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Excalibur P90-NG1 - page 1
W ARNING: 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 ...
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Excalibur P90-NG1 - page 2
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 2 T o the New Owner: Congratulations! Y ou are the owner of a state-of-the-art Excalibur ® Gas Fireplace by FPI FIREPLACE PRODUCTS INTERNA TIONAL L TD. 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 ic ...
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Excalibur P90-NG1 - page 3
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 3 T ABLE OF CONTENTS OPERA TING INSTRUCTIONS Operating Instructions ................................................. 42 Lighting Procedure ...................................................... 42 Shutdown Procedure ................................................... 42 First Fire ........ ...
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Excalibur P90-NG1 - page 4
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 4 This is a copy of the label that accompanies each P90 Zero Clearance Direct V ent Gas Fireplace. We have printed a copy of the contents here for your review . The safety label is located on the front inside base of the unit, visible when the bottom louver is open. NOTE: Excalibur ® units ...
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Excalibur P90-NG1 - page 5
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 5 REQUIREMENTS 5.08: Modifica tions to NFPA-54, Chapter 10 (2) Revise 10.8. 3 by adding the follow ing additiona l requirements: (a) For all side wall hor izontally vented ga s fueled equipment in stalled in every dwelling, bui lding or structure used in whole or in part for residential pu ...
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Excalibur P90-NG1 - page 6
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 6 INST ALLA TION CHECKLIST 1) Locate appliance, refer to the following sections: a) Locating Y our Gas Fireplace b) Combustible Mantels c) Unit Base Stand-offs d) Framing & Finishing e) Facing Requirements f) Hearth Requirements g) V enting 2) Assemble T op Standoffs, page 9. (Refer to ...
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Excalibur P90-NG1 - page 7
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 7 INST ALLA TION Side W all Clearance 6-1/2" (165mm) Horizontal V ent Clearances T op 2-1/2" (64mm) Side 1-1/2" (38mm) Bottom 1-1/2" (38mm) V ertical Vent Clearances 1-1/4" (32mm) Alcove Clearances**: Max. Depth 36" (914mm) Min. Width 48" 1219mm) Min. Heig ...
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Excalibur P90-NG1 - page 8
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 8 19-1/4"(489mm) including standoffs 10-7/8" (276mm) 49-7/8"(1267mm) 70-1/2"(1791mm) 4"(100mm) Dia. Inner 6-7/8"(175mm) Dia. Outer 46-1/2"(1 181mm) 42"(1067mm) 31" (787mm) FRAMING AND FINISHING 1) Determine the total thickness of facing material ...
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Excalibur P90-NG1 - page 9
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 9 INST ALLA TION Fireplace S tand No hearth is required when the unit is raised 3" (76mm) off of the floor surface Flooring HEARTH REQUIREMENTS Floor Mounted Fireplaces Raised Fireplaces F ACING REQUIREMENT This fi replace requires a non-combustible material extending from the framing ...
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Excalibur P90-NG1 - page 10
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 10 INST ALLA TION VENTING INTRODUCTION The P90 uses the "balanced fl ue" technology Co-axial system. The inner liner vents products of combustion to the outside while the outer liner draws outside combustion air into the combustion chamber thereby eliminating the need to use heat ...
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Excalibur P90-NG1 - page 11
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 11 VENTING FPI Direct V ent System (Flex) Horizontal T erminations Only These venting systems, in combination with the P90 Direct V ent Gas Fireplace, have been tested and listed as a direct vent heat er system by W arnock Hersey . The location of the termination cap must conform to the req ...
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Excalibur P90-NG1 - page 12
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 12 INST ALLA TION EXTERIOR VENT TERMINA TION LOCA TIONS A= Clearance above grade, veranda, porch, deck, or balcony *(min. 12"/30cm) B= Clearance to window or door that may be opened *(12"/30cm) #(9"/23cm) C= Clearance to permanently closed window *(min. 12"/30cm) D= V er ...
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Excalibur P90-NG1 - page 13
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 13 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 Simpson Direct V ent Pro ® Simpson Direct V ent GS ® Discontinued Selkirk Direct-T emp™ American Metal ...
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Excalibur P90-NG1 - page 14
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 14 Description Simpson Direct V ent Pro ® Simpson Direct V ent GS ® Discontinued Selkirk Direct-T emp™ American Metal Products ® Amerivent Direct Metal-Fab ® Sure Seal Security Secure V ent ® Attic Insulation Shield 12” 46DV A-IS - N/A from FPI N/A N/A 4DAIS12 N/A SV4RSA Attic Insu ...
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Excalibur P90-NG1 - page 15
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 15 Description Simpson Direct V ent Pro ® Simpson Direct V ent GS ® Discontinued Selkirk Direct-T emp™ Metal-Fab ® Sure Seal 6” Pipe Length, Galvanized 58DV A-06 1208 5DT -6 5D6 6” Pipe Length, Black 58DV A-06B 1208B 5DT -6B 5D6B 9” Pipe Length, Galvanized 58DV A-09 1207 5DT -9 N ...
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Excalibur P90-NG1 - page 16
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 16 FPI 946-604/P Simpson Direct V ent V ent Guard (Optional) 946-623/P AstroCap XL Horizontal Cap 770-994 Rigid Pipe Adapter (Must use with all Rigid Piping) 946-506/P V ent Guard (Optional) 946-625 Vinyl Siding Standoff - AstroCap XL Description Simpson Direct V ent Pro ® Simpson Direct V ...
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Excalibur P90-NG1 - page 17
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 17 Rigid Pipe Adaptor Pipe Length V ertical T erminal Storm Collar Part # 953 Flashing 943 or 943S Ceiling Firestop (Part # 963) 24" Pipe Length Adj.Pipe Length 1 1" - 14-5/8" 90 Elbow o Horizontal T ermination Cap W all Thimble Part # 942 Vinyl Siding Standoff (Optional) Par ...
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Excalibur P90-NG1 - page 18
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 18 Horizontal & V ertical T erminations for 5" x 8" V enting INST ALLA TION ...
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Excalibur P90-NG1 - page 19
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 19 INST ALLA TION RIGID PIPE VENTING ARRANGEMENTS - HORIZONT AL TERMINA TIONS FPI DIRECT VENT SYSTEM (FLEX) (Propane & Natural Gas) The diagram shows all allowable combinations of vertical runs with horizontal terminations, using one 90 o elbow (two 45 o elbows equal one 90 o elbow). Al ...
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Excalibur P90-NG1 - page 20
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 20 INST ALLA TION • V ent must be supported at offsets. • Firestops are required at each fl oor level and whenever passing through a wall. • Maintain clearances to combustibles. Note: Must use optional rigid pipe adaptor when using rigid vent systems (Part # 510-994). RIGID PIPE VENT ...
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Excalibur P90-NG1 - page 21
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 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 p ...
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Excalibur P90-NG1 - page 22
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 22 INST ALLA TION Horizontal V enting with T wo (2) 90 o Elbows Horizontal V enting with Three (3) 90 o Elbows One 90 o elbow = T wo 45 o elbows. Option V H + H1 A) 6" Min. 2' Max. B) 1' Min. 3' Max. C) 2' Min. 4' Max. D) 3' Min. 5' Max. E) 4' Mi ...
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Excalibur P90-NG1 - page 23
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 23 INST ALLA TION V ertical V enting with T wo (2) 90 o Elbows V ertical V enting with Three (3) 90 o Elbows Must Use: 5" x 8" Simpson Direct V ent GS Piping with FPI Increaser Starter Collar (Part #946-605), unless V1 is greater than or equal to 4'-6" then use 4" x ...
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Excalibur P90-NG1 - page 24
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 24 INST ALLA TION Min. 12"* (305mm) Adequate drainage Window Well Gravel Dura-V ent Snorkel Diagram 4 6) The arrow on the vent cap should be pointing up. Insure that the 1-1/2" clearances to combustible materials are maintained (Diagram 4). Install the termination cap. NOTE: For S ...
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Excalibur P90-NG1 - page 25
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 25 2) Set the gas appliance in its desired location. Drop a plumb bob down from the ceiling to the position of the appliance fl ue exit, and mark the location where the vent will penetrate the ceiling. Drill a small hole at his point. Next, drop a plumb bob from the roof to the hole previo ...
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Excalibur P90-NG1 - page 26
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 26 INST ALLA TION 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 ...
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Excalibur P90-NG1 - page 27
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 27 GAS PIPE PRESSURE TESTING The appliance must be isolated from the gas supply piping system by closing its individual manual shut-off valve dur in g a ny pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psig. (3 .4 5 kPa). Disconnect piping from ...
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Excalibur P90-NG1 - page 28
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 28 CONVERSION KIT #791-969 FROM NG T O LP THIS CONVERSION MUST BE DONE BY A QUALIFIED GAS FITTER IF IN DOUBT DO NOT DO THIS CONVERSION !! Each Kit contains one LPG Conversion Kit and one DC Sparker Kit. LPG Conversion Kit Contains: Qty . Part # Description 1 904-529 5/32" Allen Key 1 9 ...
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Excalibur P90-NG1 - page 29
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 29 17) Reverse steps 4) to 2). 18) Attach clear label "This unit has been converted to LPG" near or on top of the serial # decal. 19) Replace yellow "Natural Gas" label with red "LPG" label. 14) Using the Allen wrench as shown in Fig.4, rotate the screw clockwi ...
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Excalibur P90-NG1 - page 30
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 30 9) Install the plastic bushing over the outside of the hole. 10) Attach the ground wire to the DC spark mounting bracket. 11 ) Attach the DC sparker generator wires to the DC sparker . 8) Insert both the ground wire and the DC sparker generator wire through the hole of the DC spark heat ...
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Excalibur P90-NG1 - page 31
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 31 5) Locate the ground lug at the receptical box, left of the unit. Installer Notice: These instructions must be left with the appliance. 15) Check for gas leaks. 16) Check inlet and outlet pressures. 17) Check operation of fl ame control. 18) Check for proper fl ame appearance and glow ...
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Excalibur P90-NG1 - page 32
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 32 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 rst by ...
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Excalibur P90-NG1 - page 33
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 33 INST ALLA TION LOG SET INST ALLA TION Notch Bracket Bracket 02-51 02-75 02-51 3) Place the Log 02-75 on the rear log support pins with the fl at side to the back. 1) Carefully remove the logs from the box and unwrap them. The logs are fragile, handle with care - do not force into positi ...
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Excalibur P90-NG1 - page 34
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 34 Rear Bracket 02-55 02-75 02-53 7) Place the bottom left front edge of Log 02-55 against the rear bracket on the burner tray and rest the log on the cutout on Log 02-53. Cutouts 5th Grate T ab 02-54 02-53 02-51 6) Position Log 02-54 across the cutouts in Logs 02-51 and 02-53. The notch in ...
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Excalibur P90-NG1 - page 35
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 35 Log Indentation Photo shows rear grate tab. Log 02-51 was removed to show the positioning of Log 02-52. Rear Grate T ab 02-52 02-51 02-54 02-52 02-54 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. ...
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Excalibur P90-NG1 - page 36
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 36 Place embers in these 3 locations on the burner tray . 02-50 02-55 02-75 02-53 02-51 02-54 02-52 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 ...
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Excalibur P90-NG1 - page 37
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 37 Door Flange OPTIONAL SCREEN DOOR 1 ) Attach door bracket to side using 2 screws. GLASS DOOR INST ALLA TION 1) Fit top door bracket over the fl ange at the top of the fi rebox. 2) Secure with 2 screws on the bottom. Single Screen Door - only attach to right side of unit. Double Screen D ...
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Excalibur P90-NG1 - page 38
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 38 ACCENT KIT INST ALLA TION 2) T ake 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 ...
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Excalibur P90-NG1 - page 39
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 39 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 ...
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Excalibur P90-NG1 - page 40
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 40 WIRING DIAGRAMS Caution: Ensure that the wires do not touch any hot surfaces and are away from sharp edges. This heater does not require a 120V A.C. supply for operation. In case of a power failure, the burner switch and the optional remote control/ thermostat will continue to operate. H ...
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Excalibur P90-NG1 - page 41
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 41 INST ALLA TION For PROP ANE Units and Units Equipped with DC Spark Boxes* *For installation of the DC Spark Box refer to the LP Conversion instructions in this manual. ...
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Excalibur P90-NG1 - page 42
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 42 LIGHTING PROCEDURE IMPORT ANT Gas on/off knob cannot be turned from "PILOT" to "OFF" unless it is partially depressed. 1) Turn burner OFF using "ON/OFF" switch. NOTE: For all propane units and units equipped with electric spark boxes, see "Copy of Light ...
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Excalibur P90-NG1 - page 43
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 43 COPY OF THE LIGHTING PLA TE INSTRUCTIONS NORMAL OPERA TING 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 ar ...
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Excalibur P90-NG1 - page 44
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 44 GLASS GASKET If the glass gasket requires replacement use a tadpole glass gasket (Part # 936-155). DOOR GLASS Y our Excalibur ® fi replace is supplied with high temperature, 5 mm Neoceram ceramic glass that will withstand the highest heat that your unit will produce. If your glass requ ...
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Excalibur P90-NG1 - page 45
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 45 5) Connect fan ground cable to ground lug. Refer to wiring diagram. 6) Slide the thermodisc/cover assembly into the bracket clip on the underside of the fi rebox. Check that no wire will touch the hot surfaces. Diagram 2. Diagram 1 Diagram 2 Secure left side with 2 screws and right side ...
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Excalibur P90-NG1 - page 46
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 46 12) Undo the pilot tube from the valve with a 7/16" wrench. 13) Undo the quick drop out thermocouple nut on the valve with a 9mm (metric) wrench. 14) Remove the Piezo igniter wire and push button assembly . 15) Undo the "gas out" fl are nut with a 13/16" wrench. 16) ...
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Excalibur P90-NG1 - page 47
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 47 P ARTS LIST MAIN ASSEMBL Y Part # Description Part # Description Part # Description 1) 430-129 Receptacle Box Mount 2) * Thermodisc Bracket 7) 910-428 Duplex Receptacle 8) 910-429 Box - Receptacle 9) 910-430 Cover - Receptacle 10) 904-687 Clamp Connector 15) * Heat Shield - Base 20) 790- ...
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Excalibur P90-NG1 - page 48
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 48 P ARTS LIST 61 38 43 47 48 42 32 64 61 1 9 7 36 49 8 10 2 64 22 36 15 20 23 24 21 25 24 23 25 108 109 HEA T RELEASE DUCT KIT F AN SWITCH ASSEMBL Y ON-OFF SWITCH ASSEMBL Y 62 51 59 60 61 63 64 27 30 28 30 31 50 93 97 98 99 100 102 90 96 95 93 92 91 94 89 HEA T W A VE DUCT KIT BRICK P ANEL ...
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Excalibur P90-NG1 - page 49
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 49 A E TH TP TP TH TPTH A I R IN AIR IN O O T L I P 52 69 58 53 57 82 83 56 85 79 75 76 68 68 67 66 P ARTS LIST BURNER ASSEMBL Y & LOG SET Part # Description 52) 910-190 Piezo Ignitor & Nut 53) 780-021 Gasket - V alve Access Plate 790-574/P V alve Assy - Natural Gas 790-576/P V alve ...
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Excalibur P90-NG1 - page 50
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 50 164 141 156 FLUSH DOOR 132 135 136 148 148 158 SINGLE DOOR 151 DOUBLE DOORS 161 146 162 155 168 167 157 163 163 164 159 154 157 148 148 149 149 155 155 144 143 155 159 152 153 157 146 146 142 145 FLUSH FRONT ACCESSORIES 790-518 Door Assembly - Complete 132) 790-137 Flush Door Frame 135) ...
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Excalibur P90-NG1 - page 51
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 51 W ARRANTY Excalibur Fireplace Products are designed with reliability and simplicity in mind. In addition, our internal Quality Assurance T eam carefully inspects each unit thoroughly before it leaves our facility . FPI Fireplace Products International Ltd. is pleased to extend this limit ...
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Excalibur P90-NG1 - page 52
Excalibur ® P90 Zero Clearance Direct V ent Gas Fireplace 52 Installer: Please complete the following information Dealer Name & Address: ______________________________________________ ___________________________________________________________________ Installer: ___________________________________________________________ Phone #: _____________ ...
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