Excalibur P95-NG2, P95-LP2 Owners & Installation Manual

Page 1

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.

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.

www.excalibur-fire.com

P95-2 Zero Clearance Direct Vent Gas Fireplace

Owners &

Installation Manual

MODELS: P95-NG2 Natural Gas P95-LP2 Propane

Tested by:

918-456

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

Homeowner: Please keep these instructions for future reference.

Installer: Please complete the details on the back cover

and leave this manual with the homeowner.

09/28/05

Page 2

To the New Owner:

Congratulations! You are the owner of a st ate-of-the-art Excalibur Gas Fireplace by FPI FIREPLACE PRODUCTS INTERNA TIONAL LTD. The P95-2 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 P95-2 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 t ake 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 2.17-M91.

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 P95-2 Zero Clearance Direct Vent Gas Fireplace

Page 3

TABLE OF CONTENTS

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

P95-2 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

Venting: Simpson Dura Vent Direct Vent GS ............12

Venting: Simpson Dura Vent Components List..........13

Venting Arrangements

Horizontal Terminations ......................................14

Horizontal Venting ..............................................15

Vertical Venting ..................................................16

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

Horizontal Installations ..............................................19

Vertical Terminations ................................................21

Venting - Installation Procedures for Direct Vent

System (Flex).....................................................21

System Data.............................................................22

High Elevation ...........................................................22

Gas Line Installation..................................................22

Pilot Adjustment .......................................................22

Gas Pipe Pressure Test ............................................22

SIT Valve Description ................................................22

Conversion to Propane ..............................................23

Optional Brick Panels ...............................................24

Log Set Installation ...................................................24

Glass Door Installation ..............................................26

Front Facade.............................................................26

Optional Screen Door ................................................26

Accent Kit Installation ...............................................27

Remote Control (optional)..........................................28

Remote Wall Switch (optional) ..................................28

Wall Thermostat (optional) ........................................28

Wiring Diagram .........................................................29

Operating Instructions

Operating Instructions ...............................................30

Lighting Procedure ....................................................30

Shutdown Procedure .................................................30

First Fire ...................................................................30

Aeration Adjustment..................................................30

Normal Operating Sounds of

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

Lighting Plate Instructions .........................................31

Maintenance

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

General Vent Maintenance........................................32

Gold-Plated or Brass Door or Facade........................32

Log Replacement ......................................................32

Thermopile/Thermocouple .........................................32

Glass Gasket............................................................32

Door Glass................................................................32

Fan Maintenance ......................................................33

Removing Valve.........................................................34

Installing Valve ..........................................................34

Parts List

Replacement/Spare Parts List...................................35

Warranty

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

Excalibur P95-2 Zero Clearance Direct Vent Gas Fireplace 3

Page 4

SAFETY LABEL

This is a copy of the label that accompanies each P95-2 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 appliances individual manual shut-off must be a t-handle type valve.

Copy of Safety Decal for P95-2

Excalibur P95-2 Zero Clearance Direct Vent Gas Fireplace

Page 5

INSTALLATION

IMPORTANT:

SAVE THESE

INSTRUCTIONS

The P95-NG2 or P95-LP2 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:

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

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

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

GENERAL SAFETY

INFORMATION

1) The appliance installation must conform

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

2) The appliance when installed, must be electrically grounded in accordance with local codes, or in the absence of local codes with the current National Electrical Code, ANSI/NFPA 70 or CSA C22.1 Canadian Electrical Code.

3) See general construction and assembly instructions. The appliance and vent should be enclosed.

4) This appliance must be connected to the 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.

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 California to cause cancer, birth defects or other reproductive harm.

INSTALLATION

CHECKLIST

1) Locate appliance

a) Room location, page 6 b) Clearances to Combustibles,

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 9-17.

2) Assemble Top Standoffs, page 9. (NOTE: must be done before installing unit into fireplace.)

3) Install vent, pages 17-21.

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

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

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

Excalibur P95-2 Zero Clearance Direct Vent Gas Fireplace 5

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

4) Make gas and electrical connections. Test the pilot. Must be as per diagram. Page 22.

5) Install brick panels (optional), page 24.

6) Install log set where indicated on

pages 24-25.

7) Install Front Facade, page 26.

8) Install Optional Screen Door, page 26.

9) Install optional Wall Switch, Remote Con-

trol, or Wall Thermostat, page 28.

10)Final check.

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

customer.

Page 6

INSTALLATION

This includes:

1) Clocking the appliance to ensure the cor-

rect firing rate (rate noted on label 45,000 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 P95-2 Direct Vent Gas Fireplace can be installed in a recessed position or framed out into the room as in A, B, C, D. See Diagram 1.

7) We recommend that you plan your installation on paper using exact measurements for clearances and floor protection before actually installing this appliance. Have a qualified inspector, dealer, or installer review your plans before installation.

Note: For vent terminations see page

10.

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 29.

OPTIONAL

DUCT SYSTEM

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.

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.

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 carpeting, tile, etc.

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

Horizontal Vent Clearances

Top 3" Side 2" Bottom 2"

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 P95-2 Direct Vent Gas Fireplace is approved for alcove installations, which meet the clearances listed on this page.

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.

Excalibur P95-2 Zero Clearance Direct Vent Gas Fireplace

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

* see mantle clearance instructions (page 7).

WARNING:

Fire hazard is an extreme risk

if these clearances are not

adhered to.

Clearances for HeatWave and

Heat Release Kit

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

Page 7

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.

P95-2 Flat Wall Surround and Tile Kit

The P95-2 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 ma-

terial (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 50-1/8" high x 53-3/8" wide x 21-1/4" deep (1276mm high x 1346mm wide x 533mm deep).

P95-2 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 49” up to 50 1/8”.

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 reducing it by the same distance that you have lowered the unit.

Excalibur P95-2 Zero Clearance Direct Vent Gas Fireplace 7

Framing Dimensions

A B C 53-3/8" 50-1/8" 21-1/4"

1346mm 1276mm 533mm

Insert the 2 unit base stand-offs underneath the unit as shown in the diagram below. Space the stand-offs centrally, approximately 2 or 21/2 feet apart. Ensure that the unit is not unstable.

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

Stand

No hearth is required when

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

Flooring

53-3/4”

48-3/4”

Header

21-1/8” (533mm)

2-1/4”

Gas connection

on this side

Non-combustible

Material

Combustible

Material

11” dia. hole through wall

for Flex

or for DuraVent

2-7/8”

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: 53-3/4" 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 manual for details.

FACING REQUIREMENT

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

Facing Over 1" (25mm) Thick

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

FPI offers a cover plate template. See next page.

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

HEARTH REQUIREMENTS

Floor Mounted Fireplaces

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 account the depth of the floor covering (carpet, tile, linoleum, etc.) when determining the height of the fireplace stand.

Excalibur P95-2 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 correct shape. Bend up at the bend lines until the screw holes in the standoff and the prepunched 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 P95-2 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.

Not e: 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 P95-2 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 P95-2 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 # 946-615) includes all the parts needed to install the P95-2 with a maximum run of 4 feet.

1) 8" dia. flexible liner (4 ft. length)

2) 5" dia. flexible liner (4 ft. length)

3) spring spacers (4)

4) thimble (2)

5) AstroCap XL 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)

10)vinyl siding standoff

If longer runs are needed, the FPI Direct Vent system (Flex) kit is (Part # 946-616) which includes all the parts needed to install the P95-2 with a maximum 10' run.

1) 8" dia. flexible liner (10 ft. length)

2) 5" dia. flexible liner (10 ft. length)

3) spring spacers (7)

4) thimble (2)

5) AstroCap XL 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)

10)vinyl siding standoff

Notes:

1) Liner sections should be continuous without any joints 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 P95-2 Zero Clearance Direct Vent Gas Fireplace

Page 11

INSTALLATION

Fixed

Openable

Closed

Openable

Vertical

Termination

Vent terminal

Area where terminal is not permited

Air supply outlet

24"

Inside

corner detail

24"

18"

Vertical

Termination

EXTERIOR VENT TERMINATION LOCATIONS

the centerline of the regulator.

any other appliance *(12"/30cm)

*(min. 84"/2.1m)

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

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

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

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

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

Excalibur P95-2 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)

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. 18"/45cm)

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

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

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.

Page 12

INSTALLATION

SIMPSON DURA-VENT VENTING

The Simpson Dura-Vent Direct Vent System offers a complete line of component parts for installation of both horizontal and vertical installations. Many items are offered in decorative black, as well as galvanized finish. We recommend using the galvanized finish for installation with the P95-2.

The minimum components required for a basic horizontal termination are:

1 Horizontal Termination Cap 190o Elbow 1 Flue Adaptor 1 Wall Thimble 1 Length of pipe to suit wall thickness

(see chart)

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.

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"

Horizontal and Vertical Terminations for 5" x 8" Venting

(inches) Required (inches)

Flat Wall Installation

Wall Thickness Vent Length

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

9" + 9"

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

Simpson

Dura-Vent

Direct Vent GS

Alternate Horizontal

Termination Cap

The FPI AstroCap XL FPI venting systems as well as Simpson Dura-Vent® and Direct Vent GS.

The FPI AstroCap XLTM is a proprietary trademark of FPI Fireplace Products International Ltd.

Dura-Vent® and Direct Vent GS are registered and/or proprietary trademarks of Simpson Dura-Vent Co. Inc.

Excalibur P95-2 Zero Clearance Direct Vent Gas Fireplace

is certified for installations using

Page 13

SIMPSON DURA-VENT VENTING COMPONENTS LIST

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

5" x 8" Description 5" x 8" Description

INSTALLATION

1208 6" Pipe Length 1208B 6" Pipe Length, Black 1207 9" Pipe Length 1207B 9" Pipe Length, Black 1206 12" Pipe Length 1206B 12" Pipe Length, Black 1204 24" Pipe Length 1204B 24" Pipe Length, Black 1203 36" Pipe Length 1203B 36" Pipe Length, Black 1202 48" Pipe Length 1202B 48" Pipe Length, Black 1211 11" to 14-5/8" Pipe, Adjustable 1211B 11" to 14-5/8" Pipe, Adjustable, Black 1217 17" to 24" Pipe, Adjustable 1217B 17" to 24" Pipe, Adjustable, Black 1245 45 1245B 45 1245G 45 1245BG 45 1290 90 1290B 90 1290G 90 1290BG 90

Elbow

Elbow, Black

Elbow, Swivel

Elbow, Black, Swivel

Elbow

Elbow, Black

Elbow, Swivel

Elbow, Black, Swivel

1240 Round Ceiling Support/Wall Thimble Cover 1241 Cathedral Ceiling Support Box Brass Trim for Wall Thimble/

Ceiling Support 1247 Wall Thimble (only required in Canada) 1243 Flashing, 0/12 to 6/12 Roof Pitch 1243S Flashing, 7/12 to12/12 Roof Pitch 1242 Wall Firestop 1253 Storm Collar 1263 Ceiling Firestop 1288 Wall Strap 1281 Snorkel Termination (36") 1282 Snorkel Termination (14") 1284 Horizontal Square Termination 1285 Horizontal Square Termination, High Wind 1291 Vertical Termination, High Wind N/A Extended Vertical Termination 1250 Vinyl Siding Standoff

Parts not supplied by Dura-Vent

770-994 Dura-Vent Flue Adaptor

Excalibur P95-2 Zero Clearance Direct Vent Gas Fireplace 13

Page 14

INSTALLATION

VENTING ARRANGEMENTS - HORIZONTAL TERMINATIONS

SIMPSON DURA-VENT DIRECT VENT GS SYSTEM and

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 90 elbow).

Simpson Dura-Vent 5" inner diameter 8" outer diameter

Note: Must use optional flue adapter (Part # 770-994)

when using Simpson Dura-Vent pipe.

Regency Flex Vent 5" inner diameter 8" outer diameter

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

for horizontal terminations.

• 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.

A vent guard 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.

Excalibur P95-2 Zero Clearance Direct Vent Gas Fireplace

Page 15

Horizontal Venting with Two (2) 90o Elbows

One 90o elbow = Two 45o elbows.

Option V H + H1

A) 0' 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.

INSTALLATION

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

Please note minimum 1 foot between 90o elbows is required.

Horizontal Venting with Three (3) 90o Elbows

One 90o elbow = Two 45o elbows.

Option V H V + V1 H + H1

A) 0' Min. 1' Max. 1' 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 P95-2 Zero Clearance Direct Vent Gas Fireplace 15

Page 16

INSTALLATION

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 to next page.

Vertical Venting with Two (2) 90o Elbows

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

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

Vertical Venting with Three (3) 90o Elbows

One 90o elbow = Two 45o elbows.

Option V H + H1 V + V1

A) 0' 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 90o elbows is required.

Excalibur P95-2 Zero Clearance Direct Vent Gas Fireplace

Page 17

INSTALLATION

VENTING ARRANGEMENTS - VERTICAL TERMINATIONS

SIMPSON DURA-VENT DIRECT VENT GS SYSTEM

(Propane & Natural Gas)

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

Simpson Dura-Vent Direct Vent GS 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 flue adapter when using Simpson Dura-Vent pipe (Part # 770-994).

Excalibur P95-2 Zero Clearance Direct Vent Gas Fireplace 17

Page 18

INSTALLATION

The P95-2 is approved for a maximum 40 ft. straight vertical, with Simpson Dura-Vent Direct Vent GS vent systems for Propane and Natural Gas, as

per the diagram. The shaded area in the diagram shows all allowable combinations of straight

vertical and offset to vertical terminations with Simpson Dura-Vent Direct Vent GS vent systems for Propane and Natural Gas. 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.

Maximum two 45o elbows

Excalibur P95-2 Zero Clearance Direct Vent Gas Fireplace

Page 19

INSTALLATION

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 attached. If this is the case, you may want to adjust the location of the unit. Rough in the gas preferably on the right side of the unit and the electrical (junction block is on the left side) on the left.

2) Direct Vent pipe and 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 framing using nails or screws through the nailing strips.

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 11" x 11" 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 8" dia. hole is acceptable.

Note: With Dura-Vent, the minimum height is achieved by installing a 90o elbow directly to the flue adaptor.

Diagram 3

*Diagam 3 & 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 enclo-

4) Assemble the desired combination of pipe and elbows to the appliance adaptor and twist-lock for a solid connection.

Note:

a) Twist-lock procedure: Four indenta-

tions, 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 twistlock 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 sealant to outer pipe on every twist-lock joint.

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.

b) The location of the horizontal vent termi-

nation on an exterior wall must meet all local and national building codes, and must not be blocked or obstructed. For External Vent Terminal Locations, see diagram on page 11.

c) Snorkel Terminations:

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

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" clear-

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

Excalibur P95-2 Zero Clearance Direct Vent Gas Fireplace 19

Page 20

INSTALLATION

sure.

Diagram 5

The four wood screws provided should be replaced with appropriate fasteners for stucco, brick, concrete, or other types of sidings.

Note: If installing termination on a siding

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

7) Before connecting the horizontal run of

vent pipe to the vent termination, slide the Wall Thimble (Part # 1247) 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.

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 14-16 for the maximum vertical rise of the venting system and the maximum 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 t h e venting system. You may wish to relocate the appliance or to offset, as shown in Diagram 2 to avoid cutting load bearing 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 allows for small adjustments.

6) Continue to assemble pipe lengths.

Note: If an offset is necessary in the attic

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

Galvanized pipe is desirable above the roofline 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

Diagram 6

9) Install wall thimble in the center of the 11" square and attach with wood screws (Diagram 7).

Diagram 7

Note: Apply sealant "Mill-Pac" to inner

pipe and high temperature silicone sealant 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 11 inch square hole. Frame the hole as shown in Diagram 3 and install the firestop.

Diagram 3

Excalibur P95-2 Zero Clearance Direct Vent Gas Fireplace

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 21

INSTALLATION

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

7) Ensure vent is vertical and secure the base of the 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 installation more aesthetically pleasing, we recommend framing out a square to mount the terminal to.

Note: If installing termination on a siding

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

2) Level the fireplace and fasten it to the

framing using nails or screws through the nailing strips.

3) Assemble the vent assembly by applying Mill Pac to the 5"(127mm) inner collar of the termination and slipping the 5"(127mm) 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 8"(203mm) flex pipe and slip it over the 8"(203mm) 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 5"(127mm) liner and outer 8"(203mm) 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 5"(127mm) liner down over it and attach with 3 supplied screws.

8) Do the same with the 8"(203mm) liner.

9) Apply a bead of silicone between the thim-

ble 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 11"(279mm) hole in the wall (inside dimension).

Note: A 3-1/2"(76mm) clearance around

the liner must be maintained except that only a 1" (25mm) clearance is needed at the termination end. We recommend framing a 11"(279mm) x 11"(279mm) (inside dimensions) hole to give structural rigidity for mounting the termination.

Excalibur P95-2 Zero Clearance Direct Vent Gas Fireplace 21

Page 22

INSTALLATION

P95-NG2 System Data

For 0 to 4500 feet altitude

Burner Inlet Orifice Sizes: #30 Max. Input Rating 45,000 Btu/h

Min. Input Rating 23,200 Btu/h Supply Pressure min.5.0" w.c.

Manifold Pressure

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

P95-LP2 System Data

For 0 to 4500 feet altitude

Burner Inlet Orifice Sizes: #49 Max. Input Rating 40,000 Btu/h Min. Input Rating 22,400 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 200 CFM. Log Set: Ceramic fibre, 7 per set. Vent System: Simpson Dura-Vent Direct

Vent System or FPI Flex System.

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

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, probably 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 counter clockwise 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

HIGH ELEVATION

This unit is approved in Canada for altitude 0 to 4500 ft. (CAN1 2.17-M91) & U.S.A ANSI ZZ1.88a

GAS LINE

INSTALLATION

The gas line is brought in through the left 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.

Note: When the gas line is being in-

stalled from the left side, be sure to leave room to accommodate servicing of the fan.

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

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

Point

GAS PIPE PRESSURE

TESTING

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

Excalibur P95-2 Zero Clearance Direct Vent Gas Fireplace

Page 23

INSTALLATION

CONVERSION KIT FROM NATURAL GAS TO PROPANE MODEL #770-969

FOR P95-2 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) 1 904-431 Burner Orifice #49 1 908-255 Decal "Converted to Propane" 1 908-529 5/32" Allen Key 1 918-117 Instruction Sheet

1) Turn the gas off.

2) Remove the glass frame.

3) Remove the logs, embers, and brick panels

(if used).

4) Remove the burner/grate assembly, first by

removing the two screws, one on each side of the grate, then pull out the grate.

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

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

Allen Key

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

Remove screw

Pull out the

grate.

5) Remove the 2 screws, one on each side of the burner. Slide the burner to the left and then lift out.

9) Reinstall new burner orifice LP stamped #48 and tighten.

Remove screw

Slide the

burner to the

left and lift out.

Excalibur P95-2 Zero Clearance Direct Vent Gas Fireplace 23

10)Remove and discard the 3 pressure regu-

lator mounting screws (A), pressure regulator tower (B) and diagram (C).

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

12)Reverse steps 6) to 1).

Burner Orifice

13)Attach clear label "This unit has been converted 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 0.907.204" onto the valve.

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

15)Check for gas leaks.

16)Check inlet and outlet pressures.

17)Check operation of flame control.

18)Check for proper flame appearance and

glow on logs.

Page 24

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.

Log Kit # 770-930 contains the following pieces: a) 306 Rear Log 902-306

b) 307 Middle Left Log 902-307 c) 308 Center Right Log 902-308 d) 309 Middle Right Log 902-309 e) 310 Front Left Log 902-310 f ) 311 Center Left Log 902-311 g) 312 Front Bottom Log 902-312 h) Embers 902-154 i) Vermiculite 902-179

306

307

309

4) Place Log 312 on the front right side of the burner, fitting the log on the 2 pins.

312

5) Position Log 311 across the notch in Log 306 and rest the bottom of the log into the 2nd grate tab.

311

2nd Grate Tab

306

Notch

5) Install the 2 brick retaining clips, one on each side.

311

The 3-digit numbers (ie. 312) 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 Log 306 on the rear log support pins with the flat side to the back.

306

308

312310

6) Position Log 308 across the log landing in Log 311. Rest the bottom of the log against the 5th grate tab.

311

308

5th Grate Tab

7) Fit the bottom of Log 307 into the bracket on the left side of the burner.

307

Note: If the bottom brick panel must be removed:

Remove the Rear Log Stand, then remove the Burner Tray. See the instructions on page 34.

Pins on the rear log support.

Excalibur P95-2 Zero Clearance Direct Vent Gas Fireplace

Bracket

Page 25

INSTALLATION

8) Place the top of Log 307 across the notch on Log 311.

306

311

307

Notch

9) Place the back of Log 309 against the bracket on the top right side of the burner.

The picture below is a view from the back of the burner.

309

11) Fit Log

310 on the pin and then swing the

front end of the log to hit the first grate tab.

310

12) Place the embers on the front of the burner tray.

311

Place embers on the burner tray.

DO NOT BLOCK BURNER HOLES

13) 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.

14) Reverse steps 1-3 under Optional Brick Panels on page 22.

Rest log against

bracket

10) Place the top of Log 309 on Log 308, supported by the knot.

309

308

Knot

306

Rear Log

310

Front Left Log

Middle Left Log

311

Center Left Log

307

312

Front Bottom Log

309

Middle Right Log

308

Center Right Log

Excalibur P95-2 Zero Clearance Direct Vent Gas Fireplace 25

Page 26

Door

Flange

INSTALLATION

GLASS DOOR

INSTALLATION

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

2) Secure with 3 screws on the bottom.

3) Mount the 2 screws back onto the mounting plate on the rear of the facade through the tab on the glass frame and then tighten screw to secure.

Tighten both screws to secure Front

Facade to Glass Door.

Tab

Screw

OPTIONAL

SCREEN DOOR

1) Attach door bracket to side using 2 screws to the left and right side of the unit.

Door Bracket attaches with

2 screws.

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

FRONT FACADE

1) Remove the 2 screws from the mounting plate that are on the back of the facade.

Remove screws from the

mounting tabs.

2) Place the Front Facade into position by sliding the 2 holes in the bottom brackets over the pins on the base, one on each side.

Bracket

Fit the bottom brackets over

the pins on the base.

View from underneath of the

screw and the bracket.

4) 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.

Secure

Screw

5) 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.

Adjusting the Plunger: Loosen the screw that holds that plunger bracket so that you can remove the plunger.

Loosen the

screw holding

the bracket.

Once the plunger has been removed take a pin and put it in the hole that is in the round part of the plunger and adjust it accordingly by turning it to the left or right.

Adjust plunger by

turning it to the left

or right with a pin.

Excalibur P95-2 Zero Clearance Direct Vent Gas Fireplace

Page 27

ACCENT KIT INSTALLATION

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 P95-2 Zero Clearance Direct Vent Gas Fireplace 27

Page 28

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.

Option 2:

WALL SWITCH

1) Run the wire through the right or left side

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.

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.

Excalibur P95-2 Zero Clearance Direct Vent Gas Fireplace

Page 29

WIRING DIAGRAM

Ground

Green

Neutral

Live

Black Red Red

Fan Thermodisc

(normally open)

Ground

ON OFF

Rotary Speed

Control

120V AC 60 Hz

Fan A

Fan B

Lockwasher

Fan

ground wire

Power cord

ground wire

Nut

#8 Ground Lug

(for mobile home)

Star

washer

Piezo

Ignitor

To Thermocouple IN

Pilot

Assembly

P I

Gas Pilot

Thermopile

Thermocouple

Electrode

Remote Transmitter

(Optional)

ON OFF

Regency

Remote Receiver

or Thermostat

(Millivolt) (Optional)

Brown

Red

T-Stat

Black

White

"S.I.T" Valve

Burner

ON OFF

Thermostat

(To THTP)

(To TH)

White

Gas In

INSTALLATION

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.

Excalibur P95-2 Zero Clearance Direct Vent Gas Fireplace 29

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

Page 30

OPERA TING INSTRUCTIONS

OPERATING

INSTRUCTIONS

1) Read and understand these instructions

before operating this appliance.

2) Check to see that all wiring is correct and enclosed to prevent possible shock.

3) Check to ensure there are no gas leaks.

4) Make sure the glass in the door frame is

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

5) Verify that the venting and cap are unobstructed.

6) Ensure that the brick panels are installed.

7) Verify log placement. If the pilot cannot be

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

8) The unit should never be turned off, and on again without a minimum of a 60 second wait.

LIGHTING

PROCEDURE

IMPORTANT

To ignite or reignite the pilot,

remove one glass panel/door.

3) Turn gas control knob counter clockwise

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 counter clockwise 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.

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.

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

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. This adjustment is performed by the gas fitter.

Minimum Air Shutter Opening:

5/16" Natural Gas 3/8" 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.

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.

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

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

Note: When the glass is cold and the

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

Excalibur P95-2 Zero Clearance Direct Vent Gas Fireplace

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.

Page 31

OPERA TING INSTRUCTIONS

Copy of the Lighting Plate Instructions

NORMAL OPERATING

SOUNDS OF GAS

APPLIANCES

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

Blower:

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

Burner Tray:

The burner tray is positioned directly under the burner tube(s) and logs and is made of a different gauge material from the rest of the 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 P95-2 Zero Clearance Direct Vent Gas Fireplace 31

Page 32

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 annual-

ly, 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.

7) In the event this appliance has been serviced check that the vent-air system has been properly resealed & reinstalled in accordance with the manufacturer's instructions.

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 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 consequently 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

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

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.

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 cleaning, we recommend using an approved glass cleaner available at all authorized dealers. Do not use abrasive materials. Do not clean the glass when hot.

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

keting around it.

8) 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.

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.

Excalibur P95-2 Zero Clearance Direct Vent Gas Fireplace

Page 33

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. 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 by loosening the 2 hinge screws.

IMPORTANT: There are 2 fans in this fireplace. Fan A (the right side fan) and Fan B (the left side fan) are linked by a wire harness. Please do not remove the wire harness when installing the fans.

4) Move both fans and the wire harness

together to the front of the fireplace.

5) Insert Fan A in from the left sideways (see diagram below). The easiest way to insert Fan A is to put Fan B in front of the louver opening. This ensures that there is sufficient length of wire between the 2 fans.

Ensure that the fan blades do not rub against the valve tubing. See diagram 1.

Diagram 1

9) Connect the fan ground wire of Fan B and the power cord ground wire to the grounding lug. Refer to the wiring diagram.

10)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.

12)Secure the fan wires and power cord by attaching one of the adhesive backed wire holder clips (Part #910-199) onto the fireplace 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, fan blades or sharp edges.

Slide Fan A in sideways

from the left.

6) Take Fan A to the back above the mounting studs. Then flip the fan and position it onto the mounting studs.

7) Connect the ground wire from Fan A to the Grounding Lug located on the left hand side. See diagram 1.

8) Insert Fan B in from the front and position it on top of the mounting studs on the left side.

Position Fan B on

mounting studs.

Diagram 2

11)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.

13)Plug the fan power cord into the rear end of the receptacle box to provide the maximum clearance from the louvers.

To Remove the Fan

1) Shut the power off.

2) Reverse the installation 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.

Excalibur P95-2 Zero Clearance Direct Vent Gas Fireplace 33

Page 34

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.

5) Remove the logs.

6) Remove the burner/grate assembly, first by

removing the 2 screws, 1 on each side of the grill, then lift out the grill.

Remove screw

9) Remove the front bottom brick panel by sliding it out. Then remove the back bottom brick panel by tilting it slightly up and then out. The brick panel is very fragile -

handle with care.

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

11)Disconnect the 2 TP wires and the 2 TH

wires from the valve.

12)Remove the 12 screws securing the valve

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

Hint: If you are using black pipe, en-

sure 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.

7) Remove the 2 screws, 1 on each side of the burner. Slide the burner to the left and then lift out.

Remove screw

Slide the burner to

the left and lift

out.

8) Remove the rear log stand by removing the

2 screws.

Rear Log Stand

Valve Tray Assembly

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

14)Undo the quick drop out thermocouple nut on the valve with a 9mm (metric) wrench.

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

16)Undo the "gas out" flare nut with a 13/16" wrench.

17)

Undo the "gas out" flare fitting with an 11/16" wrench.

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

8) Install a new gasket and reinstall the valve tray assembly.

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 need-

ed.

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 P95-2 Zero Clearance Direct Vent Gas Fireplace

Page 35

PARTS LIST

P95-2 MAIN ASSEMBLY

Part # De scri ption 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

22) 770-033 Baffle Guide

23) 780-011 Standoff - Top

25) 770-074 Standoff

26) 770-128 Sealing Plate

27) * Outer Flue Collar

28) * Inner Flue Collar Assy

29) * Flue Mounting Bracket

30) * Gasket for Flue Collar

31) 902-305 Brick Panel - Base - Rear

32) 902-304 Brick Panel - Base (Front) 770-928 Brick Panel Set - Standard

770-901 Brick Panel Set - Standard

Brown 770-902 Brick Panel Set - Standard Red 770-903 Brick Panel Set - Herringbone

Brown 770-904 Brick Panel Set - Herringbone

Red

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

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

42) 430-517/P Fan Assembly (120 Volts) 910-331/PFan Motor (120 Volts)

770-523 Fan Switch Assembly

43) 910-813 Power Cord (120 Volts)

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 910-878 Wire Harness - Twin Fan Cable

50) 770-994 Dura-Vent Adaptor (Optional)

60) W260260 Top Relief Frame Gasket

61) 942-117 Top Relief Plate Frame

62) W260280 Top Relief Plate Gasket

63) 770-066 Top Relief Plate

64) * Hex Cap Screw 1/4 20NC 3.5

65) * Hex Cap Screw 1/4 20NC 2.0

80) * Hex Cap Screw 1/4 20NC 1.75 946-556 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/PFan 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

101)690-022 Cover Plate

102)946-010 Flexible Air Duct

946-045 Insulation 6" dia. x 60" 946-570 Heat Release Duct Kit (Opt.)

108)910-165 Fan (120 V)

109)946-000 Flexible Air Release Duct

918-456 Manual 770-969 Conversion Kit - NG to LP

*Not available as a replacement part.

432-967 Burner ON/OFF Switch Assy

Excalibur P95-2 Zero Clearance Direct Vent Gas Fireplace 35

Page 36

PARTS LIST

Excalibur P95-2 Zero Clearance Direct Vent Gas Fireplace

Page 37

P95-2 BURNER ASSEMBLY & LOG SET

Part # De scripti on

52) 910-190 Piezo Ignitor & Nut

54) 948-043 Bottom Relief Spring 770-574/P Valve Assy - Natural Gas

770-576/P Valve Assy - Propane

56) 770-071 Gasket - Valve Tray

57) 910-378 Valve - S.I.T. - Natural Gas 910-380 Valve - S.I.T. - Propane

58) * Valve Bracket

66) 910-038 Pilot Assy 3 way flame - S.I.T. - NG 910-039 Pilot Assy 3 way flame - S.I.T. - LP 904-660 Orifice #30 - Natural Gas 904-431 Orifice #49 - Propane 936-170 Orifice Gasket

67) 780-057 Pilot Holder

68) W840470 Pilot Assembly Gasket

69) 770-070 Gasket - Relief Door Bottom

79) 770-525 Burner Assy - NG/LP

82) 770-003 Burner Grate Assy

83) * Rear Log Support Bracket

85) 770-930 Log Set

PARTS LIST

*Not available as a replacement part.

Excalibur P95-2 Zero Clearance Direct Vent Gas Fireplace 37

Page 38

164

FLUSH DOOR

132

135

136

DOUBLE DOORS

161

146

162

155

168

167

157

163

164

148

141

146

148

142

157

145

155

PARTS LIST

P95-2 FLUSH FRONT ACCESSORIES

Part # Description Part # Description

771-518 Door Assembly - Complete

132) * Flush Door Frame

135) 940-328/P Glass (Flush)

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

770-920 Surround - Black - Complete 770-922 Surround - Gold - Complete 770-914 Surround - Antique Gold - Complete 770-916 Surround - Antique Nickel - Complete 770-918 Surround - Soft Copper - Complete

141) * Surround - Faceplate - Excalibur

142) * Surround - Louver

145) * Surround - Hood

146) * Handle

148) * Rivet-67-5/16 x 1/2

157) * Carriage Bolt 948-221 Logo Plate

770-931 Double Screen Door - Complete - Black 770-932 Double Screen Door - Complete - Nickel 770-933 Double Screen Door - Complete - Gold 770-941 Double Screen Door - Complete - Antique Gold 770-942 Double Screen Door - Complete - Antique Nickel 770-943 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

146) 790-105 Handle - Black 790-082/10 Handle - Nickel 790-082/02 Handle - Gold

155) 904-735 Push-Fit Ball Plunger

157) 904-722 Carriage Bolt - Black 904-722/02 Carriage Bol t - Gold 904-722/10 Carriage Bolt - Nickel

*Not available as a replacement part.

Excalibur P95-2 Zero Clearance Direct Vent Gas Fireplace

Page 39

NOTES

_____________________________________________________________________________________ ____________________________________________________________ __________________________________________________________ ____________________________________________________________ _______________________________________________________ _____________________________________________________ __________________________________________________________ _________________________________________________________ _________________________________________________________ ______________________________________________________ ______________________________________________________ _______________________________________________________________ ___________________________________________________________ __________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ _____________________________________________________________ __________________________________________________________ __________________________________________________________ _____________________________________________________ ________________________________________________________ _________________________________________________________ _________________________________________________________

Excalibur P95-2 Zero Clearance Direct Vent Gas Fireplace 39

Page 40

NOTES

Excalibur P95-2 Zero Clearance Direct Vent Gas Fireplace

Page 41

NOTES

Excalibur P95-2 Zero Clearance Direct Vent Gas Fireplace 41

Page 42

NOTES

Excalibur P95-2 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: Limited Lifetime

The combustion chamber, heat exchanger, burner tubes/pans, logs, embers and all gold plating (against defective manufacture only) are covered under the Limited Lifetime Warranty for 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 purchase. Electrical and mechanical components such as blowers, switches, wiring, thermodiscs, FPI remote controls, spill switches, thermopiles, thermocouples,

pilot assembly components, and gas valves are covered for one year parts and subsidized labour* from the date of purchase. Blowers and valves replaced under warranty are considered repairs and continue as if new with appliance. ie. twelve (12) months from original purchase date of appliance with a minimum of three (3) months coverage from date of replacement.

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

Conditions:

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

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

The authorized selling dealer is responsible for all in-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. FPI will not be liable for travel costs for service work. Installation and environmental problems are not the responsibility of the manufacturer and therefore are not covered under the terms of this warranty

policy. Refractory liners, gaskets, door handles, paint are not covered under the terms of this warranty policy. Any unit which shows signs of neglect or misuse is not covered under the terms of this warranty policy. The warranty will not extend to any part which has been tampered with or altered in any way, or in our judgment has been subject to misuse, improper

installation, negligence or accident, spillage or downdrafts caused by environmental or geographical conditions, inadequate ventilation, excessive offsets, negative air pressure caused by mechanical systems such as furnaces, fans, clothes dryer, etc.

Freight damage to stoves and replacement parts is not covered by warranty and is subject to a claim against the freight carrier by the dealer. FPI will not be liable for acts of God, or acts of terrorism, which cause malfunction of the appliance. Performance problems due to operator error will not be covered by this warranty policy. Products made or provided by other manufacturers and used in conjunction with the operation of this appliance without prior authorization from Excalibur,

may nullify your warranty on this product. Simpson Dura-Vent venting components are covered by Simpson Dura-Vent Inc. warranty.

* Subsidy according to job scale as predetermined by FPI.

Excalibur P95-2 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 Lt d. 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.: _________________________________________________________

Excalibur is a trademark of FPI Fireplace Products International Ltd.

Printed in Canada

Excalibur P95-NG2, P95-LP2 Owners & Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual