Excalibur P95 Installation manual

Excalibur P95 Installation manual
www.excalibur-fire.com
P95-3 Zero Clearance Direct Vent Gas Fireplace
MODELS:
P95-NG3 Natural Gas
Owners &
Installation Manual
P95-LP3 Propane
WARNING:
If the information in these instructions are not followed exactly,
a fire or explosion may result causing property damage,
personal injury or loss of life.
FOR YOUR SAFETY
What to do if you smell gas:
Do not try to light any appliance
Do not touch any electrical switch:
do not use any phone in your
FOR YOUR SAFETY
building.
Do not store or use gasoline or other flammable vapours and
Immediately
call your gas supplier
liquids in the vicinity of this or any other appliance.
from a neighbour's phone. Follow
the gas supplier's instructions.
Installation and service must be performed by a qualified
If you cannot reach your gas
installer, service agency or the gas supplier.
supplier, call the fire 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.
918-526
FPI FIREPLACE PRODUCTS INTERNATIONAL LTD. 6988 Venture St., Delta, BC Canada, V4G 1H4
07/17/06
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 P95-3 is a hand crafted appliance and has
been designed to provide you with all the warmth and charm of a wood fireplace at
the flick of a switch. The model P95-3 has been approved by Warnock Hersey for
both safety and efficiency. As it also bears our own mark, it promises to provide you
with economy, comfort and security for many trouble free years to follow. Please take
a moment now to acquaint yourself with these instructions and the many features of
your Excalibur® Fireplace.
INFORMATION FOR MOBILE / MANUFACTURED HOMES AFTER FIRST SALE
This Excalibur® product has been tested and listed by Warnock Hersey as a Direct Vent Wall Furnace to the following standards: VENTED GAS
FIREPLACE HEATERS ANSI Z21.88b-2003/CSA 2.33b-2003 and GAS-FIRED APPLIANCES FOR USE AT HIGH ALTITUDES CAN/CGA 2.17M91.
This Direct Vent System Appliance must be installed in accordance with the manufacturer's installation instructions and the Manufactured Home
Construction and Safety Standard, Title 24 CFR, Part 3280, or the current Standard of Fire Safety Criteria for Manufactured Home Installations,
Sites, and Communities ANSI/NFPA 501A, and with CAN/CSA Z240-MH Mobile Home Standard in Canada.
This appliance installation must comply with the manufacturer's installation instructions and local codes, if any. In the absence of local codes follow
the current National Fuel Gas Code, ANSI Z223.1 and the current National Electrical Code ANSI/NFPA 70 in the U.S.A., and the current CAN/CGA
B149 Gas Installation Code and the current Canadian Electrical Code CSA C22.1 in Canada.
This Excalibur® Mobile/Manufactured Home Listed appliance
comes factory equipped with a means to secure the unit.
This Excalibur® Mobile/Manufactured Home listed appliance
comes equipped with a dedicated #8 ground lug to which an
18 gauge copper wire from the steel chassis ground must
be attached.
This appliance may only be installed in an aftermarket
permanently located, manufactured (mobile) home,
where not prohibited by local codes.
This appliance is only use with the type of gas indicated
on the rating plate. This appliance is not convertible for
use with other gases, unless a certified kit is used.
2
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
TABLE OF CONTENTS
SAFETY LABEL
MA Code - CO Detector
(for state of Massachusetts only) ..................................5
Log Set Installation ......................................................27
Glass Door Installation ................................................29
Front Facade ...............................................................29
Optional Screen Doors ................................................29
Accent Kit Installation ..................................................30
Option 1: Remote Control ............................................31
Option 2: Wall Switch ..................................................31
Option 3: Wall Thermostat ..........................................31
Wiring Diagrams .........................................................32
INSTALLATION
OPERATING INSTRUCTIONS
Important Message ......................................................6
Before You Start ............................................................6
General Safety Information ...........................................6
Installation Checklist ......................................................6
Locating Your Gas fireplace ..........................................7
Manufactured Mobile Home Additional Requirements ..7
Optional Heatwave .......................................................7
Duct System Kit .............................................................7
Optional Heat Release Kit .............................................7
Clearances ....................................................................7
Combustible Mantels ....................................................8
Unit Base Stand-offs......................................................8
Framing and Finishing ...................................................8
Facing Requirement ......................................................9
Hearth Requirements ....................................................9
Optional Cover Plate Template ....................................10
Unit Assembly Prior To Installation ..............................10
Venting Introduction .....................................................10
Venting ........................................................................ 11
Exterior Vent Termination Locations ............................12
Simpson Dura-vent Venting .........................................13
Simpson Dura-vent Venting Components List .............14
Venting Arrangements - Horizontal Terminations ........15
Venting Arrangements - Vertical Terminations ............18
Unit Installation with Horizontal Termination ................20
Vertical Termination .....................................................21
Installation Procedures ................................................22
High Elevation .............................................................23
Gas Line Installation ....................................................23
Pilot Adjustment ...........................................................23
Gas Pipe Pressure Testing ..........................................23
Conversion Kit# 773-969 From NG To LP ..................24
Optional Brick Panels ..................................................27
Operating Instructions .................................................34
Lighting Procedure ......................................................34
Shutdown Procedure ...................................................34
First Fire ......................................................................34
Aeration Adjustment ....................................................34
Normal Operating Sounds Of Gas Appliances ............35
Serial No. Decal ............................................................4
REQUIREMENTS
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
MAINTENANCE
Maintenance Instructions ............................................36
Gold-plated Door or Surround .....................................36
Log Replacement .......................................................36
Thermopile / Thermocouple.........................................36
Glass Gasket ...............................................................36
Door Glass ..................................................................36
Fan Maintenance .........................................................37
Removing Valve...........................................................38
Installing Valve.............................................................38
P95-3 Main Assembly ..................................................39
P95-3 Burner Assembly & Log Set ..............................41
P95-3 Flush Front Accessories ...................................42
WARRANTY
The Warranty: Limited Lifetime ...................................43
3
SAFETY LABEL
This is a copy of the label that accompanies each
P95-3 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.
Copy of Safety Decal for P95-3
NOTE: Excalibur® units are constantly being
improved. Check the label on the unit and if
there is a difference, the label on the unit is the
correct one.
For the State of Massachusetts, installation
and repair must be done by a plumber or
gasfitter licensed in the Commonwealth of
Massachusetts.
For the State of Massachusetts, flexible
connectors shall not exceed 36 inches in
length.
For the State of Massachusetts, the appliances individual manual shut-off must be a
t-handle type valve.
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.
4
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
REQUIREMENTS
MA Code - CO Detector
(for the State of Massachusetts only)
5.08: Modifications to NFPA-54, Chapter 10
(2) Revise 10.8.3 by adding the following additional requirements:
(a) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for
residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than
seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall
be satisfied:
1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vented gas fueled
equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is
installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery
operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure
served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of
qualified licensed professionals for the installation of hard wired carbon monoxide detectors
a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon
monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.
b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall have a period of
thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon
monoxide detector with an alarm shall be installed.
2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the above provisions
shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.
3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight
(8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The
sign shall read, in print size no less than one-half (1/2) inch in size, "GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL
OBSTRUCTIONS".
4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation
unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR
5.08(2)(a)1 through 4.
(b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:
1. The equipment listed in Chapter 10 entitled "Equipment Not Required To Be Vented" in the most current edition of NFPA 54 as adopted by
the Board; and
2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or
structure used in whole or in part for residential purposes.
(c) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the manufacturer of Product
Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the
instructions provided by the manufacturer for installation of the equipment and the venting system shall include:
1. Detailed instructions for the installation of the venting system design or the venting system components; and
2. A complete parts list for the venting system design or venting system.
(d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the manufacturer of a
Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases, but identifies
"special venting systems", the following requirements shall be satisfied by the manufacturer:
1. The referenced "special venting system" instructions shall be included with the appliance or equipment installation instructions; and
2. The "special venting systems" shall be Product Approved by the Board, and the instructions for that system shall include a parts list and
detailed installation instructions.
(e) A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting instructions,
all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of
the installation.
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
5
INSTALLATION
IMPORTANT MESSAGE
SAVE THESE
INSTRUCTIONS
The P95-NG3 or P95-LP3 Direct Vent Fireplace
must be installed in accordance with these
instructions. Carefully read all the instructions
in this manual first. Consult the "authority
having jurisdiction" to determine the need for
a permit prior to starting the installation. It is
the responsibility of the installer to ensure
this fireplace is installed in compliance with
manufacturer's instructions and all applicable
codes.
BEFORE YOU START
Safe installation and operation of this appliance
requires common sense, however, we are
required by the Canadian Safety Standards
and ANSI Standards to make you aware of
the following:
INSTALLATION AND REPAIR
SHOULD BE DONE BY A
QUALIFIED SERVICE PERSON.
THE APPLIANCE SHOULD
BE INSPECTED BEFORE USE
AND AT LEAST ANNUALLY BY
A PROFESSIONAL SERVICE
PERSON. MORE FREQUENT
CLEANING MAY BE REQUIRED
DUE TO EXCESSIVE LINT FROM
CARPETING, BEDDING MATERIAL,
ETC. IT IS IMPERATIVE THAT
CONTROL COMPARTMENTS,
BURNERS AND CIRCULATING
AIR PASSAGEWAYS OF THE
APPLIANCE BE KEPT CLEAN.
DUE TO HIGH TEMPERATURES,
THE APPLIANCE SHOULD BE
LOCATED OUT OF TRAFFIC AND
AWAY FROM FURNITURE AND
DRAPERIES.
WARNING: FAILURE TO INSTALL
THISAPPLIANCE CORRECTLYWILL
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.
6
CLOTHING
OR
OTHER
FLAMMABLE MATERIAL SHOULD
NOT BE PLACED ON OR NEAR
THE APPLIANCE.
GENERAL SAFETY
INFORMATION
1) The appliance installation must conform
with local codes or, in the absence of local
codes, with the current Canadian or National
Gas Codes, CAN1-B149 or ANSI Z223.1
Installation Codes.
2) The appliance when installed, must be
electrically grounded in accordance with
local codes, or in the absence of local codes
with the current National Electrical Code,
ANSI/NFPA 70 or CSA C22.1 Canadian
Electrical Code.
3) See general construction and assembly
instructions. The appliance and vent should
be enclosed.
4) This appliance must be connected to the
specified vent and termination cap to the
outside of the building envelope. Never vent
to another room or inside a building. Make
sure that the vent is fitted as per Venting
instructions.
5) Inspect the venting system annually for
blockage and any signs of deterioration.
6) Venting terminals shall not be recessed into
a wall or siding.
7) Any safety glass removed for servicing
must be replaced prior to operating the
appliance.
8) To prevent injury, do not allow anyone who
is unfamiliar with the operation to use the
fireplace.
9) Wear gloves and safety glasses for protection
while doing required maintenance.
10) Be aware of electrical wiring locations in
walls and ceilings when cutting holes for
termination.
11) Under no circumstances should this
appliance be modified. Parts that have to be
removed for servicing should be replaced
prior to operating this appliance.
12) Installation and any repairs to this appliance
should be done by a qualified service person.
A professional service person should be
called to inspect this appliance annually.
Make it a practice to have all of your gas
appliances checked annually.
14) Under no circumstances should any solid
fuels (wood, paper, cardboard, coal, etc.)
be used in this appliance.
15) The appliance area must be kept clear and
free of combustible materials, (gases and
other flammable vapours and liquids).
Emissions from burning wood or gas could
contain chemicals known to the State of
California to cause cancer, birth defects or
other reproductive harm.
INSTALLATION
CHECKLIST
1) Check all clearances to combustibles. Refer
to the following sections:
a)
b)
c)
d)
e)
f)
g)
h)
Locating Your Gas Fireplace
Clearances
Combustible Mantels
Unit Base Stand-offs
Framing and Finishing
Hearth Requirement
Unit Assembly Prior to Installation
Venting
2) Make gas and electrical connections. Test
the pilot. Must be as per diagram. Refer to
the "Gas Line Installation" section.
3) Install standard and optional features. Refer
to the following sections where applicable:
a. Brick Panels
b. Log Set
c. Glass Door
d. Arch Surround
e. Double Screen Doors
f. Accent Kit (Double Door & Surround)
g. Remote Control
h. Wall Switch
i. Wall Thermostat
4) Final check.
Before leaving this unit with the customer,
the installer must ensure that the appliance is
firing correctly and operation fully explained
to customer.
This includes:
1) Clocking the appliance to ensure the correct
firing rate (rate noted on label 45,000 Btu/h)
after burning appliance for 15 minutes.
2) If required, adjusting the primary air to ensure
that the flame does not carbon. First allow
the unit to burn for 15-20 min. to stabilize.
CAUTION: Any alteration to the product that
causes sooting or carboning that results
in damage is not the responsibility of the
manufacturer.
13) Do not slam shut or strike the glass door.
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
INSTALLATION
LOCATING YOUR
GAS FIREPLACE
1) When selecting a location for your fireplace,
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.
3) The appliance must be installed on a flat,
solid, continuous surface (e.g. wood, metal,
concrete). This may be the floor, or raised up
on a platform to enhance its visual impact.
If the appliance is going to be installed
on carpeting, combustible linoleum tile or
other combustible material other than wood
flooring, the appliance must be installed on a
metal or wood panel extending the full width
and depth of the appliance.
2) Ensure proper grounding using the #8
ground lug provided. See the "Wiring
Diagram" section.
4) The P95-3 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)
B)
C)
D)
Flat on Wall
Flat on Wall Corner
Recessed into
Wall/Alcove
Corner
Diagram 1
5) This appliance is Listed for bedroom
installations when used with a Listed Millivolt
Thermostat. Some areas may have further
requirements, check local codes before
installation.
6) The P95-3 Direct Vent Gas Fireplace is
approved for alcove installations, which
meet the clearances listed on this page.
OPTIONAL
HEATWAVE
CLEARANCES
The clearances listed below are Minimum
distances unless otherwise stated:
A major cause of chimney related fires is
failure to maintain required clearances (air
space) to combustible materials. It is of the
greatest importance that this fireplace and
vent system be installed only in accordance
with these instructions.
Clearance to Combustibles from:
Back
0"
(0mm)
Side
0"
(0mm)
Floor
0"
(0mm)
NOTE: The minimum floor clearance must
be maintained from the top surface of the
carpeting, tile, etc.
DUCT SYSTEM KIT
#946-556
The HeatWave Air Duct Kit increases the
effectiveness of your fireplace by dispersing
warm air from the fireplace to remote locations in
the same room or other rooms in your home.
Up to two kits may be installed on the fireplace.
Please Note: Only 1 HeatWave kit may be
operated at one time. This includes the internal
blower option as well.
OPTIONAL
HEAT RELEASE KIT
#946-570
The Heat Release Kit expels warm air from
the fireplace to the outside of the building,
allowing the fireplace to be operated with less
heat entering the room. The kit may be used
on either the left or right side.
7) We recommend that you plan your installation
on paper using exact measurements for
clearances and floor protection before
actually installing this appliance. Have a
qualified inspector, dealer, or installer review
your plans before installation.
Note: For vent terminations see the
"Venting" section.
Side Wall Clearance
6-1/2" (165mm)
Horizontal Vent Clearances
Top
3"
Side
2"
Bottom
2"
Vertical Vent Clearances
1-1/4" (32mm)
* see mantle clearance instructions in the
"Combustible Mantels" section.
WARNING:
Fire hazard is an extreme risk if
these clearances are not adhered to.
Clearances for HeatWave and
Heat Release Kit
Heat Release Kit
The HeatWave Duct Kit and the Heat Release
Kit have different clearance and framing
requirements, check the HeatWave and Heat
Release manual for details.
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
7
INSTALLATION
COMBUSTIBLE MANTELS
FRAMING AND
FINISHING
Because of the extreme heat this fireplace
emits, the mantel clearances are critical.
Combustible mantel clearances from top of unit
are shown in Diagram below.
1) Determine the total thickness of facing
material (e.g. drywall plus ceramic tiles) to
allow the finished surface to be flush with
the front of the unit. Total facing thickness
can vary from 1/2" (13mm) to 1" (32mm)
thick.
Note: A non-combustible mantel may be
installed at a lower height if the
framing is made of metal studs
covered with a non-combustible
board.
These drawings are to scale at 1:6 (one inch
= 6 inches)
Mantel can be installed anywhere in shaded
area or higher using the above scale.
Note: Ensure the paint that is used
on the mantel and the facing is
"heat resistant" or the paint may
discolour.
Install Top Standoffs & Side Nailing Strips
before unit is slipped into position. See the
"Unit Assembly Prior to Installation" section
for assembly details.
P95-3 Flat Wall Surround and Tile Kit
The P95-3 Flat Wall Surround, Hearth Pad and Tile Kit cannot be modified in any way. It must
be installed as manufactured.
2) Frame in the enclosure for the unit with
framing material. The framed opening is
50-1/8" high x 53-3/8" wide x 21-1/4" deep
(1276mm high x 1346mm wide x 533mm
deep).
Framing Dimensions
A
B
C
53-3/8" 50-1/8" 21-1/4"
1346mm 1276mm 533mm
P95-3 Flat Wall Surround and Tile Kit Specifications
UNIT BASE STAND-OFFS
To accommodate varying thicknesses and
finishes of hearth materials, we have increased
the overall height of the appliance by a further
1-1/8”. This increase is added with the inclusion
of two stand-offs at the bottom of the unit, below
the outer box, taking the overall height of the
framing dimensions from 49” up to 50-1/8”.
In the event that you should choose to use
thinner materials to finish the hearth, you can
omit the stand-offs provided for raising the unit.
However, we recommend that you leave the
framing dimensions as they are in the manual
and alter only the facing requirement by reducing
it by the same distance that you have lowered
the unit.
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.
3) For exterior walls, insulate the enclosure to
the same degree as the rest of the house,
apply vapour barrier and drywall, as per
local installation codes. (Do not insulate
the fireplace itself.)
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
Facing Over 1" (25mm) Thick
Header
11” dia. hole
through wall
for Flex
or for DuraVent
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.
48-3/4”
CL
2"
F P I o ff e r s a c o v e r
plate template. See the
"Optional Cover Plate
Template" section.
53-3/4”
4) Note: The unit does not
have to be completely
enclosed in a chase. The
clearance on top of the
unit is 0" to the standoffs
so combustible building
materials can be laid
directly on top of the
standoffs. You must
maintain clearance from
the vent to combustible
materials for both
rigid and flex, see the
"Clearances" section.
Non-combustible Combustible
Material
Material
INSTALLATION
2-7/8”
2-1/4” 4"
Gas connection
on this side
21-1/8” (533mm)
NOTE: If using a brick
hearth, the fireplace will
need to be raised to
accommodate the brick
thickness. Example: If the
brick is 2" thick, the unit
must be raised 1".
Note: 53-3/4" is the minimum height for both flex termination or
Simpson Dura-Vent venting.
The HeatWave Duct Kit has different
clearance and framing requirements,
check the HeatWave manual for details.
FACING REQUIREMENT
HEARTH REQUIREMENTS
This fireplace requires a non-combustible
material extending from the framing
header and sides.
Floor Mounted Fireplaces
The flanges on the front face of the
fireplace are for a facing thickness of 1"
(25mm).
Please note that all vertical
measurements are taken
from the base of the unit
excluding risers or bottom
stand-offs.
Raised Fireplaces
No hearth is
required when
the unit is raised
3" (76mm) off of
the floor surface
Flo
Fireplace
Stand
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
ori
ng
Yo u m u s t t a k e
into account the
depth of the floor
covering (carpet,
tile, linoleum, etc.)
when determining
the height of the
fireplace stand.
9
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
The 2 Top Standoffs must be correctly positioned
and attached to the top before unit is slipped
into position.
Top Standoff Assembly
The top standoffs are shipped in a flat position
and must be folded into shape and attached.
1) Remove the standoffs from the fireplace
top.
2) Position bottom of cover plate over pins
located at the bottom of the firebox.
2) Take each standoff and bend into the correct
shape. Bend up at the bend lines until the
screw holes in the standoff and the prepunched screw holes on the fireplace top
line up.
3) Attach the standoff securely to the top with 2
VENTING
INTRODUCTION
The P95-3 uses the "balanced flue" technology
Co-axial system. The inner liner vents products
of combustion to the outside while the outer
liner draws outside combustion air into the
combustion chamber thereby eliminating the
need to use heated room air for combustion and
losing warm room air up the chimney.
Note:
These flue pipes must not be
connected to any other appliance.
The gas appliance and vent system must be
vented directly to the outside of the building,
and never be attached to a chimney serving a
separate solid fuel or gas burning appliance.
Each direct vent gas appliance must use it's own
separate vent system. Common vent systems
are prohibited (see "Simpson Dura-Vent Venting"
section for more details and exceptions).
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.
screws per standoff (on opposite corners).
Side Nailing Strips
Top Clip
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.
Plates can be
folded out.
2) Pull out top clip that is still hooked onto
glass.
10
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
INSTALLATION
VENTING
FPI Direct Vent System Flex Horizontal Terminations Only
These venting systems, in combination with the P95-3 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 from the "Exterior
Vent Termination Locations" section.
FPI Direct Vent Flex System Termination
Kit (Part # 946-615) includes all the parts
needed to install the P95-3 with a maximum
run of 4 feet.
If longer runs are needed, the FPI Direct Vent
system (Flex) kit is (Part # 946-616) which
includes all the parts needed to install the
P95-3 with a maximum 10' run.
1)
2)
3)
4)
5)
6)
7)
8)
9)
1)
2)
3)
4)
5)
6)
7)
8)
9)
8" dia. flexible liner (4 ft. length)
5" dia. flexible liner (4 ft. length)
spring spacers (4)
thimble (2)
AstroCap XL termination cap (1)
screws (12)
tube of Mill Pac (1)
plated screws (8)
screws #8 x 1-1/2" Drill Point,
Stainless Steel (4)
10) vinyl siding standoff
8" dia. flexible liner (10 ft. length)
5" dia. flexible liner (10 ft. length)
spring spacers (7)
thimble (2)
AstroCap XL termination cap (1)
screws (12)
tube of Mill Pac (1)
plated screws (8)
screws #8 x 1-1/2" Drill Point,
Stainless Steel (4)
10) vinyl siding standoff
Notes:
1) Liner sections should be continuous
without any joints or seams.
2) Only Flex pipe purchased from FPI may
be used for Flex installations.
3) Horizontal vent must be supported every
3 feet.
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
11
12
H= Not to be installed above a meter/regulator assembly within (3'/90cm) horizontally
from the centerline of the regulator.
J= Clearance to service regulator vent outlet *(min 36"/90cm)
K= Clearance to non-mechanical air supply inlet to building or the combustion air inlet to
any other appliance *(12"/30cm)
L= Clearance to a mechanical air supply inlet *(min. 72"/1.8m)
M= Clearance above paved sidewalk or a paved driveway located on public property
*(min. 84"/2.1m)
N= Clearance under veranda, porch, deck, or balcony *(min. 12"/30cm)
Note:
- A vent shall not terminate directly above a sidewalk or paved driveway which is located between two single family dwellings and serves both dwellings.
- Only permitted if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.
- If the vent termination is accessible, a certified guard shall be installed.
* As specified in CGA B149 Installation Code. Note: Local codes or regulations may require different clearances.
Clearance above grade, veranda, porch, deck, or balcony *(min. 12"/30cm)
Clearance to window or door that may be opened *(12"/30cm)
Clearance to permanently closed window *(min. 12"/30cm)
Vertical clearance to ventilated soffit located above the terminal within a horizontal
distance of (24"/60cm) from the centerline of the terminal (min. 18"/46cm) check with
local code.
E= Clearance to unventilated soffit (min. 18"/45cm)
F= Clearance to outside corner: with AstroCap Termination Cap (min 6"/15cm), with DuraVent Termination Cap (14"/36cm)
G= Clearance to inside corner: with AstroCap Termination Cap (min 6"/15cm), with DuraVent Termination Cap (12"/30cm)
A=
B=
C=
D=
INSTALLATION
EXTERIOR VENT TERMINATION LOCATIONS
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
INSTALLATION
SIMPSON DURA-VENT VENTING
The Simpson Dura-Vent Direct Vent System offers a complete line of component parts for installation of both horizontal and vertical installations.
Many items are offered in decorative black, as well as galvanized finish. We recommend using the galvanized finish for installation with the
P95-3.
The minimum components required for a basic horizontal termination are:
1
1
1
1
1
Horizontal Termination Cap
90o Elbow
Flue Adaptor
Wall Thimble
Length of pipe to suit wall thickness
(see chart)
Wall thickness is measured from the back standoffs to the inside mounting surface
of termination cap. For siding other than vinyl furring strips may be used, instead
of the vinyl siding standoff, to create a level surface to mount the vent terminal.
The Terminal must not be recessed into siding. Measure the wall thickness
including furring strips.
If a Vinyl Siding Standoff is required (it must be used with vinyl siding), measure
to outside surface of wall without siding and add 2 inches.
Horizontal and Vertical
Terminations for 5" x 8" Venting
Flat Wall Installation
Wall Thickness
(inches)
Vent Length Required
(inches)
4" - 5-1/2"
6"
7" - 8-1/2"
9"
10" - 1-1/2"
12"
9" - 14-1/2"
11" - 14-5/8" Adj. Pipe
15" - 23-1/2"
17" - 24" Adj.
Corner Installation
Wall Thickness
(inches)
Vent Length Required
(inches)
3-1/4" - 6-3/4"
11" - 14-5/8" Adj. Pipe
7-3/4" - 16-1/4"
17" - 24" Adj. Pipe
7-1/4" - 8-3/4"
6" + 12"
9" + 9"
4-1/4" - 5-3/4"
6" + 9"
Alternate Horizontal
Termination Cap
Simpson
Dura-Vent
Direct Vent GS
The FPI AstroCap XLTM is certified for installations using
FPI venting systems as well as Simpson Dura-Vent® and
Direct Vent GS.
The FPI AstroCap XLTM is a proprietary trademark of FPI
Fireplace Products International Ltd.
Dura-Vent® and Direct Vent GS are registered and/or
proprietary trademarks of Simpson Dura-Vent Co. Inc.
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
13
INSTALLATION
SIMPSON DURA-VENT VENTING COMPONENTS LIST
All Simpson Dura-Vent components are available directly from FPI.
5" x 8"
1208
1208B
1207
1207B
1206
1206B
1204
1204B
1203
1203B
1202
1202B
1211
1211B
1217
1217B
1245
1245B
1245G
1245BG
1290
1290B
1290G
1290BG
14
Description
6" Pipe Length
6" Pipe Length, Black*
9" Pipe Length
9" Pipe Length, Black*
12" Pipe Length
12" Pipe Length, Black*
24" Pipe Length
24" Pipe Length, Black*
36" Pipe Length
36" Pipe Length, Black*
48" Pipe Length
48" Pipe Length, Black*
11" to 14-5/8" Pipe, Adjustable
11" to 14-5/8" Pipe, Adjustable, Black*
17" to 24" Pipe, Adjustable
17" to 24" Pipe, Adjustable, Black*
45o Elbow
45o Elbow, Black*
45o Elbow, Swivel*
45o Elbow, Black, Swivel*
90o Elbow
90o Elbow, Black*
90o Elbow, Swivel*
90o Elbow, Black, Swivel*
5" x 8"
1240
1241
1247
1243
1243S
1242
1253
1263
1288
1281
1282
1284
1285
1291
N/A
1250
Description
Round Ceiling Support/Wall Thimble Cover*
Cathedral Ceiling Support Box Brass Trim for
Wall Thimble/Ceiling Support*
Wall Thimble (only required in Canada)
Flashing, 0/12 to 6/12 Roof Pitch
Flashing, 7/12 to12/12 Roof Pitch
Wall Firestop
Storm Collar
Ceiling Firestop
Wall Strap*
Snorkel Termination (36")
Snorkel Termination (14")
Horizontal Square Termination*
Horizontal Square Termination, High Wind
Vertical Termination, High Wind
Extended Vertical Termination
Vinyl Siding Standoff
Parts not supplied by Dura-Vent
770-994 Dura-Vent Flue Adaptor
* Not Supplied by FPI.
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
INSTALLATION
VENTING ARRANGEMENTS - HORIZONTAL TERMINATIONS
SIMPSON DURA-VENT DIRECT VENT GS SYSTEM and
FPI DIRECT VENT SYSTEM (FLEX)
(Propane & Natural Gas)
The diagram shows all allowable combinations of vertical runs with horizontal terminations, using one 90o elbow (two 45o elbows equal one 90o
elbow).
Simpson Dura-Vent
5" inner diameter
8" outer diameter
Regency® Flex Vent
5" inner diameter
8" outer diameter
Note: Must use optional flue adapter (Part # 770-994)
when using Simpson Dura-Vent pipe.
Note: FPI Direct Vent System (Flex) is only approved
for horizontal terminations.
A vent guard should be used whenever the
termination is lower than the specified minimum
or as per local codes.
Please note that all vertical
measurements are taken from
the base of the unit excluding
risers or bottom stand-offs.
•
•
•
Maintain clearances to combustibles as listed in the "Clearances," "Locating Your Gas Fireplace," "Combustible Mantels," "Unit Base
Stand-offs," "Framing and Finishing," "Facing Requirement," & "Hearth Requirement" sections.
Horizontal vent must be supported every 3 feet.
Firestops are required at each floor level and whenever passing through a wall.
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
15
INSTALLATION
Horizontal Venting with Two (2) 90o Elbows
One 90o elbow = Two 45o elbows.
Option
A)
B)
C)
D)
E)
F)
G)
V
0' Min.
1' Min.
2' Min.
3' Min.
4' Min.
5' Min.
6' Min.
H + H1
2' Max.
3' Max.
4' Max.
5' Max.
6' Max.
7' Max.
8' Max.
With these options,
maximum total pipe length
is 30 feet with minimum
of 6 feet total vertical
and maximum 8 feet total
horizontal.
Please note minimum 1
foot between 90o elbows
is required.
Horizontal Venting with Three (3) 90o Elbows
One 90o elbow = Two 45o elbows.
Option
A)
B)
C)
D)
E)
F)
G)
H)
16
V
0' Min.
1' Min.
2' Min.
3' Min.
4' Min.
5' Min.
6' Min.
7' Min.
H
1' Max.
2' Max.
2' Max.
2' Max.
3 Max.
4' Max.
5' Max.
6' Max.
V + V1
1' Min.
3' Min.
5' Min.
7' Min.
9' Min.
10' Min.
11' Min.
12' Min.
H + H1
2' Max.
3' Max.
4' Max.
5' Max.
6' Max.
7' Max.
8' Max.
9' Max.
With these options,
max. total pipe length
is 30 feet with min. of
12 feet total vertical
and max. 9 feet total
horizontal.
Please note min. 1
foot between 90o
elbows is required.
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
INSTALLATION
Vertical Venting with Two (2) 90o Elbows
One 90o elbow = Two 45o elbows.
Option
A)
B)
C)
D)
E)
F)
V
0' Min.
1' Min.
2' Min.
3' Min.
4' Min.
5' Min.
H
2' Max.
4' Max.
5' Max.
6' Max.
7' Max.
8' Max.
V + V1
1' Min.
2' Min.
3' Min.
4' Min.
5' Min.
6' Min.
With these options, max. total
pipe length is 30 feet with min.
of 6 feet total vertical and max.
8 feet total horizontal.
Please note min. 1 foot
between 90 o elbows is
required.
For additional vertical venting with 2
x 90o elbows, refer to next page.
Vertical Venting with Three (3) 90o Elbows
One 90o elbow = Two 45o elbows.
Option
A)
B)
C)
D)
E)
F)
G)
H)
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
V
0' Min.
1' Min.
2' Min.
3' Min.
4' Min.
5' Min.
6' Min.
7' Min.
H + H1
2' Max.
2' Max.
3' Max.
4' Max.
5' Max.
6' Max.
7' Max.
8' Max.
V + V1
3' Min.
3' Min.
4' Min.
6' Min.
7' Min.
8' Min.
9' Min.
10' Min.
With these options, max.
total pipe length is 30 feet
with min. of 10 feet total
vertical and max. 8 feet
total horizontal.
Please note min. 1 foot
between 90o elbows is
required.
17
INSTALLATION
VENTING ARRANGEMENTS - VERTICAL TERMINATIONS
SIMPSON DURA-VENT DIRECT VENT GS SYSTEM
(Propane & Natural Gas)
The shaded area in the diagram shows all allowable combinations of straight vertical and offset to vertical terminations, using two 90o elbow, with
Simpson Dura-Vent Direct Vent GS vent systems for Propane and Natural Gas.
•
•
•
Vent must be supported at offsets.
Firestops are required at each floor level and whenever passing through a wall.
Maintain clearances to combustibles.
Note: Must use optional flue adapter when using Simpson Dura-Vent pipe (Part # 770-994).
18
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
INSTALLATION
The P95-3 is approved for a maximum 40 ft. straight vertical, with Simpson
Dura-Vent Direct Vent GS vent systems for Propane and Natural Gas, as
per the diagram.
The shaded area in the diagram shows all allowable combinations of straight
vertical and offset to vertical terminations with Simpson Dura-Vent Direct
Vent GS vent systems for Propane and Natural Gas. Maximum two 45o
elbows allowed.
•
•
•
Vent must be supported at offsets
Firestops are required at each floor level and whenever passing
through a wall.
Maintain clearances to combustibles as listed in the "Clearances,"
"Locating Your Gas Fireplace," "Combustible Mantels," "Unit Base
Stand-offs," "Framing and Finishing," "Facing Requirement," & "Hearth
Requirement" sections.
Please note that all vertical
measurements are taken from
the base of the unit excluding
risers or bottom stand-offs.
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
19
INSTALLATION
UNIT INSTALLATION
WITH HORIZONTAL
TERMINATION
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.
b) Horizontal runs of vent must be
supported every three feet. Wall straps
are available for this purpose.
5) Mark the wall for a 11" x 11" square hole.
The center of the square hole should line
up with the centerline of the horizontal pipe.
Cut and frame the 10 inch square hole in
the exterior wall where the vent will be
terminated. If the wall being penetrated is
constructed of non-combustible material, i.e.
masonry block or concrete, a 8" dia. hole is
acceptable.
Note: With Dura-Vent, the minimum height is
achieved by installing a 90o elbow directly to
the flue adaptor.
2) Direct Vent pipe and fittings are designed
with special twist-lock connections to
connect the venting system to the appliance
flue outlet. A twist-lock appliance adaptor
is an available option that must be used in
conjunction with the Simpson Dura-Vent
Direct Vent GS system.
Diagram 3
*Diagam 3 & 4: As specified in CGA B149
Installation Code. Local codes or regulations
may require different clearances.
Below Grade Installation
3) Put a bead of silicone inside the outer
section of the adapter and a bead of Mill
Pac on the inner collar. Slip the adapter
over the existing inner and outer flue collar
and fasten to the outer collar only with the
3 supplied screws (drilling pilot holes will
make this easier). Level the fireplace and
fasten it to the framing using nails or screws
through the nailing strips.
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
fittings, are designed to slide straight
onto the male ends of adjacent pipes
and fittings, by orienting the four pipe
indentations so they match and slide
in to the four entry slots on the male
ends, Diagram 1. Push the pipe sections
completely together, then twist-lock
one section clockwise approximately
one-quarter turn, until the two sections
are fully locked. The female locking lugs
will not be visible from the outside, on
the Black Pipe or fittings. They may be
located by examining the inside of the
female ends.
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.
Diagram 2
Note:
a) The horizontal run of vent must be level,
or have a 1/4 inch rise for every 1 foot
of run towards the termination. Never
allow the vent to run downward. This
could cause high temperatures and may
present the possibility of a fire.
b) The location of the horizontal vent
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 from the "Exterion Vent
Termination Locations" section.
c) Snorkel Terminations:
For installations requiring a vertical rise
on the exterior of the building, 14-inch
and 36-inch tall Snorkel Terminations are
available. Follow the same installation
procedures as used for standard
Horizontal Termination. NEVER install
the snorkel upside down.
Diagram 4
NOTE: For Snorkel terminations in ABOVE
grade installations, follow national
or local code requirements.
Diagram 1
Note: Apply sealant "Mill-Pac" to inner
pipe and high temperature silicone
sealant to outer pipe on every twistlock joint.
20
6) The arrow on the vent cap should
be pointing up. Insure that the 1-1/2"
clearances to combustible materials
are maintained (Diagram 4). Install the
termination cap.
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
INSTALLATION
VERTICAL
TERMINATION
Diagram 5
The four wood screws provided should
be replaced with appropriate fasteners for
stucco, brick, concrete, or other types of
sidings.
Note: If installing termination on a siding
covered wall, a vinyl siding standoff
or furring strips must be used to
ensure that the termination is not
recessed into the siding.
7) Before connecting the horizontal run of vent
pipe to the vent termination, slide the Wall
Thimble (Part # 1247) over the vent pipe.
8) Slide the appliance and vent assembly
towards the wall carefully inserting the
vent pipe into the vent cap assembly. It is
important that the vent pipe extends into
the vent cap sufficient distance so as to
result in a minimum pipe overlap of 1-1/4
inches. Secure the connection between the
vent pipe and the vent cap by attaching the
two sheet metal strips extending from the
vent cap assembly into the outer wall of the
vent pipe. Use the two sheet metal screws
provided to connect the strips to the pipe
section. See Diagram 6.
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 "Venting Arrangements
- Vertical Temination" section
for the maximum vertical rise
of the venting system and the
maximum horizontal offset
limitations.
2) Set the gas appliance in
its desired location. Drop a
Diagram 1
plumb bob down from the
ceiling to the position of the
appliance flue exit, and mark the location
where the vent will penetrate the ceiling. Drill
a small hole at his point. Next, drop a plumb
bob from the roof to the hole previously drilled
in the ceiling, and mark the spot where the
vent will penetrate the roof. Determine if
ceiling joists, roof rafters or other framing will
obstruct the venting system.
You may wish
to relocate the
appliance or to
offset, as shown
in Diagram 2
to avoid cutting
load bearing
members.
4) Assemble the desired lengths of pipe and
elbows. Ensure that all pipes and elbow
connections are in the fully twist-locked
position and sealed.
5) Cut a hole in the roof centered on the small
drilled hole placed in the roof in Step 2. The
hole should be of sufficient size to meet
the minimum requirements for clearance
to combustibles of 1-1/2". Slip the flashing
under the shingles (shingles should overlap
half the flashing) as per Diagram 4.
Diagram 4: The upper half of the flashing is
installed under the roofing material and not
nailed down until the chimney is installed. This
allows for small adjustments.
6) Continue to assemble pipe lengths.
Note: If an offset is necessary in the attic
to avoid obstructions, it is important
to support the vent pipe every 3 feet,
to avoid excessive stress on the
elbows, and possible separation. Wall
straps are available for this purpose
(Diagram 2).
Galvanized pipe is desirable above the roofline
due to its higher corrosion resistance. Continue
to add pipe sections through the flashing until
the height of the vent cap meets the minimum
height requirements specified in Diagram 5 or
local codes. Note that for steep roof pitches,
Diagram 2
Note: Apply sealant "Mill-Pac" to inner
pipe and high temperature silicone
sealant to outer pipe on every twistlock joint.
3) A Firestop spacer must be installed in the
floor or ceiling of every level. To install the
Firestop spacer in a flat ceiling or wall,
cut a 11 inch square hole. Frame the hole
as shown in Diagram 3 and install the
firestop.
Diagram 6
9) Install wall thimble
in the center of
the 11" square
and attach with
wood screws
(Diagram 7).
Diagram 7
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
Diagram 3
Diagram 5
Roof Pitch
flat to 7/12
over 7/12 to 8/12
over 8/12 to 9/12
over 9/12 to 10/12
over 10/12 to 11/12
over 11/12 to 12/12
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
Minimum Vent Height
Feet
Meters
2
0.61
2
0.61
2
0.61
2.5
0.76
3.25
0.99
4
1.22
5
1.52
6
1.83
7
2.13
7.5
2.29
8
2.44
21
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 flashing to the roof with roofing rails,
slide storm collar over the pipe section and
seal with a mastic.
8) Install the vertical termination cap by twistlocking it.
Note: Any closets or storage spaces, which
the vent passes through must be
enclosed.
Offset Chart
GS 8" Nominal Diameter ID
Offset
5-11/16"
8-13/16"
10-15/16"
13"
21-7/16"
29-13/16"
38-1/4"
Pipe Length
0"
6"
9"
12"
24"
36"
48"
Height
15-5/16"
15-7/16"
20-9/16"
22-11/16"
31-1/16"
37-7/16"
47-7/8"
N o t e : To m a k e
the installation
more aesthetically
pleasing,
we
recommend framing
out a square to mount
the terminal to.
Note: If installing termination on a siding
covered wall, furring strips must be
used to ensure that the termination
is not recessed into the siding.
2) Level the fireplace and fasten it to the framing
using nails or screws through the nailing
strips.
3) Assemble the vent assembly by applying
Mill Pac to the 5"(127mm) inner collar of the
termination and slipping the 5"(127mm) liner
over it at least 1-3/8" (35mm). Fasten with
the 3 screws (drilling pilot holes will make this
easier). Apply Mill Pac or high temperature
silicone to the 8"(203mm) flex pipe and slip
it over the 8"(203mm) outer collar of the vent
terminal at least 1-3/8"(35mm) and fasten
with the 3 screws.
NOTE:
INSTALLATION
PROCEDURES
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".
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).
5) Slip the assembled liner and termination
assembly through the thimble making sure
the termination cap faces up (there are
markings on the cap that show which way
is up). This will position the termination cap
with proper down slope for draining water.
Fasten the cap to the outer wall with the 4
supplied screws.
6) Pull the centre 5"(127mm) liner and outer
8"(203mm) liner out enough to slip over
the flue collars of the fireplace. (You may
wish to cut the liner shorter to make it more
workable.) Do not bend liner more than
90o.
7) Apply Mill Pac over the fireplace inner collar
and slip the 5"(127mm) liner down over it
and attach with 3 supplied screws.
8) Do the same with the 8"(203mm) liner.
9) Apply a bead of silicone between the 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.
for FPI Direct Vent
System (Flex)
1) Locate the unit in the framing, rough in the
gas (preferably on the right side of the unit)
and the electrical (Junction block is on the
left side) on the left. Locate the centerline of
the termination and mark wall accordingly.
Cut a 11"(279mm) hole in the wall (inside
dimension).
Note: A 3-1/2"(76mm) clearance around
the liner must be maintained except
that only a 1" (25mm) clearance is
needed at the termination end. We
recommend framing a 11"(279mm) x
11"(279mm) (inside dimensions) hole
to give structural rigidity for mounting
the termination.
22
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
INSTALLATION
P95-NG3 System Data
For 0 to 4500 feet altitude
Burner Inlet Orifice Sizes:
#30
Max. Input Rating
Min. Input Rating
45,000 Btu/h
23,200 Btu/h
Supply Pressure
min.5.0" w.c.
Manifold Pressure
(High)
3.8"+/- 0.2"w.c.
For USA installations follow local codes and/or
the current National Fuel Gas Code, ANSI
Z223.1.
The manifold pressure is controlled by a regulator
built into the gas control, and should be checked
at the pressure test point.
When using copper or flex connectors use only
approved fittings. Always provide a union so
that gas lines can be easily disconnected for
servicing. Flare nuts for copper lines and flex
connectors are usually considered to meet this
requirement.
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 flame for leak testing.
P95-LP3 System Data
For 0 to 4500 feet altitude
Burner Inlet Orifice Sizes:
#49
Max. Input Rating 40,000 Btu/h
Min. Input Rating 22,400 Btu/h
Supply Pressure
min.12.0" w.c.
Manifold Pressure
(High)
11"+/- 0.2" w.c.
Electrical: 120 V A.C. System.
Circulation Fan: variable speed 200 CFM.
Log Set: Ceramic fibre, 7 per set.
Vent System: Simpson Dura-Vent Direct
Vent System or FPI Flex System.
PILOT ADJUSTMENT
Periodically check the pilot flames. Correct
flame pattern has three strong blue flames:
1 flowing around the thermopile, 1 around
the thermocouple and 1 flowing across the
burner (it does not have to be touching the
burner).
Note: If you have an incorrect flame pattern,
contact your Excalibur® dealer for
further instructions.
Incorrect flame pattern will have small,
probably yellow flames, not coming into
proper contact with the rear burner or
thermopile or thermocouple.
1) Make sure the valve is in the "OFF"
position.
2) Loosen the "IN" and/or "OUT" pressure
tap(s), turning counter clockwise with a
1/8" wide flat screwdriver.
3) Attach manometer to "IN" and/or "OUT"
pressure tap(s) using a 5/16" ID hose.
4) Light the pilot and turn the valve to "ON"
position.
5) The pressure check should be carried out
with the unit burning and the setting should
be within the limits specified on the safety
label.
6) When finished reading manometer, turn
off the gas valve, disconnect the hose and
tighten the screw (clockwise) with a 1/8" flat
screwdriver. Note: Screw should be snug,
but do not over tighten.
S.I.T. VALVE DESCRIPTION
1)
2)
3)
4)
5)
6)
7)
8)
9)
HIGH ELEVATION
This unit is approved in Canada for altitude
0 to 4500 ft. (CAN1 2.17-M91) & U.S.A ANSI
ZZ1.88a
Gas on/off knob
Manual high/low adjustment
Pilot Adjustment
Thermocouple Connection - option
Outlet Pressure Tap
Inlet Pressure Tap
Pilot Outlet
Main Gas Outlet
Alternative TC Connection
Point
GAS LINE
INSTALLATION
The gas line is brought in through the left side
of the appliance. The gas valve is situated on
the right hand side of the unit and the gas inlet
is on the right hand side of the valve.
Note: When the gas line is being installed
from the left side, be sure to leave
room to accommodate servicing of
the fan.
The gas line connection may be made of rigid
pipe, copper pipe or an approved flex connector.
(If you are using rigid pipe, ensure that the valve
can be removed for servicing.) Since some
municipalities have additional local codes it is
always best to consult with your local authorities
and the CAN/CGA B149 installation code.
GAS PIPE PRESSURE
TESTING
The appliance must be isolated from the gas
supply piping system by closing its individual
manual shut-off valve during any pressure
testing of the gas supply piping system at test
pressures equal to or less than 1/2 psig. (3.45
kPa). Disconnect piping from valve at pressures
over 1/2 psig.
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
23
INSTALLATION
CONVERSION KIT# 773-969 FROM NG TO LP
FOR P95-3 USING SIT 820 NOVA GAS VALVE
THIS CONVERSION MUST BE DONE BY A QUALIFIED GAS FITTER
IF IN DOUBT DO NOT DO THIS CONVERSION !!
8)
Each Kit contains one LPG
Conversion Kit and one DC
Sparker Kit.
LPG Conversion Kit Contains:
Qty.
Part #
Description
1
904-431
Burner Orifice #49
1
918-590
Label "Converted to
LPG"
1
908-528
Red "LPG" label
1
908-529
5/32" Allen Key
1
910-037
LP Injector (Pilot Orifice)
1
918-486
Instruction Sheet
DC Sparker Kit Contains:
Qty.
Part #
Description
1
820-475
Bracket DC Sparker
1
820-476
Bracket DC Sparker
1
904-153
Washer #8 External Star
1
904-330
Nut 8-32 Hex
1
904-438
Plug Nylon 0.750 Hole,
Black
1
904-531
Bushing Split Plastic
0.500 in.
1
904-543
Screw 8-32 x 3/4 Pan
Head
2
904-553
Screw #8 x 1/2 Type "B",
Black Oxide
1
910-073
Spark Generator Battery
Holder
1
910-074
Spark Generator Switch
C/W Wire
1
910-078
Battery Size AA
Energizer En91
2
910-199
Clip Wire Holder
1
910-903
Wire Fan To Power Cord
Ground 30 in.
904-781
Velcro Hook, Black
904-782
Velcro Hook, Black
Installation of LPG
Conversion Kit:
1)
Turn the gas off.
2)
Turn control knob to the “OFF” position.
3)
Remove the glass frame.
4)
Remove the logs, embers, and brick panels
(if used).
5)
Remove the burner/grate assembly, first
by removing the two screws, one on each
side of the grate, then pull out the grate.
24
Remove
screw
Unscrew the pilot orifice with the allen key
and replace with the LP pilot orifice in the
kit and replace pilot cap.
Allen Key
9)
6)
Remove the 2 screws, one on each side
of the burner. Slide the burner to the left
and then lift out.
Remove burner orifice with a 1/2" wrench
and discard. Use another wrench to hold
on to the elbow behind the orifice.
Burner
Orifice
Remove screw
10) Reinstall new burner orifice LP stamped
#49 and tighten.
Slide the burner to
the left and lift out.
7)
11) Remove the black protection cap by
hand from the high-low knob (Fig.1).
Pull off the pilot cap to expose the pilot
orifice.
Fig. 1
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
INSTALLATION
12) Insert a 5/32” or 4mm Allen wrench into
the hexagonal key-way of the screw
(Fig. 2), rotate it counter-clockwise until
it is free and extract it.
WARNING!
Do not overtighten the screw.
Recommended to
grip the wrench by the short side.
Installation of the DC Sparker:
15) Locate the Piezo Ignitor situated at the side
of valve.
Piezo
Ignitor
16) 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
16) Remove the Piezo Ignitor by unscrewing the
nut at the back of the mounting bracket.
Ignitor
Wire
Fig.2
Fig.5
13) Check that the screw is clean and if
necessary remove dirt.
14) Flip the screw (Fig. 3).
17) Re-assemble the black protection cap
(Fig. 6).
Piezo
Ignitor
17) Disconnect the ignitor wire from the Piezo
Ignitor and connect it to the DC Sparker.
DC
Sparker
Ignitor
Wire
Fig.3
15) Using the Allen wrench as shown in
Fig.4, rotate the screw clockwise until
snug, do not overtighten.
Fig. 6
18) Install the 3/4" nylon plug to cover up the
hole on the mounting bracket.
WARNING!
Also check that the pilot and main
burner injectors
are appropriate for the gas type.
12) Reverse steps 6) to 1).
13) Attach the label "This unit has been
converted to LPG near or on top of the
serial # decal.
14) Replace yellow "Natural Gas" label with
red "LPG" label.
Fig.4
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
25
INSTALLATION
19) Connect the DC spark generator wires
to the SIT Valve with the screw, which is
provided in the kit.
23) Run the other end of the ground wire and
DC spark generator wires through the
bushing on the heat shield.
27) Mount the heat shield to the DC Sparker.
Secure into place with the velcro, which is
provided in the kit.
Heat Shield
20) Locate the ground lug at the receptical box,
left of the unit.
24) Plug the DC spark generator wires to the
DC Sparker.
28) Find a location which is not too hot and
is easy to reach for changing the battery.
29) Tie up the loose wire with the wire clip.
21) Connect one end of the supplied green
ground wire to the lug with the nut and
washer from the kit.
25) Connect the ground wire to the DC Sparker
mounting bracket.
Ground
wire from
kit
30) Check inlet and outlet pressures.
22) Install the 1/2" bushing to the heat
shield.
26) Install the supplied battery into the DC
Sparker Box by opening the battery
compartment.
31) Check operation of flame control.
32) Check for proper flame appearance and
glow on logs.
NOTE: The battery in the DC Sparker Box
will need to be replaced annually.
Battery
Compartment
26
Installer Notice:
These instructions must be
left with the appliance.
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
INSTALLATION
OPTIONAL
BRICK PANELS
LOG SET
INSTALLATION
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.
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.
4) Place Log 312 on the front right side of the
burner, fitting the log on the 2 pins.
312
2) Remove facade.
3) Remove glass door. Remove logs.
Note: The logs must not be in the unit.
4) Insert the back brick panel first by carefully
slipping it between the back wall of the
firebox and the rear log bracket.
Log Kit # 770-930 contains the following
pieces:
a)
b)
c)
d)
e)
f)
g)
h)
i)
306
307
308
309
310
311
312
Rear Log
Middle Left Log
Center Right Log
Middle Right Log
Front Left Log
Center Left Log
Front Bottom Log
Embers
Vermiculite
5) Position Log 311 across the notch in Log
306 and rest the bottom of the log into the
2nd grate tab.
902-154
902-179
5) Put the side panels in next. Slide them in
from the front and push them flat up against
the wall. Be very careful not to scratch them
on the firebox hardware.
311
306
306
307
Notch
309
2nd Grate Tab
311
308
6) Install the 2 brick retaining clips, one on
each side.
310
6) Position Log 308 across the log landing in
Log 311. Rest the bottom of the log against
the 5th grate tab.
312
The 3-digit numbers (ie. 312) are
molded into the rear of each log.
311
308
NOTE: If you will be installing the optional
Brick Panels, install the Brick Panels
prior to installing the logs.
1) Carefully remove the logs from the box and
unwrap them. The logs are fragile, handle
with care - do not force into position.
2) Sprinkle the vermiculite all over the top of
the base brick panel.
5th Grate Tab
7) Fit the bottom of Log 307 into the bracket
on the left side of the burner.
3) Place Log 306 on the rear log support pins
with the flat side to the back.
307
306
Note: If the bottom brick panel must be removed:
Remove the Rear Log Stand, then remove
the Burner Tray. See the instructions in the
"Removing Valve" section.
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
Pins on the rear log support.
Bracket
27
INSTALLATION
8) Place the top of Log 307 across the notch
on Log 311.
11) Fit Log 310 on the pin and then swing the
front end of the log to hit the first grate
12) Place the embers on the front of the burner
tray.
306
311
307
310
311
Place embers on the burner tray.
DO NOT BLOCK BURNER HOLES
Notch
13) Test fire to ensure proper light off (make
sure flame flows smoothly from one end of
burner to the other). If there is any flame
hesitation, check that area for any blockage
of the burner ports.
Pin
9) Place the back of Log 309 against the bracket
on the top right side of the burner.
The picture below is a view from the back
of the burner.
14) Reverse steps 1-3 under the "Optional Brick
Panels" section.
309
Rest log against
bracket
306
Rear Log
307
Middle Left Log
309
Middle Right Log
10) Place the top of Log 309 on Log 308,
supported by the knot.
309
308
Knot
310
Front Left Log
28
311
Center Left Log
312
Front Bottom Log
308
Center Right Log
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
INSTALLATION
GLASS DOOR
INSTALLATION
3) Mount the 2 screws back onto the mounting
plate on the rear of the facade through the
tab on the glass frame and then tighten
screw to secure.
OPTIONAL
SCREEN DOORS
1) Attach door bracket to side using 2 screws
to the left and right side of the unit.
1) Fit top door bracket over the flange at the
top of the firebox.
2) Secure with 3 screws on the bottom.
Door Bracket
attaches with
2 screws.
Flange
Tighten both screws to secure Front
Facade to Glass Door.
2) Slide the door(s) onto the hinges.
Tab
Screw
Door
FRONT FACADE
1) Remove the 2 screws from the mounting
plate that are on the back of the facade.
View from underneath of the
screw and the bracket.
4) Slide Bottom Louver into position. On each
side secure the bottom screw first into the
side bracket. Do not overtighten, leave
slightly loose to allow the louver to move
freely.
Adjusting the Plunger: Loosen the screw
that holds that plunger bracket so that you can
remove the plunger.
Remove screws from the mounting tabs.
2) Place the Front Facade into position by
sliding the 2 holes in the bottom brackets
over the pins on the base, one on each
side.
Secure
Screw
Loosen the
screw holding
the bracket.
5) Attach the two control boxes to the bottom
unit base and tighten the 2 screws on the
left side and 1 screw on the right side.
Once the plunger has been removed take a pin
and put it in the hole that is in the round part of
the plunger and adjust it accordingly by turning
it to the left or right.
Bracket
Pin
Adjust plunger by
turning it to the left
or right with a pin.
Fit the bottom brackets over
the pins on the base.
Secure left side with 2 screws and right
side with one screw.
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
29
INSTALLATION
ACCENT KIT INSTALLATION
SINGLE DOOR ACCENTS
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.
4) Place the emblem over the emblem design on the surround. Insert
the studs through the holes. To secure them first put on the split lock
washer and then the nut and tighten.
5) Remove the 2 studs on the sides of the Hood. Insert the new studs
through the holes and secure them by first putting on the washer and
then tighten with a nut.
2) Take the hoseclamps and put them over the back of each rivet.
Squeeze the hoseclamp to secure onto rivets ensuring that the
hoseclamp is touching the back side of the surround. The hoseclamp
can now be released.
3) Remove the handles by removing the nut and screw. Install the
new handles by placing them in position over the holes on the
surround louver. Put the screws through the holes and secure
them by tightening them with a nut.
DOUBLE DOOR ACCENTS
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.
30
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
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
inlet opening. Be careful not to damage
wire.
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.
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.
1) Choose a convenient location on the wall
to install the receiver and the receptacle
box (protection from extreme heat is very
important). Run wires from the fireplace
to that location. Use the Thermostat Wire
Table.
2) Connect the two wires to the gas valve. See
diagram below.
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.
Thermostat Wire Table
Recommended Maximum Lead Length
(Two-Wire) When Using Wall
Thermostat (CP-2 System)
Wire Size
CAUTION
Do not connect millivolt
remote control wires to a
120V wire.
14 GA.
16 GA.
18 GA.
20 GA.
22 GA.
Max. Length
50 Ft.
32 Ft.
20 Ft.
12 Ft.
9 Ft.
3) Install 3 AAA alkaline batteries in transmitter
and 4 AA alkaline batteries in the receiver.
Install the receiver and its cover in the wall.
Switch the remote receiver to "remote"
mode. The remote control is now ready for
operation.
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
31
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.
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.
(Do not cut the ground terminal off under
any circumstances.)
Electrode
Thermocouple
Gas Pilot
Star
Lockwasher
washer
#8 Ground Lug
(for mobile home)
Thermopile
For NATURAL GAS Units and Units NOT Equipped with DC Spark Boxes
Fan B
Neutral
120V AC
60 Hz
Live
Green
Ground
ON
OFF
Black
Pilot
Assembly
Nut
(To THTP)
L
Brown
White
(To TH)
O
OFF
To Thermocouple IN
PILO
T
Red
Black
I
T-Stat
Red
Piezo
Ignitor
H
Burner ON
OFF
Thermostat
Red
Fan Thermodisc
(normally open)
Rotary Speed
Control
ON
Power cord
Fan
ground wire
ground wire
Fan A
Ground
Gas
In
"S.I.T" Valve
White
Regency
ON OFF
Remote Receiver
or Thermostat
(Millivolt) (Optional)
Caution: Ensure that the wires do
not touch any hot surfaces and are
away from sharp edges.
32
Remote Transmitter
(Optional)
CAUTION:
Label all wires
prior to disconnection when
servicing controls. Wiring
errors can cause improper and
dangerous operation.
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
INSTALLATION
For PROPANE Units and Units Equipped with DC Spark Boxes*
*For installation of the DC Spark Box refer to the LP Conversion instructions in this manual.
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
33
OPERATING INSTRUCTIONS
OPERATING
INSTRUCTIONS
1) Read and understand these instructions
before operating this appliance.
2) Check to see that all wiring is correct and
enclosed to prevent possible shock.
3) Check to ensure there are no gas leaks.
4) Make sure the glass in the door frame is
properly positioned. Never operate the
appliance with the glass removed.
5) Verify that the venting and cap are
unobstructed.
6) Ensure that the brick panels are installed.
7) Verify log placement. If the pilot cannot be
seen when lighting the unit, the logs have
been incorrectly positioned.
8) The unit should never be turned off, and on
again without a minimum of a 60 second
wait.
1) Turn burner OFF using "ON/OFF" switch.
2) Turn gas control knob so indicator points
to "OFF" position and allow 5 minutes for
any gas in the combustion chamber to
escape.
3) Turn gas control knob counter clockwise
so indicator points to the "PILOT" position.
Depress the gas control knob fully. Depress
the igniter button several times until the
pilot lights. After approximately one minute,
release the gas control knob. The pilot flame
should continue to burn. If the pilot does not
remain lit, repeat operation allowing a longer
period before releasing gas control knob.
4) When the pilot stays lit, turn the gas knob
further counter clockwise to the "ON"
position.
5) Use the wall switch, thermostat or remote
control to turn on the unit.
6) Rotate the flame height regulator to adjust
the flame height higher or lower.
SHUTDOWN
PROCEDURE
IMPORTANT
To ignite or reignite the pilot,
remove one glass panel/door.
NOTE: For all propane units and units
equipped with electric spark boxes,
see "Copy of Lighting Plate Instructions" section for more details.
Only when the pilot holds, without pressure
being applied to the control knob, resecure
the glass panel to the unit. The unit must not
be operated with the glass removed.
IMPORTANT Gas on/off knob cannot be
turned from "PILOT" to "OFF" unless it is
partially depressed.
34
During the first few fires, a white film
may develop on the glass front as part
of the curing process. The glass should
be cleaned or the film will bake on and
become very difficult to remove. Use a
non-abrasive cleaner and NEVER clean
the glass while it is hot.
AERATION
ADJUSTMENT
The air shutter can be adjusted by moving the
adjusting wire up or down. The wire is accessed
through the bottom louver opening. Open the
air shutter for a blue flame or close for a more
yellow flame. The burner aeration is factory
set but may need adjusting due to either the
local gas supply or altitude. This adjustment is
performed by the gas fitter.
Minimum Air Shutter Opening:
5/16"
Natural Gas
3/8"
Propane
1) Use the wall switch, thermostat or remote
control to turn off the main burner.
CAUTION: Carbon will be produced if air shutter
is closed too much.
2) Turn the main gas control clockwise to the
"OFF" position to turn off the pilot.
Note: Any damage due to carboning
resulting from improperly setting
the aeration controls is NOT covered
under warranty.
3) Turn off all electric power to appliance if
service is to be performed.
LIGHTING
PROCEDURE
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
FIRST FIRE
The first fire in your fireplace is part of the paint
curing process. To ensure that the paint is
properly cured, it is recommended that you burn
your fireplace for at least four (4) hours the first
time before you use it with the fan on.
When first operated, the unit will release an odour
caused by the curing of the paint, the burning
off of any oils remaining from manufacturing.
Smoke detectors in the house may go off at
this time. Open a few windows to ventilate the
room for a couple of hours.
The glass panel may require cleaning after the
unit has cooled down.
DO NOT ATTEMPT TO CLEAN THE
GLASS WHILE IT IS HOT.
Adjustment Wire: Push to close or
pull to open aeration cap.
Closed - Tall yellow
Open - Short Blue
Note: Aeration Adjustment should only
be performed by an authorized
Excalibur® Installer at the time of
installation or service.
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
OPERATING INSTRUCTIONS
Copy of the Lighting Plate Instructions
NORMAL OPERATING
SOUNDS OF GAS
APPLIANCES
It is possible that you will hear some sounds
from your gas appliance. This is perfectly normal
due to the fact that there are various gauges
and types of steel used within your appliance.
Listed below are some examples. All are normal
operating sounds and should not be considered
as defects in your appliance.
Blower:
Excalibur® gas appliances use high tech blowers
to push heated air farther into the room. It is not
unusual for the fan to make a "whirring" sound
when ON. This sound will increase or decrease
in volume depending on the speed setting of
your fan speed control.
Burner Tray:
The burner tray is positioned directly under the
burner tube(s) and logs and is made of a different
gauge material from the rest of the firebox and
body. Therefore, the varying thicknesses of steel
will expand and contract at slightly different
rates which can cause "ticking" and "cracking"
sounds. You should also be aware that as there
are temperature changes within the unit these
sounds will likely re-occur. Again, this is normal
for steel fireboxes.
Blower Thermodisc:
When this thermally activated switch turns ON
it will create a small "clicking" sound. This is the
switch contacts closing and is normal.
OFF
Gas Inlet
Pilot Flame:
While the pilot flame is on it can make a very
slight "whisper" sound.
Gas Control Valve:
As the gas control valve turns ON and OFF, a
dull clicking sound may be audible, this is normal
operation of a gas regulator or valve.
Unit Body/Firebox:
Different types and thicknesses of steel will
expand and contract at different rates resulting
in some "cracking" and "ticking" sounds will be
heard throughout the cycling process.
Gas Inlet
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
35
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 fireplace glass cleaner.
The glass should be cleaned when it
starts looking cloudy.
3) The heater is finished in a heat resistant
paint and should only be refinished with heat
resistant paint. Excalibur® uses StoveBright
Paint - Metallic Black #6309.
4) Make a periodic check of burner for proper
position and condition. Visually check the
flame of the burner periodically, making sure
the flames are steady; not lifting or floating.
If there is a problem, call a qualified service
person.
5) The appliance and venting system must be
inspected before use, and at least annually,
by a qualified field service person, to ensure
that the flow of combustion and ventilation
air is not obstructed.
Note: Never operate the appliance without
the glass properly secured in place.
6) Do not use this appliance if any part has been
under water. Immediately call a qualified
service technician to inspect the appliance
and to replace any part of the control system
and any gas control which has been under
water.
7) In the event this appliance has been
serviced check that the vent-air system
has been properly resealed & reinstalled
in accordance with the manufacturer's
instructions.
8) Verify operation after servicing.
General Vent Maintenance
Conduct an inspection of the venting system
semi-annually. Recommended areas to inspect
as follows:
1) Check the Venting System for corrosion in
areas that are exposed to the elements.
These will appear as rust spots or
streaks, and in extreme cases, holes.
These components should be replaced
immediately.
36
2) Remove the Cap, and shine a flashlight
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.
5) Reinstall the new ones in reverse order.
3) Check for evidences of excessive
condensation, such as water droplets forming
in the inner liner, and subsequently dripping
out the joints, Continuous condensation can
cause corrosion of caps, pipe, and fittings.
It may be caused by having excessive
lateral runs, too many elbows, and exterior
portions of the system being exposed to cold
weather.
4) Inspect joints, to verify that no pipe
sections or fittings have been disturbed,
and consequently loosened. Also check
mechanical supports such as Wall Straps,
or plumbers' tape for rigidity.
GOLD-PLATED DOOR
Or SURROUND
The 24 carat gold-plated finish on the surround
and door requires little maintenance, and need
only be cleaned with a damp cloth.
DO NOT use abrasive materials or chemical
cleaners, as they may harm the finish and void
the warranty. Clean any fingerprints off before
turning the unit on.
LOG REPLACEMENT
The unit should never be used with broken logs.
Turn off the gas valve and allow the unit to cool
before opening door and carefully remove the
logs. (The pilot light generates enough heat to
burn someone.) If for any reason a log should
need replacement, you must use the proper
replacement log. The position of these logs
must be as shown in the diagrams under Log
Installation.
GLASS GASKET
If the glass gasket requires replacement use a
tadpole glass gasket (Part # 936-155).
DOOR GLASS
Your Excalibur® fireplace is supplied with high
temperature, 5 mm Neoceram ceramic glass that
will withstand the highest heat that your unit will
produce. If your glass requires cleaning, we
recommend using an approved glass cleaner
available at all authorized dealers. Do not use
abrasive materials. Do not clean the glass
when hot.
In the event that you break your glass by impact,
purchase your replacement from an authorized
Excalibur® dealer only, and follow our step-bystep instructions for replacement.
WARNING: Do not operate the
appliance with the glass panels
removed, cracked or broken.
Replacement of the glass panels
should be done by a licensed or
qualified service person.
Caution: Wear gloves when removing
damaged or broken glass.
Glass Replacement
Remove the glass door front. 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.
Note: Improperpositioningoflogsmaycreate
carbon build-up and will severely alter
the unit's performance which is not
covered under warranty.
THERMOPILE /
THERMOCOUPLE
1) Open the bottom louvers.
2) Loosen the thermocouple or thermopile with
a 7/16" wrench.
3) Disconnect thermocouple by loosening
nut from the valve with a 9mm wrench.
Disconnect thermopile by loosening 2 screws
marked TP on the valve.
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
MAINTENANCE
FAN MAINTENANCE
Ensure that the fan blades do not rub against
the valve tubing. See diagram 1.
Unit must be grounded at all times. Do
not cut the ground terminal off under any
circumstances.
To Install the Fans
1) Shut the power off.
2) Open the bottom louver. Loosen the 2
screws holding the Burner ON/OFF switch
and bracket to the bottom louver and lift the
assembly out.
3) Remove the bottom louver by loosening the
2 hinge screws.
IMPORTANT: There are 2 fans in this fireplace.
Fan A (the right side fan) and Fan B (the
left side fan) are linked by a wire harness.
Please do not remove the wire harness when
installing the fans.
Diagram 1
4) Move both fans and the wire harness
together to the front of the fireplace.
5)
Insert Fan A in from the left sideways (see
diagram below). The easiest way to insert
Fan A is to put Fan B in front of the louver
opening. This ensures that there is sufficient
length of wire between the 2 fans.
9) Connect the fan ground wire of Fan B and
the power cord ground wire to the grounding
lug. Refer to the wiring diagram.
10)
Slide the thermodisc/cover assembly
into the bracket clip on the underside of the
firebox. Check that no wire will touch the hot
surfaces. Diagram 2.
12) Secure the fan wires and power cord by
attaching one of the adhesive backed
wire holder clips (Part #910-199) onto
the fireplace base. Use the second clip
to bundle up the wires approximately 4"
from the control box. Ensure that there is
no interference with the wires when the
louver is closed and that no wire will touch
the hot metal surfaces, fan blades or sharp
edges.
13) Plug the fan power cord into the rear end of
the receptacle box to provide the maximum
clearance from the louvers.
To Remove the Fans
Slide Fan A in sideways
from the left.
1) Shut the power off.
2) Reverse the installation instructions.
6) Take Fan A to the back above the mounting
studs. Then flip the fan and position it onto
the mounting studs.
7) Connect the ground wire from Fan A to the
Grounding Lug located on the left hand
side. See diagram 1.
Diagram 2
11) Attach the two control boxes to the bottom
unit base and tighten the 2 screws on the
left side and 1 screw on the right side.
8) Insert Fan B in from the front and position
it on top of the mounting studs on the left
side.
Position Fan B on
mounting studs.
Note: The bearings are lubricated for life. Do
not lubricate them. Make sure you vacuum
the fan area on a regular basis.
IMPORTANT:
These fans collect a lot of dust from within
your home. Ensure you maintain these fan
motors on a regular basis by vacuuming
out the fan blades and housing using a soft
brush nozzle.
Secure left side with 2 screws and right
side with one screw.
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
37
MAINTENANCE
REMOVING VALVE
1) Shut the power off.
2) Open the bottom louver door. Loosen the 2
screws holding the Burner ON/OFF switch
and bracket to the bottom louver and lift the
assembly out.
9) Remove the front bottom brick panel by
sliding it out. Then remove the back bottom
brick panel by tilting it slightly up and then out.
The brick panel is very fragile - handle
with care.
Hint:
If you are using black pipe, ensure
that there is a union by the valve,
otherwise removal will be almost
impossible.
INSTALLING VALVE
3) Remove the facade if installed.
1) Attach the valve to the valve bracket with
the 4 (m5x8 metric) screws provided.
4) Remove the glass door.
5) Remove the logs.
6) Remove the burner/grate assembly, first by
removing the 2 screws, 1 on each side of
the grill, then lift out the grill.
10) Disconnect the inlet gas line. See dia. 2.
2) Reconnect the "gas out" flare fitting with an
11/16" wrench.
11) Disconnect the 2 TP wires and the 2 TH
wires from the valve.
3) Reconnect the "gas out" flare nut with a
13/16" wrench.
12) Remove the 12 screws securing the valve
tray assembly in place and then lift the entire
assembly out.
4) Install piezo ignitor push button assembly
and reconnect wire.
5) Reconnect the quick drop out thermocouple
nut with a 9mm wrench.
6) Reconnect the pilot tube nut with a 7/16"
wrench.
7) Scrape off the old gasket from the floor of the
firebox and from the valve tray assembly.
Remove screw
8) Install a new gasket and reinstall the valve
tray assembly.
7) Remove the 2 screws, 1 on each side of the
burner. Slide the burner to the left and then
lift out.
Valve Tray Assembly
Note: Failure to install a new gasket may
severely affect the appliance performance.
9) Reinstall the 10 hold down screws.
10) Hook up the 2 TP and 2 TH wires to the
appropriate connections on the valve.
Remove screw
Slide the
burner to
the left
and lift
out.
11) Reinstall the bottom brick panel, then screw
the 2 screws & sleeves through the brick
panel to the firebox base (reversing step 8)
leaving them about 1/4" (6mm) above the
brick panel. Reinstall the rear log stand.
12) Install Burner/grate assembly
13) Undo the pilot tube from the valve with a
7/16" wrench.
8) Remove the rear log stand by removing the
2 screws.
Rear Log Stand
14) Undo the quick drop out thermocouple nut
on the valve with a 9mm (metric) wrench.
15) Remove the Piezo igniter wire and push
button assembly.
16) Undo the "gas out" flare nut with a 13/16"
wrench.
17) Undo the "gas out" flare fitting with an
11/16" wrench.
18) Remove the 4 Phillips head screws from
the sides of the valve bracket and remove
valve.
38
13) Hook up the gas line and check for gas
leaks with a soap and water solution or a
gas leak detector. (Do not use open flame
for leak testing.)
14) Fire up the unit temporarily
15) Check the manifold pressure.
16) Reinstall the logs and brick panels as
needed.
17) Reinstall the glass door and the facade.
18) Fire up the unit again and check for proper
flame appearance and glow on logs.
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
PARTS LIST
P95-3 MAIN ASSEMBLY
Part #
1)
2)
7)
8)
9)
10)
22)
430-129
*
910-428
910-429
910-430
904-687
770-033
Description
Receptacle Box Mount
Thermodisc Bracket
Duplex Receptacle
Box - Receptacle
Cover - Receptacle
Clamp Connector
Baffle Guide
23) 780-011
25) 770-074
Standoff - Top
Standoff
26)
27)
28)
29)
30)
Sealing Plate
Outer Flue Collar
Inner Flue Collar Assy
Flue Mounting Bracket
Gasket for Flue Collar
770-128
*
*
*
*
773-528
31) *
32) *
770-901
770-902
770-903
770-904
33)
34)
35)
36)
*
*
*
904-716
511-031
Brick Panel Base (set of 3)
Brick Panel - Base Rear
Brick Panel - Base Front
Brick Panel Set - Standard
Brown
Brick Panel Set
- Standard Red
Brick Panel Set
- Herringbone Brown
Brick Panel Set
- Herringbone Red
Brick Panel - Back
Brick Panel - Left
Brick Panel - Right
#10 x 5/8" Butt Spacer
Brick Panel Clip
Part #
432-967
38) 910-241
910-899
Description
Burner ON/OFF Switch Assy
Burner ON/OFF - Switch
Wire Harness - Valve to
Burner
42) 430-517/P Fan Assembly (120 Volts)
910-331/P Fan Motor (120 Volts)
43)
46)
47)
48)
49)
770-523
Fan Switch Assembly
910-813
910-330
904-586
910-199
910-142
910-878
Power Cord (120 Volts)
Fan Speed Control Switch
Knob - Speed Control
Wire Holder Clip
Thermodisc-Fan Auto On/Off
Wire Harness - Twin Fan
Cable
50) 770-994
Dura-Vent Adaptor (Optional)
60)
61)
62)
63)
64)
65)
80)
W260260
942-117
W260280
770-066
*
*
*
Top Relief Frame Gasket
Top Relief Plate Frame
Top Relief Plate Gasket
Top Relief Plate
Hex Cap Screw 1/4 20NC 3.5
Hex Cap Screw 1/4 20NC 2.0
Hex Cap Screw 1/4 20NC 1.75
89)
90)
91)
92)
93)
946-556
946-004
946-000
946-002
946-001
946-007
Heat Wave Duct Kit (Optional)
Junction Box
Round Duct Adaptor
Round to Oval Adaptor
Oval Duct Adaptor
Angle Bracket
Part #
Description
94) 946-517/P Fan Assy - HeatWave Option
95) 946-006 Grill Plate - White
96) 946-005/01 Wall Adaptor Plate - White
97) 910-417 Knob - White
98) 910-366 Switch Cover Plate - White
99) 910-412 Fan Speed Controller
100) 910-367 Box-Plastic Switch
Receptacle
101) 690-022 Cover Plate
102) 946-010 Flexible Air Duct
946-045 Insulation 6" dia. x 60"
946-570
108) 910-165
109) 946-000
918-526
773-969
Heat Release Duct Kit (Opt.)
Fan (120 V)
Flexible Air Release Duct
Manual
Conversion Kit - NG to LP
*Not available as a replacement part.
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
39
PARTS LIST
40
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
PARTS LIST
P95-3 BURNER ASSEMBLY & LOG SET
Part #
Description
52) 910-190
54) 948-043
Piezo Ignitor & Nut
Bottom Relief Spring
770-574/P
770-576/P
56) 770-071
57) 910-478
Valve Assy - Natural Gas
Valve Assy - Propane
Gasket - Valve Tray
Valve - S.I.T. - NG/LP
58) *
66) 910-038
910-039
904-660
904-431
936-170
67) 780-057
68) W840470
Valve Bracket
Pilot Assy 3 way flame - S.I.T. - NG
Pilot Assy 3 way flame - S.I.T. - LP
Orifice #30 - Natural Gas
Orifice #49 - Propane
Orifice Gasket
Pilot Holder
Pilot Assembly Gasket
69) 770-070
79) 770-525
82) 770-003
83) *
85) 770-930
Gasket - Relief Door Bottom
Burner Assy - NG/LP
Burner Grate Assy
Rear Log Support Bracket
Log Set
*Not available as a replacement part.
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
41
PARTS LIST
P95-3 FLUSH FRONT ACCESSORIES
Part #
771-518
132) *
135) 940-328/P
136) 936-155
904-691
141)
142)
145)
146)
148)
157)
Description
Part #
Description
790-082/10
790-082/02
155) 904-735
157) 904-722
904-722/02
904-722/10
Door Assembly - Complete
Flush Door Frame
Glass (Flush)
Glass Gasket (Tadpole)
U-Clip
770-920
770-922
770-914
770-916
770-918
Surround - Black - Complete
Surround - Polished Gold - Complete
Surround - Antique Gold - Complete
Surround - Antique Nickel - Complete
Surround - Antique Copper - Complete
*
*
*
*
*
*
948-221
Surround - Faceplate - Excalibur®
Surround - Louver
Surround - Hood
Handle
Rivet-67-5/16 x 1/2
Carriage Bolt
Logo Plate
770-931
770-933
770-941
770-942
770-943
Double Screen Door - Complete - Black
Double Screen Door - Complete - Polished Gold
Double Screen Door - Complete - Antique Gold
Double Screen Door - Complete - Antique Nickel
Double Screen Door - Complete - Antique Copper
*
*
*
*
*
*
790-105
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
Handle - Black
Handle - Nickel
Handle - Gold
Push-Fit Ball Plunger
Carriage Bolt - Black
Carriage Bolt - Gold
Carriage Bolt - Nickel
*Not available as a replacement part.
136
161)
162)
163)
164)
167)
168)
146)
135
132
FLUSH DOOR
145
164
141
163
155
164
148
168
163
162
157
148
155
146
161
DOUBLE DOORS
167
148
155
146
142
146
157
42
148
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
WARRANTY
Excalibur® Fireplace Products are designed with reliability and simplicity in mind. In addition, our internal Quality Assurance Team carefully inspects
each unit thoroughly before it leaves our facility. FPI Fireplace Products International Ltd. is pleased to extend this limited lifetime warranty to
the original purchaser of a Excalibur® Product.
THE WARRANTY: LIMITED LIFETIME
The combustion chamber, heat exchanger, burner tubes/pans, logs, embers and all gold plating (against defective manufacture only) are covered under the
Limited Lifetime Warranty for five (5) years for parts and subsidized labour* and parts only thereafter.
Glass is covered for lifetime against thermal breakage only, parts and subsidized labour* for three (3) years and parts only thereafter from date of
purchase.
Electrical and mechanical components such as blowers, switches, wiring, thermodiscs, FPI remote controls, spill switches, thermopiles, thermocouples, pilot
assembly components, and gas valves are covered for one year parts and subsidized labour* from the date of purchase. Blowers and valves replaced under
warranty are considered repairs and continue as if new with appliance. ie. twelve (12) months from original purchase date of appliance with a minimum of
three (3) months coverage from date of replacement.
FPI venting components are covered parts and subsidized labour* for three (3) years from date of installation and parts only thereafter.
Conditions:
Any part or parts of this unit which in our judgement show evidence of such defects will be repaired or replaced at FPI's option, through an accredited distributor
or agent provided that the defective part be returned to the distributor or agent Transportation Prepaid, if requested.
It is the general practice of FPI to charge for larger, higher priced replacement parts and issue credit once the replaced component has been returned to FPI
and evaluated for manufacturer defect.
The authorized selling dealer is responsible for all in-field service work carried out on your Excalibur® product. FPI will not be liable for results or costs of
workmanship from unauthorized service persons or dealers.
At all times FPI reserves the right to inspect product in the field which is claimed to be defective.
All claims must be submitted to FPI by authorized selling dealers. It is essential that all submitted claims provide all of the necessary information including
customer name, purchase date, serial #, type of unit, problem, and part or parts requested, without this information the warranty will be invalid.
Exclusions:
This limited Lifetime Warranty does not extend to or include paint, door or glass gasketing or trim.
At no time will FPI be liable for any consequential damages which exceed the purchase price of the unit. FPI has no obligation to enhance or modify any unit
once manufactured. ie. as products evolve, field modifications or upgrades will not be performed.
FPI will not be liable for travel costs for service work.
Installation and environmental problems are not the responsibility of the manufacturer and therefore are not covered under the terms of this warranty
policy.
Refractory liners, gaskets, door handles, paint are not covered under the terms of this warranty policy.
Any unit which shows signs of neglect or misuse is not covered under the terms of this warranty policy.
The warranty will not extend to any part which has been tampered with or altered in any way, or in our judgment has been subject to misuse, improper
installation, negligence or accident, spillage or downdrafts caused by environmental or geographical conditions, inadequate ventilation, excessive offsets,
negative air pressure caused by mechanical systems such as furnaces, fans, clothes dryer, etc.
Freight damage to stoves and replacement parts is not covered by warranty and is subject to a claim against the freight carrier by the dealer.
FPI will not be liable for acts of God, or acts of terrorism, which cause malfunction of the appliance.
Performance problems due to operator error will not be covered by this warranty policy.
Products made or provided by other manufacturers and used in conjunction with the operation of this appliance without prior authorization from Excalibur®,
may nullify your warranty on this product.
Simpson Dura-Vent venting components are covered by Simpson Dura-Vent Inc. warranty.
Excalibur® P95-3 Zero Clearance Direct Vent Gas Fireplace
43
Excalibur® fireplace products are designed with
reliability and simplicity in mind. In addition, our
internal Quality Assurance Team carefully inspects
each unit thoroughly before it leaves our door.
FPI Fireplace Products International Ltd. is pleased to
extend this Limited Lifetime Warranty to the original
purchaser of a Excalibur® Product.
See the inside back cover for details.
Register your Excalibur® online at
http://www.excalibur-fire.com
Installer: Please complete the following information
Dealer Name & Address: ______________________________________________
___________________________________________________________________
Installer: ___________________________________________________________
Phone #: ___________________________________________________________
Date Installed: ______________________________________________________
Serial No.: __________________________________________________________
Excalibur® is a trademark of FPI Fireplace Products International Ltd.
© Copyright 2006, FPI Fireplace Products International Ltd. All rights reserved.
Printed in Canada
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