P90 Zero Clearance Direct Vent Gas Fireplace Owners & Installation

www.excalibur-fi re.com

P90 Zero Clearance Direct Vent Gas Fireplace

Owners &

Installation Manual

MODELS: P90-NG1 Natural Gas P90-LP1 Propane

WARNING:

If the information in these instructions are not followed exactly, a fi re or explosion may result causing property damage,

FOR YOUR SAFETY

What to do if you smell gas: personal injury or loss of life.

FOR YOUR SAFETY

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

do not use any phone in your building.

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

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

supplier, call the fi re department.

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.

918-525b

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

08/13/09

WARNING

HOT GLASS

WILL

CAUSE BURNS

DO NOT TOUCH

GLASS

UNTIL COOLED

NEVER

ALLOW CHILDREN

TO TOUCH GLASS

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.

To the New Owner:

Congratulations!

You are the owner of a state-of-the-art Excalibur

®

Gas Fireplace by FPI FIREPLACE PRODUCTS

INTERNATIONAL LTD. The P90 is a hand crafted appliance and has been designed to provide you with all the warmth and charm of a wood fi replace at the fl ick of a switch. The model P90 has been approved by Warnock Hersey for both safety and effi ciency. As it also bears our own mark, it promises to provide you with economy, comfort and security for many trouble free years to follow.

Please take a moment now to acquaint yourself with these instructions and the many features of your Excalibur

®

Fireplace.

INFORMATION FOR MOBILE/MANUFACTURED HOMES AFTER FIRST SALE

This Excalibur ® product has been tested and listed by Warnock Hersey as a Direct Vent Wall Furnace to the following standards: VENTED GAS

FIREPLACE HEATERS ANSI Z21.88a-2007/CSA 2.33a-2007 and GAS-FIRED APPLIANCES FOR USE AT HIGH ALTITUDES CAN/CGA 2.17-

M91.

This Direct Vent System Appliance must be installed in accordance with the manufacturer's installation instructions and the Manufactured Home

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

Sites, and Communities ANSI/NFPA 501A, and with CAN/CSA Z240-MH Mobile Home Standard in Canada.

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

B149 Gas Installation Code and the current Canadian Electrical Code CSA C22.1 in Canada.

This Excalibur

®

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

This Excalibur

®

Mobile/Manufactured Home listed appliance comes equipped with a dedicated #8 ground lug to which an

18 gauge copper wire from the steel chassis ground must be attached.

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

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

2

Excalibur ® P90 Zero Clearance Direct Vent Gas Fireplace

TABLE OF CONTENTS

UNIT DIMENSIONS

OPERATING INSTRUCTIONS

Unit Dimensions ............................................................4

INSTALLATION

Important Message ......................................................7

Before You Start ............................................................7

General Safety Information............................................7

Installation Checklist ......................................................7

Heatwave Duct System Optional Kit .............................8

Clearances ....................................................................8

Locating Your Gas fi replace...........................................8

Manufactured Mobile Home Additional Requirements ..8

Combustible Mantels ....................................................9

Unit Base Stand-offs ......................................................9

Framing And Finishing ...................................................9

Facing Requirement ....................................................10

Hearth Requirements ..................................................10

Optional Cover Plate Template .................................... 11

Unit Assembly Prior To Installation .............................. 11

Venting Introduction ..................................................... 11

Venting.........................................................................12

Exterior Vent Termination Locations ............................13

4” x 6-5/8” Rigid Pipe Cross Reference Chart .............14

5” x 8” Rigid Pipe Cross Reference Chart ...................16

Rigid Pipe Venting Systems ........................................18

Horizontal Terminations ...............................................20

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

Horizontal terminations ................................................24

Vertical Terminations ...................................................25

Installation Procedures ................................................26

High Elevation .............................................................27

Gas Line Installation ....................................................27

Pilot Adjustment ...........................................................27

Gas Pipe Pressure Testing ..........................................27

Conversion from NG to LP .........................................28

Optional Brick Panels ..................................................32

Log set Installation.......................................................33

Glass Door Installation ................................................37

Arch surround ..............................................................37

Optional Screen Door .................................................37

Accent Kit Installation ..................................................38

Remote Control ...........................................................39

Wall Switch ..................................................................39

Wall Thermostat ..........................................................39

Wiring Diagrams .........................................................40

Operating Instructions .................................................42

Lighting Procedure ......................................................42

Shutdown Procedure ...................................................42

First Fire ......................................................................42

Aeration Adjustment ....................................................42

Normal operating Sounds of Gas Appliances ..............43

Copy Of The Lighting Plate Instructions ......................43

MAINTENANCE

Maintenance Instructions.............................................44

Gold-plated door or surround ......................................44

Log Replacement ........................................................44

Thermopile / Thermocouple ........................................44

Glass Gasket ...............................................................44

Door Glass...................................................................44

Fan Maintenance .........................................................45

Removing Valve ...........................................................46

Installing Valve .............................................................46

PARTS LIST

Main Assembly ............................................................47

Burner Assembly & Log Set.........................................49

Flush Front Accessories ..............................................50

WARRANTY

Warranty ......................................................................51


3

UNIT DIMENSIONS

B

A

H

I

C

D

F

G E

4

Unit Dimensions

D

E

F

A

B

C

I

G

H

Description

Front Firebox Width

Rear Firebox Width

Front Firebox Height

Height w/ Standoff

Unit Depth

Height to Vent

Faceplate Width

Faceplate Height (center)

Faceplate Height (edge)

P90

42” (1067mm)

31” (787mm)

38” (965mm)

45” (1143mm)

19-1/4” (489mm)

40-1/4” (1022mm)

37” (940mm)

29-1/4” (743mm)

24” (610mm)


This is a copy of the label that accompanies each

P90 Zero Clearance Direct Vent Gas Fireplace.

We have printed a copy of the contents here for your review. The safety label is located on the front inside base of the unit, visible when the bottom louver is open.

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

Wall

Wall

SAFETY LABEL

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

Massachusetts.

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

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

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


Model/Modele:

P90-NG1

Model/Modele:

P90-LP1

5

REQUIREMENTS

MA Code - CO Detector

(for the State of Massachusetts only)

5.08: Modifications to NFPA-54, Chapter 10

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

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

1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level. b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.

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

3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight

(8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, "GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL

OBSTRUCTIONS".

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

5.08(2)(a)1 through 4.

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

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

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

(c) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the manufacturer of Product

Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include:

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

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

(d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the manufacturer of a

Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases, but identifies

"special venting systems", the following requirements shall be satisfied by the manufacturer:

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

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

6

(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.


INSTALLATION

IMPORTANT MESSAGE

SAVE THESE

INSTRUCTIONS

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

BEFORE YOU START

GENERAL SAFETY

INFORMATION

Emissions from burning wood or gas could contain chemicals known to the State of

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

1) The appliance installation must conform with local codes or, in the absence of local codes, with the current Canadian or National

Gas Codes, CAN1-B149 or ANSI Z223.1

Installation Codes.

INSTALLATION

CHECKLIST

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.

1) Locate appliance, refer to the following sections: a) Locating Your Gas Fireplace

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

c) Unit Base Stand-offs d) Framing & Finishing f) Hearth Requirements

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

INSTALLATION AND REPAIR SHOULD

BE DONE BY A QUALIFIED SERVICE

PERSON. THE APPLIANCE SHOULD

B E I N S P E C T E D B E F O R E U S E

AND AT LEAST ANNUALLY BY A

PROFESSIONAL SERVICE PERSON.

MORE FREQUENT CLEANING MAY

BE REQUIRED DUE TO EXCESSIVE

LINT FROM CARPETING, BEDDING

MATERIAL, ETC. IT IS IMPERATIVE

THAT CONTROL COMPARTMENTS,

BURNERS AND CIRCULATING AIR

PASSAGEWAYS OF THE APPLIANCE

BE KEPT CLEAN.

DUE TO HIGH TEMPERATURES, THE

APPLIANCE SHOULD BE LOCATED

OUT OF TRAFFIC AND AWAY FROM

FURNITURE AND DRAPERIES.

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

2) Assemble Top Standoffs, page 9. (Refer to the "Unit Assembly Prior to Installation" section.) NOTE: must be done before installing unit into fi replace.

5) Inspect the venting system annually for blockage and any signs of deterioration.

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

6) Venting terminals shall not be recessed into a wall or siding.

4) Make gas and electrical connections. Test the pilot. Must be as per diagram. Refer to the "Pilot Adjustment" section.

7) Any safety glass removed for servicing must be replaced prior to operating the appliance.

8) To prevent injury, do not allow anyone who is unfamiliar with the operation to use the fi replace.

6) Install standard and optional features.

Refer to the following sections where applicable: a. Brick Panels b. Log Set Installation

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.

d. Glass Door Installation e. Screen Door f. Accent Kit Installation g. Option 1: Remote Control h. Option 2: Wall Switch i. Option 3: Wall Thermostat

WARNING: FAILURE TO INSTALL THIS

APPLIANCE CORRECTLY WILL VOID

YOUR WARRANTY AND MAY CAUSE

A SERIOUS HOUSE FIRE.

CHILDREN AND ADULTS SHOULD

BE ALERTED TO THE HAZARDS OF

HIGH SURFACE TEMPERATURES,

ESPECIALLY THE FIREPLACE GLASS,

AND SHOULD STAY AWAY TO AVOID

BURNS OR CLOTHING IGNITION.

YOUNG CHILDREN SHOULD BE

CAREFULLY SUPERVISED WHEN

THEY ARE IN THE SAME ROOM AS

THE APPLIANCE.

CLOTHING OR OTHER FLAMMABLE

MATERIAL SHOULD NOT BE PLACED

ON OR NEAR THE APPLIANCE.

11) Under no circumstances should this appliance be modifi ed. Parts that have to be removed for servicing should be replaced prior to operating this appliance.

10) Final check.

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

to customer.

12) Installation and any repairs to this appliance should be done by a qualifi ed service person.

A professional service person should be called to inspect this appliance annually.

Make it a practice to have all of your gas appliances checked annually.

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

This includes:

1) Clocking the appliance to ensure the correct fi ring rate (rate noted on label 35,000 Btu/h) after burning appliance for 15 minutes.

14) Under no circumstances should any solid fuels (wood, paper, cardboard, coal, etc.) be used in this appliance.

15) The appliance area must be kept clear and free of combustible materials, (gases and other fl ammable vapours and liquids).

2) If required, adjusting the primary air to ensure that the fl ame does not carbon. First allow the unit to burn for 15-20 min. to stabilize.

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


7

8

INSTALLATION

LOCATING YOUR

GAS FIREPLACE

1) When selecting a location for your fi replace, ensure that the clearances outlined on this page are met.

MANUFACTURED

MOBILE HOME

ADDITIONAL

REQUIREMENTS

2) P r o v i d e a d e q u a t e c l e a r a n c e s f o r servicing.

1) Ensure that structural members are not cut or weakened during installation.

Clearance to Combustibles from:

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

3) The appliance must be installed on a fl at, solid, continuous surface (e.g. wood, metal, concrete). This may be the fl oor, or raised up on a platform to enhance its visual impact.

If the appliance is going to be installed on carpeting, combustible linoleum tile or other combustible material other than wood fl ooring, the appliance must be installed on a metal or wood panel extending the full width and depth of the appliance.

4) The P90 Direct Vent Gas Fireplace can be installed in a recessed position or framed out into the room as in A, B, C, D.

See Diagram 1.

A) Flat on Wall

B) Flat on Wall Corner

Wall/Alcove

D) Corner

Diagram 1

5) This appliance is Listed for bedroom installations when used with a Listed Millivolt

Thermostat. Some areas may have further requirements, check local codes before installation.

6) The P90 Direct Vent Gas Fireplace is approved for alcove installations, which meet the clearances listed on this page.

2) Ensure proper grounding using the #8 ground lug provided. See the "Wiring Diagram" section.

HEATWAVE

DUCT SYSTEM

OPTIONAL KIT

#946-556

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

Up to two kits may be installed on the fi replace.

Please Note: Only 1 HeatWave kit may be operated at one time. This includes the internal blower option as well.

Side Wall Clearance

Horizontal Vent Clearances

Top

Side

Bottom

6-1/2" (165mm)

Alcove Clearances**:

OPTIONAL

HEAT RELEASE KIT

#946-570

* see mantle clearance instructions

(Refer to the "Combustible Mantels" section).

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

WARNING:

Fire hazard is an extreme risk if these clearances are not adhered to.

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

CLEARANCES

The clearances listed below are Minimum distances unless otherwise stated:

Note: For vent terminations see the

"Exterior Vent Termination

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

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.


INSTALLATION

COMBUSTIBLE MANTELS

Because of the extreme heat this fi replace

emits, the mantel clearances are critical.

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

Note: A non-combustible mantel may be installed at a lower height if the framing is made of metal studs covered with a non-combustible board.

These drawings are to scale at 1:6 (one inch

= 6 inches)

Mantel can be installed anywhere in shaded area or higher using the above scale.

FRAMING AND

FINISHING

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

Note: Ensure the paint that is used on the mantel and the facing is

"heat resistant" or the paint may discolour.

Install Top Standoffs & Side Nailing Strips before unit is slipped into position. See the

"Unit Assembly Prior to Installation" section for assembly details.

P90 Flat Wall Surround and Tile Kit

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

2) Frame in the enclosure for the unit with framing material. The framed opening is

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

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

P90 Flat Wall Surround and Tile Kit Specifi cations

UNIT BASE STAND-OFFS

To accommodate varying thicknesses and fi nishes of hearth materials, we have increased the overall height of the appliance by a further 1

1/8”. This increase is added with the inclusion of two stand-offs at the bottom of the unit, below the outer box, taking the overall height of the framing dimensions from 45-1/4” up to 46-3/8”.

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.

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

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)

49-7/8"(1267mm)

4"(100mm)

Dia. Inner

6-7/8"(175mm)

Dia. Outer

31"

(787mm)

42"(1067mm)

46-1/2"(1181mm)

70-1/2"(1791mm)

3) For exterior walls, insulate the enclosure to the same degree as the rest of the house, apply vapour barrier and drywall, as per local installation codes. (Do not insulate

the fi replace itself.)


9

INSTALLATION

4) Note: The unit does not have to be completely enclosed in a chase. The clearance on top of the unit is 0" to the standoffs so combustible building materials can be laid directly on top of the standoffs. You must maintain clearance from the vent to combustible m a t e r i a l s f o r b o t h rigid and fl ex, see the

"Clearances" section.

Note: 4 8 " ( 1 1 2 1 9 m m ) i s t h e m i n i m u m height for both fl ex termination or Rigid

Pipe venting.

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

Facing Over 1" (25mm) Thick

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

FPI offers a cover plate template. See next page.

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

FACING REQUIREMENT

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

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

HEARTH REQUIREMENTS

Floor Mounted Fireplaces

Raised Fireplaces

10

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

No hearth is required when the unit is raised

3" (76mm) off of the floor surface

Fireplace

Stand

Flooring

Yo u m u s t t a k e i n t o account the depth of the floor covering (carpet, tile, linoleum, etc.) when determining the height of the fi replace stand.


INSTALLATION

OPTIONAL COVER

PLATE TEMPLATE

1) Ensure top clip screws are at top of oblong holes before installation.

Oblong Screw

Holes

UNIT ASSEMBLY

PRIOR TO

INSTALLATION

VENTING

INTRODUCTION

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

Top Standoff Assembly

The P90 uses the "balanced fl ue" technology

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

2) Position bottom of cover plate over pins located at the bottom of the fi rebox.

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

Note: These flue pipes must not be connected to any other appliance.

1) Remove the standoffs from the fi replace top.

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

The gas appliance and vent system must be vented directly to the outside of the building, and never be attached to a chimney serving a separate solid fuel or gas burning appliance.

Each direct vent gas appliance must use it's own separate vent system. Common vent systems are prohibited.

Pins

3) Bring cover plate towards the unit and hook top clip over and behind the glass frame.

The top clip may need to be adjusted. Loosen the 2 screws that secure the top clip to let the cover plate settle over and behind the glass frame. Once settled tighten screws.

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

Top Clip

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.

Back View of

Cover Plate

Pin Holes

TO REMOVE:

1) Remove 2 screws that secure top clip. Ensure to hold cover plate as it will fall forward.

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


Plates can be folded out.

11

INSTALLATION

VENTING

FPI Direct Vent System (Flex) Horizontal Terminations Only

These venting systems, in combination with the P90 Direct Vent Gas Fireplace, have been tested and listed as a direct vent heater system by

Warnock Hersey. The location of the termination cap must conform to the requirements in the Vent Terminal Locations diagram in the "Exterior Vent

Termination Locations" section.

FPI Direct Vent (Flex) System Termination

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

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

Notes:

1) Liner sections should be continuous without any joints or seams.

3) spring spacers (4) 3) spring spacers (7)

5) AstroCap termination cap (1) 5) AstroCap termination cap (1)

7) tube of Mill Pac (1)

8) plated screws (8)

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

Steel (4)

7) tube of Mill Pac (1)

8) plated screws (8)

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

Steel (4)

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

3) Horizontal vent must be supported every

3 feet.

12


INSTALLATION

EXTERIOR VENT TERMINATION LOCATIONS

Minimum Clearance Requirements

Clearance above grade, veranda, porch, deck, or balcony

Canada

1

USA

2

A

12"(30cm) 12"(30cm)

D

E

B

C

Clearance to window or door that may be opened

Clearance to permanently closed window

Vertical clearance to ventilated soffi t located above the terminal within a horizontal distance of 2 feet (61cm)

Clearance to unventilated soffi t

12"(30cm)

*

18"(46cm)

15"(38cm)

9" (23cm)

*

18"(46cm)

15"(38cm)

F

Clearance to outside corner: with AstroCap Termination Cap.

Clearance to outside corner: with all other approved Termination Caps.

6"(15cm)

14"(36cm)

6"(15cm)

6"(15cm)

14"(36cm)

G

H

J

Clearance to inside corner: with AstroCap Termination Cap

Clearance to inside corner: with all other approved Termination Caps.

Clearance to each side of center line extended above meter/regulator assembly

Clearance to service regulator vent outlet

12"(30cm)

36"(90cm) a

36"(90cm)

6"(12cm)

12"(30cm)

*

*

K

L

M

Clearance to non-mechanical air supply inlet to building or the combustion air inlet to any other appliance

Clearance to a mechanical air supply inlet

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

12"(30cm)

72"(1.8m)

84"(2.1m)

┼

9" (23cm)

36"(90cm)

*

N

Clearance under veranda, porch, deck, or balcony 12"(30cm)

‡

*

1

In accordance with current CSA B149.1, Natural Gas and Propane Installation Code

2

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

┼

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

‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the fl oor

* Clearance in accordance with local installation codes and the requirements of the gas supplier

3 feet (91cm) within a height of 15 feet (4.5m) above the meter / regulator assembly b

3 feet (91cm) above - if within 10 feet (3m) horizontally b


13

INSTALLATION

4” X 6-5/8” RIGID PIPE CROSS REFERENCE CHART

Components from different Manufacturers may not be mixed. Not All Rigid Pipe components are available directly from FPI.

Description

6” Pipe Length-Galvanized

6” Pipe Length-Black

















4 X 6 5/8 RIGID PIPE CROSS REFERENCE CHART

Components from different Manufacturers may not be mixed. Not all rigid pipe components are available directly from Regency.

Simpson

Direct Vent Pro ®

46DVA-06

46DVA-06B

N/A

N/A

46DVA-09

46DVA-09B

46DVA-12

46DVA-12B

46DVA-18

46DVA-18B

46DVA-24

46DVA-24B

46DVA-36

46DVA-36B

46DVA-48

46DVA-48B

46DVA-60

46DVA-60B

Selkirk

Direct Temp™

4DT-18

4DT-18B

4DT-24

4DT-24B

4DT-36

4DT-36B

4DT-48

4DT-48B

4DT-60

4DT-60B

4DT-6

4DT-6B

N/A

N/A

4DT-9

4DT-9B

4DT-12

4DT-12B

4D18

4D18B

4D24

4D24B

4D36

4D36B

4D48

4D48B

N/A

N/A

American Metal

Products®

Amerivent Direct

N/A

N/A

4D7

4D7B

N/A

N/A

4D12

4D12B

Metal-Fab™

Sure Seal

4D18

4D18B

4D24

4D24B

4D36

4D36B

4D48

4D48B

N/A

N/A

4D6

4D6B

N/A

N/A

N/A

N/A

4D12

4D12B

Security

Secure- Vent®

SV4LA

SV4LA

SV4L24

SV4LB24

SV4L36

SV4LB36

SV4L48

SV4LB48

N/A

N/A

SV4L6

SV4LB6

N/A

N/A

N/A

N/A

SV4L12

SV4LB12

ICC Excel

Direct

TC-4DL6

TC-4DL6B

N/A

N/A

N/A

N/A

TC-4DL1

TC-4DL1B

TC-4DL18

TC-4DL18B

TC-4DL2

TC-4DL2B

TC-4DL3

TC-4DL3B

TC-4DL4

TC-4DL4B

N/A

N/A

Adjustable Length 3”-10”-Galvanized

Adjustable Length 3”-10”-Black

Adjustable Length 7”-Galvanized

Adjustable Length 7”-Black

Extension Pipe 8-1/2”-Galvanized

Extension Pipe 8-1/2”-Black

Adjustable Length 12”-Galvanized

Adjustable Length 12”-Black

Extension Pipe 16”-Galvanized

Extension Pipe 16”-Black

45

º Elbow-Galvanized

45

º Elbow-Black

45

º Elbow Swivel-Galvanized

45

º Elbow Swivel-Black

90

º Elbow-Galvanized

90

º Elbow-Black

90

º Elbow, Swivel-Galvanized

90

º Elbow, Swivel-Black

90

º Starter Elbow, Swivel-Galvanized

Adaptor*

Ceiling Support

Cathedral Support Box

Wall Support/Band

Offset Support

Wall Thimble-Black

Wall Thimble Support/Ceiling Support

Firestop Spacer

Trim Plate-Black

N/A

N/A

N/A

N/A

46DVA-08A

46DVA-08AB

N/A

N/A

46DVA-16A

46DVA-16AB

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

46DVA-E45

46DVA-E45B

See 46DVA-E45

See 46DVA-E45B

46DVA-E90

46DVA-E90B

See 46DVA-E90

See 46DVA-E90B

N/A

N/A

N/A

N/A

N/A

N/A

4DT-EL45

4DT-EL45B

N/A

N/A

4DT-EL90S

4DT-EL90SB

N/A

46DVA-CS

46DVA-WS

46DVA-ES (N/A - FPI)

46DVA-WT

46DVA-DC

46DVA-FS

N/A

4DT-CS

4DT-CSS

4DT-WS/B

4DT-OS

4DT-WT

N/A

4DT-FS

4DT-TP

N/A

N/A

4D7A

4D7AB

N/A

N/A

4D12A

4D12A

N/A

N/A

4DFSP

4DRSB

4DWS

N/A

4DWT

N/A

4DFSP

4DFPB

N/A

N/A

N/A

N/A

4D45L

4DT-EL45B

N/A

N/A

4DT-EL90S

4DT-EL90SB

TC-4DLT

TC-4DLTB

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

TE-4DE45

TE-4DE45B

N/A

N/A

TE-4DE90

TE-4DE90B

TE-4DE45

TE-4DE45B

N/A

N/A

TE-4DE90

TE-4DE90B

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

SV4LA12

SV4LBA12

N/A

N/A

SV4SD

SV4CSB

SV4BM

SV4SU

SV4RSM

SV4PF

SV4BF

SV4LA

N/A

N/A

SV4E45

SV4EB45

N/A

SV4EBR90-1

SV4E90-1

SV4EB90-1

N/A

N/A

4DSP

4DRS

4DWS

N/A

4DWT

N/A

4DFS

4DCP

N/A

N/A

4D45L

4D45LB

N/A

N/A

4D90L

4D90LB

4D90A

4D90L

4DAL

4DALB

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

14


INSTALLATION

Description

Simpson

Direct Vent Pro ®

Attic Insulation Shield 12”

Attic Insulation Shield -

Cold Climates

36”

46DVA-IS

N/A@ FPI

N/A

N/A

N/A

Selkirk

Direct Temp™

American Metal

Products®

Amerivent Direct

4DAIS12

4DAIS12

N/A

N/A

Metal-Fab™

Sure Seal

Security

Secure- Vent®

SV4RSA

N/A

Basic Horizontal Termination Kit (A)

Horizontal Termination Kit (B)

Vertical Termination Kit

High Wind Vertical Cap

High Wind Horizontal Cap

Horizontal Square Termination Cap

Vertical Termination Cap

Storm Collar

Adjustable Flashing 0/12-6/12


Vinyl Siding Standoff

Vinyl Siding Shield Plate

Disc.

46DVA-KHA

(Changed Components)

Disc.

46DVA-VCH

46DVA-HC

See 46DVA-HC

N/A

46DVA-08A

N/A

N/A

46DVA-VSS

N/A

4DT-HKA

4DT-HKB

4DT-VKC

N/A

N/A

4DT-HHC

4DT-HVC

4DT-SC

4DT-ST14

4DT-ST36

4DT-VS

4DT-VSP

4DHTK2

4DHTK1

4DHTK

N/A

N/A

4DHC

4DVC

4DSC

4D12S

4D36S

N/A

N/A

4DHTKA

4DHTKB

4DHTK

N/A

N/A

4DHT

4DVT

4DSC

4DST14

4DST36

4DVS

N/A

SV-SHK

SV-HK

SV-FK

N/A

N/A

SV4CHC-1

SV4CGV-1

SV4FC

SV4STC14

SV4STC36

SV4VS

SV4VS

ICC Excel

Direct

N/A

TM-4AS

N/A

N/A

N/A

TM-4VT

TM-4DHT

TM-4HT

TM-4VT

TM-SC

TF-4FA

TF-4FB

TM-VSS

N/A

Snorkel Termination 14”


46DVA-VCH

46DVA-HC

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

TM-4ST14

TM-4ST36

Restrictor Disk

Extended Vertical Termination Cap

Chimney Conversion Kit A (USA only)

Chimney Conversion Kit B (USA only)

Chimney Conversion Kit C (USA only)

Chimney Conversion Kit Masonry

(USA only)

Wall Firestop

Colinear Flex Connectors

46DVA-RD

46DVA-VCE

46DVA-KCA

46DVA-KCB

46DVA-KCC

46DVA-KMC

46DVA-WFS

46DVA-ADF

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

TM-4DS

N/A

TM-4CA6

TM-4CA7

TM-4CA8

N/A

TM-4TR

N/A

FPI

946-506/P

510-994

640-530/P

946-605

Vent Guard (Optional) for AstroCap

Rigid Pipe Adaptor (Must use with all rigid piping)

Riser Vent Terminal

Starter Collar Increaser 4” x 6-5/8” to 5” x 8”

946-205

946-208/P

946-523/P

946-206

Vinyl Siding Shield for Riser Vent Terminal

Vent Guard (Optional) for Riser Vent Terminal

AstroCap Horizontal Cap

Vinyl Siding Standoff for AstroCap

Note: When using Metal-Fab Sure Seal Rigid Piping - please note that the Adaptor (4DDA) must be used in conjunction with FPI Rigid Pipe Adaptor (510-994).

Offset Pipe Selection: Use this table to determine offset pipe lengths.

Pipe Length

(L)

4” x 6-5/8” Venting

Run (X) Rise (Y)

0” (0mm)

6” (152mm)

9” (229mm)

12” (305mm)

4-7/8” (124mm)

8” (203mm)

10-1/8” (257mm)

12-1/4” (311mm)

13-7/8” (340mm)

16-1/2” (419mm)

18-5/8” (473mm)

20-3/4” (527mm)

24” (610mm)

36” (914mm)

48” (1219mm)

20-5/8” (524mm)

29” (737mm)

37-7/16” (951mm)

29-1/8” (740mm)

37-1/2” (953mm)

45-15/16” (1167mm)

For specifi c instructions on venting components - visit the manufacturers website listed below.

Simpson Direct Vent Pro: www.duravent.com

Selkirk Direct-Temp: www.selkirkcorp.com

American Metal Products: www.americanmetalproducts.com

Metal-Fab Sure Seal: www.mtlfab.com

Security Secure Vent: www.securitychimneys.com

Industrial Chimney Company: www.icc-rsf.com

Note: Horizontal runs of vent must be level, or have a 1/4” 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 a possible fi re hazard.


15

INSTALLATION

5” X 8” RIGID PIPE CROSS REFERENCE CHART

Components from different Manufacturers may not be mixed. Not All Rigid Pipe components are available directly from FPI.

5” X 8” RIGID PIPE CROSS REFERENCE CHART

Components from different Manufacturers may not be mixed. Not all rigid pipe components are available directly from Regency.

Description

Simpson

Direct Vent Pro

®

Selkirk

Direct Temp™

Metal-Fab™

Sure Seal

ICC Excel

Direct

















58DVA-06

58DVA-06B

58DVA-09

58DVA-09B

58DVA-12

58DVA-12B

58DVA-18

58DVA-18B - N/A from FPI

58DVA-24

58DVA-24B

58DVA-36

58DVA-36B

58DVA-48

58DVA-48B

58DVA-60

58DVA-60B - N/A from FPI

5DT-6

5DT-6B

5DT-9

5DT-9B

5DT-12

5DT-12B

5DT-18

5DT-18B

5DT-24

5DT-24B

5DT-36

5DT-36B

5DT-48

5DT-48B

N/A

N/A

5D6

5D6B

N/A

N/A

5D12

5D12B

5D18

5D18B

5D24

5D24B

5D36

5D36B

5D48

5D48B

N/A

N/A

TC-5DL6

TC-5DL6B

N/A

N/A

TC-5DL1

TC-5DL1B

TC-5DL18

TC-5DL18B

TC-5DL2

TC-4DL2B

TC-5DL3

TC-5DL3B

TC-5DL4

TC-5DL4B

N/A

N/A

Adjustable Length 3”-10”-Galvanized

Adjustable Length 3”-10”-Black

Adjustable Length 11”-14” -Galvanized

Adjustable Length 11”-14” -Black

Extension Pipe 17”-24” -Galvanized

Extension Pipe 17”-24” -Black

Adjustable Length 8-1/2”-Galvanized

Adjustable Length 8-1/2”-Black

Extension Pipe 16”-Galvanized

Extension Pipe 16”-Black

N/A

N/A

Disc. - See 58DV-08A

Disc. - See 58DV-08B

Disc. - See 58DV-16A

Disc. - See 58DV-16AB

58DVA-08A - N/A from FPI

58DVA-08AB

58DVA-16A - N/A from FPI

46DVA-16AB

45

º Elbow-Galvanized

45

º Elbow-Black

45

º Elbow Swivel-Galvanized

45

º Elbow Swivel-Black

90

º Elbow-Galvanized

90

º Elbow-Black

90

º Elbow, Swivel-Galvanized

90

º Elbow, Swivel-Black

90

º Starter Elbow, Swivel-Galvanized

Adaptor*

58DVA-E45

58DVA-E45B

Disc. - See 58DVA-E45

Disc.-See 58DVA-E45B

58DVA-E90

58DVA-E90B



N/A

N/A

N/A

N/A

5DT-AJ

5DT-AJB

N/A

N/A

N/A

N/A

N/A

N/A

5DT-EL45

5DT-EL45B

N/A

N/A

5DT-EL90S

5DT-EL90SB

N/A

N/A

N/A

N/A

5DAL

5DALB

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

5DT-EL45

5DT-EL45B

N/A

N/A

5DT-EL90S

5DT-EL90SB

N/A

N/A

N/A

N/A

TE-5DE45

TE-5DE45B

N/A

N/A

TE-5DE90

TE-5DE90B

N/A

N/A

N/A

N/A

TC-5DLT

TC-5DLTB

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

Ceiling Support

Cathedral Support Box

Wall Support/Band

Offset Support

Wall Thimble-Black

Wall Thimble Support/Ceiling Support

Firestop Spacer

Trim Plate-Black

58DVA-DC

58DVA-CS

58DVA-WS

58DVA-ES - N/A from FPI

58DVA-WT

58DVA-DC

- N/A from FPI

58DVA-FS

58DAV-WFS

5DT-CS

5DT-CSS

5DT-WS/B

5DT-OS

5DT-WT

N/A

5DT-FS

5DT-TP

5DSP

5DRS

5DWS

N/A

5DWT

N/A

5DFS

5DCP

TE-5DE45

TE-5DE45B

N/A

N/A

TE-5DE90

TE-5DE90B

N/A

N/A

16


INSTALLATION

Description

Attic Insulation Shield 12”

Basic Horizontal Termination Kit (A)

Horizontal Termination Kit (B)

Vertical Termination Kit

Simpson

Direct Vent Pro

®

58DVA-IS

N/A from FPI

N/A

58DVA-KHA

58DVA-VHA

N/A

5DT-HKA

5DT-HKB

5DT-VKC

Selkirk

Direct Temp™

N/A

N/A

N/A

N/A

Metal-Fab™

Sure Seal

N/A

N/A

N/A

N/A

ICC Excel

Direct

High Wind Vertical Cap

High Wind Horizontal Cap

Horizontal Square Termination Cap

Vertical Termination Cap

Storm Collar



58DVA-VCH

N/A

N/A

N/A

58DVA-SC

58DVA-F6

58DVA-F12

N/A

N/A

5DT-HHC

5DT-HVC

5DT-SC

5DT-AF6

5DT-AF12

N/A

N/A

5DHT

5DVT

5DSC

5DF

5DF1-2

TM-5VT

TM-5DHT

TM-5HT

TM-5VT

TM-SC

TF-5FA

TF-5FB

Vinyl Siding Standoff

Vinyl Siding Shield Plate

58DVA-VSS

N/A

5DT-VS

5DT-VSP

5DVS

N/A

TM-VSS

N/A



Restrictor Disk

Colinear Flex Connectors

58DVA-SNK14

58DVA-SNK36 (N/A - FPI)

58DVA-RD

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

TM-5ST14

TM-5ST36

TM-5DS

N/A

FPI

946-604/P

770-994

946-606

Simpson Direct Vent -Vent Guard (Optional)

Rigid Pipe Adaptor (Must use with all rigid piping)

Starter collar reducer 5” x 8” to 4” x 6-5/8”

946-623/P

946-506/P

946-625

AstroCap XL Horizontal Cap

Vent Guard (Optional)

Vinyl Siding Standoff - AstroCap XL

Note: When using Metal-Fab Sure Seal Rigid Piping - please note that the Adaptor (4DDA) must be used in conjunction with FPI Rigid Pipe Adaptor (510-994).

Offset Pipe Selection: Use this table to determine offset pipe lengths.

Pipe Length

(L)

5” x 8” Venting

Run (X) Rise (Y)

0” (0mm)

6” (152mm)

9” (229mm)

5-11/16” (144mm)

8-13/16” (224mm)

10-15/16” (278mm)

15-5/16” (389mm)

18-7/16” (468mm)

20-9/16” (522mm)

12” (305mm)

24” (610mm)

36” (914mm)

48” (1219mm)

13” (330mm)

21-7/16” (697mm)

29-13/16” (757mm)

38-1/4” (972mm)

22-11/16” (576mm)

31-1/16” (789mm)

39-7/16” (1002mm)

47-7/8” (1216mm)

For specifi c instructions on venting components - visit the manufacturers website listed below.

Simpson Direct Vent Pro: www.duravent.com

Selkirk Direct-Temp: www.selkirkcorp.com

Metal-Fab Sure Seal: www.mtlfab.com

Industrial Chimney Company: www.icc-rsf.com

Note: Horizontal runs of vent must be level, or have a 1/4” 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 a possible fi re hazard.

L676 & L900 DIRECT VENT FIREPLACE

IMPORTANT NOTE

• A Vent Guard is required when the AstroCap is installed above grade at 7 feet or lower.

• The Simpson Dura-Vent and Selkirk Direct Temp horizontal termination caps cannot be used in any applications.

• Only the AstroCap XL and Snorkels are certifi ed for horizontal terminations.


17

INSTALLATION

RIGID PIPE VENTING SYSTEMS

The minimum components required for a basic horizontal termination are:

1 90 o Elbow

1 Length of pipe to suit wall thickness

1 4" x 6-5/8" to 5" x 8" increaser for 5" x 8" venting

Wall thickness is measured from the back standoffs to the inside mounting surface of termination cap. For siding other than vinyl furring strips may be used, instead of the vinyl siding standoff, to create a level surface to mount the vent terminal. The

Terminal must not be recessed into siding. Measure the wall thickness including furring strips.

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

Horizontal and Vertical

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

Vertical

Terminal

Storm Collar

Vinyl Siding

Standoff (Optional)

Flashing

943 or 943S

Ceiling Firestop

Horizontal

Termination

Cap

Wall Thimble

Pipe Length

Adj.Pipe Length

Flat Wall Installation

Wall Thickness

(inches)

4" - 5-1/2"

Vent Length Required

(inches)

6"

7" - 8-1/2"

10" - 1-1/2"

9" - 14-1/2"

15" - 23-1/2"

9"

12"

11" - 14-5/8" Adj. Pipe

17" - 24" Adj.

Corner Installation

Wall Thickness

(inches)

3-1/4" - 6-3/4"

Vent Length Required

(inches)

11" - 14-5/8" Adj. Pipe

7-3/4" - 16-1/4"

7-1/4" - 8-3/4"

4-1/4" - 5-3/4"

17" - 24" Adj. Pipe

6" + 12"

9" + 9"

6" + 9"

WARNING:

Do not combine venting components from different venting systems.

However use of the the AstroCap TM and FPI

Riser is acceptable with all systems.

Pipe

Length

Rigid Pipe Adaptor

Alternate

Horizontal

Termination

Caps

This product has been evaluated by Intertek for using a Rigid Pipe Adaptor in conjunction with Duravent Direct-Vent , Selkirk Direct-Temp,

Ameri Vent Direct venting and Security Secure

Vent systems. Use of these systems with the

Rigid Pipe adaptor is deemed acceptable and does not affect the Intertek WHI listing of components.

When using Rigid Vent other than

Simpson Dura-Vent, 3 screws must be used to secure rigid pipe to adaptor.

The FPI AstroCap

TM and FPI Riser Vent terminal are certifi ed for installations using FPI venting systems as well as Simpson Dura-Vent

®

Direct Vent, American Metal Products Ameri Vent Direct Vent, Security Secure Vent ® , Selkirk Direct-Temp. AstroCap TM is a proprietary trademark of FPI Fireplace Products

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

18


INSTALLATION

Horizontal & Vertical Terminations for 5" x 8" Venting


19

INSTALLATION

RIGID PIPE VENTING ARRANGEMENTS - HORIZONTAL TERMINATIONS

FPI DIRECT VENT SYSTEM (FLEX)

(Propane & Natural Gas)

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

All Rigid Pipe Systems

4" inner diameter

6-5/8" outer diameter

FPI Flex Vent


6-7/8" outer diameter

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

994) when using Rigid Pipe.

Note: FPI Direct Vent System (Flex) is only approved for horizontal terminations.

All Rigid Pipe Systems


8" outer diameter

Note: Must use FPI increaser starter collar

(Part # 946-605) at beginning of vent run.

5" x 8" venting starts at unit.

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


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

• Horizontal vent must be supported every 3 feet.

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

20


INSTALLATION

RIGID PIPE VENTING

ARRANGEMENTS - VERTICAL

TERMINATIONS

The shaded area in the diagram shows all allowable combinations of straight vertical and offset to vertical terminations, using two 90 o elbow, with rigid pipe vent systems for Propane and Natural Gas.

The P90 is approved for a maximum 40 ft. straight vertical, with rigid pipe

4" x 6-5/8" vent systems for Propane and Natural Gas, as per diagram.

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

elbows allowed.

• Vent must be supported at offsets


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

• Vent must be supported at offsets.


• Maintain clearances to combustibles.

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



21

INSTALLATION

Horizontal Venting with Two (2) 90

o

Elbows

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

One 90 o

elbow = Two 45 o

elbows.

Option V

A)

B)

C)

H + H1

6" Min. 2' Max.

1' Min. 3' Max.

2' Min. 4' Max.

W i t h t h e s e o p t i o n s , maximum total pipe length is 30 feet with minimum of 6 feet total vertical and maximum 8 feet total horizontal.

D) 3' Min. 5' Max.

E) 4' Min. 6' Max.

F) 5' Min. 7' Max.

Please note minimum 1

G) 6' Min. 8' Max.

foot between 90 o

elbows

Horizontal Venting with Three (3) 90

o

Elbows

Must Use: 5" x 8" Simpson Direct Vent Piping with FPI Increaser

Starter Collar (Part #946-605).

One 90 o


elbows.

Option V H V + V1 H + H1

A) 6" Min. 1' Max. 1'6" Min. 2' Max.

B) 1' Min. 2' Max. 3' Min. 3' Max.

C) 2' Min. 2' Max. 5' Min. 4' Max.

D) 3' Min. 2' Max. 7' Min. 5' Max.

E) 4' Min. 3 Max. 9' Min. 6' Max.

F) 5' Min. 4' Max. 10' Min. 7' Max.

G) 6' Min. 5' Max. 11' Min. 8' Max.

H) 7' Min. 6' Max. 12' Min. 9' Max.

With these options, max. total pipe length is 30 feet with min. of

12 feet total vertical and max. 9 feet total horizontal.

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

22


Vertical Venting with Two (2) 90

o

Elbows

INSTALLATION


Starter Collar (Part #946-605), unless V1 is greater than or equal to 4'-6" then use 4" x 6-5/8" piping.

One 90 o


elbows.

Option V

A)

B)

H V + V1

0' Min. 2' Max. 1' Min.

1' Min. 4' Max. 2' Min.

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

8 feet total horizontal.

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.

Please note min. 1 foot between 90 o

elbows is required.

For additional vertical venting with 2 x 90

o

elbows, refer to the

"Rigid Pipe Venting Arrangements - Horizontal Termination" section.

Vertical Venting with Three (3) 90

o

Elbows


Starter Collar (Part #946-605).

One 90 o elbow = Two 45 o elbows.

Option V H + H1 V + V1

A) 6" Min. 2' Max. 3' Min.

B) 1' Min. 2' Max. 3' Min.

C) 2' Min. 3' Max. 4' Min.

D) 3' Min. 4' Max. 6' Min.

E) 4' Min. 5' Max. 7' Min.

F) 5' Min. 6' Max. 8' Min.

G) 6' Min. 7' Max. 9' Min.

H) 7' Min. 8' Max. 10' Min.

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

Please note min. 1 foot between 90 o

elbows is required.


23

INSTALLATION

HORIZONTAL

TERMINATIONS

b) Horizontal runs of vent must be supported every three feet. Wall straps are available for this purpose.

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

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

2) Direct Vent pipe and fi ttings are designed with special twist-lock connections to connect the venting system to the appliance fl ue outlet. A twist-lock appliance adaptor is an available option that must be used in conjunction with the Simpson Dura-Vent Direct Vent system.

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

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

The center of the square hole should line up with the centerline of the horizontal pipe.

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

Note: With

D u r a - Ve n t , the minimum h e i g h t i s achieved by installing a

9 0 o

e l b o w directly to the rigid pipe adaptor.

Diagram 2

Note:

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

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

Diagram 3a

*Dia 3, 3a & 4: As specifi ed in CGA B149

Installation Code. Local codes or regulations may require different clearances.

Below Grade Installation

If the Snorkel Termination must be installed below grade, i.e. basement application, proper drainage must be provided to prevent water from entering the Snorkel Termination. Refer to Diagram 4. Do not attempt to enclose the

Snorkel within the wall, or any other type of enclosure.

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

Note:

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

Diagram 1

NOTE: For best results and optimum

performance with each approved venting system, it is highly recommended to apply

“Mill-Pac” sealant (supplied) to every inner pipe connection. Failure to do so may result in drafting or performance issues not covered under warranty. Silicone (red RTV) is optional.

b) The location of the horizontal vent termination on an exterior wall must meet all local and national building codes, and must not be blocked or obstructed. For

External Vent Terminal Locations, see diagram in the "Exterior Vent Termination

Locations" section.

c) Snorkel Terminations:

For installations requiring a vertical rise on the exterior of the building, 14inch and 36-inch tall

Snorkel Terminations are available, as well as the standard

Riser Vent. Follow the same installation procedures as used for s t a n d a r d

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 4

NOTE: For Snorkel terminations in ABOVE grade installations, follow national or local code requirements.

6) The arrow on the vent cap should

be pointing up. Insure that the 1-1/2" clearances to combustible materials are maintained (Diagram 4). Install the termination cap.

24


INSTALLATION

Diagram 5

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

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

7) Before connecting the horizontal run of vent pipe to the vent termination, slide the Wall

Thimble (Part # 620-926) over the vent pipe.

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

VERTICAL

TERMINATIONS

1) M a i n t a i n t h e 1 - 1 / 2 " clearances (air spaces) to combustibles when passing through ceilings, walls, roofs, enclosures, attic rafter, or other nearby combustible surfaces. Do not pack air spaces with insulation. Check the "Rigid

Pipe Venting Systems"

& "Rigid Pipe Venting

Arrangements" sections for the maximum vertical rise of the venting system and the maximum horizontal offset limitations.

Diagram 1

2) Set the gas appliance in its desired location.

Drop a plumb bob down from the ceiling to the position of the appliance fl ue exit, and mark the location where the vent will penetrate the ceiling. Drill a small hole at his point. Next, drop a plumb bob from the roof to the hole previously drilled in the ceiling, and mark the spot where the vent will penetrate the roof. Determine if ceiling joists, roof rafters or other framing will obstruct the venting system.

You may wish to relocate the appliance or to offset, as shown in Diagram 2 to avoid cutting load bearing members.

Diagram 2

4) Assemble the desired lengths of pipe and elbows. Ensure that all pipes and elbow connections are in the fully twist-locked position and sealed.

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

Diagram 4: The upper half of the fl ashing is installed under the roofi ng material and not nailed down until the chimney is installed.

This allows for small adjustments.

6) Continue to assemble pipe lengths.

Note: If an offset is necessary in the attic to avoid obstructions, it is important to support the vent pipe every 3 feet, to avoid excessive stress on the elbows, and possible separation.

Wall straps are available for this purpose (Diagram 2).

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

Diagram 6

9) Install wall thimble in the center of the 10" square and attach with wood screws

(Diagram 7).

Diagram 7

NOTE: For best results and optimum performance

with each approved venting system, it is highly recommended to apply “Mill-Pac” sealant (supplied) to every inner pipe connection. Failure to do so may result in drafting or performance issues not covered under warranty. Silicone (red RTV) is optional.

3) A Firestop spacer must be installed in the fl oor or ceiling of every level. To install the

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

Roof Pitch Minimum Vent Height

Feet Meters fl at to 7/12 over 7/12 to 8/12

2

2

0.61

0.61

over 8/12 to 9/12 over 9/12 to 10/12 over 10/12 to 11/12 over 11/12 to 12/12

2

2.5

3.25

4

0.61

0.76

0.99

1.22

over 12/12 to 14/12 over 14/12 to 16/12 over 16/12 to 18/12 over 18/12 to 20/12 over 20/12 to 21/12

5

6

7

7.5

8

1.52

1.83

2.13

2.29

2.44

Diagram 3

Diagram 5


25

INSTALLATION

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

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

INSTALLATION

PROCEDURES for FPI Direct Vent

System (Flex)

N o t e : To m a k e t h e i n s t a l l a t i o n more aesthetically p l e a s i n g , w e recommend framing out a square to mount the terminal to.

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

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

8) Install the vertical termination cap by twistlocking it.

Note: Any closets or storage spaces, which the vent passes through must be enclosed.

Offset Chart

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.

using nails or screws through the nailing strips.

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.

3) Assemble the vent assembly by applying

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

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

6-7/8"(175mm) liner out enough to slip over the fl ue collars of the fi replace. (You may wish to cut the liner shorter to make it more workable.) Do not bend liner more than

90 o

.

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

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

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).

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

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

1) Locate the unit in the framing, rough in the gas (preferably on the right side of the unit) and the electrical (Junction block is on the left side) on the left. Locate the centerline of the termination and mark wall accordingly.

Cut a 10"(254mm) hole in the wall (inside dimension).

Note: A 1-1/2"(38mm) clearance around the liner must be maintained except that only a 1" (25mm) clearance is needed at the termination end. We recommend framing a 10"(254mm) x

10"(254mm) (inside dimensions) hole to give structural rigidity for mounting the termination.

26


INSTALLATION

P90-NG1 System Data

For 0 to 4500 feet altitude

Burner Inlet Orifi ce Sizes:

#34

Min. Input Rating

18,200 Btu/h

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

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

Note: To properly check gas pressure, both inlet and manifold pressures should be checked using the valve pressure ports on the valve.

Important: Always check for gas leaks with a soap and water solution or gas leak detector.

Do not use open fl ame for leak testing.

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

Manifold Pressure

P90-LP1 System Data

For 0 to 2000 feet altitude


#51

Max. Input Rating

35,000 Btu/h


17,950 Btu/h

PILOT ADJUSTMENT

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

Periodically check the pilot fl ames. Correct fl ame pattern has three strong blue fl ames:

1 fl owing around the thermopile, 1 around the thermocouple and 1 fl owing across the burner (it does not have to be touching the burner).

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.

High Altitude: For 2000 to 4500 feet altitude


Max. Input Rating

31,000 Btu/h


#52

15,500 Btu/h

Manifold Pressure

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

Electrical: 120 V A.C. System.

Circulation Fan: variable speed 130

CFM.

Log Set: Ceramic fi bre, 7 per set.

contact your Excalibur further instructions.

® dealer for

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

thermopile or thermocouple.

5) The pressure check should be carried out with the unit burning and the setting should be within the limits specifi ed on the safety label.

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

but do not over tighten.

S.I.T. VALVE DESCRIPTION

1) Gas on/off knob

2) Manual high/low adjustment

HIGH ELEVATION

4) Thermocouple Connection - option

5) Outlet Pressure Tap

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

8) Main Gas Outlet

GAS LINE

INSTALLATION

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

The gas line connection may be made of rigid pipe, copper pipe or an approved fl ex connector.

(If you are using rigid pipe, ensure that the valve can be removed for servicing.) Since some municipalities have additional local codes it is always best to consult with your local authorities and the CAN/CGA B149 installation code.

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

Z223.1.

GAS PIPE PRESSURE

TESTING

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

(3.45 kPa). Disconnect piping from valve at pressures over 1/2 psig.


27

INSTALLATION

CONVERSION KIT #791-969 FROM NG TO LP

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

Each Kit contains one LPG

Conversion Kit and one DC

Sparker Kit.

LPG Conversion Kit Contains:

Qty. Part # Description

Orifi #51

1 918-590 Label "Converted to

LPG"

1 910-037 LP Injector (Pilot Orifi ce)

4) Remove the 2 screws holding the Burner

Assembly to the fi rebox base. Push the

Burner Assembly to the left and lift out.

9

) Turn control knob to the “OFF” position.

10

) Remove the black protection cap by hand from the high-low knob (Fig.1).

Remove the 2 screws, push Burner

Assembly to the left and lift out.

DC Sparker Kit Contains:

Qty. Part # Description

1 904-153 Washer #8 External Star

1 904-438 Plug Nylon 0.750 Hole,

Black (for H35 only)

1 904-531 Bushing Split Plastic

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

Head

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

1 910-073 Spark Generator Battery

Holder

1 910-074 Spark Generator Switch

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 pilot cap to expose the pilot orifi ce.

Fig. 1

6) Unscrew the pilot orifi ce with the allen key and replace with the LP pilot orifi ce in the kit and replace pilot cap.

11

) Insert a 5/32” or 4mm Allen wrench into the hexagonal key-way of the screw (Fig. 2), rotate it counterclockwise until it is free and extract it.

Fig.2

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

12

) Check that the screw is clean and if necessary remove dirt.

13

) Flip the screw (Fig. 3).

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 installed. Remove the glass door (refer to the glass door section in the manual).

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

Burner Orifi ce

8) Reinstall new burner orifi ce LP stamped

#51 and tighten.

Fig.3

28


INSTALLATION

14) Using the Allen wrench as shown in

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

17) Reverse steps 4) to 2).

18) Attach clear label "This unit has been converted to LPG" near or on top of the serial # decal.

19) Replace yellow "Natural Gas" label with red "LPG" label.

4) Attach the DC sparker generator connector to the valve with a screw.

Fig.4

Installation of the DC Sparker for the H35-1 Units Only:

1) Remove the control panel by unscrewing the 2 screws.

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).

Red o-ring visible

LPG Configuration

2) First, remove the Piezo Ignition Wire from the Piezo Ignitor. Then remove the

Piezo Ignitor from the control panel.

5) Remove the stove’s rear panel by unscrewing the two screws.

Fig.5

16

) Reassemble the black protection cap

(Fig. 6).

3) Plug up the Piezo hole with the plastic bushing.

6) Attach the ground wire to the grounding stud.

Before

Fig. 6

WARNING!

Also check that the pilot and main burner injectors

are appropriate for the gas type.

After


29

INSTALLATION

7) Attach the Piezo ignition wire to the DC

Sparker.

11) Attach the DC sparker generator wires to the DC sparker.

Installation of the DC Sparker for the P90 Units Only:

Piezo

Ignitor

1) Locate the Piezo Ignitor situated at the side of valve.

Piezo

Ignitor

8) Insert both the ground wire and the DC sparker generator wire through the hole of the DC spark heat shield.

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

2) Remove the Piezo Ignitor by unscrewing the nut at the back of the mounting bracket.

Ignitor

Wire

9) Install the plastic bushing over the outside of the hole.

10) Attach the ground wire to the DC spark mounting bracket.

Piezo

Ignitor

13) Attach the heat shield to the DC sparker, then mount this onto the stove.

3) Disconnect the ignitor wire from the

Piezo Ignitor and connect it to the DC

Sparker.

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).

DC

Sparker

Ignitor

Wire

4) Connect the DC spark generator wires to the SIT Valve with the screw, which is provided in the kit.

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

30


INSTALLATION

5) Locate the ground lug at the receptical box, left of the unit.

9) Plug the DC spark generator wires to the

DC Sparker.

12) Mount the heat shield to the DC Sparker.

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

6) Connect one end of the supplied green ground wire to the lug with the nut and washer from the kit.

Ground wire from kit

10) Connect the ground wire to the DC

Sparker mounting bracket.

13) Find a location which is not too hot and is easy to reach for changing the battery.

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

7) Install the 1/2" bushing to the heat shield.

8) Run the other end of the ground wire and DC spark generator wires through the bushing on the heat shield.

Heat Shield

11) 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

17) Check operation of fl ame control.

18) Check for proper fl ame appearance and glow on logs.

Installer Notice:

These instructions must be left with the appliance.


31

INSTALLATION

OPTIONAL BRICK PANELS

1) Open the bottom louver door. Loosen the 2 screws holding the Burner

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

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

3) Remove glass door. Remove logs.

Note: The logs must not be in the unit.

4) Insert the back brick panel fi rst by carefully slipping it between the back wall of the fi rebox and the rear log bracket.

5) Put the side panels in next. Slide them in from the front and push them fl at up against the wall. Be very careful not to scratch them on the fi rebox hardware.

Note:

If the bottom brick panel must be removed: Remove the Rear Log Stand, then remove the Burner Tray. See the "Removing Valve" section.

32


INSTALLATION

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.

3) Place the Log 02-75 on the rear log support pins with the

fl at side to the back.

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) 902-156 Embers

02-75

j) 946-669 Platinum Embers

(supplied with packaged manual)

NOTE: If you will be installing the optional Brick Panels

(P36D & P90 only), install the Brick Panels prior to installing the logs.

Model shown has P36D and P90 burner/grate with brick panel option.

4)

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

02-75

02-75

02-51

02-51

02-54

02-55

02-53

Bracket

Bracket

Notch

02-50

02-52

The "02" reference numbers (i.e. 02-75) are molded into the rear of each log.

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 over base brick panel.

02-51

Notch


33

INSTALLATION

5) Position Log 02-53 across the cutouts in Logs 02-75 and

02-51 with the notch on the left side of the log fi tting into the 2nd grate tab.

02-53

02-75

02-51

5th Grate Tab

7) Place the bottom left front edge of Log 02-55 against the

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

2nd Grate Tab

Cutouts

02-51

02-53

02-75

02-55

02-53

6) Position Log 02-54 across the cutouts in Logs 02-51 and

02-53. The notch in the bottom right end fi tting against the

5th grate tab.

Rear Bracket

Cutouts

02-53

02-54

02-51

5th Grate Tab

34


INSTALLATION

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.

9) Sit Log 02-50 on the front left side of the burner. Push

the back of the log against the 2 front brackets with the notch on the bottom of the log fi tting into the fi rst grate tab.

02-50

02-53

02-52

02-51

02-54

Log Indentation

02-52

02-54

Rear

Grate Tab

Photo shows rear grate tab.

Log 02-51 was removed to show the positioning of Log 02-52.

Notch

Front Brackets

02-50

02-55

02-53


35

INSTALLATION

10) Place the embers on the front of the burner tray in the

places shown on the photos below.

Separate platinum embers and place on the front burner on and around the embers. Avoid stacking platinum embers.

Platinum embers may be placed over burner ports.

02-51

Place embers in these 3 locations on the burner tray.

02-54

Do not block the burner ports in this area adjacent to the Log 02-54

IMPORTANT

When placing Embers, do not block burner ports as this can cause an incorrect fl ame pattern, carbon deposits and delayed ignition.

11) Test fi re to ensure proper light off (make sure fl ame fl ows

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

02-50

02-75

02-55

02-53

02-52

02-51

02-54

36


GLASS DOOR

INSTALLATION

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

2) Secure with 2 screws on the bottom.

Flange

Tighten both screws to secure Arch Surround to Glass Door.

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

INSTALLATION

OPTIONAL

SCREEN DOOR

1) Attach door bracket to side using 2 screws.

Door Bracket attaches with

2 screws.

Bottom

Screw

Door

ARCH SURROUND

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

Top

Screw

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.

Fit the bottom brackets over the pins on the base.

2) Slide the 2 screws on the rear of the Arch

Surround into the bracket on the Glass Door and then tighten screw to secure.

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.

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.

Bracket

Secure left side with 2 screws and right side with one screw.

Screw

View from underneath of the screw and the bracket.


37

INSTALLATION

ACCENT KIT INSTALLATION

1) Remove the rivets from the surround by pulling out the hoseclamp with a screwdriver or plyer. Re-install the rivets by putting them through the holes on the sides of the surround.

5) Remove the 2 studs on the sides of the Hood. Insert the new studs through the holes and secure them by fi rst putting on the washer and then tighten with a nut.

DOUBLE & SINGLE DOOR OPTION

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.

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.

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 fi rst put on the split lock washer and then the nut and tighten.

38


INSTALLATION

Option 1:

REMOTE CONTROL

Option 2:

WALL SWITCH

Option 3:

WALL THERMOSTAT

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

1) Run the wire through the right or left side gas inlet opening. Be careful not to damage wire.

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.

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

Note: We recommend a maximum of 15' of wire but if you wish to go with a longer run, use the Thermostat Wire

Table.

1) Choose a convenient location on the wall to install the receiver and the receptacle box (protection from extreme heat is very important). Run wires from the fi replace to that location. Use the Thermostat Wire

Table.

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

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.

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

Excalibur ® offers an optional programmable thermostat but any 250-750 millivolt rated nonanticipator type thermostat that is CSA, ULC or

UL approved may be used.

CAUTION

Do not connect millivolt wall thermostat wires to a 120V wire.

CAUTION

Do not connect millivolt remote control wires to a

120V wire.

Thermostat Wire Table

Recommended Maximum Lead Length

(Two-Wire) When Using Wall

Thermostat (CP-2 System)

Wire Size Max. Length

14 GA.

16 GA.

18 GA.

20 GA.

22 GA.

50 Ft.

32 Ft.

20 Ft.

12 Ft.

9 Ft.

3) Install 3 AAA alkaline batteries in transmitter and 4 AA alkaline batteries in the receiver.

Install the receiver and its cover in the wall.

Switch the remote receiver to "remote" mode. The remote control is now ready for operation.


39

INSTALLATION

WIRING DIAGRAMS

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

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.

For

NATURAL GAS

Units and Units

NOT

Equipped with DC Spark Boxes

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

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

Openings for electrical connections

120 Volt

Power IN

Millivolt

Wires

40


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.


41


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.

2) Turn gas control knob so indicator points to "OFF" position and allow 5 minutes for any gas in the combustion chamber to escape.

Note: When the glass is cold and the appliance is lit, it may cause condensation and fog the glass.

This condensation is normal and will disappear in a few minutes as the glass heats up.

3) Turn gas control knob counterclockwise so indicator points to the "PILOT" position.

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

4) When the pilot stays lit, turn the gas knob further counterclockwise to the "ON" position.

DO NOT BURN THE APPLIANCE

WITHOUT THE GLASS FRONT IN

PLACE.

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

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.

5) Use the wall switch, thermostat or remote control to turn on the unit.

AERATION

ADJUSTMENT

the fl ame height higher or lower.

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

SHUTDOWN

PROCEDURE

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

1) Use the wall switch, thermostat or remote control to turn off the main burner.

Minimum Air Shutter Opening:

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.

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

FIRST FIRE

LIGHTING

PROCEDURE

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

IMPORTANT

To ignite or reignite the pilot, remove one glass panel/door.

NOTE: For all propane units and units equipped with electric spark boxes, see "Copy of Lighting Plate Instructions" section for more details.

When fi rst operated, the unit will release an odour caused by the curing of the paint, the burning off of any oils remaining from manufacturing.

Smoke detectors in the house may go off at this time. Open a few windows to ventilate the room for a couple of hours.

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.

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

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

DO NOT ATTEMPT TO CLEAN THE

GLASS WHILE IT IS HOT.

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

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.

42



COPY OF THE LIGHTING PLATE INSTRUCTIONS NORMAL OPERATING

SOUNDS OF GAS

APPLIANCES

OFF

It is possible that you will hear some sounds from your gas appliance. This is perfectly normal due to the fact that there are various gauges and types of steel used within your appliance.

Listed below are some examples. All are normal

operating sounds and should not be considered as defects in your appliance.

Blower:

Excalibur

®

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

Burner Tray:

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

Blower Thermodisc:

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

Pilot Flame:

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

Gas Control Valve:

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

Unit Body/Firebox:

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

a


43

MAINTENANCE

MAINTENANCE

INSTRUCTIONS

1) Always turn off the gas valve before cleaning.

For relighting, refer to lighting instructions.

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

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

The glass should be cleaned when it starts looking cloudy.

condensation, such as water droplets forming in the inner liner, and subsequently dripping out the joints, Continuous condensation can cause corrosion of caps, pipe, and fi ttings.

It may be caused by having excessive lateral runs, too many elbows, and exterior portions of the system being exposed to cold weather.

4) Inspect joints, to verify that no pipe sections or fi ttings have been disturbed, and consequently loosened. Also check mechanical supports such as Wall Straps, or plumbers' tape for rigidity.

GOLD-PLATED DOOR

OR SURROUND

3) The heater is fi nished in a heat resistant paint and should only be refi nished with heat resistant paint. Excalibur

®

uses StoveBright

Paint - Metallic Black #6309.

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

GLASS GASKET

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

DOOR GLASS

Your Excalibur

®

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

In the event that you break your glass by impact, purchase your replacement from an authorized

Excalibur ® dealer only, and follow our step-bystep instructions for replacement.

4) Make a periodic check of burner for proper position and condition. Visually check the fl ame of the burner periodically, making sure the fl ames are steady; not lifting or fl oating.

If there is a problem, call a qualifi ed service person.

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

turning the unit on.

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

LOG REPLACEMENT

Caution: Wear gloves when removing damaged or broken glass.

5) The appliance and venting system must be inspected before use, and at least annually, by a qualifi ed fi eld service person, to ensure that the fl ow of combustion and ventilation air is not obstructed.

Note: Never operate the appliance without the glass properly secured in place.

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.

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.

6) Do not use this appliance if any part has been under water. Immediately call a qualifi ed service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

Note: Improper positioning of logs may create carbon build-up and will severely alter the unit's performance w h i c h i s n o t c o v e r e d u n d e r warranty.

7) Verify operation after servicing.

General Vent Maintenance

THERMOPILE /

THERMOCOUPLE

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

1) Open the bottom louvers.

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) 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.

2) Remove the Cap, and shine a fl ashlight down the Vent. Remove any bird nests, or other foreign material.

4) Drop the thermocouple or thermopile down from the bracket and pull it out of the unit.

3) Check for evidences of excessive

5) Reinstall the new ones in reverse order.

44


MAINTENANCE

FAN MAINTENANCE

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

To Remove the Fan

1) Shut the power off.

To Install the Fan

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.

2) Open the bottom louver door. Loosen the 2 screws holding the Burner ON/OFF switch and bracket to the bottom louver and lift the assembly out.

3) Remove the bottom louver door.

4) Slide the fan in towards the rear of the unit and slip it over the two mounting studs. Take care not to damage the insulation on the fan base. Ensure that the fan blades do not

rub against the valve tubing. Diagram

1.

Diagram 2

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

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.

Secure left side with 2 screws and right side with one screw.

Diagram 1

5) Connect fan ground cable to ground lug.

Refer to wiring diagram.

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.

6) Slide the thermodisc/cover assembly into the bracket clip on the underside of the fi rebox. Check that no wire will touch the hot surfaces. Diagram 2.

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


45

MAINTENANCE

REMOVING VALVE


Hint: If you are using black pipe, ensure that there is a union by the valve, otherwise removal will be almost impossible.

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.

INSTALLING VALVE

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

10) Disconnect the 2 TP wires and the 2 TH wires from the valve.

1) Attach the valve to the valve bracket with the 4 (m5x8 metric) screws provided.

11) Remove the 12 Phillips head screws securing the valve tray assembly in place and then lift the entire assembly out.

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

11/16" wrench.

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

13/16" wrench.

4) Install piezo ignitor push button assembly and reconnect wire.

5) Reconnect the quick drop out thermocouple nut with a 9mm wrench.

screws

Valve Tray Assembly

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

7) Scrape off the old gasket from the fl oor of the fi rebox and from the valve tray assembly.

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

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

9) Reinstall the 10 hold down screws.

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

7) Remove the rear log stand by removing the

2 screws.

screws

Rear Log Stand

10) Hook up the 2 TP and 2 TH wires to the appropriate connections on the valve.

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

12) Install Burner/grate assembly

12) Undo the pilot tube from the valve with a

13) Hook up the gas line and check for gas leaks with a soap and water solution or a gas leak detector. (Do not use open fl ame for leak testing.)

14) Fire up the unit temporarily

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

15) Check the manifold pressure.

8) Remove the 2 screws & sleeves on the bottom brick panel and lift out the bottom brick panel. The brick panel is very fragile

- handle with care.

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

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

16) Reinstall the logs and brick panels as needed.

17) Reinstall the glass door and the facade.

screws

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

18) Fire up the unit again and check for proper fl ame appearance and glow on logs.

46

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


PARTS LIST

Part # Description

1) 430-129 Receptacle Box Mount

2) *

8) 910-429 Box - Receptacle

9) 910-430 Cover - Receptacle

15) * Heat Shield - Base

20) 790-021 Front Filler - Left Corner

21) 790-022 Front Filler - Right Corner

22) 790-012 Baffl e

23) 780-011 Standoff Top

24) 780-013 Standoff - Side

25) 780-091 Standoff - Rear

27) *

28) *

30) *

31) *

Outer Flue Collar

Inner Flue Collar Assy

Gasket for Flue Collar

Flue Mounting Bracket

32) 902-600 Brick Panel - Base

790-901 Brick Panel Set -



33) *

34) *

35) *

Brick Panel - Back

Brick Panel - Left

Brick Panel - Right

36) 904-716 #10 x 5/8" Butt Spacer

511-031 Brick Panel Clip

MAIN ASSEMBLY

Part # Description Part # Description

432-967 Burner ON/OFF Switch Assy

38) 910-241 Switch-Burner

ON/OFF(3-way)

910-899 Wire Harness - Valve

42) 910-331/P Fan Motor (120 Volts)

432-966 Fan Switch Assembly-120 V

43) *

(Optional)

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

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

64) 790-093 Gasket - Exchanger Relief

946-556 Heat Wave Duct Kit (Optional)

91) 946-002 Round to Oval Adaptor

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

95) 946-006 Grill Plate - White

96) 946-005 Wall Adaptor Plate - White

97) 910-417 Knob - White

98) 910-366 Switch Cover Plate - White

99) 910-412 Fan Speed Controller

100) 910-367 Box-Plastic Switch

Receptacle

102) 946-010 Flexible Air Duct

946-038 Insulation 6" dia. x 24"

946-570 Heat Release Duct Kit

(Optional)

108) 910-165 Fan (120 V)

109) 946-000 Flexible Air Release Duct

791-969 Conversion Kit - NG to LP

*Not available as a replacement part.


47

PARTS LIST

64

63

62

61

60

59

51

61

64

22

10

1

8

7

9

2

36

49

48

38

ON-OFF SWITCH

ASSEMBLY

43

47

FAN SWITCH ASSEMBLY

36

32

42

20

61

64

HEAT WAVE

DUCT KIT

93

95

96

31

30

50

99

100

97 98

28

30

27

23

90

89

92

91

94

93

102

25

25

23

34

33

24

109

108

15

21

24

HEAT RELEASE DUCT KIT

BRICK PANELS

35

48


Part #

52) 910-190

53) 780-021

790-574/P

790-576/P

56) *

57) 910-478

58) *

65) *

66) 910-038

910-039

904-617

904-645

936-170

67) *

68) W840470

BURNER ASSEMBLY & LOG SET

Description

Piezo Ignitor & Nut

Gasket - Valve Access Plate

Valve Assy - Natural Gas

Valve Assy - Propane

Valve Tray - NG/LP

Valve - S.I.T. - NG/LPG

Valve Bracket

Pilot Bracket

Pilot Assy-NG 3 way fl ame - S.I.T.

Pilot Assy-LP 3 way fl ame - S.I.T.

Orifi ce #34 - Natural Gas

Orifi ce #51 - Propane

Orifi ce Gasket

Pilot Holder

Pilot Assembly Gasket

69) *

75) *

76) *

79) 791-535

82) 511-030

83) 780-028

85) 780-930

Firebox Base

Defl ector - Left

Defl ector - Right

Burner Assy - NG/LP

Burner Grate Assy

Rear Log Support Bracket

Log Set (Complete)


66

68

67

82

83

75

68

56

53

69

PARTS LIST

85

79

76

52

58

57


49

PARTS LIST


FLUSH FRONT ACCESSORIES


790-518

132) 790-137

Door Assembly - Complete

Flush Door Frame

135) 940-326/P Glass (Flush)

136) 936-155 Glass Gasket (Tadpole)

904-691 U-Clip

790-920

790-922

790-914

790-916

Surround - Black - Complete

Surround - Gold - Complete

Surround - Antique Gold - Complete

Surround - Antique Nickel - Complete

790-918

141) *

142) *

Surround - Antique Copper - Complete

Surround - Faceplate - Excalibur ®

Surround - Louver

143) 904-621 Hole Plug

144) 790-122 Emblem

145) *

146) *

148) 904-719

Surround - Hood

Handle

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

790-930

790-932

790-941

790-942

790-943

161) *

162) *

163) *

164) *

167) *

168) *

Double Screen Door - Complete - Black

Double Screen Door - Complete - Gold

Double Screen Door - Complete - Antique Gold

Double Screen Door - Complete - Antique Nickel

Double Screen Door - Complete - Antique Copper

Double Screen Door Frame - Right

Double Screen Door Frame - Left

Mesh Screen - Double Door

Retaining Plate - Double Door

Door Mounting Bracket - Right

Door Mounting Bracket - Left


136

790-924

790-926

790-951

790-952

790-953

151) *

Single Screen Door - Complete - Black

Single Screen Door - Complete - Gold

Single Screen Door - Complere - Antique Gold

Single Screen Door - Complete - Antique Nickel

Single Screen Door - Complete - Antique Copper

Single Screen Door Frame

152) *

153) *

154) *

Mesh Screen - Single Door

Retaining Plate - Single Door

Handle - Single Door

155) 904-721

156) *

157) *

Push-Fit Ball Plunger

Door Mounting Bracket - Right

Carriage Bolt

158) 948-221 Logo Plate

159) 904-724 Plunger Clamp

132

FLUSH DOOR

135

145

164

141

163

164

159

168

155

162

157

146

161

DOUBLE DOORS

157

167

154

163

148

148

158

144

143

155

159

155

148

155

146

142

146

157

148

152

153

149

149

SINGLE DOOR

151

156

50


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. This warranty is not transferable.

The Warranty: Limited Lifetime

The combustion chamber, heat exchanger, burner tubes/pans, logs, brick panels and gold plating (against defective manufacture only) are covered under the Limited

Lifetime Warranty for fi ve (5) years for parts and subsidized labour* and parts only thereafter.

Glass is covered for lifetime against thermal breakage only, parts and subsidized labour* for fi ve (5) years and parts only thereafter from date of purchase.

Special Finishes - One year on brushed nickel, antique gold and antique copper surrounds and doors. You can expect some changes in color as the product "ages" with constant heating and cooling. FPI warranties the product for any manufacturing defects on the original product. However, the manufacturers warranty does not cover changing colors and marks, ie. fi nger prints, etc applied after the purchase of the product. Damage from the use of abrasive cleaners is not covered by warranty.

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 two years parts and one year 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 purchase.

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

Repair/replacement parts purchased by the consumer from FPI after the original coverage has expired on the unit will carry a 90 day warranty, valid with a receipt only.

Any item shown to be defective will be repaired or replaced at our discretion. No labor coverage is included with these parts.

Conditions:

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

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

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

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

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

Exclusions:

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

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

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

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

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

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

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

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

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

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

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

Any alteration to the unit which causes sooting or carboning that results in damage to the interior / exterior facia is not the responsibility of FPI.

* Subsidy according to job scale as predetermined by FPI.


51

Excalibur

®

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

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

®

Product.

See the inside back cover for details.

Register your Excalibur

®

online at http://www.excalibur-fi re.com

Installer: Please complete the following information

Dealer Name & Address: ______________________________________________

___________________________________________________________________

Installer: ___________________________________________________________

Phone #: ___________________________________________________________

Date Installed: ______________________________________________________

Serial No.: __________________________________________________________

Excalibur ® is a trademark of FPI Fireplace Products International Ltd.

© Copyright 2008, FPI Fireplace Products International Ltd. All rights reserved.

52

Printed in Canada


P90 Zero Clearance Direct Vent Gas Fireplace Owners & Installation

www.excalibur-fi re.com

P90 Zero Clearance Direct Vent Gas Fireplace

Owners &

Installation Manual

WARNING:

If the information in these instructions are not followed exactly, a fi re or explosion may result causing property damage,

FOR YOUR SAFETY

What to do if you smell gas: personal injury or loss of life.

FOR YOUR SAFETY

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

do not use any phone in your building.

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

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

supplier, call the fi re department.

Installer: Please complete the details on the back cover and leave this manual with the homeowner.

Homeowner: Please keep these instructions for future reference.

WARNING

HOT GLASS

WILL

CAUSE BURNS

DO NOT TOUCH

GLASS

UNTIL COOLED

NEVER

ALLOW CHILDREN

TO TOUCH GLASS

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.

To the New Owner:

Congratulations!

You are the owner of a state-of-the-art Excalibur

Gas Fireplace by FPI FIREPLACE PRODUCTS

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

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.

UNIT DIMENSIONS

OPERATING INSTRUCTIONS

INSTALLATION

MAINTENANCE

PARTS LIST

WARRANTY

D

E

F

A

B

C

I

G

H

Front Firebox Width

Rear Firebox Width

Front Firebox Height

Height w/ Standoff

Unit Depth

Height to Vent

Faceplate Width

Faceplate Height (center)

Faceplate Height (edge)

42” (1067mm)

31” (787mm)

38” (965mm)

45” (1143mm)

19-1/4” (489mm)

40-1/4” (1022mm)

37” (940mm)

29-1/4” (743mm)

24” (610mm)

MA Code - CO Detector

IMPORTANT MESSAGE

SAVE THESE

INSTRUCTIONS

**Clearances for HeatWave and**