Osburn 1100 MODEL INSERT User manual

45229A
Printed in Canada 24-01-2013
OWNER’S MANUAL
1100 MODEL INSERT
US ENVIRONMENTAL PROTECTION
AGENCY PHASE II CERTIFIED
WOOD INSERT
Verified and tested following
ULC S628 and UL 1482 Standards
by:
Manufactured by : STOVE BUILDER INTERNATIONAL INC.
250, rue de Copenhague, Saint-Augustin-de-Desmaures (Quebec) G3A 2H3
Tel: ( 418 ) 878-3040 Fax: ( 418 ) 878-3001
www.osburn-mfg.com
READ AND KEEP THIS MANUAL FOR REFERENCE
This manual is available for free download on the manufacturer’s web site. It is a copyrighted
document. Re-sale is strictly prohibited. The manufacturer may update thismanual from time
to time and cannot be responsible for problems, injuries, or damages arising out of the use of
information contained in any manual obtained from unauthorized sources.

2
INTRODUCTION
SBI INC., one of the most important wood stove and fireplace manufacturers in Canada,
congratulates you on your purchase and wishes to help you get maximum satisfaction from your
wood insert. In the pages that follow, we will give you advice on wood heating and controlled
combustion aswellastechnical specifications regardinginstallation, operationand maintenanceof
the model you have chosen.
The instructions pertaining to the installation of your wood stove comply with ULC-S628 and UL-
1482 standards.
We recommend that our wood burninghearth products beinstalledand serviced by professionals
who are certified in theUnited States byNFI(National Fireplace Institute®)or inCanada by WETT
(Wood Energy Technical Training) or in Quebec by APC (Association des Professionnels du
Chauffage).
Read this entire manual before you install and use your new insert. If this insert is not
properly installed, a house fire mayresult. To reduce the risk of fire, follow the installation
instructions. Failure to follow instructions may result in property damage, bodily injury, or
even death.
Consult your municipal building department or fire officials about restrictions and
installations requirements in your area and the need to obtain a permit.
Keep and save this instructions manual for future references.
CAUTIONS:
THEINFORMATIONGIVENONTHE CERTIFICATION LABELAFFIXED TO THEAPPLIANCEALWAYSOVERRIDES
THE INFORMATION PUBLISHED,IN ANY OTHER MEDIA (OWNER’S MANUAL,CATALOGUES,FLYERS,
MAGAZINES AND/OR WEB SITES).
HOT WHILE IN OPERATION.KEEP CHILDREN,CLOTHING AND FURNITURE AWAY.CONTACT MAY CAUSE
SKIN BURNS.
DO NOT USE CHEMICALS OR FLUIDS TO START THE FIRE.
DO NOT LEAVE THE STOVE UNATTENDED WHEN THE DOOR IS SLIGHTLY OPENED.
DO NOT BURN WASTES,FLAMMABLE FLUID SUCH AS GASOLINE,NAPHTHA OR MOTOR OIL.
DO NOT CONNECT TO ANY AIR DISTRIBUTION DUCT OR SYSTEM.
ALWAYS CLOSE THE DOOR AFTER THE IGNITION.
REGISTER YOU WARRANTY ONLINE
To receive full warranty coverage, you will need to show evidence of the date
you purchased your stove. Keep your sales invoice. We also recommend
that you register your warranty online at
http://www.osburn-mfg.com/warranty-registration.aspx
Registering your warranty online will help us track rapidly the information
we need on your insert.

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TABLE OF CONTENTS
INTRODUCTION............................................................................. 2
Section 1.0 Pre-Installation Requirements..................................... 5
1.1 Masonry & Zero Clearance Requirements .................................................................................. 5
1.2 Venting Requirements.................................................................................................................... 6
1.3 Door overlay installation................................................................................................................ 7
Section 2.0 Installation...................................................................... 8
2.9 Air control plate, faceplate and fan Assembly Instructions..................................................... 18
2.10 Decorative sides installation....................................................................................................... 19
Section 3.0 Operation...................................................................... 20
3.1 Safety Information........................................................................................................................ 20
3.2 Fuel................................................................................................................................................. 21
3.2.1 Simple Wood Moisture Test...................................................................................................... 22
3.3 Notes About First Firing .............................................................................................................. 22
3.4 Lighting A Fire.............................................................................................................................. 22
3.5 Maintaining The Fire.................................................................................................................... 24
3.6 Fan Operation ............................................................................................................................... 24
Section 4.0 Maintenance................................................................. 25
4.1 Care And Cleaning ....................................................................................................................... 25
4.1.1 Glass Cleaning and maintenance.............................................................................................. 25
4.2 Ash Removal.................................................................................................................................. 26
4.3 Chimney Cleaning......................................................................................................................... 26
4.4 Baffle Installation for Osburn 1100 Insert................................................................................. 27
4.5 Secondary Air Tube Replacement............................................................................................... 28
4.6 Fan Maintenance & Care............................................................................................................. 29
4.7 Removal instructions.................................................................................................................... 29
Section 5.0 Specifications................................................................ 30
OSBURN LIMITED LIFETIME WARRANTY......................... 31

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Osburn 1100 Insert Dimensions

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Section 1.0 Pre-Installation Requirements
1.1 Masonry & Zero Clearance Requirements
We recommend that our woodburning hearth products be installed and serviced by professionals who are
certified in the United States by NFI (National Fireplace Institute®) or in Canada by WETT (Wood Energy
Technical Training) or in Quebec by APC (Association des Professionnels du Chauffage).
The masonry fireplace must meet the minimum code requirements, or NFPA 211 or the equivalent for a
safe installation. Contact your local Building Inspector for requirements in your area. An inspection of
the fireplace should include the following:
1. CONDITION OF THE FIREPLACE AND CHIMNEY: Examine the masonry fireplace and
chimney prior to installation to determine that they are free from cracks, loose mortar, creosote
deposits, blockage, or other signs of deterioration. If evidence of deterioration is noted, the fireplace
or chimney should be upgraded prior to installation.
2. ZERO CLEARANCEORMETAL HEATFORM FIREPLACE: These fireplacesand chimneys
must meet the conditions above, and the factory built zero clearance fireplace must be listed. They
must be suitable for use with solid fuel. The chimney must be at least 1" (25mm) larger in diameter
to accommodate a required continuous stainless steelliner running from the flue collar to the top of
the chimney termination.
Only readily detachable parts that are easily replaced, such as damper parts, screens, doors, and side
and back refractory panels, are to be removed from the fireplace. These parts must be stored nearby
and available for retrofit if the insert is ever removed. Removal of any parts which render the
fireplace unfit for use with solid fuel requires the fireplace to be permanently labeled 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.
3. CHIMNEYCAPS: Mesh type chimney caps must have provision for regular cleaning, or the mesh
should be removed to eliminate the potential of plugging.
4. LINER:The chimney must have an acceptable masonry liner suitable for solid fuel; otherwise a
continuous stainless steel liner must be installed.
5. ADJACENT COMBUSTIBLES: The fireplace should be inspected to make sure that there is
adequate clearance to combustibles, both exposed combustibles to the top, side, and front as well
as concealed combustibles, in the chimney and mantel area. Your local inspector should have
information on whether older fireplaces are of adequate construction.
6. OPENING SIZE: Refer to “Suitable Fireplace Dimensions” (Sec. 2.2) for suitable size fireplace
openings.

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1.2 Venting Requirements
The flue is a critical component to a satisfactory installation. Your Osburn insert will attain its best
performance if installed with a chimney that generates its own draft. The minimum requirement of a
flue will be the installation of a flue connector (the liner must conformto UL1777 chimney liners) from
the insert into the first flue tile of the chimney (USA), see Figure 2.3 , or a continuous stainless steel
liner (the liner must conform to the Class 3 requirements of CAN/ULC-S635) directly connected to the
flue outlet (Canada), see Figure 2.2. A continuous 6" (152mm) stainless steel liner from the top of the
chimney is the optimum system and will provide the best performance, as well as compensate for poor
draft situations caused by large cross-sectional chimneys. The insert will not work without a positive
seal in the chimney.
Chimneys constructed outside of the home, on an exterior wall, should be avoided if possible, especially
in colder climates. Outside chimneys may not draw as well and may downdraft due to the difficulty in
heating them up to operating temperature. Cooler chimneys will result in increased creosoting, less
draft, and poorer performance. Draft is proportional to overall chimney height as well as to stack
temperature. Draft can be increased by increasing chimney height, and by reducing heat loss from the
chimney through an insulated liner.
Ensure that all joints in the flue systems are tightly sealed, since any leaks will result in reduced
performance as well as a possible safety hazard.

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1.3 Door overlay installation
In order to complete the assembly of your freestanding Osburn 1100 wood insert, you need to install the
door overlay. See table below for installation instructions :
1- Position the overlay on the door frame and fix it in place from behind using the 4 screws.
Note: It is not necessary to remove the glass or any other component to install the overlay.

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Section 2.0 Installation
2.1 Safety information
NOTE: THIS APPLIANCE IS NOT RECOMMENDED FOR USE IN A HOME IF AN
OCCUPANT HAS ANY RESPIRATORY OR ANY OTHER RELATED PROBLEMS.
1. It is important to follow the installation and operation instructions. An improperly installed or
operated insert could result in a safety hazard or fire, or damage to the unit, which would not be
covered by the warranty. Contact local building or fire officials about restrictions and installation
requirements in your area. You should be familiar with the installation and be sure that the work is
done in accordance with this manual.
WARNING: DO NOT INSTALL THIS INSERT IN A SLEEPING ROOM.
2. Where lesser clearances are desired, consult your local authority as regulations may vary regarding
the use of clearance reducing devices. Listed wall and floor shields are available to reduce
clearances, and most building codes provide information on materials which may be used to reduce
clearances.
1. Maintain at least the minimum clearances to combustible material as specified in this manual.
Clearances are measured to the nearest part of the insert (i.e. top edge on the side). Clearances to
any combustibles, when measured directly out from the front, must be a minimum of 48"
(1219mm).
4. Maintain at least the minimum floor protection for combustible floor materials as specified in this
manual. Floor protection to the front is to be measured from the fuel loading door opening.
5. Osburn recommends that you install a listed smoke detector or alarm in your home. Normal
operation of the insert will have no effect on the detector or alarm.
6. The insert is to be connected only to a lined masonry chimney and masonry fireplace conforming to
building codes for use with solid fuel. Do not remove bricks or mortar from the existing fireplace
when installing the insert.
7. Minimum chimney size is 6" (152mm) diameter. Maintain a 15' (4.5m) minimum overall height
measured from the base of the appliance. Chimneys should be inspected to check for deterioration
and to determine if they meet the minimum requirements, and be upgraded if necessary. The
chimney must extend at least 3' (914mm) above the roof and at least 2' (610mm) above the highest
point within an area of 10' (3m) of the chimney.
8. Do not use makeshift compromises during installation, as they could create a safety hazard and a fire
could result.
9. DONOTCONNECT THIS APPLIANCETOTHECHIMNEY OR FLUESERVINGANOTHER
APPLIANCE.

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2.2 Installation instructions
Inspect the masonry fireplace according to the safety information and fireplace requirements and have it
cleaned and/or upgraded as necessary.
2.3 Compliance of the masonry fireplace
Where the masonry fireplace opening is 6 ft2(0.56 m2) or larger, the hearth extension shall extend at least 20''
(508 mm) in front of the facing material and at least 12'' (305 mm) beyond each side of the fireplace opening.
Where the masonry fireplace opening is less than 6 ft2(0.56 m2), the hearth extension shall extend at least 16''
(406 mm) in front of the facing material and at least 8'' (203 mm) beyond each side of the fireplace opening.
Notethat if you mustmodifythe hearth extension tocomply withthese measures,depending on thesize of the
masonry fireplace opening, the hearth extension must have a minimum of
4'' (102 mm ) thick (see Figure 2.6a and 2.6b.)

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2.4 The masonry fireplace's draft control system
Ifthe fireplace's draftcontrol systemisto remainin the masonryfireplace, itmust belockedopen foraccessof
the chimney liner or removed entirely. If you remove draft control system from the masonry hearth, you will
needto installthe metalplate (27009),supplied withthe owner’smanualkit, indicating thatthe masonryhearth
has been modified. It must be secured inside the masonry hearth, in a visible place and easy to locate.
2.5 Compliance of a combustible top shelf
To ensure compliance of an existing top shelf or to install any combustible shelf, refer to table below and
Figure 2.5 for a safe installation or to perform changes if necessary. For example, a shelf with a 6’’ depth
(152 mm) must be installed at least 27" (686 mm) above the top of the insert (see Figure 2.5). Different shelf
dimensions are listed in the following table in order to facilitate installation. However, no combustible shelf
can be installed at less than 27" (686 mm) above the top of the insert. If the depth of the shelf is not listed in
the table, add 21" (533 mm) to the depth of your shelf to obtain the safe positioning of your shelf. For
example, for a 9" (229 mm) shelf, the safe positioning would be 30" (762 mm) above the top of the insert
(21" (533 mm) + 9" (229 mm)).
SHELF POSITIONING
MAXIMUM SHELF
DIMENSION (X) SHELF POSITION (I)
6" / 152 mm 27" / 686 mm
8" / 203 mm 29" / 737 mm
10" / 254 mm 31" / 787 mm
12" / 305mm 33" / 838 mm

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2.6 Positioning the unit
In addition to ensuring compliance of the masonry fireplace hearth extension (see Compliance of the
masonry fireplace in Section 2.3), it is necessary to have a floor protection made of non-combustible
materials that meets the measurements specified in table FLOOR PROTECTION (see Section 2.7). To
determine the need to add a floor protection (D) beyond the hearth extension, you must do the following
calculation using the data in Table Data for floor protection calculation of this section: D = B - (A - C). If
the value (D) is negative or zero, you do not have to add more floor protection in front of the unit, because
the masonry fireplace hearth extension is long enough. If the value (D) is positive, you will need a floor
protection in front of the hearth extension at least equivalent to the result (D).
Here is a sample calculation to determine the need to add a non-combustible materials floor protection. For
someone living in the USA whose fireplace opening is less than 6ft2and which the insert would protrude 3"
(76 mm) into the room (C) the calculation would be:
Value D = B - (A - C)
Value D = 16" - (16" - 3")
Value D = 16" - 13"
Value D = 3"
This person should install a non-combustible floor protection of at least 3"(76 mm)in front of the fireplace
hearth extension.

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If a non-combustible material floor protection needs to beadded in front and level with the hearth extension
masonry fireplace (see Figure 2.6a), an R factor equal to or greater than 1.00 is required. If the extension of
the masonry hearth is raised at least 4" from the floor protection (see Figure 2.6b), a non-combustible
material without an R factor is sufficient.
Figure 2.6a
Figure 2.6b

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The use of an R value is convenient when more than one material is going to be usedin the hearth extension
to cover the combustible surface. This is because R values are additive, whereas K values are not. To find
the corresponding R factor to use for some selected materials, please see TableThermal characteristics of
common floor protection materials in this section.
There are two ways to calculate the R factor of the floor protection. First, by adding the R-values of
materials used, or by the conversion if the K factor and thickness of the floor protection are given.
To calculate the total R factor from R factors of the materials used, simply add the R-values of materials. If
the result is equal to or greater than the R-value requirements, the combination is acceptable. To know the
R-values of some selected materials, see table Thermal characteristics of common floor protection
materials.
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 inch of Durock®(R = 1 x 0.52 = 0.52).
0.8 + 0.52 = 1.32.
This R value is larger than the required 1.00 and is therefore acceptable
In the case of a known Kand thickness of alternative materials to be used in combination, convert all K
values to R by dividing the thickness of each material by its Kvalue. Add the Rvalues of your proposed
materials as shown in the previous example.
Example:
K value = 0.75
Thickness = 1
R value = Thickness/K = 1/0.75 = 1.33
Data for floor protection calculation
A B
(Note 1) C E
Smaller
than 6 ft2* Bigger or
= to 6 ft2*
INCHES 16" 20"
CAN: 18"
USA: 16" 3 7/8" 9"
MILLIMETRES 406
mm 508 mm CAN: 457 mm USA: 406 mm 98 mm 229 mm
*Refers to masonry fireplace opening.

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Thermal characteristics of common floor protection materials*
MATERIAL CONDUCTIVITY
(k) PER INCH RESISTANCE (R) PER INCH THICKNESS
Micore®160 0.39 2.54
Micore®300 0.49 2.06
Durock®1.92 0.52
Hardibacker®1.95 0.51
Hardibacker®500 2.3 0.44
Wonderboard®3.23 0.31
Cement mortar 5.00 0.2
Common 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** (1/8") 0.135 0,920**
* Information as reported by manufacturers and other resources
**For a 1/8" thickness. You cannot «stack» horizontal still air to accumulateR-values; you must separateeach laterofhorizontalstill
air with another noncombustible material.
2.7 Minimum masonry opening, clearances to combustibles, and floor protector

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MINIMUM MASONRY
OPENING
J 21 3/4" (552 mm)
K 26" (660 mm)
L 12 7/8" (327 mm)
CLEARANCES
F 13” (330 mm)
G 9” (229 mm)
H 27” (686 mm)
I 27” (686 mm)*
FLOOR PROTECTOR
CANADA USA
B 18’’ (457 mm) – Note1 16’’ (406 mm) – Note 1
M 8’’ (203 mm) N/A (Canada only)
N N/A (USA only) 8’’ (203 mm)
* For a 6" (152 mm) shelf. See Table SHELFPOSITIONING (Section 2.5) for other shelf dimensions.
Note 1: From door opening. The depth of a non-combustible shelf in from of the insert is included in
the calculation of the floor protector’s dimensions.
IMPORTANT: The masonry hearth should be at least 4 inches (102 mm) higher than the combustible
floor in front of it. If the hearth elevation is lower than 4 inches, the non-combustible floor protector in
front of the insert should have an R value equal or greater than 1.00.

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2.8 Connector installation
A masonry flue connector may provide acceptable performance (Figure 2.8a); however, we recommend the
use of a chimney liner (rigid or flexible) to ensure satisfactory performance (Figure 2.8b). To ensure an
optimal draft, we also strongly recommend adding a minimum of 18” rigid liner between the roof flashing
and the rain cap. Slip connectors for continuous liners should also be installed. Use Listed Chimney Liners
– UL1777, CAN/ULC-S635.
Figure 2.8a* Figure 2.8b*
*Generic illustrations. The model of your insert can differ from the one shown above.
ATTENTION INSTALLER: When positioning the unit in a fireplace opening prior to the flue
installation, install the insert into the opening until the top lip of air jacket is flush with fireplace
facing.
If lag-bolts and anchors are to be used to secure the insert, the whole locations should be marked
with the unit in place. Remove the insert and locate the anchors.

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2.8.1 Chimney liner installation
To the chimney liner to the insert’s flue outlet, you have two options:
A) Install the chimney liner starter adapter, provided with the chimney liner. Follow the chimney liner
starter adapter manufacturer's instructions.
B) You can get from your dealer a liner fixation system (AC02006), sold separately. Follow the
installation instructions provided with the liner fixation system.

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2.9 Air control plate, faceplate and fan Assembly Instructions
1. Place the faceplate panels with the finished side down on a flat, soft, non-abrasive surface.
2. Assemble the faceplate trim, attaching the mitered corners with the corner brackets.
(see Figure 2.9a)
3. Line up the holes of the side and top panels and secure with the screws and nuts. (see Figure
2.2.9b)
4. Slide the assembled trim over the edges of the faceplate.
5. Secure trim to faceplate using "U" shaped clips. (see Figure 2.9c)
Figure 2.9a Figure 2.9b
Figure 2.9c Figure 2.9d
6. Fan is already attached to the unit at the factory with two tie straps. Remove the two tie straps
and clip the blower assembly back onto the unit.

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2.10 Decorative sides installation
Your Osburn 1100 insert comes with decorative sides. To install, simply clip them back into place (see
figure 2.10 below).
Figure 2.10

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Section 3.0 Operation
3.1 Safety Information
1. This insert is designed for safe operation WHENBURNINGCORDWOODONLY. Altering or modifying
the unit or the installation without proper authorization will void the certification, warranty, and
safety listing, and may result in a safety hazard.
2. For safety reasons, never leave the unit unattended with the door open or ajar. An open door and
especially a door partially open or cracked, if left for longer than required for good ignition can
potentially result in unsafe chimney temperatures, and if left unattended, hot embers or ignited fuel
may fall out of the unit. Prolonged door open operation is not necessary provided the unit has
been properly installed and dry kindling is used to start the fire.
3. Do not abuse the unit, either by over firing or by using wood or combustibles with salt content or
harmful chemicals. Misuse is not covered by warranty.
4. Even though your Osburn insert has been specifically designed and tested to prevent smoke
spillage, always open the door slowly as this will minimize the likelihood of smoke spillage or a
back draft causing flame or smoke to spill into the room.
5. Never use gasoline type lantern fuel, kerosene, solvents, charcoal lighter fluid, or inflammable
liquids to start or "freshen" a fire in the insert. Keep all such liquids well away from the insert
while it is in use.
6. All insert surfaces become very hot during operation. Care is needed, especially with children, to
avoid contacting these surfaces.
7. Do not elevate the fire by means of grates, and irons or other means.
8. CAUTION:DO NOT OVER FIRE THIS HEATER.Do not burn fuel in the insert at a rate higher than that
which will cause the ember bed level to exceed half the door opening height. If burning hot fires
regularly, purchase an insert top thermometer, and do not exceed 840oF (450oC) as measured on
the cooktop. If the door handle of the insert becomes excessively hot to the touch, consider this to
be an indication of over firing. Over firing can result in a safety hazard and can permanently
damage the insert and chimney. This damage is not covered by the warranty.
9. Although the ceramic glass is extremely durable under any normal use, a few precautions are
required. Do not attempt to push logs further into the fire by using the door, as the glass may
break if it is heavily contacted by any solid object.
10. Never operate the insert with the door open, or cracked slightly open, except briefly during the
lighting operation, and during refueling. Leaving the door open continuously could seriously
overheat the chimney and adjacent combustibles. Do not operate the insert ifthere is an abnormal
air leakage into the unit, such as through deteriorated gaskets or cracked or broken glass. Do not
operate the insert without a door gasket. Leakage can result in overheating, or in very airtight
homes, could possibly cause smoke spillage into the room. Smoke may contain carbon monoxide,
which is poisonous, and in sufficient quantities is a health hazard.