P95-4 Zero Clearance Direct Vent Gas Fireplace

Owners &Installation Manual

www.excalibur-fire.com
MODELS:

P95-NG4 Natural Gas

P95-LP4 Propane

WARNING:
If the information in these instructions are not followed exactly,
a fire or explosion may result causing property damage,personal injury or loss of life.

FOR YOUR SAFETY
What to do if you smell gas:Do not try to light any applianceDo not touch any electrical switch:
do not use any phone in yourFOR YOUR SAFETY
building.
Do not store or use gasoline or other flammable vapours andImmediately call your gas supplierliquids in the vicinity of this or any other appliance.
from a neighbour's phone. Follow
the gas supplier's instructions.
Installation and service must be performed by a qualifiedIfyou cannot reach your gas
installer, service agency or the gas supplier.
supplier, call the fire department.
Tested by:

Installer: Please complete the details on the back coverand leave this manual with the homeowner.
Homeowner: Please keep these instructions for future reference.
918-683b

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

06/16/10

To the New Owner:

Congratulations!
You are the owner of a state-of-the-art Excalibur® Gas Fireplace by FPI FIREPLACEPRODUCTS INTERNATIONAL LTD. The P95-4 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 ofa switch. The model P95-4 has been approved by Warnock Hersey for both safety andefficiency. 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 acquaintyourself with these instructions and the many features of your Excalibur® Fireplace.

2

Excalibur® P95-4 Zero Clearance Direct Vent Gas 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 GASFIREPLACE HEATERS ANSI Z21.88a-2007/CSA 2.33a-2007 and GAS-FIRED APPLIANCES FOR USE AT HIGH ALTITUDES CAN/CGA 2.17M91.
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 appliancecomes factory equipped with a means to secure the unit.
This Excalibur® Mobile/Manufactured Home listed appliancecomes equipped with a dedicated #8 ground lug to which an
18 gauge copper wire from the steel chassis ground mustbe 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 indicatedon the rating plate. This appliance is not convertible foruse with other gases, unless a certified kit is used.

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace

3

TABLE OF CONTENTSSAFETY LABEL
Copy of Serial No. Decal .............................................4

Accent Kit Installation ..................................................36
Option 1: Remote Control ............................................37
Option 2: Wall Switch ..................................................37
Option 3: Wall Thermostat ..........................................37
Wiring Diagrams .........................................................38

REQUIREMENTS
MA Code - CO Detector

INSTALLATION
Important Message ......................................................8
General Safety Information............................................8
Installation Checklist ......................................................8
Locating Your Gas fireplace...........................................9
Manufactured Mobile Home Additional Requirements ..9
Optional Heatwave .......................................................9
Duct System Kit .............................................................9
Optional Heat Release Kit .............................................9
Clearances ....................................................................9Combustible Mantels ..................................................10
Unit Base Stand-offs....................................................10
Framing And Finishing .................................................10
Facing Requirement .................................................... 11Hearth Requirements .................................................. 11
Optional Cover Plate Template ....................................12
Unit Assembly Prior To Installation ..............................12
Venting Introduction .....................................................12
Venting Exterior Vent Termination Locations ...............14
Simpson Dura-vent Venting .........................................15
5” x 8” Rigid Pipe Cross Reference Chart ...................16
Venting Arrangements - Horizontal Terminations ........18
Venting Arrangements - Vertical Terminations ............21
Unit installation with Horizontal termination .................23
Vertical Termination .....................................................24
Installation Procedures ................................................25
High Elevation .............................................................26
Gas Line Installation ....................................................26
Pilot Adjustment ...........................................................26
Gas Pipe Pressure Testing ..........................................26
Conversion From NG To LP .......................................27
Optional Brick Panels ..................................................30
Log Set Installation ......................................................31
Glass Door Installation Front Facade ..........................35
Optional Screen Doors ................................................35

4

OPERATING INSTRUCTIONS
Operating Instructions .................................................40
Lighting Procedure ......................................................40
Shutdown Procedure ...................................................40
First Fire ......................................................................40
Aeration Adjustment ....................................................40
Normal Operating Sounds Of Gas Appliances ............41

MAINTENANCE
Maintenance Instructions.............................................42
Gold-plated door Or surround......................................42
Log Replacement ........................................................42
Thermopile / Thermocouple.........................................42
Glass Gasket ...............................................................42
Door Glass...................................................................42
Fan Maintenance .........................................................43
Removing Valve...........................................................44
Installing Valve.............................................................44
Main Assembly ............................................................45

PARTS LIST
Burner Assembly & Log Set.........................................47
Flush Front Accessories ..............................................48

WARRANTY
Warranty ......................................................................51

Excalibur® P95-4 Zero Clearance Direct Vent Gas FireplaceDuplicate S/N

331

This is a copy of the label that accompanies eachP95-4 Zero Clearance Direct Vent Gas Fireplace.
We have printed a copy of the contents here foryour review. The safety label is located on thefront inside base of the unit, visible when thebottom 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 thecorrect one.

For the State of Massachusetts, installation
and repair must be done by a plumber orgasfitter licensed in the Commonwealth of
Massachusetts.

For the State of Massachusetts, flexible
connectors shall not exceed 36 inches inlength.

For the State of Massachusetts, the appliances individual manual shut-off must be at-handle type valve.

The State of Massachusetts requires theinstallation of a carbon monoxide alarm inaccordance with NFPA 720 and a CO alarmwith battery back up in the same room where
the gas appliance is installed.

Model/Modele:P95-NG4WC(3.00 kPa)
WC(2.74 kPa)
WC(0.72 kPa)
DMS
Btu/h (6.55 kW)
Btu/h (11.71 kW)
ft/pi(0-1372 m)

APPAREIL FONCTIONNANT AU GAZ PROPANE
CONCU POUR ETRE POELE: Modéle P95-LP4
Pression d'allimentation minimum
Pression à la tubulure d'échappement élevée
Pression à la tubulure d'échappement basse
Grandeur de l'injecteur
Débit Calorifique minimum selon
Débit Calorifique maximum selon
l'altitude

6-1/2"(See Instruction Manual for
Detailed Instructions)

Minimum Vent Clearances:
Horizontal Top
3" (76mm)
Horizontal Side2” (50mm)
Horizontal Bottom 2" (50mm)

Side Wall Clearance
from Side Facing
6-1/2" (165mm)

DOOR SEAL: Please check that the door is properly sealed

6-1/2"

Wall

Model/Modele:P95-LP4

VENTED GAS FIREPLACE HEATER - NOT FOR USE WITH SOLID FUELS. / FOYER AU GAZ À ÉVACUATION - NE PAS UTILISER AVEC DU
918-684a
COMBUSTIBLE SOLIDE.

This appliance must be installed in accordance with local codes, if any; if none, follow the National Fuel Gas Code, ANSI Z223.1, or Natural Gas and Propane Installation Code, CSA B149.1.
This appliance must be installed in accordance with the Standard CAN/CSA Z240 MH, Mobile Housing, in Canada, or with the Manufactured Home Construction and Safety Standard, Title 24 CFR, Part 3280, in the UnitedStates, or when such a standard is not applicable, ANSI/NCSBCS A225.1/NFPA 501A, Manufactured Home Installations Standard or ANSI A119.2 ou NFPA 501C Standard for Recreational Vehicles
This appliance is only for use with the type of gas indicated on the rating plate and may be installed in an aftermarket, permanently located, manufactured (mobile) home where not prohibited by local codes. See owner's manualfor details. Optional Heat Wave Kit # 946-556 Optional Heat Release Kit # 946-570
Installer l'appareil selon les codes ou règlements locaux, ou, en l'absence de tels règlements, selon les codes d'installation ANSI Z223.1, National Fuel Gas Code ou CSA-B149.1 en vigueur.
Installer l'appareil selon la norme CAN/CSA-Z240, Série MM, Maison mobiles ou CAN/CSA-Z240 VC, Véhicules de camping, ou la norme 24 CFR Part 3280, Manufactured Home Construction and Safety Standard. Si cesnormes ne sont pas pertinentes, utilisez la norme ANSI/NCSBCS A225.1/NFPA 501A, Manufactured Home Installations Standard, ou ANSI A119.2 ou NFPA 501C Standard for Recreational Vehicles.
Cet appareil doit être utilize uniquement avec le type de gaz indiqué sur la plaque signalétique. Cet appareil peut être installé dans une maison préfabriquée ou mobile (É.-U. seulement) installée à demeure si les règlements
locaux le permettent. Voir la notice de l'utilisateur pour plus de renseignements. Cet appareil ne peut pas être utilisé avec d'autres gaz sauf si une trousse de conversion certifiée est fournie.
This vented gas fireplace heater is not for use with air filters.
Ne pas utiliser de filtre à air avec ce foyer au gaz à évacuation.
For use with glass doors certified with the appliance only
Pour utilisation uniquement avec les portes en verre certifiées avec l'appareil
Made in Canada/ Fabrique au Canada

PROPANE: Model P95-LP4
L
Minimum supply pressure 12"
Manifold pressure high11"
Manifold pressure low
2.9"
Orifice size
# 49
Minimum input
22,400Maximum input
40,000
Altitude0-4500Wall

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace

DO NOT REMOVE THIS LABEL / NE PAS ENLEVER CETTE ÉTIQUETTE
Listed: VENTED GAS FIREPLACE HEATER / FOYER AU GAZ À ÉVACUATION
Certified for/Certifiée pour: CANADA and U.S.A.
Serial No./ No de serie
Tested to: Gas-Fired Appliances For Use At High Altitudes CAN/CGA-2.17-M91,
331
Vented Gas Fireplace Heaters ANSI Z21.88a-2007/CSA 2.33a-2007
WN# 16476
MAY BE INSTALLED IN MANUFACTURED (MOBILE)
APPAREIL FONCTIONNANT AU NATURAL GAZ
NATURAL GAS: Model P95-NG4HOMES AFTER FIRST SALE.
CONCU POUR ETRE POELE: Modéle P95-NG4
Pression d'allimentation minimum
Minimum supply pressure 5"
WC(1.25 kPa)
Minimum Clearances to Combustibles
Pression à la tubulure d'échappement élevée
Manifold pressure high3.8"
WC(0.95 kPa)
/Degagement Minimum De Materiaux Combustibles
Pression à la tubulure d'échappement basse
Manifold pressure low
1.1"
WC(0.27 kPa)
0" Clearance to
48” To CeilingGrandeur de l'injecteur
Orifice size
combustibles from:# 30
DMS
Top, bottom, sides & rear of unité
CalorifiqueDbitminimum
selon
Minimum input
23,200 Btu/h (6.79 kW)
éCalorifiqueDbitmaximumselon
Maximum input
45,000 Btu/h (13.17 kW)
Mantel Clearances from Top:18" (A)
0-4500 ft/pi(0-1372 m)l'altitudeMin. 18” (457mm) (A)Altitude

Copy of Safety Decal for P95-4

SAFETY LABEL

5REQUIREMENTS
MA Code - CO Detector(for the State of Massachusetts only)
5.08: Modifications to NFPA-54, Chapter 10(2) Revise 10.8.3 by adding the following additional requirements:(a) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part forresidential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less thanseven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shallbe satisfied:
1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vented gas fueled
equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is
installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery
operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure
served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services ofqualified licensed professionals for the installation of hard wired carbon monoxide detectors
a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon
monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.
b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall have a period ofthirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon
monoxide detector with an alarm shall be installed.
2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the above provisions
shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.
3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight(8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The
sign shall read, in print size no less than one-half (1/2) inch in size, "GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL
OBSTRUCTIONS".
4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation
unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR
5.08(2)(a)1 through 4.
(b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:
1. The equipment listed in Chapter 10 entitled "Equipment Not Required To Be Vented" in the most current edition of NFPA 54 as adopted by
the Board; and2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or
structure used in whole or in part for residential purposes.
(c) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the manufacturer of ProductApproved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, theinstructions provided by the manufacturer for installation of the equipment and the venting system shall include:
1. Detailed instructions for the installation of the venting system design or the venting system components; and2. A complete parts list for the venting system design or venting system.
(d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the manufacturer of a
Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases, but identifies"special venting systems", the following requirements shall be satisfied by the manufacturer:
1. The referenced "special venting system" instructions shall be included with the appliance or equipment installation instructions; and2. The "special venting systems" shall be Product Approved by the Board, and the instructions for that system shall include a parts list anddetailed installation instructions.
(e) A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting instructions,
all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of
the installation.

6

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace

INSTALLATIONBEFORE YOU START
Safe installation and operation of this appliancerequires common sense, however, we are requiredby the Canadian Safety Standards and ANSIStandards to make you aware of the following:

INSTALLATION AND REPAIR SHOULD
BE DONE BY AN AUTHORIZEDSERVICE PERSON. THE APPLIANCESHOULD 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 IMPERATIVETHATCONTROL COMPARTMENTS, BURNERS
AND CIRCULATING AIR PASSAGEWAYS
OF THE APPLIANCE BE KEPT CLEAN.

YOUNG CHILDREN SHOULD BE CAREFULLY SUPERVISED WHEN THEY ARE
IN THE SAME AREA AS THE APPLIANCE. TODDLERS, YOUNG CHILDRENAND OTHERS MAY BE SUSCEPTIBLE
TO ACCIDENTAL CONTACT BURNS. A
PHYSICAL BARRIERS IS RECOMMENDED IF THERE ARE AT RISK INDIVIDUAL
IN THE HOUSE. TO RESTRICT ACCESSTO A FIREPLACE OR STOVE, INSTALL
AN ADJUSTABLE SAFETY GATE TO
KEEP TODDLERS, YOUNG CHILDRENAND OTHER AT RISK INDIVIDUALS OUT
OF THE ROOM AND AWAY FROM HOT
SURFACES.
CLOTHING OR OTHER FLAMMABLE
MATERIAL SHOULD NOT BE PLACEDON OR NEAR THE APPLIANCE.

DUE TO HIGH TEMPERATURES, THE
APPLIANCE SHOULD BE LOCATEDOUT OF TRAFFIC AND AWAY FROMFURNITURE AND DRAPERIES.

WARNING: FAILURE TO INSTALL THISAPPLIANCE 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.

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace

7

INSTALLATIONIMPORTANT MESSAGE
SAVE THESE
INSTRUCTIONSThe P95-NG4 or P95-LP4 Direct Vent Fireplacemust be installed in accordance with these
instructions. Carefully read all the instructions inthis 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 incompliance with manufacturer's instructions andall applicable codes.

GENERAL SAFETYINFORMATION
1) The appliance installation must conform withlocal 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 thecurrent 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 thespecified vent and termination cap to the outsideof the building envelope. Never vent to anotherroom or inside a building. Make sure that thevent is fitted as per Venting instructions.
5) Inspect the venting system annually forblockage and any signs of deterioration.
6) Venting terminals shall not be recessed into awall 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 isunfamiliar with the operation to use the fireplace.

11) Under no circumstances should this appliancebe modified. Parts that have to be removed forservicing should be replaced prior to operating
this appliance.
12) Installation and any repairs to this applianceshould be done by a qualified service person.
A professional service person should be called
to inspect this appliance annually. Make it apractice 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 inthis appliance.
15) The appliance area must be kept clear andfree of combustible materials, (gases and otherflammable vapours and liquids).

Emissions from burning wood or gas could
contain chemicals known to the State ofCalifornia to cause cancer, birth defects orother reproductive harm.

INSTALLATIONCHECKLIST
1) Check all clearances to combustibles. Referto the following sections:
a)
b)
c)
d)
e)
f)
g)
h)

Locating Your Gas Fireplace
Clearances
Combustible Mantels
Unit Base Stand-offs
Framing and Finishing
Hearth Requirement
Unit Assembly Prior to Installation
Venting2) Make gas and electrical connections. Test thepilot. Must be as per diagram. Refer to the "GasLine Installation" section.
3) Install standard and optional features. Referto the following sections where applicable:
a. Brick Panels
b. Log Set
c. Glass Doord. Arch Surrounde. Double Screen Doorsf. Accent Kit (Double Door & Surround)g. Remote Control
h. Wall Switch
i. Wall Thermostat4) Final check.
Before leaving this unit with the customer, theinstaller must ensure that the appliance is firingcorrectly and operation fully explained tocustomer.
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 ensurethat the flame does not carbon. First allow theunit to burn for 15-20 min. to stabilize.
CAUTION: Any alteration to the product thatcauses sooting or carboning that results
in damage is not the responsibility of the
manufacturer.

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.

8

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace

INSTALLATIONLOCATING YOURGAS FIREPLACE
1) When selecting a location for your fireplace,ensure that the clearances outlined on thispage are met.

MANUFACTUREDMOBILE HOME
ADDITIONALREQUIREMENTS

2) P r o v i d e a d e q u a t e c l e a r a n c e s f o rservicing.

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

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 installedon carpeting, combustible linoleum tile orother combustible material other than woodflooring, the appliance must be installed on ametal or wood panel extending the full widthand depth of the appliance.

2) Ensure proper grounding using the #8
ground lug provided. See the "Wiring
Diagram" section.

OPTIONAL
HEATWAVE

4) The P95-4 Direct Vent Gas Fireplace
can be installed in a recessed position orframed out into the room as in A, B, C, D.
See Diagram 1.

A)
B)
C)
D)

Flat on Wall
Flat on Wall Corner
Recessed into
Wall/Alcove
Corner6) The P95-4 Direct Vent Gas Fireplace isapproved for alcove installations, whichmeet the clearances listed on this page.

The clearances listed below are Minimum
distances unless otherwise stated:
A major cause of chimney related fires isfailure to maintain required clearances (airspace) to combustible materials. It is of thegreatest importance that this fireplace andvent system be installed only in accordancewith 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.

DUCT SYSTEM KIT#946-556
The HeatWave Air Duct Kit increases theeffectiveness of your fireplace by dispersing
warm air from the fireplace to remote locationsin the same room or other rooms in your home.
Up to two kits may be installed on the fireplace.

OPTIONAL
HEAT RELEASE KIT#946-570

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.

CLEARANCESThe Heat Release Kit expels warm air fromthe fireplace to the outside of the building,allowing the fireplace to be operated with lessheat entering the room. The kit may be usedon either the left or right side.

7) We recommend that you plan your installation
on paper using exact measurements forclearances and floor protection before
actually installing this appliance. Have aqualified inspector, dealer, or installer review
your plans before installation.
Note: For vent terminations see the"Venting" section.

Side Wall Clearance

6-1/2" (165mm)

Horizontal Vent Clearances
Top
3"
Side
2"
Bottom2"
Vertical Vent Clearances

1-1/4" (32mm)* see mantle clearance instructions in the"Combustible Mantels" section.

WARNING:
Fire hazard is an extreme risk if
these clearances are not adhered to.

Clearances for HeatWave andHeat 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.

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace

9

INSTALLATIONCOMBUSTIBLE MANTELS
Mantel Clearances
10

24

6

2

12" Mantel

22
204” Mantel

181) Determine the total thickness of facing
material (e.g. drywall plus ceramic tiles) toallow the finished surface to be flush withthe front of the unit. Total facing thickness
can vary from 1/2" (13mm) to 1" (32mm)
thick.

16

No Mantel
in thisarea

14

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.

4

12

22”

18”

10

7" Standoff

Note: A non-combustible mantel may beinstalled at a lower height if theframing is made of metal studs
covered with a non-combustible
board.

8

0

12

Non-Combustible Combustible
Material
Material

Because of the extreme heat this fireplaceemits, the mantel clearances are critical.
Combustible mantel clearances from top of unit
are shown in Diagram below.

FRAMING AND
FINISHING

8
6

Note: Ensure the paint that is usedon the mantel and the facing is"heat resistant" or the paint may
discolour.

4
2
0

31”
to floor

Top of
Front Opening

Install Top Standoffs & Side Nailing Strips
before unit is slipped into position. See the"Unit Assembly Prior to Installation" section
for assembly details.

Side View

P95-4 Flat Wall Surround and Tile Kit
The P95-4 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 withframing material. The framed opening is50-1/8" high x 53-3/8" wide x 21-1/4" deep
(1276mm high x 1346mm wide x 533mmdeep).

A
B*
C
P95-4 Flat Wall Surround and Tile Kit Specifications* 50-1/8" is when the unit is raised up
using the unit base standoffs, otherwise
the framed opening is 49" when the unit
sits on the floor.

UNIT BASE STAND-OFFS
To accommodate varying thicknesses andfinishes of hearth materials, we have increased
the overall height of the appliance by a further
1-1/8”. This increase is added with the inclusionof two stand-offs at the bottom of the unit, below
the outer box, taking the overall height of theframing dimensions from 49” up to 50-1/8”.
In the event that you should choose to use thinnermaterials to finish the hearth, you can omit thestand-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 thesame distance that you have lowered the unit.

10

Framing Dimensions
53-3/8" (1346mm)
50-1/8" (1276mm)
21-1/4" (533mm)

Insert the 2 unit base stand-offs underneath theunit as shown in the diagram below. Space thestand-offs centrally, approximately 2 or 2-1/2
feet apart. Ensure that the unit is not unstable.

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® P95-4 Zero Clearance Direct Vent Gas Fireplace

Facing Over 1" (25mm) Thick

Header

11” dia. holethrough wall
for Flexor for DuraVent

If the facing material is over 1" (25mm) thick (example: brick or riverrock), install the facing around the perimeter of the face. You may wish
to make a face template as shown on the diagram.

48-3/4”CL

2"

F P I o ff e r s a c o v e rplate template. See the"Optional Cover Plate
Template" section.

53-3/4”4) Note: The unit does nothave to be completely
enclosed in a chase. The
clearance on top of theunit is 0" to the standoffs
so combustible building
materials can be laid
directly on top of thestandoffs. You must
maintain clearance fromthe vent to combustible
materials for bothrigid and flex, see the"Clearances" section.

Non-combustible Combustible
Material
Material

INSTALLATION

2-7/8”

2-1/4” 4"
Gas connection
on this side

21-1/8” (533mm)

NOTE: If using a brickhearth, the fireplace willneed to be raised toaccommodate the brickthickness. Example: If thebrick is 2" thick, the unit
must be raised 1".

Note: 53-3/4" is the minimum height for both flex termination or
Simpson Dura-Vent venting.
The HeatWave Duct Kit has different
clearance and framing requirements,
check the HeatWave manual for details.

FACING REQUIREMENTHEARTH REQUIREMENTS

This fireplace requires a non-combustible
material extending from the framing
header and sides.

Floor Mounted Fireplaces

The flanges on the front face of thefireplace are for a facing thickness of 1"(25mm) or less.

Please note that all verticalmeasurements are takenfrom the base of the unit
excluding risers or bottom
stand-offs.

Raised Fireplaces

No hearth isrequired when
the unit is raised3" (76mm) off ofthe floor surface

Flo
FireplaceStand

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace

ori

ng

Yo u m u s t t a k e
into account thedepth of the floor
covering (carpet,
tile, linoleum, etc.)
when determining
the height of thefireplace stand.
11

INSTALLATION
P95 FLAT WALL
SURROUND AND TILE KITThe P95 Flat Wall Surround , Hearth Pad andTile Kit cannot be modified in any way. It must
be installed as manufactured.

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 theglass frame. Once settled tighten screws.

Top Clip

Back View of
Cover Plate

Side Nailing Strips
Pin Holes
The side nailing strips come attached to the unit.
There are 2 plates, one on the top and bottomthat can be folded out as required.

TO REMOVE:
1) Remove 2 screws that secure top clip.
Ensure to hold cover plate as it will fall
forward.
2) Pull out top clip that is still hooked onto
glass.

OPTIONAL COVER
PLATE TEMPLATE
Plates can befolded out.

1) Ensure top clip screws are at top of oblong
holes before installation.

Oblong Screw
Holes

UNIT ASSEMBLYPRIOR TO
INSTALLATIONVENTINGINTRODUCTION

The 2 Top Standoffs must be correctly positioned
and attached to the top before unit is slipped
into position.
2) Position bottom of cover plate over pins
located at the bottom of the firebox.

Top Standoff Assembly
The top standoffs are shipped in a flat position
and must be folded into shape and attached.
1) Remove the standoffs from the fireplace
top.

Pins
12

2) Take each standoff and bend into the correct
shape. Bend up at the bend lines until thescrew holes in the standoff and the prepunched screw holes on the fireplace top
line up.
3) Attach the standoff securely to the top with 2screws per standoff (on opposite corners).

The P95-4 uses the "balanced flue" technology
Co-axial system. The inner liner vents productsof combustion to the outside while the outer
liner draws outside combustion air into the
combustion chamber thereby eliminating theneed to use heated room air for combustion andlosing warm room air up the chimney.
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 aseparate solid fuel or gas burning appliance.
Each direct vent gas appliance must use it's own
separate vent system. Common vent systems
are prohibited (see "Simpson Dura-Vent Venting"section for more details and exceptions).

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace

INSTALLATIONVENTINGFPI Direct Vent System Flex Horizontal Terminations Only
These venting systems, in combination with the P95-4 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 from the "Exterior
Vent Termination Locations" section.
FPI Direct Vent Flex System Termination
Kit (Part # 946-618) includes all the partsneeded to install the P95-4 with a maximum
run of 6 feet.

If longer runs are needed, the FPI Direct Vent
system (Flex) kit is (Part # 946-616) which
includes all the parts needed to install theP95-4 with a maximum 10' run.

1)
2)
3)
4)
5)
6)
7)
8)
9)

1)
2)
3)
4)
5)
6)
7)
8)
9)

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

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

Vinyl SidingStandoff
Wall Thimble(required in
Canada only)TM

AstroCap XL
Termination Cap(Part # 946-623/P)

5” dia. flue pipe8” dia.
Flue pipe

spring spacer

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.

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace

13

INSTALLATIONEXTERIOR VENT TERMINATION LOCATIONSMinimum Clearance Requirements

Canada1

USA2

A

Clearance above grade, veranda, porch, deck, or balcony12"(30cm)

12"(30cm)

B

Clearance to window or door that may be opened

12"(30cm)

9" (23cm)

C

Clearance to permanently closed window

*

*

D

Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 feet (61cm)

18"(46cm)

18"(46cm)

E

Clearance to unventilated soffit

18"(45cm)

18"(45cm)

F

Clearance to outside corner: with AstroCap Termination Cap.

6"(15cm)

6"(15cm)

Clearance to outside corner: with all other approved Termination Caps.

14"(36cm)

14"(36cm)

Clearance to inside corner: with AstroCap Termination Cap

6"(15cm)

6"(12cm)G

Clearance to inside corner: with all other approved Termination Caps.

12"(30cm)

12"(30cm)

H

Clearance to each side of center line extended above meter/regulator assembly

36"(90cm)a*J

Clearance to service regulator vent outlet

36"(90cm)*

K

Clearance to non-mechanical air supply inlet to building or the combustion air inlet to any other appliance12"(30cm)

9" (23cm)

L

Clearance to a mechanical air supply inlet

72"(1.8m)

36"(90cm)b

M

Clearance above paved sidewalk or a paved driveway located on public property

84"(2.1m)┼*

Clearance under veranda, porch, deck, or balcony12"(30cm)‡*N
1

In accordance with current CSA B149.1, Natural Gas and Propane Installation Code2
In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code┼A vent shall not terminate directly above a sidewalk or paved driveway which is located between two single family dwellings and serves both dwellings‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor*a Clearance in accordance with local installation codes and the requirements of the gas supplier
3 feet (91cm) within a height of 15 feet (4.5m) above the meter / regulator assemblyb 3 feet (91cm) above - if within 10 feet (3m) horizontally

14

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace

INSTALLATIONSIMPSON DURA-VENT VENTINGThe 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 theP95-4.
The minimum components required for a basic horizontal termination are:
1
1
1
1
1

Horizontal Termination Cap
90o Elbow
Flue Adaptor
Wall Thimble
Length of pipe to suit wall thickness(see chart)

Wall thickness is measured from the back standoffs to the inside mounting surfaceof termination cap. For siding other than vinyl furring strips may be used, insteadof the vinyl siding standoff, to create a level surface to 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.

Horizontal and Vertical
Terminations for 5" x 8" Venting

Flat Wall Installation
Wall Thickness(inches)

Vent Length Required(inches)4" - 5-1/2"

6"7" - 8-1/2"

9"10" - 1-1/2"

12"9" - 14-1/2"

11" - 14-5/8" Adj. Pipe15" - 23-1/2"

17" - 24" Adj.

Corner Installation
Wall Thickness(inches)

Vent Length 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"WARNING:
Do not combine venting components fromdifferent venting systems.
However use of the the AstroCapTM and FPI
Riser is acceptable with all systems.
This product has been evaluated by Intertek
for using a Rigid Pipe Adaptor in conjunction
with Duravent Direct-Vent , Selkirk Direct-Temp,
Ameri Vent Direct venting and Security Secure
Vent systems. Use of these systems with the
Rigid Pipe adaptor is deemed acceptableand does not affect the Intertek WHI listing ofcomponents.

Alternate Horizontal
Termination Cap

SimpsonDura-Vent Direct Vent

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

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace

15

INSTALLATION
5” X 8” RIGID PIPE CROSS REFERENCE CHART
Components from different Manufacturers may not be mixed. Not All Rigid Pipe components are available directly from FPI.
Components from different Manufacturers may not be mixed. Not all rigid pipe components are available directly from Regency.

Description

16

SimpsonSelkirk

Metal-Fab™

ICC Excel

Direct Vent Pro®

Direct Temp™

Sure Seal

Direct6” Pipe Length-Galvanized

58DVA-06

5DT-6

5D6

6” Pipe Length-Black58DVA-06B

5DT-6B

5D6B

TC-5DL6
TC-5DL6B

9” Pipe Length-Galvanized

58DVA-09

5DT-9

N/A

N/A
N/A

9” Pipe Length-Black58DVA-09B

5DT-9B

N/A

12” Pipe Length-Galvanized

58DVA-12

5DT-125D12

TC-5DL1

12” Pipe Length-Black58DVA-12B

5DT-12B

5D12B

TC-5DL1B

18” Pipe Length-Galvanized

58DVA-18

5DT-185D18

TC-5DL18

18” Pipe Length-Black58DVA-18B - N/A from FPI

5DT-18B

5D18B

TC-5DL18B

24” Pipe Length-Galvanized

58DVA-24

5DT-245D24

TC-5DL224” Pipe Length-Black58DVA-24B

5DT-24B

5D24B

TC-4DL2B

36” Pipe Length-Galvanized

58DVA-36

5DT-36

5D36

TC-5DL3
TC-5DL3B

36” Pipe Length-Black58DVA-36B

5DT-36B

5D36B

48” Pipe Length-Galvanized

58DVA-48

5DT-485D48

TC-5DL4

48” Pipe Length-Black58DVA-48B

5DT-48B

5D48B

TC-5DL4B

60” Pipe Length-Galvanized

58DVA-60

N/A

N/A

N/A

60” Pipe Length-Black58DVA-60B - N/A from FPI

N/A

N/A

N/A

Adjustable Length 3”-10”-Galvanized

N/A

N/A

5DAL

TC-5DLT

Adjustable Length 3”-10”-Black

N/A

N/A

5DALB

TC-5DLTB

Adjustable Length 11”-14” -Galvanized

Disc. - See 58DV-08A

5DT-AJ

N/A

N/A

Adjustable Length 11”-14” -Black

Disc. - See 58DV-08B

5DT-AJB

N/A

N/A

Extension Pipe 17”-24” -Galvanized

Disc. - See 58DV-16A

N/A

N/A

N/A

Extension Pipe 17”-24” -Black

Disc. - See 58DV-16AB

N/A

N/A

N/A

Adjustable Length 8-1/2”-Galvanized

58DVA-08A - N/A from FPI

N/A

N/A

N/A

Adjustable Length 8-1/2”-Black58DVA-08AB

N/A

N/A

N/A

Extension Pipe 16”-Galvanized

58DVA-16A - N/A from FPI

N/A

N/A

N/A

Extension Pipe 16”-Black46DVA-16AB

N/A

N/A

N/A

45º Elbow-Galvanized

58DVA-E45

5DT-EL45

5DT-EL45

TE-5DE45

45º Elbow-Black58DVA-E45B

5DT-EL45B

5DT-EL45B

TE-5DE45B

45º Elbow Swivel-Galvanized

Disc. - See 58DVA-E45

N/A

N/A

N/A

45º Elbow Swivel-Black

Disc.-See 58DVA-E45B

N/A

N/A

N/A

90º Elbow-Galvanized

58DVA-E90

5DT-EL90S

5DT-EL90S

TE-5DE90

90º Elbow-Black58DVA-E90B

5DT-EL90SB

5DT-EL90SB

TE-5DE90B

90º Elbow, Swivel-Galvanized

Disc. - See 46DVA-E45

N/A

N/A

N/A

90º Elbow, Swivel-Black

Disc. - See 46DVA-E45

N/A

N/A

N/A

90º Starter Elbow, Swivel-Galvanized

N/A

N/A

N/A

N/A

Adaptor*

N/A

N/A

N/A

N/A

Ceiling Support

58DVA-DC

5DT-CS

5DSP

TE-5DE45

Cathedral Support Box

58DVA-CS

5DT-CSS

5DRS

TE-5DE45B

Wall Support/Band

58DVA-WS

5DT-WS/B

5DWS

N/A

Offset Support

58DVA-ES - N/A from FPI

5DT-OS

N/A

N/A

Wall Thimble-Black58DVA-WT

5DT-WT

5DWT

TE-5DE90

Wall Thimble Support/Ceiling Support

58DVA-DC - N/A from FPI

N/A

N/A

TE-5DE90B

Firestop Spacer

58DVA-FS

5DT-FS

5DFS

N/A

Trim Plate-Black58DAV-WFS

5DT-TP

5DCP

N/A

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace

INSTALLATION

Description

Attic Insulation Shield 12”

SimpsonSelkirk

Metal-Fab™

ICC Excel

Direct Vent Pro®

Direct Temp™

Sure Seal

Direct58DVA-IS N/A from FPI

N/A

N/A

N/A

Basic Horizontal Termination Kit (A)N/A

5DT-HKA

N/A

N/A

Horizontal Termination Kit (B)

58DVA-KHA

5DT-HKB

N/A

N/A

Vertical Termination Kit

58DVA-VHA

5DT-VKC

N/A

N/A

High Wind Vertical Cap

58DVA-VCH

N/A

N/A

TM-5VT

High Wind Horizontal Cap

N/A

N/A

N/A

TM-5DHT

Horizontal Square Termination Cap

N/A

5DT-HHC

5DHT

TM-5HT

Vertical Termination Cap

N/A

5DT-HVC

5DVT

TM-5VT

Storm Collar

58DVA-SC

5DT-SC

5DSC

TM-SC

Adjustable Flashing 0/12-6/12

58DVA-F6

5DT-AF65DF

TF-5FA

Adjustable Flashing 6/12-12/12

58DVA-F12

5DT-AF125DF1-2

TF-5FB

Vinyl Siding Standoff

58DVA-VSS

5DT-VS

5DVS

TM-VSS

Vinyl Siding Shield Plate

N/A

5DT-VSP

N/A

N/A

Snorkel Termination 14”

58DVA-SNK14

N/A

N/A

TM-5ST14

Snorkel Termination 36”

58DVA-SNK36 (N/A - FPI)

N/A

N/A

TM-5ST36

Restrictor Disk

58DVA-RD

N/A

N/A

TM-5DS

Colinear Flex Connectors

N/A

N/A

N/A

N/A

FPI
946-604/P

Simpson Direct Vent -Vent Guard (Optional)

946-623/P

AstroCap XL Horizontal Cap

770-994

Rigid Pipe Adaptor (Must use with all rigid piping)

946-506/P

Vent Guard (Optional)

946-606

Starter collar reducer 5” x 8” to 4” x 6-5/8”

946-625

Vinyl Siding Standoff - AstroCap XL

Note: When using Metal-Fab Sure Seal Rigid Piping - please note that the Adaptor (4DDA) must be used in conjunction with FPI Rigid Pipe Adaptor (510-994).
Offset Pipe Selection: Use this table to determine offset pipe lengths.
Pipe Length(L)5” x 8” Venting
Run (X)

Rise (Y)For specific instructions on venting components - visit the
manufacturers website listed below.

0” (0mm)5-11/16” (144mm)

15-5/16” (389mm)

Simpson Direct Vent Pro: www.duravent.com

6” (152mm)

8-13/16” (224mm)

18-7/16” (468mm)

Selkirk Direct-Temp: www.selkirkcorp.com

9” (229mm)

10-15/16” (278mm)

20-9/16” (522mm)

Metal-Fab Sure Seal: www.mtlfab.com

12” (305mm)

13” (330mm)

22-11/16” (576mm)

Industrial Chimney Company: www.icc-rsf.com

24” (610mm)

21-7/16” (697mm)

31-1/16” (789mm)

36” (914mm)

29-13/16” (757mm)

39-7/16” (1002mm)

48” (1219mm)

38-1/4” (972mm)

47-7/8” (1216mm)

Note: Horizontal runs of vent must be level, or have a 1/4”
rise for every 1 foot of run towards the termination.
Never allow the vent to run downward - this could cause hightemperatures and may present a possible fire hazard.

L676 & L900 DIRECT VENT FIREPLACEIMPORTANT NOTE
• A Vent Guard is required when the AstroCap is installed above grade at 7 feet or lower.
• The Simpson Dura-Vent and Selkirk Direct Temp horizontal termination caps cannot be used in any applications.
• Only the AstroCap XL and Snorkels are certified for horizontal terminations.

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace

17

INSTALLATIONVENTING ARRANGEMENTS - HORIZONTAL TERMINATIONSSIMPSON DURA-VENT DIRECT VENT SYSTEM andFPI 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
5" inner diameter8" outer diameter

Regency® Flex Vent
5" inner diameter8" outer diameter

Note: Must use optional flue adapter (Part # 770-994)
when using Simpson Dura-Vent pipe.

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

A vent guard should be used whenever thetermination is lower than the specified minimum
or as per local codes.

Please note that all verticalmeasurements are taken fromthe base of the unit excluding
risers or bottom stand-offs.

•
•
•

18

Maintain clearances to combustibles as listed in the "Clearances," "Locating Your Gas Fireplace," "Combustible Mantels," "Unit BaseStand-offs," "Framing and Finishing," "Facing Requirement," & "Hearth Requirement" sections.
Horizontal vent must be supported every 3 feet.
Firestops are required at each floor level and whenever passing through a wall.

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace

INSTALLATION
Horizontal Venting with Two (2) 90o Elbows
One 90o elbow = Two 45o elbows.

OptionVA)
0' Min.
B)
1' Min.
C)
2' Min.
D)
3' Min.
E)
4' Min.
F)
5' Min.
G)
6' Min.

H + H1 W i t h t h e s e o p t i o n s ,2' Max.
maximum total pipe lengthis 30 feet with minimum
3' Max.
of 6 feet total vertical
4' Max.
and maximum 8 feet total
5' Max.
horizontal.
6' Max.
7' Max. Please note minimum 1
foot between 90o elbows
8' Max.
is required.

Horizontal Venting with Three (3) 90o Elbows
One 90o elbow = Two 45o elbows.

Option
A)
B)
C)
D)
E)
F)
G)
H)

Excalibur® P95-4 Zero Clearance Direct Vent Gas FireplaceV
0' Min.
1' Min.
2' Min.
3' Min.
4' Min.
5' Min.
6' Min.
7' Min.

H
1' Max.
2' Max.
2' Max.
2' Max.
3 Max.
4' Max.
5' Max.
6' Max.

V + V1
1' Min.
3' Min.
5' Min.
7' Min.
9' Min.
10' Min.
11' Min.
12' Min.

H + H12' Max.
3' Max.
4' Max.
5' Max.
6' Max.
7' Max.
8' Max.
9' Max.

With these options,max. total pipe lengthis 30 feet with min. of
12 feet total verticaland max. 9 feet total
horizontal.
Please note min. 1
foot between 90oelbows is required.

19

INSTALLATION
Vertical Venting with Two (2) 90o Elbows

One 90o elbow = Two 45o elbows.

Option
A)
B)
C)
D)
E)
F)

V
0' Min.
1' Min.
2' Min.
3' Min.
4' Min.
5' Min.

H
2' Max.
4' Max.
5' Max.
6' Max.
7' Max.
8' Max.

V + V1 With these options, max. total
1' Min. pipe length is 30 feet with min.
2' Min. of 6 feet total vertical and max.
8 feet total horizontal.
3' Min.
4' Min. Please note min. 1 foot5' Min. between 90 o elbows is
6' Min. required.

For additional vertical venting with 2
x 90o elbows, refer to next page.

Vertical Venting with Three (3) 90o Elbows

One 90o elbow = Two 45o elbows.

Option
A)
B)
C)
D)
E)
F)
G)
H)

20

V
0' Min.
1' Min.
2' Min.
3' Min.
4' Min.
5' Min.
6' Min.
7' Min.

H + H12' Max.
2' Max.
3' Max.
4' Max.
5' Max.
6' Max.
7' Max.
8' Max.

V + V1
3' Min. With these options, max.
total pipe length is 30 feet
3' Min.
with min. of 10 feet total
4' Min. vertical and max. 8 feet
6' Min. total horizontal.
7' Min.
Please note min. 1 foot8' Min.
between 90o elbows is
9' Min. required.
10' Min.

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace

INSTALLATIONVENTING ARRANGEMENTS VERTICAL TERMINATIONSSIMPSON DURA-VENT DIRECT VENTSYSTEM(Propane & Natural Gas)
The shaded area in the diagram shows all allowable combinations ofstraight vertical and offset to vertical terminations, using two 90o elbow,
with Simpson Dura-Vent Direct Vent vent systems for Propane andNatural Gas.

•••

Vent must be supported at offsets.
Firestops are required at each floor level and whenever passing through a wall.
Maintain clearances to combustibles.

Note: Must use optional flue adapter when using Simpson Dura-Vent pipe (Part # 770-994).
Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace

21

INSTALLATIONThe P95-4 is approved for a maximum 40 ft. straight vertical, with Simpson
Dura-Vent Direct Vent vent systems for Propane and Natural Gas, as per
the diagram.
The shaded area in the diagram shows all allowable combinations of straight
vertical and offset to vertical terminations with Simpson Dura-Vent Direct
Vent 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 in the "Clearances,""Locating Your Gas Fireplace," "Combustible Mantels," "Unit BaseStand-offs," "Framing and Finishing," "Facing Requirement," & "Hearth
Requirement" sections.
Please note that all verticalmeasurements are taken fromthe base of the unit excluding
risers or bottom stand-offs.

22

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace

INSTALLATIONUNIT INSTALLATIONWITH HORIZONTALTERMINATION
Install the vent system according to the
manufacturer's instructions included withthe components.
1) Set the unit in its desired location. Checkto determine if wall studs or roof rafters
are in the way when the venting system is
attached. If this is the case, you may wantto adjust the location of the unit. Rough inthe gas preferably on the right side of theunit and the electrical (junction block is on
the left side) on the left.

b) Horizontal runs of vent must be
supported every three feet. Wall straps
are available for this purpose.
5) Mark the wall for a 11" x 11" 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 beterminated. If the wall being penetrated isconstructed of non-combustible material, i.e.
masonry block or concrete, a 8" dia. hole isacceptable.
Note: With Dura-Vent, the minimum height isachieved by installing a 90o elbow directly tothe flue adaptor.

2) Direct Vent pipe and fittings are designedwith special twist-lock connections toconnect the venting system to the appliance
flue outlet. A twist-lock appliance adaptor
is an available option that must be used inconjunction with the Simpson Dura-Vent
Direct Vent system.

Diagram 3*Diagam 3 & 4: As specified in CGA B149
Installation Code. Local codes or regulations
may require different clearances.

Below Grade Installation
If the Snorkel Termination must be installed
below grade, i.e. basement application, proper
drainage must be provided to prevent waterfrom entering the Snorkel Termination. Refer
to Diagram 4. Do not attempt to enclose theSnorkel within the wall, or any other type of
enclosure.

3) Put a bead of silicone inside the outer
section of the adapter and a bead of MillPac 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 andfasten it to the framing using nails or screws
through the nailing strips.
4) Assemble the desired combination of pipeand elbows to the appliance adaptor andtwist-lock for a solid connection.
Note:a) Twist-lock procedure: Four indentations,located on the female ends of pipes andfittings, are designed to slide straightonto 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 maleends, Diagram 1. Push the pipe sections
completely together, then twist-lock
one section clockwise approximately
one-quarter 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 belocated by examining the inside of thefemale ends.

Diagram 2
Note:a) The horizontal run of vent must be level,or have a 1/4 inch rise for every 1 footof run towards the termination. Neverallow the vent to run downward. This
could cause high temperatures and may
present the possibility of a fire.

Diagram 1
NOTE: For best results and optimum performance with each approved venting system, it ishighly recommended to apply “Mill-Pac” sealant (supplied) to every inner pipe connection.
Failure to do so may result in drafting or performance issues not covered under warranty.
Silicone (red RTV) is optional.

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplaceb) The location of the horizontal venttermination 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 from the "Exterion Vent
Termination Locations" section.
c) Snorkel Terminations:
For installations requiring a vertical riseon the exterior of the building, 14-inch
and 36-inch tall Snorkel Terminations areavailable. Follow the same installation
procedures as used for standard
Horizontal Termination. NEVER install
the snorkel upside down.

Diagram 4
NOTE: For Snorkel terminations in ABOVE
grade installations, follow nationalor 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 thetermination cap.

23

INSTALLATION
4) Assemble the desired lengths of pipe andelbows. Ensure that all pipes and elbow
connections are in the fully twist-locked
position and sealed.

VERTICALTERMINATION

Diagram 5
The four wood screws provided should
be replaced with appropriate fasteners forstucco, brick, concrete, or other types ofsidings.
Note: If installing termination on a siding
covered wall, a vinyl siding standoff
or furring strips must be used toensure that the termination is notrecessed into the siding.
7) Before connecting the horizontal run of ventpipe to the vent termination, slide the Wall
Thimble (Part # 1247) over the vent pipe.
8) Slide the appliance and vent assembly
towards the wall carefully inserting thevent pipe into the vent cap assembly. It is
important that the vent pipe extends into
the vent cap sufficient distance so as toresult in a minimum pipe overlap of 1-1/4
inches. Secure the connection between thevent pipe and the vent cap by attaching thetwo sheet metal strips extending from thevent cap assembly into the outer wall of thevent pipe. Use the two sheet metal screws
provided to connect the strips to the pipe
section. See Diagram 6.

1) M a i n t a i n t h e 1 - 1 / 2 "clearances (air spaces) to
combustibles when passing
through ceilings, walls, roofs,
enclosures, attic rafter, orother nearby combustible
surfaces. Do not pack air
spaces with insulation. Checkthe "Venting Arrangements Vertical Temination" section
for the maximum vertical riseof the venting system and the
maximum horizontal offset
limitations.

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 meetthe minimum requirements for clearance
to combustibles of 1-1/2". Slip the flashingunder the shingles (shingles should overlap
half the flashing) as per Diagram 4.

2) Set the gas appliance inits desired location. Drop a
Diagram 1
plumb bob down from theceiling to the position of theappliance flue exit, and mark the location
where the vent will penetrate the ceiling. Drilla small hole at his point. Next, drop a plumbbob from the roof to the hole previously drilledin the ceiling, and mark the spot where thevent will penetrate the roof. Determine if
ceiling joists, roof rafters or other framing will
obstruct the venting system.
You may wish
to relocate theappliance or tooffset, as shownin Diagram 2
to avoid cutting
load bearing
members.

3) A Firestop spacer must be installed in thefloor or ceiling of every level. To install theFirestop spacer in a flat ceiling or wall,
cut a 11 inch square hole. Frame the holeas shown in Diagram 3 and install thefirestop.

9) Install wall thimble
in the center ofthe 11" square
and attach withwood screws(Diagram 7).
Diagram 7
246) Continue to assemble pipe lengths.
Note: If an offset is necessary in the attic
to avoid obstructions, it is importantto support the vent pipe every 3 feet,to avoid excessive stress on theelbows, and possible separation. Wallstraps 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 the minimum
height requirements specified in Diagram 5 or
local codes. Note that for steep roof pitches,

Diagram 2
NOTE: For best results and optimum
performance with each approved venting
system, it is highly recommended to apply“Mill-Pac” sealant (supplied) to every inner pipe connection. Failure to do so may
result in drafting or performance issues notcovered under warranty. Silicone (red RTV)
is optional.

Diagram 6

Diagram 4: The upper half of the flashing isinstalled under the roofing material and not
nailed down until the chimney is installed. This
allows for small adjustments.

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® P95-4 Zero Clearance Direct Vent Gas Fireplace

INSTALLATION
the vertical height must be increased. A poor
draft, or down drafting can result from highwind conditions near big trees or adjoining
roof lines, in these cases, increasing the ventheight may solve the problem.
7) Ensure vent is vertical and secure the baseof the flashing to the roof with roofing rails,
slide storm collar over the pipe section andseal with a mastic.
8) Install the vertical termination cap by twistlocking it.
Note: Any closets or storage spaces, which
the vent passes through must be
enclosed.

Offset Chart
GS 8" Nominal Diameter ID
Offset5-11/16"
8-13/16"
10-15/16"
13"
21-7/16"
29-13/16"
38-1/4"

Pipe Length
0"
6"
9"
12"
24"
36"
48"

Height15-5/16"
15-7/16"
20-9/16"
22-11/16"
31-1/16"
37-7/16"
47-7/8"N o t e : To m a k e
the installation
more aestheticallypleasing,
werecommend framingout a square to
mount the terminal

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 nailingstrips.
3) Assemble the vent assembly by applying
Mill Pac to the 5"(127mm) inner collar of thetermination and slipping the 5"(127mm) liner
over it at least 1-3/8" (35mm). Fasten withthe 3 screws (drilling pilot holes will make thiseasier). Apply Mill Pac or high temperaturesilicone to the 8"(203mm) flex pipe and slip
it over the 8"(203mm) outer collar of the ventterminal at least 1-3/8"(35mm) and fasten
with the 3 screws.
NOTE:

INSTALLATIONPROCEDURES

Horizontal sections must be
supported at intervals not exceeding
3 feet (0.9 meter). (Flame picture andperformance will be affected by sagsin the liner).

4) Separate the 2 halves of the wall thimble andsecurely fasten the one with the tabs to theoutside wall making sure that the tabs areon 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 terminationassembly through the thimble making surethe 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 5"(127mm) liner and outer
8"(203mm) liner out enough to slip overthe flue collars of the fireplace. (You may
wish to cut the liner shorter to make it moreworkable.) Do not bend liner more than90o.
7) Apply Mill Pac over the fireplace inner collar
and slip the 5"(127mm) liner down over it
and attach with 3 supplied screws.
8) Do the same with the 8"(203mm) liner.
9) Apply a bead of silicone between the thimble
and termination and around the outer edgeof 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 venttermination area after snow falls, and clear
to prevent accidental blockage of venting
system. When using snow blowers, makesure snow is not directed towards venttermination area.

for FPI Direct Vent
System (Flex)
1) Locate the unit in the framing, rough in thegas (preferably on the right side of the unit)
and the electrical (Junction block is on theleft side) on the left. Locate the centerline of
the termination and mark wall accordingly.
Cut a 11"(279mm) hole in the wall (inside
dimension).
Note: Only a 1" (25mm) clearance isneeded at the termination end when
passing thru the wall. We recommend
framing a 11"(279mm) x 11"(279mm)(inside dimensions) hole to give
structural rigidity for mounting thetermination.

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace

25

INSTALLATION
P95-NG4 System Data
For 0 to 4500 feet altitude
Burner Inlet Orifice Sizes:#30

Max. Input Rating
Min. Input Rating

45,000 Btu/h
23,200 Btu/h

Supply Pressure

min.5.0" w.c.

Manifold Pressure(High)
3.8"+/- 0.2"w.c.

For USA installations follow local codes and/or
the current National Fuel Gas Code, ANSI
Z223.1.

The manifold pressure is controlled by a regulator
built into the gas control, and should be checkedat the pressure test point.

When using copper or flex connectors use only
approved fittings. Always provide a union sothat gas lines can be easily disconnected forservicing. Flare nuts for copper lines and flex
connectors are usually considered to meet thisrequirement.

Note: To properly check gas pressure, both
inlet and manifold pressures should
be checked using the valve pressure
ports on the valve.

Important: Always check for gas leaks with asoap and water solution or gas leak detector.
Do not use open flame for leak testing.

P95-LP4 System Data
For 0 to 4500 feet altitude
Burner Inlet Orifice Sizes:#49
Max. Input Rating 40,000 Btu/hMin. Input Rating 22,400 Btu/h

Supply Pressuremin.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.

1) Make sure the valve is in the "OFF"position.
2) Loosen the "IN" and/or "OUT" pressuretap(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.

PILOT ADJUSTMENT
Periodically check the pilot flames. Correct
flame pattern has three strong blue flames:
1 flowing around the thermopile, 1 aroundthe thermocouple and 1 flowing across theburner (it does not have to be touching theburner).
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 orthermopile or thermocouple.

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, turnoff the gas valve, disconnect the hose andtighten the screw (clockwise) with a 1/8" flatscrewdriver. Note: Screw should be snug,
but do not over tighten.

S.I.T. VALVE DESCRIPTION
1)
2)
3)
4)
5)
6)
7)
8)
9)

HIGH ELEVATIONThis unit is approved in Canada for altitude
0 to 4500 ft. (CAN1 2.17-M91) & U.S.A ANSI
ZZ1.88a

Gas on/off knob
Manual high/low adjustment
Pilot Adjustment
Thermocouple Connection - option
Outlet Pressure Tap
Inlet Pressure Tap
Pilot Outlet
Main Gas Outlet
Alternative TC Connection
Point

GAS LINE
INSTALLATION
The gas line is brought in through the right sideof 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: When the gas line is being installedfrom the left side, be sure to leaveroom 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 somemunicipalities have additional local codes it isalways best to consult with your local authorities
and the CAN/CGA B149 installation code.

26

GAS PIPE PRESSURETESTING
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 pressuresover 1/2 psig.

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace

INSTALLATIONCONVERSION KIT# 773-969 FROM NG TO LP
FOR P95-4 USING SIT 820 NOVA GAS VALVE
THIS CONVERSION MUST BE DONE BY A QUALIFIED GAS FITTERIF IN DOUBT DO NOT DO THIS CONVERSION !!

8)

Each Kit contains one LPG
Conversion Kit and one DC
Sparker Kit.
LPG Conversion Kit Contains:
Qty.
Part #
Description
1904-431
Burner Orifice #49
1
918-590
Label "Converted toLPG"
1908-528
Red "LPG" label
1908-529
5/32" Allen Key
1
910-037
LP Injector (Pilot Orifice)1918-486
Instruction Sheet
DC Sparker Kit Contains:
Qty.
Part #
Description
1820-475
Bracket DC Sparker
1820-476
Bracket DC Sparker
1904-153
Washer #8 External Star1
904-330
Nut 8-32 Hex
1
904-531
Bushing Split Plastic
0.500 in.
1
904-543
Screw 8-32 x 3/4 PanHead2
904-553
Screw #8 x 1/2 Type "B",Black Oxide
1910-073
Spark Generator Battery
Holder1
910-074
Spark Generator Switch
C/W Wire
1
910-078
Battery Size AA
Energizer En912
910-199
Clip Wire Holder
1910-903
Wire Fan To Power Cord
Ground 30 in.
904-781
Velcro Hook, Black
904-782
Velcro Hook, Black

Installation of LPG
Conversion Kit:
1)

Turn the gas off.

2)

Turn control knob to the “OFF” position.

3)

Remove the glass frame.

4)

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

5)

Remove the burner/grate assembly, firstby removing the two screws, one on eachside of the grate, then pull out the grate.

Removescrew

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

Allen Key

9)
6)

Remove the 2 screws, one on each sideof the burner. Slide the burner to the left
and then lift out.

Remove burner orifice with a 1/2" wrenchand discard. Use another wrench to holdon to the elbow behind the orifice.
BurnerOrificeRemove screw

10) Reinstall new burner orifice LP stamped#49 and tighten.
Slide the burner tothe left and lift out.

7)

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace

11) Remove the black protection cap byhand from the high-low knob (Fig.1).

Pull off the pilot cap to expose the pilot
orifice.

Fig. 1

27

INSTALLATIONINSTALLATION

12) Insert a 5/32” or 4mm Allen wrench into
the hexagonal key-way of the screw(Fig. 2), rotate it counter-clockwise until
it is free and extract it.

WARNING!
Do not overtighten the screw.
Recommended togrip the wrench by the short side.

Installation of the DC Sparker:21) Locate the Piezo Ignitor situated at the sideof valve.
Piezo
Ignitor16) Verify that if the conversion is fromNG to LPG, the screw must be reassembled with the red o-ring visible(Fig. 5).

Red o-ring visible

LPG Configuration

22) Remove the Piezo Ignitor by unscrewing thenut at the back of the mounting bracket.
Ignitor
Wire

Fig.2
Fig.5
13) Check that the screw is clean and if
necessary remove dirt.
14) Flip the screw (Fig. 3).

Piezo
Ignitor17) Re-assemble the black protection cap(Fig. 6).

23) Disconnect the ignitor wire from the Piezo
Ignitor and connect it to the DC Sparker.

DC
Sparker

Ignitor
Wire

Fig.3

15) Using the Allen wrench as shown in
Fig.4, rotate the screw clockwise until
snug, do not overtighten.

Fig. 6WARNING!
Also check that the pilot and mainburner injectors
are appropriate for the gas type.

24) Connect the DC spark generator wires
to the SIT Valve with the screw, which isprovided in the kit.

18) Reverse steps 6) to 1).
19) Attach the label "This unit has been
converted to LPG near or on top of theserial # decal.
20) Replace yellow "Natural Gas" label with
red "LPG" label.

Fig.4
28

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace

INSTALLATIONINSTALLATION

25) Locate the ground lug at the receptical box,
left of the unit.

29) Plug the DC spark generator wires to the
DC Sparker.

33) Find a location which is not too hot andis easy to reach for changing the battery.

34) Tie up the loose wire with the wire clip.
26) Connect one end of the supplied green
ground wire to the lug with the nut andwasher from the kit.

30) Connect the ground wire to the DC Sparker
mounting bracket.

Groundwire fromkit27) Install the 1/2" bushing to the heatshield.

31) Install the supplied battery into the DC
Sparker Box by opening the battery
compartment.
NOTE: The battery in the DC Sparker Box
will need to be replaced annually.
Battery
Compartment

35) Check inlet and outlet pressures.
36) Check operation of flame control.
37) Check for proper flame appearance andglow on logs.

Installer Notice:
These instructions must beleft with the appliance.
28) Run the other end of the ground wire andDC spark generator wires through thebushing on the heat shield.

32) Mount the heat shield to the DC Sparker.
Secure into place with the velcro, which isprovided in the kit.

Heat Shield

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace

29

INSTALLATIONOPTIONAL BRICK PANELS
1) Open the bottom louver door. Loosen the 2 screws holding the
Burner ON/OFF switch and bracket to the bottom louver and lift theassembly out.

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

2) Remove facade.
3) Remove glass door. Remove logs.
Note: The logs must not be in the unit.
4) Insert the back brick panel first by carefully slipping it between theback wall of the firebox and the rear log bracket.

5) Put the side panels in next. Slide them in from the front and pushthem flat up against the wall. Be very careful not to scratch them on
the firebox hardware.

Note: If the bottom brick panel must be removed: Remove
the Rear Log Stand, then remove the Burner Tray. See
the instructions in the "Removing Valve" section.

30

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace

INSTALLATIONLOG SET INSTALLATION
Read the instructions below carefully and refer to the images.
Dangerous operating conditions may occur if the logs are notpositioned in their correct locations. If the logs are broken
do not use the unit until they are replaced. Broken logs caninterfere with the pilot operation.

3) Fit log 27-45 into the pins on the rear log tray.

Log kit (Part # 774-930) contains the following pieces:
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)

27-45
27-46
27-47
27-48
27-49
27-50
27-51
27-52
902-154902-151902-179946-669

Rear Log
Middle Log
Left Log
Right Log
Front Log
Front Right Log
Front Left Log
Top Log
Embers Lava
EmbersVermiculite
Platinum Embers (supplied with packaged manual)
27-45
27-45

27-50

27-52
4) Fit log 27-46 into the pins at the middle of the burner.

27-51

27-48
27-47
27-49
27-46

27-46

1) Carefully remove the logs from the box and unwrap them. The logs
are fragile, handle with care - do not force into position.
2) Spread vermiculite around the base brick panel. Then take someembers and spread them over the vermiculite as shown.

27-46

Vermiculite and Embers
Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace

31

INSTALLATION
5) Place the top end of log 27-48 into the pin on log 27-46 and rest thenotch at the bottom end of log 27-48 against the right side of the 5th
grate post.

27-48

27-47

27-46

1st Grate Post

5th Grate Post

27-47

27-48

7) Spread some embers lava along the front of the burner as shown.
Ensure not to cover any burner ports.
Separate platinum embers and place on and around the embers on
the front burner. Avoid stacking platinum embers.
6) Rest the top end of log 27-47 on the notch in log 27-45 and rest thenotch on bottom right end of log 27-47 onto the left side of the 1st
grate post. The bottom left side of the log will touch the left side brickpanel.

27-45
27-47

32

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace

INSTALLATION
8) Place log 27-49 at the front of the burner with the grate post cut-outs
resting tight against the 3rd and 4th grate posts.

27-50
27-49

4th Grate Post

3rd Grate Post

10) Rest the top end of log 27-51 in the notch on the left side of log 27-49,
with the bottom end of log 27-51 sitting on the base brick panel.

27-51

27-49
27-49

9) Rest the top end of log 27-50 in the notch on the right side of log
27-49, with the bottom end of log 27-50 sitting on the base brickpanel.

27-51

27-49

27-50

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace

33

INSTALLATION
11) Fit log 27-52 into the pins on logs 27-45 and 27-49, with the bottom
left end of log 27-52 resting on the 2nd grate post.
27-52

27-45

27-52

2nd Grate Post
27-49

27-52

Completed Log Set Installation

27-45

27-49

27-47

34

27-51

27-52

27-46

27-50

27-48

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace

INSTALLATIONGLASS DOORINSTALLATION

3) Mount the 2 screws back onto the mounting
plate on the rear of the facade through thetab on the glass frame and then tighten
screw to secure.

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

1) Fit top door bracket over the flange at the
top of the firebox.
2) Secure with 3 screws on the bottom.

Door Bracket
attaches with
2 screws.

FlangeTighten both screws to secure Front
Facade to Glass Door.

2) Slide the door(s) onto the hinges.
Tab
Screw
Door

View from underneath of thescrew and the bracket.

FRONT FACADE
1) Remove the 2 screws from the mounting
plate that are on the back of the facade.

4) Slide Bottom Louver into position. On eachside secure the bottom screw first into theside bracket. Do not overtighten, leaveslightly loose to allow the louver to movefreely.
Adjusting the Plunger: Loosen the screwthat holds that plunger bracket so that you canremove the plunger.

Remove screws from themounting tabs.

2) Place the Front Facade into position bysliding the 2 holes in the bottom brackets
over the pins on the base, one on eachside.

SecureScrew
Loosen thescrew holding
the bracket.
5) Attach the two control boxes to the bottom
unit base and tighten the 2 screws on theleft side and 1 screw on the right side.
Once the plunger has been removed take a pin
and put it in the hole that is in the round part ofthe plunger and adjust it accordingly by turning
it to the left or right.

BracketAdjust plunger by
turning it to the leftor right with a pin.

Pin

Fit the bottom brackets overthe pins on the base.

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace

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

35

INSTALLATIONACCENT KIT INSTALLATIONSINGLE DOOR ACCENTS
1) Remove the rivets from the surround by pulling out the hoseclamp
with a screwdriver or plyer. Re-install the rivets by putting themthrough the holes on the sides of the surround.

4) Place the emblem over the emblem design on the surround. Insert
the studs through the holes. To secure them first put on the split lockwasher and then the nut and tighten.

5) Remove the 2 studs on the sides of the Hood. Insert the new studs
through the holes and secure them by first putting on the washer andthen tighten with a nut.

2) Take the hoseclamps and put them over the back of each rivet.
Squeeze the hoseclamp to secure onto rivets ensuring that the
hoseclamp is touching the back side of the surround. The hoseclamp
can now be released.

3) Remove the handles by removing the nut and screw. Install the
new handles by placing them in position over the holes on thesurround louver. Put the screws through the holes and securethem by tightening them with a nut.
DOUBLE DOOR ACCENTS
1) Remove the handles by removing the nut and screw. Install the
new handles by placing them in position over the holes on thedoor(s). Put the studs through the holes and secure them bytightening them with a nut.

36

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace

INSTALLATION
Option 1:
REMOTE CONTROL

Option 2:
WALL SWITCH

Option 3:
WALL THERMOSTATUse the Excalibur® Remote Control Kit approved
for this unit. Use of other systems may void
your warranty.

1) Run the wire through the right or left side
inlet opening. Be careful not to damage
wire.

The remote control kit comes with a hand heldtransmitter, a receiver and a wall mounting
plate.

Note: We recommend a maximum of 15'
of wire but if you wish to go with alonger run, use the Thermostat Wire
Table.

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.

1) Choose a convenient location on the wallto install the receiver and the receptaclebox (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.

2) 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.

Note: Preferable if the thermostat is installedon an interior wall.
Excalibur offers an optional programmablethermostat 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.
Thermostat Wire Table
Recommended Maximum Lead Length(Two-Wire) When Using Wall
Thermostat (CP-2 System)
Wire Size

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

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

Max. Length

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

3) Install 3 AAA alkaline batteries in transmitterand 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.

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace

37

INSTALLATIONWIRING DIAGRAMSThis heater does not require a 120V A.C. supply
for operation. In case of a power failure, theburner 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 purchasedwith the unit, it is still a good idea tobring power to the receptacle box(provided with the unit) in case thefan is installed at a later date.

For NATURAL GAS Units and Units NOT Equipped with DC Spark Boxes

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

38

CAUTION:
Label all wires
prior to disconnection whenservicing controls. Wiring
errors can cause improper anddangerous operation.

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace

INSTALLATIONFor PROPANE Units and Units Equipped with DC Spark Boxes**For installation of the DC Spark Box refer to the LP Conversion instructions in this manual.

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace

39

OPERATING INSTRUCTIONSOPERATING
INSTRUCTIONS
1) Read and understand these instructions
before operating this appliance.
2) Check to see that all wiring is correct andenclosed to prevent possible shock.
3) Check to ensure there are no gas leaks.
4) Make sure the glass in the door frame isproperly positioned. Never operate theappliance with the glass removed.
5) Verify that the venting and cap areunobstructed.
6) Ensure that the brick panels are installed.
7) Verify log placement. If the pilot cannot beseen when lighting the unit, the logs havebeen incorrectly positioned.
8) The unit should never be turned off, and on
again without a minimum of a 60 second
wait.

1) Turn burner OFF using "ON/OFF" switch.
2) Turn gas control knob so indicator points
to "OFF" position and allow 5 minutes forany gas in the combustion chamber toescape.
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 thepilot lights. After approximately one minute,release the gas control knob. The pilot flame
should continue to burn. If the pilot does notremain lit, repeat operation allowing a longer
period before releasing gas control knob.
4) When the pilot stays lit, turn the gas knob
further counter clockwise to the "ON"position.
5) Use the wall switch, thermostat or remotecontrol to turn on the unit.
6) Rotate the flame height regulator to adjust
the flame height higher or lower.

SHUTDOWNPROCEDURE

IMPORTANT
To ignite or reignite the pilot,
remove one glass panel/door.
NOTE: For all propane units and units
equipped with electric spark boxes,
see "Copy of Lighting Plate Instructions" section for more details.
Only when the pilot holds, without pressure
being applied to the control knob, resecure
the glass panel to the unit. The unit must not
be operated with the glass removed.
IMPORTANT Gas on/off knob cannot be
turned from "PILOT" to "OFF" unless it ispartially depressed.

40

During the first few fires, a white film
may develop on the glass front as partof the curing process. The glass should
be cleaned or the film will bake on andbecome very difficult to remove. Use a
non-abrasive cleaner and NEVER clean
the glass while it is hot.

AERATION
ADJUSTMENT
The air shutter can be adjusted by moving theadjusting 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 moreyellow flame. The burner aeration is factory
set but may need adjusting due to either the
local gas supply or altitude. This adjustment isperformed by the gas fitter.
Minimum Air Shutter Opening:
5/16"
Natural Gas
3/8"
Propane1) Use the wall switch, thermostat or remotecontrol to turn off the main burner.

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

2) Turn the main gas control clockwise to the"OFF" position to turn off the pilot.

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

3) Turn off all electric power to appliance if
service is to be performed.

LIGHTING
PROCEDURE

Note: When the glass is cold and theappliance is lit, it may cause
condensation and fog the glass.
This condensation is normal andwill disappear in a few minutes as

FIRST FIRE
The first fire in your fireplace is part of the paintcuring process. To ensure that the paint isproperly cured, it is recommended that you burnyour fireplace for at least four (4) hours the firsttime before you use it with the fan on.
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 theroom for a couple of hours.
The glass panel may require cleaning after theunit has cooled down.

DO NOT ATTEMPT TO CLEAN THE
GLASS WHILE IT IS HOT.

Adjustment Wire: Push to close orpull to open aeration cap.

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.

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace

OPERATING INSTRUCTIONSINSTALLATIONNORMAL OPERATINGSOUNDS OF GASAPPLIANCES

Copy of the Lighting Plate Instructions

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
unusual for the fan to make a "whirring" soundwhen ON. This sound will increase or decreasein volume depending on the speed setting ofyour fan speed control.
Burner Tray:
The burner tray is positioned directly under theburner tube(s) and logs and is made of a different
gauge material from the rest of the firebox andbody. 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 thesesounds 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 theswitch contacts closing and is normal.
OFF

Pilot Flame:
While the pilot flame is on it can make a veryslight "whisper" sound.
Gas Control Valve:
As the gas control valve turns ON and OFF, adull 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 beheard throughout the cycling process.

a

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace

41

MAINTENANCE

MAINTENANCE

MAINTENANCE
INSTRUCTIONS
1) Always turn off the gas valve before cleaning.
For relighting, refer to lighting instructions.
Keep the burner and control compartment
clean by brushing and vacuuming at least
once a year. When cleaning the logs, use asoft clean paint brush as the logs are fragileand easily damaged.
2) Clean appliance and door with a damp
cloth (never when unit is hot). Never usean abrasive cleaner. The glass should becleaned with a gas fireplace glass cleaner.
The glass should be cleaned when it
starts looking cloudy.
3) The heater is finished in a heat resistantpaint 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 theflame of the burner periodically, making surethe flames are steady; not lifting or floating.
If there is a problem, call a qualified service
person.
5) The appliance and venting system must be
inspected before use, and at least annually,
by a qualified field service person, to ensurethat 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 applianceand to replace any part of the control system
and any gas control which has been underwater.
7) In the event this appliance has been
serviced check that the vent-air system
has been properly resealed & reinstalledin accordance with the manufacturer's
instructions.
8) Verify operation after servicing.

General Vent MaintenanceConduct an inspection of the venting systemsemi-annually. Recommended areas to inspect
as follows:
1) Check the Venting System for corrosion inareas 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.

422) Remove the Cap, and shine a flashlightdown the Vent. Remove any bird nests, orother foreign material.

4) Drop the thermocouple or thermopile downfrom the bracket and pull it out of the unit.
5) Reinstall the new ones in reverse order.

3) Check for evidences of excessive
condensation, such as water droplets formingin the inner liner, and subsequently drippingout the joints, Continuous condensation cancause 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.
4) Inspect joints, to verify that no pipe
sections or fittings have been disturbed,
and consequently loosened. Also checkmechanical supports such as Wall Straps,
or plumbers' tape for rigidity.

GOLD-PLATED DOOROr SURROUND
The 24 carat gold-plated finish on the surroundand door requires little maintenance, and need
only be cleaned with a damp cloth.
DO NOT use abrasive materials or chemicalcleaners, as they may harm the finish and void
the warranty. Clean any fingerprints off before
turning the unit on.

LOG REPLACEMENTThe 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 thelogs. (The pilot light generates enough heat toburn someone.) If for any reason a log shouldneed replacement, you must use the proper
replacement log. The position of these logs
must be as shown in the diagrams under Log
Installation.

GLASS GASKET
If the glass gasket requires replacement use atadpole glass gasket (Part # 936-155).

DOOR GLASSYour Excalibur® fireplace is supplied with hightemperature, 5 mm Neoceram ceramic glass thatwill withstand the highest heat that your unit willproduce. 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 step-bystep instructions for replacement.

WARNING: Do not operate theappliance 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. 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 havegasketing around it.

Note: Improperpositioningoflogsmaycreatecarbon build-up and will severely alter
the unit's performance which is notcovered under warranty.

THERMOPILE /THERMOCOUPLE
1) Open the bottom louvers.
2) Loosen the thermocouple or thermopile witha 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.

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace

MAINTENANCE

MAINTENANCE

FAN MAINTENANCE

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

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

To Install the Fans
1) Shut the power off.
2) Open the bottom louver. Loosen the 2screws holding the Burner ON/OFF switch
and bracket to the bottom louver and lift theassembly 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 (theleft side fan) are linked by a wire harness.
Please do not remove the wire harness when
installing the fans.

Diagram 1

4) Move both fans and the wire harness
together to the front of the fireplace.
5)

Insert Fan A in from the left sideways (seediagram 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.

9) Connect the fan ground wire of Fan B andthe 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 thefirebox. Check that no wire will touch the hot
surfaces. Diagram 2.

12) 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 isno interference with the wires when thelouver is closed and that no wire will touch
the hot metal surfaces, fan blades or sharpedges.
13) Plug the fan power cord into the rear end of
the receptacle box to provide the maximum
clearance from the louvers.

To Remove the Fans
Slide Fan A in sideways
from the left.

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

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 handside. See diagram 1.

Diagram 211) Attach the two control boxes to the bottom
unit base and tighten the 2 screws on theleft side and 1 screw on the right side.

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

Position Fan B on
mounting studs.

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace

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 withinyour home. Ensure you maintain these fan
motors on a regular basis by vacuumingout the fan blades and housing using a softbrush nozzle.

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

43

MAINTENANCEREMOVING VALVE
1) Shut the power off.
2) Open the bottom louver door. Loosen the 2screws holding the Burner ON/OFF switch
and bracket to the bottom louver and lift theassembly out.

9) Remove the front bottom brick panel bysliding 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, ensurethat there is a union by the valve,otherwise removal will be almost
impossible.

INSTALLING VALVE

3) Remove the facade if installed.
1) Attach the valve to the valve bracket withthe 4 (m5x8 metric) screws provided.

4) Remove the glass door.
5) Remove the logs.
6) Remove the burner/grate assembly, first byremoving the 2 screws, 1 on each side of
the grill, then lift out the grill.

10) Disconnect the inlet gas line. See dia. 2.

2) Reconnect the "gas out" flare fitting with an
11/16" wrench.

11) Disconnect the 2 TP wires and the 2 TH
wires from the valve.

3) Reconnect the "gas out" flare nut with a
13/16" wrench.

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

4) Install piezo ignitor push button assembly
and reconnect wire.
5) Reconnect the quick drop out thermocouple
nut with a 9mm wrench.
6) Reconnect the pilot tube nut with a 7/16"
wrench.
7) Scrape off the old gasket from the floor of thefirebox and from the valve tray assembly.

Remove screw

8) Install a new gasket and reinstall the valve
tray assembly.
7) Remove the 2 screws, 1 on each side of theburner. Slide the burner to the left and thenlift out.

Note: Failure to install a new gasket may
severely affect the appliance performance.

Valve Tray Assembly

9) Reinstall the 10 hold down screws.
10) Hook up the 2 TP and 2 TH wires to theappropriate connections on the valve.
Remove screw

Slide theburner to
the leftand liftout.

11) Reinstall the bottom brick panel, then screw
the 2 screws & sleeves through the brickpanel to the firebox base (reversing step 8)
leaving them about 1/4" (6mm) above thebrick panel. Reinstall the rear log stand.
12) Install Burner/grate assembly13) Undo the pilot tube from the valve with a
7/16" wrench.

8) Remove the rear log stand by removing the
2 screws.
Rear Log Stand

14) Undo the quick drop out thermocouple nut
on the valve with a 9mm (metric) wrench.
15) Remove the Piezo igniter wire and pushbutton assembly.
16) Undo the "gas out" flare nut with a 13/16"
wrench.

14) Fire up the unit temporarily15) Check the manifold pressure.
16) Reinstall the logs and brick panels as
needed.
17) Reinstall the glass door and the facade.

17) Undo the "gas out" flare fitting with an
11/16" wrench.
18) Remove the 4 Phillips head screws fromthe sides of the valve bracket and remove
valve.
4413) Hook up the gas line and check for gas
leaks with a soap and water solution or agas leak detector. (Do not use open flamefor leak testing.)

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

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace

PARTS LIST
MAIN ASSEMBLY
Part #
1)
2)
7)
8)
9)
10)
22)

430-129*910-428910-429910-430904-687770-033

Description
Receptacle Box Mount
Thermodisc Bracket
Duplex Receptacle
Box - Receptacle
Cover - Receptacle
Clamp Connector
Baffle Guide23) 780-011
25) 770-074

Standoff - Top
Standoff

26)
27)
28)
29)
30)

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

770-128****773-528
31) *
32) *

Brick Panel Base (set of 3)
Brick Panel - Base Rear
Brick Panel - Base Front

770-901

Brick Panel Set - Standard
Brown
Brick Panel Set- Standard Red
Brick Panel Set- Herringbone Brown

770-902770-903

33)
34)
35)
36)

*
*
*
904-716511-031

Brick Panel - Back
Brick Panel - Left
Brick Panel - Right#10 x 5/8" Butt Spacer
Brick Panel ClipPart #
432-96738) 910-241
910-899

Description
Burner ON/OFF Switch Assy
Burner ON/OFF - Switch
Wire Harness - Valve to
Burner42) 430-517/P Fan Assembly (120 Volts)
910-331/P Fan Motor (120 Volts)

43)
46)
47)
48)
49)

770-523

Fan Switch Assembly

910-813910-330
904-586910-199910-142910-878

Power Cord (120 Volts)
Fan Speed Control Switch
Knob - Speed Control
Wire Holder Clip
Thermodisc-Fan Auto On/Off
Wire Harness - Twin Fan
Cable50) 770-994

Dura-Vent Adaptor (Optional)

60)
61)
62)
63)
64)
65)
80)

W260260 Top Relief Frame Gasket
942-117 Top Relief Plate Frame
W260280 Top Relief Plate Gasket
770-066 Top Relief Plate*
Hex Cap Screw 1/4 20NC 3.5*
Hex Cap Screw 1/4 20NC 2.0*
Hex Cap Screw 1/4 20NC 1.75

89)
90)
91)
92)
93)

946-556946-004
946-000
946-002
946-001
946-007

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace

Part #

Description94) 946-517/P Fan Assy - HeatWave Option95) 946-006 Grill Plate - White96) 946-005 Wall Adaptor Plate - White97) 910-417 Knob - White98) 910-366 Switch Cover Plate - White99) 910-412 Fan Speed Controller100) 910-367 Box-Plastic Switch
Receptacle101) 690-022F Cover Plate
102) 946-010 Flexible Air Duct946-045 Insulation 6" dia. x 60"
946-570108) 910-165
109) 946-000

Heat Release Duct Kit (Opt.)
Fan (120 V)
Flexible Air Release Duct910-063

Wall Switch

918-683773-969

ManualConversion Kit - NG to LP*Not available as a replacement part.

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

45

PARTS LIST

46

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace

PARTS LISTBURNER ASSEMBLY & LOG SETPart #

Description52) 910-190
54) 948-043

Piezo Ignitor & Nut
Bottom Relief Spring

770-574/P
770-576/P
56) 770-071
57) 910-478

Valve Assy - Natural Gas
Valve Assy - Propane
Gasket - Valve Tray
Valve - S.I.T. - NG/LP58) *66) 910-038
910-039904-660
904-431936-17067) 780-057
68) W840470

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 Gasket69) 770-070
79) 770-52582) 770-003
83) *Gasket - Relief Door Bottom
Burner Assy - NG/LP
Burner Grate Assy
Rear Log Support Bracket

774-930

Log Set*Not available as a replacement part.

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace47

PARTS LISTPARTS LIST

FLUSH FRONT ACCESSORIESPart #
771-518132) *
135) 940-328/P
136) 936-155
904-691
770-920770-922770-914770-916770-918141) *142) *
145) *
146) *
148) *
157) *
948-221

Description

Part #

Description

790-082N
790-082G
790-082AG
790-082BC
790-082BN

Door Assembly - Complete
Flush Door Frame
Glass (Flush)
Glass Gasket (Tadpole)
U-Clip155) 904-735
157) 904-722
904-722G
904-722N
904-722AG
904-722BC
904-722BN

Surround - Black - Complete
Surround - Polished Gold - Complete
Surround - Antique Gold - Complete
Surround - Antique Nickel - Complete
Surround - Antique Copper - Complete
Surround - Faceplate - Excalibur®
Surround - Louver
Surround - Hood
HandleRivet-67-5/16 x 1/2
Carriage Bolt
Logo Plate

Handle - Nickel
Handle - Gold
Handle - Antique Gold
Handle - Brushed Copper
Handle - Brushed Nickel
Push-Fit Ball Plunger
Carriage Bolt - Black
Carriage Bolt - Gold
Carriage Bolt - Nickel
Carriage Bolt - Antique Gold
Carriage Bolt - Brushed Copper
Carriage Bolt - Brushed Nickel*Not available as a replacement part.

136
770-931770-933
770-941770-942770-943161) *
162) *
163) *
164) *
167) *
168) *
146) 790-082

Double Screen Door - Complete - Black
Double Screen Door - Complete - Polished GoldDouble Screen Door - Complete - Antique GoldDouble Screen Door - Complete - Antique Nickel
Double Screen Door - Complete - Antique 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
Handle - Black

135

132
FLUSH DOOR

145

164
141
163
155
164
148

168
163
162
157

148

155

146
161
DOUBLE DOORS

167

148
155

146
142
146
157

48

148

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace

NOTES

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace

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Excalibur® P95-4 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 purchaserof a Excalibur Product. This warranty is not transferable.
The Warranty: Limited Lifetime
The combustion chamber, heat exchanger, burner tubes/pans, logs, brick panels and 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 five (5) years and parts only thereafter from date of purchase.
Special Finishes - One year on brushed nickel, antique gold and antique copper surrounds and doors. You can expect some changes in color as the product "ages" withconstant heating and cooling. FPI warranties the product for any manufacturing defects on the original product. However, the manufacturers warranty does not coverchanging colors and marks, ie. finger prints, etc applied after the purchase of the product. Damage from the use of abrasive cleaners is not covered by warranty.
Electrical and mechanical components such as blowers, switches, wiring, thermodiscs, FPI remote controls, spill switches, thermopiles, thermocouples, pilot assemblycomponents, and gas valves are covered for two years parts and one year 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 purchase.
Simpson Dura-Vent venting components are covered by Simpson Dura-Vent Inc. warranty.
Repair/replacement parts purchased by the consumer from FPI after the original coverage has expired on the unit will carry a 90 day warranty, valid with a receipt only.
Any item shown to be defective will be repaired or replaced at our discretion. No labor coverage is included with these parts.
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 workmanshipfrom 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.
Embers, 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 pressurecaused 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 FPI, may nullify yourwarranty on this product.
Any alteration to the unit which causes sooting or carboning that results in damage to the interior / exterior facia is not the responsibility of FPI.
* Subsidy according to job scale as predetermined by FPI.

Excalibur® P95-4 Zero Clearance Direct Vent Gas Fireplace51

Excalibur® fireplace products are designed withreliability and simplicity in mind. In addition, ourinternal Quality Assurance Team carefully inspects
each unit thoroughly before it leaves our door.
FPI Fireplace Products International Ltd. is pleased toextend 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.
52© Copyright 2010, FPI Fireplace Products International Ltd. All rights reserved.

Printed in Canada®

Excalibur P95-4 Zero Clearance Direct Vent Gas Fireplace