P90 Zero Clearance Direct Vent Gas Fireplace Owners & Installation Manual www.excalibur-fire.com MODELS: P90-NG1 Natural Gas P90-LP1 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.
To the New Owner: Congratulations! You are the owner of a state-of-the-art Excalibur® Gas Fireplace by FPI FIREPLACE PRODUCTS INTERNATIONAL LTD. The P90 is a hand crafted appliance and has been designed to provide you with all the warmth and charm of a wood fireplace at the flick of a switch. The model P90 has been approved by Warnock Hersey for both safety and efficiency. As it also bears our own mark, it promises to provide you with economy, comfort and security for many trouble free years to follow.
INFORMATION FOR MOBILE/MANUFACTURED HOMES AFTER FIRST SALE This Excalibur® product has been tested and listed by Warnock Hersey as a Direct Vent Wall Furnace to the following standards: VENTED GAS FIREPLACE HEATERS ANSI Z21.88a-2007/CSA 2.33a-2007 and GAS-FIRED APPLIANCES FOR USE AT HIGH ALTITUDES CAN/CGA 2.17M91.
TABLE OF CONTENTS DIMENSIONS Copy of Safety Decal .....................................................6 Glass Door Installation ................................................39 Arch surround ..............................................................39 Optional Screen Door .................................................39 Accent Kit Installation ..................................................40 Optional Remote Control .............................................41 OptionalWall Switch .........
DIMENSIONS B A C H D F I G Unit Dimensions Description A Front Firebox Width E P90 42” (1067mm) B Rear Firebox Width 31” (787mm) C Front Firebox Height 38” (965mm) D Height w/ Standoff E Unit Depth 19-1/4” (489mm) F Height to Vent 40-1/4” (1022mm) G Faceplate Width H Faceplate Height (center) 29-1/4” (743mm) I Faceplate Height (edge) 24” (610mm) Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace 45” (1143mm) 37” (940mm) 5
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. 6 P90-NG1 Model/Modele: 12" WC (3.00 kPa) 11" WC (2.74 kPa) 2.9" WC (0.
REQUIREMENTS MA Code - CO Detector (for the State of Massachusetts only) 5.08: Modifications to NFPA-54, Chapter 10 (2) Revise 10.8.
INSTALLATION IMPORTANT MESSAGE SAVE THESE INSTRUCTIONS The P90-NG1 or P90-LP1 Direct Vent Fireplace must be installed in accordance with these instructions. Carefully read all the instructions in this manual 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.
INSTALLATION GENERAL SAFETY INFORMATION INSTALLATION CHECKLIST 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. 1) Locate appliance, refer to the following sections: 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.
INSTALLATION 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. 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.
INSTALLATION COMBUSTIBLE MANTELS Because of the extreme heat this fireplace emits, the mantel clearances are critical. Combustible mantel clearances from top of unit are shown in Diagram below. FRAMING AND FINISHING 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.
INSTALLATION 4) Note: The unit does not have to be completely enclosed in a chase. The clearance on top of the unit is 0" to the standoffs so combustible building materials can be laid directly on top of the standoffs. You must maintain clearance from the vent to combustible materials for both rigid and flex, see the "Clearances" section. Facing Over 1" (25mm) Thick If the facing material is over 1" (25mm) thick (example: brick or river rock), install the facing around the perimeter of the face.
INSTALLATION OPTIONAL COVER PLATE TEMPLATE UNIT ASSEMBLY PRIOR TO INSTALLATION 1) Ensure top clip screws are at top of oblong holes before installation. The 2 Top Standoffs must be correctly positioned and attached to the top before unit is slipped into position. Oblong Screw Holes Top Standoff Assembly The top standoffs are shipped in a flat position and must be folded into shape and attached. 1) Remove the standoffs from the fireplace top. 2) Take each standoff and bend into the correct shape.
INSTALLATION VENTING FPI Direct Vent System (Flex) Horizontal Terminations Only These venting systems, in combination with the P90 Direct Vent Gas Fireplace, have been tested and listed as a direct vent heater system by Warnock Hersey. The location of the termination cap must conform to the requirements in the Vent Terminal Locations diagram in the "Exterior Vent Termination Locations" section.
INSTALLATION EXTERIOR VENT TERMINATION LOCATIONS Minimum Clearance Requirements Canada1 USA2 A Clearance above grade, veranda, porch, deck, or balcony 12"(30cm) 12"(30cm) B Clearance to window or door that may be opened 12"(30cm) 9" (23cm) C Clearance to permanently closed window * * D Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 feet (61cm) from the center line of the terminal (check with the local code) 18"(46cm) 18"(46cm) E Clea
INSTALLATION 4” X 6-5/8” RIGID PIPE CROSS REFERENCE CHART Components from different Manufacturers may not be mixed. Not All Rigid Pipe components are available directly from FPI. 4 X 6 5/8 RIGID PIPE CROSS REFERENCE CHART Components from different Manufacturers may not be mixed. Not all rigid pipe components are available directly from Regency.
INSTALLATION INSTALLATION Description Simpson Selkirk Direct Vent Pro® Direct Temp™ American Metal Products® Metal-Fab™ Security ICC Excel Sure Seal Secure- Vent® Direct Amerivent Direct Attic Insulation Shield 12” 46DVA-IS N/A@ FPI N/A 4DAIS12 N/A SV4RSA N/A Attic Insulation Shield - Cold Climates 36” N/A N/A 4DAIS12 N/A N/A TM-4AS Basic Horizontal Termination Kit (A) Disc.
INSTALLATION INSTALLATION 5” X 8” RIGID PIPE CROSS REFERENCE CHART Components from different Manufacturers may not be mixed. Not All Rigid Pipe components are available directly from FPI. 5” X 8” RIGID PIPE CROSS REFERENCE CHART Components from different Manufacturers may not be mixed. Not all rigid pipe components are available directly from Regency.
INSTALLATION Description Simpson Selkirk Metal-Fab™ ICC Excel Direct Vent Pro® Direct Temp™ Sure Seal Direct Attic Insulation Shield 12” 58DVA-IS N/A from FPI N/A N/A N/A Basic Horizontal Termination Kit (A) N/A 5DT-HKA N/A N/A Horizontal Termination Kit (B) 58DVA-KHA 5DT-HKB N/A N/A Vertical Termination Kit 58DVA-VHA 5DT-VKC N/A N/A High Wind Vertical Cap 58DVA-VCH N/A N/A TM-5VT High Wind Horizontal Cap N/A N/A N/A TM-5DHT Horizontal Square Termination Cap N/A 5DT
INSTALLATION RIGID PIPE VENTING SYSTEMS The minimum components required for a basic horizontal termination are: 1 1 1 1 1 1 Flat Wall Installation Horizontal Termination Cap 90o Elbow Rigid Pipe Adaptor Wall Thimble Length of pipe to suit wall thickness (see chart) 4" x 6-5/8" to 5" x 8" increaser for 5" x 8" venting 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.
INSTALLATION Horizontal & Vertical Terminations for 5" x 8" Venting Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace 21
INSTALLATION RIGID PIPE VENTING ARRANGEMENTS - HORIZONTAL TERMINATIONS FPI DIRECT VENT SYSTEM (FLEX) (Propane & Natural Gas) The diagram shows all allowable combinations of vertical runs with horizontal terminations, using one 90o elbow (two 45o elbows equal one 90o elbow).
INSTALLATION RIGID PIPE VENTING ARRANGEMENTS - VERTICAL TERMINATIONS The shaded area in the diagram shows all allowable combinations of straight vertical and offset to vertical terminations, using two 90o elbow, with rigid pipe vent systems for Propane and Natural Gas. • • • The P90 is approved for a maximum 40 ft. straight vertical, with rigid pipe 4" x 6-5/8" vent systems for Propane and Natural Gas, as per diagram.
INSTALLATION Horizontal Venting with Two (2) 90o Elbows Must Use: 5" x 8" Simpson Direct Vent Piping with FPI Increaser Starter Collar (Part #946-605). One 90o elbow = Two 45o elbows. Option A) B) C) D) E) F) G) V 6" 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.
INSTALLATION Vertical Venting with Two (2) 90o Elbows Must Use: 5" x 8" Simpson Direct Vent Piping with FPI Increaser Starter Collar (Part #946-605), unless V1 is greater than or equal to 4'-6" then use 4" x 6-5/8" piping. One 90o elbow = Two 45o elbows. Option 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.
INSTALLATION HORIZONTAL TERMINATIONS Install the vent system according to the manufacturer's instructions included with the components. 1) Set the unit in its desired location. Check to determine if wall studs or roof rafters are in the way when the venting system is attached. If this is the case, you may want to adjust the location of the unit. Rough in the gas preferably on the right side of the unit and the electrical (junction block is on the left side) on the left.
INSTALLATION VERTICAL TERMINATIONS Diagram 5 The four wood screws provided should be replaced with appropriate fasteners for stucco, brick, concrete, or other types of sidings. Note: If installing termination on a siding covered wall, a vinyl siding standoff or furring strips must be used to ensure that the termination is not recessed into the siding. 7) Before connecting the horizontal run of vent pipe to the vent termination, slide the Wall Thimble (Part # 620-926) over the vent pipe.
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.
INSTALLATION P90-NG1 System Data For 0 to 4500 feet altitude Burner Inlet Orifice Sizes: #34 Max. Input Rating Min. Input Rating 35,000 Btu/h 18,200 Btu/h Supply Pressure min.5.0" w.c. 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.
INSTALLATION CONVERSION KIT #791-969 FROM NG TO LP THIS CONVERSION MUST BE DONE BY A QUALIFIED GAS FITTER IF IN DOUBT DO NOT DO THIS CONVERSION !! 4) Each Kit contains one LPG Conversion Kit and one DC Sparker Kit. 9) Turn control knob to the “OFF” position. 10) Remove the black protection cap by hand from the high-low knob (Fig.1). LPG Conversion Kit Contains: Qty.
INSTALLATION 14) Using the Allen wrench as shown in Fig.4, rotate the screw clockwise until snug, do not overtighten. 17) Reverse steps 4) to 2). 4) Attach the DC sparker generator connector to the valve with a screw. 5) Remove the stove’s rear panel by unscrewing the two screws. 6) Attach the ground wire to the grounding stud. 18) Attach clear label "This unit has been converted to LPG" near or on top of the serial # decal. 19) Replace yellow "Natural Gas" label with red "LPG" label.
INSTALLATION 7) Attach the Piezo ignition wire to the DC Sparker. 11) Attach the DC sparker generator wires to the DC sparker. Piezo Ignitor Installation of the DC Sparker for the P90 Units Only: 1) Locate the Piezo Ignitor situated at the side of valve. Piezo Ignitor 12) Install the supplied battery into the DC Sparker Box by opening the battery compartment. 8) Insert both the ground wire and the DC sparker generator wire through the hole of the DC spark heat shield.
INSTALLATION 5) Locate the ground lug at the receptical box, left of the unit. 9) Plug the DC spark generator wires to the DC Sparker. 12) Mount the heat shield to the DC Sparker. Secure into place with the velcro, which is provided in the kit. 13) Find a location which is not too hot and is easy to reach for changing the battery. 6) Connect one end of the supplied green ground wire to the lug with the nut and washer from the kit. 10) Connect the ground wire to the DC Sparker mounting bracket.
INSTALLATION OPTIONAL BRICK PANELS 1) Open the bottom louver door. Loosen the 2 screws holding the Burner ON/OFF switch and bracket to the bottom louver and lift the assembly out. 6) Install the 2 brick retaining clips, one on each side. 2) Remove Arch Surround. 3) Remove glass door. Remove logs. Note: The logs must not be in the unit. 4) Insert the back brick panel first by carefully slipping it between the back wall of the firebox and the rear log bracket. 5) Put the side panels in next.
INSTALLATION LOG SET INSTALLATION Read the instructions below carefully and refer to the diagrams. If logs are broken do not use the unit until they are replaced. Broken logs can interfere with the pilot operation. 3) Place the Log 02-75 on the rear log support pins with the flat side to the back.
INSTALLATION 5) Position Log 02-53 across the cutouts in Logs 02-75 and 02-51 with the notch on the left side of the log fitting into the 2nd grate tab. 02-53 02-75 5th Grate Tab 02-51 7) Place the bottom left front edge of Log 02-55 against the rear bracket on the burner tray and rest the log on the cutout on Log 02-53. Cutouts 2nd Grate Tab 02-51 02-53 02-75 02-55 6) 02-53 Position Log 02-54 across the cutouts in Logs 02-51 and 02-53.
INSTALLATION 8) Place Log 02-52 between Logs 02-51 and 02-75 and on the indentation on Log 02-54. The bottom right end sits behind the rear grate tab. 9) Sit Log 02-50 on the front left side of the burner. Push the back of the log against the 2 front brackets with the notch on the bottom of the log fitting into the first grate tab. 02-50 02-53 02-52 02-51 02-54 Front Brackets Log Indentation 02-55 02-53 Notch 02-50 02-52 02-54 Rear Grate Tab Photo shows rear grate tab.
INSTALLATION 10) Place the embers on the front of the burner tray in the places shown on the photos below. 02-51 02-54 Separate platinum embers and place on the front burner on and around the embers. Avoid stacking platinum embers. Platinum embers may be placed over burner ports. Do not block the burner ports in this area adjacent to the Log 02-54 IMPORTANT When placing Embers, do not block burner ports as this can cause an incorrect flame pattern, carbon deposits and delayed ignition.
INSTALLATION GLASS DOOR INSTALLATION OPTIONAL SCREEN DOOR 1) Attach door bracket to side using 2 screws. 1) Fit top door bracket over the flange at the top of the firebox. 2) Secure with 2 screws on the bottom. Tighten both screws to secure Arch Surround to Glass Door. 3) Slide Bottom Louver into position. On each side secure the bottom screw first into the side bracket. Do not overtighten, leave slightly loose to allow the louver to move freely. Then tighten the top screw.
INSTALLATION ACCENT KIT INSTALLATION 1) Remove the rivets from the surround by pulling out the hoseclamp with a screwdriver or plyer. Re-install the rivets by putting them through the holes on the sides of the surround. 5) Remove the 2 studs on the sides of the Hood. Insert the new studs through the holes and secure them by first putting on the washer and then tighten with a nut. DOUBLE & SINGLE DOOR OPTION 2) Take the hoseclamps and put them over the back of each rivet.
INSTALLATION Option 1: REMOTE CONTROL Option 2: WALL SWITCH Option 3: WALL THERMOSTAT Use the Excalibur® Remote Control Kit approved for this unit. Use of other systems may void your warranty. 1) Run the wire through the right or left side gas inlet opening. Be careful not to damage wire. A wall thermostat may be installed if desired, connect the wires as per the wiring diagram. Use the table below to determine the maximum wire length.
INSTALLATION WIRING DIAGRAMS This heater does not require a 120V A.C. supply for operation. In case of a power failure, the burner switch and the optional remote control/ thermostat will continue to operate. However, a 120V A.C. power supply is needed for the fan/blower operation. (Do not cut the ground terminal off under any circumstances.
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.
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.
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.
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.
MAINTENANCE FAN MAINTENANCE To Remove the Fan Unit must be grounded at all times. Do not cut the ground terminal off under any circumstances. 1) Shut the power off. 2) Reverse the above instructions. To Install the Fan Note: The bearings are lubricated for life. Do not lubricate them. Make sure you vacuum the fan area on a regular basis. 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.
MAINTENANCE REMOVING VALVE Hint: 1) Shut the power off. 2) Open the bottom louver door. Loosen the 2 screws holding the Burner ON/OFF switch and bracket to the bottom louver and lift the assembly out. 3) Remove the facade if installed. 4) Remove the glass door (Refer to the "Glass Door Installation" section). 5) Remove the logs. If you are using black pipe, ensure that there is a union by the valve, otherwise removal will be almost impossible. INSTALLING VALVE 9) Disconnect the inlet gas line. See dia.
PARTS LIST PARTS LIST MAIN ASSEMBLY Part # 1) 2) 7) 8) 9) 10) 430-129 * 910-428 910-429 910-430 904-687 Description Receptacle Box Mount Thermodisc Bracket Duplex Receptacle Box - Receptacle Cover - Receptacle Clamp Connector 15) * 20) 790-021 21) 790-022 Heat Shield - Base Front Filler - Left Corner Front Filler - Right Corner 22) 23) 24) 25) 790-012 780-011 780-013 780-091 Baffle Standoff - Top Standoff - Side Standoff - Rear 27) 28) 30) 31) * * * * Outer Flue Collar Inner Flue Collar Assy Gas
PARTS LIST 89 HEAT WAVE DUCT KIT 93 94 93 95 92 91 96 50 102 100 31 99 30 97 98 64 90 28 63 30 62 25 23 27 61 25 23 60 59 51 20 61 24 109 61 64 64 22 10 1 108 15 8 7 24 21 HEAT RELEASE DUCT KIT 9 36 2 36 34 32 48 33 BRICK PANELS 49 43 38 ON-OFF SWITCH ASSEMBLY 35 47 42 FAN SWITCH ASSEMBLY 50 Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace
PARTS LIST BURNER ASSEMBLY & LOG SET Part # Description 52) 910-190 53) 780-021 Piezo Ignitor & Nut Gasket - Valve Access Plate 790-574/P 790-576/P 56) * 57) 910-478 58) * 65) * 66) 910-038 910-039 904-617 904-645 936-170 67) * 68) W840470 Valve Assy - Natural Gas Valve Assy - Propane Valve Tray - NG/LP Valve - S.I.T. - NG/LPG Valve Bracket Pilot Bracket Pilot Assy-NG 3 way flame - S.I.T. Pilot Assy-LP 3 way flame - S.I.T.
PARTS LIST FLUSH FRONT ACCESSORIES Part # Description 790-518 132) 790-137 135) 940-326/P 136) 936-155 904-691 141) 142) 143) 144) 145) 146) 148) 149) Part # Door Assembly - Complete Flush Door Frame Glass (Flush) Glass Gasket (Tadpole) U-Clip 790-920 790-922 790-914 790-916 790-918 * * 904-621 790-122 * * 904-719 904-719/G 904-720 161) 162) 163) 164) 167) 168) Surround - Black - Complete Surround - Gold - Complete Surround - Antique Gold - Complete Surround - Antique Nickel - Complete Surround - An
NOTES Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace 53
NOTES 54 Excalibur® P90 Zero Clearance Direct Vent Gas Fireplace
WARRANTY WARRANTY Excalibur Fireplace Products are designed with reliability and simplicity in mind. In addition, our internal Quality Assurance Team carefully inspects each unit thoroughly before it leaves our facility. FPI Fireplace Products International Ltd. is pleased to extend this limited lifetime warranty to the original purchaser of a Excalibur Product. This warranty is not transferable.
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.