Osburn SATURNA User manual

SATURNA
Natural Gas & Propane
Direct Vent Gas Fireplace Insert
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 vapors and liquids in the vicinity of this or any other appliance.
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 building.
 Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.
 If you cannot reach your gas supplier, call the fire department.
Installation and service must be performed by 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.

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Table of Contents
1.0 INTRODUCTION.............................................................................................................................. 3
1.1 SPECIFICATIONS ..................................................................................................................................... 3
1.2 FEATURES................................................................................................................................................. 5
1.3 INTENDED USE......................................................................................................................................... 5
1.4 GENERAL SAFETY................................................................................................................................... 5
2.0 OPERATION........................................................................................................................................ 6
2.1 OPERATION SAFETY............................................................................................................................... 6
2.2 LIGHTING INSTRUCTIONS ...................................................................................................................... 7
2.3 HEAT OUTPUT ADJUSTMENT ................................................................................................................ 8
2.4 FAN OPERATION...................................................................................................................................... 8
3.0 INSTALLATION................................................................................................................................8
3.1 INSTALLATION AND SAFETY NOTES..................................................................................................... 8
3.2 UNPACKING.............................................................................................................................................. 8
3.3 INSTALLATION .......................................................................................................................................... 9
3.3.1 MINIMUM CLEARANCES TO COMBUSTIBLES .............................................................................................. 9
3.3.2 GAS LINE INSTALLATION.......................................................................................................................... 11
3.3.3 THERMOSTAT OR WALL SWITCH INSTALLATION ...................................................................................... 11
3.3.4 VENT INSTALLATION ......................................................................................................................... 14
3.3.5 FACEPLATE INSTALLATION.................................................................................................................... 19
3.3.6 FIRE BOX COMPONENTS INSTALLATION .................................................................................................. 21
3.3.6.3 DECORATIVE DOORS INSTALLATION.................................................................................................... 23
3.3.7 INITIAL FIRING.......................................................................................................................................... 24
3.3.7.4 DAMPER ADJUSTMENT................................................................................................................. 27
3.3.8 BURNER REMOVAL .................................................................................................................................. 29
3.3.9 FIELD CONVERSIONS.................................................................................................................... 30
4.0 MAINTENANCE............................................................................................................................ 31
4.1 MAINTENANCE SAFETY........................................................................................................................ 31
4.2 RECOMMENDED SERVICE ................................................................................................................... 31
4.3 GLASS CLEANING.................................................................................................................................. 31
4.4 CLEANING OF GOLD PLATED SURFACES ......................................................................................... 32
4.5 BURNER & PILOT CLEANING............................................................................................................... 32
4.6 FAN REPLACEMENT & ELECTRICAL SCHEMATIC............................................................................ 32
5.0 TROUBLE SHOOTING............................................................................................................. 34
6.0 REPLACEMENT PARTS......................................................................................................... 36
OSBURN LIMITED LIFETIME WARRANTY.................................................................. 37

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1.0 INTRODUCTION
1.1 Specifications
TABLE 1
ITEM NATURAL GAS (NG) PROPANE (LPG)
INPUT: Hi 35,000 Btu/hr (10.25kW) 35,000 Btu/hr (10.25kW)
INPUT: Lo 17,500 Btu/hr (5.13kW) 17,500 Btu/hr (5.13kW)
MANIFOLD PRESSURE: Hi 3.5” w.c. (0.82kPa) 10.0” w.c. (2.49kPa)
Minimum: 5.0" w.c. (1.2 kPa) Minimum: 11.0" w.c. (2.7 kPa)
Normal: 7.0" w.c. (1.7 kPa) Normal: 13.3" w.c. (3.3 kPa)
GAS INLET SUPPLY
PRESSURE: Maximum: 13.5" w.c. (3.4 kPa) Maximum: 13.5" w.c. (3.4 kPa)
ORIFICE SIZE: @ 0-4500’ # 36 DMS (.120”) (3.05mm) # 50 DMS (.070“) (1.78mm)
AIR SHUTTER OPENING *CLOSED *25% to 50% OPEN
CONTROL VALVE TYPE: SIT 820 Nova SIT 820 Nova
VENTING TERMINATION Simpson « Dura-Vent »,
Security « Secure Vent » or
Selkirk « Direct Temp »
Simpson « Dura-Vent »,
Security « Secure Vent » or
Selkirk « Direct Temp »
FAN Variable Speed (120 Volt) Variable Speed (120 Volt)
*May vary (±25%) depending on the installations. Judgment of the installer is required.

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APPLIANCE DIMENSIONS
Figure 1
INSTALLATION CODES
Installation must conform to local codes. In the absence of local codes, installation must conform to
the National Fuel Gas Code, ANSI Z233.1 1988, (in the U.S.), or with the current installation code
CAN/CGA B149.1 – M86 (in Canada). The heater, when installed, must be electrically grounded in
accordance with local codes or, in the absence of local codes, with the National Electric Code
ANSI/NFPA No. 70-1990 (in the U.S.) or with the current CSA C22.1 Canadian Electrical Code (in
Canada). In the state of Massachusetts, this product can only be installed by a licensed plumber or a
licensed gas fitter. Failure to comply will void the warranty. In mobile homes the installation must
meet the Manufactured Home Construction and Safety Standard Title 24 CFR, Part 3280, or the
current Standard for Fire Safety Criteria for Manufactured Home Installations, Sites, and Communities
ANSI/NFPA 501A, and with CAN/CSA Z240 MH Mobile Home Standard 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:
Automatic millivolt powered combination gas control valve with variable flame control for convenience
and on/off 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,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.
Safety controls:
A safety switch (thermocouple) will shut the system down in the event of loss of pilot flame,
installation is not adequate or if flue is blocked.
Outside combustion air supply:
The combustion air supply is obtained entirely from outside the heated living space by the intake of
outside air through the vent termination and down a 3" aluminum vent.
1.3 Intended use
This appliance is intended to be used as a direct vent (top venting) fireplace insert heater and is
suitable for installation into masonry fireplaces, or into certified factory built fireplaces which include 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. Factory built 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. . In Massachusetts the
Saturna may be installed in a bedroom only when used as a direct vent unit (sealed combustion). For
other states or provinces it may be installed in a bedroom provided that CR89-00 and/or ANSI
A225.1/NFPA 501A standards are followed, all required clearances are met, a wall thermostat is
installed and where the maximum input is within 50 cubic feet of room volume per 1000 BTU/hr,
(i.e.1500 minimum cubic feet) and hooked up to a Simpson GS Dura Vent , Security Chimneys
International (Secure Vent) or Selkirk (Direct-Temp) vent termination.
1.4 General safety
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 any other appliance. It is equipped with a
safety control system to protect against improper venting of flue products.
WARNING: Operation of this unit 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

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clearances around air openings, for combustion and ventilation air, and allow accessibility clearance
for servicing and proper operation.
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.
The glass door 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.
Control panel knobs, from left to right :
Fan rheostat, Piezo igniter, Hi-lo flame adjustment and On-Off-Pilot gas control.
Figure 2

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2.2 Lighting instructions

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2.3 Heat output adjustment
The valve supplied with the appliance has a HI/LO knob to control the heat output and flame height
(Figures 2 & 3).
2.4 Fan operation
The fan control knob is located behind the decorative doors, below the firebox 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 set to minimum speed.
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 controls
which have been under water.
3.0 INSTALLATION
3.1 Installation and 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 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.
ELECTRICAL GROUNDING NOTE: A three-prong (grounding) plug, for your protection against
shock hazard, is provided 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 to the gas control valve or it’s 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. This unit is shipped with the logs in a separate
package.

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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.
3.3.1 Minimum clearances to combustibles
Inspect the fireplace to ensure the insert will correspond to the measurements (Figure 4).
Minimum enclosures are as follow: Figure 4
Top view Side view

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Minimum Clearances to Combustibles :
Combustible
surface
Non-combustible
surface
No floor protection needed,
if unit is sitting at least 5
inches above the floor
Figure 5 Figure 6
10"
(255mm)
4"
(102mm)
6"
(153mm)
8"
(204mm)
8.50"
(217mm)
9.75"
(249mm)
11.25"
(287mm)
14.00"
(357mm)
12.50"
(319mm) 2"
(51mm)
DC
B
A
G
F
COMBUSTIBLE SIDE WALL
COMBUSTIBLE TOP MANTLE
COMBUSTIBLE SHELF
FLOOR PROTECTION
COMBUSTIBLE
SIDE MANTLE
E
H
Figure 7a Figure 7b
A- Combustible side wall to unit
B- Combustible side mantle to unit
C- Combustible top mantle to unit
D- Combustible shelf to unit
E- Minimum floor protection in front of unit
F,G,H- Minimum enclosure dimension
10”
8”
8 ½”
8 ½” to 14” (figure 7a)
0” (figure 6) or 16” (figure 5)
(figure 4)
Note: When using paint or lacquer to finish the mantle, such paint or lacquer must be heat resistant
to prevent discoloration.

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3.3.2 Gas line installation
 Install supply line using any piping approved for your installation meeting CAN/CGA 6.10, AA 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 1/2 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 1/2 psig (3.45
kPa).
 Install the gas line as follows:
The gas line connection found on the back of the valve is a 3/8" black iron nipple. An AGA and/or
CGA approved shut off valve can be installed in conjunction with the nipple if so desired.
Installing the shut off valve on the end of the nipple will allow quick accessibility.
 Upon initial firing check manifold pressure at pressure tap located on the front of the control valve
(Figure 3).
WARNING: Do not use an open flame to test for gas leaks.
3.3.3 Thermostat or wall switch installation
The burner control switch is located on the bottom right hand side of the faceplate (Figure 16). For
your convenience, the unit can also be operated by a thermostat, or a wall switch control. Millivolt
thermostats are available from any 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.
3.3.3.1 Remote control installation
Please refer to instructions included with the optional accessory kit.
3.3.3.2 Thermostat or wall switch installation
1. Mount the thermostat or wall switch in the desired location and run "two conductor thermostat
wire" to the burner control switch (Figure 8a). To bypass the burner control switch, run the wires
directly to the gas valve (Figure 8b).
Purchase "two conductor thermostat 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 below and the information packaged with the
thermostat. Be aware that, as the length of wire increases, the probability of adequate operating
voltage decreases.
THERMOSTAT WIRE INFORMATION

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WIRE SIZE MAX. WIRE LENGTH
AWG mm ft. m
22 0.6 10 3.1
20 0.8 25 7.6
18 1.0 40 12.2
16 1.3 64 19.5
14 1.6 100 30.5
TABLE 2
2. Solder an appropriate wire connector to each wire. To connect to the burner switch, 1/4" female
quick connects are required and to connect directly to the valve use spade tongue connectors.
3. Check tests can be performed on the valve by referring to the trouble shooting guide.

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INLET
PILOT
TH
OFF
ON
LO
HI
TP-TH TP
OUTLET THERMOPILE
Figure 8a
INLET
OFF
ON
PILOT
TP-TH
LO
HI
TP TH
OUTLET THERMOPILE
Figure 8b

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3.3.4 Vent installation
3.3.4.1 Chimney Liner Installation
The insert must be connected to a pair of three-inch diameter listed liners suitable for use with gas.
The liners must run within the existing chimney from the vent collars on the insert, to the top of the
masonry or factory built chimney (Figures 9a, 9b and 10).
When installing this appliance into large fireplace cavities, the vents may be connected directly to
their attachments with the appliance in place. Smaller cavities may require detaching the flue collar
plate so that it can be installed separately prior to the main assembly.
Figures 9a & 9b below show the completed installations in both a masonry and a factory built
fireplace.
CO-LINEAR VENTING
MASONERY CHIMNEY
FLASHING
VENT ADAPTER
CAP
FACTORY BUILT FIREPLACE
CO-LINEAR VENTING
FACTORY BUILT CHIMNEY
FLASHING
VENT ADAPTER
CAP
Figure 9a Figure 9b

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Installation steps are as follows:
1. Position the insert in the fireplace cavity and note the required positions of the vent and gas
line.
2. To prevent damage to the insert, remove it until after the gas and vent lines have been
positioned.
3 a. Measure and cut two liner lengths just slightly longer than required.
Reminder: Minimum overall vent height is 11' and maximum is 30'.
Joining two lengths of liner can be accomplished using 3" DF Flex Couplings. Join the
lengths by liberally applying High Temperature Sealant to the end of the liner before
inserting it onto the coupling, and once inserted, secure each connection with three
screws.
From the top of the chimney:
b. Install the flashing onto the existing chimney.
c. Attach the liners to the two 3" outlets on the approved Chimney Liner Termination Kit by
first liberally applying High Temperature Sealant to the gasketed joint, and then pushing
the liner onto the collar. Secure each joint using three screws.
d. CLEARLY IDENTIFY the lower end of the liners for intake and exhaust.
e. Feed the liners down the chimney through the flashing.
f. Install the cap onto the Round Adapter.
From below:
4. Liberally apply High Temperature Sealant to the outsides of the vent collars.
5. For installations that do not require the removal of the vent connector plate:
a. Push the insert back into the enclosure
b. Slide the liner onto the appropriate vent collars and secure them with three screws each
and/or hose clamps.
Note: Make sure the previously identified exhaust liner is connected to the exhaust collar (see
Figures 10 & 11).

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3" LINER
COUPLER
ADAPTERS
(OPTIONAL)
INTAKE VENT
EXHAUST
3" LINER
FLASHING
HIGH WIND CAP
ADAPTER
ADAPTERS
(OPTIONAL)
EXHAUST
INTAKE VENT
3" LINER
FLASHING ADAPTER
HIGH WIND CAP
Figure 10

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Figure 11

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Figure 12
6. For installations that do require the removal of the vent connector plate:
a. Detach the vent connector plate by removing the screw securing the positioning strip to
the top of the air jacket (Figure 11) and slide the vent connector plate off to the rear
(Figure 12).
b. Liberally apply High-temperature Sealant to the outsides of the vent collars.
c. Attach the vent connector plate to the appropriate vent liners and secure with three
screws each and/or hose clamps. The vent connector plate should be located 16"-20"
(406-508mm) above the hearth.
d. Push the insert back into the enclosure, feeding the positioning strap through the slot at
the top rear of the air jacket. Ensure that the strap passes freely under the air jacket
and that it doesn’t get caught in parts protruding from the firebox top. Continue to push
the insert back as the strap is fed through until the hole on the strap lines up with the
corresponding hole on the air jacket. A screwdriver can be used, if required, to help pull
the strap forward. Secure the strap in position by replacing and tightening the screw in
the top of the air jacket (Figure 11).
e. Bend the forward end of the strap back and up against the fireplace front so that the
faceplate can be installed (Figure 11).

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3.3.5 Faceplate Installation
1. Remove the faceplate panels from the packaging and assemble according to the following
instructions:
2. Using two (2) screws, fix the upper faceplate panel onto the faceplate frame pre-mounted on
the insert (Figure 13).
3. Using two(2) screws (per panel), install the side panels onto the frame in a way where the side
panels overlaps the upper panel and the bent strip of the side panels slides under the upper
panel(Figure 14).
4. Secure left and right end of the upper panel to the side panels using one (1) screw each side
(Figure 14).
5. Attach the left and right brass trim sides to the top trim with the corner brackets supplied
(Figure 15a).
6. Slip the assembled trim over the faceplate and push the faceplate trim clips between the trim
and the faceplate (two on the top edge and three down each side) (Figure 15b).
7. Push the burner switch through the hole in the front right hand faceplate and connect the
switch to the gas valve (Figure 16 & 17).
8. ***The faceplate frame is attached to the unit with four (4) screws, when loosen the frame can
be move front to rear for faceplate adjustment (Figure 14).
9. Push the insert into the fireplace opening until the faceplate trim is sealed against the fireplace
facing.
Figure 13 Figure 14

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Figure 15a Figure 15b
Figure 16 Figure 17