and local codes, if any. In the absence of local codes follow the current National Fuel Gas Code, ANSI Z223.1 and the current National Electrical Code ANSI/NFPA 70 in the U.S.A., and the current CAN/CGA B149 Gas Installation Code and the current Canadian Electrical Code CSA C22.1 in Canada.

This Excalibur® Mobile/Manufactured Home Listed appliance comes factory equipped with a means to secure the unit.

This Excalibur® Mobile/Manufactured Home listed appliance comes equipped with a dedicated #8 ground lug to which an 18 gauge copper wire from the steel chassis ground must be attached.

This appliance may only be installed in an aftermarket permanently located, manufactured (mobile) home, where not prohibited by local codes.

This appliance is only use with the type of gas indicated on the rating plate. This appliance is not convertible for use with other gases, unless a certiﬁ ed kit is used.

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace

Page 3

TABLE OF CONTENTS

SAFETY LABEL

Serial No. Decal ..........................................................4

REQUIREMENTS

MA Code - CO Detector

(for state of Massachusetts only) ..................................5

INSTALLATION

Important Message ......................................................6

Before You Start ............................................................6

General Safety Information ...........................................6

Installation Checklist ......................................................6

Locating Your Gas ﬁ replace ..........................................7

Manufactured Mobile Home Additional Requirements ..7

Heatwave Duct System Optional Kit ............................7

Clearances ....................................................................7

Combustible Mantels ....................................................8

Unit Base Stand-offs ......................................................8

Framing And Finishing ...................................................8

Facing Requirement ......................................................9

Hearth Requirements ....................................................9

Optional Cover Plate Template ....................................10

Unit Assembly Prior To Installation ..............................10

Venting Introduction .....................................................10

Venting ........................................................................11

Exterior Vent Termination Locations ............................ 12

Rigid Pipe Venting Components List ...........................13

Rigid Pipe Venting Systems ........................................14

Rigid Pipe Venting Arrangements

- Horizontal Terminations ............................................. 16

Rigid Pipe Venting Arrangements

- Vertical Terminations ................................................17

Horizontal Terminations ...............................................21

Vertical Terminations ...................................................22

Installation Procedures ................................................23

High Elevation .............................................................24

Gas Line Installation ....................................................24

Pilot Adjustment ...........................................................24

Gas Pipe Pressure Testing ..........................................24

Conversion Kit #791-969 from NG to LP .................... 25

Optional Brick Panels ..................................................29

Log Set Installation ......................................................29

Glass Door Installation ................................................31

Arch Surround .............................................................31

Optional Screen Door .................................................31

Accent Kit Installation ..................................................32

Option 1: Remote Control ............................................33

Option 2: Wall Switch ..................................................33

Option 3: Wall Thermostat ..........................................33

Wiring Diagrams ......................................................... 34

OPERATING INSTRUCTIONS

Operating Instructions .................................................36

Lighting Procedure ......................................................36

Shutdown Procedure ...................................................36

First Fire ......................................................................36

Aeration Adjustment ....................................................36

Normal operating Sounds of Gas Appliances ..............37

Copy Of The Lighting Plate Instructions ...................... 37

MAINTENANCE

Maintenance Instructions ............................................38

Gold-plated Door or Surround .....................................38

Log Replacement ........................................................38

Thermopile / Thermocouple ........................................38

Glass Gasket ...............................................................38

Door Glass ..................................................................38

Fan Maintenance .........................................................39

Removing Valve ...........................................................40

Installing Valve .............................................................40

PARTS LIST

P90 Main Assembly .....................................................41

P90 Burner Assembly & Log Set ................................. 43

P90 Flush Front Accessories .......................................44

WARRANTY

The Warranty: Limited Lifetime ...................................47

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace 3

Page 4

SAFETY LABEL

This is a copy of the label that accompanies each P90 Zero Clearance Direct Vent Gas Fireplace. We have printed a copy of the contents here for your review. The safety label is located on the front inside base of the unit, visible when the bottom louver is open.

NOTE: Excalibur improved. Check the label on the unit and if there is a difference, the label on the unit is the correct one.

units are constantly being

309

Serial No./ No de serie

309

0" Clearance to

combustibles from:

Top, bottom, sides & rear of unit

Mantel Clearances from Top:

Min. 18-1/4" (464mm)

Side Wall Clearance

from Side Facing

6-1/2" (165mm)

6-1/2"

Alcove Clearances:

Max. Depth 36" (914mm)

Min. Width 48" (1219mm),

Min. Height 72" (1229mm)

1-1/2" (38mm)

(See Instruction Manual for

Minimum Vent Clearances:

Horizontal Top 2-1/2" (64mm)

Horizontal Side

Horizontal Bottom 1-1/2" (38mm)

918--503

Detailed Instructions)

For the State of Massachusetts, installation and repair must be done by a plumber or gasﬁ tter licensed in the Commonwealth of Massachusetts.

HOMES AFTER FIRST SALE.

Minimum Clearances to Combustibles

MAY BE INSTALLED IN MANUFACTURED (MOBILE)

/Degagement Minimum De Materiaux Combustibles

Duplicate S/N

DO NOT REMOVE THIS LABEL / NE PAS ENLEVER CETTE ÉTIQUETTE

Modéle P90-NG1

ééé

CAN/CGA-2.17-M91,

Copy of Safety Decal for P90

APPAREIL FONCTIONNANT AU NATURAL GAZ

CONCU POUR ETRE POELE:

Pression d'allimentation minimum

Pression à la tubulure d' chappement lev e

Pression à la tubulure d' chappement basse

CANADA and U.S.A.

44-1/4" To Ceiling

Calorifique

Grandeur de l'injecteur

D bit minimum selon

D bit maximum selon

18-1/4"

l'altitude

APPAREIL FONCTIONNANT AU GAZ PROPANE

6-1/2"

Modéle P90-LP1

ééé

CONCU POUR ETRE POELE:

Pression d'allimentation minimum

Pression à la tubulure d' chappement lev e

Pression à la tubulure d' chappement basse

l'altitude

Calorifique

Grandeur de l'injecteur

D bit minimum selon

D bit maximum selon

tu/h kW

properly sealed

DOOR SEAL: Please

check that the door is

l'altitude

Grandeur de l'injecteur

D bit Calorifique minimum selon

é D bit Calorifique maximum selon

FPI Fireplace Products International Ltd. Delta, BC, Canada

For the State of Massachusetts, ﬂ exible connectors shall not exceed 36 inches in length.

For the State of Massachusetts, the appliances individual manual shut-off must be a t-handle type valve.

The State of Massachusetts requires the installation of a carbon monoxide alarm in accordance with NFPA 720 and a CO alarm with battery back up in the same room where the gas appliance is installed.

Gas-Fired Appliances For Use At High Altitudes

VENTED GAS FIREPLACE HEATER

Listed:

Certified for/Certifi e pour:

Tested to:

476-3059100 (June 2004)

Model P90-NG1

Report No.

Vented Gas Fireplace Heaters ANSI Z21.88b-2003/CSA 2.33b-2003

NATURAL GAS:

5" WC(1.25 kPa)

3.8" WC(0.95 kPa)

1.1" WC(0.27 kPa)

# 34 DMS

18,200 Btu/h (5.42 kW)

35,000 B (10.26 )tu/h kW

Minimum supply pressure

Manifold pressure high

Manifold pressure low

Orifice size

Minimum input

Maximum input

Model/Modele: P90-NG1

0-4500 ft/pi (0-1372 m)

Model P90-LP1

Altitude

PROPANE:

0-2000 ft/pi (0-610 m)

Minimum supply pressure

Manifold pressure high

Manifold pressure low

Altitude

Model/Modele: P90-LP1

Orifice size

Minimum input

2000-4500 ft/pi (610-1372 m)

Altitude

Maximum input

High

# 52 DMS

Orifice size

15,500 Btu/h (4.54 kW)

Minimum input

31,000 Btu/h (9.08 kW)

Maximum input

12" WC(3.00 kPa)

11" WC(2.74 kPa)

2.9" WC(0.72 kPa)

# 51 DMS

17,950 Btu/h (5.26 kW)

35,000 B (10.26 )

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace

VENTING: This appliance must be installed in accordance withthe manufacturer's installation instructions and withlocal codes, if any; if not,follow the currentANSI Z223.1 in the USA or

the current CAN 1-B149 in Canada. For Manufactured Home Installation: This Direct Vent System Appliance must be installed in accordance with the manufacturer's installation

instructions and Manufactured Home Construction and Safety Standard Title 24 CFR, Part 3280, or the current Standard for Fire Safety Criteria for Manufactured Home Installations,

Sites, and Communities ANSI /NFPA 501A, and with CAN/CSA Z240 MH Mobile Home Standard in Canada. Optional Fan (Part # 432-917) Optional Heat Wave Kit # 946-556

Optional Heat Release Kit# 946-570. Electrical supply115VAC, 1.13 A, 60Hz.

Made in Canada/ Fabrique au Canada

Not for use withsolid fuel. This ventedgasfireplaceis not for use withfilters. Forhorizontalrunsexceeding 10’, 5” x 8”piping mustbe used.

Page 5

REQUIREMENTS

MA Code - CO Detector

(for the State of Massachusetts only)

5.08: Modifications to NFPA-54, Chapter 10

(2) Revise 10.8.3 by adding the following additional requirements:

(a) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors

a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.

b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.

3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, "GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL

OBSTRUCTIONS".

4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR

5.08(2)(a)1 through 4.

(b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:

1. The equipment listed in Chapter 10 entitled "Equipment Not Required To Be Vented" in the most current edition of NFPA 54 as adopted by the Board; and

2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes.

(c) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include:

1. Detailed instructions for the installation of the venting system design or the venting system components; and

2. A complete parts list for the venting system design or venting system.

(d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases, but identifies "special venting systems", the following requirements shall be satisfied by the manufacturer:

1. The referenced "special venting system" instructions shall be included with the appliance or equipment installation instructions; and

2. The "special venting systems" shall be Product Approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions.

(e) A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace 5

Page 6

INSTALLATION

IMPORTANT MESSAGE

SAVE THESE

INSTRUCTIONS

The P90-NG1 or P90-LP1 Direct Vent Fireplace must be installed in accordance with these instructions. Carefully read all the instructions in this manual ﬁ rst. Consult the "authority having jurisdiction" to determine the need for a permit prior to starting the installation. It is the responsibility of the installer to ensure this ﬁ replace is installed in compliance with manufacturer's instructions and all applicable

codes.

BEFORE YOU START

Safe installation and operation of this appliance requires common sense, however, we are required by the Canadian Safety Standards and ANSI Standards to make you aware of the following:

INSTALLATION AND REPAIR SHOULD BE DONE BY A QUALIFIED SERVICE PERSON. THE APPLIANCE SHOULD BE INSPECTED BEFORE USE AND AT LEAST ANNUALLY BY A PROFESSIONAL SERVICE PERSON. MORE FREQUENT CLEANING MAY BE REQUIRED DUE TO EXCESSIVE LINT FROM CARPETING, BEDDING MATERIAL, ETC. IT IS IMPERATIVE THAT CONTROL COMPARTMENTS, BURNERS AND CIRCULATING AIR PASSAGEWAYS OF THE APPLIANCE BE KEPT CLEAN.

DUE TO HIGH TEMPERATURES, THE APPLIANCE SHOULD BE LOCATED OUT OF TRAFFIC AND AWAY FROM FURNITURE AND DRAPERIES.

WARNING: FAILURE TO INSTALL THIS APPLIANCE CORRECTLY WILL VOID YOUR WARRANTY AND MAY CAUSE A SERIOUS HOUSE FIRE.

CHILDREN AND ADULTS SHOULD BE ALERTED TO THE HAZARDS OF HIGH SURFACE TEMPERATURES, ESPECIALLY THE FIREPLACE GLASS, AND SHOULD STAY AWAY TO AVOID BURNS OR CLOTHING IGNITION.

YOUNG CHILDREN SHOULD BE CAREFULLY SUPERVISED WHEN THEY ARE IN THE SAME ROOM AS THE APPLIANCE.

CLOTHING OR OTHER FLAMMABLE MATERIAL SHOULD NOT BE PLACED ON OR NEAR THE APPLIANCE.

GENERAL SAFETY

INFORMATION

1) The appliance installation must conform

with local codes or, in the absence of local codes, with the current Canadian or National Gas Codes, CAN1-B149 or ANSI Z223.1 Installation Codes.

2) The appliance when installed, must be

electrically grounded in accordance with local codes, or in the absence of local codes with the current National Electrical Code, ANSI/NFPA 70 or CSA C22.1 Canadian Electrical Code.

3) See general construction and assembly

instructions. The appliance and vent should be enclosed.

4) This appliance must be connected to the

speciﬁ ed vent and termination cap to the outside of the building envelope. Never vent to another room or inside a building. Make sure that the vent is ﬁ tted as per Venting instructions.

5) Inspect the venting system annually for

blockage and any signs of deterioration.

6) Venting terminals shall not be recessed into

a wall or siding.

7) Any safety glass removed for servicing

must be replaced prior to operating the appliance.

8) To prevent injury, do not allow anyone who

is unfamiliar with the operation to use the ﬁ replace.

9) Wear gloves and safety glasses for protection

while doing required maintenance.

10) Be aware of electrical wiring locations in

walls and ceilings when cutting holes for termination.

11) Under no circumstances should this

appliance be modiﬁ ed. Parts that have to be removed for servicing should be replaced prior to operating this appliance.

12) Installation and any repairs to this appliance

should be done by a qualiﬁ ed service person. A professional service person should be called to inspect this appliance annually. Make it a practice to have all of your gas appliances checked annually.

13) Do not slam shut or strike the glass door.

14) Under no circumstances should any solid

fuels (wood, paper, cardboard, coal, etc.) be used in this appliance.

15) The appliance area must be kept clear and

free of combustible materials, (gases and other ﬂ ammable vapours and liquids).

Emissions from burning wood or gas could contain chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

INSTALLATION

CHECKLIST

1) Locate appliance, refer to the following

sections:

a) Locating Your Gas Fireplace b) Combustible Mantels c) Unit Base Stand-offs d) Framing & Finishing e) Facing Requirements f) Hearth Requirements g) Venting

2) Assemble Top Standoffs, page 9. (Refer

to the "Unit Assembly Prior to Installation" section.) NOTE: must be done before installing unit into ﬁ replace.

3) Install vent, refer to the "Venting" section.

4) Make gas and electrical connections. Test

the pilot. Must be as per diagram. Refer to the "Pilot Adjustment" section.

6) Install standard and optional features.

Refer to the following sections where applicable:

a. Brick Panels b. Log Set Installation c. Arch Surround d. Glass Door Installation e. Screen Door f. Accent Kit Installation g. Option 1: Remote Control h. Option 2: Wall Switch i. Option 3: Wall Thermostat

10) Final check.

Before leaving this unit with the customer, the installer must ensure that the appliance is ﬁ ring correctly and operation fully explained

to customer.

This includes:

1) Clocking the appliance to ensure the correct

ﬁ ring rate (rate noted on label 35,000 Btu/h) after burning appliance for 15 minutes.

2) If required, adjusting the primary air to ensure

that the ﬂ ame does not carbon. First allow the unit to burn for 15-20 min. to stabilize.

CAUTION: Any alteration to the product that causes sooting or carboning that results in damage is not the responsibility of the manufacturer.

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace

Page 7

INSTALLATION

LOCATING YOUR

GAS FIREPLACE

1) When selecting a location for your ﬁ replace,

ensure that the clearances outlined on this page are met.

2) Provide adequate clearances for

servicing.

3) The appliance must be installed on a ﬂ at,

solid, continuous surface (e.g. wood, metal, concrete). This may be the ﬂ oor, or raised up on a platform to enhance its visual impact. If the appliance is going to be installed on carpeting, combustible linoleum tile or other combustible material other than wood ﬂ ooring, the appliance must be installed on a metal or wood panel extending the full width and depth of the appliance.

4) The P90 Direct Vent Gas Fireplace can

be installed in a recessed position or framed out into the room as in A, B, C, D.

See Diagram 1.

A) Flat on Wall B) Flat on Wall Corner C) Recessed into

Wall/Alcove D) Corner

Diagram 1

5) This appliance is Listed for bedroom

installations when used with a Listed Millivolt Thermostat. Some areas may have further requirements, check local codes before installation.

6) The P90 Direct Vent Gas Fireplace is

approved for alcove installations, which meet the clearances listed on this page.

7) We recommend that you plan your instal-

lation on paper using exact measurements for clearances and ﬂ oor protection before actually installing this appliance. Have a qualiﬁ ed inspector, dealer, or installer review your plans before installation.

Note: For vent terminations see the

"Exterior Vent Termination

Locations" section.

MANUFACTURED

MOBILE HOME

ADDITIONAL

REQUIREMENTS

1) Ensure that structural members are not cut

or weakened during installation.

2) Ensure proper grounding using the #8 ground

lug provided. See the "Wiring Diagram" section.

HEATWAVE

DUCT SYSTEM

OPTIONAL KIT

#946-556

The HeatWave Air Duct Kit increases the effectiveness of your ﬁ replace by dispersing warm air from the ﬁ replace to remote locations in the same room or other rooms in your home.

Up to two kits may be installed on the ﬁ replace. Please Note: Only 1 HeatWave kit may be operated at one time. This includes the internal blower option as well.

OPTIONAL

HEAT RELEASE KIT

#946-570

The Heat Release Kit expels warm air from the ﬁ replace to the outside of the building, allowing the ﬁ replace to be operated with less heat entering the room. The kit may be used on either the left or right side.

CLEARANCES

The clearances listed below are Minimum distances unless otherwise stated:

A major cause of chimney related ﬁ res is failure to maintain required clearances (air space) to combustible materials. It is of the greatest importance that this ﬁ replace and vent system be installed only in accordance with these instructions.

Clearance to Combustibles from: Back 0" (0mm) Side 0" (0mm) Floor 0" (0mm)

NOTE: The minimum ﬂ oor clearance must be maintained from the top surface of the carpeting, tile, etc.

Side Wall Clearance 6-1/2" (165mm)

Horizontal Vent Clearances

Top 2-1/2" (64mm) Side 1-1/2" (38mm) Bottom 1-1/2" (38mm)

Vertical Vent Clearances 1-1/4" (32mm)

Alcove Clearances**: Max. Depth 36" (914mm) Min. Width 48" 1219mm) Min. Height 72" 1829mm)

* see mantle clearance instructions (Refer to the "Combustible Mantels" section).

WARNING:

Fire hazard is an extreme risk

if these clearances are not

adhered to.

Clearances for HeatWave and

Heat Release Kit

The HeatWave Duct Kit and the Heat Release Kit have different clearance and framing requirements, check the HeatWave and Heat Release manual for details.

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace 7

Page 8

INSTALLATION

COMBUSTIBLE MANTELS

Because of the extreme heat this ﬁ replace emits, the mantel clearances are critical.

Combustible mantel clearances from top of unit are shown in Diagram below.

Note: A non-combustible mantel may be

installed at a lower height if the framing is made of metal studs covered with a non-combustible board.

These drawings are to scale at 1:6 (one inch = 6 inches) Mantel can be installed anywhere in shaded area or higher using the above scale.

Note: Ensure the paint that is used

on the mantel and the facing is "heat resistant" or the paint may discolour.

P90 Flat Wall Surround and Tile Kit

The P90 Flat Wall Surround, Hearth Pad and Tile Kit cannot be modiﬁ ed in any way. It must be installed as manufactured.

FRAMING AND

FINISHING

1) Determine the total thickness of facing

material (e.g. drywall plus ceramic tiles) to allow the ﬁ nished surface to be ﬂ ush with the front of the unit. Total facing thickness can vary from 1/2" (13mm) to 1" (32mm) thick.

Install Top Standoffs & Side Nailing Strips before unit is slipped into position. See the "Unit Assembly Prior to Installation" section for assembly details.

2) Frame in the enclosure for the unit with

framing material. The framed opening is

46-3/8" high x 46-1/2" wide x 19-1/2" deep

(1168mm high x 1181mm wide x 495mm deep).

P90 Flat Wall Surround and Tile Kit Speciﬁ cations

UNIT BASE STAND-OFFS

To accommodate varying thicknesses and ﬁ nishes of hearth materials, we have increased the overall height of the appliance by a further 1 1/8”. This increase is added with the inclusion of two stand-offs at the bottom of the unit, below the outer box, taking the overall height of the framing dimensions from 45-1/4” up to 46-3/8”.

In the event that you should choose to use thinner materials to ﬁ nish the hearth, you can omit the stand-offs provided for raising the unit. However, we recommend that you leave the framing dimensions as they are in the manual and alter only the facing requirement by reducing it by the same distance that you have lowered the unit.

Insert the 2 unit base stand-offs underneath the unit as shown in the diagram below. Space the stand-offs centrally, approximately 2 or 2-1/2 feet apart. Ensure that the unit is not unstable.

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace

Framing Dimensions

A B C

46-1/2" 46-3/8" 19-1/2"*

1181mm 1168mm 495mm *If HeatWave option is installed, minimum depth is 20" (508mm)

*If HeatWave option is installed,

minimum depth is 20" (508mm)

4"(100mm)

Dia. Inner

6-7/8"(175mm)

Dia. Outer

10-7/8"

(276mm)

3) For exterior walls, insulate the enclosure to

the same degree as the rest of the house, apply vapour barrier and drywall, as per local installation codes. (Do not insulate

the ﬁ replace itself.)

(787mm)

42"(1067mm)

46-1/2"(1181mm)

70-1/2"(1791mm)

49-7/8"(1267mm)

31"

19-1/4"(489mm)

including standoffs

Page 9

INSTALLATION

4) Note: The unit does not have to be completely enclosed in a chase. The clearance on top of the unit is 0" to the standoffs so combustible building materials can be laid directly on top of the standoffs. You must maintain clearance from the vent to combustible materials for both rigid and ﬂ ex, see the "Clearances" section.

Note: 4 8 " ( 1121 9 m m )

is the minimum height for both ﬂ ex termination or Rigid Pipe venting.

The HeatWave Duct Kit has different clearance and framing requirements, check the HeatWave manual for details.

FACING REQUIREMENT

This ﬁ replace requires a non-combustible material extending from the framing header and sides.

The ﬂ anges on the front face of the ﬁ replace are for a facing thickness of 1" (25mm).

Facing Over 1" (25mm) Thick

If the facing material is over 1" (25mm) thick (example: brick or river rock), install the facing around the perimeter of the face. You may wish to make a face template as shown on the diagram.

FPI offers a cover plate template. See next page.

NOTE: If using a brick hearth, the ﬁ replace will need to be raised to accommodate the brick thickness. Example: If the brick is 2" thick, the unit must be raised 1".

HEARTH REQUIREMENTS

Floor Mounted Fireplaces

Raised Fireplaces

Please note that all vertical measurements are taken from the base of the unit excluding risers or bottom stand-offs.

No hearth is required when

the unit is raised 3" (76mm) off of the floor surface

Flooring

Fireplace

Stand

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace 9

You must take into account the depth of the floor covering (carpet, tile, linoleum, etc.) when determining the height of the ﬁ replace stand.

Page 10

INSTALLATION

OPTIONAL COVER

PLATE TEMPLATE

1) Ensure top clip screws are at top of oblong

holes before installation.

Oblong Screw

Holes

2) Position bottom of cover plate over pins

located at the bottom of the ﬁ rebox.

UNIT ASSEMBLY

PRIOR TO

INSTALLATION

The 2 Top Standoffs must be correctly positioned and attached to the top before unit is slipped into position.

Top Standoff Assembly

The top standoffs are shipped in a ﬂ at position and must be folded into shape and attached.

1) Remove the standoffs from the ﬁ replace top.

2) Take each standoff and bend into the correct shape. Bend up at the bend lines until the screw holes in the standoff and the pre-punched screw holes on the ﬁ replace top line up.

VENTING

INTRODUCTION

The P90 uses the "balanced ﬂ ue" technology Co-axial system. The inner liner vents products of combustion to the outside while the outer liner draws outside combustion air into the combustion chamber thereby eliminating the need to use heated room air for combustion and losing warm room air up the chimney.

Note: These flue pipes must not be

connected to any other appliance.

The gas appliance and vent system must be vented directly to the outside of the building, and never be attached to a chimney serving a separate solid fuel or gas burning appliance. Each direct vent gas appliance must use it's own separate vent system. Common vent systems are prohibited.

Pins

3) Bring cover plate towards the unit and hook

top clip over and behind the glass frame.

The top clip may need to be adjusted. Loosen

the 2 screws that secure the top clip to let the cover plate settle over and behind the glass frame. Once settled tighten screws.

Top Clip

Back View of

Cover Plate

Pin Holes

TO REMOVE:

1) Remove 2 screws that secure top clip. Ensure

to hold cover plate as it will fall forward.

2) Pull out top clip that is still hooked onto

glass.

3) Attach the standoff securely to the top with 2 screws per standoff (on opposite corners).

Side Nailing Strips

The side nailing strips come attached to the unit. There are 2 plates, one on the top and bottom that can be folded out as required.

Plates can be

folded out.

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace

Page 11

INSTALLATION

VENTING

FPI Direct Vent System (Flex) Horizontal Terminations Only

These venting systems, in combination with the P90 Direct Vent Gas Fireplace, have been tested and listed as a direct vent heater system by Warnock Hersey. The location of the termination cap must conform to the requirements in the Vent Terminal Locations diagram in the "Exterior Vent Termination Locations" section.

FPI Direct Vent (Flex) System Termination Kit (Part # 946-515) includes all the parts needed to install the P90 with a maximum run of 4 feet.

If a longer run is needed, the FPI Direct Vent system (Flex) kit is 946-516 which includes all the parts needed to install the P90 with a maximum 10' run.

Notes:

1) Liner sections should be continuous without any joints or

seams.

1) 6-7/8" dia. ﬂ exible liner (4 ft. length)

2) 4" dia. ﬂ exible liner (4 ft. length)

3) spring spacers (4)

4) thimble (2)

5) AstroCap termination cap (1)

6) screws (12)

7) tube of Mill Pac (1)

8) plated screws (8)

9) screws #8 x 1-1/2" Drill Point, Stainless

Steel (4)

1) 6-7/8" dia. ﬂ exible liner (10 ft. length)

2) 4" dia. ﬂ exible liner (10 ft. length)

3) spring spacers (7)

4) thimble (2)

5) AstroCap termination cap (1)

6) screws (12)

7) tube of Mill Pac (1)

8) plated screws (8)

9) screws #8 x 1-1/2" Drill Point, Stainless Steel

(4)

2) Only Flex pipe purchased from FPI may be used for Flex installations.

3) Horizontal vent must be supported every 3 feet.

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace 11

Page 12

INSTALLATION

EXTERIOR VENT TERMINATION LOCATIONS

from the centerline of the regulator.

any other appliance *(12"/30cm) #(9"/23cm)

H= Not to be installed above a meter/regulator assembly within (3'/90cm) horizontally

J= Clearance to service regulator vent outlet *(min 36"/90cm)

K= Clearance to non-mechanical air supply inlet to building or the combustion air inlet to

*(min. 84"/2.1m)

L= Clearance to a mechanical air supply inlet *(min. 72"/1.8m)

#3' (91cm) above if within 10' (3m) horizontally.

M= Clearance above paved sidewalk or a paved driveway located on public property

N= Clearance under veranda, porch, deck, or balcony *(min. 12"/30cm)

distance of (24"/60cm) from the centerline of the terminal (min. 18"/46cm) check with

local code.

Vent Termination Cap (14"/36cm)

Vent Termination Cap (12"/30cm)

Note:

- A vent shall not terminate directly above a sidewalk or paved driveway which is located between two single family dwellings and serves both dwellings.

- Only permitted if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the ﬂ oor.

- If the vent termination is accessible, a certiﬁ ed guard shall be installed.

* As speciﬁ ed in CGA B149 Installation Code. Note: Local codes or regulations may require different clearances.

A= Clearance above grade, veranda, porch, deck, or balcony *(min. 12"/30cm)

B= Clearance to window or door that may be opened *(12"/30cm) #(9"/23cm)

C= Clearance to permanently closed window *(min. 12"/30cm)

D= Vertical clearance to ventilated sofﬁ t located above the terminal within a horizontal

E= Clearance to unventilated sofﬁ t (min. 15"/38cm)

F= Clearance to outside corner: with AstroCap Termination Cap (min 6"/15cm), with Dura-

G= Clearance to inside corner: with AstroCap Termination Cap (min 6"/15cm), with Dura-

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace

# In accordance with the current ANSI Z223.1/NFPA 54, Natioinal Fuel Gas Code.

Page 13

INSTALLATION

RIGID PIPE VENTING COMPONENTS LIST

All Simpson Dura-Vent components are available directly from FPI.

Description Simpson Dura-Vent Selkirk Amerivent Direct VentGS

Direct-Temp

Direct Vent Secure Vent

Security

6" Pipe Length, Galvanized 908 4DT-6 N/A 6" Pipe Length, Black 908B 4DT-6B N/A 7" Pipe Length, Galvanized N/A N/A 4D7 7" Pipe Length, Black N/A N/A 4D7B 9" Pipe Length, Galvanized 907 4DT-9 N/A 9" Pipe Length, Black 907B 4DT-9B N/A 12" Pipe Length, Galvanized 906 4DT-12 4D12 12" Pipe Length, Black 906B 4DT-12B 4D12B 18" Pipe Length, Galvanized N/A 4DT-18 N/A 18" Pipe Length, Black N/A 4DT-18B N/A 24" Pipe Length, Galvanized 904 4DT-24 4D2 24" Pipe Length, Black 904B 4DT-24B 4D2B 36" Pipe Length, Galvanized 903 4DT-36 4D3 36" Pipe Length, Black 903B 4DT-36B 4D3B 48" Pipe Length, Galvanized 902 4DT-48 4D4 48" Pipe Length, Black 902B 4DT-48B 4D4B

Adjustable Length, 11"-14", Galv. 911 4DT-AJ N/A Adjustable Length, 11"-14", Black 911B 4DT-AJB N/A Adjustable Length, 17"-24", Black 917B N/A N/A Adjustable Length, 7" Galvinized N/A N/A 4D7A Adjustable Length, 7" Black N/A N/A 4D7AB Adjustable Length, 12" Galvinized N/A N/A 4D12A Adjustable Length, 12" Black N/A N/A 4D12AB

45O Elbow, Galvinized 945 4DT-EL45 4D45L 45O Elbow, Black 945B 4DT-EL45B 4D45LB 45O Elbow, Swivel, Galvinized 945G N/A N/A 45O Elbow, Swivel, Black 945BG N/A N/A 90O Elbow, Galvinized 990 4DT-EL90S 4D90LS 90O Elbow, Black 990B 4DT-EL90SB 4D90LBS 90O Elbow, Swivel, Galvinized 990G N/A N/A 90O Elbow, Swivel, Black 990BG N/A N/A

Ceiling Support 949 - n/a from FPI 4DT-CS 4DFSP Cathedral Support Box 941 4DT-CSS 4DRSB Wall Support/Band 988 4DT-WS/B 4DWS Offset Support 989 - n/a from FPI 4DT-OS N/A Wall Thimble, Black 942 4DT-WT 4DWT Wall Thimble Support Box/Ceiling Support 940 N/A N/A Firestop Spacer 963 4DT-FS 4DFSP Trim Plate, Black N/A 4DT-TP 4DFPB Brass Trim for Wall Thimble/Ceiling Support 3951 N/A N/A

Attic Insulation Shield 12" N/A N/A 4DAIS12 Attic Insulation Shield - Cold Climates 36" N/A N/A 4DAIS36

Basic Horizontal Termination Kit (A) 970 4DT-HKA 4DHTK2 Horizontal Termination Kit (B) 971 4DT-HKB 4DHTK1 Vertical Termination Kit 978 4DT-VKC 4DVTK

High Wind Vertical Cap 991 N/A N/A High Wind Horizontal Cap 985 N/A N/A Horizontal Square Termination Cap 984 4DT-HHC 4DHC Verical Termination Cap 980 4DT-HVC 4DVC Storm Collar 953 4DT-SC 4DSC

Adjustable Flashing, 0/12-6/12 943 4DT-AF6 4DF Adjustable Flashing, 6/12-12/12 943S 4DT-AF12 4DF12

Vinyl Siding Standoff 950 4DT-VS N/A Vinyl Siding Shield Plate N/A 4DT-VSP N/A

Snorkel Termination 14" 982 4DT-ST14 4D12S Snorkel Termination 36" 981 4DT-ST36 4D36S

SV4L6 SV4LB6 #N/A #N/A #N/A #N/A SV4L12 SV4LB12 SV4LA SV4LA SV4L24 SV4LB24 SV4L36 SV4LB36 SV4L48 SV4LB48

#N/A #N/A SV4LBA24 #N/A #N/A SV4LA12 SV4LBA12

#N/A #N/A SV4E45 SV4EB45 #N/A SV4EBR90-1 SV4E90-1 SV4EB90-1

SV4SD SV4CSB SV4BM SV4SU SV4RSM SV4PF SV4BF SV4LA #N/A

SV4RSA #N/A

SV - SHK SV - HK SV - FK

#N/A #N/A SV4CHC-1 SV4CGV-1 SV4FC

SV4FA SV4FB

SV4VS SV4VS

SV4STC14 SV4STC36

FPI 946-506/P Vent Guard (Optional) 510-994 Rigid Pipe Adaptor (Must use with all Rigid Piping) 640-530/P Riser Vent Terminal

946-205 Vinyl Siding Shield for Riser Vent Terminal 946-208/P Vent Guard (Optional) - Riser Vent Terminal 946-523/P AstroCap Horizontal Cap 946-206 Vinyl Siding Standoff - AstroCap

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace 13

Page 14

INSTALLATION

RIGID PIPE VENTING SYSTEMS

The minimum components required for a basic horizontal termination are:

1 Horizontal Termination Cap 1 90o Elbow 1 Rigid Pipe Adaptor 1 Wall Thimble 1 Length of pipe to suit wall thickness (see chart) 1 4" x 6-5/8" to 5" x 8" increaser for 5" x 8" venting

Wall thickness is measured from the back standoffs to the inside mounting surface of termination cap. For siding other than vinyl furring strips may be used, instead of the vinyl siding standoff, to create a level surface to mount the vent terminal. The Terminal must not be recessed into siding. Measure the wall thickness including furring strips.

If a Vinyl Siding Standoff is required (it must be used with vinyl siding), measure to outside surface of wall without siding and add 2 inches.

Horizontal and Vertical

Terminations for 4" x 6-5/8" Venting

Vertical

Terminal

Storm Collar

Part # 953

Flashing

943 or 943S

Vinyl Siding

Standoff (Optional)

Part #950

Flat Wall Installation

Wall Thickness

(inches)

4" - 5-1/2" 6"

7" - 8-1/2" 9"

10" - 1-1/2" 12"

9" - 14-1/2" 11" - 14-5/8" Adj. Pipe

15" - 23-1/2" 17" - 24" Adj.

Corner Installation

Wall Thickness

(inches)

3-1/4" - 6-3/4" 11" - 14-5/8" Adj. Pipe

7-3/4" - 16-1/4" 17" - 24" Adj. Pipe

7-1/4" - 8-3/4" 6" + 12"

4-1/4" - 5-3/4" 6" + 9"

Vent Length Required

(inches)

Vent Length Required

(inches)

9" + 9"

Ceiling Firestop

(Part # 963)

Pipe Length

Adj.Pipe Length

90 Elbow

24" Pipe

Length

Rigid Pipe Adaptor

11" - 14-5/8"

Termination

Wall Thimble

Part # 942

Horizontal

Termination

Horizontal

Cap

Alternate

Caps

WARNING:

Do not combine venting components from different venting systems.

However use of the the AstroCapTM and FPI Riser is acceptable with all systems.

This product has been evaluated by Intertek for using a Rigid Pipe Adaptor in conjunction with Duravent Direct-Vent GS, Selkirk Direct-Temp, Ameri Vent Direct venting and Security Secure Vent systems. Use of these systems with the Rigid Pipe adaptor is deemed acceptable and does not affect the Intertek WHI listing of components.

When using Rigid Vent other than

Simpson Dura-Vent, 3 screws must be

used to secure rigid pipe to adaptor.

The FPI AstroCap American Metal Products Ameri Vent Direct Vent, Security Secure Vent®, Selkirk Direct-Temp. AstroCapTM is a proprietary trademark of FPI Fireplace Products International Ltd. Dura-Vent® and Direct Vent GS are registered and/or proprietary trademarks of Simpson Dura-Vent Co. Inc.

and FPI Riser Vent terminal are certiﬁ ed for installations using FPI venting systems as well as Simpson Dura-Vent® Direct Vent GS,

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace

Page 15

INSTALLATION

Horizontal & Vertical Terminations for 5" x 8" Venting

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace 15

Page 16

INSTALLATION

RIGID PIPE VENTING ARRANGEMENTS - HORIZONTAL TERMINATIONS

FPI DIRECT VENT SYSTEM (FLEX)

(Propane & Natural Gas)

The diagram shows all allowable combinations of vertical runs with horizontal terminations, using one 90o elbow (two 45o elbows equal one 90o elbow).

All Rigid Pipe Systems 4" inner diameter 6-5/8" outer diameter

FPI Flex Vent 4" inner diameter 6-7/8" outer diameter

Note: Must use optional rigid pipe adaptor (Part # 510-

994) when using Rigid Pipe.

Note: FPI Direct Vent System (Flex) is only approved

for horizontal terminations.

All Rigid Pipe Systems 5" inner diameter 8" outer diameter

Note: Must use FPI increaser starter collar (Part # 946-605) at beginning of vent run.

• Maintain clearances to combustibles as listed in the "Clearances" section.

• Horizontal vent must be supported every 3 feet.

• Firestops are required at each ﬂ oor level and whenever passing through a wall.

5" x 8" venting starts at unit.

A vent guard (Part# 946-506/P) should be used whenever the termination is lower than the speciﬁ ed minimum or as per local codes.

Please note that all vertical measurements are taken from the base of the unit excluding risers or bottom stand-offs.

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace

Page 17

INSTALLATION

RIGID PIPE VENTING ARRANGEMENTS - VERTICAL TERMINATIONS

The shaded area in the diagram shows all allowable combinations of straight vertical and offset to vertical terminations, using two 90o elbow, with

rigid pipe vent systems for Propane and Natural Gas.

• Vent must be supported at offsets.

• Firestops are required at each ﬂ oor level and whenever passing through a wall.

• Maintain clearances to combustibles.

Note: Must use optional rigid pipe adaptor when using rigid vent systems (Part # 510-994).

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace 17

Page 18

INSTALLATION

The P90 is approved for a maximum 40 ft. straight vertical, with rigid pipe 4" x 6-5/8" vent systems for Propane and Natural Gas, as per diagram.

The shaded area in the diagram show all allowable combinations of straight vertical and offset to vertical terminations with rigid pipe vent systems for Propane and Natural Gas. Maximum two 45

• Vent must be supported at offsets

• Firestops are required at each ﬂ oor level and whenever passing through a wall.

• Maintain clearances to combustibles as listed in the "Clearances" section.

Please note that all vertical measurements are taken from the base of the unit excluding risers or bottom stand-offs.

elbows allowed.

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace

Page 19

Horizontal Venting with Two (2) 90o Elbows

Must Use: 5" x 8" Simpson Direct Vent GS Piping with FPI Increaser Starter Collar (Part #946-605).

One 90o elbow = Two 45o elbows.

Option V H + H1

A) 6" Min. 2' Max. B) 1' Min. 3' Max. C) 2' Min. 4' Max. D) 3' Min. 5' Max. E) 4' Min. 6' Max. F) 5' Min. 7' Max. G) 6' Min. 8' Max.

With these options, maximum total pipe length is 30 feet with minimum of 6 feet total vertical and maximum 8 feet total horizontal.

Please note minimum 1 foot between 90o elbows

INSTALLATION

Horizontal Venting with Three (3) 90o Elbows

Must Use: 5" x 8" Simpson Direct Vent GS Piping with FPI Increaser Starter Collar (Part #946-605).

One 90o elbow = Two 45o elbows.

Option V H V + V1 H + H1

A) 6" Min. 1' Max. 1'6" Min. 2' Max. B) 1' Min. 2' Max. 3' Min. 3' Max. C) 2' Min. 2' Max. 5' Min. 4' Max. D) 3' Min. 2' Max. 7' Min. 5' Max. E) 4' Min. 3 Max. 9' Min. 6' Max. F) 5' Min. 4' Max. 10' Min. 7' Max. G) 6' Min. 5' Max. 11' Min. 8' Max. H) 7' Min. 6' Max. 12' Min. 9' Max.

With these options, max. total pipe length is 30 feet with min. of 12 feet total vertical and max. 9 feet total horizontal.

Please note min. 1 foot between 90 elbows is required.

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace 19

Page 20

INSTALLATION

Must Use: 5" x 8" Simpson Direct Vent GS Piping with FPI Increaser Starter Collar (Part #946-605), unless V1 is greater than or equal to 4'-6" then use 4" x 6-5/8" piping.

One 90o elbow = Two 45o elbows.

Option V H V + V1 A) 0' Min. 2' Max. 1' Min. B) 1' Min. 4' Max. 2' Min. C) 2' Min. 5' Max. 3' Min. D) 3' Min. 6' Max. 4' Min. E) 4' Min. 7' Max. 5' Min. F) 5' Min. 8' Max. 6' Min.

Vertical Venting with Two (2) 90o Elbows

With these options, max. total pipe length is 30 feet with min. of 6 feet total vertical and max. 8 feet total horizontal.

Please note min. 1 foot between 90 required.

elbows is

For additional vertical venting with 2 x 90o elbows, refer to the "Rigid Pipe Venting Arrangements - Horizontal Termination" section.

Must Use: 5" x 8" Simpson Direct Vent GS Piping with FPI Increaser Starter Collar (Part #946-605).

One 90o elbow = Two 45o elbows.

Option V H + H1 V + V1 A) 6" Min. 2' Max. 3' Min. B) 1' Min. 2' Max. 3' Min. C) 2' Min. 3' Max. 4' Min. D) 3' Min. 4' Max. 6' Min. E) 4' Min. 5' Max. 7' Min. F) 5' Min. 6' Max. 8' Min. G) 6' Min. 7' Max. 9' Min. H) 7' Min. 8' Max. 10' Min.

Vertical Venting with Three (3) 90o Elbows

With these options, max. total pipe length is 30 feet with min. of 10 feet total vertical and max. 8 feet total horizontal.

Please note min. 1 foot between 90 required.

elbows is

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace

Page 21

INSTALLATION

HORIZONTAL

TERMINATIONS

Install the vent system according to the manufacturer's instructions included with the components.

1) Set the unit in its desired location. Check

to determine if wall studs or roof rafters are in the way when the venting system is attached. If this is the case, you may want to adjust the location of the unit. Rough in the gas preferably on the right side of the unit and the electrical (junction block is on the left side) on the left.

2) Direct Vent pipe and ﬁ ttings are designed with

special twist-lock connections to connect the venting system to the appliance ﬂ ue outlet. A twist-lock appliance adaptor is an available option that must be used in conjunction with the Simpson Dura-Vent Direct Vent GS system.

3) Put a bead of silicone inside the outer section

of the adapter and a bead of Mill Pac on the inner collar. Slip the adapter over the existing inner and outer ﬂ ue collar and fasten to the outer collar only with the 3 supplied screws (drilling pilot holes will make this easier). Level the ﬁ replace and fasten it to the framing using nails or screws through the nailing strips.

4) Assemble the desired combination of pipe

and elbows to the appliance adaptor and twist-lock for a solid connection.

Note:

a) Twist-lock procedure: Four indentations,

located on the female ends of pipes and ﬁ ttings, are designed to slide straight onto the male ends of adjacent pipes and ﬁ ttings, by orienting the four pipe indentations so they match and slide in to the four entry slots on the male ends, Diagram 1. Push the pipe sections completely together, then twist-lock one section clockwise approximately one-quarter turn, until the two sections are fully locked. The female locking lugs will not be visible from the outside, on the Black Pipe or ﬁ ttings. They may be located by examining the inside of the female ends.

Diagram 1

Note: Apply sealant "Mill-Pac" to inner

pipe and high temperature silicone sealant to outer pipe on every twistlock joint.

b) Horizontal runs of vent must be

supported every three feet. Wall straps are available for this purpose.

5) Mark the wall for a 10" x 10" square hole.

The center of the square hole should line up with the centerline of the horizontal pipe. Cut and frame the 10 inch square hole in the exterior wall where the vent will be terminated. If the wall being penetrated is constructed of non-combustible material, i.e. masonry block or concrete, a 7"(178mm) dia. (7-1/2"(191mm) dia. for ﬂ ex) hole is acceptable.

Note: With Dura-Vent, the minimum height is achieved by installing a

elbow

90 directly to the rigid pipe adaptor.

Diagram 2

Note:

a) The horizontal run of vent must be level,

or have a 1/4 inch rise for every 1 foot of run towards the termination. Never allow the vent to run downward. This could cause high temperatures and may present the possibility of a ﬁ re.

b) The location of the horizontal vent termi-

nation on an exterior wall must meet all local and national building codes, and must not be blocked or obstructed. For External Vent Terminal Locations, see diagram in the "Exterior Vent Termination Locations" section.

c) Snorkel Terminations: For installations requiring a vertical

rise on the exterior of the building, 14inch and 36-inch tall Snorkel Terminations are available, as well as the standard Riser Vent. Follow the same installation procedures as used for standard Horizontal Termination. NEVER install the snorkel upside down.

Diagram 3

Note: Riser Vent is only for use in above grade terminations.

Diagram 3a

*Dia 3, 3a & 4: As speciﬁ ed in CGA B149 Installation Code. Local codes or regulations may require different clearances.

Below Grade Installation

If the Snorkel Termination must be installed below grade, i.e. basement application, proper drainage must be provided to prevent water from entering the Snorkel Termination. Refer to Diagram 4. Do not attempt to enclose the Snorkel within the wall, or any other type of enclosure.

Dura-Vent

Snorkel

(305mm)

Min. 12"*

Window

Well

Adequate

drainage

Gravel

Diagram 4

NOTE: For Snorkel terminations in ABOVE

grade installations, follow national or local code requirements.

6) The arrow on the vent cap should be pointing up. Insure that the 1-1/2"

clearances to combustible materials are maintained (Diagram 4). Install the termination cap.

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace 21

Page 22

INSTALLATION

Diagram 5

The four wood screws provided should

be replaced with appropriate fasteners for stucco, brick, concrete, or other types of sidings.

Note: If installing termination on a siding

covered wall, a vinyl siding standoff or furring strips must be used to ensure that the termination is not recessed into the siding.

7) Before connecting the horizontal run of vent

pipe to the vent termination, slide the Wall Thimble (Part # 620-926) over the vent pipe.

8) Slide the appliance and vent assembly

towards the wall carefully inserting the vent pipe into the vent cap assembly. It is important that the vent pipe extends into the vent cap sufﬁ cient distance so as to result in a minimum pipe overlap of 1-1/4 inches. Secure the connection between the vent pipe and the vent cap by attaching the two sheet metal strips extending from the vent cap assembly into the outer wall of the vent pipe. Use the two sheet metal screws provided to connect the strips to the pipe section. See Diagram 6.

Diagram 6

9) Install wall thimble in

the center of the 10" square and attach with wood screws (Diagram 7).

Diagram 7

VERTICAL

TERMINATIONS

1) Maintain the 1-1/2"

clearances (air spaces) to combustibles when passing through ceilings, walls, roofs, enclosures, attic rafter, or other nearby combustible surfaces. Do not pack air spaces with insulation. Check the "Rigid Pipe Venting Systems" & "Rigid Pipe Venting Arrangements" sections for the maximum vertical rise of the venting system and the maximum horizontal offset limitations.

Diagram 1

2) Set the gas appliance in its desired location.

Drop a plumb bob down from the ceiling to the position of the appliance ﬂ ue exit, and mark the location where the vent will penetrate the ceiling. Drill a small hole at his point. Next, drop a plumb bob from the roof to the hole previously drilled in the ceiling, and mark the spot where the vent will penetrate the roof. Determine if ceiling joists, roof rafters or other framing will obstruct the venting system. You may wish to relocate the appliance or to offset, as shown in Diagram 2 to avoid cutting load bearing members.

3) A Firestop spacer must be installed in the

ﬂ oor or ceiling of every level. To install the Firestop spacer in a ﬂ at ceiling or wall, cut a 10 inch square hole. Frame the hole as shown in Diagram 3 and install the ﬁ restop.

Diagram 2

Note: Apply sealant "MillPac" to inner pipe and high temperature silicone sealant to outer pipe on every twist-lock joint.

Diagram 3

4) Assemble the desired lengths of pipe and

elbows. Ensure that all pipes and elbow connections are in the fully twist-locked position and sealed.

5) Cut a hole in the roof centered on the small

drilled hole placed in the roof in Step 2. The hole should be of sufﬁ cient size to meet the minimum requirements for clearance to combustibles of 1-1/2". Slip the ﬂ ashing under the shingles (shingles should overlap half the ﬂ ashing) as per Diagram 4.

Diagram 4: The upper half of the ﬂ ashing is

installed under the rooﬁ ng material and not

nailed down until the chimney is installed.

This allows for small adjustments.

6) Continue to assemble pipe lengths.

Note: If an offset is necessary in the attic

to avoid obstructions, it is important to support the vent pipe every 3 feet, to avoid excessive stress on the elbows, and possible separation. Wall straps are available for this purpose (Diagram 2).

Galvanized pipe is desirable above the rooﬂ ine

due to its higher corrosion resistance. Continue to add pipe sections through the ﬂ ashing until the height of the vent cap meets the minimum height requirements speciﬁ ed in Diagram 5 or local codes. Note that for steep roof pitches,

Diagram 5

Roof Pitch Minimum Vent Height

Feet Meters

ﬂ at to 7/12 2 0.61

over 7/12 to 8/12 2 0.61

over 8/12 to 9/12 2 0.61

over 9/12 to 10/12 2.5 0.76

over 10/12 to 11/12 3.25 0.99

over 11/12 to 12/12 4 1.22

over 12/12 to 14/12 5 1.52

over 14/12 to 16/12 6 1.83

over 16/12 to 18/12 7 2.13

over 18/12 to 20/12 7.5 2.29

over 20/12 to 21/12 8 2.44

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace

Page 23

INSTALLATION

the vertical height must be increased. A poor draft, or down drafting can result from high wind conditions near big trees or adjoining roof lines, in these cases, increasing the vent height may solve the problem.

7) Ensure vent is vertical and secure the base

of the ﬂ ashing to the roof with rooﬁ ng rails, slide storm collar over the pipe section and seal with a mastic.

8) Install the vertical termination cap by twist-

locking it.

Note: Any closets or storage spaces, which

the vent passes through must be enclosed.

Offset Chart

INSTALLATION

PROCEDURES

for FPI Direct Vent

System (Flex)

Note: To make the installation more aesthetically pleasing, we recommend framing out a square to mount the terminal to.

Note: If installing termination on a siding

covered wall, furring strips must be used to ensure that the termination is not recessed into the siding.

2) Level the ﬁ replace and fasten it to the framing

using nails or screws through the nailing strips.

3) Assemble the vent assembly by applying

Mill Pac to the 4"(100mm) inner collar of the termination and slipping the 4"(100mm) liner over it at least 1-3/8" (35mm). Fasten with the 3 screws (drilling pilot holes will make this easier). Apply Mill Pac or high temperature silicone to the 6-7/8"(175mm) ﬂ ex pipe and slip it over the 6-7/8" outer collar of the vent terminal at least 1-3/8"(35mm) and fasten with the 3 screws.

NOTE: H or iz ontal sections must be

supported at intervals not exceeding 3 feet (0.9 meter). (Flame picture and performance will be affected by sags in the liner).

4) Separate the 2 halves of the wall thimble and

securely fasten the one with the tabs to the outside wall making sure that the tabs are on top and bottom. Fasten the other thimble half to the inside wall. The thimble halves slip inside each other and can be adjusted for 2 x 4 or 2 x 6 walls. The liners must slip

over the collars a minimum of 1-3/8".

5) Slip the assembled liner and termination assembly through the thimble making sure the termination cap faces up (there are markings on the cap that show which way is up). This will position the termination cap with proper down slope for draining water. Fasten the cap to the outer wall with the 4 supplied screws.

6) Pull the centre 4"(100mm) liner and outer

6-7/8"(175mm) liner out enough to slip over

the ﬂ ue collars of the ﬁ replace. (You may wish to cut the liner shorter to make it more workable.) Do not bend liner more than

7) Apply Mill Pac over the ﬁ replace inner collar and slip the 4"(100mm) liner down over it and attach with 3 supplied screws.

8) Do the same with the 6-7/8"(175mm) liner.

9) Apply a bead of silicone between the thimble and termination and around the outer edge of the terminal at the wall in order to keep the water out.

IMPORTANT: Do not locate termination hood where excessive snow or ice buildup may occur. Be sure to check vent termination area after snow falls, and clear to prevent accidental blockage of venting system. When using snow blowers, make sure snow is not directed towards vent termination area.

1) Locate the unit in the framing, rough in the

gas (preferably on the right side of the unit) and the electrical (Junction block is on the left side) on the left. Locate the centerline of the termination and mark wall accordingly. Cut a 10"(254mm) hole in the wall (inside dimension).

Note: A 1-1/2"(38mm) clearance around

the liner must be maintained except that only a 1" (25mm) clearance is needed at the termination end. We recommend framing a 10"(254mm) x 10"(254mm) (inside dimensions) hole to give structural rigidity for mounting the termination.

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace 23

Page 24

INSTALLATION

P90-NG1 System Data

For 0 to 4500 feet altitude

Burner Inlet Oriﬁ ce Sizes: #34

Max. Input Rating 35,000 Btu/h Min. Input Rating 18,200 Btu/h

Supply Pressure min.5.0" w.c.

Manifold Pressure (High) 3.8"+/- 0.2"w.c.

P90-LP1 System Data

For 0 to 2000 feet altitude

Burner Inlet Oriﬁ ce Sizes: # 5 1 Max. Input Rating 35,000 Btu/h Min. Input Rating 17,950 Btu/h

High Altitude: For 2000 to 4500 feet altitude

Burner Inlet Oriﬁ ce Sizes: # 5 2 Max. Input Rating 31,000 Btu/h Min. Input Rating 15,500 Btu/h

Supply Pressure min.12.0" w.c.

Manifold Pressure (High) 11"+/- 0.2" w.c.

Electrical: 120 V A.C. System. Circulation Fan: variable speed 130

CFM.

Log Set: Ceramic ﬁ bre, 7 per set.

HIGH ELEVATION

This unit is approved in Canada for altitude 0 to 4500 ft. (CAN1 2.17-M91).

When using copper or ﬂ ex connectors use only approved ﬁ ttings. Always provide a union so that gas lines can be easily disconnected for servicing. Flare nuts for copper lines and ﬂ ex connectors are usually considered to meet this requirement.

Important: Always check for gas leaks with a soap and water solution or gas leak detector. Do not use open ﬂ ame for leak testing.

PILOT ADJUSTMENT

Periodically check the pilot ﬂ ames. Correct ﬂ ame pattern has three strong blue ﬂ ames: 1 ﬂ owing around the thermopile, 1 around the thermocouple and 1 ﬂ owing across the burner (it does not have to be touching the burner).

Note: If you have an incorrect ﬂ ame pattern,

contact your Excalibur® dealer for further instructions.

Incorrect ﬂ ame pattern will have small, probably yellow ﬂ ames, not coming into proper contact with the rear burner or thermopile or thermocouple.

The manifold pressure is controlled by a regulator built into the gas control, and should be checked at the pressure test point.

Note: To properly check gas pressure, both

inlet and manifold pressures should be checked using the valve pressure ports on the valve.

1) Make sure the valve is in the "OFF"

position.

2) Loosen the "IN" and/or "OUT" pressure

tap(s), turning counterclockwise with a

1/8" wide ﬂ at screwdriver.

3) Attach manometer to "IN" and/or "OUT"

pressure tap(s) using a 5/16" ID hose.

4) Light the pilot and turn the valve to "ON"

position.

5) The pressure check should be carried out

with the unit burning and the setting should be within the limits speciﬁ ed on the safety label.

6) When ﬁ nished reading manometer, turn

off the gas valve, disconnect the hose and tighten the screw (clockwise) with a 1/8" ﬂ at screwdriver. Note: Screw should be snug,

but do not over tighten.

S.I.T. VALVE DESCRIPTION

1) Gas on/off knob

2) Manual high/low adjustment

3) Pilot Adjustment

4) Thermocouple Connection - option

5) Outlet Pressure Tap

6) Inlet Pressure Tap

7) Pilot Outlet

8) Main Gas Outlet

9) Alternative TC Connection

GAS LINE

INSTALLATION

The gas line is brought through the right side of the appliance. The gas valve is situated on the right hand side of the unit and the gas inlet is on the right hand side of the valve.

The gas line connection may be made of rigid pipe, copper pipe or an approved ﬂ ex connector. (If you are using rigid pipe, ensure that the valve can be removed for servicing.) Since some municipalities have additional local codes it is always best to consult with your local authorities and the CAN/CGA B149 installation code.

For USA installations follow local codes and/or the current National Fuel Gas Code, ANSI Z223.1.

GAS PIPE PRESSURE

TESTING

The appliance must be isolated from the gas supply piping system by closing its individual manual shut-off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psig. (3.45 kPa). Disconnect piping from valve at pressures over 1/2 psig.

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace

Page 25

INSTALLATION

CONVERSION KIT #791-969 FROM NG TO LP

THIS CONVERSION MUST BE DONE BY A QUALIFIED GAS FITTER IF IN DOUBT DO NOT DO THIS CONVERSION !!

Each Kit contains one LPG Conversion Kit and one DC Sparker Kit.

LPG Conversion Kit Contains: Qty. Part # Description

1 904-529 5/32" Allen Key 1 904-645 Burner Oriﬁ ce #51 1 918-590 Label "Converted to

LPG" 1 908-528 Red "LPG" label 1 910-037 LP Injector (Pilot Oriﬁ ce) 1 918-487 Instruction Sheet

DC Sparker Kit Contains: Qty. Part # Description

1 820-475 Bracket DC Sparker 1 820-476 Bracket DC Sparker 1 904-153 Washer #8 External Star 1 904-330 Nut 8-32 Hex 1 904-438 Plug Nylon 0.750 Hole,

Black 1 904-531 Bushing Split Plastic

0.500 in.

1 904-543 Screw 8-32 x 3/4 Pan

Head 2 904-553 Screw #8 x 1/2 Type "B",

Black Oxide 1 910-073 Spark Generator Battery

Holder 1 910-074 Spark Generator Switch

C/W Wire 1 910-078 Battery Size AA

Energizer En91 2 910-199 Clip Wire Holder 1 910-903 Wire Fan To Power Cord

Ground 30 in. 904-781 Velcro Hook, Black 904-782 Velcro Hook, Black

4) Remove the 2 screws holding the Burner

Assembly to the ﬁ rebox base. Push the Burner Assembly to the left and lift out.

Remove the 2 screws, push Burner

Assembly to the left and lift out.

5) Pull off the

pilot cap to expose the pilot oriﬁ ce.

6) Unscrew the pilot oriﬁ ce with the allen

key and replace with the LP pilot oriﬁ ce in the kit and replace pilot cap.

7) Remove burner oriﬁ ce with a 1/2" wrench

and discard. Use another wrench to hold on to the elbow behind the oriﬁ ce.

9) Turn control knob to the “OFF”

position.

10) Remove the black protection cap by

hand from the high-low knob (Fig.1).

Fig. 1

11) Insert a 5/32” or 4mm Allen wrench

into the hexagonal key-way of the screw (Fig. 2), rotate it counterclockwise until it is free and extract it.

Fig.2

12) Check that the screw is clean and if

necessary remove dirt.

Installation of LPG

13) Flip the screw (Fig. 3).

Conversion Kit:

1) Shut off the gas supply.

2) H35-1: Lift off the Cast Top and remove

the glass front. Also, open up the control

panel door.

P90-1: Remove the facade if it is in-

stalled. Remove the glass door (refer to

the glass door section in the manual).

3) Remove the logs, embers, and brick

panels (if used).

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace 25

8) Reinstall new burner oriﬁ ce LP stamped

#51 and tighten.

Burner Oriﬁ ce

Fig.3

Page 26

INSTALLATION

14) Using the Allen wrench as shown in

Fig.4, rotate the screw clockwise until snug, do not overtighten.

Fig.4

WARNING!

Do not overtighten the screw.

Recommended to

grip the wrench by the short side.

) Verify that if the conversion is from NG

to LPG, the screw must be reassembled with the red o-ring visible (Fig. 5).

17) Reverse steps 4) to 2).

18) Attach clear label "This unit has been

converted to LPG" near or on top of the serial # decal.

19) Replace yellow "Natural Gas" label with

red "LPG" label.

Installation of the DC Sparker

for the H35-1 Units Only:

1) Remove the control panel by unscrewing

the 2 screws.

4) Attach the DC sparker generator

connector to the valve with a screw.

5) Remove the stove’s rear panel by unscrew-

ing the two screws.

Red o-ring visible

LPG Configuration

Fig.5

16) Reassemble the black protection cap

(Fig. 6).

Fig. 6

2) First, remove the Piezo Ignition Wire

from the Piezo Ignitor. Then remove the Piezo Ignitor from the control panel.

6) Attach the ground wire to the grounding

stud.

3) Plug up the Piezo hole with the plastic

bushing.

Before

WARNING!

Also check that the pilot and main

burner injectors

are appropriate for the gas type.

After

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace

Page 27

INSTALLATION

7) Attach the Piezo ignition wire to the DC

Sparker.

Piezo

Ignitor

8) Insert both the ground wire and the DC

sparker generator wire through the hole of the DC spark heat shield.

11) Attach the DC sparker generator wires to

the DC sparker.

12) Install the supplied battery into the DC

Sparker Box by opening the battery compartment.

NOTE: The battery in the DC Sparker

Box will need to be replaced annually.

Battery

Compartment

Installation of the DC Sparker

for the P90 Units Only:

1) Locate the Piezo Ignitor situated at the

side of valve.

Piezo

Ignitor

2) Remove the Piezo Ignitor by unscrewing

the nut at the back of the mounting bracket.

Ignitor

Wire

9) Install the plastic bushing over the

outside of the hole.

10) Attach the ground wire to the DC spark

mounting bracket.

13) Attach the heat shield to the DC sparker,

then mount this onto the stove.

Note: We recommend attaching the

DC sparker box to the bottom rear of the stove (or place this in a convenient location, away from the heat source).

14) Tie up the loose wire with the wire clip.

Piezo

Ignitor

3) Disconnect the ignitor wire from the

Piezo Ignitor and connect it to the DC Sparker.

Sparker

Ignitor

Wire

4) Install the 3/4" nylon plug to cover up the

hole on the mounting bracket.

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace 27

Page 28

INSTALLATION

5) Connect the DC spark generator wires

to the SIT Valve with the screw, which is provided in the kit.

6) Locate the ground lug at the receptical

box, left of the unit.

9) Run the other end of the ground wire

and DC spark generator wires through the bushing on the heat shield.

Heat Shield

10) Plug the DC spark generator wires to the

DC Sparker.

13) Mount the heat shield to the DC Sparker.

Secure into place with the velcro, which is provided in the kit.

14) Find a location which is not too hot and

is easy to reach for changing the battery.

15) Tie up the loose wire with the wire clip.

7) Connect one end of the supplied green

ground wire to the lug with the nut and washer from the kit.

Ground

wire from

kit

8) Install the 1/2" bushing to the heat

shield.

11) Connect the ground wire to the DC

Sparker mounting bracket.

12) Install the supplied battery into the DC

Sparker Box by opening the battery compartment.

NOTE: The battery in the DC Sparker

Box will need to be replaced annually.

Battery

Compartment

16) Check for gas leaks.

17) Check inlet and outlet pressures.

18) Check operation of ﬂ ame control.

19) Check for proper ﬂ ame appearance and

glow on logs.

Installer Notice:

These instructions must

be left with the appliance.

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace

Page 29

INSTALLATION

OPTIONAL

BRICK PANELS

1) Open the bottom louver door. Loosen the 2

screws holding the Burner ON/OFF switch and bracket to the bottom louver and lift the assembly out.

2) Remove Arch Surround.

3) Remove glass door. Remove logs.

Note: The logs must not be in the unit.

4) Insert the back brick panel ﬁ rst by carefully

slipping it between the back wall of the ﬁ rebox and the rear log bracket.

5) Put the side panels in next. Slide them in

from the front and push them ﬂ at up against the wall. Be very careful not to scratch them on the ﬁ rebox hardware.

LOG SET

INSTALLATION

Read the instructions below carefully and refer to the diagrams. If logs are broken do not use the unit until they are replaced. Broken logs can interfere with the pilot operation.

The gas log kit (Part # 780-930) contains the following pieces:

a) 02-75 Rear Log b) 02-55 Middle Left Log c) 02-50 Front Left Log d) 02-53 Center Left Log e) 02-51 Front Bottom Log f) 02-54 Center Right Log g) 02-52 Middle Right Log h) Embers 902-156

02-75

02-54 02-52

02-5102-75

Bracket

5) Position Log 02-53 across the cutouts in Logs 02-75 and 02-51 with the notch on the left side of the log ﬁ tting into the 2nd grate tab.

02-51

Bracket

02-53

Notch

6) Install the 2 brick retaining clips, one on

each side.

Note: If the bottom brick panel must be removed:

Remove the Rear Log Stand, then remove the Burner Tray. See the "Removing Valve" section.

02-50 02-53 02-51

The "02" refer numbers (i.e. 02-75) are

molded into the rear of each log.

NOTE: If you will be installing the optional

Brick Panels, install the Brick Panels prior to installing the logs.

1) Carefully remove the logs from the box and unwrap them. The logs are fragile, handle with care - do not force into position.

2) Sprinkle the vermiculite all over the top of the base brick panel.

3) Place the Log 02-75 on the rear log support pins with the ﬂ at side to the back.

02-75

4) Place Log 02-51 on the front right side of the burner. Push the back of the log against the 2 brackets with the notch on the bottom right side of the log ﬁ tting into the right side of the grate.

02-54

02-75

02-51

2nd Grate Tab

6) Position Log 02-54 across the cutouts in Logs 02-51 and 02-53. The notch in the bottom right end ﬁ tting against the 5th grate tab.

02-53

02-54

02-51

5th Grate Tab

Cutouts

02-51

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace 29

Page 30

INSTALLATION

7) Place the bottom left front edge of Log 02-55 against the rear bracket on the burner

tray and rest the log on the cutout on Log 02-53.

02-75

02-55

02-53

02-51

9) Sit Log 02-50 on the front left side of the burner. Push the back of the log against the 2 front brackets with the notch on the bottom of the log ﬁ tting into the ﬁ rst grate tab.

02-50

Front Brackets

02-55

02-50

02-53

10) Place the embers on the front of the burner tray in the places shown on the photos below.

Place embers in these 3 locations

on the burner tray.

02-51

Do not block the burner holes in this

area adjacent to the Log 02-54

02-54

Rear Bracket

8) Place Log 02-52 between Logs 02-51 and 02-75 and on the indentation on Log 02-54. The bottom right end sits behind the rear grate tab.

02-52

02-51

02-54

Log indentation

02-52

02-54

Cutouts

02-75

Rear

Grate

Tab

Notch

02-50

02-75

02-55

02-53

11) Test ﬁ re to ensure proper light off (make sure ﬂ ame ﬂ ows smoothly from one end of burner to the other). If there is any ﬂ ame hesitation, check that area for any blockage of the burner ports.

12) Install ﬂ ush glass and bay glass (if used) as per instructions in this manual.

02-55

02-54

02-51

Photo shows rear grate tab.

Log 02-51 was removed to show

the positioning of Log 02-52.

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace

Page 31

INSTALLATION

GLASS DOOR

INSTALLATION

1) Fit top door bracket over the ﬂ ange at the top of the ﬁ rebox.

2) Secure with 2 screws on the bottom.

Flange

Door

Tighten both screws to secure Arch Surround

to Glass Door.

3) Slide Bottom Louver into position. On each side secure the bottom screw ﬁ rst into the side bracket. Do not overtighten, leave slightly loose to allow the louver to move freely. Then tighten the top screw.

Bottom

Screw

OPTIONAL

SCREEN DOOR

1) Attach door bracket to side using 2 screws.

Door Bracket attaches with

2 screws.

Single Screen Door - only attach to right

side of unit.

Double Screen Door - attach to left and right

side of unit.

2) Slide the door(s) onto the hinges.

ARCH SURROUND

1) Place the Arch Surround into position by sliding the 2 holes in the bottom brackets over the pins on the base.

Fit the bottom brackets over

the pins on the base.

2) Slide the 2 screws on the rear of the Arch Surround into the bracket on the Glass Door and then tighten screw to secure.

Screw Bracket

Top

Screw

4) Attach the two control boxes to the bottom unit base and tighten the 2 screws on the left side and 1 screw on the right side.

Secure left side with 2 screws and right side

with one screw.

3) Single Screen Door only: Push the Locking

Ball Pin into the hole on the left side. Squeeze the clamp (use pliers) and slide it over the end of the Locking Ball Pin and tight against the Facade edge.

View from underneath of the

screw and the bracket.

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace 31

Page 32

INSTALLATION

ACCENT KIT INSTALLATION

1) Remove the rivets from the surround by pulling out the hoseclamp with

a screwdriver or plyer. Re-install the rivets by putting them through the holes on the sides of the surround.

2) Take the hoseclamps and put them over the back of each rivet. Squeeze

the hoseclamp to secure onto rivets ensuring that the hoseclamp is touching the back side of the surround. The hoseclamp can now be released.

3) Remove the handles by removing the nut and screw. Install the new

handles by placing them in position over the holes on the surround louver. Put the screws through the holes and secure them by tightening them with a nut.

5) Remove the 2 studs on the sides of the Hood. Insert the new studs

through the holes and secure them by ﬁ rst putting on the washer and then tighten with a nut.

DOUBLE & SINGLE DOOR OPTION

1) Remove the handles by removing the nut and screw. Install the new

handles by placing them in position over the holes on the door(s). Put the studs through the holes and secure them by tightening them with a nut.

4) Place the emblem over the emblem design on the surround. Insert

the studs through the holes. To secure them ﬁ rst put on the split lock washer and then the nut and tighten.

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace

Page 33

INSTALLATION

Option 1:

REMOTE CONTROL

Use the Excalibur® Remote Control Kit approved for this unit. Use of other systems may void your warranty.

The remote control kit comes with a hand held transmitter, a receiver and a wall mounting plate.

1) Choose a convenient location on the wall

to install the receiver and the receptacle box (protection from extreme heat is very important). Run wires from the ﬁ replace to that location. Use the Thermostat Wire Ta bl e .

2) Connect the two wires to the gas valve. See

diagram below.

CAUTION

Do not connect millivolt

remote control wires to a

120V wire.

3) Install 3 AAA alkaline batteries in transmitter

and 4 AA alkaline batteries in the receiver. Install the receiver and its cover in the wall. Switch the remote receiver to "remote" mode. The remote control is now ready for operation.

Option 2:

WALL SWITCH

1) Run the wire through the right or left side

gas inlet opening. Be careful not to damage wire.

Note: We recommend a maximum of 15'

of wire but if you wish to go with a longer run, use the Thermostat Wire Table.

2) Connect the wire to the wall switch and install

into the receptacle box.

CAUTION

Do not connect millivolt

wall switch wire to a 120V wire.

Option 3:

WALL THERMOSTAT

A wall thermostat may be installed if desired, connect the wires as per the wiring diagram. Use the table below to determine the maximum wire length.

Note: Preferable if the thermostat is installed on an interior wall.

Excalibur thermostat but any 250-750 millivolt rated nonanticipator type thermostat that is CSA, ULC or UL approved may be used.

offers an optional programmable

CAUTION

Do not connect millivolt

wall thermostat wires

to a 120V wire.

Thermostat Wire Table

Recommended Maximum Lead Length

(Two-Wire) When Using Wall

Thermostat (CP-2 System)

Wire Size Max. Length

14 GA. 16 GA. 18 GA. 20 GA. 22 GA.

50 Ft. 32 Ft. 20 Ft. 12 Ft.

9 Ft.

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace 33

Page 34

INSTALLATION

WIRING DIAGRAMS

This heater does not require a 120V A.C. supply for operation. In case of a power failure, the burner switch and the optional remote control/ thermostat will continue to operate.

For NATURAL GAS Units and Units NOT Equipped with DC Spark Boxes

Lockwasher

Star washer

ground wire

Burner

OFF

Thermostat

Fan

#8 Ground Lug

(mobile home

Nut

T-Stat

Red

Black

approved)

Assembly

Piezo

Ignitor

(To THTP)

(To TH)

However, a 120V A.C. power supply is needed for the fan/blower operation.

(Do not cut the ground terminal off under any circumstances.)

Neutral

Thermopile

Gas Pilot

Electrode

60 Hz

120V AC

Thermocouple

Live

Pilot

To Thermocouple IN

Ground

ON OFF

Rotary Speed

Brown

White

NOTE: Even if the fan is not purchased

with the unit, it is still a good idea to bring power to the receptacle box (provided with the unit) in case the fan is installed at a later date.

Fan

Green

Black Red Red

Fan Thermodisc

P I

(normally open)

Gas In

Control

"S.I.T" Valve

White

Caution: Ensure that the wires do not touch any hot surfaces and are away from sharp edges.

ON OFF

Remote Receiver

or Thermostat

(Millivolt) (Optional)

Remote Transmitter

(Optional)

CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.

Regency

Openings for

electrical connections

120 Volt

Power IN

Millivolt

Wires

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace

Page 35

INSTALLATION

For PROPANE Units and Units Equipped with DC Spark Boxes*

*For installation of the DC Spark Box refer to the LP Conversion instructions in this manual.

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace 35

Page 36

OPERATING INSTRUCTIONS

OPERATING

INSTRUCTIONS

1) Read and understand these instructions

before operating this appliance.

2) Check to see that all wiring is correct and

enclosed to prevent possible shock.

3) Check to ensure there are no gas leaks.

4) Make sure the glass in the door frame is

properly positioned. Never operate the appliance with the glass removed.

5) Verify that the venting and cap are

unobstructed.

6) Ensure that the brick panels are installed.

7) Verify log placement. If the pilot cannot be

seen when lighting the unit, the logs have been incorrectly positioned.

8) The unit should never be turned off, and on

again without a minimum of a 60 second wait.

LIGHTING

PROCEDURE

IMPORTANT

To ignite or reignite the pilot,

remove one glass panel/door.

NOTE: For all propane units and units

equipped with electric spark boxes, see "Copy of Lighting Plate Instructions" section for more details.

Only when the pilot holds, without pressure being applied to the control knob, resecure the glass panel to the unit. The unit must not be operated with the glass removed.

IMPORTANT Gas on/off knob cannot be turned from "PILOT" to "OFF" unless it is partially depressed.

1) Turn burner OFF using "ON/OFF" switch.

2) Turn gas control knob so indicator points

to "OFF" position and allow 5 minutes for any gas in the combustion chamber to escape.

3) Turn gas control knob counterclockwise

so indicator points to the "PILOT" position. Depress the gas control knob fully. Depress the igniter button several times until the pilot lights. After approximately one minute, release the gas control knob. The pilot ﬂ ame should continue to burn. If the pilot does not remain lit, repeat operation allowing a longer period before releasing gas control knob.

4) When the pilot stays lit, turn the gas knob

further counterclockwise to the "ON" position.

5) Use the wall switch, thermostat or remote

control to turn on the unit.

6) Rotate the ﬂ ame height regulator to adjust

the ﬂ ame height higher or lower.

SHUTDOWN

PROCEDURE

1) Use the wall switch, thermostat or remote

control to turn off the main burner.

2) Turn the main gas control clockwise to the

"OFF" position to turn off the pilot.

3) Turn off all electric power to appliance if

service is to be performed.

FIRST FIRE

The ﬁ rst ﬁ re in your ﬁ replace is part of the paint curing process. To ensure that the paint is properly cured, it is recommended that you burn your ﬁ replace for at least four (4) hours the ﬁ rst time before you use it with the fan on.

When ﬁ rst operated, the unit will release an odour caused by the curing of the paint, the burning off of any oils remaining from manufacturing. Smoke detectors in the house may go off at this time. Open a few windows to ventilate the room for a couple of hours.

The glass panel may require cleaning after the unit has cooled down.

DO NOT ATTEMPT TO CLEAN THE GLASS WHILE IT IS HOT.

Note: When the glass is cold and the

appliance is lit, it may cause condensation and fog the glass. This condensation is normal and will disappear in a few minutes as the glass heats up.

DO NOT BURN THE APPLIANCE WITHOUT THE GLASS FRONT IN PLACE.

During the ﬁ rst few ﬁ res, a white ﬁ lm may develop on the glass front as part of the curing process. The glass should be cleaned or the ﬁ lm will bake on and become very difﬁ cult to remove. Use a non-abrasive cleaner and NEVER clean the glass while it is hot.

AERATION

ADJUSTMENT

The air shutter can be adjusted by moving the adjusting wire up or down. The wire is accessed through the bottom louver opening. Open the air shutter for a blue ﬂ ame or close for a more yellow ﬂ ame. The burner aeration is factory set but may need adjusting due to either the local gas supply or altitude.

Minimum Air Shutter Opening: 3/16" Natural Gas 5/16" Propane

CAUTION: Carbon will be produced if air shutter is closed too much.

Note: Any damage due to carboning

resulting from improperly setting the aeration controls is NOT covered under warranty.

Adjustment Wire: Push to close or

pull to open aeration cap.

Closed - Tall yellow

Open - Short Blue

Note: Aeration Adjustment should only

be performed by an authorized Excalibur® Installer at the time of installation or service.

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace

Page 37

OPERATING INSTRUCTIONS

COPY OF THE LIGHTING PLATE INSTRUCTIONS NORMAL OPERATING

SOUNDS OF GAS

APPLIANCES

It is possible that you will hear some sounds from your gas appliance. This is perfectly normal due to the fact that there are various gauges and types of steel used within your appliance. Listed below are some examples. All are normal operating sounds and should not be considered as defects in your appliance.

Blower:

Excalibur® gas appliances use high tech blowers to push heated air farther into the room. It is not unusual for the fan to make a "whirring" sound when ON. This sound will increase or decrease in volume depending on the speed setting of your fan speed control.

Burner Tray:

The burner tray is positioned directly under the burner tube(s) and logs and is made of a different gauge material from the rest of the ﬁ rebox and body. Therefore, the varying thicknesses of steel will expand and contract at slightly different rates which can cause "ticking" and "cracking" sounds. You should also be aware that as there are temperature changes within the unit these sounds will likely re-occur. Again, this is normal for steel ﬁ reboxes.

Gas Inlet

Blower Thermodisc:

When this thermally activated switch turns ON it will create a small "clicking" sound. This is the switch contacts closing and is normal.

OFF

Pilot Flame: While the pilot ﬂ ame is on it can make a very slight "whisper" sound.

Gas Control Valve: As the gas control valve turns ON and OFF, a dull clicking sound may be audible, this is normal operation of a gas regulator or valve.

Unit Body/Firebox: Different types and thicknesses of steel will expand and contract at different rates resulting in some "cracking" and "ticking" sounds will be heard throughout the cycling process.

Gas Inlet

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace 37

Page 38

MAINTENANCE

MAINTENANCE INSTRUCTIONS

1) Always turn off the gas valve before cleaning.

For relighting, refer to lighting instructions. Keep the burner and control compartment clean by brushing and vacuuming at least once a year. When cleaning the logs, use a soft clean paint brush as the logs are fragile and easily damaged.

2) Clean appliance and door with a damp

cloth (never when unit is hot). Never use an abrasive cleaner. The glass should be cleaned with a gas ﬁ replace glass cleaner.

The glass should be cleaned when it starts looking cloudy.

3) The heater is ﬁ nished in a heat resistant

paint and should only be reﬁ nished with heat resistant paint. Excalibur® uses StoveBright Paint - Metallic Black #6309.

4) Make a periodic check of burner for proper

position and condition. Visually check the ﬂ ame of the burner periodically, making sure the ﬂ ames are steady; not lifting or ﬂ oating. If there is a problem, call a qualiﬁ ed service person.

5) The appliance and venting system must be

inspected before use, and at least annually, by a qualiﬁ ed ﬁ eld service person, to ensure that the ﬂ ow of combustion and ventilation air is not obstructed.

Note: Never operate the appliance without

the glass properly secured in place.

6) Do not use this appliance if any part has been

under water. Immediately call a qualiﬁ ed service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

7) Verify operation after servicing.

condensation, such as water droplets forming in the inner liner, and subsequently dripping out the joints, Continuous condensation can cause corrosion of caps, pipe, and ﬁ ttings. It may be caused by having excessive lateral runs, too many elbows, and exterior portions of the system being exposed to cold weather.

4) Inspect joints, to verify that no pipe

sections or ﬁ ttings have been disturbed, and consequently loosened. Also check mechanical supports such as Wall Straps, or plumbers' tape for rigidity.

GOLD-PLATED DOOR

OR SURROUND

The 24 carat gold-plated ﬁ nish on the surround and door requires little maintenance, and need only be cleaned with a damp cloth.

DO NOT use abrasive materials or chemical cleaners, as they may harm the ﬁ nish and void the warranty. Clean any ﬁ ngerprints off before

turning the unit on.

LOG REPLACEMENT

The unit should never be used with broken logs. Turn off the gas valve and allow the unit to cool before opening door and carefully remove the logs. (The pilot light generates enough heat to burn someone.) If for any reason a log should need replacement, you must use the proper replacement log. The position of these logs must be as shown in the diagrams under Log Installation.

Note: Improper positioning of logs may

create carbon build-up and will severely alter the unit's performance which is not covered under warranty.

GLASS GASKET

If the glass gasket requires replacement use a tadpole glass gasket (Part # 936-155).

DOOR GLASS

Your Excalibur® ﬁ replace is supplied with high temperature, 5 mm Neoceram ceramic glass that will withstand the highest heat that your unit will produce. If your glass requires cleaning, we recommend using an approved glass cleaner available at all authorized dealers. Do not use abrasive materials. Do not clean the glass when hot.

In the event that you break your glass by impact, purchase your replacement from an authorized Excalibur® dealer only, and follow our step-bystep instructions for replacement.

WARNING: Do not operate the appliance with the glass panels removed, cracked or broken. Replacement of the glass panels should be done by a licensed or qualiﬁ ed service person.

Caution: Wear gloves when removing damaged or broken glass.

Glass Replacement

Remove the glass door front (Refer to the "Glass Door Installation" section). Remove the 4 glass clips from each corner. Slide in the new replacement glass. Push the 4 glass clips back onto the frame. The glass must have

gasketing around it.

General Vent Maintenance

Conduct an inspection of the venting system semi-annually. Recommended areas to inspect as follows:

1) Check the Venting System for corrosion in

areas that are exposed to the elements. These will appear as rust spots or streaks, and in extreme cases, holes. These components should be replaced immediately.

2) Remove the Cap, and shine a ﬂ ashlight

down the Vent. Remove any bird nests, or other foreign material.

3) Check for evidences of excessive

THERMOPILE /

THERMOCOUPLE

1) Open the bottom louvers.

2) Loosen the thermocouple or thermopile with

a 7/16" wrench.

3) Disconnect thermocouple by loosening

nut from the valve with a 9mm wrench. Disconnect thermopile by loosening 2 screws marked TP on the valve.

4) Drop the thermocouple or thermopile down

from the bracket and pull it out of the unit.

5) Reinstall the new ones in reverse order.

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace

Page 39

FAN MAINTENANCE

MAINTENANCE

Unit must be grounded at all times. Do not cut the ground terminal off under any circumstances.

To Install the Fan

1) Shut the power off.

2) Open the bottom louver door. Loosen the 2

screws holding the Burner ON/OFF switch and bracket to the bottom louver and lift the assembly out.

3) Remove the bottom louver door.

4) Slide the fan in towards the rear of the unit

and slip it over the two mounting studs. Take care not to damage the insulation on the fan base. Ensure that the fan blades do not rub against the valve tubing. Diagram

Diagram 2

7) Attach the two control boxes to the bottom

unit base and tighten the 2 screws on the left side and 1 screw on the right side.

To Remove the Fan

1) Shut the power off.

2) Reverse the above instructions.

Note: The bearings are lubricated for life. Do not lubricate them. Make sure you vacuum the fan area on a regular basis.

IMPORTANT: These fans collect a lot of dust from within your home. Ensure you maintain these fan motors on a regular basis by vacuuming out the fan blades and housing using a soft brush nozzle.

Diagram 1

5) Connect fan ground cable to ground lug.

Refer to wiring diagram.

6) Slide the thermodisc/cover assembly into

the bracket clip on the underside of the ﬁ rebox. Check that no wire will touch the hot surfaces. Diagram 2.

Secure left side with 2 screws and right side

with one screw.

8) Secure the fan wires and power cord by

attaching one of the adhesive backed wire holder clips (Part #910-199) onto the stove base. Use the second clip to bundle up the wires approximately 4" from the control box. Ensure that there is no interference with the wires when the louver is closed and that no wire will touch the hot metal surfaces or sharp edges.

9) Plug the fan power cord into the rear end of

the receptacle box to provide the maximum clearance from the louvers.

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace 39

Page 40

MAINTENANCE

REMOVING VALVE

1) Shut the power off.

2) Open the bottom louver door. Loosen the 2

screws holding the Burner ON/OFF switch and bracket to the bottom louver and lift the assembly out.

3) Remove the facade if installed.

4) Remove the glass door (Refer to the "Glass

Door Installation" section).

5) Remove the logs.

6) Remove the burner/grate assembly by

removing the two Phillips head screws and then slide the burner assembly to the left and lift out.

9) Disconnect the inlet gas line. See dia. 2.

10) Disconnect the 2 TP wires and the 2 TH

wires from the valve.

11) Remove the 12 Phillips head screws securing

the valve tray assembly in place and then lift the entire assembly out.

screws

Valve Tray Assembly

Hint: If you are using black pipe, ensure

that there is a union by the valve, otherwise removal will be almost impossible.

INSTALLING VALVE

1) Attach the valve to the valve bracket with

the 4 (m5x8 metric) screws provided.

2) Reconnect the "gas out" ﬂ are ﬁ tting with an

11/16" wrench.

3) Reconnect the "gas out" ﬂ are nut with a

13/16" wrench.

4) Install piezo ignitor push button assembly

and reconnect wire.

5) Reconnect the quick drop out thermocouple

nut with a 9mm wrench.

6) Reconnect the pilot tube nut with a 7/16"

wrench.

7) Scrape off the old gasket from the ﬂ oor of the

ﬁ rebox and from the valve tray assembly.

8) Install a new gasket and reinstall the valve

tray assembly.

Diagram 1: Remove the left and right screws

and then slide the burner/grate assembly to

7) Remove the rear log stand by removing the

2 screws.

8) Remove the 2 screws & sleeves on the

bottom brick panel and lift out the bottom brick panel. The brick panel is very fragile

- handle with care.

the left and lift out.

screws

Rear Log Stand

12) Undo the pilot tube from the valve with a 7/16" wrench.

13) Undo the quick drop out thermocouple nut

on the valve with a 9mm (metric) wrench.

14) Remove the Piezo igniter wire and push button assembly.

15) Undo the "gas out" ﬂ are nut with a 13/16" wrench.

16)

Undo the "gas out" ﬂ are ﬁ tting with an

11/16" wrench.

Note: Failure to install a new gasket may severely affect the appliance performance.

9) Reinstall the 10 hold down screws.

10) Hook up the 2 TP and 2 TH wires to the

appropriate connections on the valve.

11) Reinstall the bottom brick panel, then screw

the 2 screws & sleeves through the brick panel to the ﬁ rebox base (reversing step 8) leaving them about 1/4" (6mm) above the brick panel. Reinstall the rear log stand.

12) Install Burner/grate assembly

13) Hook up the gas line and check for gas

leaks with a soap and water solution or a gas leak detector. (Do not use open ﬂ ame for leak testing.)

14) Fire up the unit temporarily

15) Check the manifold pressure.

16) Reinstall the logs and brick panels as

needed.

17) Reinstall the glass door and the facade.

18) Fire up the unit again and check for proper

ﬂ ame appearance and glow on logs.

17) Remove the 4 Phillips head screws from

the sides of the valve bracket and remove valve.

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace

Page 41

PARTS LIST

P90 MAIN ASSEMBLY

Part # Description Part # Description Part # Description

1) 430-129 Receptacle Box Mount

2) * Thermodisc Bracket

7) 910-428 Duplex Receptacle

8) 910-429 Box - Receptacle

9) 910-430 Cover - Receptacle

10) 904-687 Clamp Connector

15) * Heat Shield - Base

20) 790-021 Front Filler - Left Corner

21) 790-022 Front Filler - Right Corner

22) 790-012 Bafﬂ e

23) 780-011 Standoff - Top

24) 780-013 Standoff - Side

25) 780-091 Standoff - Rear

27) * Outer Flue Collar

28) * Inner Flue Collar Assy

30) * Gasket for Flue Collar

31) * Flue Mounting Bracket

32) 902-600 Brick Panel - Base 790-901 Brick Panel Set Standard Brown 790-902 Brick Panel Set Standard Red 790-903 Brick Panel Set Herringbone Brown 790-904 Brick Panel Set Herringbone Red

432-967 Burner ON/OFF Switch Assy

38) 910-241 Switch-Burner ON/OFF(3-way) 910-899 Wire Harness - Valve to Burner

42) 910-331/P Fan Motor (120 Volts) 432-966 Fan Switch Assembly-120 V (Optional)

43) * Power Cord (120 Volts) 910-845 Wire Harness - Plug In Fan

46) 910-330 Fan Speed Control Switch

47) 904-586 Knob - Speed Control

48) 910-199 Wire Holder Clip

49) 910-142 Thermodisc-Fan Auto On/Off 910-845 Wire Harness - Plug in Fan 904-713 U-clip at Louver

50) 510-994 Rigid Pipe Adaptor (Optional)

51) 790-011 Relief Frame Gasket

59) 790-009 Relief Door Mounting Plate

60) W260260 Top Relief Frame Gasket

61) 942-117 Top Relief Plate Frame

62) W260280 Top Relief Plate Gasket

63) 290-021 Air Bafﬂ e Plate

64) 790-093 Gasket - Exchanger Relief

946-556 Heat Wave Duct Kit (Optional)

89) 946-004 Junction Box

90) 946-000 Round Duct Adaptor

91) 946-002 Round to Oval Adaptor

92) 946-001 Oval Duct Adaptor

93) 946-007 Angle Bracket

94) 946-517/P Fan Assy - HeatWave Option

95) 946-006 Grill Plate - White

96) 946-005 Wall Adaptor Plate - White

97) 910-417 Knob - White

98) 910-366 Switch Cover Plate - White

99) 910-412 Fan Speed Controller

100) 910-367 Box-Plastic Switch Receptacle

102) 946-010 Flexible Air Duct 946-038 Insulation 6" dia. x 24"

946-570 Heat Release Duct Kit (Optional)

108) 910-165 Fan (120 V)

109) 946-000 Flexible Air Release Duct

918-525 Manual 791-969 Conversion Kit - NG to LP

*Not available as a replacement part.

33) * Brick Panel - Back

34) * Brick Panel - Left

35) * Brick Panel - Right

36) 904-716 #10 x 5/8" Butt Spacer 511-031 Brick Panel Clip

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace 41

Page 42

PARTS LIST

HEAT WAVE DUCT KIT

100

102

ON-OFF SWITCH

ASSEMBLY

FAN SWITCH ASSEMBLY

BRICK PANELS

109

108

HEAT RELEASE DUCT KIT

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace

Page 43

TPTH

AIR

PARTS LIST

P90 BURNER ASSEMBLY & LOG SET

Part # Description

52) 910-190 Piezo Ignitor & Nut

53) 780-021 Gasket - Valve Access Plate

790-574/P Valve Assy - Natural Gas 790-576/P Valve Assy - Propane

56) * Valve Tray - NG/LP

57) 910-478 Valve - S.I.T. - NG/LPG

58) * Valve Bracket

65) * Pilot Bracket

66) 910-038 Pilot Assy-NG 3 way ﬂ ame - S.I.T. 910-039 Pilot Assy-LP 3 way ﬂ ame - S.I.T. 904-617 Oriﬁ ce #34 - Natural Gas 904-645 Oriﬁ ce #51 - Propane 936-170 Oriﬁ ce Gasket

67) * Pilot Holder

68) W840470 Pilot Assembly Gasket

69) * Firebox Base

75) * Deﬂ ector - Left

76) * Deﬂ ector - Right

79) 790-525 Burner Assy - NG/LP

82) 511-030 Burner Grate Assy

83) 780-028 Rear Log Support Bracket

85) 780-930 Log Set (Complete)

*Not available as a replacement part.

TP TH

IN R I

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace 43

Page 44

PARTS LIST

P90 FLUSH FRONT ACCESSORIES

Part # Description Part # Description

790-518 Door Assembly - Complete

132) 790-137 Flush Door Frame

135) 940-326/P Glass (Flush)

136) 936-155 Glass Gasket (Tadpole) 904-691 U-Clip

790-920 Surround - Black - Complete 790-922 Surround - Gold - Complete 790-914 Surround - Antique Gold - Complete 790-916 Surround - Antique Nickel - Complete 790-918 Surround - Antique Copper - Complete

141) * Surround - Faceplate - Excalibur

142) * Surround - Louver

143) 904-621 Hole Plug

144) 790-122 Emblem

145) * Surround - Hood

146) * Handle

148) 904-719 Rivet-67-5/16 x 1/2 Black 904-719/G Rivet-67-5/16 x 1/2 Gold

149) 904-720 Pushnut Fastener 5/16" hole

790-924 Single Screen Door - Complete - Black 790-926 Single Screen Door - Complete - Gold 790-951 Single Screen Door - Complere - Antique Gold 790-952 Single Screen Door - Complete - Antique Nickel 790-953 Single Screen Door - Complete - Antique Copper

151) * Single Screen Door Frame

790-930 Double Screen Door - Complete - Black 790-932 Double Screen Door - Complete - Gold 790-941 Double Screen Door - Complete - Antique Gold 790-942 Double Screen Door - Complete - Antique Nickel 790-943 Double Screen Door - Complete - Antique Copper

161) * Double Screen Door Frame - Right

162) * Double Screen Door Frame - Left

163) * Mesh Screen - Double Door

164) * Retaining Plate - Double Door

167) * Door Mounting Bracket - Right

168) * Door Mounting Bracket - Left

*Not available as a replacement part.

136

152) * Mesh Screen - Single Door

153) * Retaining Plate - Single Door

154) * Handle - Single Door

155) 904-721 Push-Fit Ball Plunger

156) * Door Mounting Bracket - Right

157) * Carriage Bolt

158) 948-221 Logo Plate

159) 904-724 Plunger Clamp

164

163

168

157

162

146

159

155

161

DOUBLE DOORS

157

167

154

163

132

FLUSH DOOR

164

148

141

158

146

152

144

142

153

145

155

157

143

146

135

155

148

149

159

155

149

SINGLE DOOR

151

156

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace

Page 45

NOTES

___________________________________________________

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace 45

Page 46

NOTES

___________________________________________________

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace

Page 47

WARRANTY

Excalibur® Fireplace Products are designed with reliability and simplicity in mind. In addition, our internal Quality Assurance Team carefully inspects each unit thoroughly before it leaves our facility. FPI Fireplace Products International Ltd. is pleased to extend this limited lifetime warranty to the original purchaser of a Excalibur® Product.

THE WARRANTY: LIMITED LIFETIME

The combustion chamber, heat exchanger, burner tubes/pans, logs, embers and all gold plating (against defective manufacture only) are covered under the Limited Lifetime Warranty for ﬁ ve (5) years for parts and subsidized labour* and parts only thereafter.

Glass is covered for lifetime against thermal breakage only, parts and subsidized labour* for three (3) years and parts only thereafter from date of purchase.

Electrical and mechanical components such as blowers, switches, wiring, thermodiscs, FPI remote controls, spill switches, thermopiles, thermocouples, pilot assembly components, and gas valves are covered for one year parts and subsidized labour* from the date of purchase. Blowers and valves replaced under warranty are considered repairs and continue as if new with appliance. ie. twelve (12) months from original purchase date of appliance with a minimum of three (3) months coverage from date of replacement.

FPI venting components are covered parts and subsidized labour* for three (3) years from date of installation and parts only thereafter.

Conditions:

Any part or parts of this unit which in our judgement show evidence of such defects will be repaired or replaced at FPI's option, through an accredited distributor or agent provided that the defective part be returned to the distributor or agent Transportation Prepaid, if requested.

It is the general practice of FPI to charge for larger, higher priced replacement parts and issue credit once the replaced component has been returned to FPI and evaluated for manufacturer defect.

The authorized selling dealer is responsible for all in-ﬁ eld service work carried out on your Excalibur® product. FPI will not be liable for results or costs of workmanship from unauthorized service persons or dealers.

At all times FPI reserves the right to inspect product in the ﬁ eld which is claimed to be defective.

All claims must be submitted to FPI by authorized selling dealers. It is essential that all submitted claims provide all of the necessary information including customer name, purchase date, serial #, type of unit, problem, and part or parts requested, without this information the warranty will be invalid.

Exclusions:

This limited Lifetime Warranty does not extend to or include paint, door or glass gasketing or trim.

At no time will FPI be liable for any consequential damages which exceed the purchase price of the unit. FPI has no obligation to enhance or modify any unit once manufactured. ie. as products evolve, ﬁ eld modiﬁ cations or upgrades will not be performed.

FPI will not be liable for travel costs for service work.

Installation and environmental problems are not the responsibility of the manufacturer and therefore are not covered under the terms of this warranty policy.

Refractory liners, gaskets, door handles, paint are not covered under the terms of this warranty policy.

Any unit which shows signs of neglect or misuse is not covered under the terms of this warranty policy.

The warranty will not extend to any part which has been tampered with or altered in any way, or in our judgment has been subject to misuse, improper installation, negligence or accident, spillage or downdrafts caused by environmental or geographical conditions, inadequate ventilation, excessive offsets, negative air pressure caused by mechanical systems such as furnaces, fans, clothes dryer, etc.

Freight damage to stoves and replacement parts is not covered by warranty and is subject to a claim against the freight carrier by the dealer.

FPI will not be liable for acts of God, or acts of terrorism, which cause malfunction of the appliance.

Performance problems due to operator error will not be covered by this warranty policy.

Products made or provided by other manufacturers and used in conjunction with the operation of this appliance without prior authorization from Excalibur®, may nullify your warranty on this product.

Simpson Dura-Vent venting components are covered by Simpson Dura-Vent Inc. warranty.

Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace 47

Page 48

Excalibur® ﬁ replace products are designed with reliability and simplicity in mind. In addition, our internal Quality Assurance Team carefully inspects each unit thoroughly before it leaves our door.

FPI Fireplace Products International Ltd. is pleased to extend this Limited Lifetime Warranty to the original purchaser of a Excalibur

Product.

See the inside back cover for details.

http://www.excalibur-ﬁ re.com

Installer: Please complete the following information

Dealer Name & Address: ______________________________________________

___________________________________________________________________

Installer: ___________________________________________________________

Phone #: ___________________________________________________________

Date Installed: ______________________________________________________

Serial No.: __________________________________________________________

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