Excalibur P90-NG, P90-LP Owners & Installation Manual

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Page 1

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P90 Zero Clearance Direct Vent Gas Fireplace

Owners &

Installation Manual

MODELS: P90-NG Natural Gas P90-LP Propane

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

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

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

Tested by:

918-072d

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 ﬁre department.

01/09/06

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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 ﬁreplace at the ﬂick of a switch. The model P90 has been approved by Warnock Hersey for both safety and efﬁciency. 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 certiﬁed kit is used.

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace

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TABLE OF CONTENTS

Page

Safety Label

Safety Label ............................................................... 4

Installation

Important Message ..................................................... 5

Before You Start ......................................................... 5

General Safety Information ........................................ 5

Installation Checklist ................................................... 5

Locating Your Gas Stove ............................................ 6

Manufactured Home Additional Requirements ........... 6

Optional HeatWave Duct System ............................... 6

Optional Heat Release Kit .......................................... 6

Clearances ................................................................. 6

Combustible Mantel Clearances ............................... 7

P90 Flat Surround and Tile Kit ................................... 7

Unit Base Stand-Offs .................................................. 7

Framing and Finishing ................................................ 7

Facing Requirements ................................................. 8

Hearth Requirements ................................................. 8

Optional Cover Plate Template ................................... 9

Unit Assembly Prior to Installation

Top Standoff Assembly ........................................ 9

Side Nailing Strips ................................................ 9

Venting Introduction .................................................... 9

Venting: Direct Vent System (Flex) ........................... 10

Exterior Vent Termination Locations ..........................11

Rigid Pipe Venting Components List ........................ 12

Rigid Pipe Venting Systems:

Horizontal and Vertical Terminations .................. 13

Venting Arrangements

Horizontal Terminations .................................... 15

Vertical Terminations .......................................... 16

Horizontal Venting .............................................. 18

Vertical Venting .................................................. 19

Venting - Dura-Vent Horizontal Installations ............. 20

Venting - Dura-Vent Vertical Termination .................. 21

Venting - Installation Procedures for Direct Vent

System (Flex) ..................................................... 22

System Data ............................................................. 23

High Elevation .......................................................... 23

Gas Line Installation ................................................. 23

Pilot Adjustment ........................................................ 23

Gas Pipe Pressure Test ............................................ 23

Page

SIT Valve Description ............................................... 23

Conversion to Propane ............................................. 24

Optional Brick Panels ............................................... 25

Log Set Installation ................................................... 25

Glass Door Installation ............................................. 27

Front Facade ............................................................ 27

Optional Screen Door ............................................... 27

Accent Kit Installation ............................................... 28

Remote Control (optional) ........................................ 29

Remote Wall Switch (optional) ................................. 29

Wall Thermostat (optional) ....................................... 29

Wiring Diagram ......................................................... 30

Operating Instructions

Operating Instructions .............................................. 31

Lighting Procedure ................................................... 31

Shutdown Procedure ................................................ 31

First Fire ................................................................... 31

Aeration Adjustment ................................................. 31

Normal Operating Sounds of

Gas Appliances .................................................. 31

Lighting Plate Instructions ........................................ 32

Maintenance

Maintenance Instructions ........................................ 32

General Vent Maintenance ....................................... 33

Gold-Plated or Brass Door or Facade ...................... 33

Log Replacement ..................................................... 33

Thermopile/Thermocouple ....................................... 33

Glass Gasket ............................................................ 33

Door Glass ............................................................... 33

Fan Maintenance ...................................................... 34

Removing Valve ........................................................ 35

Installing Valve .......................................................... 35

Parts List

Replacement/Spare Parts List .................................. 36

Warranty

Warranty ................................................................... 43

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 3

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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 units are constantly being improved. Check the label on the unit and if there is a difference, the label on the unit is the correct one.

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

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

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

Copy of Safety Decal for P90

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace

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INSTALLATION

IMPORTANT:

SAVE THESE

INSTRUCTIONS

The P90-NG or P90-LP Direct Vent Fireplace must be installed in accordance with these instructions. Carefully read all the instructions in this manual ﬁrst. 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 ﬁreplace 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:

INSTAL L AT I O N AND R E PA I R SHOULD BE DONE BY A QUALI FIED SERVICE PERSON. THE APPLIANCE SHOUL D BE IN SPECTED BEFORE USE AND AT LEAST ANNUALLY BY A PRO FESSIONAL SERVICE PERSON. MORE FREQUENT CLEANING MAY BE REQUIRED DUE TO EX CESSIVE LINT FROM CARPETING, BEDDING MATERIAL, ETC. IT IS IMPERATIVE THAT CONTROL COMPAR T MENTS, BURNERS AND CIRCULATING AIR PAS SAGEWAYS 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 TEMPERA TURES, ESPECIALLY THE FIRE PLACE 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 FLAM

MABLE MATERIAL SHOULD NOT BE PLACED ON OR NEAR THE APPLIANCE.

GENERAL SAFETY IN-

FORMATION

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 speciﬁed 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 ﬁtted 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 ﬁreplace.

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 ap pliance be modiﬁed. 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 qualiﬁed 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 ﬂammable vapours and liquids).

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

INSTALLATION

CHECKLIST

1) Locate appliance

a) Room location, page 6 b) C l ea ra nc es t o C o m bu st ib l es ,

pages 6-7. c) Mantle Clearances, page 7 d) Framing & Finishing Requirements, page 7. e) Facing and Hearth Requirements,

page 8. f) Venting Requirements, pages 10-17.

2) Assemble Top Standoffs, page 9. (NOTE:

must be done before installing unit into ﬁreplace.)

3) Install vent, pages 20-22.

4) Make gas and electrical connections. Test

the pilot. Must be as per diagram. Page

23.

5) Install brick panels (optional), page 25.

6) Inst a l l log set w h e r e in d i c ated o n

page 25-26.

7) Install Front Facade, page 27.

8) Install Optional Screen Door, page 27.

9) Install optional Wall Switch, Remote Control,

or Wall Thermostat, page 29.

10) Final check.

Before leaving this unit with the customer, the

installer must ensure that the appliance is ﬁr

ing correctly and operation fully explained to customer.

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 5

Page 6

INSTALLATION

This includes:

1) Clocking the appliance to ensure the correct

ﬁring 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 ﬂame 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.

LOCATING YOUR

GAS STOVE

1) When selecting a location for your stove,

ensure that the clearances outlined on this page are met.

2) Provide adequate clearances for servicing.

3) The appliance must be installed on a ﬂat, solid, continuous surface (e.g. wood, metal, concrete). This may be the ﬂoor, 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 ﬂooring, 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

actually installing this appliance. Have a qualiﬁed inspector, dealer, or installer review your plans before installation.

Note: For vent terminations see page 11.

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 page 30.

DUCT SYSTEM

OPTION

KIT #946-556

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

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

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

NOTE: The minimum ﬂoor clearance must be maintained from the top surface of the

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 (page 7).

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 installation on paper using exact measurements for clearances and ﬂoor protection before

OPTIONAL

HEAT RELEASE

KIT #946-570

The Heat Release Kit expels warm air from the ﬁreplace to the outside of the building, allowing the ﬁreplace 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 ﬁres is failure to maintain required clearances (air space) to combustible materials. It is of the greatest importance that this ﬁreplace and vent system be installed only in accordance with these instructions.

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace

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 re quirements, check the HeatWave and Heat

Page 7

19-1/4"(489mm)

including

andof

10-7/8"

(276mm)

49-7/8"(1267mm)

70-1/2"(1791mm)

4"(100mm)

Dia. Inner

6-7/8"(175mm)

Dia. Outer

46-1/2"(1181mm)

42"(1067mm)

31"

(787mm)

INSTALLATION

COMBUSTIBLE MANTELS

Because of the extreme heat this ﬁreplace 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 modiﬁed in any way. It must be installed as manufactured.

FRAMING AND

FINISHING

1) Determine the total thickness of facing mate-

rial (e.g. drywall plus ceramic tiles) to allow the ﬁnished surface to be ﬂush 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 page 9 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 Speciﬁcations

UNIT BASE STAND-OFFS

To accommodate varying thicknesses and ﬁnishes 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 ﬁnish 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 re ducing it by the same distance that you have lowered the unit.

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 7

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.

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)

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 ﬁreplace itself.)

Page 8

INSTALLATION

Fireplace

and

No hearth is required when

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

Flooring

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 ﬂex, see Vent Clearances, page 6.

Note: 48" (11219mm) is the

minimum height for both ﬂex termination or Simpson Dura-Vent venting.

The HeatWave Duct Kit has different clearance and framing requirements, check the

HeatWave

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 te m p l at e . S e e n e xt page.

NOTE: If using a brick hearth, the ﬁreplace will need to b e rai sed to accommodate the brick thickness. Example: If the

HEARTH REQUIREMENTS

manual for details.

Floor Mounted Fireplaces

FACING REQUIREMENT

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

The ﬂanges on the front face of the ﬁreplace are for a facing thickness of 1" (25mm).

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

Raised Fireplaces

You must take into ac count the depth of the floor covering (carpet, tile, linoleum, etc.) when determining the height of the ﬁreplace stand.

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace

Page 9

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 ﬁrebox.

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 ﬂat position and must be folded into shape and attached.

1) Remove the standoffs from the ﬁreplace top.

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

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.

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.

VENTING

INTRODUCTION

The P90 uses the "balanced ﬂue" technology Coaxial 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.

2) Pull out top clip that is still hooked onto glass.

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 9

Page 10

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 on page 11.

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.

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

2) 4" dia. ﬂexible 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)

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.

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

2) 4" dia. ﬂexible 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)

Notes:

1) Liner sections should be co nti nuo us w ith out a ny jo int s or

seams.

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

Page 11

INSTALLATION

Fixed

Openable

Closed

Openabl

Vertical

Termination

Vent

terminal

Area

where

terminal

not

permited

Air

supply

outlet

24"

Inside

corner

detail

24"

18"

Vertical

Termination

EXTERIOR VENT TERMINATION LOCATIONS

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

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

from the centerline of the regulator.

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)

AstroCap Termination Cap (min 6"/15cm), with Dura-

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 11

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)

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 sofﬁt located above the terminal within a horizontal

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

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

G= Clearance to inside corner: with

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 ﬂoor.

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

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

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

Page 12

INSTALLATION

RIGID PIPE VENTING COMPONENTS LIST

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

Description Simpson Dura-Vent Selkirk AmeriventR Direct VentGS

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

Direct-Temp

Direct Vent

946-506/P Vent Guard (Optional) 640-530/P Riser Vent Terminal 946-205 Vinyl Siding Shield for Riser Vent Terminal 946-605 FPI Increaser (5" x 8" Venting)

510-994 Rigid Pipe Adaptor (4" x 6 5/8" Venting) 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

Page 13

Rigid Pipe Adaptor

Pipe Length

Vertical

Terminal

Storm Collar

Part # 953

Flashing

943 or 943S

Ceiling Firestop

(Part # 963)

24" Pipe

Length

Adj.Pipe

Length

11" - 14-5/8"

90 Elbow

Horizontal

Termination

Cap

Wall Thimble

Part #

942

Vinyl Siding

Standoff (Optional)

Part

#950

RIGID PIPE VENTING SYSTEMS

The minimum components required for a basic horizontal termination are:

1 Horizontal Termination Cap 1 90 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.

Elbow

Horizontal and Vertical Terminations for 4" x 6-5/8" Venting

INSTALLATION

Flat Wall Installation

Wall Thickness Vent Length (inches) Required (inches)

4" - 5-1/2" 6" 7" - 8-1/2" 9" 10" - 11-1/2" 12" 9" - 14-1/2" 11" - 14-5/8" Adj. Pipe 15" - 23-1/2" 17" - 24" Adj. Pipe

Corner Installation

Wall Thickness Vent Length (inches) Required (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" 9" + 9" 4-1/4" - 5-3/4" 6" + 9"

Alternate

Horizontal Ter-

mination Caps

WARNING:

Do not combine venting components from different venting systems.

However use of the the AstroCap Riser is acceptable with all systems.

This product has been evaluated by Intertek for using a Dura-Vent Flue Adaptor in conjunction with Selkirk Direct-Temp and Ameri Vent Direct venting systems. Use of these systems with the Direct Vent GS starting collar is deemed acceptable and does not affect the Intertek WHI listing of components.

When using piping other than Simpson

Dura-Vent, 3 screws must be used to

secure rigid pipe to adaptor.

and FPI

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

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 13

and FPI Riser Vent terminal is certiﬁed for installations using FPI venting systems as well as Simpson Dura-Vent®, Direct Vent GS,

Page 14

INSTALLATION

Horizontal & Vertical Terminations for 5" x 8" Venting

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace

Page 15

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 Simpson Dura-Vent and AmeriVent Direct-Vent 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 on pages 6 to 8.

• Horizontal vent must be supported every 3 feet.

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

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 15

5" x 8" venting starts at unit.

A vent guard (Part# 946-506/P) should be used whenever the termination is lower than the speciﬁed 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.

Page 16

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 ﬂoor level and whenever passing through a wall.

• Maintain clearances to combustibles.

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

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace

Page 17

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 45o elbows allowed.

• Vent must be supported at offsets

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

• Maintain clearances to combustibles as listed on pages 6 to 8.

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

INSTALLATION

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 17

Page 18

INSTALLATION

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 90 is required.

elbows

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

Page 19

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.

For additional vertical venting with 2 x 90o elbows, refer page 15.

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.

Ple as e note min. 1 foot between 90 quired.

elbows is re-

INSTALLATION

Vertical 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 + 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.

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 19

Page 20

INSTALLATION

Min. 12"*

(305mm)

Adequate

drainage

Window

Well

Gravel

Dura-Vent

Snorkel

HORIZONTAL

INSTALLATIONS

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 at tached. 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 ﬁttings are designed with special twist-lock connections to connect the venting system to the appliance ﬂue 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 ﬂue collar and fasten to the outer collar only with the 3 supplied screws (drilling pilot holes will make this easier). Level the ﬁreplace and fasten it to the fram ing 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.

b) Horizontal runs of vent must be sup

ported 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 ﬂex) hole is acceptable.

Note: With DuraVent, the min imum height is achieved by installing a 90o elbow dire c t l y t o 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 ﬁre.

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

Diagram 3a

*Dia 3, 3a & 4: As speciﬁed 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.

Note:

a) Twist-lock procedure: Four indentations,

located on the female ends of pipes and ﬁttings, are designed to slide straight onto the male ends of adjacent pipes and ﬁttings, 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 ﬁttings. 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 seal ant to outer pipe on every twist-lock joint.

b) The location of the horizontal vent ter-

mination 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 on page 11.

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 us e d fo r stan dard Ho rizo n tal Termin a t i o n . N E V E R install the s no r k el u p s i d e down.

Diagram 3

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

Page 21

INSTALLATION

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 sufﬁcient 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 5

VERTICAL

TERMINATION

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 pages 13-15 for the maximum vertical rise of the venting system a nd the max im um horizontal offset limitations.

2) Set the gas appliance in its desired location. Drop a plumb bob down from the ceiling to the position of the appliance ﬂue 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 sys tem. You may wish to relocate the appliance or to off s et, as show n i n Diagram 2 to avoid cutting lo ad b eari ng members.

Diagram 1

Diagram 2

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 sufﬁcient size to meet the minimum requirements for clearance to combustibles of 1-1/2". Slip the ﬂashing under the shingles (shingles should overlap half the ﬂashing) as per Diagram 4.

Diagram 4: The upper half of the ﬂashing is

installed under the rooﬁng material and not

nailed down until the chimney is installed. This

6) Continue to assemble pipe lengths.

Note: If an offset is necessary in the attic

Galvanized pipe is desirable above the roof

allows for small adjustments.

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

line due to its higher corrosion resistance. Continue to add pipe sections through the ﬂashing until the height of the vent cap meets the minimum height requirements speciﬁed in Diagram 5 or local codes. Note that for steep roof pitches, the vertical height must be

Diagram 6

9) Install wall thimble in the center of the 10" squa re a nd a tta ch wi t h wood sc r ews (Diagram 7).

Diagram 7

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 21

Note: Apply sealant "Mill-Pac" to inner pipe

and high temperature silicone seal ant to outer pipe on every twist-lock joint.

3) A Firestop spacer must be installed in the

ﬂoor or ceiling of every level. To install the Firestop spacer in a ﬂat ceiling or wall, cut a 10 inch square hole. Frame the hole as shown in Diagram 3 and install the ﬁrestop.

Diagram 3

Diagram 5

Roof Pitch Minimum Vent Height

Feet Meters

ﬂat 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

Page 22

INSTALLATION

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

7) Ensure vent is vertical and secure the base of the ﬂashing to the roof with rooﬁng rails, slide storm collar over the pipe section and seal with a mastic.

8) Install the vertical termination cap by twistlocking 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 instal l a t i o n more aesthetically pleas ing, we recommend framing out a square to mount the termi nal 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 ﬁreplace and fasten it to the fram-

ing 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) ﬂex 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: Horizontal sections must be sup

ported 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 ﬂue collars of the ﬁreplace. (You may wish to cut the liner shorter to make it more workable.) Do not bend liner more than 90o.

7) Apply Mill Pac over the ﬁreplace 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

Page 23

INSTALLATION

P90-NG System Data

For 0 to 4500 feet altitude

Burner Inlet Oriﬁce 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-LP System Data

For 0 to 2000 feet altitude

Burner Inlet Oriﬁce Sizes: #51 Max. Input Rating 35,000 Btu/h Min. Input Rating 17,950 Btu/h

High Altitude: For 2000 to 4500 feet alti tude

Burner Inlet Oriﬁce Sizes: #52 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 ﬁbre, 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 ﬂex connectors use only approved ﬁttings. Always provide a union so that gas lines can be easily disconnected for servicing. Flare nuts for copper lines and ﬂex 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 ﬂame for leak testing.

PILOT ADJUSTMENT

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

Note: If you have an incorrect ﬂame pat

tern, contact your Excalibur dealer for further instructions.

Incorrect ﬂame pattern will have small, prob ably yellow ﬂames, 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" posi-

tion.

2) Loosen the "IN" and/or "OUT" pressure tap(s), turning counterclockwise with a

1/8" wide ﬂat 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 speciﬁed on the safety label.

6) When ﬁnished reading manometer, turn

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

but do not over tighten.

S.I.T. VALVE DESCRIPTION

1) Gas cock 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 ﬂex connec tor. (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.

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 23

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.

Page 24

INSTALLATION

CONVERSION KIT FROM NATURAL GAS TO PROPANE MODEL #790-969

FOR P90 USING SIT 820 NOVA GAS VALVE

THIS CONVERSION MUST BE DONE BY A QUALIFIED GAS FITTER

IF IN DOUBT DO NOT DO THIS CONVERSION !!

Conversion Kit Contains:

Qty. Part # Description 1 910-018 SIT Conversion Kit-50% Turndown LP 1 910-037 LP Injector (Pilot Oriﬁce) 1 904-645 Burner Oriﬁce #51 1 908-255 Decal "Converted to Propane" 1 908-529 5/32" Allen Key 1 918-077 Instruction Sheet

1) Shut the power off.

2) Remove the louvers. Open the ﬂush door

and remove the door.

3) Remove the logs, embers, and brick panels (if used).

4) Remove the burner/grate assembly by removing the two Phillips head screws and then slide the burner assembly to the left and lift out.

7) Pull off the pilot cap to expose the pilot oriﬁce.

8) Unscrew the pilot oriﬁce with the allen key and replace with the LP pilot oriﬁce in the kit and replace pilot cap.

Diagram 1: Remove the left and right screws and then slide the burner/ grate assembly to the left and lift out.

5) Remove the rear log stand by removing the 2 screws.

6) 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.

screws

Rear Log Stand

9) Remove burner oriﬁce with a 1/2" wrench and discard. Use another wrench to hold on to the elbow behind the oriﬁce.

Burner Oriﬁce

10) Reinstall new burner oriﬁce LP stamped #51 and tighten.

11) Remove and discard the 3 pressure regula tor mounting screws (A), pressure regulator tower (B) and diagram (C).

12) Insure that the rubber gasket (D) is properly positioned and install the new HI/LO pres sure regulator assembly to the valve using the new screws (E) supplied with the kit. Tighten screws securely.

13) Reverse steps 6) to 1).

14) Attach clear label "This unit has been con verted to Propane" near or on the serial # decal. Attach white label "This valve has been converted from NG to LPG using SIT conversion Kit Code 0.907.202" onto the valve.

15) Replace yellow "Natural Gas" label with red "Propane" label

16) Check for gas leaks.

17) Check inlet and outlet pressures.

18) Check operation of ﬂame control.

19) Check for proper ﬂame appearance and glow on logs.

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace

Page 25

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 facade.

3) Remove glass door. Remove logs.

Note: The logs must not be in the unit.

4) Insert the back brick panel ﬁrst by carefully

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

5) Put the side panels in next. Slide them in from the front and push them ﬂat up against the wall. Be very careful not to scratch them on the ﬁrebox 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 902-277 b) 02-55 Middle Left Log 902-237 c) 02-50 Front Left Log 902-242 d) 02-53 Center Left Log 902-239 e) 02-51 Front Bottom Log 902-241 f) 02-54 Center Right Log 902-238 g) 02-52 Middle Right Log 902-240 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 ﬁtting into the 2nd grate tab.

02-51

Bracket

02-53

Notch

5) 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 instructions on page 35.

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 pins with the ﬂat side to the back.

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 ﬁtting into the right side of the grate.

02-75 on the rear log support

02-75

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 ﬁtting 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 25

Page 26

INSTALLATION

7) Place the bottom left front edge of Log 0255 against the rear bracket on the burner tray and rest the log on the cutout on L o g 02-53.

02-75

02-55

02-53

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.

02-51

Cutouts

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 ﬁtting into the ﬁrst grate tab.

Notch

Front Brackets

02-50

02-55

02-53

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

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

below.

11) Test ﬁre to ensure proper light off (make

sure ﬂame ﬂows smoothly from one end of burner to the other). If there is any ﬂame hesitation, check that area for any blockage of the burner ports.

12) Install ﬂush glass and bay glass (if used) as

per instructions in this manual.

02-54

02-52

02-51

02-54

Log indentation

02-52

02-54

Photo shows rear grate tab.

Log 02-51 was removed to show

the positioning of Log 02-52.

02-75

Rear

Grate

Tab

02-50

02-75

02-55

02-53

02-55

02-54

02-51

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace

Page 27

Door

Flange

INSTALLATION

GLASS DOOR

INSTALLATION

1) Fit top door bracket over the ﬂange at the top of the ﬁrebox.

2) Secure with 2 screws on the bottom.

Tighten both screws to secure Front Facade

to Glass Door.

3) Slide Bottom Louver into position. On each side secure the bottom screw ﬁrst 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) At tach door brack et t o sid e usi ng 2 screws.

Single Screen Door - only attach to right side

of unit.

Door Bracket attaches with

2 screws.

Double Screen Door - attach to left and

right side of unit.

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

FRONT FACADE

1) Place the Front Facade 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 Front Facade 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 Lock- ing 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 27

Page 28

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 ﬁrst 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 ﬁrst put on the split lock washer and then the nut and tighten.

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace

Page 29

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 ﬁreplace to that location. Use the Thermostat Wire Table.

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

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 29

Page 30

Openings for

electrical connections

120

Volt

Power IN

Millivolt

Wires

INSTALLATION

Lockwasher

Fan

ground wire

Nut

#8 Ground Lug

(mobile home

approved)

ar washer

Ground

Green

Neutral

Live

Black Red R

Fan Thermodisc (normally open)

Ground

ON OFF

Rotary Speed

Control

120V AC 60 Hz

Fan

Piezo

Ignitor

To Thermocouple IN

Pilot

Assembly

P I

Gas P

ilot

Thermopile

Thermocoupl

Electrode

Remote Transmitter

(Optional)

ON OFF

Regency

Remote Receiver

or Thermostat

(Millivolt) (Optional)

Brown

Red

T-St

Black

White

"S.I.T" Valve

Burner

ON OFF

Thermostat

(To THTP)

(To TH)

White

Gas In

WIRING DIAGRAM

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

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

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.

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

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

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace

Page 31

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 ap pliance 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.

OPERATING INSTRUCTIONS

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 ﬂame 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 ﬂame height regulator to adjust the ﬂame 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.

During the ﬁrst few ﬁres, a white ﬁlm may develop on the glass front as part of the curing process. The glass should be cleaned or the ﬁlm will bake on and become very difﬁcult 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 ﬂame or close for a more yellow ﬂame. 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 re

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

LIGHTING

PROCEDURE

IMPORTANT

To ignite or reignite the pilot,

remove one glass panel/door.

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 cock 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.

FIRST FIRE

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

When ﬁrst 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 appli-

ance 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.

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 31

Page 32

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 op erating 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 differ ent gauge material from the rest of the ﬁrebox 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 ﬁreboxes.

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.

Pilot Flame: While the pilot ﬂame 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.

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace

Page 33

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 ﬁreplace glass cleaner.

The glass should be cleaned when it starts looking cloudy.

3) The heater is ﬁnished in a heat resistant paint and should only be reﬁnished 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 ﬂame of the burner periodically, making sure the ﬂames are steady; not lifting or ﬂoating. If there is a problem, call a qualiﬁed service person.

5) The appliance and venting system must be inspected before use, and at least an nually, by a qualiﬁed ﬁeld service person, to ensure that the ﬂow of combustion and ventilation air is not obstructed.

Note: Never operate the appliance with

out the glass properly secured in place.

6) Do not use this appliance if any part has

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

out the joints, Continuous condensation can cause corrosion of caps, pipe, and ﬁttings. 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 ﬁttings have been disturbed, and conse quently loosened. Also check mechanical supports such as Wall Straps, or plumbers' tape for rigidity.

GOLD-PLATED DOOR

OR FACADE

The 24 carat gold-plated ﬁnish on the facade 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 ﬁnish and void the warranty. Clean any ﬁngerprints 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 cre

ate 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 ﬁreplace 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 clean ing, 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 qualiﬁed service person.

Caution: Wear gloves when removing damaged or broken glass.

Glass Replacement

Remove the glass door front (as per instructions on page 26). 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.

7) Verify operation after servicing.

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

3) Check for evidences of excessive condensation, such as water droplets forming in the inner liner, and subsequently dripping

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 33

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.

Page 34

MAINTENANCE

FAN 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 ﬁrebox. 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

Page 35

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 (page 26).

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" ﬂare ﬁtting with an 11/16" wrench.

3) Reconnect the "gas out" ﬂare 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 ﬂoor of the ﬁrebox 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" ﬂare nut with a 13/16" wrench.

16)

Undo the "gas out" ﬂare ﬁtting 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 ﬁrebox 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 ﬂame 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

ﬂame appearance and glow on logs.

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 35

17) Remove the 4 Phillips head screws from the sides of the valve bracket and remove valve.

Page 36

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 Bafﬂe

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) 902-278 Brick Panel - Base 790-928 Brick Panel Set - Standard 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

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 Bafﬂe 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) 946-005/01 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

918-072 Manual 790-969 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

432-967 Burner ON/OFF Switch Assy

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace

Page 37

PARTS LIST

108

109

HEAT RELEASE DUCT KIT

N SWITCH ASSEMBLY

ON-OFF SWITCH

ASSEMBLY

100

102

HEAT WAVE DUCT KIT

BRICK PANELS

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 37

Page 38

TP TH

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) 910-378 Valve - S.I.T. - Natural Gas 910-380 Valve - S.I.T. - Propane

58) * Valve Bracket

65) * Pilot Bracket

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

67) * Pilot Holder

68) W840470 Pilot Assembly Gasket

69) * Firebox Base

75) * Deﬂector - Left

76) * Deﬂector - 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

*Not available as a replacement part.

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace

Page 39

164

141

156

FLUSH DOOR

132

135

136

148

158

SINGLE DOOR

151

DOUBLE DOORS

161

146

162

155

168

167

157

163

164

159

154

157

148

149

155

144

143

155

159

152

153

157

146

142

145

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 - Soft Copper - Complete

141) * Surround - Faceplate - Excalibur

142) * Surround - Louver

143) 904-621 Hole Plug

144) 790-122 Emblem

145) * Surround - Hood

146) * Handle

148) 907-719 Rivet-67-5/16 x 1/2 Black 904-719/02 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 790-925 Single Screen Door - Complete - Nickel 790-951 Single Screen Door - Complere - Antique Gold 790-952 Single Screen Door - Complete - Antique Nickel 790-953 Single Screen Door - Complete - Soft Copper

151) * Single Screen Door Frame

790-930 Double Screen Door - Complete - Black 790-932 Double Screen Door - Complete - Gold 790-931 Double Screen Door - Complete - Nickel 790-941 Double Screen Door - Complete - Antique Gold 790-942 Double Screen Door - Complete - Antique Nickel 790-943 Double Screen Door - Complete - Soft 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.

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

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 39

Page 40

NOTES

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Excalibur P90 Zero Clearance Direct Vent Gas Fireplace

Page 41

NOTES

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Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 41

Page 42

NOTES

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Excalibur P90 Zero Clearance Direct Vent Gas Fireplace

Page 43

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:

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 ﬁve (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 pur chase.

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-ﬁeld 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 ﬁeld 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, ﬁeld modiﬁcations or upgrades will not be performed.

Limited Lifetime

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 instal lation, 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 43

Page 44

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 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-ﬁre.com

Installer: Please complete the following information

Dealer Name & Address: ______________________________________________

___________________________________________________________________

Installer: ___________________________________________________________

Phone #: ___________________________________________________________

Date Installed: ______________________________________________________

Serial No.: __________________________________________________________

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