Excalibur P90 Quick start guide

WARNING:
Iftheinformationintheseinstructionsarenotfollowedexactly
,
a fire or explosion may result causing property damage
,
personal injury or loss of life.
FOR YOUR SAFETY
Do not store or use gasoline or other flammable vapours an
d
liquids in the vicinity of this or any other appliance.
Installation and service must be performed by a qualifie
d
installer, service agency or the gas supplier.
FOR YOUR SAFETY
What to do if you smell gas:
!!
!!
!Do not try to light any appliance
!!
!!
!Do not touch any electrical switch
:
do not use any phone in you
r
building.
!!
!!
!Immediately call your gas supplie
r
from a neighbour's phone. Follow
the gas supplier's instructions.
!!
!!
!If you cannot reach your ga
s
supplier, call the fire department.
FPI FIREPLACE PRODUCTS INTERNATIONAL LTD. 6988 Venture St., Delta, BC Canada, V4G 1H4
918-072b
MODELS: P90-NG Natural Gas P90-LP Propane
01/15/04
P90 Zero Clearance Direct Vent Gas Fireplace
Owners &
Installation Manual
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.
www.excalibur-fire.com

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace
2
To the New Owner:
Congratulations!
You are the owner of a state-of-the-art Excalibur Gas Fireplace by FPI FIREPLACE
PRODUCTS INTERNATIONAL LTD. The P90 is a hand crafted appliance and has
been designed to provide you with all the warmth and charm of a wood fireplace at
the flick of a switch. The model P90 has been approved by Warnock Hersey for both
safety and efficiency. As it also bears our own mark, it promises to provide you with
economy, comfort and security for many trouble free years to follow. Please take a
momentnowtoacquaintyourselfwiththeseinstructionsandthemanyfeaturesofyour
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
FIREPLACEHEATERSANSIZ21.88-2002/CSA2.33-2002andGAS-FIREDAPPLIANCESFORUSEATHIGHALTITUDESCAN/CGA2.17-M91.
This Direct Vent System Appliance must be installed in accordance with the manufacturer's installation instructions and the Manufactured Home
ConstructionandSafetyStandard,Title24CFR, Part 3280, orthecurrentStandardofFireSafetyCriteriaforManufacturedHome 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 appli-
ance 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
permanentlylocated,manufactured(mobile)home,where
notprohibitedbylocalcodes.
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.

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 3
TABLE OF CONTENTS
Operating Instructions
OperatingInstructions ...............................................29
LightingProcedure ....................................................29
ShutdownProcedure .................................................29
First Fire ...................................................................29
AerationAdjustment..................................................29
NormalOperatingSoundsof
GasAppliances ..................................................29
LightingPlateInstructions .........................................30
Maintenance
MaintenanceInstructions ..........................................30
GeneralVentMaintenance ........................................31
Gold-PlatedorBrassDoororFacade........................31
LogReplacement ......................................................31
Thermopile/Thermocouple .........................................31
Glass Gasket............................................................31
DoorGlass................................................................31
FanMaintenance ......................................................32
RemovingValve.........................................................33
InstallingValve ..........................................................33
PartsList
Replacement/SparePartsList...................................34
Warranty
Warranty ...................................................................39
Safety Label
SafetyLabel............................................................... 4
Installation
ImportantMessage .................................................... 5
BeforeYouStart ........................................................ 5
GeneralSafetyInformation ......................................... 5
InstallationChecklist .................................................. 5
LocatingYourGasStove............................................ 6
ManufacturedHomeAdditionalRequirements ............ 6
OptionalHeatWaveDuctSystem ............................... 6
OptionalHeat ReleaseKit .......................................... 6
Clearances................................................................. 6
CombustibleMantelClearances................................. 7
P90FlatSurround and Tile Kit.................................... 7
UnitBaseStand-Offs ................................................. 7
FramingandFinishing................................................ 7
FacingRequirements ................................................. 8
HearthRequirements ................................................. 8
OptionalCoverPlateTemplate ................................... 9
Unit Assembly Prior to Installation
TopStandoffAssembly........................................ 9
Side Nailing Strips ............................................... 9
VentingIntroduction ................................................... 9
Venting: Direct Vent System (Flex)...........................10
ExteriorVentTerminationLocations..........................11
Venting: Simpson Dura Vent Direct Vent GS ............12
Venting:Simpson Dura VentComponentsList..........13
VentingArrangements
HorizontalTerminations ......................................14
VerticalTerminations ..........................................15
Venting-Dura-VentHorizontalInstallations ..............18
Venting-Dura-VentVerticalTermination...................19
Venting-InstallationProceduresfor DirectVent
System (Flex).....................................................20
System Data.............................................................21
HighElevation ...........................................................21
GasLineInstallation..................................................21
Pilot Adjustment .......................................................21
Gas Pipe Pressure Test ............................................21
SITValveDescription ................................................21
ConversiontoPropane ..............................................22
Optional Brick Panels ...............................................23
LogSetInstallation ...................................................23
GlassDoorInstallation ..............................................25
FrontFacade.............................................................25
OptionalScreenDoor ................................................25
Accent Kit Installation ...............................................26
RemoteControl(optional)..........................................27
RemoteWallSwitch(optional) ..................................27
WallThermostat(optional) ........................................27
WiringDiagram .........................................................28

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace
4
This is a copy of the label that accompanies
each P90 Zero Clearance Direct Vent Gas
Fireplace. We have printed a copy of the
contents here for your review. The safety label
is located on the front inside base of the unit,
visible when the bottom louver is open.
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.
SAFETY LABEL
Copy of Safety Decal for P90
FortheStateofMassachusetts,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 appli-
ances individual manual shut-off must be a
t-handle type valve.

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 5
INSTALLATION
CHECKLIST
1) 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 10-16.
2) Assemble Top Standoffs, page 9. (NOTE:
must be done before installing unit into
fireplace.)
3) Install vent, pages 18-20.
4) Make gas and electrical connections. Test
thepilot. Must be as per diagram. Page 21.
5) Install brick panels (optional), page 23.
6) Install log set where indicated on
page 23-24.
7) Install Front Facade, page 25.
8) Install Optional Screen Door, page 25.
9) Install optional Wall Switch, Remote Con-
trol, or Wall Thermostat, page 27.
10)Final check.
Before leaving this unit with the customer, the
installermustensurethattheapplianceisfiring
correctly and operation fully explained to
customer.
INSTALLATION
IMPORTANT:
SAVE THESE
INSTRUCTIONS
TheP90-NGorP90-LPDirectVentFireplacemust
be installed in accordance with these instruc-
tions. Carefully read all the instructions in this
manual first. Consult the "authority having juris-
diction"todeterminetheneedforapermitpriorto
startingtheinstallation.Itistheresponsibilityofthe
installer to ensure this fireplace is installed in
compliance with manufacturer's instructions and
all applicable codes.
BEFORE YOU START
Safeinstallationand operationofthisappliance
requires common sense, however, we are
required by the Canadian Safety Standards
and ANSI Standards to make you aware of the
following:
GENERAL SAFETY
INFORMATION
1) The appliance installation must conform
with local codes or, in the absence of local
codes, with the current Canadian or Na-
tional 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 orCSA C22.1 Cana-
dian Electrical Code.
3) See general construction and assembly
instructions.Theapplianceandventshould
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) Ventingterminalsshallnotberecessedinto
a wall or siding.
7) Any safety glass removed for servicing
must be replaced prior to operating the
appliance.
8) To prevent injury, do not allow anyone who
is unfamiliar with the operation to use the
fireplace.
9) Wear gloves and safety glasses for pro-
tection 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 appli-
ance be modified. Parts that have to be
removed for servicing should be replaced
prior to operating this appliance.
INSTALLATION AND REPAIR
SHOULD BE DONE BY A QUALI-
FIEDSERVICE PERSON. THEAP-
PLIANCESHOULDBEINSPECTED
BEFOREUSEANDATLEASTAN-
NUALLY BY A PROFESSIONAL
SERVICE PERSON. MORE FRE-
QUENT CLEANING MAY BE RE-
QUIREDDUETOEXCESSIVELINT
FROMCARPETING,BEDDINGMA-
TERIAL, ETC. IT IS IMPERATIVE
THAT CONTROL COMPART-
MENTS,BURNERSANDCIRCULAT-
ING AIR PASSAGEWAYS OF THE
APPLIANCEBEKEPTCLEAN.
DUE TO HIGH TEMPERATURES,
THEAPPLIANCESHOULDBELO-
CATED OUT OF TRAFFIC AND
AWAY FROM FURNITURE AND
DRAPERIES.
WARNING:FAILURETOINSTALL
THIS APPLIANCE CORRECTLY
WILLVOIDYOURWARRANTYAND
MAY CAUSE A SERIOUS HOUSE
FIRE.
CHILDRENANDADULTSSHOULD
BEALERTEDTOTHEHAZARDSOF
HIGHSURFACETEMPERATURES,
ESPECIALLY THE FIREPLACE
GLASS,ANDSHOULDSTAYAWAY
TO AVOID BURNS OR CLOTHING
IGNITION.
YOUNG CHILDREN SHOULD BE
CAREFULLY SUPERVISEDWHEN
THEYAREINTHESAMEROOMAS
THEAPPLIANCE.
CLOTHING OR OTHER FLAMMA-
BLEMATERIALSHOULDNOTBE
PLACEDONORNEARTHEAPPLI-
ANCE.
12)Installationandanyrepairstothisappliance
should be done by a qualified service per-
son. A professional service person should
becalledtoinspect thisapplianceannually.
Make it a practice to have all of your gas
appliances checked annually.
13)Do not slam shut or strike the glass door.
14)Under no circumstances should any solid
fuels (wood, paper, cardboard, coal, etc.)
be used in this appliance.
15)The appliance area must be kept clear and
free of combustible materials, (gases and
other flammable vapours and liquids).
Emissions from burning wood or gas could
contain chemicals known to the State of
California to cause cancer, birth defects or
other reproductive harm.

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace
6
INSTALLATION
Side Wall Clearance 6-1/2"(165mm)
Horizontal Vent Clearances
Top 2-1/2"(64mm)
Side 1-1/2"(38mm)
Bottom 1-1/2"(38mm)
Vertical Vent Clearances 1-1/4" (32mm)
Alcove Clearances**:
Max. Depth 36" (914mm)
Min. Width 48" 1219mm)
Min. Height 72" 1829mm)
* see mantle clearance instructions
(page 7).
CLEARANCES
The clearances listed below are Minimum dis-
tances 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 fire-
place and vent system be installed only in
accordance with these instructions.
Diagram 1
This includes:
1) Clocking the appliance to ensure the cor-
rect firing rate (rate noted on label 35,000
Btu/h) after burning appliance for 15 min-
utes.
2) If required, adjusting the primary air to
ensurethattheflamedoes notcarbon.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 responsibil-
ity of the manufacturer.
LOCATING YOUR
GAS STOVE
1) When selecting a location for your stove,
ensure that the clearances outlined on this
page are met.
2) Provide adequate clearances for servic-
ing.
3) The appliance must be installed on a flat,
solid, continuous surface (e.g. wood, met-
al, concrete). This may be the floor, or
raiseduponaplatformtoenhanceitsvisual
impact. If the appliance is going to be in-
stalled on carpeting, combustible linoleum
tileorothercombustiblematerialother than
wood flooring, the appliance must be in-
stalled on a metal or wood panel extending
the full width and depth of the appliance.
4) The P90 Direct Vent Gas Fireplace can be
installed in a recessed position or framed
out into the room as in A, B, C, D. See
Diagram1.
for clearances and floor protection before
actually installing this appliance. Have a
qualified inspector, dealer, or installer re-
view your plans before installation.
Note: For vent terminations see page
11.
MANUFACTURED
MOBILE HOME
ADDITIONAL
REQUIREMENTS
1) Ensurethatstructuralmembersarenotcut
or weakened during installation.
2) Ensure proper grounding using the #8
ground lug provided. See page 28.
5) ThisapplianceisListedforbedroom instal-
lations when used with a Listed Millivolt
Thermostat. Some areas may have further
requirements, check local codes before
installation.
6) The P90 Direct Vent Gas Fireplace is ap-
proved for alcove installations, which meet
the clearances listed on this page.
7) We recommend that you plan your installa-
tion on paper using exact measurements
A) Flat on Wall
B) Flat on Wall Corner
C) Recessed into
Wall/Alcove
D) Corner
DUCT SYSTEM
OPTION
KIT #946-556
The HeatWave Air Duct Kit increases the
effectiveness of your fireplace by dispersing
warm air from the fireplace to remote locations
inthesameroom or other rooms inyourhome.
Upto twokitsmaybeinstalledonthefireplace.
Please Note: Only 1 HeatWave kit may be
operatedatonetime.Thisincludestheinternal
blower option as well.
OPTIONAL
HEAT RELEASE
KIT #946-570
TheHeat ReleaseKitexpelswarmair from the
fireplace to the outside of the building, allowing
the fireplace to be operated with less heat
enteringtheroom.Thekitmaybeusedoneither
the left or right side.
WARNING:
Fire hazard is an extreme risk
if these clearances are not
adhered to.
Clearances for HeatWave and
Heat Release Kit
Heat Release Kit
TheHeatWaveDuctKitandtheHeatRelease
Kit have different clearance and framing
requirements,checktheHeatWaveandHeat
Release manual for details.
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.

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 7
19-1/4"(489mm)
including standoffs
10-7/8"
(276mm)
49-7/8"(1267mm)
70-1/2"(1791mm)
4"(100mm)
Dia. Inner
6-7/8"(175mm)
Dia. Outer
46-1/2"(1181mm)
42"(1067mm)
31"
(787mm)
FRAMING AND
FINISHING
1) Determine the total thickness of facing ma-
terial (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.
Install Top Standoffs & Side Nailing Strips
beforeunitisslippedintoposition. Seepage
9 for assembly details.
2) Frame in the enclosure for the unit with
framing material. The framed opening is
46-3/8" high x 46-1/2" wide x 19-1/2" deep
(1168mm high x 1181mm wide x 495mm
deep).
Framing Dimensions
A B C
46-1/2" 46-3/8" 19-1/2"*
1181mm 1168mm 495mm
*If HeatWave option is installed,
minimum depth is 20" (508mm)
*If HeatWave option is installed,
minimum depth is 20" (508mm)
INSTALLATION
COMBUSTIBLE MANTELS
Because of the extreme heat this fire-
place emits, the mantel clearances
are critical. Combustible mantel clearanc-
es 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-com-
bustible board.
Thesedrawingsaretoscaleat1:6(oneinch
= 6 inches)
Mantelcanbe installed anywhere inshaded
area or higher using the above scale.
Note: Ensure the paint that is used on
the mantel and the facing is
"heat resistant" or the paint
may discolour.
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.)
P90 Flat Wall Surround and Tile Kit
The P90 Flat Wall Surround, Hearth Pad and Tile Kit cannot be modified in any way. It must be
installed as manufactured.
P90 Flat Wall Surround and Tile Kit Specifications
UNIT BASE STAND-OFFS
To accommodate varying thicknesses and fin-
ishes of hearth materials, we have increased
the overall height of the appliance by a further
11/8”.Thisincreaseisaddedwiththeinclusion
of two stand-offs at the bottom of the unit,
belowtheouter box, taking the overallheightof
the framing dimensions from 45-1/4” up to 46-
3/8”.
In the event that you should choose to use
thinner materials to finish the hearth, you can
omitthe stand-offs provided forraising the unit.
However, we recommend that you leave the
framing dimensions as they are in the manual
and alter only the facing requirement by reduc-
ing it by the same distance that you have
lowered the unit.
Insert the 2 unit base stand-offs underneath
the unit as shown in the diagram below. Space
the stand-offs centrally, approximately 2 or 2-
1/2 feet apart. Ensure that the unit is not unsta-
ble.

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace
8
INSTALLATION
Fireplace
Stand
No hearth is
required when
the unit is raised
3" (76mm) off of
the floor surface
Flooring
HEARTH REQUIREMENTS
Floor Mounted Fireplaces
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).
Facing Over 1" (25mm) Thick
Ifthefacingmaterialisover1"(25mm) thick(example:brickorriverrock),
installthe facing aroundthe perimeter ofthe face. Youmay 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 ac-
commodate the brick
thickness.Example:Ifthe
brick is 2" thick, the unit
must be raised 1".
Note: 48" (11219mm) is the
minimum height for
both flex termination
or Simpson Dura-
Vent venting.
4) Note: The unit does
not have to be com-
pletely enclosed in
a chase. The clear-
ance on top of the
unit is 0" to the
standoffs so com-
bustible building
materials can be
laid directly on top
of the standoffs.
You must maintain
clearance from the
vent to combusti-
ble materials for
both rigid and flex,
see Vent Clearanc-
es, page 6.
You must take into ac-
count the depth of the
floor covering (carpet,
tile, linoleum, etc.) when
determining the height of
the fireplace stand.
Raised Fireplaces
Please note that all verti-
cal measurements are
takenfrom the base ofthe
unit excluding risers or
bottom stand-offs.
The HeatWave Duct Kit has different clear-
ance and framing requirements, check the
HeatWave manual for details.

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 9
INSTALLATION
VENTING
INTRODUCTION
The P90 uses the "balanced flue" technology Coaxial system. The inner liner vents products
ofcombustionto the outside whiletheouter liner draws outsidecombustionair into the combustion
chambertherebyeliminatingtheneedtouseheatedroomairforcombustionandlosingwarmroom
air up the chimney.
Note: These flue pipes must not be connected to any other appliance.
Thegasappliance andventsystemmustbeventeddirectlytotheoutsideofthebuilding,andnever
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.
Side Nailing Strips
Thesidenailingstripscome attachedtotheunit.
Thereare2plates,oneonthetopandbottomthat
can be folded out as required.
Plates can
be folded out.
1) Ensure top clip screws are at top of oblong
holes before installation.
Back View of
Cover Plate
Pin Holes
Top Clip
Pins
2) Position bottom of cover plate over pins
located at the bottom of the firebox.
Oblong Screw
Holes
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 tight-
en screws.
TOREMOVE:
1) Remove 2 screws that secure top clip.
Ensure to hold cover plate as it will fall
forward.
2) Pullouttopclipthatisstillhookedontoglass.
OPTIONAL COVER
PLATE TEMPLATE UNIT ASSEMBLY
PRIOR TO
INSTALLATION
The 2 Top Standoffs must be correctly posi-
tioned and attached to the top before unit is
slipped into position.
TopStandoffAssembly
Thetopstandoffs are shipped in aflat position
and must be folded into shape and attached.
1) Remove the standoffs from the fireplace
top.
2) Take each standoff and bend into the
correct shape. Bend up at the bend lines
until the screw holes in the standoff and
the pre-punched screw holes on the fire-
place top line up.
3) Attach the standoff securely to the top with
2 screws per standoff (on opposite cor-
ners).

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace
10
VENTING
FPI Direct Vent System (Flex) Horizontal Terminations Only
Theseventingsystems,incombinationwiththeP90DirectVentGasFireplace,havebeentestedandlistedasadirectventheatersystembyWarnock
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 P90 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)
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)
If longer runs are needed, the FPI Direct
Vent system (Flex) kits are:
946-516 includes all the parts needed to
install the P90 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.
946-620 includes all the parts needed to
install the P90 with a maximum 20' run.
1) 6-7/8" dia. flexible liner (20 ft. length)
2) 4" dia. flexible liner (20 ft. length)
3) spring spacers (19)
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)
INSTALLATION

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 11
INSTALLATION
EXTERIOR VENT TERMINATION LOCATIONS
.
BB
B
B
A
C
V
V
V
V
V
VV
A
A
V
Fixed
Fixed
Openable
Closed Closed
Openable
NL
B
E
B
M
D
F
K
H
j
Vertical
Termination
V
Vent terminal Area where terminal is not permited
A
Air supply outlet
24"
V
A
G
Inside
corner detail
V
24"
18"
Vertical
Termination
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. 15"/38cm) F= Clearancetooutsidecorner:withAstroCapTerminationCap(min6"/15cm),withDura-
Vent Termination Cap (14"/36cm)
G= Clearance to inside corner: with AstroCap Termination Cap (min 6"/15cm), with Dura-
Vent Termination Cap (12"/30cm)
H= Nottobeinstalledaboveameter/regulatorassemblywithin(3'/90cm)horizontallyfrom
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.

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace
12
INSTALLATION
Simpson
Dura-Vent
Direct Vent GS
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 P90.
Theminimum components required for a basic
horizontal termination are:
1 HorizontalTerminationCap
190
oElbow
1 Flue Adaptor
1 WallThimble
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
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
Alternate
Horizontal
Termination
Caps
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"
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 Dura-
Vent Co. Inc.
Horizontal and Vertical Terminations for 4" x 6-5/8" 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
vinylsiding),measuretooutside
surface of wall without siding
and add 2 inches.

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 13
SIMPSON DURA-VENT VENTING COMPONENTS LIST
All Simpson Dura-Vent components are available directly from FPI.
971 Horiz. Termination Kit includes: 90oblack elbow, wall
thimble cover, horiz. square termination cap, 24" black
pipe, and 11" -14" 5/8" adjustable black pipe
970 Basic Horizontal Termination Kit includes:
90oblack elbow, wall thimble cover, horiz. square
termination cap
978 Vertical Termination Kit includes:
0/12 - 6/12 pitch adjustable flashing, storm collar, low
profile termination cap
908 1208 6" Pipe Length
908B 1208B 6" Pipe Length, Black
907 1207 9" Pipe Length
907B 1207B 9" Pipe Length, Black
906 1206 12" Pipe Length
906B 1206B 12" Pipe Length, Black
904 1204 24" Pipe Length
904B 1204B 24" Pipe Length, Black
903 1203 36" Pipe Length
903B 1203B 36" Pipe Length, Black
902 1202 48" Pipe Length
902B 1202B 48" Pipe Length, Black
911 1211 11" to 14-5/8" Pipe, Adjustable
911B 1211B 11" to 14-5/8" Pipe, Adjustable, Blk
917 1217 17" to 24" Pipe, Adjustable
917B 1217B 17" to 24" Pipe, Adjustable, Blk
945 1245 45o Elbow
945B 1245B 45o Elbow, Black
945G 1245G 45o Elbow, Swivel
45BG 1245BG 45o Elbow, Black, Swivel
4" x 6-5/8" 5" x 8" Description 4" x 6-5/8" 5" x 8" Description
Horizontal Terminations for 5" x 8" Venting
(forventingexceeding10feethorizontal)
990 1290 90o Elbow
990B 1290B 90o Elbow, Black
990G 1290G 90o Elbow, Swivel
990BG 1290BG 90o Elbow, Black, Swivel
940 1240 RndCeilingSupp/WallThimbleCover
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 StormCollar
963 1263 CeilingFirestop
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
INSTALLATION

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace
14
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 90oelbow (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.
• 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.
A vent guard (Part# 946-506/P) should be
used whenever the termination is lower than
the specified minimum or as per local codes.
Note: FPI Direct Vent System (Flex) is only approved
for horizontal terminations.
Please note that all vertical
measurements are taken from
the base of the unit excluding
risers or bottom stand-offs.
Simpson Dura-Vent
5" inner diameter
8" outer diameter
Note: Must use FPI increaser starter collar
(Part # 946-605) at beginning of vent run.
5" x 8" venting starts at unit.

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 15
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 90oelbows (two 45o elbows equal one 90oelbow).
Note: 1) A maximum of two 90oelbows are permitted.
2) A minimum of 6 ft. (1.8m) vertical from base of unit is required if two 90oelbows 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 90oelbow.
Simpson Dura-Vent
4" inner diameter
6-5/8" outer diameter
FPI Flex Vent
4" inner diameter
6-7/8" outer diameter
• 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.
A vent guard should be used whenever the
terminationislowerthanthespecifiedminimum
or as per local codes.
If length "B" is increased, length "A" must
be decreased by a corresponding amount.
INSTALLATION
Please note that all vertical
measurements are taken from
the base of the unit excluding
risers or bottom stand-offs.

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace
16
INSTALLATION
VENTING ARRANGEMENTS - VERTICAL TERMINATIONS
SIMPSON DURA-VENT DIRECT VENT GS SYSTEM (Propane & Natural Gas)
The P90 is approved for a maximum 23 ft. (7.0m) vertical, with a maximum 12 ft. (3.7m) horizontal offset
using two 90oelbows (two 45o elbows equal one 90oelbow) with Simpson Dura-Vent Direct Vent
GS vent systems for Propane and Natural Gas, as per diagram 1.
The P90 is approved for a maximum 37 ft. (11.3m) straight vertical, including a maximum 20" (0.5m)
horizontal offset using two 90oelbow (two 45o elbows equal one 90oelbow) 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).
Note: FPI Direct Vent System (Flex) is only approved for horizontal terminations.
Diagram 1 Diagram 2

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 17
The P90 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.
Theshadedareain thediagram3showsallallowable combinationsofstraight
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.
Diagram 3
INSTALLATION
Please note that all vertical
measurements are taken from
the base of the unit excluding
risers or bottom stand-offs.

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace
18
INSTALLATION
Min. 12"*
(305mm)
Adequate
drainage
Window
Well
Gravel
Dura-Vent
Snorkel
Diagram 4
6) The arrow on the vent cap should be
pointing up. Insure that the 1-1/2" clear-
ances to combustible materials are main-
tained (Diagram 4). Install the termination
cap.
NOTE: For Snorkel terminations in ABOVE
grade installations, follow nation-
al or local code requirements.
BelowGradeInstallation
If the Snorkel Termination must be installed
below grade, i.e. basement application, proper
drainage must be provided to prevent water
fromenteringtheSnorkelTermination.Referto
Diagram4.DonotattempttoenclosetheSnor-
kel within the wall, or any other type of enclo-
sure.
*Dia 3, 3a & 4: As specified in CGA B149
Installation Code. Local codes or regula-
tions may require different clearances.
HORIZONTAL
INSTALLATIONS
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 at-
tached. 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
andtheelectrical(junctionblockisontheleft
side) on the left.
2) Direct Vent pipe and fittings are designed
with special twist-lock connections to con-
necttheventingsystemtotheapplianceflue
outlet. A twist-lock appliance adaptor is an
available option that must be used in con-
junction with the Simpson Dura-Vent Direct
Vent GS system.
3) Putabeadofsiliconeinsidetheoutersection
of the adapter and a bead of Mill Pac on the
inner collar. Slip the adapter over the exist-
ing 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-lockprocedure:Fourindentations,
locatedon thefemaleendsofpipesand
fittings, are designed to slide straight
ontothemaleendsofadjacentpipesand
fittings, by orienting the four pipe inden-
tations so they match and slide in to the
four entry slots on the male ends, Dia-
gram 1. Push the pipe sections com-
pletely together, then twist-lock one
section clockwise approximately one-
quarter turn, until the two sections are
fullylocked. The female locking lugswill
not be visible from the outside, on the
BlackPipeorfittings.Theymaybelocat-
edbyexaminingtheinside ofthefemale
ends.
Diagram 1
b) Horizontal runs of vent must be sup-
portedevery three feet. Wall straps are
available for this purpose.
5) Mark the wall for a 10" x 10" square hole.
Thecenterofthesquareholeshouldlineup
with the centerline of the horizontal pipe.
Cutandframethe10inchsquareholeinthe
exterior wall where the vent will be termi-
nated. If the wall being penetrated is con-
structed of non-combustible material, i.e.
masonry block or concrete, a 7"(178mm)
dia. (7-1/2"(191mm) dia. for flex) hole is
acceptable.
Diagram 2
Note:
a) Thehorizontalrunofventmustbelevel,
or have a 1/4 inch rise for every 1 foot
of run towards the termination. Never
allow the vent to run downward. This
couldcausehightemperaturesandmay
present the possibility of a fire.
b) Thelocationofthehorizontalventtermi-
nation 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 Snor-
kel Terminations are
available, as well as
the standard Riser
Vent.Followthesame
installation proce-
duresasused
for standard
Horizontal
Termina-
tion.NEV-
ER install
the snor-
kelupside
down.
Diagram 3
Diagram 3a
Note: Riser Vent
is only for use
in above grade
terminations.
Note: Apply sealant "Mill-Pac" to inner
pipe and high temperature sili-
cone sealant to outer pipe on eve-
ry twist-lock joint.
Note: With Dura-
Vent, the mini-
mum height
is achieved
by installing
a 90oelbow
directly to
the flue
adaptor.

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace 19
Diagram 3
Diagram 5
Diagram 1
Diagram 2
Note: Apply sealant "Mill-Pac" to inner
pipe and high temperature sili-
cone sealant to outer pipe on eve-
ry twist-lock joint.
Diagram 5
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 combus-
tible surfaces. Do not pack air
spaces with insulation. Check
pages 12-14 for the maximum
vertical rise of the venting sys-
temandthemaximum horizon-
tal offset limitations.
Diagram 7
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 stand-
off 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
WallThimble(Part#620-926)overthevent
pipe.
8) Slide the appliance and vent assembly to-
wards the wall carefully inserting the vent
pipeinto the vent cap assembly. It is impor-
tant 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. Se-
cure the connection between the vent pipe
andthe vent capby attaching thetwo 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.
9) Install wall thimble
in the center of the
10" square and
attach with wood
screws (Diagram
7).
2) Set the gas appliance in its
desiredlocation.Dropaplumb
bob down from the ceiling to
the position of the appliance
flue exit, and mark the location where the
vent will penetrate the ceiling. Drill a small
hole at his point. Next, drop a plumb bob
from the roof to the hole previously drilled
in the ceiling, and mark the spot where the
vent will penetrate the roof. Determine if
ceiling joists, roof rafters or other
framingwillobstructthevent-
ing system.
You may wish
to relocate the
appliance or to
offset, as
shown in Dia-
gram 2 to avoid
cutting load
bearing mem-
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
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
minimumrequirementsforclearancetocom-
bustibles of 1-1/2". Slip the flashing under
the shingles (shingles should overlap half
the flashing) as per Diagram 4.
Roof Pitch Minimum Vent Height
Feet Meters
flat to 7/12 2 0.61
over 7/12 to 8/12 2 0.61
over 8/12 to 9/12 2 0.61
over 9/12 to 10/12 2.5 0.76
over 10/12 to 11/12 3.25 0.99
over 11/12 to 12/12 4 1.22
over 12/12 to 14/12 5 1.52
over 14/12 to 16/12 6 1.83
over 16/12 to 18/12 7 2.13
over 18/12 to 20/12 7.5 2.29
over 20/12 to 21/12 8 2.44
Diagram 4: The upper half of the flashing is
installed under the roofing material and not
nailed down until the chimney is installed.
This allows for small adjustments.
6) Continue to assemble pipe lengths.
Note: If an offset is necessary in the attic
to avoid obstructions, it is impor-
tant to support the vent pipe every
3 feet, to avoid excessive stress
on the elbows, and possible sep-
aration. Wall straps are available
for this purpose (Diagram 2).
Galvanized pipe is desirable above the roof-
line due to its higher corrosion resistance.
Continue to add pipe sections through the
flashinguntiltheheight oftheventcapmeets
theminimumheightrequirementsspecifiedin
Diagram5orlocalcodes. Notethatforsteep
INSTALLATION

Excalibur P90 Zero Clearance Direct Vent Gas Fireplace
20
INSTALLATION
4) Separate the 2 halves of the wall thimble
and securely fasten the one with the tabs
totheoutsidewallmakingsurethatthetabs
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)lineroutenoughtoslipover
the flue collars of the fireplace. (You may
wish to cut the liner shorter to make it more
workable.)Donotbendliner more than 90o.
7) ApplyMillPacoverthefireplaceinnercollar
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 thim-
ble 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 build-
up may occur. Be sure to check vent
terminationareaaftersnowfalls,andclear
to prevent accidental blockage of venting
system. When using snow blowers, make
sure snow is not directed towards vent
termination area.
Note: To make the
installation more
aesthetically pleas-
ing, we recom-
mend framing out a
square to mount
the terminal to.
OffsetChart
INSTALLATION
PROCEDURES
for FPI Direct Vent
System (Flex)
1) Locate the unit in the framing, rough in the
gas (preferably on the right side of the unit)
and the electrical (Junction block is on the
left side) on the left. Locate the centerline
oftheterminationandmarkwall according-
ly.Cuta10"(254mm)holeinthewall(inside
dimension).
Note: A 1-1/2"(38mm) clearance around
the liner must be maintained ex-
cept that only a 1" (25mm) clear-
ance is needed at the termination
end. We recommend framing a
10"(254mm) x 10"(254mm) (inside
dimensions) hole to give struc-
tural rigidity for mounting the ter-
mination.
Note: If installing termination on a siding
covered wall, furring strips must
be used to ensure that the termi-
nation 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
MillPac to the 4"(100mm) inner collar of the
terminationand slippingthe4"(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 temper-
aturesiliconetothe6-7/8"(175mm)flexpipe
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 sup-
ported at intervals not exceeding 3
feet (0.9 meter). (Flame picture and
performance will be affected by
sags in the liner).
roof pitches, the vertical height must be in-
creased. A poor draft, or down drafting can
resultfromhighwindconditionsnearbig trees
oradjoiningrooflines,inthesecases,increas-
ing 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 twist-
locking it.
Note: Any closets or storage spaces,
which the vent passes through
must be enclosed.