Osburn Cordova Series User manual

OSBURN CORDOVA SERIES
Gas Fireplace Inserts - Installation and Operating Instructions
WARNING: If the information in this manual is not followed exactly, a fire or explosion may result causing
property damage, personal injury or loss of life.
FOR YOUR SAFETY
Do not store or use gasoline, or other flammable vapours and liquids, in the vicinity of this, or any other appliance.
WHAT TO DO IF YOU SMELL GAS
• Open windows
• Extinguish any open flame
• Do not try to light any appliance
• Do not touch any electrical switch
• Do not use any phone in your building
• Immediately call your gas supplier from a neighbour's phone. Follow the gas supplier's instructions.
• If you cannot reach your gas supplier call the fire department.
WARNING
Improper installation, service, adjustment, alteration, or maintenance can cause injury or property damage. Refer to this
manual. For assistance or additional information, consult a qualified installer, service agency, or the gas supplier.
Please read this manual before installing or using this appliance. Retain this manual for future
reference.
Patents Pending
Made in Canada
06/05/02
KA1125
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T
ABLE OF CONTENTS
1.0 Introduction ....................................................................................................................................................................... 3
1.1 Specifications ........................................................................................................................................................3
1.2 Features ..................................................................................................................................................................5
1.3 Intended Use...........................................................................................................................................................5
1.4 General Safety ........................................................................................................................................................6
2.0 Operation............................................................................................................................................................................ 7
2.1 Operation Safety.....................................................................................................................................................7
2.2 Lighting Instructions...............................................................................................................................................8
2.3 Heat Output Adjustment.......................................................................................................................................10
2.4 Fan Operation.......................................................................................................................................................10
2.5 Remote Control Operation....................................................................................................................................10
3.0 Installation........................................................................................................................................................................ 11
3.1 Installation & Safety Notes...................................................................................................................................11
3.2 Unpacking ............................................................................................................................................................11
3.3 Installation............................................................................................................................................................11
3.3.1 Minimum Clearances To Combustible Construction.................................................................................12
3.3.2 Chimney Liner Or Vent Installation..........................................................................................................14
3.3.3 Gas Line Installation..................................................................................................................................15
3.3.4 Thermostat, Wall Switch, Or Remote Control Installation...................................................................... 16
3.3.5 Vent, Gas Line, & Wiring Connections.....................................................................................................18
3.3.6 Lower Grille Installation ...........................................................................................................................19
3.3.7 Faceplate Installation.................................................................................................................................20
3.3.8 Firebox Component Installation ................................................................................................................22
3.3.8.1 Log-Set Installation.........................................................................................................................22
3.3.8.2 Coal and Ember Placement..............................................................................................................23
3.3.8.3 Installing the Lower Door Trim.......................................................................................................24
3.3.8.4 Installing the Door...........................................................................................................................25
3.3.8.5 Installing the Vertical Trims (Contemporary Grille Kits Only).......................................................25
3.3.8.6 Installing the Top Grille Assembly .................................................................................................25
3.3.9 Initial Firing...............................................................................................................................................26
3.3.9.1 Manifold Pressure Regulator Adjustment .......................................................................................26
3.3.9.2 Pilot Flame Adjustment...................................................................................................................26
3.3.9.3 Flue Spillage Test............................................................................................................................27
3.3.9.4 Altitude Adjustment ........................................................................................................................27
4.0 Maintenance......................................................................................................................................................................28
4.1 Maintenance Safety ..............................................................................................................................................28
4.2 Recommended Service .........................................................................................................................................28
4.3 Glass Cleaning......................................................................................................................................................28
4.4 Cleaning Of Brass Plated Surfaces.......................................................................................................................28
4.5 Cleaning Of Gold Plated Surfaces........................................................................................................................28
4.6 Burner & Pilot Cleaning.......................................................................................................................................29
4.7 Fan Replacement & Electrical Schematic.............................................................................................................29
4.8 Heater Disassembly & Reassembly......................................................................................................................31
5.0 Trouble Shooting...............................................................................................................................................................32
6.0 Replacement Parts............................................................................................................................................................35
7.0 Osburn’s Warranty ..........................................................................................................................................................37
8.0 Label Information.............................................................................................................................................................39
1.0 Introduction
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1.1 Specifications
Table 1 Specifications
Item Natural Gas (NG) Propane (LPG)
Btu Input :
Maximum 25,000 Btu/hr (26.4 MJ/hr) 25,000 Btu/hr (26.4 MJ/hr)
12,500 Btu/hr ( 13.2 MJ/hr) 16,750 Btu/hr (17.6 MJ/hr)
Minimum
Flue Loss: Efficiency: Fan off 70% 72%
Fan on 75% 76%
Output: Fan off 17,500 Btu/hr (18.5 MJ/hr) 18,000 Btu/hr (19 MJ/hr)
Fan on 18,750 Btu/hr (19.8 MJ/hr) 19,000 Btu/hr (20 MJ/hr)
AFUE: Efficiency: Fan off 64%
Manifold Pressure: 3.8" w.c. (0.9 kPa) 10.0" w.c. (2.5 kPa)
Gas Inlet Supply Pressure: Minimum: 5.0" w.c. (1.2 kPa) Minimum: 11.0" w.c. 2.7kPa)
Normal: 7.0" w.c. (1.7 kPa) Normal: 13.5" w.c. (3.4 kPa)
Maximum: 13.5" w.c. (3.4
kPa) Maximum: 13.5" w.c. (3.4 kPa)
Orifice Size: #38 #52
Control Valve Type: SIT 820 Nova (50% reduction) SIT 820 Nova (33 % reduction)
Shipping Weight: 80lbs 80lbs
Flue Outlet Size: 4"DIA. (102mm) 4"DIA. (102mm)
Fan: Variable Speed
NOTE:The efficiency rating of the appliance is a product thermal efficiency rating determined under
CONTINOUS
operating conditions and was determined independently of any installed system. AFUE was tested
by Manufacturer.
Options: Bevelled Faceplates
Remote Control
Thermostat
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Figure 1
Installation Codes
Installation must conform to local codes. In the absence of local codes, installation must conform to the
current National Fuel Gas Code, ANSI Z233.1, (in the U.S.), or with the current CAN/CGA B149.1
installation code (in Canada). In Australia, the Australian Gas Association installation code for gas burning
heaters and equipment must be used. The heater, when installed, must be electrically grounded in
accordance with local codes or, in the absence of local codes, with the current National Electric Code
ANSI/NFPA No. 70 (in the U.S.) or with the current CSA C22.1 Canadian Electrical Code (in Canada).
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1.2 Features
Ignition system:
Standing pilot ignition system with thermopile and thermocouple flame detection and piezo igniter.
Gas control:
Gas control valve type:
Automatic millivolt powered combination gas control valve with variable flame control for
convenience, and on/off switch. Optional remote on/off wall switch, optional wall thermostat,
and/or optional wireless remote control are available. The gas valve does not require electricity
from an external source.
Fan control:
Variable Speed Control:
For units equipped with a fan control, the knob controls the fan speed in connection with a heat
sensitive switch which turns on when the heater reaches operating temperature. Turning the knob
counter-clockwise turns it to the “OFF”position.
Auto/Off Switch:
For units equipped with a fan switch, the fan may be switched between the “AUTOMATIC”& the
“OFF”settings.
Safety controls:
A safety switch will shut the system down in the event of any one of the following conditions:
Incorrectly installed vent system
Blocked vent causing flue spillage
Flow reversal or sustained down draft situation
Drafthood:
The appliance is provided with a drafthood design which minimizes the effects of down drafts or flue
blockages on the quality of combustion. It will vent out of the appliance upon down draft or flue blockage
and, by design, it exhausts to the same pressure zone as the combustion air inlet to the appliance.
1.3 Intended Use
This appliance is intended to be used as a heater, wheninstalled as an insert for code complying masonry, or
listed factory built solid fuel burning fireplaces which meet the minimum requirements as described in detail
in the installation instructions. This insert is certified for installation in a bedroom or a bed sitting room
where the maximum input is within 50 cubic feet per 1000 Btu/hr, (i.e. 1250 cubic feet). All bedroom
installations require the use of wall thermostats.
1.4 General Safety
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The appliance must be properly connected to a venting system in accordance with local codes. This unit
must not be connected to a chimney or flue serving anyother appliance. It is equipped with a safety control
system to protect against improper venting of flue products.
WARNING: Operation of this insert when not connected to a properly installed and maintained
venting system, may result in carbon monoxide poisoning.
Installation and repair should be done by a qualified service person. The appliance should be inspected
before use and at least annually by a professional service technician. Provide adequate clearancesaround air
openings and allow accessibility clearance for servicing and proper operation. In Australia, a dress guard
has been installed to cover the glass and to protect users against accidental contact with hot surfaces. Do not
operate the appliance without the dress guard in place.
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2
.0 Operation
2.1 Operation Safety
Inspect the appliance before use. Always keep the appliance area clear and free from combustible materials,
gasoline and other flammable vapours and liquids. Never obstruct the flow of ventilation air. Keep the
front of the appliance clear of all obstacles and foreign materials. Never obstruct or modify the air
inlet/outlet grilles of the fireplace in any manner.
CAUTION: Children and adults should be alerted to the hazards of high surface temperature and
should stay away to avoid burns or contact with hot surfaces. Young children should be
carefully supervised when they are in the same room as the heater. Clothing or other
flammable material should not be placed on or near the unit. Due to high temperatures,
the appliance should be located out of traffic and away from furniture and draperies.
The glass door and top grille must be properly installed prior to operation. NEVER operate the unit with the
glass door off or broken since this may cause dangerous indoor air pollution. This unit is NOT for use with
solid fuel. DO NOT substitute any parts or materials. DO NOT abuse the glass door.
Figure 2
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2.2 Lighting Instructions
FOR YOUR SAFETY, READ BEFORE LIGHTING
WARNING:If you do not follow these instructions exactly, a fire or explosion may result causing
property damage, personal injury or loss of life.
A. This appliance is provided with a standing pilot flame. When lighting the pilot, follow these instructions
exactly:
B. BEFORE LIGHTING smell all around the appliance area for gas. Be sure to smell next to the floor because
some gas is heavier than air and will settle on the floor.
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 your home.
• Immediately call your gas supplier from a neighbour's phone. Follow the gas suppliers instructions.
• If you cannot reach your gas supplier, call the fire department.
C. Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not push in
or turn by hand, do not try to force or repair it; call a qualified service technician. Forcing or attempted
repair may result in a fire or explosion.
D. Do not use this appliance if any part has been under water. Immediately call a qualified service
technician to inspect the appliance and to replace any part of the control system and any gas control
which has been under water.
Lighting Procedures
1. “STOP!” Read the safety information in the previous section.
2. Set the thermostat to the lowest setting.
3. Turn off all electrical power to the appliance.
4. Open the access door, hinged to open downward, by gently pulling the top toward you.
5. Push in the gas control knob slightly and turn clockwise to the “OFF” position as shown in Figure 3.
6. Wait a minimumof five minutes to clear out any residual gas. If you then smell gas, STOP!Follow "B"
in the Lighting Instruction section described on the previous page. If you don't smell gas, go to the next
step.
7. Press in the gas control knob and turn counter-clockwise to the "PILOT" position.
Lighting Procedures Cont’d
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8. Push the control knob in all the way and hold it in. Immediately push the piezo ignition button (the
black button second from the left) repeatedly so that it clicks; continue until the pilot ignites. Maintain
pressure on the knob for about one minute after ignition. Then release the knob; if the pilot flame goes
out repeat step 8; if the pilot flame remains on then turn the knob counter-clockwise to the "ON"
position.
9. If the pilot lights, but will not stay on after several tries, turn the gas control knob to the "OFF" position
and call your service technician or gas supplier. If the control knob does not pop out when released,
STOP - shut off the gas supply to the control valve, and IMMEDIATELY call your service technician or gas
supplier.
10. If equipped with a wall switch, select the "ON" position. If equipped with a thermostat or auxiliary
control, set it to the desired setting.
11. Close the access door by lifting it, allowing the springs to pull it closed.
Figure 3
Shutdown Procedure
1. To turn off the main burner only, turn off the wall switch, thermostat, or the On/Off switch located on
the lower right side behind the access door.
2. For complete shutdown of the appliance, depress the gas control knob and turn it clockwise to the "OFF"
position.
2.3 HEAT OUTPUT ADJUSTMENT
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The valve supplied with the appliance has a HI/LOknob to control the heat output and flame height (see
Figures 2 & 3).
2.4 FAN OPERATION
For units equipped with a fan control knob, the knob is located behind the access door and may be adjusted
to the following settings:
OFF: Turn the control fully counter-clockwise until the switch operates.
Variable Speed Setting:
Turn the control to the desired setting. When the knob is turned fully clockwise the fan will be set to
minimum speed.
For units equipped with a fan switch, the fan may be switched between the “OFF”and “AUTOMATIC”
settings.
2.5 Remote Control Operation
An optional hand held remote control kit for turning the unit On and Off is also available. Detailed
instructions for the optional Remote Control are included with the kit.
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3
.0 Installation
3.1 Installation & Safety Notes
Read all instructions before starting installation and follow them carefully during installation to ensure
maximum benefit and safety. Failure to follow these instructions will void your warranty and may present a
fire hazard. See the Osburn warranty at the back of this manual for disclaimers regarding improper
installation. This fireplace insert and its components are tested and safe when installed in accordance with
this installation manual. This insert must never be installed in direct contact with combustible
construction.
ELECTRICALGROUNDINGNOTE: This heater fan is equipped with a three-prong (grounding) plug for
your protection against shock hazard and should be plugged directly into a properly grounded three-prong
receptacle. Do not cut or remove the grounding prong from this plug.
WARNING: Do not connect 120 VAC (240 VAC in Australia) to the gas control valve or its
wiring, as this will damage the valve.
3.2 Unpacking
Please check the appliance carefully for any damaged or missing components (specifically check the glass
condition). Report any problems to your dealer. The insert is shipped with the logs and coals in separate
packages inside the firebox. The faceplate, with the levelling screws, and the grille kit are packaged
separately. All other standard parts are already in place.
3.3 Installation
For satisfactory results it is necessary to plan certain aspects of the installation prior to the appliance's final
positioning. These include the vent system, the gas piping, and the fan wiring. Combustible surfaces such as
the hearth, mantle and facing must also be planned for.
NOTE:All Installations Require Venting.
(In Australia, a minimumvent length of 11' (3.4m) must be used off the top of the vent collar of
the appliance).
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3.3.1 Minimum Clearances
This top venting insert is suitable for installation into masonry fireplaces, or into factory built certified
clearance fireplaces which have a gas line knockout and proper floor clearances.
A masonry fireplace must meet the minimum building code requirements, or the equivalent, for a safe
installation.
Listed factory built solid fuel burning fireplaces and their chimneys must be certified and meet local code
requirements. Both must be free from cracks, blockage, creosote deposits, loose mortar, or other types of
deterioration.
Inspect the fireplace to ensure the insert will fit (see Figure 4).
Minimum enclosures are as follows:
Fi
g
ure 4
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Minimum Clearances To Combustibles:
A. Sidewall 10" (254mm) measured from glass
B. Ceiling 34" (864mm) measured from top grille
C. Facing: sides 1" (25mm) measured from standard faceplate
top 8.5" (216mm) measured from top grille
D. Floor 2" (51mm) (see Figure 5)
E. Mantle 12.5” (318mm) measured from top grille to 8” (204mm) mantle
NOTES:
1. When using paint or lacquer to finish the mantle, such paint or lacquer must be heat resistant to
prevent discolouration.
2. When installing the unit flush to the flooring, there must be a 16” non-combustible hearth extension
(see Figure 5b).
3. For more mantle options see Figure 6.
Figure 5a Figure 5b
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Fi
g
ure 6
3.3.2 CHIMNEY LINER OR VENT INSTALLATION
Figures 7 and 8 show the completed installations into a masonry and a factory built certified fireplace.
Figure 7 Figure 8
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The insert must be connected to a listed gas vent liner or B-vent suitable for use with gas. The vent must run
within the existing chimney from theoutlet collar of the drafthood to the top of the masonry or factory built
chimney. Install the vent according to the manufacturer's instructions. Use a maximum of two offsets; (four
45o o elbows), or two 90 elbows. Slope the horizontal pipe at least 1/4" (6.4mm) rise per foot of run.
Horizontal runs should not exceed the vertical rise.
3.3.3 Gas Line Installation
• Install supply line using any piping approved for your installation meeting CAN/CGA 6.10, AGA 3,
ANSI Z21.24 or Z21.45. A qualified gas fitter should install the gas line in accordance with all local
building codes. If codes permit, coiled copper tubing may be used for gas supply.
• Pressure taps are provided on the gas control for test gauge connections to measure the manifold and
inlet pressures.
• This 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 ½” psig (3.45 kPa).
• The appliance and its individual shut off valve must be disconnected from the gas supply piping system
during any pressure testing of the system at test pressures in excess of ½” psig (3.45 kPa).
• Install the gas line as follows:
WARNING: Do not use an open flame to test for gas leaks.
The gas line connection on the right side of the insert is shown in Figure 9. An AGA and/or CGA
approved shutoff valve can be installed to the flexline if so desired. Installing the shutoff valve
between the gas valve and the flex line will allow quick accessibility.
Figure 9
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3.3.4 Thermostat, Wall Switch, Or Remote Control Installation
The burner control switch is located on the right top side of the faceplate (see Figure 2). For your
convenience, the insert can also be operated by a thermostat, a wall switch or a remote control. Millivolt
thermostats and remote control kits are available fromany authorized Osburn dealer. Bedroom installations
require the use of a wall thermostat.
NOTE:The thermostat or wall switch MUST be rated for millivolt use. Minimize splicing in all millivolt
wiring & solder all unavoidable splices.
Remote Control Installation: Please refer to the instructions included with kit.
Thermostat or Wall Switch Installation
1. Mount the thermostat or wall switch in the desired location and run "two conductor thermostat
wire" to the heater's lower right hand corner, close to the gas supply line.
Purchase "twoconductorthermostat wire,"which is not provided, at any local supplier. The gauge
of thermostat wire will determine the maximum wire length and distance at which to locate the
thermostat or wall switch. See Table 2 and the information packaged with thermostat. Be aware
that as the length of wire increases, the probability of adequate operating voltage decreases.
TABLE 2 Thermostat Wire Information
Wire Size Max. Wire Length
AWG mm ft. m
22 0.6 10 3.0
20 0.8 25 7.6
18 1.0 40 12.2
16 1.3 64 19.5
14 1.6 100 30.5
2a. After the insert is installed and the gas line hooked up, solder a female spade connector to each wire
and join them to the male connectors provided on the rear of the burner switch (see Figure 10), or
2b. Solder a fork connector to each wire and install them to the valve.
3. Check tests can be performed on the valve by using the trouble shooting guide, Section 5.0.
4. This switch may be connected in parallel with a thermostat, wall switch, or remote control (see
Figure 11).
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Figure 10
Figure 11
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3.3.5 Vent, Gas Line, & Wiring Connections
Unless it is more easily installed with the insert, install the drafthood separately first as follows:
1. Disconnect the drafthood from the insert and fit its collar to the end of the previously installed vent,
whether the flue-liner in an existing masonry fireplace or the flue-liner in an existing factory built
certified fireplace.
2. Wiring:
i) Cut the plastic pull-tie securing the blue wires.
ii) Cut the plastic pull-tie securing the fan power cord to the heater.
3. Two captive nuts are attached to the air jacket bottom.
i) Remove the two 1/4"-20 screws (2.5" (64mm) long) provided with the faceplate package.
ii) Turn the screws through the two captive nuts to level the unit as required.
4. Push the drafthood upward to 18 1/2" (470mm) above the hearth or fireplace bottom, and start
sliding the insert into the fireplace cavity.
5. Connect the wiring for the thermostat, wall or faceplate switch, or the remote control as noted in #2
of section 3.3.4.
6. The fan power cord is on the left side of the insert and can be routed to the right if desired. Route
the power cord along the bottom outside edge of the heater, not underneath, nor under any sharp
edges.
7. Push the insert back until the front firebox flanges are 1/4" (6mm) in front of the masonry or factory
built fireplace facing. As the heater is pushed back, pull the drafthood positioning strips firmly
toward the heater front until the drafthood flange is secured under the top clips of the heater (Figure
12).
Figure 12
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8. Bend the positioning strips down over the top front edge, cut off the excess strip length, and fold the
strips back over the top flange.
9. Connect the union of the gas supply line.
10. Purge the gas line of air.
11. Test the gas line for leaks using an electronic gas leak detector or soapy solution.
WARNING: DO NOT USE AN OPEN FLAME TO TEST FOR GAS LEAKS.
3.3.6 Lower Grille Installation
1. Pull the control panel forward to release it from the retaining clips.
2. Remove the four screws from the firebox supports.
NOTE:The Contemporary Bay (KC155) lower grille has two adapter plates attached to the grille assembly.
Remove these plates from the grille assembly and attach them to the firebox supports.
3. Place the lower grille assembly in position against the front of the firebox supports.
4. Secure the lower grille assembly with the four screws that were previously removed (see Figure 13).
Figure 13
5. Push the control panel back into position under the retaining clips.
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3.3.7 Faceplate Installation
Remove the faceplate panels and the edge trim fromthe packaging and assemble according to the following
instructions:
1. Place the faceplate panels with the finished side down on a flat, soft, non-abrasive surface.
2. Line up the holes of the top and side panels and secure them with six (6) bolts, twelve (12) washers
and six (6) nuts (See Figure 14).
3. Assemble the faceplate trim, joining the mitred corners with
corner brackets (See Figure 15).
Figure 14 Figure 15
4. Slide the trim over the edges of the faceplate assembly.
5. Secure the trim to the faceplate with four (4) brass bolts, washers and nuts (See Figure 16).
6. Insert the rocker switch into the rectangular slot of the trim and connect with the two (2) wires from
the fan assembly. This switch will control the fan operation. (See Figure 17a).
7. Place the faceplate assembly around the front of the insert. NOTE: THE ROCKER SWITCH SHOULD BE
ON THE RIGHT HAND SIDE.
8. Align the attachment holes and secure the faceplate to the sides of the unit with the four (4) black
oxide Phillips head sheet metal screws. NOTE: DO NOT ADJUST THE FACEPLATE DEPTH ON THE
CORDOVA BAY.
9. Adjust the faceplate mounts to the desired setting (See Figure 17b).
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