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CarAlarms P90-NG1 User's Manual

1. 36 Shutdown Procedure 36 First Fire 36 Aeration Adjustment 36 Normal operating Sounds of Gas Appliances 37 Copy Of The Lighting Plate Instructions 37 MAINTENANCE Maintenance Instructions 38 Gold plated Door or Surround 38 Log Replacement 38 Thermopile Thermocouple 38 Glass Gasket 38 Door Glass 38 Fan Maintenance 39 Removing Valve 40 Installing Valve 40 PARTS LIST P90 Main Assembly 41 P90 Burner Assembly amp Log Set 43 P90 Flush Front Accessories 44 WARRANTY The Warranty Limited Lifetime 47 SAFETY LABEL Serial No Decal
2. 2 The special venting systems shall be Product Approved by the Board and the instructions for that system shall include a parts list and detailed installation instructions e A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment all venting instructions all parts lists for venting instructions and or all venting design instructions shall remain with the appliance or equipment at the completion of the installation MA Code CO Detector for the State of Massachusetts only Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 6 INSTALLATION CHECKLIST 1 Locate appliance refer to the following sections a Locating Your Gas Fireplace b Combustible Mantels c Unit Base Stand offs d Framing amp Finishing e Facing Requirements f Hearth Requirements g Venting 2 Assemble Top Standoffs page 9 Refer to the Unit Assembly Prior to Installation section NOTE must be done before installing unit into replace 3 Install vent refer to the Venting section 4 Make gas and electrical connections Test the pilot Must be as per diagram Refer to the Pilot Adjustment section 6 Install standard and optional features Refer to the following sections where applicable a Brick Panels b Log Set Installation c Arch Surround d Glass Door Installation e Screen Door f Accent Kit Installation g Option 1 Remote Control h Option 2 Wall
3. 4 REQUIREMENTS MA Code CO Detector for state of Massachusetts only 5 INSTALLATION Important Message 6 Before You Start 6 General Safety Information 6 Installation Checklist 6 Locating Your Gas replace 7 Manufactured Mobile Home Additional Requirements 7 Heatwave Duct System Optional Kit 7 Clearances 7 Combustible Mantels 8 Unit Base Stand offs 8 Framing And Finishing 8 Facing Requirement 9 Hearth Requirements 9 Optional Cover Plate Template 10 Unit Assembly Prior To Installation 10 Venting Introduction 10 Venting 11 Exterior Vent Termination Locations 12 Rigid Pipe Venting Components
4. AstroCap Horizontal Cap 946 206 Vinyl Siding Standoff AstroCap RIGID PIPE VENTING COMPONENTS LIST All Simpson Dura Vent components are available directly from FPI Description Simpson Dura Vent Selkirk Amerivent Security Direct VentGS Direct TempTM Direct Vent Secure Vent 6 Pipe Length Galvanized 908 4DT 6 N A 6 Pipe Length Black 908B 4DT 6B N A 7 Pipe Length Galvanized N A N A 4D7 7 Pipe Length Black N A N A 4D7B 9 Pipe Length Galvanized 907 4DT 9 N A 9 Pipe Length Black 907B 4DT 9B N A 12 Pipe Length Galvanized 906 4DT 12 4D12 12 Pipe Length Black 906B 4DT 12B 4D12B 18 Pipe Length Galvanized N A 4DT 18 N A 18 Pipe Length Black N A 4DT 18B N A 24 Pipe Length Galvanized 904 4DT 24 4D2 24 Pipe Length Black 904B 4DT 24B 4D2B 36 Pipe Length Galvanized 903 4DT 36 4D3 36 Pipe Length Black 903B 4DT 36B 4D3B 48 Pipe Length Galvanized 902 4DT 48 4D4 48 Pipe Length Black 902B 4DT 48B 4D4B Adjustable Length 11 14 Galv 911 4DT AJ N A Adjustable Length 11 14 Black 911B 4DT AJB N A Adjustable Length 17 24 Black 917B N A N A Adjustable Length 7 Galvinized N A N A 4D7A Adjustable Length 7 Black N A N A 4D7AB Adjustable Length 12 Galvinized N A N A 4D12A Adjustable Length 12 Black N A N A 4D12AB 45O Elbow Galvinized 945 4DT EL45 4D45L 45O Elbow Black 945B 4DT EL45B 4D45LB 45O Elbow Swivel Galvinized 945G
5. and does not affect the Intertek WHI listing of components WARNING Do not combine venting components from different venting systems However use of the the AstroCapTM and FPI Riser is acceptable with all systems Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 15 Horizontal amp Vertical Terminations for 5 x 8 Venting INSTALLATION Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 16 INSTALLATION RIGID PIPE VENTING ARRANGEMENTS HORIZONTAL TERMINATIONS FPI DIRECT VENT SYSTEM FLEX Propane amp Natural Gas The diagram shows all allowable combinations of vertical runs with horizontal terminations using one 90o elbow two 45o elbows equal one 90o elbow All Rigid Pipe Systems 4 inner diameter 6 5 8 outer diameter FPI Flex Vent 4 inner diameter 6 7 8 outer diameter Note Must use optional rigid pipe adaptor Part 510 994 when using Rigid Pipe Maintain clearances to combustibles as listed in the Clearances section Horizontal vent must be supported every 3 feet Firestops are required at each oor level and whenever passing through a wall A vent guard Part 946 506 P should be used whenever the termination is lower than the speci ed minimum or as per local codes Note FPI Direct Vent System Flex is only approved for horizontal terminations All Rigid Pipe Systems 5 inner diameter 8 outer diameter Note Must use FPI increaser starter collar P
6. burner tubes pans logs embers and all gold plating against defective manufacture only are covered under the Limited Lifetime Warranty for ve 5 years for parts and subsidized labour and parts only thereafter Glass is covered for lifetime against thermal breakage only parts and subsidized labour for three 3 years and parts only thereafter from date of purchase Electrical and mechanical components such as blowers switches wiring thermodiscs FPI remote controls spill switches thermopiles thermocouples pilot assembly components and gas valves are covered for one year parts and subsidized labour from the date of purchase Blowers and valves replaced under warranty are considered repairs and continue as if new with appliance ie twelve 12 months from original purchase date of appliance with a minimum of three 3 months coverage from date of replacement FPI venting components are covered parts and subsidized labour for three 3 years from date of installation and parts only thereafter Conditions Any part or parts of this unit which in our judgement show evidence of such defects will be repaired or replaced at FPI s option through an accredited distributor or agent provided that the defective part be returned to the distributor or agent Transportation Prepaid if requested It is the general practice of FPI to charge for larger higher priced replacement parts and issue credit once the replaced component has been returned to
7. it must be used with vinyl siding measure to outside surface of wall without siding and add 2 inches Horizontal and Vertical Terminations for 4 x 6 5 8 Venting Alternate Horizontal Termination Caps Flat Wall Installation Wall Thickness inches Vent Length Required inches 4 5 1 2 6 7 8 1 2 9 10 1 1 2 12 9 14 1 2 11 14 5 8 Adj Pipe 15 23 1 2 17 24 Adj Corner Installation Wall Thickness inches Vent Length Required inches 3 1 4 6 3 4 11 14 5 8 Adj Pipe 7 3 4 16 1 4 17 24 Adj Pipe 7 1 4 8 3 4 6 12 9 9 4 1 4 5 3 4 6 9 When using Rigid Vent other than Simpson Dura Vent 3 screws must be used to secure rigid pipe to adaptor The FPI AstroCapTM and FPI Riser Vent terminal are certi ed for installations using FPI venting systems as well as Simpson Dura Vent Direct Vent GS American Metal Products Ameri Vent Direct Vent Security Secure Vent Selkirk Direct Temp AstroCapTM is a proprietary trademark of FPI Fireplace Products International Ltd Dura Vent and Direct Vent GS are registered and or proprietary trademarks of Simpson Dura Vent Co Inc This product has been evaluated by Intertek for using a Rigid Pipe Adaptor in conjunction with Duravent Direct Vent GS Selkirk Direct Temp Ameri Vent Direct venting and Security Secure Vent systems Use of these systems with the Rigid Pipe adaptor is deemed acceptable
8. 16 Check for gas leaks 17 Check inlet and outlet pressures 18 Check operation of ame control 19 Check for proper ame appearance and glow on logs 7 Connect one end of the supplied green ground wire to the lug with the nut and washer from the kit 8 Install the 1 2 bushing to the heat shield Ground wire from kit 10 Plug the DC spark generator wires to the DC Sparker 11 Connect the ground wire to the DC Sparker mounting bracket 13 Mount the heat shield to the DC Sparker Secure into place with the velcro which is provided in the kit Heat Shield 9 Run the other end of the ground wire and DC spark generator wires through the bushing on the heat shield 15 Tie up the loose wire with the wire clip 14 Find a location which is not too hot and is easy to reach for changing the battery 12 Install the supplied battery into the DC Sparker Box by opening the battery compartment NOTE The battery in the DC Sparker Box will need to be replaced annually Battery Compartment INSTALLATION Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 29 5th Grate Tab 02 54 5 Position Log 02 53 across the cutouts in Logs 02 75 and 02 51 with the notch on the left side of the log tting into the 2nd grate tab Cutouts 2nd Grate Tab 02 53 02 75 02 51 02 51 02 53 02 53 02 51 Notch Bracket Bracket 02 51 02 75 4 Place Log 02 51 on the front right
9. 21 INSTALLATION Min 12 305mm Adequate drainage Window Well Gravel Dura Vent Snorkel Diagram 4 6 The arrow on the vent cap should be pointing up Insure that the 1 1 2 clearances to combustible materials are maintained Diagram 4 Install the termination cap NOTE For Snorkel terminations in ABOVE grade installations follow national or local code requirements Below Grade Installation If the Snorkel Termination must be installed below grade i e basement application proper drainage must be provided to prevent water from entering the Snorkel Termination Refer to Diagram 4 Do not attempt to enclose the Snorkel within the wall or any other type of enclosure Dia 3 3a amp 4 As speci ed in CGA B149 Installation Code Local codes or regulations may require different clearances HORIZONTAL TERMINATIONS Install the vent system according to the manufacturer s instructions included with the components 1 Set the unit in its desired location Check to determine if wall studs or roof rafters are in the way when the venting system is attached If this is the case you may want to adjust the location of the unit Rough in the gas preferably on the right side of the unit and the electrical junction block is on the left side on the left 2 Direct Vent pipe and ttings are designed with special twist lock connections to connect the venting system to the appliance ue outlet A twist l
10. 67 Pilot Holder 68 W840470 Pilot Assembly Gasket 69 Firebox Base 75 De ector Left 76 De ector Right 79 790 525 Burner Assy NG LP 82 511 030 Burner Grate Assy 83 780 028 Rear Log Support Bracket 85 780 930 Log Set Complete Not available as a replacement part Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 44 164 141 156 FLUSH DOOR 132 135 136 148 148 158 SINGLE DOOR 151 DOUBLE DOORS 161 146 162 155 168 167 157 163 163 164 159 154 157 148 148 149 149 155 155 144 143155 159 152 153 157 146 146 142 145 P90 FLUSH FRONT ACCESSORIES 790 518 Door Assembly Complete 132 790 137 Flush Door Frame 135 940 326 P Glass Flush 136 936 155 Glass Gasket Tadpole 904 691 U Clip 790 920 Surround Black Complete 790 922 Surround Gold Complete 790 914 Surround Antique Gold Complete 790 916 Surround Antique Nickel Complete 790 918 Surround Antique Copper Complete 141 Surround Faceplate Excalibur 142 Surround Louver 143 904 621 Hole Plug 144 790 122 Emblem 145 Surround Hood 146 Handle 148 904 719 Rivet 67 5 16 x 1 2 Black 904 719 G Rivet 67 5 16 x 1 2 Gold 149 904 720 Pushnut Fastener 5 16 hole 790 924 Single Screen Door Complete Black 790 926 Single Screen Door Complete Gold 790 951 Single Screen Door Co
11. FPI and evaluated for manufacturer defect The authorized selling dealer is responsible for all in eld service work carried out on your Excalibur product FPI will not be liable for results or costs of workmanship from unauthorized service persons or dealers At all times FPI reserves the right to inspect product in the eld which is claimed to be defective All claims must be submitted to FPI by authorized selling dealers It is essential that all submitted claims provide all of the necessary information including customer name purchase date serial type of unit problem and part or parts requested without this information the warranty will be invalid Exclusions This limited Lifetime Warranty does not extend to or include paint door or glass gasketing or trim At no time will FPI be liable for any consequential damages which exceed the purchase price of the unit FPI has no obligation to enhance or modify any unit once manufactured ie as products evolve eld modi cations or upgrades will not be performed FPI will not be liable for travel costs for service work Installation and environmental problems are not the responsibility of the manufacturer and therefore are not covered under the terms of this warranty policy Refractory liners gaskets door handles paint are not covered under the terms of this warranty policy Any unit which shows signs of neglect or misuse is not covered under the terms of this warranty
12. INSTALLATION For PROPANE Units and Units Equipped with DC Spark Boxes For installation of the DC Spark Box refer to the LP Conversion instructions in this manual Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 36 LIGHTING PROCEDURE IMPORTANT Gas on off knob cannot be turned from PILOT to OFF unless it is partially depressed 1 Turn burner OFF using ON OFF switch NOTE For all propane units and units equipped with electric spark boxes see Copy of Lighting Plate Instruc tions section for more details Only when the pilot holds without pressure being applied to the control knob resecure the glass panel to the unit The unit must not be operated with the glass removed OPERATING INSTRUCTIONS OPERATING INSTRUCTIONS 1 Read and understand these instructions before operating this appliance 2 Check to see that all wiring is correct and enclosed to prevent possible shock 3 Check to ensure there are no gas leaks 4 Make sure the glass in the door frame is properly positioned Never operate the appliance with the glass removed 5 Verify that the venting and cap are unobstructed 6 Ensure that the brick panels are installed 7 Verify log placement If the pilot cannot be seen when lighting the unit the logs have been incorrectly positioned 8 The unit should never be turned off and on again without a minimum of a 60 second wait 2 Turn gas control knob so indicator points
13. N A N A 45O Elbow Swivel Black 945BG N A N A 90O Elbow Galvinized 990 4DT EL90S 4D90LS 90O Elbow Black 990B 4DT EL90SB 4D90LBS 90O Elbow Swivel Galvinized 990G N A N A 90O Elbow Swivel Black 990BG N A N A Ceiling Support 949 n a from FPI 4DT CS 4DFSP Cathedral Support Box 941 4DT CSS 4DRSB Wall Support Band 988 4DT WS B 4DWS Offset Support 989 n a from FPI 4DT OS N A Wall Thimble Black 942 4DT WT 4DWT Wall Thimble Support Box Ceiling Support 940 N A N A Firestop Spacer 963 4DT FS 4DFSP Trim Plate Black N A 4DT TP 4DFPB Brass Trim for Wall Thimble Ceiling Support 3951 N A N A Attic Insulation Shield 12 N A N A 4DAIS12 Attic Insulation Shield Cold Climates 36 N A N A 4DAIS36 Basic Horizontal Termination Kit A 970 4DT HKA 4DHTK2 Horizontal Termination Kit B 971 4DT HKB 4DHTK1 Vertical Termination Kit 978 4DT VKC 4DVTK High Wind Vertical Cap 991 N A N A High Wind Horizontal Cap 985 N A N A Horizontal Square Termination Cap 984 4DT HHC 4DHC Verical Termination Cap 980 4DT HVC 4DVC Storm Collar 953 4DT SC 4DSC Adjustable Flashing 0 12 6 12 943 4DT AF6 4DF Adjustable Flashing 6 12 12 12 943S 4DT AF12 4DF12 Vinyl Siding Standoff 950 4DT VS N A Vinyl Siding Shield Plate N A 4DT VSP N A Snorkel Termination 14 982 4DT ST14 4D12S Snorkel Termination 36 981 4DT ST36 4D36S SV4L6 SV4LB6 N A N A N A N A SV4L12 SV4LB12 S
14. Not to be installed above a meter regulator assembly within 3 90cm horizontally from the centerline of the regulator J Clearance to service regulator vent outlet min 36 90cm K Clearance to non mechanical air supply inlet to building or the combustion air inlet to any other appliance 12 30cm 9 23cm L Clearance to a mechanical air supply inlet min 72 1 8m 3 91cm above if within 10 3m horizontally M Clearance above paved sidewalk or a paved driveway located on public property min 84 2 1m N Clearance under veranda porch deck or balcony min 12 30cm Note A vent shall not terminate directly above a sidewalk or paved driveway which is located between two single family dwellings and serves both dwellings Only permitted if veranda porch deck or balcony is fully open on a minimum of two sides beneath the oor If the vent termination is accessible a certi ed guard shall be installed As speci ed in CGA B149 Installation Code Note Local codes or regulations may require different clearances In accordance with the current ANSI Z223 1 NFPA 54 Natioinal Fuel Gas Code Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 13 INSTALLATION FPI 946 506 P Vent Guard Optional 510 994 Rigid Pipe Adaptor Must use with all Rigid Piping 640 530 P Riser Vent Terminal 946 205 Vinyl Siding Shield for Riser Vent Terminal 946 208 P Vent Guard Optional Riser Vent Terminal 946 523 P
15. Switch i Option 3 Wall Thermostat 10 Final check Before leaving this unit with the customer the installer must ensure that the appliance is ring correctly and operation fully explained to customer This includes 1 Clocking the appliance to ensure the correct ring rate rate noted on label 35 000 Btu h after burning appliance for 15 minutes 2 If required adjusting the primary air to ensure that the ame does not carbon First allow the unit to burn for 15 20 min to stabilize CAUTION Any alteration to the product that causes sooting or carboning that results in damage is not the responsibility of the manufacturer INSTALLATION IMPORTANT MESSAGE SAVE THESE INSTRUCTIONS The P90 NG1 or P90 LP1 Direct Vent Fireplace must be installed in accordance with these instructions Carefully read all the instructions in this manual rst Consult the authority having jurisdiction to determine the need for a permit prior to starting the installation It is the responsibility of the installer to ensure this replace is installed in compliance with manufacturer s instructions and all applicable codes BEFORE YOU START Safe installation and operation of this appliance requires common sense however we are required by the Canadian Safety Standards and ANSI Standards to make you aware of the following GENERAL SAFETY INFORMATION 1 The appliance installation must conform with local codes or in the
16. 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 at position and must be folded into shape and attached 1 Remove the standoffs from the replace top 2 Take each standoff and bend into the correct shape Bend up at the bend lines until the screw holes in the standoff and the pre punched screw holes on the replace top line up 3 Attach the standoff securely to the top with 2 screws per standoff on opposite corners Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 11 VENTING FPI Direct Vent System Flex Horizontal Terminations Only These venting systems in combination with the P90 Direct Vent Gas Fireplace have been tested and listed as a direct vent heater system by Warnock Hersey The location of the termination cap must conform to the requirements in the Vent Terminal Locations diagram in the Exterior Vent Termination Locations section FPI Direct Vent Flex System Termination Kit Part 946 515 includes all the parts needed to install the P90 with a maximum run of 4 feet 1 6 7 8 dia exible liner 4 ft length 2 4 dia exible liner 4 ft length 3 spring spacers 4 4 thimble 2 5 AstroCap termination cap 1 6 screws 12 7 tube of Mill Pac 1 8 plated screws 8 9 screws 8 x 1 1 2 Drill Point Stainless Steel 4 If
17. 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 speci ed vent and termination cap to the outside of the building envelope Never vent to another room or inside a building Make sure that the vent is tted as per Venting instructions 5 Inspect the venting system annually for blockage and any signs of deterioration 6 Venting terminals shall not be recessed into a wall or siding 7 Any safety glass removed for servicing must be replaced prior to operating the appliance 8 To prevent injury do not allow anyone who is unfamiliar with the operation to use the replace 9 Wear gloves and safety glasses for protection while doing required maintenance 10 Be aware of electrical wiring locations in walls and ceilings when cutting holes for termination 11 Under no circumstances should this appliance be modi ed Parts that have to be removed for servicing should be replaced prior to operating this appliance 12 Installation and any repairs to this appliance should be done by a
18. 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 roo ine due to its higher corrosion resistance Continue to add pipe sections through the ashing until the height of the vent cap meets the minimum height requirements speci ed in Diagram 5 or local codes Note that for steep roof pitches INSTALLATION Roof Pitch Minimum Vent Height Feet Meters at to 7 12 2 0 61 over 7 12 to 8 12 2 0 61 over 8 12 to 9 12 2 0 61 over 9 12 to 10 12 2 5 0 76 over 10 12 to 11 12 3 25 0 99 over 11 12 to 12 12 4 1 22 over 12 12 to 14 12 5 1 52 over 14 12 to 16 12 6 1 83 over 16 12 to 18 12 7 2 13 over 18 12 to 20 12 7 5 2 29 over 20 12 to 21 12 8 2 44 1 Maintain the 1 1 2 clearances air spaces to combustibles when passing through ceilings walls roofs enclosures attic rafter or other nearby combustible surfaces Do not pack air spaces with insulation Check the Rigid Pipe Venting Systems amp Rigid Pipe Venting Arrangements sections for the maximum vertical rise of the venting system and the maximum horizontal offset limitations Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 23 INSTALLATION 4 Sep
19. all the warmth and charm of a wood replace at the ick of a switch The model P90 has been approved by Warnock Hersey for both safety and ef ciency As it also bears our own mark it promises to provide you with economy comfort and security for many trouble free years to follow Please take a moment now to acquaint yourself with these instructions and the many features of your Excalibur Fireplace INFORMATION FOR MOBILE MANUFACTURED HOMES AFTER FIRST SALE This Excalibur product has been tested and listed by Warnock Hersey as a Direct Vent Wall Furnace to the following standards VENTED GAS FIREPLACE HEATERS ANSI Z21 88b 2003 CSA 2 33b 2003 and GAS FIRED APPLIANCES FOR USE AT HIGH ALTITUDES CAN CGA 2 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 C
20. is achieved by installing a 90 o elbow directly to the rigid pipe adaptor Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 22 2 Set the gas appliance in its desired location Drop a plumb bob down from the ceiling to the position of the appliance ue exit and mark the location where the vent will penetrate the ceiling Drill a small hole at his point Next drop a plumb bob from the roof to the hole previously drilled in the ceiling and mark the spot where the vent will penetrate the roof Determine if ceiling joists roof rafters or other framing will obstruct the venting system You may wish to relocate the appliance or to offset as shown in Diagram 2 to avoid cutting load bearing members Diagram 3 Diagram 5 Diagram 1 Diagram 2 Note Apply sealant Mill Pac to inner pipe and high temperature silicone sealant to outer pipe on every twist lock joint Diagram 5 Diagram 6 VERTICAL TERMINATIONS Diagram 7 The four wood screws provided should be replaced with appropriate fasteners for stucco brick concrete or other types of sidings Note If installing termination on a siding covered wall a vinyl siding standoff or furring strips must be used to ensure that the termination is not recessed into the siding 7 Before connecting the horizontal run of vent pipe to the vent termination slide the Wall Thimble Part 620 926 over the vent pipe 8 Slide the appliance and v
21. label This unit has been converted to LPG near or on top of the serial decal 19 Replace yellow Natural Gas label with red LPG label 14 Using the Allen wrench as shown in Fig 4 rotate the screw clockwise until snug do not overtighten Fig 4 WARNING Do not overtighten the screw Recommended to grip the wrench by the short side 15 Verify that if the conversion is from NG to LPG the screw must be reassembled with the red o ring visible Fig 5 16 Reassemble the black protection cap Fig 6 WARNING Also check that the pilot and main burner injectors are appropriate for the gas type LPG Configuration Red o ring visible Fig 5 Fig 6 Installation of the DC Sparker for the H35 1 Units Only 1 Remove the control panel by unscrewing the 2 screws 3 Plug up the Piezo hole with the plastic bushing 4 Attach the DC sparker generator connector to the valve with a screw 5 Remove the stove s rear panel by unscrew ing the two screws 6 Attach the ground wire to the grounding stud 2 First remove the Piezo Ignition Wire from the Piezo Ignitor Then remove the Piezo Ignitor from the control panel Before After INSTALLATION Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 27 9 Install the plastic bushing over the outside of the hole 10 Attach the ground wire to the DC spark mounting bracket 11 Attach the DC sparker generator wires to the DC spa
22. same room where the gas appliance is installed Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 5 REQUIREMENTS 5 08 Modifications to NFPA 54 Chapter 10 2 Revise 10 8 3 by adding the following additional requirements a For all side wall horizontally vented gas fueled equipment installed in every dwelling building or structure used in whole or in part for residential purposes including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven 7 feet above finished grade in the area of the venting including but not limited to decks and porches the following requirements shall be satisfied 1 INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back up is installed on the floor level where the gas equipment is to be installed In addition the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling building or structure served by the side wall horizontal vented gas fueled equipment It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors a In the
23. the front left side of the burner Push the back of the log against the 2 front brackets with the notch on the bottom of the log tting into the rst grate tab 10 Place the embers on the front of the burner tray in the places shown on the photos below 11 Test re to ensure proper light off make sure ame ows smoothly from one end of burner to the other If there is any ame hesitation check that area for any blockage of the burner ports 12 Install ush glass and bay glass if used as per instructions in this manual Do not block the burner holes in this area adjacent to the Log 02 54 02 51 02 54 INSTALLATION Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 31 Door Flange OPTIONAL SCREEN DOOR 1 Attach door bracket to side using 2 screws GLASS DOOR INSTALLATION 1 Fit top door bracket over the ange at the top of the rebox 2 Secure with 2 screws on the bottom Single Screen Door only attach to right side of unit Double Screen Door attach to left and right side of unit 2 Slide the door s onto the hinges 3 Single Screen Door only Push the Locking Ball Pin into the hole on the left side Squeeze the clamp use pliers and slide it over the end of the Locking Ball Pin and tight against the Facade edge Door Bracket attaches with 2 screws ARCH SURROUND 1 Place the Arch Surround into position by sliding the 2 holes in the bottom br
24. through 4 b EXEMPTIONS The following equipment is exempt from 248 CMR 5 08 2 a 1 through 4 1 The equipment listed in Chapter 10 entitled Equipment Not Required To Be Vented in the most current edition of NFPA 54 as adopted by the Board and 2 Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling building or structure used in whole or in part for residential purposes c MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM PROVIDED When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment the instructions provided by the manufacturer for installation of the equipment and the venting system shall include 1 Detailed instructions for the installation of the venting system design or the venting system components and 2 A complete parts list for the venting system design or venting system d MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases but identifies special venting systems the following requirements shall be satisfied by the manufacturer 1 The referenced special venting system instructions shall be included with the appliance or equipment installation instructions and
25. ALLATION Vertical Venting with Two 2 90o Elbows Vertical Venting with Three 3 90o Elbows Must Use 5 x 8 Simpson Direct Vent GS Piping with FPI Increaser Starter Collar Part 946 605 unless V1 is greater than or equal to 4 6 then use 4 x 6 5 8 piping 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 One 90o elbow Two 45o 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 For additional vertical venting with 2 x 90o elbows refer to the Rigid Pipe Venting Arrangements Horizontal Termination section Must Use 5 x 8 Simpson Direct Vent GS Piping with FPI Increaser Starter Collar Part 946 605 Option V H H1 V V1 A 6 Min 2 Max 3 Min B 1 Min 2 Max 3 Min C 2 Min 3 Max 4 Min D 3 Min 4 Max 6 Min E 4 Min 5 Max 7 Min F 5 Min 6 Max 8 Min G 6 Min 7 Max 9 Min H 7 Min 8 Max 10 Min One 90o elbow Two 45o elbows With these options max total pipe length is 30 feet with min of 10 feet total vertical and max 8 feet total horizontal Please note min 1 foot between 90o elbows is required Excalibur P90 Zero Clearance Direct Vent Gas Fireplace
26. D The 24 carat gold plated nish on the surround and door requires little maintenance and need only be cleaned with a damp cloth DO NOT use abrasive materials or chemical cleaners as they may harm the nish and void the warranty Clean any ngerprints off before turning the unit on LOG REPLACEMENT The unit should never be used with broken logs Turn off the gas valve and allow the unit to cool before opening door and carefully remove the logs The pilot light generates enough heat to burn someone If for any reason a log should need replacement you must use the proper replacement log The position of these logs must be as shown in the diagrams under Log Installation Note Improper positioning of logs may create carbon build up and will severely alter the unit s performance which is not covered under warranty THERMOPILE THERMOCOUPLE 1 Open the bottom louvers 2 Loosen the thermocouple or thermopile with a 7 16 wrench 3 Disconnect thermocouple by loosening nut from the valve with a 9mm wrench Disconnect thermopile by loosening 2 screws marked TP on the valve 4 Drop the thermocouple or thermopile down from the bracket and pull it out of the unit 5 Reinstall the new ones in reverse order Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 39 5 Connect fan ground cable to ground lug Refer to wiring diagram 6 Slide the thermodisc cover assembly into the bracket clip on the un
27. FULLY 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 Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 7 INSTALLATION Side Wall Clearance 6 1 2 165mm Horizontal Vent Clearances Top 2 1 2 64mm Side 1 1 2 38mm Bottom 1 1 2 38mm Vertical Vent Clearances 1 1 4 32mm Alcove Clearances Max Depth 36 914mm Min Width 48 1219mm Min Height 72 1829mm see mantle clearance instructions Refer to the Combustible Mantels section CLEARANCES The clearances listed below are Minimum distances unless otherwise stated A major cause of chimney related res is failure to maintain required clearances air space to combustible materials It is of the greatest importance that this replace and vent system be installed only in accordance with these instructions LOCATING YOUR GAS FIREPLACE 1 When selecting a location for your replace ensure that the clearances outlined on this page are met 2 Provide adequate clearances for servicing 3 The appliance must be installed on a at solid continuous surface e g wood metal concrete This may be the oor or raised up on a platform to enhance its visual impact If the appliance is going to be installed on carpeting combustible linoleum tile or other combustible material other than wood ooring the appliance mu
28. List 13 Rigid Pipe Venting Systems 14 Rigid Pipe Venting Arrangements Horizontal Terminations 16 Rigid Pipe Venting Arrangements Vertical Terminations 17 Horizontal Terminations 21 Vertical Terminations 22 Installation Procedures 23 High Elevation 24 Gas Line Installation 24 Pilot Adjustment 24 Gas Pipe Pressure Testing 24 Conversion Kit 791 969 from NG to LP 25 Optional Brick Panels 29 Log Set Installation 29 Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 4 This is a copy of the label that accompanies each P90 Zero Clearance Direct Vent Gas Fireplace We have printed a copy of the contents here for your review The safety label is located on the front inside base of the unit visible when the bottom louver is open NOTE Excalibur units are constantly being improved Check the label on the unit a
29. SA 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 certi ed kit is used Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 3 TABLE OF CONTENTS Glass Door Installation 31 Arch Surround 31 Optional Screen Door 31 Accent Kit Installation 32 Option 1 Remote Control 33 Option 2 Wall Switch 33 Option 3 Wall Thermostat 33 Wiring Diagrams 34 OPERATING INSTRUCTIONS Operating Instructions 36 Lighting Procedure
30. V4LA SV4LA SV4L24 SV4LB24 SV4L36 SV4LB36 SV4L48 SV4LB48 N A N A SV4LBA24 N A N A SV4LA12 SV4LBA12 N A N A SV4E45 SV4EB45 N A SV4EBR90 1 SV4E90 1 SV4EB90 1 SV4SD SV4CSB SV4BM SV4SU SV4RSM SV4PF SV4BF SV4LA N A SV4RSA N A SV SHK SV HK SV FK N A N A SV4CHC 1 SV4CGV 1 SV4FC SV4FA SV4FB SV4VS SV4VS SV4STC14 SV4STC36 Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 14 Rigid Pipe Adaptor Pipe Length Vertical Terminal Storm Collar Part 953 Flashing 943 or 943S Ceiling Firestop Part 963 24 Pipe Length Adj Pipe Length 11 14 5 8 90 Elbow o Horizontal Termination Cap Wall Thimble Part 942 Vinyl Siding Standoff Optional Part 950 INSTALLATION RIGID PIPE VENTING SYSTEMS The minimum components required for a basic horizontal termination are 1 Horizontal Termination Cap 1 90o Elbow 1 Rigid Pipe Adaptor 1 Wall Thimble 1 Length of pipe to suit wall thickness see chart 1 4 x 6 5 8 to 5 x 8 increaser for 5 x 8 venting Wall thickness is measured from the back standoffs to the inside mounting surface of termination cap For siding other than vinyl furring strips may be used instead of the vinyl siding standoff to create a level surface to mount the vent terminal The Terminal must not be recessed into siding Measure the wall thickness including furring strips If a Vinyl Siding Standoff is required
31. WARNING If the information in these instructions are not followed exactly a re or explosion may result causing property damage personal injury or loss of life FOR YOUR SAFETY Do not store or use gasoline or other ammable vapours and liquids in the vicinity of this or any other appliance Installation and service must be performed by a quali ed 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 re department FPI FIREPLACE PRODUCTS INTERNATIONAL LTD 6988 Venture St Delta BC Canada V4G 1H4 918 525 MODELS P90 NG1 Natural Gas P90 LP1 Propane 07 17 06 P90 Zero Clearance Direct Vent Gas Fireplace Owners amp Installation Manual Tested by Installer Please complete the details on the back cover and leave this manual with the homeowner Homeowner Please keep these instructions for future reference www excalibur re com Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 2 To the New Owner Congratulations You are the owner of a state of the art Excalibur Gas Fireplace by FPI FIREPLACE PRODUCTS INTERNATIONAL LTD The P90 is a hand crafted appliance and has been designed to provide you with
32. _________________________________________ ___________________________________________________ ___________________________________________________ ___________________________________________________ ___________________________________________________ Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 46 NOTES ___________________________________________________ ___________________________________________________ ___________________________________________________ ___________________________________________________ ___________________________________________________ ___________________________________________________ ___________________________________________________ ___________________________________________________ ___________________________________________________ ___________________________________________________ ___________________________________________________ ___________________________________________________ Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 47 WARRANTY Excalibur Fireplace Products are designed with reliability and simplicity in mind In addition our internal Quality Assurance Team carefully inspects each unit thoroughly before it leaves our facility FPI Fireplace Products International Ltd is pleased to extend this limited lifetime warranty to the original purchaser of a Excalibur Product THE WARRANTY LIMITED LIFETIME The combustion chamber heat exchanger
33. _____________________________________________ Printed in Canada Excalibur replace products are designed with reliability and simplicity in mind In addition our internal Quality Assurance Team carefully inspects each unit thoroughly before it leaves our door FPI Fireplace Products International Ltd is pleased to extend this Limited Lifetime Warranty to the original purchaser of a Excalibur Product See the inside back cover for details Excalibur is a trademark of FPI Fireplace Products International Ltd Register your Excalibur online at http www excalibur re com Copyright 2006 FPI Fireplace Products International Ltd All rights reserved
34. a longer run is needed the FPI Direct Vent system Flex kit is 946 516 which includes all the parts needed to install the P90 with a maximum 10 run 1 6 7 8 dia exible liner 10 ft length 2 4 dia exible liner 10 ft length 3 spring spacers 7 4 thimble 2 5 AstroCap termination cap 1 6 screws 12 7 tube of Mill Pac 1 8 plated screws 8 9 screws 8 x 1 1 2 Drill Point Stainless Steel 4 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 INSTALLATION Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 12 INSTALLATION EXTERIOR VENT TERMINATION LOCATIONS A Clearance above grade veranda porch deck or balcony min 12 30cm B Clearance to window or door that may be opened 12 30cm 9 23cm C Clearance to permanently closed window min 12 30cm D Vertical clearance to ventilated sof t located above the terminal within a horizontal distance of 24 60cm from the centerline of the terminal min 18 46cm check with local code E Clearance to unventilated sof t min 15 38cm F Clearance to outside corner with AstroCap Termination Cap min 6 15cm with Dura Vent Termination Cap 14 36cm G Clearance to inside corner with AstroCap Termination Cap min 6 15cm with Dura Vent Termination Cap 12 30cm H
35. acket to the bottom louver and lift the assembly out 3 Remove the bottom louver door 4 Slide the fan in towards the rear of the unit and slip it over the two mounting studs Take care not to damage the insulation on the fan base Ensure that the fan blades do not rub against the valve tubing Diagram 1 Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 40 12 Undo the pilot tube from the valve with a 7 16 wrench 13 Undo the quick drop out thermocouple nut on the valve with a 9mm metric wrench 14 Remove the Piezo igniter wire and push button assembly 15 Undo the gas out are nut with a 13 16 wrench 16 Undo the gas out are tting with an 11 16 wrench 17 Remove the 4 Phillips head screws from the sides of the valve bracket and remove valve Hint If you are using black pipe ensure that there is a union by the valve otherwise removal will be almost impossible INSTALLING VALVE 1 Attach the valve to the valve bracket with the 4 m5x8 metric screws provided 2 Reconnect the gas out are tting with an 11 16 wrench 3 Reconnect the gas out are nut with a 13 16 wrench 4 Install piezo ignitor push button assembly and reconnect wire 5 Reconnect the quick drop out thermocouple nut with a 9mm wrench 6 Reconnect the pilot tube nut with a 7 16 wrench 7 Scrape off the old gasket from the oor of the rebox and from the valve tray assembl
36. ackets over the pins on the base 2 Slide the 2 screws on the rear of the Arch Surround into the bracket on the Glass Door and then tighten screw to secure Fit the bottom brackets over the pins on the base View from underneath of the screw and the bracket Screw Bracket Tighten both screws to secure Arch Surround to Glass Door 3 Slide Bottom Louver into position On each side secure the bottom screw rst into the side bracket Do not overtighten leave slightly loose to allow the louver to move freely Then tighten the top screw 4 Attach the two control boxes to the bottom unit base and tighten the 2 screws on the left side and 1 screw on the right side Bottom Screw Top Screw Secure left side with 2 screws and right side with one screw INSTALLATION Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 32 ACCENT KIT INSTALLATION 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 4 Place the emblem over the emblem design on the surround Insert the studs through the holes To secure them rst put on the spli
37. arate the 2 halves of the wall thimble and securely fasten the one with the tabs to the outside wall making sure that the tabs are on top and bottom Fasten the other thimble half to the inside wall The thimble halves slip inside each other and can be adjusted for 2 x 4 or 2 x 6 walls The liners must slip over the collars a minimum of 1 3 8 5 Slip the assembled liner and termination assembly through the thimble making sure the termination cap faces up there are markings on the cap that show which way is up This will position the termination cap with proper down slope for draining water Fasten the cap to the outer wall with the 4 supplied screws 6 Pull the centre 4 100mm liner and outer 6 7 8 175mm liner out enough to slip over the ue collars of the replace 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 replace inner collar and slip the 4 100mm liner down over it and attach with 3 supplied screws 8 Do the same with the 6 7 8 175mm liner 9 Apply a bead of silicone between the thimble and termination and around the outer edge of the terminal at the wall in order to keep the water out IMPORTANT Do not locate termination hood where excessive snow or ice buildup may occur Be sure to check vent termination area after snow falls and clear to prevent accidental blockage of venting system When using snow blowers make s
38. art 946 605 at beginning of vent run 5 x 8 venting starts at unit Please note that all vertical measurements are taken from the base of the unit excluding risers or bottom stand offs Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 17 INSTALLATION Vent must be supported at offsets Firestops are required at each oor level and whenever passing through a wall Maintain clearances to combustibles Note Must use optional rigid pipe adaptor when using rigid vent systems Part 510 994 RIGID PIPE VENTING ARRANGEMENTS VERTICAL TERMINATIONS The shaded area in the diagram shows all allowable combinations of straight vertical and offset to vertical terminations using two 90o elbow with rigid pipe vent systems for Propane and Natural Gas Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 18 The P90 is approved for a maximum 40 ft straight vertical with rigid pipe 4 x 6 5 8 vent systems for Propane and Natural Gas as per diagram The shaded area in the diagram show all allowable combinations of straight vertical and offset to vertical terminations with rigid pipe vent systems for Propane and Natural Gas Maximum two 45o elbows allowed Vent must be supported at offsets Firestops are required at each oor level and whenever passing through a wall Maintain clearances to combustibles as listed in the Clearances section INSTALLATION Please note that all vertical me
39. asurements are taken from the base of the unit excluding risers or bottom stand offs Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 19 INSTALLATION Horizontal Venting with Two 2 90o Elbows Horizontal Venting with Three 3 90o Elbows One 90o elbow Two 45o elbows Option V H H1 A 6 Min 2 Max B 1 Min 3 Max C 2 Min 4 Max D 3 Min 5 Max E 4 Min 6 Max F 5 Min 7 Max G 6 Min 8 Max With these options maximum total pipe length is 30 feet with minimum of 6 feet total vertical and maximum 8 feet total horizontal Please note minimum 1 foot between 90o elbows Must Use 5 x 8 Simpson Direct Vent GS Piping with FPI Increaser Starter Collar Part 946 605 Must Use 5 x 8 Simpson Direct Vent GS Piping with FPI Increaser Starter Collar Part 946 605 One 90o elbow Two 45o elbows Option V H V V1 H H1 A 6 Min 1 Max 1 6 Min 2 Max B 1 Min 2 Max 3 Min 3 Max C 2 Min 2 Max 5 Min 4 Max D 3 Min 2 Max 7 Min 5 Max E 4 Min 3 Max 9 Min 6 Max F 5 Min 4 Max 10 Min 7 Max G 6 Min 5 Max 11 Min 8 Max H 7 Min 6 Max 12 Min 9 Max With these options max total pipe length is 30 feet with min of 12 feet total vertical and max 9 feet total horizontal Please note min 1 foot between 90o elbows is required Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 20 INST
40. at Release Duct Kit Optional 108 910 165 Fan 120 V 109 946 000 Flexible Air Release Duct 918 525 Manual 791 969 Conversion Kit NG to LP Not available as a replacement part Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 42 PARTS LIST 61 38 43 47 48 42 32 64 61 1 9 7 36 49 8 10 2 64 22 36 15 20 23 24 21 25 24 23 25 108 109 HEAT RELEASE DUCT KIT FAN SWITCH ASSEMBLY ON OFF SWITCH ASSEMBLY 62 51 59 60 61 63 64 27 30 28 30 31 50 93 97 98 99 100 102 90 96 95 93 92 91 94 89 HEAT WAVE DUCT KIT BRICK PANELS 33 34 35 Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 43 A E TH TP TP TH TP TH AIR IN AIR IN O O T L I P 52 69 58 53 57 82 83 56 85 79 75 76 68 68 67 66 PARTS LIST P90 BURNER ASSEMBLY amp LOG SET Part Description 52 910 190 Piezo Ignitor amp Nut 53 780 021 Gasket Valve Access Plate 790 574 P Valve Assy Natural Gas 790 576 P Valve Assy Propane 56 Valve Tray NG LP 57 910 478 Valve S I T NG LPG 58 Valve Bracket 65 Pilot Bracket 66 910 038 Pilot Assy NG 3 way ame S I T 910 039 Pilot Assy LP 3 way ame S I T 904 617 Ori ce 34 Natural Gas 904 645 Ori ce 51 Propane 936 170 Ori ce Gasket
41. ay be installed on the replace Please Note Only 1 HeatWave kit may be operated at one time This includes the internal blower option as well OPTIONAL HEAT RELEASE KIT 946 570 The Heat Release Kit expels warm air from the replace to the outside of the building allowing the replace to be operated with less heat entering the room The kit may be used on either the left or right side WARNING Fire hazard is an extreme risk if these clearances are not adhered to Clearances for HeatWave and Heat Release Kit 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 Clearance to Combustibles from Back 0 0mm Side 0 0mm Floor 0 0mm NOTE The minimum oor clearance must be maintained from the top surface of the carpeting tile etc Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 8 19 1 4 489mm including standoffs 10 7 8 276mm 49 7 8 1267mm 70 1 2 1791mm 4 100mm Dia Inner 6 7 8 175mm Dia Outer 46 1 2 1181mm 42 1067mm 31 787mm FRAMING AND FINISHING 1 Determine the total thickness of facing material e g drywall plus ceramic tiles to allow the nished surface to be ush with the front of the unit Total facing thickness can vary from 1 2 13mm to 1 32mm thick 2 Frame in the enclosure for the unit wit
42. ce person Caution Wear gloves when removing damaged or broken glass Glass Replacement Remove the glass door front Refer to the Glass Door Installation section Remove the 4 glass clips from each corner Slide in the new replacement glass Push the 4 glass clips back onto the frame The glass must have gasketing around it MAINTENANCE MAINTENANCE INSTRUCTIONS 1 Always turn off the gas valve before cleaning For relighting refer to lighting instructions Keep the burner and control compartment clean by brushing and vacuuming at least once a year When cleaning the logs use a soft clean paint brush as the logs are fragile and easily damaged 2 Clean appliance and door with a damp cloth never when unit is hot Never use an abrasive cleaner The glass should be cleaned with a gas replace glass cleaner The glass should be cleaned when it starts looking cloudy 3 The heater is nished in a heat resistant paint and should only be re nished with heat resistant paint Excalibur uses StoveBright Paint Metallic Black 6309 4 Make a periodic check of burner for proper position and condition Visually check the ame of the burner periodically making sure the ames are steady not lifting or oating If there is a problem call a quali ed service person 5 The appliance and venting system must be inspected before use and at least annually by a quali ed eld service person to ensur
43. d line up with the centerline of the horizontal pipe Cut and frame the 10 inch square hole in the exterior wall where the vent will be terminated If the wall being penetrated is constructed of non combustible material i e masonry block or concrete a 7 178mm dia 7 1 2 191mm dia for ex hole is acceptable 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 re b The location of the horizontal vent termi nation on an exterior wall must meet all local and national building codes and must not be blocked or obstructed For External Vent Terminal Locations see diagram in the Exterior Vent Termination Locations section c Snorkel Terminations For installations requiring a vertical rise on the exterior of the building 14 inch and 36 inch tall Snorkel Terminations are available as well as the standard Riser Vent Follow the same installation procedures as used for standard Horizontal Termination N E V E R install the s n o r k e l u p s i d e down Diagram 3 Diagram 3a Note Riser Vent is only for use in above grade terminations Note Apply sealant Mill Pac to inner pipe and high temperature silicone sealant to outer pipe on every twist lock joint Note With Dura Vent the minimum height
44. d then slide the burner grate assembly to the left and lift out 7 Remove the rear log stand by removing the 2 screws Rear Log Stand screws 9 Disconnect the inlet gas line See dia 2 10 Disconnect the 2 TP wires and the 2 TH wires from the valve 11 Remove the 12 Phillips head screws securing the valve tray assembly in place and then lift the entire assembly out screws Valve Tray Assembly 8 Remove the 2 screws amp sleeves on the bottom brick panel and lift out the bottom brick panel The brick panel is very fragile handle with care screws MAINTENANCE Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 41 PARTS LIST P90 MAIN ASSEMBLY Part Description Part Description Part Description 1 430 129 Receptacle Box Mount 2 Thermodisc Bracket 7 910 428 Duplex Receptacle 8 910 429 Box Receptacle 9 910 430 Cover Receptacle 10 904 687 Clamp Connector 15 Heat Shield Base 20 790 021 Front Filler Left Corner 21 790 022 Front Filler Right Corner 22 790 012 Baf e 23 780 011 Standoff Top 24 780 013 Standoff Side 25 780 091 Standoff Rear 27 Outer Flue Collar 28 Inner Flue Collar Assy 30 Gasket for Flue Collar 31 Flue Mounting Bracket 32 902 600 Brick Panel Base 790 901 Brick Panel Set Standard Brown 790 902 Brick Panel Set Standard Red 790 903 Brick Panel Set Herringbone Brown 790 904 Brick Panel Set H
45. derside of the rebox Check that no wire will touch the hot surfaces Diagram 2 Diagram 1 Diagram 2 Secure left side with 2 screws and right side with one screw 8 Secure the fan wires and power cord by attaching one of the adhesive backed wire holder clips Part 910 199 onto the stove base Use the second clip to bundle up the wires approximately 4 from the control box Ensure that there is no interference with the wires when the louver is closed and that no wire will touch the hot metal surfaces or sharp edges 9 Plug the fan power cord into the rear end of the receptacle box to provide the maximum clearance from the louvers 7 Attach the two control boxes to the bottom unit base and tighten the 2 screws on the left side and 1 screw on the right side MAINTENANCE To Remove the Fan 1 Shut the power off 2 Reverse the above instructions Note The bearings are lubricated for life Do not lubricate them Make sure you vacuum the fan area on a regular basis IMPORTANT These fans collect a lot of dust from within your home Ensure you maintain these fan motors on a regular basis by vacuuming out the fan blades and housing using a soft brush nozzle FAN MAINTENANCE Unit must be grounded at all times Do not cut the ground terminal off under any circumstances To Install the Fan 1 Shut the power off 2 Open the bottom louver door Loosen the 2 screws holding the Burner ON OFF switch and br
46. e that the ow of combustion and ventilation air is not obstructed Note Never operate the appliance without the glass properly secured in place 6 Do not use this appliance if any part has been under water Immediately call a quali ed service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water 7 Verify operation after servicing General Vent Maintenance Conduct an inspection of the venting system semi annually Recommended areas to inspect as follows 1 Check the Venting System for corrosion in areas that are exposed to the elements These will appear as rust spots or streaks and in extreme cases holes These components should be replaced immediately 2 Remove the Cap and shine a ashlight 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 ttings It may be caused by having excessive lateral runs too many elbows and exterior portions of the system being exposed to cold weather 4 Inspect joints to verify that no pipe sections or ttings have been disturbed and consequently loosened Also check mechanical supports such as Wall Straps or plumbers tape for rigidity GOLD PLATED DOOR OR SURROUN
47. ection may be made of rigid pipe copper pipe or an approved ex connector If you are using rigid pipe ensure that the valve can be removed for servicing Since some municipalities have additional local codes it is always best to consult with your local authorities and the CAN CGA B149 installation code For USA installations follow local codes and or the current National Fuel Gas Code ANSI Z223 1 When using copper or ex connectors use only approved ttings Always provide a union so that gas lines can be easily disconnected for servicing Flare nuts for copper lines and ex connectors are usually considered to meet this requirement Important Always check for gas leaks with a soap and water solution or gas leak detector Do not use open ame for leak testing PILOT ADJUSTMENT Periodically check the pilot ames Correct ame pattern has three strong blue ames 1 owing around the thermopile 1 around the thermocouple and 1 owing across the burner it does not have to be touching the burner Note If you have an incorrect ame pattern contact your Excalibur dealer for further instructions Incorrect ame pattern will have small probably yellow ames not coming into proper contact with the rear burner or thermopile or thermocouple The manifold pressure is controlled by a regulator built into the gas control and should be checked at the pressure test point Note To pro
48. ent 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 suf cient distance so as to result in a minimum pipe overlap of 1 1 4 inches Secure the connection between the vent pipe and the vent cap by attaching the two sheet metal strips extending from the vent cap assembly into the outer wall of the vent pipe Use the two sheet metal screws provided to connect the strips to the pipe section See Diagram 6 9 Install wall thimble in the center of the 10 square and attach with wood screws Diagram 7 3 A Firestop spacer must be installed in the oor or ceiling of every level To install the Firestop spacer in a at ceiling or wall cut a 10 inch square hole Frame the hole as shown in Diagram 3 and install the restop 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 suf cient size to meet the minimum requirements for clearance to combustibles of 1 1 2 Slip the ashing under the shingles shingles should overlap half the ashing as per Diagram 4 Diagram 4 The upper half of the ashing is installed under the roo ng material and not nailed down until the chimney is installed This allows for small
49. erringbone 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 432 967 Burner ON OFF Switch Assy 38 910 241 Switch Burner ON OFF 3 way 910 899 Wire Harness Valve to Burner 42 910 331 P Fan Motor 120 Volts 432 966 Fan Switch Assembly 120 V Optional 43 Power Cord 120 Volts 910 845 Wire Harness Plug In Fan 46 910 330 Fan Speed Control Switch 47 904 586 Knob Speed Control 48 910 199 Wire Holder Clip 49 910 142 Thermodisc Fan Auto On Off 910 845 Wire Harness Plug in Fan 904 713 U clip at Louver 50 510 994 Rigid Pipe Adaptor Optional 51 790 011 Relief Frame Gasket 59 790 009 Relief Door Mounting Plate 60 W260260 Top Relief Frame Gasket 61 942 117 Top Relief Plate Frame 62 W260280 Top Relief Plate Gasket 63 290 021 Air Baf e Plate 64 790 093 Gasket Exchanger Relief 946 556 Heat Wave Duct Kit Optional 89 946 004 Junction Box 90 946 000 Round Duct Adaptor 91 946 002 Round to Oval Adaptor 92 946 001 Oval Duct Adaptor 93 946 007 Angle Bracket 94 946 517 P Fan Assy HeatWave Option 95 946 006 Grill Plate White 96 946 005 Wall Adaptor Plate White 97 910 417 Knob White 98 910 366 Switch Cover Plate White 99 910 412 Fan Speed Controller 100 910 367 Box Plastic Switch Receptacle 102 946 010 Flexible Air Duct 946 038 Insulation 6 dia x 24 946 570 He
50. event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic the hard wired carbon monoxide detector with alarm and battery back up may be installed on the next adjacent floor level b In the event that the requirements of this subdivision can not be met at the time of completion of installation the owner shall have a period of thirty 30 days to comply with the above requirements provided however that during said thirty 30 day period a battery operated carbon monoxide detector with an alarm shall be installed 2 APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI UL 2034 listed and IAS certified 3 SIGNAGE A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS 4 INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless upon inspection the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5 08 2 a 1
51. f 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 Openings for electrical connections 120 Volt Power IN Millivolt Wires CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Lockwasher Fan ground wire Nut 8 Ground Lug mobile home approved Star washer Ground Green Neutral Live Black Red Red Fan Thermodisc normally open Ground ON OFF Rotary Speed Control 120V AC 60 Hz Fan Piezo Ignitor To Thermocouple IN Pilot Assembly H I L O O F F O N PI L O T 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 For NATURAL GAS Units and Units NOT Equipped with DC Spark Boxes Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 35
52. h framing material The framed opening is 46 3 8 high x 46 1 2 wide x 19 1 2 deep 1168mm high x 1181mm wide x 495mm deep Framing Dimensions A B C 46 1 2 46 3 8 19 1 2 1181mm 1168mm 495mm If HeatWave option is installed minimum depth is 20 508mm If HeatWave option is installed minimum depth is 20 508mm INSTALLATION COMBUSTIBLE MANTELS Because of the extreme heat this replace emits the mantel clearances are critical Combustible mantel clearances from top of unit are shown in Diagram below Note A non combustible mantel may be installed at a lower height if the framing is made of metal studs covered with a non combustible board These drawings are to scale at 1 6 one inch 6 inches Mantel can be installed anywhere in shaded area or higher using the above scale Note Ensure the paint that is used on the mantel and the facing is heat resistant or the paint may discolour 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 replace itself P90 Flat Wall Surround and Tile Kit The P90 Flat Wall Surround Hearth Pad and Tile Kit cannot be modi ed in any way It must be installed as manufactured P90 Flat Wall Surround and Tile Kit Speci cations UNIT BASE STAND OFFS To accommodate varying thicknesses and nishes of hearth materials we have inc
53. ile the outer liner draws outside combustion air into the combustion chamber thereby eliminating the need to use heated room air for combustion and losing warm room air up the chimney Note These flue pipes must not be connected to any other appliance The gas appliance and vent system must be vented directly to the outside of the building and never be attached to a chimney serving a separate solid fuel or gas burning appliance Each direct vent gas appliance must use it s own separate vent system Common vent systems are prohibited 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 1 Ensure top clip screws are at top of oblong holes before installation Back View of Cover Plate Pin Holes Top Clip Pins 2 Position bottom of cover plate over pins located at the bottom of the rebox Oblong Screw Holes 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 TO REMOVE 1 Remove 2 screws that secure top clip Ensure to hold cover plate as it will fall forward 2 Pull out top clip that is still hooked onto glass OPTIONAL COVER PLATE TEMPLATE UNIT ASSEMBLY PRIOR
54. ions Sites and Communities ANSI NFPA 501A and with CAN CSA Z240 MH Mobile Home Standard in Canada Optional Fan Part 432 917 Optional Heat Wave Kit 946 556 Optional Heat Release Kit 946 570 Electrical supply 115VAC 1 13A 60Hz Not for use with solid fuel This vented gas fireplace is not for use with filters For horizontal runs exceeding 10 5 x 8 piping must be used MAY BE INSTALLED IN MANUFACTURED MOBILE HOMES AFTER FIRST SALE Listed Certified for Certifi e pour Tested to Report No VENTED GAS FIREPLACE HEATER CANADA and U S A Gas Fired Appliances For Use At High Altitudes 476 3059100 June 2004 CAN CGA 2 17 M91 Vented Gas Fireplace Heaters ANSI Z21 88b 2003 CSA 2 33b 2003 Made in Canada Fabrique au Canada Duplicate S N See Instruction Manual for Detailed Instructions Model Modele P90 NG1 Model Modele P90 LP1 309 6 1 2 6 1 2 Wall Wall 18 1 4 44 1 4 To Ceiling For the State of Massachusetts installation and repair must be done by a plumber or gas tter licensed in the Commonwealth of Massachusetts For the State of Massachusetts exible connectors shall not exceed 36 inches in length For the State of Massachusetts the appli ances individual manual shut off must be a t handle type valve The State of Massachusetts requires the installation of a carbon monoxide alarm in accordance with NFPA 720 and a CO alarm with battery back up in the
55. it will create a small clicking sound This is the switch contacts closing and is normal Pilot Flame While the pilot ame is on it can make a very slight whisper sound Gas Control Valve As the gas control valve turns ON and OFF a dull clicking sound may be audible this is normal operation of a gas regulator or valve Unit Body Firebox Different types and thicknesses of steel will expand and contract at different rates resulting in some cracking and ticking sounds will be heard throughout the cycling process OPERATING INSTRUCTIONS Gas Inlet OFF Gas Inlet Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 38 GLASS GASKET If the glass gasket requires replacement use a tadpole glass gasket Part 936 155 DOOR GLASS Your Excalibur replace is supplied with high temperature 5 mm Neoceram ceramic glass that will withstand the highest heat that your unit will produce If your glass requires cleaning we recommend using an approved glass cleaner available at all authorized dealers Do not use abrasive materials Do not clean the glass when hot In the event that you break your glass by impact purchase your replacement from an authorized Excalibur dealer only and follow our step by 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 quali ed servi
56. l at least 1 3 8 35mm and fasten with the 3 screws NOTE Horizontal sections must be supported at intervals not exceeding 3 feet 0 9 meter Flame picture and performance will be affected by sags in the liner 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 ashing to the roof with roo ng rails slide storm collar over the pipe section and seal with a mastic 8 Install the vertical termination cap by twist locking it Note Any closets or storage spaces which the vent passes through must be enclosed Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 24 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 HIGH ELEVATION This unit is approved in Canada for altitude 0 to 4500 ft CAN1 2 17 M91 GAS LINE INSTALLATION The gas line is brought through the right side of the appliance The gas valve is situated on the right hand side of the unit and the gas inlet is on the right hand side of the valve The gas line conn
57. lot cap to expose the pilot ori ce Remove the 2 screws push Burner Assembly to the left and lift out Burner Ori ce Installation of LPG Conversion Kit 1 Shut off the gas supply 2 H35 1 Lift off the Cast Top and remove the glass front Also open up the control panel door P90 1 Remove the facade if it is in stalled Remove the glass door refer to the glass door section in the manual 3 Remove the logs embers and brick panels if used 4 Remove the 2 screws holding the Burner Assembly to the rebox base Push the Burner Assembly to the left and lift out 6 Unscrew the pilot ori ce with the allen key and replace with the LP pilot ori ce in the kit and replace pilot cap 7 Remove burner ori ce with a 1 2 wrench and discard Use another wrench to hold on to the elbow behind the ori ce 8 Reinstall new burner ori ce LP stamped 51 and tighten 9 Turn control knob to the OFF position 10 Remove the black protection cap by hand from the high low knob Fig 1 Fig 1 11 Insert a 5 32 or 4mm Allen wrench into the hexagonal key way of the screw Fig 2 rotate it counter clockwise until it is free and extract it 12 Check that the screw is clean and if necessary remove dirt 13 Flip the screw Fig 3 Fig 2 Fig 3 INSTALLATION Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 26 17 Reverse steps 4 to 2 18 Attach clear
58. m Horizontal Side Horizontal Bottom 1 1 2 38mm 1 1 2 38mm Alcove Clearances Max Depth 36 914mm Min Width 48 1219mm Min Height 72 1229mm Serial No No de serie 918 503 5 WC 1 25 kPa 3 8 WC 0 95 kPa 1 1 WC 0 27 kPa 34 DMS 18 200 Btu h 5 42 kW 0 4500 ft pi 0 1372 m 35 000 B 10 26 tu h kW 12 WC 3 00 kPa 11 WC 2 74 kPa 2 9 WC 0 72 kPa 51 DMS 17 950 Btu h 5 26 kW 35 000 B 10 26 0 2000 ft pi 0 610 m tu h kW 2000 4500 ft pi 610 1372 m 52 DMS 15 500 Btu h 4 54 kW 31 000 Btu h 9 08 kW APPAREIL FONCTIONNANT AU NATURAL GAZ CONCU POUR ETRE POELE Pression d allimentation minimum Pression la tubulure d chappement lev e Pression la tubulure d chappement basse Grandeur de l injecteur D bit minimum selon D bit maximum selon l altitude Mod le P90 NG1 Calorifique Calorifique VENTING This appliance must be installed in accordance with the manufacturer s installation instructions and with local codes if any if not follow the currentANSI Z223 1 in the USAor the current CAN 1 B149 in Canada For Manufactured Home Installation This Direct Vent System Appliance must be installed in accordance with the manufacturer s installation instructions and Manufactured Home Construction and Safety Standard Title 24 CFR Part 3280 or the current Standard for Fire Safety Criteria for Manufactured Home Installat
59. mplere Antique Gold 790 952 Single Screen Door Complete Antique Nickel 790 953 Single Screen Door Complete Antique Copper 151 Single Screen Door Frame 152 Mesh Screen Single Door 153 Retaining Plate Single Door 154 Handle Single Door 155 904 721 Push Fit Ball Plunger 156 Door Mounting Bracket Right 157 Carriage Bolt 158 948 221 Logo Plate 159 904 724 Plunger Clamp PARTS LIST 790 930 Double Screen Door Complete Black 790 932 Double Screen Door Complete Gold 790 941 Double Screen Door Complete Antique Gold 790 942 Double Screen Door Complete Antique Nickel 790 943 Double Screen Door Complete Antique Copper 161 Double Screen Door Frame Right 162 Double Screen Door Frame Left 163 Mesh Screen Double Door 164 Retaining Plate Double Door 167 Door Mounting Bracket Right 168 Door Mounting Bracket Left Not available as a replacement part Part Description Part Description Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 45 NOTES ___________________________________________________ ___________________________________________________ ___________________________________________________ ___________________________________________________ ___________________________________________________ ___________________________________________________ ___________________________________________________ __________
60. nd if there is a difference the label on the unit is the correct one SAFETY LABEL Copy of Safety Decal for P90 APPAREIL FONCTIONNANT AU GAZ PROPANE CONCU POUR ETRE POELE Pression d allimentation minimum Pression la tubulure d chappement lev e Pression la tubulure d chappement basse Grandeur de l injecteur D bit minimum selon D bit maximum selon Mod le P90 LP1 l altitude Calorifique Calorifique l altitude Grandeur de l injecteur D bit Calorifique minimum selon D bit Calorifique maximum selon DO NOT REMOVE THIS LABEL NE PAS ENLEVER CETTE TIQUETTE 309 NATURAL GAS Minimum supply pressure Manifold pressure high Manifold pressure low Orifice size Minimum input Maximum input Altitude Model P90 NG1 L PROPANE Minimum supply pressure Manifold pressure high Manifold pressure low Altitude Orifice size Minimum input Maximum input High Model P90 LP1 L Altitude Orifice size Minimum input Maximum input DOOR SEAL Please check that the door is properly sealed FPI Fireplace Products International Ltd Delta BC Canada Minimum Clearances to Combustibles Degagement Minimum De Materiaux Combustibles 0 Clearance to combustibles from Mantel Clearances from Top Side Wall Clearance from Side Facing Top bottom sides amp rear of unit Min 18 1 4 464mm 6 1 2 165mm Minimum Vent Clearances Horizontal Top 2 1 2 64m
61. ock 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 ue collar and fasten to the outer collar only with the 3 supplied screws drilling pilot holes will make this easier Level the replace and fasten it to the framing using nails or screws through the nailing strips 4 Assemble the desired combination of pipe and elbows to the appliance adaptor and twist lock for a solid connection Note a Twist lock procedure Four indentations located on the female ends of pipes and ttings are designed to slide straight onto the male ends of adjacent pipes and ttings by orienting the four pipe indentations so they match and slide in to the four entry slots on the male ends Diagram 1 Push the pipe sections completely together then twist lock one section clockwise approximately one quarter turn until the two sections are fully locked The female locking lugs will not be visible from the outside on the Black Pipe or ttings They may be located by examining the inside of the female ends Diagram 1 b Horizontal runs of vent must be supported every three feet Wall straps are available for this purpose 5 Mark the wall for a 10 x 10 square hole The center of the square hole shoul
62. perly check gas pressure both inlet and manifold pressures should be checked using the valve pressure ports on the valve 1 Make sure the valve is in the OFF position 2 Loosen the IN and or OUT pressure tap s turning counterclockwise with a 1 8 wide at screwdriver 3 Attach manometer to IN and or OUT pressure tap s using a 5 16 ID hose 4 Light the pilot and turn the valve to ON position 5 The pressure check should be carried out with the unit burning and the setting should be within the limits speci ed on the safety label 6 When nished reading manometer turn off the gas valve disconnect the hose and tighten the screw clockwise with a 1 8 at screwdriver Note Screw should be snug but do not over tighten S I T VALVE DESCRIPTION 1 Gas on off knob 2 Manual high low adjustment 3 Pilot Adjustment 4 Thermocouple Connection option 5 Outlet Pressure Tap 6 Inlet Pressure Tap 7 Pilot Outlet 8 Main Gas Outlet 9 Alternative TC Connection INSTALLATION P90 NG1 System Data For 0 to 4500 feet altitude Burner Inlet Ori ce Sizes 34 Max Input Rating 35 000 Btu h Min Input Rating 18 200 Btu h Supply Pressure min 5 0 w c Manifold Pressure High 3 8 0 2 w c P90 LP1 System Data For 0 to 2000 feet altitude Burner Inlet Ori ce Sizes 51 Max Input Rating 35 000 Btu h Min Input Rating 17 950 Btu h High Altitude For 2000 to 4500 feet alti
63. 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 Installer Please complete the following information Dealer Name amp Address ______________________________________________ ___________________________________________________________________ Installer ___________________________________________________________ Phone ___________________________________________________________ Date Installed ______________________________________________________ Serial No _____________
64. quali ed service person A professional service person should be called to inspect this appliance annually Make it a practice to have all of your gas appliances checked annually 13 Do not slam shut or strike the glass door 14 Under no circumstances should any solid fuels wood paper cardboard coal etc be used in this appliance 15 The appliance area must be kept clear and free of combustible materials gases and other ammable vapours and liquids 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 Emissions from burning wood or gas could contain chemicals known to the State of California to cause cancer birth defects or other reproductive harm DUE TO HIGH TEMPERATURES THE APPLIANCE SHOULD BE LOCATED OUT OF TRAFFIC AND AWAY FROM FURNITURE AND DRAPERIES WARNING FAILURE TO INSTALL THIS APPLIANCE CORRECTLY WILL VOID YOUR WARRANTY AND MAY CAUSE A SERIOUS HOUSE FIRE CHILDREN AND ADULTS SHOULD BE ALERTED TO THE HAZARDS OF HIGH SURFACE TEMPERATURES ESPECIALLY THE FIREPLACE GLASS AND SHOULD STAY AWAY TO AVOID BURNS OR CLOTHING IGNITION YOUNG CHILDREN SHOULD BE CARE
65. reased the overall height of the appliance by a further 1 1 8 This increase is added with the inclusion of two stand offs at the bottom of the unit below the outer box taking the overall height of the framing dimensions from 45 1 4 up to 46 3 8 In the event that you should choose to use thinner materials to nish the hearth you can omit the stand offs provided for raising the unit However we recommend that you leave the framing dimensions as they are in the manual and alter only the facing requirement by reducing it by the same distance that you have lowered the unit Insert the 2 unit base stand offs underneath the unit as shown in the diagram below Space the stand offs centrally approximately 2 or 2 1 2 feet apart Ensure that the unit is not unstable Install Top Standoffs amp Side Nailing Strips before unit is slipped into position See the Unit Assembly Prior to Installation section for assembly details Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 9 INSTALLATION Fireplace Stand No hearth is required when the unit is raised 3 76mm off of the floor surface Flooring HEARTH REQUIREMENTS Floor Mounted Fireplaces Raised Fireplaces FACING REQUIREMENT This replace requires a non combustible material extending from the framing header and sides The anges on the front face of the replace are for a facing thickness of 1 25mm Facing Over 1 25mm Thick If
66. rker 8 Insert both the ground wire and the DC sparker generator wire through the hole of the DC spark heat shield 7 Attach the Piezo ignition wire to the DC Sparker Piezo Ignitor 13 Attach the heat shield to the DC sparker then mount this onto the stove Note We recommend attaching the DC sparker box to the bottom rear of the stove or place this in a convenient location away from the heat source 14 Tie up the loose wire with the wire clip Installation of the DC Sparker for the P90 Units Only 1 Locate the Piezo Ignitor situated at the side of valve 2 Remove the Piezo Ignitor by unscrewing the nut at the back of the mounting bracket 3 Disconnect the ignitor wire from the Piezo Ignitor and connect it to the DC Sparker Piezo Ignitor Ignitor Wire Piezo Ignitor Ignitor Wire DC Sparker 4 Install the 3 4 nylon plug to cover up the hole on the mounting bracket 12 Install the supplied battery into the DC Sparker Box by opening the battery compartment NOTE The battery in the DC Sparker Box will need to be replaced annually Battery Compartment INSTALLATION Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 28 5 Connect the DC spark generator wires to the SIT Valve with the screw which is provided in the kit 6 Locate the ground lug at the receptical box left of the unit Installer Notice These instructions must be left with the appliance
67. se condensation and fog the glass This condensation is normal and will disappear in a few minutes as the glass heats up DO NOT BURN THE APPLIANCE WITHOUT THE GLASS FRONT IN PLACE Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 37 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 rebox and body Therefore the varying thicknesses of steel will expand and contract at slightly different rates which can cause ticking and cracking sounds You should also be aware that as there are temperature changes within the unit these sounds will likely re occur Again this is normal for steel reboxes Blower Thermodisc When this thermally activated switch turns ON
68. side of the burner Push the back of the log against the 2 brackets with the notch on the bottom right side of the log tting into the right side of the grate LOG SET INSTALLATION Read the instructions below carefully and refer to the diagrams If logs are broken do not use the unit until they are replaced Broken logs can interfere with the pilot operation The gas log kit Part 780 930 contains the following pieces a 02 75 Rear Log b 02 55 Middle Left Log c 02 50 Front Left Log d 02 53 Center Left Log e 02 51 Front Bottom Log f 02 54 Center Right Log g 02 52 Middle Right Log h Embers 902 156 NOTE If you will be installing the optional Brick Panels install the Brick Panels prior to installing the logs 1 Carefully remove the logs from the box and unwrap them The logs are fragile handle with care do not force into position 2 Sprinkle the vermiculite all over the top of the base brick panel 3 Place the Log 02 75 on the rear log support pins with the at side to the back The 02 refer numbers i e 02 75 are molded into the rear of each log OPTIONAL BRICK PANELS 1 Open the bottom louver door Loosen the 2 screws holding the Burner ON OFF switch and bracket to the bottom louver and lift the assembly out 2 Remove Arch Surround 3 Remove glass door Remove logs Note The logs must not be in the unit 4 Insert the back brick panel rst by carefully slipping i
69. st be installed on a metal or wood panel extending the full width and depth of the appliance 4 The P90 Direct Vent Gas Fireplace can be installed in a recessed position or framed out into the room as in A B C D See Diagram 1 MANUFACTURED MOBILE HOME ADDITIONAL REQUIREMENTS 1 Ensure that structural members are not cut or weakened during installation 2 Ensure proper grounding using the 8 ground lug provided See the Wiring Diagram section 5 This appliance is Listed for bedroom installations when used with a Listed Millivolt Thermostat Some areas may have further requirements check local codes before installation 6 The P90 Direct Vent Gas Fireplace is approved for alcove installations which meet the clearances listed on this page 7 We recommend that you plan your instal lation on paper using exact measurements for clearances and oor protection before actually installing this appliance Have a quali ed inspector dealer or installer review your plans before installation Note For vent terminations see the Exterior Vent Termination Locations section Diagram 1 A Flat on Wall B Flat on Wall Corner C Recessed into Wall Alcove D Corner HEATWAVE DUCT SYSTEM OPTIONAL KIT 946 556 The HeatWave Air Duct Kit increases the effectiveness of your replace by dispersing warm air from the replace to remote locations in the same room or other rooms in your home Up to two kits m
70. t between the back wall of the rebox and the rear log bracket 5 Put the side panels in next Slide them in from the front and push them at up against the wall Be very careful not to scratch them on the rebox hardware 6 Install the 2 brick retaining clips one on each side 02 75 Note If the bottom brick panel must be removed Remove the Rear Log Stand then remove the Burner Tray See the Removing Valve section 02 75 02 54 02 52 02 50 02 53 02 51 02 54 02 51 Notch 6 Position Log 02 54 across the cutouts in Logs 02 51 and 02 53 The notch in the bottom right end tting against the 5th grate tab INSTALLATION Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 30 Place embers in these 3 locations on the burner tray Log indentation Photo shows rear grate tab Log 02 51 was removed to show the positioning of Log 02 52 Rear Grate Tab 02 52 02 75 02 51 02 54 02 52 02 54 Rear Bracket 02 55 02 75 02 51 02 53 7 Place the bottom left front edge of Log 02 55 against the rear bracket on the burner tray and rest the log on the cutout on L o g 02 53 Cutouts 8 Place Log 02 52 between Logs 02 51 and 02 75 and on the indentation on Log 02 54 The bottom right end sits behind the rear grate tab Front Brackets Notch 02 50 02 50 02 55 02 75 02 53 02 51 02 54 02 55 02 53 02 50 02 55 02 53 9 Sit Log 02 50 on
71. t lock washer and then the nut and tighten 5 Remove the 2 studs on the sides of the Hood Insert the new studs through the holes and secure them by rst putting on the washer and then tighten with a nut DOUBLE amp 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 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 INSTALLATION Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 33 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 replace to that location Use the Thermostat Wire Table 2 Connect the two wires to the gas valve See diagram below Option 2 WALL SWITCH 1 Run the wire through the right or left side gas inlet opening Be careful not to damage wire Note We recommend a maximum of 15 of wire but if you wish to go with a longer run use
72. 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 CAUTION Do not connect millivolt remote control wires to a 120V wire Thermostat Wire Table 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 non anticipator type thermostat that is CSA ULC or UL approved may be used CAUTION Do not connect millivolt wall thermostat wires to a 120V wire 3 Install 3 AAA alkaline batteries in transmitter and 4 AA alkaline batteries in the receiver Install the receiver and its cover in the wall Switch the remote receiver to remote mode The remote control is now ready for operation 14 GA 16 GA 18 GA 20 GA 22 GA 50 Ft 32 Ft 20 Ft 12 Ft 9 Ft Recommended Maximum Lead Length Two Wire When Using Wall Thermostat CP 2 System Wire Size Max Length INSTALLATION Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 34 WIRING DIAGRAMS Caution Ensure that the wires do not touch any hot surfaces and are away from sharp edges This heater does not require a 120V A C supply for operation In case o
73. 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 replace will need to be raised to accommodate the brick thickness Example If the brick is 2 thick the unit must be raised 1 Note 48 11 219 mm is the minimum height for both ex termination or Rigid Pipe venting 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 ex see the Clearances section You must take into account the depth of the floor covering carpet tile linoleum etc when determining the height of the replace stand The HeatWave Duct Kit has different clearance and framing requirements check the HeatWave manual for details Please note that all vertical measurements are taken from the base of the unit excluding risers or bottom stand offs Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 10 INSTALLATION VENTING INTRODUCTION The P90 uses the balanced ue technology Co axial system The inner liner vents products of combustion to the outside wh
74. to OFF position and allow 5 minutes for any gas in the combustion chamber to escape 3 Turn gas control knob counterclockwise so indicator points to the PILOT position Depress the gas control knob fully Depress the igniter button several times until the pilot lights After approximately one minute release the gas control knob The pilot ame should continue to burn If the pilot does not remain lit repeat operation allowing a longer period before releasing gas control knob 4 When the pilot stays lit turn the gas knob further counterclockwise to the ON position 5 Use the wall switch thermostat or remote control to turn on the unit 6 Rotate the ame height regulator to adjust the ame height higher or lower SHUTDOWN PROCEDURE 1 Use the wall switch thermostat or remote control to turn off the main burner 2 Turn the main gas control clockwise to the OFF position to turn off the pilot 3 Turn off all electric power to appliance if service is to be performed FIRST FIRE The rst re in your replace is part of the paint curing process To ensure that the paint is properly cured it is recommended that you burn your replace for at least four 4 hours the rst time before you use it with the fan on When rst operated the unit will release an odour caused by the curing of the paint the burning off of any oils remaining from manufacturing Smoke detectors in the house ma
75. tude Burner Inlet Ori ce Sizes 52 Max Input Rating 31 000 Btu h Min Input Rating 15 500 Btu h Supply Pressure min 12 0 w c Manifold Pressure High 11 0 2 w c Electrical 120 V A C System Circulation Fan variable speed 130 CFM Log Set Ceramic bre 7 per set Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 25 CONVERSION KIT 791 969 FROM NG TO LP THIS CONVERSION MUST BE DONE BY A QUALIFIED GAS FITTER IF IN DOUBT DO NOT DO THIS CONVERSION Each Kit contains one LPG Conversion Kit and one DC Sparker Kit LPG Conversion Kit Contains Qty Part Description 1 904 529 5 32 Allen Key 1 904 645 Burner Ori ce 51 1 918 590 Label Converted to LPG 1 908 528 Red LPG label 1 910 037 LP Injector Pilot Ori ce 1 918 487 Instruction Sheet DC Sparker Kit Contains Qty Part Description 1 820 475 Bracket DC Sparker 1 820 476 Bracket DC Sparker 1 904 153 Washer 8 External Star 1 904 330 Nut 8 32 Hex 1 904 438 Plug Nylon 0 750 Hole Black 1 904 531 Bushing Split Plastic 0 500 in 1 904 543 Screw 8 32 x 3 4 Pan Head 2 904 553 Screw 8 x 1 2 Type B Black Oxide 1 910 073 Spark Generator Battery Holder 1 910 074 Spark Generator Switch C W Wire 1 910 078 Battery Size AA Energizer En91 2 910 199 Clip Wire Holder 1 910 903 Wire Fan To Power Cord Ground 30 in 904 781 Velcro Hook Black 904 782 Velcro Hook Black 5 Pull off the pi
76. ure snow is not directed towards vent termination area Note To make the installation more aesthetically p l e a s i n g w e recommend framing out a square to mount the terminal to Offset Chart INSTALLATION PROCEDURES for FPI Direct Vent System Flex 1 Locate the unit in the framing rough in the gas preferably on the right side of the unit and the electrical Junction block is on the left side on the left Locate the centerline of the termination and mark wall accordingly Cut a 10 254mm hole in the wall inside dimension Note A 1 1 2 38mm clearance around the liner must be maintained except that only a 1 25mm clearance is needed at the termination end We recommend framing a 10 254mm x 10 254mm inside dimensions hole to give structural rigidity for mounting the termination 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 replace and fasten it to the framing using nails or screws through the nailing strips 3 Assemble the vent assembly by applying Mill Pac to the 4 100mm inner collar of the termination and slipping the 4 100mm liner over it at least 1 3 8 35mm Fasten with the 3 screws drilling pilot holes will make this easier Apply Mill Pac or high temperature silicone to the 6 7 8 175mm ex pipe and slip it over the 6 7 8 outer collar of the vent termina
77. y 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 amp sleeves through the brick panel to the rebox base reversing step 8 leaving them about 1 4 6mm above the brick panel Reinstall the rear log stand 12 Install Burner grate assembly 13 Hook up the gas line and check for gas leaks with a soap and water solution or a gas leak detector Do not use open ame for leak testing 14 Fire up the unit temporarily 15 Check the manifold pressure 16 Reinstall the logs and brick panels as needed 17 Reinstall the glass door and the facade 18 Fire up the unit again and check for proper ame appearance and glow on logs REMOVING VALVE 1 Shut the power off 2 Open the bottom louver door Loosen the 2 screws holding the Burner ON OFF switch and bracket to the bottom louver and lift the assembly out 3 Remove the facade if installed 4 Remove the glass door Refer to the Glass Door Installation section 5 Remove the logs 6 Remove the burner grate assembly by removing the two Phillips head screws and then slide the burner assembly to the left and lift out Diagram 1 Remove the left and right screws an
78. y go off at this time Open a few windows to ventilate the room for a couple of hours The glass panel may require cleaning after the unit has cooled down DO NOT ATTEMPT TO CLEAN THE GLASS WHILE IT IS HOT During the rst few res a white lm may develop on the glass front as part of the curing process The glass should be cleaned or the lm will bake on and become very dif cult to remove Use a non abrasive cleaner and NEVER clean the glass while it is hot AERATION ADJUSTMENT The air shutter can be adjusted by moving the adjusting wire up or down The wire is accessed through the bottom louver opening Open the air shutter for a blue ame or close for a more yellow ame The burner aeration is factory set but may need adjusting due to either the local gas supply or altitude Minimum Air Shutter Opening 3 16 Natural Gas 5 16 Propane CAUTION Carbon will be produced if air shutter is closed too much Note Any damage due to carboning resulting from improperly setting the aeration controls is NOT covered under warranty Adjustment Wire Push to close or pull to open aeration cap Closed Tall yellow Open Short Blue Note Aeration Adjustment should only be performed by an authorized Excalibur Installer at the time of installation or service IMPORTANT To ignite or reignite the pilot remove one glass panel door Note When the glass is cold and the appliance is lit it may cau

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