Osburn 3500-I Installation And Operation Manual Download

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Installation and

Operation Manual

2.5

g/h

<≤

EPA

CONTACT LOCAL BUILDING OR FIRE OFFICIALS ABOUT RESTRICTIONS AND INSTALLATION INSPECTION REQUIREMENTS IN
THE AREA.

READ THIS ENTIRE MANUAL BEFORE INSTALLATION AND USE OF THIS WOOD INSERT. FAILURE TO FOLLOW THESE
INSTRUCTIONS COULD RESULT IN PROPERTY DAMAGE, BODILY INJURY OR EVEN DEATH.

US Environmental Protection

Agency phase II certified

wood insert compliant with

2020 cord wood standard.

Safety tested according to

ULC S628, UL 1482 and

UL 737 by an accredited

laboratory.

OSBURN 3500-I

(OB03510 Model)

ENGLISH

READ AND KEEP THIS MANUAL FOR REFERENCE

Printed in Canada

46180A

2020-07-15

Summary of Contents for 3500-I

Page 1: ... THIS WOOD INSERT FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN PROPERTY DAMAGE BODILY INJURY OR EVEN DEATH US Environmental Protection Agency phase II certified wood insert compliant with 2020 cord wood standard Safety tested according to ULC S628 UL 1482 and UL 737 by an accredited laboratory OSBURN 3500 I OB03510 Model ENGLISH READ AND KEEP THIS MANUAL FOR REFERENCE Printed in Canada 461...

Page 2: ......

Page 3: ... the chimney that it is connected to It is also recommended to inform your home insurance company Please read this entire manual before installing and using this insert A primary alternative heat source should be available in the home This heating unit may serve as a supplementary heat source The manufacturer cannot be responsible for additional heating costs associated with the use of an alternat...

Page 4: ...sed Wood Logs 14 3 5 Drying Time 15 4 Operating the Insert 16 4 1 Blower 17 4 2 Fire Screen 17 5 Burning Wood Efficiently 18 5 1 First Use 18 5 2 Lighting Fires 18 5 3 Combustion Cycles 19 5 4 Rekindling a Fire 20 5 5 Removing Ashes 20 5 6 Air Intake Control 21 5 7 Fire Types 21 6 Maintenance 23 6 1 Insert 23 6 2 Glass Door 23 6 3 Door 25 6 4 Exhaust System 27 PART B INSTALLATION 29 7 Masonry Fire...

Page 5: ...35 10 3 Suitable Chimneys 35 10 4 Chimney Liner Installation 36 10 5 Liner Connection 36 10 6 Minimum Chimney Height 38 10 7 Chimney Location 38 10 8 Supply of Combustion Air 39 Appendix 1 Blower and Ash Lip Installation 40 Appendix 2 Door Overlay Installation 41 Appendix 3 Fresh Air Intake Kit Installation 42 Appendix 4 Faceplate And Trims Installation 43 Appendix 5 Optional Fire Screen Installat...

Page 6: ...Page 6 Installation and Operation Manual Osburn 3500 I ENGLISH CERTIFICATION PLATE ...

Page 7: ...ening the loading door NEVER USE GASOLINE LANTERN FUEL NAPHTHA FUEL OIL MOTOR OIL KEROSENE CHARCOAL LIGHTER FLUID OR SIMILAR LIQUIDS OR AEROSOLS TO START A FIRE IN THIS INSERT KEEP ALL SUCH LIQUIDS OR AEROSOLS WELL AWAY FROM THE INSERT WHILE IT IS IN USE Do not store fuel within heater minimum installation clearances Burn only seasoned natural firewood This wood heater needs periodic inspection an...

Page 8: ...d maximum burn time may vary subject to location in home chimney draft heat loss factors climate fuel type and other variables The recommended heated area for a given appliance is defined by the manufacturer as its capacity to maintain a minimum acceptable temperature in the designated area in case of a power failure 2 The maximum heat output dry cordwood is based on a loading density varying betw...

Page 9: ...h south ends of the logs visible East west sides of the logs visible 11 Mobile homes Canada or manufactured homes USA The US Department of Housing and Urban Development describes manufactured homes better known as mobile homes as follows buildings built on fixed wheels and those transported on temporary wheels axles and set on a permanent foundation In Canada a mobile home is a dwelling for which ...

Page 10: ... 28 3 4 731mm ø 6 153mm 7 1 8 182mm 18 1 4 464mm 4 7 8 122mm MIN Top View Side View Minimum Insert Projection 27 5 8 703mm 11 3 4 298mm 19 482mm 21 1 4 540mm 1 7 8 48mm MAX 24 1 8 614mm 24 1 2 623mm 24 7 8 631mm 9 1 8 232mm 23 1 8 586mm 24 1 8 613mm 29 735mm 23 1 4 591mm Front View Side View Maximum Insert Projection ...

Page 11: ...1 Installation and Operation Manual Osburn 3500 I ENGLISH 19 483mm 10 5 8 269mm Door Opening 22 7 8 581mm 3 16 5mm 3 8 10mm 20 1 8 510mm 12 7 8 326mm Front View Combustion Chamber Side View Combustion Chamber ...

Page 12: ... into a solvent free solution Disposal at an ecocentre is recommended The door glass is a 5 32 4 mm thick ceramic material that contains no toxic chemicals It is made of natural raw materials such as sand and quartz that are combined in such a way to form a high temperature glass Ceramic glass cannot be recycled in the same way as normal glass so it should not be disposed of with the regular house...

Page 13: ... of the air supply meaning controlling the heat output while maintaining clean and efficient flaming combustion which boosts the efficient delivery of heat to the home The emission control and advanced combustion features of this insert can only work properly if the fuel used is in the correct moisture content range of 15 to 20 Refer to the following section for suggestions on preparing fuelwood a...

Page 14: ...ood trees more valuable The advice that only hardwoods are good to burn is outdated Old leaky cast iron inserts wouldn t hold a fire overnight unless they were fed large pieces of hardwood That is no longer true 3 2 Log Length Logs should be cut at least 1 25 mm shorter than the firebox so they fit in easily Pieces that are even slightly too long makes loading the insert very difficult The most co...

Page 15: ...ther Small pieces dry more quickly than large pieces Split pieces dry more quickly than unsplit rounds Softwoods like pine spruce poplar and aspen take less time to dry than hardwoods they can be dry enough to burn after being stacked to air dry only for the summer months Hardwoods like oak maple and ash can take one or even two years to dry fully especially if the pieces are big Firewood dries mo...

Page 16: ...s should be completed Empty the combustion chamber and install the air control handle A with the set screw B as shown below A B Empty the combustion chamber Installing the air control wood handle Install the combustion chamber side bricks as shown below Install the ash lip and the blower see Appendix 1 Blower and Ash Lip Installation Install the door overlay see Appendix 2 Door Overlay Installatio...

Page 17: ...en the blower is ON it will start automatically when the insert is hot enough and it will stop when the insert has cooled down Therefore the blower speed control can be left at the desired setting OFF HI LO Blower rheostat 4 2 Fire Screen This insert has been tested for use with an open door in conjunction with a fire screen sold separately The fire screen must be properly secured on the insert to...

Page 18: ...he conventional method to build a wood fire is to crumple 5 to 10 sheets of newspaper and place them in the firebox and hold them in place with ten pieces of kindling wood The kindling should be placed on and behind the newspaper Then add two or three small pieces of firewood Open the air intake control completely and ignite the newspaper Leave the door slightly ajar Once the fire has ignited the ...

Page 19: ... experienced wood burners these are advantages of zone heating wood burning Wood heaters don t have a steady heat output It is normal for the temperature to rise after a new load of wood is ignited and for its temperature to gradually decrease throughout the burning cycle This increasing and decreasing temperature can be matched with the household routines For example the temperature in the area c...

Page 20: ...ge is pleasant when the room temperature is cool but can be unpleasant when the room is already warm Therefore it is best to let each load of wood burn completely so that the room cools down before putting a load of wood back on 5 5 Removing Ashes Ash should be removed from the firebox every two to three days of full time heating Ash should not accumulate excessively in the firebox since it will a...

Page 21: ... the insert heat output to the desired temperature in the house A house will need far less heating in October than in January to maintain a comfortable temperature Filling the firebox full in fall weather will overheat the space Otherwise the combustion rate will have to be reduced to a minimum and the fire will be smoky and inefficient Here are some suggestions for building fires suitable for dif...

Page 22: ...e of the space to be heated the climate zone where the house is and the time of the year The table below gives an approximate maximum burn cycle times based on firebox volume Table 1 Approximate Maximum Burn Cycle Time FIREBOX VOLUME MAXIMUM BURN CYCLE TIME 1 5 cubic feet 3 to 5 hours 1 5 c f to 2 0 c f 5 to 6 hours 2 0 c f to 2 5 c f 6 to 8 hours 2 5 c f to 3 0 c f 8 to 9 hours 3 0 c f 9 to 10 ho...

Page 23: ...e sanded lightly with sandpaper and then wiped off to remove dust Apply two thin layers of paint 6 1 2 Refractory Material and Baffle Inspect the firebricks or the refractory panels and the baffle for damage periodically and replace anything that is cracked or broken Operation of the heater with a cracked or missing baffle may cause unsafe temperatures and hazardous conditions and will void the wa...

Page 24: ...d see procedure below 4 Reinstall the glass being careful to centre the glass in the door and not to over tightening the retaining screw 2x 8x 8x Replacing the glass The two main causes of broken door glass are uneven placement in the door and over tightening the retaining screws 6 2 3 Gasket The glass gasket is flat adhesive backed woven fibreglass The gasket must be centred on the edge of the gl...

Page 25: ...The tightness of the door seal can be verified by closing and latching the door on a strip of paper The test must be performed all around the door If the paper slips out easily anywhere either adjust the door or replace the gasket Door gasket seal verification 6 3 1 Adjustment The gasket seal may be improved with a simple latch mechanism adjustment 1 Remove the split pin by pulling and turning it ...

Page 26: ...ss the gasket into the groove The gasket must not be stretched during installation 4 Leave about long of the gasket when cutting and press the end into the groove Tuck any loose fibers under the gasket and into the silicone 5 Close the door Do not use the insert for 24 hours Door gasket 6 3 3 Door Alignment To align open the door and loosen the pressures screws located on the lower and upper hinge...

Page 27: ...ote builds up in the system it can ignite when a hot fire is burned in the insert A very hot fire can progress to the top of the chimney Severe chimney fires can damage even the best chimneys Smouldering smoky fires can quickly cause a thick layer of creosote to form When the insert is operated properly the exhaust from the chimney is mostly clear and creosote builds up more slowly Creosote Format...

Page 28: ...ney fire 6 4 2 Sweeping the Chimney Chimney sweeping can be a difficult and dangerous job People with no chimney sweeping experience will often prefer to hire a professional chimney sweep to inspect and clean the system for the first time After seeing the cleaning process some will choose to do it themselves The chimney should be checked regularly for creosote build up Inspection and cleaning of t...

Page 29: ...or use with solid fuel requires the fireplace to be permanently labelled by the installer as being no longer suitable for solid fuel until the removed parts are replaced and the fireplace is restored to its original certified condition Also any air vents grilles or louvers that allow air circulation around the fireplace must not be removed or blocked 7 2 Chimney Caps Mesh type chimney caps must ha...

Page 30: ...sidential installations but is not intended for installation in a bedroom In Canada the CSA B365 Installation Code for Solid Fuel Burning Appliances and Equipment and the CSA C22 1 Canadian National Electrical Code are to be followed in the absence of local code requirements In the USA the ANSI NFPA 211 Standard for Chimneys Fireplaces Vents and Solid Fuel Burning Appliances and the ANSI NFPA 70 N...

Page 31: ...TEL SHELF CLEARANCES I 12 305mm max 27 686 mm min X I Shelf Clearances 9 2 Floor Protection It is necessary to have a floor protection made of non combustible materials that meets the measurements specified in the Table 3 Floor Protection below Table 3 Floor Protection FLOOR PROTECTION Canada USA B13 18 457 mm 16 406 mm M 8 203 mm N A N N A 8 203 mm N M B DOOR Floor Protection 13 From door opening...

Page 32: ... G A C D B G 8 216 mm Back from fireplace facing 2 If the value D is negative or zero additional floor protection in front of the unit is not needed because the masonry fireplace hearth extension is long enough If the value D is positive an additional floor protection in front of the hearth extension at least equivalent to the result D must be added 9 2 1 Installation Raised of 6 152 mm and Less I...

Page 33: ...mmon brick 5 00 0 2 Face brick 9 00 0 11 Marble 14 3 20 00 0 07 0 05 Ceramic tile 12 5 0 008 Concrete 1 050 0 950 Mineral wool insulation 0 320 3 120 Limestone 6 5 0 153 Ceramic board Fibremax 0 450 2 2 Horizontal still air thick 15 0 135 0 920 Example Required floor protection R of 1 00 Proposed materials four inches of brick and one inch of Durock board Four inches of brick R 4 x 0 2 0 8 plus 1 ...

Page 34: ...ND ADJACENT SIDE WALL FLOOR PROTECTION J I H Q G F K L O P Masonry Opening and Clearances MINIMUM CLEARANCES F 19 483 mm G 9 229 mm H 27 686 mm I 27 686 mm Q 84 213 cm MAXIMUM THICKNESS O 5 127 mm P 12 305 mm MINIMUM MASONRY OPENING J 26 660 mm K16 31 787 mm L 18 3 8 457 mm 16 If a fresh air intake is required it is recommended to add at least 4 to the width of the minimum opening of the hearth ...

Page 35: ... cut the pipe hole slightly larger than the liner diameter and pass the liner through the hole Install the block off plate and secure it with masonry nails Seal the joints between the plate and the chimney with high temperature silicone and use stove cement to seal between the pipe and the plate In Canada the CSA B365 Standard permits Roxul type wool to be stuffed around the liner as it passes thr...

Page 36: ...lip of air jacket is flush with fireplace facing If lag bolts or anchors are to be used to secure the insert the holes location should be marked with the unit in place Remove the insert and locate the anchors 6 STAINLESS STEEL RIGID OR FLEX LINER RAIN CAP MASONRY FLUE FLASHING RIGID LINER 12 305mm MIN 36 914mm MIN Liner Installation 10 5 Liner Connection Two options are possible to connect the lin...

Page 37: ... other option is possible and if the total height of the fireplace and chimney is at least 20 feet This kind of adaptor is restricting the free flow of exhaust gases and may result in smoke roll out from the insert when the door is open for reloading When installing a liner offset adapter secure the three brackets provided in the user manual on top of the insert The long end of the brackets must b...

Page 38: ...e is buoyant so it tends to rise This creates a slight pressure difference in the house Called stack effect it produces a slightly negative pressure in the lower part of the house compared to the outside and a slightly positive pressure zone in the high part of the house If there is no fire burning in a heater connected to a chimney that is shorter than the warm space inside the house the slight n...

Page 39: ...cted by wind pressures on the house Contrary to commonly expressed concerns almost all tightly sealed new houses have enough natural leakage to provide a small amount of air needed by the insert The only case in which the wood insert may not have adequate access to combustion air is if the operation of a powerful exhaust device such as a kitchen range exhaust causes the pressure in the house to be...

Page 40: ...ation Manual Osburn 3500 I ENGLISH Appendix 1 BLOWER AND ASH LIP INSTALLATION 1 Install the ash lip A on the insert with three screws B 2 Center the blower on the ash lip and push it against the firebox Then push it until it clips ...

Page 41: ... 2 DOOR OVERLAY INSTALLATION Position the overlay C on the door frame and secure it in place from behind using the screws D To ease the installation do not tighten the screws until they are all installed Note It is not necessary to remove the glass to install the overlay 8x ...

Page 42: ... clear the opening for the outside air intake A B C D E D F 2 Install the fresh air intake adapter B with four screws C then secure the flexible pipe17 E not included to the adapter B using one of the pipe clamps D Secure the other end of the pipe to the outside wall termination F using the other pipe clamp D The outside wall termination F must be installed outside of the home 17 The pipe must be ...

Page 43: ...ecorative molding fasteners 2x Kit of molding brackets and screws 2x Nuts 10 24 8X A 1 Remove the faceplate extension K secured between the firebox and the convection air jacket A DETAIL A D E A B C 2 Place the faceplate panels with the finished side down on a flat soft non abrasive surface Line up the holes of the upper faceplate panel A with the holes of the side panels B and C Secure them toget...

Page 44: ...imposed brackets in the groove of each decorative trim T U and V Align the corners of the angled side of each trim and then tighten the screws S to secure the trims L 5 Align the trim assembly with the left and right edge of the faceplate and slowly slide it down over the faceplate 6 Secure the trim to the faceplate by squeezing the eight trim retainers L between the inner edge of the trim and the...

Page 45: ... and Operation Manual Osburn 3500 I ENGLISH M 7 Align the holes in the faceplate extension M with the holes in each faceplate side panels A DETAIL A O N 8 Secure both assemblies together using 6 bolts N and nuts O provided ...

Page 46: ...ed and slide the faceplate assembly just over the bolt s head and washer Q and P Then push towards the fireplace If necessary adjust the height of the insert using the leveling bolts S on each side of the convection air jacket until the faceplate is properly seated on the floor of the hearth extension 11 Once the faceplate is in place secure the assembly by tightening nuts P using a 7 16 11 mm ope...

Page 47: ...nforced ex US EPA 1 Open the door 2 Hold the fire screen by the two handles and bring it close to the door opening 3 Lean the upper part of the fire screen against the top door opening making sure to insert the top fire screen brackets behind the primary air deflector 4 Lift the fire screen upwards and push the bottom part towards the insert then let the fire screen rest on the bottom of the door ...

Page 48: ...ole Then lift and insert the left end of the tube into the rear left channel 2 Align the notch in the left end of the tube with the key of the left air channel hole Using a Wise grip hold the tube and lock it in place by turning the tube as shown Make sure the notch reaches the end of the key way 3 Install the baffle 4 Repeat steps 1 and 2 for the three other tubes 5 To remove the tubes use the ab...

Page 49: ...Page 49 Installation and Operation Manual Osburn 3500 I ENGLISH Note that secondary air tubes A can be replaced without removing the baffle board B and that all tubes are identical ...

Page 50: ...d to be removed To remove the insert follow these instructions 1 Unscrew the faceplate fastener C holding the faceplate B on the insert 2 Remove faceplate B by pulling on it 3 Remove the blower assembly A 4 Remove the three screws securing the pipe connector D 5 Unscrew the bolts securing the insert to the floor on each side of the unit E ...

Page 51: ...D DIAGRAM AND PARTS LIST 2 9 8 2 10 13 12 14 15 16 18 17 19 20 8 22 21 24 23 53 52 29 30 30 30 29 30 30 30 32 29 30 30 30 30 29 30 30 34 38 39 41 42 43 45 44 47 48 49 46 50 28 25 26 40 37 27 B DETAIL B 35 36 25 C DETAIL C 33 1 3 4 5 6 7 11 30 30 30 30 30 31 31 31 31 31 31 31 31 54 51 ...

Page 52: ...DOOR GLASS 1 11 AC06400 3 4 FLAT X 6 BLACK SELF ADHESIVE GLASS GASKET 1 12 PL70815 RIGHT GLASS FRAME 1 13 PL70814 RIGHT GLASS FRAME 1 14 SE53585 GLASS RETAINER KIT WITH SCREWS 12 PER KIT 1 15 SE70933 ASH LIP ASSEMBLY 1 16 30206 ZINC WASHER 5 16 ID X 3 4 OD 1 17 30064 3 16 X 1 CLEVIS PIN 1 18 PL70921 AIR CONTRÔL DAMPER 1 19 30059 5 32 ID PUSHNUT 1 20 30506 SCREW PAN TORX TYPE F 1 4 20 X 1 BLACK 1 2...

Page 53: ...NNEL 32 X 44 1 42 PL70941 FACEPLATE SIDE PANNEL 32 S 44 2 43 SE18286 BLOWER ASSEMBLY 1 44 60013 POWER CORD 96 X 18 3 type SJT 50 pcs per carton 1 45 44028 CERAMIC THERMODISC F110 20F 1 46 44089 DOUBLE CAGE BLOWER 144 CFM 115V 60Hz 1 1A 1 47 44085 RHEOSTAT KNOB 1 48 44087 RHEOSTAT NUT 1 49 44080 RHEOSTAT WITHOUT NUT MODEL KBMS 13BV 1 50 SE46180 OSBURN 3500 ONSERT INSTRUCTION MANUAL KIT 1 51 21564 C...

Page 54: ...er at its discretion may decide to repair or replace any part or unit after inspection and investigation of the defect The manufacturer may at its discretion fully discharge all obligations with respect to this warranty by refunding the wholesale price of any warranted but defective parts The manufacturer shall in no event be responsible for any uncommon indirect consequential damages of any natur...

Page 55: ......

Page 56: ...al com This document is available for free download on the manufacturer s website It is a copyrighted document Resale is strictly prohibited The manufacturer may update this document from time to time and cannot be responsible for problems injuries or damages arising out of the use of information contained in any document obtained from unauthorized sources ...

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