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P90 Zero Clearance Direct Vent Gas Fireplace
WARNING:
If the information in these instructions are not followed exactly,
a fi re or explosion may result causing property damage,
personal injury or loss of life.
FOR YOUR SAFETY
Do not store or use gasoline or other fl ammable vapours and
liquids in the vicinity of this or any other appliance.
Installation and service must be performed by a qualifi ed
installer, service agency or the gas supplier.
Tested by:
918-525a
FPI FIREPLACE PRODUCTS INTERNATIONAL LTD. 6988 Venture St., Delta, BC Canada, V4G 1H4
www.excalibur-fi re.com
MODELS:
P90-NG1 Natural Gas
Installer: Please complete the details on the back cover
and leave this manual with the homeowner.
Homeowner: Please keep these instructions for future reference.
Installation Manual
P90-LP1 Propane
FOR YOUR SAFETY
What to do if you smell gas:
Do not try to light any appliance
Do not touch any electrical switch:
do not use any phone in your
building.
Immediately call your gas supplier
from a neighbour's phone. Follow
the gas supplier's instructions.
If you cannot reach your gas
supplier, call the fi re department.
Owners &
03/06/08
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Summary of Contents for Excalibur P90-NG1
- Page 1 FPI FIREPLACE PRODUCTS INTERNATIONAL LTD. 6988 Venture St., Delta, BC Canada, V4G 1H4 www.excalibur-fi re.com MODELS: P90-NG1 Natural Gas Installer: Please complete the details on the back cover and leave this manual with the homeowner. Homeowner: Please keep these instructions for future reference.
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Page 2: Information For Mobile/Manufactured Homes After First Sale
Congratulations! You are the owner of a state-of-the-art Excalibur INTERNATIONAL LTD. The P90 is a hand crafted appliance and has been designed to provide you with all the warmth and charm of a wood fi replace at the fl ick of a switch. The model P90 has been approved by Warnock Hersey for both safety and effi... -
Page 3: Table Of Contents
SAFETY LABEL Copy of P90 Safety Decal ...4 REQUIREMENTS MA Code - CO Detector ...5 INSTALLATION 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 Heatwave Duct System Optional Kit ...7 Clearances ...7 Combustible Mantels ...8... -
Page 4: Safety Label
SAFETY LABEL This is a copy of the label that accompanies each P90 Zero Clearance Direct Vent Gas Fireplace. We have printed a copy of the contents here for your review. The safety label is located on the front inside base of the unit, visible when the bottom louver is open. -
Page 5: Requirements
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:... -
Page 6: Installation
INSTALLATION IMPORTANT MESSAGE SAVE THESE INSTRUCTIONS The P90-NG1 or P90-LP1 Direct Vent Fireplace must be installed in accordance with these instructions. Carefully read all the instructions in this manual fi rst. Consult the "authority having jurisdiction" to determine the need for a permit prior to starting the installation. -
Page 7: Locating Your Gas Fireplace
LOCATING YOUR GAS FIREPLACE 1) When selecting a location for your fi replace, ensure that the clearances outlined on this page are met. 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. -
Page 8: Combustible Mantels
INSTALLATION COMBUSTIBLE MANTELS Because of the extreme heat this fi replace emits, the mantel clearances are critical. Combustible mantel clearances from top of unit are shown in Diagram below. Note: A non-combustible mantel may be installed at a lower height if the framing is made of metal studs covered with a non-combustible board. -
Page 9: Facing Requirement
4) Note: The unit does not have to be completely enclosed in a chase. The clearance on top of the unit is 0" to the standoffs so combustible building materials can be laid directly on top of the standoffs. You must maintain clearance from the vent to combustible m a t e r i a l s f o r b o t h... -
Page 10: Optional Cover Plate Template
INSTALLATION OPTIONAL COVER PLATE TEMPLATE 1) Ensure top clip screws are at top of oblong holes before installation. Oblong Screw Holes 2) Position bottom of cover plate over pins located at the bottom of the fi rebox. Pins 3) Bring cover plate towards the unit and hook top clip over and behind the glass frame. -
Page 11: Venting
FPI Direct Vent System (Flex) Horizontal Terminations Only These venting systems, in combination with the P90 Direct Vent Gas Fireplace, have been tested and listed as a direct vent heater system by Warnock Hersey. The location of the termination cap must conform to the requirements in the Vent Terminal Locations diagram in the "Exterior Vent Termination Locations"... -
Page 12: Exterior Vent Termination Locations
INSTALLATION EXTERIOR VENT TERMINATION LOCATIONS ® Excalibur P90 Zero Clearance Direct Vent Gas Fireplace... -
Page 13: 4" X 6-5/8" Rigid Pipe Cross Reference Chart
4” X 6-5/8” RIGID PIPE CROSS REFERENCE CHART Components from different Manufacturers may not be mixed. Not All Rigid Pipe components are available directly from FPI. Description 6” Pipe Length, Galvanized 6” Pipe Length, Black 7” Pipe Length, Galvanized 7” Pipe Length, Black 9”... - Page 14 INSTALLATION 4” x 6-5/8” Rigid Pipe Cross Reference Chart (Cont.) Components from different Manufacturers may not be mixed. Not All Rigid Pipe components are available directly from FPI. Description Attic Insulation Shield 12” Attic Insulation Shield - 36” Cold Climates Basic Horizontal Termination Kit (A) Horizontal Termination Kit (B) Vertical Termination Kit...
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Page 15: 5" X 8" Rigid Pipe Cross Reference Chart
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. Description 6” Pipe Length, Galvanized 6” Pipe Length, Black 9” Pipe Length, Galvanized 9” Pipe Length, Black 12”... - Page 16 INSTALLATION 5” x 8” Rigid Pipe Cross Reference Chart (Cont.) Components from different Manufacturers may not be mixed. Not All Rigid Pipe components are available directly from FPI. Description Round Support / Radiation Sheild Flat Flashing Attic Insulation Shield 12” Basic Horizontal Termination Kit (A) Horizontal Termination Kit (B) Vertical Termination Kit...
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Page 17: Rigid Pipe Venting Systems
RIGID PIPE VENTING SYSTEMS The minimum components required for a basic horizontal termination are: Horizontal Termination Cap 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 is measured from the back standoffs to the inside mounting surface of termination cap. - Page 18 INSTALLATION Horizontal & Vertical Terminations for 5" x 8" Venting ® Excalibur P90 Zero Clearance Direct Vent Gas Fireplace...
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Page 19: Rigid Pipe Venting Arrangements - Horizontal Terminations
RIGID PIPE VENTING ARRANGEMENTS - HORIZONTAL TERMINATIONS The diagram shows all allowable combinations of vertical runs with horizontal terminations, using one 90 elbow). All Rigid Pipe Systems 4" inner diameter 6-5/8" outer diameter FPI Flex Vent 4" inner diameter 6-7/8" outer diameter Note: Must use optional rigid pipe adaptor (Part # 510- 994) when using Rigid Pipe. -
Page 20: Rigid Pipe Venting Arrangements - Vertical Terminations
INSTALLATION RIGID PIPE VENTING ARRANGEMENTS - VERTICAL TERMINATIONS The shaded area in the diagram shows all allowable combinations of straight vertical and offset to vertical terminations, using two 90 rigid pipe vent systems for Propane and Natural Gas. • Vent must be supported at offsets. •... - Page 21 The P90 is approved for a maximum 40 ft. straight vertical, with rigid pipe 4" x 6-5/8" vent systems for Propane and Natural Gas, as per diagram. The shaded area in the diagram show all allowable combinations of straight vertical and offset to vertical terminations with rigid pipe vent systems for Propane and Natural Gas.
- Page 22 INSTALLATION Must Use: 5" x 8" Simpson Direct Vent GS Piping with FPI Increaser Starter Collar (Part #946-605). One 90 elbow = Two 45 elbows. Option H + H1 W i t h t h e s e o p t i o n s , 6"...
- Page 23 Must Use: 5" x 8" Simpson Direct Vent GS Piping with FPI Increaser Starter Collar (Part #946-605), unless V1 is greater than or equal to 4'-6" then use 4" x 6-5/8" piping. One 90 elbow = Two 45 Option V V + V1 With these options, max.
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Page 24: Horizontal Terminations
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. -
Page 25: 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. -
Page 26: Installation Procedures
INSTALLATION the vertical height must be increased. A poor draft, or down drafting can result from high wind conditions near big trees or adjoining roof lines, in these cases, increasing the vent height may solve the problem. 7) Ensure vent is vertical and secure the base of the fl... -
Page 27: High Elevation
P90-NG1 System Data For 0 to 4500 feet altitude Burner Inlet Orifi ce Sizes: Max. Input Rating 35,000 Btu/h Min. Input Rating 18,200 Btu/h Supply Pressure min.5.0" w.c. Manifold Pressure (High) 3.8"+/- 0.2"w.c. P90-LP1 System Data For 0 to 2000 feet altitude Burner Inlet Orifi... -
Page 28: Conversion Kit #791-969 From Ng To Lp
INSTALLATION CONVERSION KIT #791-969 FROM NG TO LP THIS CONVERSION MUST BE DONE BY A QUALIFIED GAS FITTER IF IN DOUBT DO NOT DO THIS CONVERSION !! Each Kit contains one LPG Conversion Kit and one DC Sparker Kit. LPG Conversion Kit Contains: Qty. -
Page 29: Installation Of The Dc Sparker
14) Using the Allen wrench as shown in Fig.4, rotate the screw clockwise until snug, do not overtighten. Fig.4 WARNING! Do not overtighten the screw. Recommended to grip the wrench by the short side. ) Verify that if the conversion is from NG to LPG, the screw must be reassembled with the red o-ring visible (Fig. - Page 30 INSTALLATION Attach the Piezo ignition wire to the DC Sparker. Piezo Ignitor Insert both the ground wire and the DC sparker generator wire through the hole of the DC spark heat shield. Install the plastic bushing over the outside of the hole. 10) Attach the ground wire to the DC spark mounting bracket.
- Page 31 Locate the ground lug at the receptical box, left of the unit. Connect one end of the supplied green ground wire to the lug with the nut and washer from the kit. Ground wire from Install the 1/2" bushing to the heat shield.
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Page 32: Optional Brick Panels
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. 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 fi... -
Page 33: Log Set Installation
Read the instructions below carefully and refer to the diagrams. If logs are broken do not use the unit until they are replaced. Broken logs can interfere with the pilot operation. The gas log kit (Part #780-930) contains the following pieces: a) 02-75 Rear Log... - Page 34 INSTALLATION Position Log 02-53 across the cutouts in Logs 02-75 and 02-51 with the notch on the left side of the log fi tting into the 2nd grate tab. 02-53 2nd Grate Tab 02-53 Position Log 02-54 across the cutouts in Logs 02-51 and 02-53.
- Page 35 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. 02-51 Log Indentation 02-52 02-54 Photo shows rear grate tab. Log 02-51 was removed to show the positioning of Log 02-52.
- Page 36 INSTALLATION 10) Place the embers on the front of the burner tray in the places shown on the photos below. Separate platinum embers and place on the front burner on and around the embers. Avoid stacking platinum embers. Platinum embers may be placed over burner ports. Place embers in these 3 locations on the burner tray.
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Page 37: Glass Door Installation
GLASS DOOR INSTALLATION 1) Fit top door bracket over the fl ange at the top of the fi rebox. 2) Secure with 2 screws on the bottom. Flange Door ARCH SURROUND 1) Place the Arch Surround into position by sliding the 2 holes in the bottom brackets over the pins on the base. -
Page 38: Accent Kit Installation
INSTALLATION 1) Remove the rivets from the surround by pulling out the hoseclamp with a screwdriver or plyer. Re-install the rivets by putting them through the holes on the sides of the surround. 2) Take the hoseclamps and put them over the back of each rivet. Squeeze the hoseclamp to secure onto rivets ensuring that the hoseclamp is touching the back side of the surround. -
Page 39: Option 1: Remote Control
Option 1: REMOTE CONTROL Use the Excalibur ® Remote Control Kit approved for this unit. Use of other systems may void your warranty. The remote control kit comes with a hand held transmitter, a receiver and a wall mounting plate. 1) Choose a convenient location on the wall to install the receiver and the receptacle box (protection from extreme heat is very... -
Page 40: Wiring Diagrams
INSTALLATION This heater does not require a 120V A.C. supply for operation. In case of a power failure, the burner switch and the optional remote control/ thermostat will continue to operate. NATURAL GAS Caution: Ensure that the wires do not touch any hot surfaces and are away from sharp edges. - Page 41 INSTALLATION PROPANE Units and Units Equipped with DC Spark Boxes* *For installation of the DC Spark Box refer to the LP Conversion instructions in this manual. ® Excalibur P90 Zero Clearance Direct Vent Gas Fireplace...
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Page 42: Operating Instructions
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. -
Page 43: Normal Operating Sounds Of Gas Appliances
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. -
Page 44: Maintenance
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. -
Page 45: Fan Maintenance
Unit must be grounded at all times. Do not cut the ground terminal off under any circumstances. To Install the Fan 1) Shut the power off. 2) Open the bottom louver door. Loosen the 2 screws holding the Burner ON/OFF switch and bracket to the bottom louver and lift the assembly out. -
Page 46: Removing Valve
MAINTENANCE REMOVING VALVE 1) Shut the power off. 2) Open the bottom louver door. Loosen the 2 screws holding the Burner ON/OFF switch and bracket to the bottom louver and lift the assembly out. 3) Remove the facade if installed. 4) Remove the glass door (Refer to the "Glass Door Installation"... -
Page 47: Parts List
Part # Description 430-129 Receptacle Box Mount Thermodisc Bracket 910-428 Duplex Receptacle 910-429 Box - Receptacle 910-430 Cover - Receptacle 10) 904-687 Clamp Connector 15) * Heat Shield - Base 20) 790-021 Front Filler - Left Corner 21) 790-022 Front Filler - Right Corner 22) 790-012 Baffl... -
Page 48: On/Off Switch
PARTS LIST ON-OFF SWITCH ASSEMBLY FAN SWITCH ASSEMBLY HEAT WAVE DUCT KIT 97 98 BRICK PANELS HEAT RELEASE DUCT KIT ® Excalibur P90 Zero Clearance Direct Vent Gas Fireplace... -
Page 49: Burner Assembly & Log Set
BURNER ASSEMBLY & LOG SET Part # Description 52) 910-190 Piezo Ignitor & Nut 53) 780-021 Gasket - Valve Access Plate 790-574/P Valve Assy - Natural Gas 790-576/P Valve Assy - Propane 56) * Valve Tray - NG/LP 57) 910-478 Valve - S.I.T. -
Page 50: Flush Front Accessories
PARTS LIST Part # Description 790-518 Door Assembly - Complete 132) 790-137 Flush Door Frame 135) 940-326/P Glass (Flush) 136) 936-155 Glass Gasket (Tadpole) 904-691 U-Clip 790-920 Surround - Black - Complete 790-922 Surround - Gold - Complete 790-914 Surround - Antique Gold - Complete 790-916 Surround - Antique Nickel - Complete 790-918... -
Page 51: 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. - Page 52 ® Excalibur 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 See the inside back cover for details.
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