P95 Zero Clearance Direct Vent Gas Fireplace

Product Information:

The P95 Zero Clearance Direct Vent Gas Fireplace is a product
manufactured by FPI Fireplace Products International Ltd. It is
available in two models: P95-NG for Natural Gas and P95-LP for
Propane. This gas fireplace is designed to provide heating and
ambiance in residential spaces. It has been tested and listed by
Warnock Hersey as a Direct Vent Wall Furnace, meeting the standards
of VENTED GAS FIREPLACE HEATERS ANSI Z21.88-2002/CSA 2.33-2002 and
GAS-FIRED APPLIANCES FOR USE AT HIGH ALTITUDES CAN/CGA
2.17-M91.

The installation of this appliance must be performed by a
qualified installer, service agency, or the gas supplier. It must
be installed according to the manufacturer’s installation
instructions and in compliance with local codes and regulations. In
the absence of local codes, the installation should 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 appliance is designed for use in mobile/manufactured homes
where it is not prohibited by local codes. It must be installed in
accordance with 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.

It is important to note that this appliance is only compatible
with the type of gas indicated on the rating plate. It cannot be
converted for use with other gases unless a certified kit is
used.

Product Usage Instructions:

Lighting Procedure:

1. Ensure that the gas supply to the fireplace is turned on.

2. Locate the control knob or switch for ignition and set it to
   the “Off” position.

3. Wait for at least five minutes to allow any accumulated gas to
   dissipate.

4. Follow the specific lighting instructions provided in the
   manufacturer’s installation manual.

5. Use a long fireplace lighter or match to ignite the gas burner
   while holding the control knob or switch in the “Pilot”
   position.

6. Once the pilot flame is ignited, continue holding the control
   knob or switch in the “Pilot” position for about 30 seconds to
   allow the thermocouple to heat up.

7. Release the control knob or switch and verify that the pilot
   flame remains lit.

8. Turn the control knob or switch to the desired heat setting or
   flame level.

Shutdown Procedure:

1. Turn the control knob or switch to the “Off” position.
2. Wait for at least five minutes to allow any remaining gas to
   dissipate.

Note: It is important to follow all safety
precautions and guidelines provided in the manufacturer’s
installation manual and to consult with a qualified professional
for specific installation and usage instructions.

www.excalibur-fire.com

P95 Zero Clearance Direct Vent Gas Fireplace

Owners & Installation Manual

MODELS: P95-NG Natural Gas P95-LP Propane

WARNING:

FOR YOUR SAFETY

If the information in these instructions are not followed exactly, What to do if you smell gas:

a fire or explosion may result causing property damage, ! Do not try to light any appliance

personal injury or loss of life.

! Do not touch any electrical switch:

FOR YOUR SAFETY

do not use any phone in your

Do not store or use gasoline or other flammable vapours and building.

liquids in the vicinity of this or any other appliance.

! Immediately call your gas supplier

from a neighbour’s phone. Follow

Installation and service must be performed by a qualified the gas supplier’s instructions.

installer, service agency or the gas supplier.

! If you cannot reach your gas

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.

918-108b

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

04/27/04

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 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 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 Z21.88-2002/CSA 2.33-2002 and GAS-FIRED APPLIANCES FOR USE AT HIGH ALTITUDES CAN/CGA 2.17-M91.
This Direct Vent System Appliance must be installed in accordance with the manufacturer’s installation instructions and the Manufactured Home Construction and Safety Standard, Title 24 CFR, Part 3280, or the current Standard of Fire Safety Criteria for Manufactured Home Installations, Sites, and Communities ANSI/NFPA 501A, and with CAN/CSA Z240-MH Mobile Home Standard in Canada.
This appliance installation must comply with the manufacturer’s installation instructions and local codes, if any. In the absence of local codes follow the current National Fuel Gas Code, ANSI Z223.1 and the current National Electrical Code ANSI/NFPA 70 in the U.S.A., and the current CAN/CGA B149 Gas Installation Code and the current Canadian Electrical Code CSA C22.1 in Canada.
This Excalibur Mobile/Manufactured Home Listed appliance comes factory equipped with a means to secure the unit.
This Excalibur Mobile/Manufactured Home listed appliance comes equipped with a dedicated #8 ground lug to which an 18 gauge copper wire from the steel chassis ground must be attached.
This appliance may only be installed in an aftermarket permanently located, manufactured (mobile) home, where not prohibited by local codes.
This appliance is only use with the type of gas indicated on the rating plate. This appliance is not convertible for use with other gases, unless a certified kit is used.

2

Excalibur P95 Zero Clearance Direct Vent Gas Fireplace

TABLE OF CONTENTS

Safety Label
Safety Label ……………………………………………………… 4
Installation
Important Message ……………………………………………. 5 Before You Start ……………………………………………….. 5 General Safety Information ………………………………….. 5 Installation Checklist ………………………………………….. 5 Locating Your Gas Stove …………………………………….. 6 Manufactured Home Additional Requirements ………… 6 Optional HeatWave Duct System …………………………. 6 Optional Heat Release Kit …………………………………… 6 Clearances ……………………………………………………….. 6 Combustible Mantel Clearances …………………………… 7 P95 Flat Surround and Tile Kit ……………………………… 7 Unit Base Stand-Offs …………………………………………. 7 Framing and Finishing ………………………………………… 7 Facing Requirements …………………………………………. 8 Hearth Requirements …………………………………………. 8 Optional Cover Plate Template …………………………….. 9 Unit Assembly Prior to Installation
Top Standoff Assembly …………………………………. 9 Side Nailing Strips ……………………………………….. 9 Venting Introduction …………………………………………… 9 Venting: Direct Vent System (Flex) ……………………… 10 Exterior Vent Termination Locations …………………….. 11 Venting: Simpson Dura Vent Direct Vent GS ………… 12 Venting: Simpson Dura Vent Components List ………. 13 Venting Arrangements Horizontal Terminations ……………………………….. 14 Vertical Terminations …………………………………… 16 Venting – Dura-Vent Horizontal Installations ………….. 18 Venting – Dura-Vent Vertical Termination ………………. 19 Venting – Installation Procedures for Direct Vent System (Flex) …………………………………………….. 20 System Data ……………………………………………………. 21 High Elevation ………………………………………………….. 21 Gas Line Installation ………………………………………….. 21 Pilot Adjustment ………………………………………………. 21 Gas Pipe Pressure Test …………………………………….. 21 SIT Valve Description ………………………………………… 21 Conversion to Propane ………………………………………. 22 Optional Brick Panels ……………………………………….. 23 Log Set Installation …………………………………………… 23 Glass Door Installation ………………………………………. 25 Front Facade ……………………………………………………. 25 Optional Screen Door ………………………………………… 25 Accent Kit Installation ……………………………………….. 26 Remote Control (optional) …………………………………… 27 Remote Wall Switch (optional) ……………………………. 27 Wall Thermostat (optional) …………………………………. 27 Wiring Diagram ………………………………………………… 28

Operating Instructions
Operating Instructions ……………………………………….. 29 Lighting Procedure ……………………………………………. 29 Shutdown Procedure …………………………………………. 29 First Fire …………………………………………………………. 29 Aeration Adjustment ………………………………………….. 29 Normal Operating Sounds of
Gas Appliances ………………………………………….. 29 Lighting Plate Instructions ………………………………….. 30
Maintenance
Maintenance Instructions …………………………………… 30 General Vent Maintenance …………………………………. 31 Gold-Plated or Brass Door or Facade …………………… 31 Log Replacement ……………………………………………… 31 Thermopile/Thermocouple ………………………………….. 31 Glass Gasket …………………………………………………… 31 Door Glass ………………………………………………………. 31 Fan Maintenance ……………………………………………… 32 RemovingValve ………………………………………………… 33 Installing Valve …………………………………………………. 33
Parts List
Replacement/Spare Parts List …………………………….. 34
Warranty
Warranty …………………………………………………………. 39

Excalibur P95 Zero Clearance Direct Vent Gas Fireplace

3

SAFETY LABEL
This is a copy of the label that accompanies each P95 Zero Clearance Direct Vent Gas Fireplace. We have printed a copy of the contents here for your review. The safety label is located on the front inside base of the unit, visible when the bottom louver is open.
NOTE: Excalibur units are constantly being improved. Check the label on the unit and if there is a difference, the label on the unit is the correct one.

Copy of Safety Decal for P95

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.
4

Excalibur P95 Zero Clearance Direct Vent Gas Fireplace

INSTALLATION

IMPORTANT: SAVE THESE INSTRUCTIONS
The P95-NG or P95-LP 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.

YOUNG CHILDREN SHOULD BE CAREFULLY SUPERVISED WHEN THEY ARE IN THE SAME ROOM AS THE APPLIANCE.
CLOTHING OR OTHER FLAMMABLE MATERIAL SHOULD NOT BE PLACED ON OR NEAR THE APPLIANCE.
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. 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.

7. Do not slam shut or strike the glass door.

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

9. 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

10. Locate appliance a) Room location, page 6 b) Clearances to Combustibles, pages 6-7. c ) Mantle Clearances, page 7 d) Framing & Finishing Requirements, page 7. e) Facing and Hearth Requirements, page 8. f ) Venting Requirements, pages 9-16.

11. Assemble Top Standoffs, page 9. (NOTE: must be done before installing unit into fireplace.)

12. Install vent, pages 18-20.

DUE TO HIGH TEMPERATURES, THE APPLIANCE SHOULD BE LOCATED OUT OF TRAFFIC AND AWAY FROM FURNITURE AND DRAPERIES.
WARNING: FAILURE TO INSTALL THIS APPLIANCE CORRECTLY WILL VOID YOUR WARRANTY AND MAY CAUSE A SERIOUS HOUSE FIRE.
CHILDREN AND ADULTS SHOULD BE ALERTED TO THE HAZARDS OF HIGH SURFACE TEMPERATURES, ESPECIALLY THE FIREPLACE GLASS, AND SHOULD STAY AWAY TO AVOID BURNS OR CLOTHING IGNITION.

6. Venting terminals shall not be recessed into 4) Make gas and electrical connections. Test

a wall or siding.

the pilot. Must be as per diagram. Page 21.

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. Install brick panels (optional), page 23.

13. Install log set where indicated on pages 23-24.

14. Install Front Facade, page 25.

15. Install Optional Screen Door, page 25.

16. Install optional Wall Switch, Remote Control, or Wall Thermostat, page 27.

17. 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.

Excalibur P95 Zero Clearance Direct Vent Gas Fireplace

5

INSTALLATION

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.
   LOCATING YOUR GAS STOVE

3. When selecting a location for your stove, ensure that the clearances outlined on this page are met.

4. 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 page 10.
   MANUFACTURED MOBILE HOME ADDITIONAL REQUIREMENTS

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

6. Ensure proper grounding using the #8 ground lug provided. See page 28.

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.

2. Provide adequate clearances for servicing.

OPTIONAL

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.
4. The P95 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.

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.

Side Wall Clearance

6-1/2″ (165mm)

Horizontal Vent Clearances

Top

3″

Side

2″

Bottom

2″

Vertical Vent Clearances 1-1/4″ (32mm)

A) Flat on Wall B) Flat on Wall Corner C) Recessed into
Wall/Alcove D) Corner
Diagram 1
5) This appliance is Listed for bedroom installations when used with a Listed Millivolt Thermostat. Some areas may have further requirements, check local codes before installation.

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.

6. The P95 Direct Vent Gas Fireplace is approved for alcove installations, which meet the clearances listed on this page.

• see mantle clearance instructions (page 7).
  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.

6

Excalibur P95 Zero Clearance Direct Vent Gas Fireplace

INSTALLATION

COMBUSTIBLE
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.
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.

MANTELS

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.

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 page 9 for assembly details.

P95 Flat Wall Surround and Tile Kit
The P95 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).

P95 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″.

Insert the 2 unit base stand-offs underneath the unit as shown in the diagram below. Space the stand-offs centrally, approximately 2 or 21/2 feet apart. Ensure that the unit is not unstable.

Framing Dimensions

A

B

C

53-3/8″ 50-1/8″ 21-1/4″

1346mm 1276mm 533mm

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.

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 Zero Clearance Direct Vent Gas Fireplace

7

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 Vent Clearances, page 6.
   Note: 52″ (1320mm) is the minimum height for both flex termination or Simpson Dura-Vent venting.

Facing Over 1″ (25mm) Thick
If the facing material is over 1″ (25mm) thick (example: brick or river rock), install the facing around the perimeter of the face. You may wish to make a face template as shown on the diagram.
FPI offers a cover plate template. See next page.
NOTE: If using a brick hearth, the fireplace will need to be raised to accommodate the brick thickness. Example: If the brick is 2″ thick, the unit must be raised 1″.

The HeatWave Duct Kit has different clearance and framing requirements, check the HeatWave manual for details.
FACING REQUIREMENT
This fireplace requires a non-combustible material extending from the framing header and sides.
The flanges on the front face of the fireplace are for a facing thickness of 1″ (25mm).

HEARTH REQUIREMENTS
Floor Mounted Fireplaces

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

Fireplace Stand

Flooring

You must take into account the depth of the floor covering (carpet, tile, linoleum, etc.) when determining the height of the fireplace stand.

8

Excalibur P95 Zero Clearance Direct Vent Gas Fireplace

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

3. Attach the standoff securely to the top with 2 screws per standoff (on opposite corners).
   Side Nailing Strips
   The side nailing strips come attached to the unit. There are 2 plates, one on the top and bottom that can be folded out as required.

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.

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

Plates can be folded out.

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.

Top Clip

VENTING INTRODUCTION

Back View of Cover Plate

The P95 uses the “balanced flue” technology Coaxial 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.

Pin Holes
TO REMOVE:

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

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.

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

Excalibur P95 Zero Clearance Direct Vent Gas Fireplace

9

INSTALLATION

VENTING
FPI Direct Vent System (Flex) Horizontal Terminations Only
These venting systems, in combination with the P95 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 on page 11.

FPI Direct Vent (Flex) System Termination Kit (Part # 946-515) includes all the parts needed to install the P95 with a maximum run of 4 feet.

1. 6-7/8″ dia. flexible liner (4 ft. length) 2) 4″ dia. flexible liner (4 ft. length) 3) spring spacers (4) 4) thimble (2) 5) AstroCap termination cap (1)
2. screws (12) 7) tube of Mill Pac (1) 8) plated screws (8) 9) screws #8 x 1-1/2″ Drill Point, Stainless
   Steel (4)

If longer runs are needed, the FPI Direct Vent system (Flex) kits are:
946-516 includes all the parts needed to install the P95 with a maximum 10′ run.

1. 6-7/8″ dia. flexible liner (10 ft. length) 2) 4″ dia. flexible liner (10 ft. length) 3) spring spacers (7) 4) thimble (2) 5) AstroCap termination cap (1) 6) screws (12) 7) tube of Mill Pac (1) 8) plated screws (8) 9) screws #8 x 1-1/2″ Drill Point, Stainless
   Steel (4)

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.

10

Excalibur P95 Zero Clearance Direct Vent Gas Fireplace

Excalibur P95 Zero Clearance Direct Vent Gas Fireplace

Vertical Termination
24″

Inside corner detail
G
V
A

Vertical Termination
24″ 18″

INSTALLATION
EXTERIOR VENT TERMINATION LOCATIONS

D E
V
B
V
M
.
V Vent terminal

V
H

C
V Fixed Closed

FV

Openable

B

B

B

V

V Openable Fixed Closed

B

B

V

K

A

A

N j

L

V

A

A Air supply outlet

Area where terminal is not permited

A= Clearance above grade, veranda, porch, deck, or balcony (min. 12″/30cm) B= Clearance to window or door that may be opened (12″/30cm) C= Clearance to permanently closed window *(min. 12″/30cm) D= 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)

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.

11

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.

The minimum components required for a basic horizontal termination are:
1 Horizontal Termination Cap 1 90o Elbow 1 Flue Adaptor 1 Wall Thimble 1 Length of pipe to suit wall thickness
(see chart) 1 4″ x 6-5/8″ to 5″ x 8″ increaser for 5″ x
8″ venting

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.

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

Flat Wall Installation

Wall Thickness

Vent Length

(inches)

Required (inches)

4″ – 5-1/2″

6″

7″ – 8-1/2″

9″

10″ – 11-1/2″

12″

9″ – 14-1/2″

11″ – 14-5/8″ Adj. Pipe

15″ – 23-1/2″ 17″ – 24″ Adj. Pipe

Corner Installation

Wall Thickness

Vent Length

(inches)

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″

Horizontal and Vertical Terminations for 4″ x 6-5/8″ Venting

Alternate Horizontal Termination
Caps

Simpson Dura-Vent Direct Vent GS

The FPI AstroCapTM is certified for installations using FPI venting systems as well as Simpson Dura-Vent® and Direct Vent GS.
The FPI AstroCapTM is a proprietary trademark of FPI Fireplace Products International Ltd.
Dura-Vent® and Direct Vent GS are registered and/or proprietary trademarks of Simpson DuraVent Co. Inc.

12

Excalibur P95 Zero Clearance Direct Vent Gas Fireplace

INSTALLATION
Horizontal Terminations for 5″ x 8″ Venting (for venting exceeding 10 feet horizontal)

SIMPSON DURA-VENT VENTING COMPONENTS LIST

4″ x 6-5/8″ 971
970
978
908 908B 907 907B 906 906B 904 904B 903 903B 902 902B 911 911B 917 917B 945 945B 945G 945BG

All Simpson Dura-Vent components are available directly from FPI.

5″ x 8″

Description

4″ x 6-5/8″

5″ x 8″ Description

Horiz. Termination Kit includes: 90o black elbow, wall thimble cover, horiz. square termination cap, 24″ black pipe, and 11″ -14″ 5/8″ adjustable black pipe Basic Horiz. Termination. Kit includes: 90o black elbow, wall thimble cover, horiz. square termination cap Vert. Termination Kit includes: 0/12 – 6/12 pitch adjustable flashing, storm collar, low profile term. cap

1208 1208B 1207 1207B 1206 1206B 1204 1204B 1203 1203B 1202 1202B 1211 1211B 1217 1217B 1245 1245B 1245G 1245BG

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, Blk 17″ to 24″ Pipe, Adjustable 17″ to 24″ Pipe, Adjustable, Blk 45o Elbow 45o Elbow, Black 45o Elbow, Swivel 45o Elbow, Black, Swivel

990

1290 90o Elbow

990B

1290B 90o Elbow, Black

990G

1290G 90o Elbow, Swivel

990BG

1290BG 90o Elbow, Black, Swivel

940

1240 Rnd Ceiling Supp/Wall Thimble Cover

941

1241 Cathedral Ceiling Support Box

3951

Brass Trim for Wall Thimble/Ceiling Sup.

942

1247 Wall Thimble (only required in Canada)

943

1243 Flashing, 0/12 to 6/12 Roof Pitch

943S

1243S Flashing, 7/12 to12/12 Roof Pitch

947

1242 Wall Firestop

953

1253 Storm Collar

963

1263 Ceiling Firestop

988

1288 Wall Strap

981

1281 Snorkel Termination (36″)

982

1282 Snorkel Termination (14″)

984

1284 Horizontal Square Termination

985

1285 Horizontal Square Term., High Wind

980

1280 Vertical Termination

991

1291 Vertical Termination, High Wind

930

N/A

Extended Vertical Termination

950

1250 Vinyl Siding Standoff

946-605 FPI Increaser Starter Collar

Parts not supplied by Dura-Vent

946-506/P

Vent Guard (Optional)

510-994

Dura-Vent Flue Adaptor

640-530/P

Riser Vent Terminal

946-205

Vinyl Siding Shield for Riser Vent

Terminal

946-206

AstroCap Standoff

Excalibur P95 Zero Clearance Direct Vent Gas Fireplace

13

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 4″ inner diameter 6-5/8″ outer diameter
FPI Flex Vent 4″ inner diameter 6-7/8″ outer diameter
Note: Must use optional flue adapter (Part # 510-994) when using Simpson Dura- Vent pipe.

Simpson Dura-Vent 5″ inner diameter 8″ outer diameter
Note: Must use FPI increaser starter collar (Part # 946-605) at beginning of vent run.

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

5″ x 8″ venting starts at unit.

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

· Maintain clearances to combustibles as listed on pages 6 to 8. · Horizontal vent must be supported every 3 feet. · Firestops are required at each floor level and whenever passing through a wall.

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

14

Excalibur P95 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 below shows examples of horizontal termination arrangements using two 90o elbows (two 45o elbows equal one 90o elbow).

Note:

1. A maximum of two 90o elbows are permitted. 2) A minimum of 6 ft. (1.8m) vertical from base of unit is required if two 90o elbows are used. 3) Minimum distance between elbows is 2 ft. (0.6m). 4) Determine the permitted range of horizontal termination arrangements by using chart on page 14.
   and deducting 3 ft. (0.9m) from the maximum horizontal distance for the second 90o elbow.

If length “B” is increased, length “A” must be decreased by a corresponding amount.

Simpson Dura-Vent 4″ inner diameter 6-5/8″ outer diameter FPI Flex Vent 4″ inner diameter 6-7/8″ outer diameter
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 on pages 6 to 8. · Horizontal vent must be supported every 3 feet. · Firestops are required at each floor level and whenever passing through a wall.

Excalibur P95 Zero Clearance Direct Vent Gas Fireplace

15

INSTALLATION
VENTING ARRANGEMENTS – VERTICAL TERMINATIONS
SIMPSON DURA-VENT DIRECT VENT GS SYSTEM (Propane & Natural Gas)
The P95 is approved for a maximum 23 ft. (7.0m) vertical, with a maximum 12 ft. (3.7m) horizontal offset using two 90o elbows (two 45o elbows equal one 90o elbow) with Simpson Dura-Vent Direct Vent GS vent systems for Propane and Natural Gas, as per diagram 1.
The P95 is approved for a maximum 37 ft. (11.3m) straight vertical, including a maximum 20″ (0.5m) horizontal offset using two 90o elbow (two 45o elbows equal one 90o elbow) with Simpson Dura-Vent Direct Vent GS vent systems for Propane and Natural Gas, as per the diagram 2.
· Vent must be supported at offsets · Maintain clearances to combustibles as listed on pages 6 to 8. · Firestops are required at each floor level and whenever passing through a wall.
Note: Must use optional flue adapter when using Simpson Dura-Vent pipe (Part # 510-994).

Diagram 1

Diagram 2

16

Excalibur P95 Zero Clearance Direct Vent Gas Fireplace

The P95 is approved for a maximum 37 ft. (11.3m) straight vertical, with Simpson Dura-Vent Direct Vent GS vent systems for Propane and Natural Gas, as per the diagram 3.
The shaded area in the diagram 3 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 on pages 6 to 8.
Please note that all vertical measurements are taken from the base of the unit excluding risers or bottom stand-offs.

INSTALLATION

Diagram 3

Excalibur P95 Zero Clearance Direct Vent Gas Fireplace

17

INSTALLATION

HORIZONTAL INSTALLATIONS

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

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

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

2. Direct Vent pipe and 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.

3. Mark the wall for a 10″ x 10″ square hole. The center of the square hole should line up with the centerline of the horizontal pipe. Cut and frame the 10 inch square hole in the exterior wall where the vent will be terminated. If the wall being penetrated is constructed of non-combustible material, i.e. masonry block or concrete, a 7″(178mm) dia. (7-1/2″(191mm) dia. for flex) hole is acceptable.

Note: With Dura-

Vent, the mini-

mum height

is achieved

by installing

a 90o elbow

directly to

the

flue

adaptor.

Note: Riser Vent is only for use in above grade terminations.
Diagram 3a
*Dia 3, 3a & 4: As specified in CGA B149 Installation Code. Local codes or regulations may require different clearances.

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 onequarter 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.
   Diagram 1
   Note: Apply sealant “Mill-Pac” to inner pipe and high temperature silicone sealant to outer pipe on every twist-lock joint.

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 on page 11.
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, as well as the standard Riser Vent. Follow the same installation procedures as used for standard Horizontal Termination. NEVER install the snorkel upside down.
Diagram 3

Below Grade Installation If the Snorkel Termination must be installed below grade, i.e. basement application, proper drainage must be provided to prevent water from entering the Snorkel Termination. Refer to Diagram 4. Do not attempt to enclose the Snorkel within the wall, or any other type of enclosure.
Diagram 4 NOTE: For Snorkel terminations in ABOVE
grade installations, follow national or local code requirements.
6) The arrow on the vent cap should be pointing up. Insure that the 1-1/2″ clearances to combustible materials are maintained (Diagram 4). Install the termination cap.

18

Excalibur P95 Zero Clearance Direct Vent Gas Fireplace

INSTALLATION

Diagram 5
The four wood screws provided should be replaced with appropriate fasteners for stucco, brick, concrete, or other types of sidings.
Note: If installing termination on a siding covered wall, a vinyl siding standoff or furring strips must be used to ensure that the termination is not recessed into the siding.
7) Before connecting the horizontal run of vent pipe to the vent termination, slide the Wall Thimble (Part # 620-926) over the vent pipe.
8) Slide the appliance and vent assembly towards the wall carefully inserting the vent pipe into the vent cap assembly. It is important that the vent pipe extends into the vent cap 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.

VERTICAL TERMINATION

1. Maintain the 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 pages 14-16 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 plumb

bob down from the ceiling to the position of the appliance Diagram 1

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 vent-

ing system.

You may wish

to relocate the

appliance or to

offset, as

shown in Dia-

gram 2 to avoid

cutting load

bearing mem-

Diagram 2

shown in Diagram 3 and install the firestop.
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
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.
the flashing) as per Diagram 4.
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

Diagram 6

9. Install wall thimble in the center of the 10″ square and attach with wood screws (Diagram 7).

Diagram 7

Note: Apply sealant “Mill-Pac” to inner pipe and high temperature silicone sealant to outer pipe on every twist-lock joint.
bers. 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 10 inch square hole. Frame the hole as
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

Excalibur P95 Zero Clearance Direct Vent Gas Fireplace

19

INSTALLATION

the minimum height requirements specified in Diagram 5 or local codes. Note that for steep roof pitches, 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 bOe fefsnceltoCsehda.rt
INSTALLATION PROCEDURES
for FPI Direct Vent System (Flex)

Note: To make 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 4″(100mm) inner collar of the termination and slipping the 4″(100mm) liner over it at least 1-3/8″ (35mm). Fasten with the 3 screws (drilling pilot holes will make this easier). Apply Mill Pac or high temperature silicone to the 6-7/8″(175mm) flex pipe and slip it over the 6-7/8″ outer collar of the vent terminal at least 1-3/8″(35mm) and fasten with the 3 screws.
NOTE: Horizontal sections must be supported at intervals not exceeding 3 feet (0.9 meter). (Flame picture and performance will be affected by sags in the liner).

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″.

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 4″(100mm) liner and outer 6-7/8″(175mm) 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 4″(100mm) liner down over it and attach with 3 supplied screws.

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

10. Locate the unit in the framing, rough in the gas (preferably on the right side of the unit) and the electrical (Junction block is on the left side) on the left. Locate the centerline of the termination and mark wall accordingly. Cut a 10″(254mm) hole in the wall (inside dimension).

Note: A 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 10″(254mm) x 10″(254mm) (inside dimensions) hole to give structural rigidity for mounting the termination.

20

Excalibur P95 Zero Clearance Direct Vent Gas Fireplace

INSTALLATION

P95-NG System Data

For 0 to 4500 feet altitude Burner Inlet Orifice Sizes: #30

Max. Input Rating 45,000 Btu/h Min. Input Rating 23,200 Btu/h

Supply Pressure min.5.0″ w.c.

Manifold Pressure

(High)

3.8″+/- 0.2″w.c.

P95-LP System Data

For USA installations follow local codes and/or the current National Fuel Gas Code, ANSI Z223.1.
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.
Important: Always check for gas leaks with a soap and water solution or gas leak detector. Do not use open flame for leak testing.

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.

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 LINE INSTALLATION

The manifold pressure is controlled by a regulator built into the gas control, and should be checked at the pressure test point.
Note: To properly check gas pressure, both inlet and manifold pressures should be checked using the valve pressure ports on the valve.

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
7. Gas cock knob 2) Manual high/low adjustment 3) Pilot Adjustment 4) Thermocouple Connection – option 5) Outlet Pressure Tap 6) Inlet Pressure Tap
8. Pilot Outlet 8) Main Gas Outlet 9) Alternative TC Connection
   Point

The gas line can be brought through either the right or 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: If 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 Zero Clearance Direct Vent Gas Fireplace

21

INSTALLATION

CONVERSION KIT FROM NATURAL GAS TO PROPANE MODEL #770-969 FOR P95 USING SIT 820 NOVA GAS VALVE

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

Conversion Kit Contains:

Qty. Part # 1 910-018
1 910-037 1 904-431 1 908-255 1 908-529 1 918-117

Description SIT Conversion Kit-50% Turndown LP LP Injector (Pilot Orifice) Burner Orifice #49 Decal “Converted to Propane” 5/32″ Allen Key Instruction Sheet

1. Turn the gas off.

2. Remove the glass frame.

3. Pull off the pilot cap to expose the pilot orifice.

4. Unscrew the pilot orifice with the allen key and replace with the LP pilot orifice in the kit and replace pilot cap.

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

6. Remove the burner/grate assembly, first by removing the two screws, one on each side of the grate, then pull out the grate.

Allen Key

8. Remove burner orifice with a 1/2″ wrench and discard. Use another wrench to hold on to the elbow behind the orifice.

Remove screw
Pull out the grate.

5. Remove the 2 screws, one on each side of the burner. Slide the burner to the left and then lift out.
   Remove screw
   Slide the burner to the left and lift out.

Burner Orifice
9) Reinstall new burner orifice LP stamped #48 and tighten.

13. Attach clear label “This unit has been converted to Propane” near or on the serial # decal. Attach white label “This valve has been converted from NG to LPG using SIT conversion Kit Code 0.907.204” onto the valve.

14. Remove and discard the 3 pressure regulator mounting screws (A), pressure regulator tower (B) and diagram (C).

15. Insure that the rubber gasket (D) is properly positioned and install the new HI/LO pressure regulator assembly to the valve using the new screws (E) supplied with the kit. Tighten screws securely.

16. Reverse steps 6) to 1).

17. Replace yellow “Natural Gas” label with red “Propane” label

18. Check for gas leaks.

19. Check inlet and outlet pressures.

20. Check operation of flame control.

21. Check for proper flame appearance and glow on logs.

22

Excalibur P95 Zero Clearance Direct Vent Gas Fireplace

INSTALLATION

OPTIONAL BRICK PANELS

LOG SET INSTALLATION

3. Place Log 02-89 on the front right side of the burner, fitting the log on the 2 pins.

4. 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.

5. Remove facade.

6. Remove glass door. Remove logs.
   Note: The logs must not be in the unit.

7. Insert the back brick panel first by carefully slipping it between the back wall of the firebox and the rear log bracket.

8. 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.

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.

02-89

The gas log kit (Part # 770-930) contains the following pieces:

a) 02-83 b) 02-84 c) 02-85 d) 02-86 e) 02-87 f ) 02-88 g) 02-89 h)

Rear Log Middle Left Log Center Right Log Middle Right Log Front Left Log Center Left Log Front Bottom Log Embers

902-306 902-307 902-308 902-309 902-310 902-311 902-312 902-154

4. Position Log 02-88 across the notch in Log 02-83 and rest the bottom of the log into the 2nd grate tab.
   02-88 02-83

02-84

02-83

02-88

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

02-87

02-86

2nd Grate Tab

Notch

02-85 02-89

5. Position Log 02-85 across the log landing in Log 02-88. Rest the bottom of the log against the 5th grate tab.

The “02” refer numbers (i.e. 02-83) are molded into the rear of each log.
NOTE: If you will be installing the optional Brick Panels, install the Brick Panels prior to installing the logs.

02-88

02-85

1. Carefully remove the logs from the box and unwrap them. The logs are fragile, handle with care – do not force into position.

5th Grate Tab

2. Place Log 02-83 on the rear log support pins

with the flat side to the back.

6. Fit the bottom of Log 02-84 into the bracket

on the left side of the burner.

02-83

02-84

Note: If the bottom brick panel must be removed: Remove the Rear Log Stand, then remove the Burner Tray. See the instructions on page 33.

Pins on the rear log support.

Excalibur P95 Zero Clearance Direct Vent Gas Fireplace

Bracket 23

INSTALLATION

7. Place the top of Log 02-84 across the notch 10) Fit Log 02-87 on the pin and then swing the 11) Place the embers on the front of the burner

on Log 02-88.

front end of the log to hit the first grate tab.

tray.

02-83 02-84

02-88

02-87

Notch Pin
8) Place the back of Log 02-86 against the bracket on the top right side of the burner.
The picture below is a view from the back of the burner.
02-86

02-88
Place embers on the burner tray. DO NOT BLOCK BURNER HOLES
12) 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.
13) Reverse steps 1-3 under Optional Brick Panels on page 23.

Rest log against bracket
9) Place the top of Log 02-86 on Log 02-85, supported by the knot.

02-83 Rear Log

02-84 Middle Left Log

02-86 Middle Right Log

02-86

Knot

02-85

24

02-87 Front Left Log

02-88 Center Left Log

02-89 Front Bottom Log

02-85 Center Right Log

Excalibur P95 Zero Clearance Direct Vent Gas Fireplace

INSTALLATION

GLASS DOOR INSTALLATION

1. Fit top door bracket over the flange at the top of the firebox.

2. 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 DOOR

1. Attach door bracket to side using 2 screws to the left and right side of the unit.

2. Secure with 3 screws on top and 3 screws on the bottom.

Tighten both screws to secure Front Facade to Glass Door.

Door Bracket attaches with
2 screws.

Tab Screw

2. Slide the door(s) onto the hinges.

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.

Secure Screw

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.

3. 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.

Loosen the screw holding the bracket.

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

Fit the bottom brackets over the pins on the base.

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

Adjust plunger by turning it to the left or right with a pin.

Excalibur P95 Zero Clearance Direct Vent Gas Fireplace

25

INSTALLATION

ACCENT KIT INSTALLATION

1. Remove the rivets by pulling out the hairclip with a screwdriver or plyer. Install the new rivets by putting them through the holes on the sides of the surround.

2. 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.

3. Take the hairclips and put it over the back of each rivet. Once the hairclip has been put on, cross over the ends of the hairclip to secure.

DOUBLE & SINGLE DOOR OPTION

Note: You may need to use some force to push the hairclip over the back of the rivet.
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.

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.

2. 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.

26

Excalibur P95 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.
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 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.

3. Run the wire through the right or left side inlet opening. Be careful not to damage wire.
   Note: We recommend a maximum of 15′ of wire but if you wish to go with a longer run, use the Thermostat Wire Table.

4. 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.

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.
Note: Preferable if the thermostat is installed on an interior wall.
Excalibur offers an optional programmable thermostat but any 250-750 millivolt rated nonanticipator type thermostat that is CSA, ULC or UL approved may be used.
CAUTION Do not connect millivolt
wall thermostat wires to a 120V wire.

CAUTION Do not connect millivolt remote
control wires to a 120V wire.
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.

Thermostat Wire Table

Recommended Maximum Lead Length (Two-Wire) When Using Wall Thermostat (CP-2 System)

Wire Size

Max. Length

14 GA. 16 GA. 18 GA. 20 GA. 22 GA.

50 Ft. 32 Ft. 20 Ft. 12 Ft.
9 Ft.

Excalibur P95 Zero Clearance Direct Vent Gas Fireplace

27

INSTALLATION

WIRING DIAGRAM

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

However, a 120V A.C. power supply is needed for the fan/blower operation.
(Do not cut the ground terminal off under any circumstances.)

NOTE: Even if the fan is not purchased with the unit, it is still a good idea to bring power to the receptacle box (provided with the unit) in case the fan is installed at a later date.

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

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

28

Excalibur P95 Zero Clearance Direct Vent Gas Fireplace

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. When the pilot stays lit, turn the gas knob further counter clockwise to the “ON” position.

AERATION ADJUSTMENT

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
7. Use the wall switch, thermostat or remote control to turn off the main burner.
8. Turn the main gas control clockwise to the “OFF” position to turn off the pilot.
9. Turn off all electric power to appliance if service is to be performed.

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

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

Note: Any damage due to carboning resulting from improperly setting the aeration controls is NOT covered under warranty.

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

FIRST FIRE
The first fire in your stove 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.

LIGHTING PROCEDURE
IMPORTANT Gas cock knob cannot be turned from “PILOT” to “OFF” unless it is partially depressed.

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.

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.

Adjustment Wire: Push to close or pull to open aeration cap.

The glass panel may require cleaning after the
unit has cooled down. DO NOT ATTEMPT TO CLEAN THE GLASS WHILE IT IS HOT.
Note: When the glass is cold and the appliance is lit, it may cause condensation and fog the glass. This condensation is normal and will disappear in a few minutes as the glass heats up.
DO NOT BURN THE APPLIANCE WITHOUT THE GLASS FRONT IN PLACE.
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.

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.
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

Excalibur P95 Zero Clearance Direct Vent Gas Fireplace

29

OPERATING INSTRUCTIONS

Copy of the Lighting Plate Instructions

FOR YOUR SAFETY READ BEFORE LIGHTING

This appliance must be installed in accordance with local codes, if any; if not, follow the current CAN1-B149/ANSI Z 223.1 (Australia: AG601, New Zealand: NZS 5261)

WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. Refer to the owner’s information manual provided with this appliance. For assistance or additional
information consult a qualified installer, service agency or gas supplier.

A)This appliance has a pilot which C)Use only your hand to push in or turn

must be lighted by hand. When the gas control knob. Never use tools.

lighting the pilot, follow these If the knob will not push in or turn by

instructions exactly.

hand, don’t try to repair it, call a qualified

service technician. Force or attempted

B) BEFORE LIGHTING smell all around repair may result in a fire or explosion.

the appliance area for gas. Be sure to

smell next to the floor because some D) Do not use this appliance if any part has

gas is heavier than air and will settle been under water. Immediately call a

on the floor.

qualified service technician to inspect the

appliance and to replace any part of the

WHAT TO DO IF YOU SMELL GAS

control system and any gas control which

– Do not try to light any appliance

has been under water.

– Do not touch any electric switch, do

not use any phone in your building This appliance needs fresh air for safe

– Immediately call your gas supplier operation and must be installed so there are

from a neighbours phone. Follow the provisions for adequate combustion and

gas supplier’s instructions.

ventilation air.

– If you cannot reach your gas supplier,

call the fire department.

CAUTION: Hot while in operation. Do not touch. Severe Burns may result. Due

to high surface temperatures keep children, clothing and furniture, gasoline

and other liquids having fammable vapors away. Keep burner and control

compartment clean. See installation and operating instructions

accompanying appliance.

LIGHTING INSTRUCTIONS

STOP! Read the safety information 4) Push in control knob all the way and

above on this label.

hold in. Continually push and release

1. Push in gas control knob slightly and the black button on spark igniter until

turn clockwise

to “OFF”. Knob pilot lights. Continue to hold the

cannot be turned from “PILOT” to “OFF” control knob in for about 1/2 minute

unless knob is pushed in slightly. Do after the pilot is lit. Release knob and

not force.

it will pop back up. Pilot should remain

2. Wait five (5) minutes to clear out any lit. If it goes out, repeat steps 1) to 4).

gas. If you then smell gas STOP! follow If knob does not pop up when released,

“B” in the safety information above on stop and immediately call your service

this label. If you don’t smell gas, go to technician or gas supplier. If the pilot will

the next step.

not stay lit after several tries, turn the gas

3. Turn knob on gas control counter- control knob to “OFF” and call your

clockwise

to”PILOT”.

service technician or gas supplier.

PILOT BURNER VEILLEUSE

OFF 5) Turn gas control knob counterclock-wise

THERMOPILE
ELEMENT THERMOELECTRIQUE

to “ON”. 6) Use rocker switch to op-
erate main burner.

TO TURN OFF GAS APPLIANCE

1. Push in the gas control knob slightly and 2) Turn off all electric power to the turn clockwise to “OFF”. Do not force. appliance if service is to be performed.

You may shut off the pilot during prolonged non use periods to conserve fuel.
DO NOT REMOVE THIS INSTRUCTION PLATE 908-017a

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.
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.
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.

30

Excalibur P95 Zero Clearance Direct Vent Gas Fireplace

MAINTENANCE

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:
9. 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.
10. Remove the Cap, and shine a flashlight down the Vent. Remove any bird nests, or other foreign material.
11. 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.
12. 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 FACADE
The 24 carat gold-plated finish on the facade 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.
Note: Improper positioning of logs may create 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.
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.

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 stepby-step 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 (as per instructions on page 25). 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.

Excalibur P95 Zero Clearance Direct Vent Gas Fireplace

31

MAINTENANCE

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

Ensure that the fan blades do not rub against the valve tubing. See diagram 1.

To Install the Fan

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.
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.

Diagram 1

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.

11. 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.

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

Slide Fan A in sideways from the left.
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.
8) Insert Fan B in from the front and position it on top of the mounting studs on the left side.

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.

To Remove the Fan

1. Shut the power off. 2) Reverse the installation instructions.
   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.

Position Fan B on mounting studs.
32

Secure left side with 2 screws and right side with one screw.
Excalibur P95 Zero Clearance Direct Vent Gas Fireplace

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 (page 25).

5. 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

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

2. Remove the logs.

3. Remove the burner/grate assembly, first by removing the 2 screws, 1 on each side of the grill, then lift out the grill.

4. Disconnect the inlet gas line. See dia. 2.

5. Disconnect the 2 TP wires and the 2 TH wires from the valve.

6. Reconnect the “gas out” flare fitting with an 11/16″ wrench.

7. Reconnect the “gas out” flare nut with a 13/ 16″ wrench.

8. Remove the 12 screws securing the valve tray assembly in place and then lift the entire assembly out.

9. Install piezo ignitor push button assembly and reconnect wire.

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

11. Reconnect the pilot tube nut with a 7/16″ wrench.

Remove screw
7) Remove the 2 screws, 1 on each side of the burner. Slide the burner to the left and then lift out.
Remove screw

screws

Valve Tray Assembly

7. Scrape off the old gasket from the floor of the firebox and from the valve tray assembly.

8. Install a new gasket and reinstall the valve tray assembly.
   Note: Failure to install a new gasket may severely affect the appliance performance.

9. Reinstall the 10 hold down screws.

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

Slide the burner to
the left and lift
out.

8. Remove the rear log stand by removing the 2 screws.

screws

Rear Log Stand

13. Undo the pilot tube from the valve with a 7/16″ wrench.

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.

19. 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.

20. Install Burner/grate assembly

21. 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.)

22. Fire up the unit temporarily

23. Check the manifold pressure.

24. Reinstall the logs and brick panels as needed.

25. Reinstall the glass door and the facade.

26. Fire up the unit again and check for proper flame appearance and glow on logs.

Excalibur P95 Zero Clearance Direct Vent Gas Fireplace

33

PARTS LIST

Part #

Description

P95 MAIN ASSEMBLY
Part # Description

Part # Description

1. 430-129 2) * 7) 910-428 8) 910-429 9) 910-430 10) 904-687 22) 770-033
2. 780-011 25) 770-074
3. 790-102 27) 28) 29) 30)
4. 902-305 32) 902-304
   770-928 770-901 770-902 770-903 770-904

Receptacle Box Mount Thermodisc Bracket Duplex Receptacle

432-967 Burner ON/OFF Switch Assy 38) 910-241 Burner ON/OFF – Switch
910-899 Wire Harness – Valve to Burner

Box – Receptacle Cover – Receptacle Clamp Connector

42. 430-517/P Fan Assembly (120 Volts) 910-331/P Fan Motor (120 Volts)

Baffle Guide

770-523 Fan Switch Assembly

Standoff – Top Standoff

43. 910-813 Power Cord (120 Volts) 46) 910-330 Fan Speed Control Switch

Sealing Plate Outer Flue Collar Inner Flue Collar Assy Flue Mounting Bracket

47. 904-586 48) 910-199 49) 910-142
    910-878

Knob – Speed Control Wire Holder Clip Thermodisc-Fan Auto On/Off Wire Harness – Twin Fan Cable

Gasket for Flue Collar

50. 510-994 Dura-Vent Adaptor (Optional)

Brick Panel – Base – Rear Brick Panel – Base (Front)

60. W260260 Top Relief Frame Gasket 61) 942-117 Top Relief Plate Frame

Brick Panel Set – Standard

62. W260280 Top Relief Plate Gasket

Brick Panel Set – Standard Brown 63) 770-066 Top Relief Plate

Brick Panel Set – Standard Red 64) *

Hex Cap Screw 1/4 20NC 3.5

Brick Panel Set – Herringbone Brown 65) *

Hex Cap Screw 1/4 20NC 2.0

Brick Panel Set – Herringbone Red 80) *

Hex Cap Screw 1/4 20NC 1.75

92. 946-001 Oval Duct Adaptor 93) 946-007 Angle Bracket

93. 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 Heat Release Duct Kit (Opt.) 108) 910-165 Fan (120 V) 109) 946-000 Flexible Air Release Duct
    918-108b Manual 770-969 Conversion Kit – NG to LP
    *Not available as a replacement part.

94. • 34. • 35. • 36. 904-716
                      511-031

Brick Panel – Back Brick Panel – Left Brick Panel – Right #10 x 5/8″ Butt Spacer Brick Panel Clip

946-556 89) 946-004 90) 946-000 91) 946-002

Heat Wave Duct Kit (Optional) Junction Box Round Duct Adaptor Round to Oval Adaptor

34

Excalibur P95 Zero Clearance Direct Vent Gas Fireplace

PARTS LIST

Excalibur P95 Zero Clearance Direct Vent Gas Fireplace

35

PARTS LIST

Part #
52) 910-190 54) 948-043

P95 BURNER ASSEMBLY & LOG SET
Description
Piezo Ignitor & Nut Bottom Relief Spring

770-574/P 770-576/P 56) 770-071 57) 910-378 910-380 58) * 66) 910-038 910-039 904-660 904-431 936-170 67) 780-057 68) W840470

Valve Assy – Natural Gas Valve Assy – Propane Gasket – Valve Tray Valve – S.I.T. – Natural Gas Valve – S.I.T. – Propane 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.

36

Excalibur P95 Zero Clearance Direct Vent Gas Fireplace

PARTS LIST

Part # 770-518 132) * 135) 940-328/P 136) 936-155 904-691
770-920 770-922 770-914 770-916 770-918

P95 FLUSH FRONT ACCESSORIES

Description Door Assembly – Complete Flush Door Frame Glass (Flush) Glass Gasket (Tadpole) U-Clip
Surround – Black – Complete Surround – Gold – Complete Surround – Antique Gold – Complete Surround – Antique Nickel – Complete Surround – Soft Copper – Complete

Part #

Description

146. 790-105 Handle – Black

790-082/10 Handle – Nickel

790-082/02 Handle – Gold

155. 904-735 Push-Fit Ball Plunger

156. 904-722 Carriage Bolt – Black

904-722/02 Carriage Bolt – Gold

904-722/10 Carriage Bolt – Nickel

*Not available as a replacement part.

141. • 142. • 145. • 146. • 148. • 157. • 948-221

Surround – Faceplate – Excalibur Surround – Louver Surround – Hood Handle Rivet-67-5/16 x 1/2 Carriage Bolt Logo Plate

770-931 770-932 770-933 770-941 770-942 770-943

Double Screen Door – Complete – Black Double Screen Door – Complete – Nickel Double Screen Door – Complete – Gold Double Screen Door – Complete – Antique Gold Double Screen Door – Complete – Antique Nickel Double Screen Door – Complete – Soft Copper

Double Screen Door Frame – Right Double Screen Door Frame – Left Mesh Screen – Double Door Retaining Plate – Double Door Door Mounting Bracket – Right Door Mounting Bracket – Left

Excalibur P95 Zero Clearance Direct Vent Gas Fireplace

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NOTES

38

Excalibur P95 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.

• Subsidy according to job scale as predetermined by FPI.

Excalibur P95 Zero Clearance Direct Vent Gas Fireplace

39

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 2004, FPI Fireplace Products International Ltd. All rights reserved.

Printed in Canada

References

• excalibur-fire.com

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