CLEAN BURN CB-1750, CB-2500, CB-3250, CB 140 Operator's Manual

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OPERATOR'S MANUAL

CLEAN BURN MODELS: CB-1750, CB-2500, and CB-3250

MULTI-OIL FURNACES

with CB-525-S2 BURNER

USED-OIL BURNING

APPLIANCE

ENERGY SYSTEMS

www.cleanburn.com

FOR YOUR SAFETY -

DO NOT STORE GASOLINE

OR OTHER FLAMMABLE VAPORS AND LIQUIDS

IN THE VICINITY OF THIS OR ANY APPLIANCE !!

I88435-D

#MH15393 (N)

LISTED

USED OIL-FIRED

FURNACE

PUBLICATION DATE: 05/12/14, Rev. 14 CLEAN BURN PART # 43195

WARNING: DO NOT assemble, install, operate, or maintain this equipment without rst

reading and understanding the information provided in this manual. Installation and

service must be accomplished by qualied personnel. Failure to follow all safety precautions and procedures as stated in this manual may result in property damage, serious personal injury

or death.

IMPORTANT FOR U.S. INSTALLATIONS: All installations must be made in accordance with state and local codes which may differ from the information provided in this manual. Save these instructions for reference.

IMPORTANT FOR CANADIAN INSTALLATIONS: These instructions have been reviewed and accepted by Underwriters' Laboratories of Canada as being appropriate for the installation of the ULC labelled products

identied herein. The use of these instructions for the installation of products NOT bearing the ULC label and NOT identied herein may result in an unacceptable or hazardous installation.

IMPORTANT FOR CANADIAN INSTALLATIONS: The installation of this equipment is to be accomplished by

qualied personnel and in accordance with the regulation of authorities having jurisdiction and CSA Standard B 139,

Installation Code for Oil Burning Equipment.

CLEAN BURN

WASTE OIL FURNACE

WARRANTY INFORMATION

Clean Burn, LLC, MANUFACTURER, hereby warrants that MANUFACTURER’s products shall be free from defect in material and workmanship under normal use according to the provisions and limitations herein set forth.

MANUFACTURER warrants the heat exchanger/combustion chamber for a period of ten (10) years or 15,000 hours, whichever comes rst), from the date of purchase by the original purchaser, as follows:

If the defect occurs within the rst ten (10 years or 15,000 hours, whichever comes rst), Clean Burn will replace or repair

the heat exchanger/combustion chamber.

MANUFACTURER warrants all other Clean Burn component parts, including the energy retention disk, for a period of

one (1) year from the date of purchase by the original purchaser.

LIMITATIONS:

The obligation of MANUFACTURER for breach of warranty shall be limited to products manufactured by

MANUFACTURER, (1) that are installed, operated and maintained according to MANUFACTURER’s instructions furnished and/or available to the purchaser upon request; (2) that are installed according to all other applicable Federal, State and local codes or regulations; and (3) that the purchaser substantiates were defective in material and workmanship notwithstanding

that they were properly installed and correctly maintained as set forth above and were not abused or misused. The MANUFACTURER may request service records or require photos of the installation or defect.

The obligation of MANUFACTURER shall be limited to replacing or repairing the defective product, at the option of the MANUFACTURER. MANUFACTURER shall not be responsible for any labor or costs or removal or reinstallation of its products and shall not be liable for transportation costs to and from its plant at Janesville, Wisconsin.

Use of parts for modication or repair of the product or any component part thereof not authorized or manufactured by MANUFACTURER specically for such product shall void this warranty.

This warranty shall not apply to any damage to or defect in any of MANUFACTURER’s products that is directly or indirectly

caused by (1) force majeure, Act of God or other accident not related to an inherent product defect; or (2) abuse, misuse or neglect of such product, including any damage caused by improper assembly, installation, adjustment, service, maintenance

or faulty instruction of the purchaser.

Other than as expressly set forth hereinabove, MANUFACTURER makes no other warranty, express or implied, with

respect to any of MANUFACTURER’s products, including but not limited to any warranty of merchantability or tness for a

particular purpose.

And in no event shall MANUFACTURER be responsible for any incidental or consequential damages of any nature suffered by purchaser or any other person or entity caused in whole or in part by any defect in any of MANUFACTURER’s products. Any person or entity to whom this warranty extends and who claims breach of warranty against MANUFACTURER must bring suit thereon within one year from the date of occurrence of such breach of warranty or be forever barred from any and all legal or other remedies for such breach of warranty.

MANUFACTURER is not responsible for and hereby disclaims any undertaking, representation or warranty made by any dealer, distributor or other person that is inconsistent with or in any way more expansive than the provisions of this limited warranty.

Warranty (continued)

This warranty grants specic legal rights and shall be read in conformity with applicable state law. In some jurisdictions,

the applicable law mandates warranty provisions that provide greater legal rights than those provided for herein. In such case, this limited warranty shall be read to include such mandated provisions; and any provision herein that is prohibited

or unenforceable in any such jurisdiction shall, as to such jurisdiction, be ineffective to the extent of such prohibition or

unenforceability without invalidating the remaining provisions and without affecting the validity or enforceability of such

provision in any other jurisdiction(s).

TRADEMARKS

The Clean Burn logo is a trademark of Clean Burn, LLC. All other brand or product names mentioned are the registered trademarks or trademarks of their respective owners.

Copyright © 2013 Clean Burn, LLC. All rights reserved. No part of this publication may be reproduced, or distributed without the prior written permission of Clean Burn, LLC. 4109 Capital Circle, Janesville, WI 53546. Subject to change

without notice.

TABLE OF CONTENTS

SECTION 1: INTRODUCTION ............................................................................................................ 1-1

Guide to this Manual ..................................................................................................................... 1-1

For Your Safety... ........................................................................................................................... 1-2

Guidelines for Furnace Usage ................................................................................................ 1-4

Guidelines for Used Oil Tanks ............................................................................................... 1-5

Safety Labels .......................................................................................................................... 1-6

SECTION 2: UNPACKING ................................................................................................................... 2-1

Removing the Shipping Crate ....................................................................................................... 2-1

Unpacking and Inspecting All Components .................................................................................. 2-1

Furnace Component List ....................................................................................................... 2-1

Unpacking Items Packed Inside the Furnace 2-2

Warranty Registration .................................................................................................................... 2-2

SECTION 3: FURNACE ASSEMBLY ................................................................................................ 3-1

Understanding Assembly ............................................................................................................... 3-1

Required Tools and Materials ................................................................................................ 3-1

Installing the CB-1750 and CB-2500 Blower Assembly .............................................................. 3-3

Wiring the CB-1750 and CB-2500 Blower Motor ................................................................ 3-4

Installing the CB-3250 Blower Assembly ..................................................................................... 3-6

Mounting the CB-3250 Blower .............................................................................................. 3-6

Installing the CB-3250 Blower Motor on the Blower ............................................................ 3-6

Wiring the CB-3250 Blower Motor ...................................................................................... 3-6

Installing the Motor Pulley, Blower Pulley, and V-Belt ......................................................... 3-8

Installing the Belt Guard and Blower Guard ....................................................................... 3-10

Determining the Air Discharge Conguration ............................................................................ 3-10

Installing the Hot Air Discharge Components ............................................................................. 3-12

Installing the Energy Retention Disc ........................................................................................... 3-14

Installing the Energy Retention Disc on the Combustion Chamber .................................... 3-14

Closing the Furnace Door .................................................................................................... 3-14

Installing the Burner .................................................................................................................... 3-15

Checking the Burner Nozzle and Electrodes ....................................................................... 3-15

Mounting the Burner on the Hinge Bracket ......................................................................... 3-16

Installing the Connector Block, Oil Line Tubing, and Air Line Tubing...................................... 3-17

Installing the Connector Block on the Furnace Door .......................................................... 3-17

Installing the Oil Line Tubing .............................................................................................. 3-17

Installing the Air Line Tubing .............................................................................................. 3-18

Locking the Burner into Firing Position .............................................................................. 3-19

SECTION 4: FURNACE INSTALLATION ......................................................................................... 4-1

Understanding Installation............................................................................................................. 4-1

Selecting a Location ...................................................................................................................... 4-3

Guidelines for Selecting a Location ....................................................................................... 4-3

Mounting the Furnace.................................................................................................................... 4-4

Ceiling Mounting ................................................................................................................... 4-4

Raised Platform Mounting ..................................................................................................... 4-5

Floor Mounting ...................................................................................................................... 4-5

Oil Tank Installation Specications ............................................................................................... 4-7

Installing the Tank Vent and Emergency Vent ....................................................................... 4-8

Installing the Metering Pump ........................................................................................................ 4-9

TABLE OF CONTENTS

Preparing for Installation ....................................................................................................... 4-9

Standard Mounting: Vertical Positioning ............................................................................... 4-9

SECTION 4: FURNACE INSTALLATION (continued) .........................................................................

Alternate Mounting: Horizontal Positioning ................................................................................4-11

Wiring the Furnace and Pump ..................................................................................................... 4-12

Wiring to the Furnace ........................................................................................................... 4-12

Wiring to the Metering Pump............................................................................................... 4-12

Installing the Suction Oil Line Components ............................................................................... 4-13

Installing the Pressure Relief Oil Line Back to the Tank ............................................................ 4-16

Installing the Pressure Oil Line Components .............................................................................. 4-17

Installing the Compressed Air Line ............................................................................................. 4-17

Installing the Stack ...................................................................................................................... 4-18

Stack Design and Specications .......................................................................................... 4-18

Installing the Interior Stack .................................................................................................. 4-21

Installing the Barometric Damper ........................................................................................ 4-21

Installing the Stack Safety Switch For Canadian Installations ............................................ 4-22

Resetting the Stack Safety Switch ................................................................................. 4-23

Understanding the Stack Safety Switch ......................................................................... 4-23

Installing the Stack Penetration ............................................................................................ 4-24

Installing the Exterior Stack ................................................................................................. 4-24

Installing the Stack Cap ....................................................................................................... 4-24

Installing the Optional Draft Inducer ................................................................................... 4-24

Installing the Wall Thermostat ..................................................................................................... 4-26

Replacing the Wall Thermostat Batteries ............................................................................. 4-26

Inspecting the Furnace Installation .............................................................................................. 4-26

SECTION 5: METERING PUMP PRIMING .............................................................................. 5-1

Understanding Metering Pump Priming ........................................................................................ 5-1

Required Tools and Materials ................................................................................................ 5-1

Priming the Metering Pump .......................................................................................................... 5-2

Vacuum Testing the Oil Pump ....................................................................................................... 5-4

SECTION 6: STARTING AND ADJUSTING THE BURNER ................................................... 6-1

Understanding Burner Startup and Adjustment 6-1

Preparing the Burner for Startup ................................................................................................... 6-1

Starting the Burner ........................................................................................................................ 6-3

Checking the Operation of the Blower Motor ............................................................................. 6-4

SECTION 7: RESETTING THE FURNACE AND BURNER .................................................... 7-1

Understanding Furnace/Burner Shutdowns ................................................................................... 7-1

The Oil Primary Control ................................................................................................................ 7-1

Resetting the Oil Primary Control ......................................................................................... 7-1

The Blower Switch ........................................................................................................................ 7-2

The Hi-Temp Limit Switches ........................................................................................................ 7-2

Understanding the L-200 Hi-Temp Limit Switch .................................................................. 7-2

Understanding the L-290 Auxiliary Auto Reset Hi-Temp Limit Switch ............................... 7-2

SECTION 8: ADJUSTING THE DRAFT OVER FIRE .............................................................. 8-1

Checking for Correct Draft Over Fire ........................................................................................... 8-1

Adjusting the Barometric Damper................................................................................................. 8-2

TABLE OF CONTENTS

SECTION 8: FURNACE INSTALLATION (continued) .........................................................................

Solving Draft Overre Problems ........................................................................................... 8-2

Understanding the Effect of Exhaust Fans on Draft .............................................................. 8-3

Checking Draft Overre to Determine Severity of Backdraft ............................................... 8-3

Installing a Make-up Air Louver ............................................................................................ 8-5

SECTION 9: MAINTENANCE .................................................................................................. 9-1

Understanding Maintenance .......................................................................................................... 9-1

Periodic Burner Inspection ............................................................................................................ 9-2

Cleaning the Canister Filter ........................................................................................................... 9-3

Servicing the Metering Pump ........................................................................................................ 9-4

Cleaning the Check Valve ............................................................................................................. 9-5

Cleaning the Tank .......................................................................................................................... 9-6

Cleaning Ash from the Furnace ..................................................................................................... 9-7

Annual Burner Tune-up ................................................................................................................. 9-9

End of Season Maintenance .......................................................................................................... 9-9

Cleaning and Maintaining the Optional draft Inducer ................................................................... 9-9

SECTION 10: TROUBLESHOOTING .................................................................................... 10-1

Flow Chart ................................................................................................................................... 10-2

Troubleshooting Tables ............................................................................................................... 10-3

APPENDIX A

Furnace Technical Specications ................................................................................................. A-1

Burner Technical Specications ................................................................................................... A-2

Furnace Dimensions .................................................................................................................... A-2

Burner Components ...................................................................................................................... A-4

Removing the Nozzle for cleaning ........................................................................................ A-9

CB-1750 Furnace Components .................................................................................................. A-10

CB-1750 Blower Components ................................................................................................... A-12

CB-2500 Furnace Components .................................................................................................. A-14

CB-2500 Blower Components ................................................................................................... A-16

CB-3250 Furnace Components .................................................................................................. A-18

CB-3250 Blower Components ................................................................................................... A-20

Metering Pump Components ...................................................................................................... A-22

APPENDIX B

Wiring Diagrams ...........................................................................................................................B-1

CB-1750 Furnace Wiring Diagram ........................................................................................B-1

CB-2500 Furnace Wiring Diagram ........................................................................................B-2

CB-3250 Furnace Wiring Diagram (115 Volts) .....................................................................B-3

CB-3250 Furnace Wiring Diagram (230 Volts) .....................................................................B-4

Burner Wiring Diagram..........................................................................................................B-5

CB-1750 Ladder Schematic ...................................................................................................B-6

CB-2500 Ladder Schematic ...................................................................................................B-7

CB-3250 Ladder Schematic (115 Volts) ................................................................................B-8

CB-3250 Ladder Schematic (230 Volts) ................................................................................B-9

Metering Pump Wiring Schematic .......................................................................................B-10

CAD Cell Oil Primary Control Data Sheets ........................................................................B-11

TABLE OF CONTENTS

APPENDIX C

Furnace Service Record .................................................................................................................C-1

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

SECTION 1: INTRODUCTION

Guide to this Manual

This manual contains all the information necessary to safely install and operate the Clean Burn Furnace

Models CB-1750, CB-2500 and CB-3250. Consult the Table of Contents for a detailed list of topics covered. You'll nd this manual's step-by-step procedures easy to follow and understand. Should ques-

tions arise, please contact your Clean Burn dealer before starting any of the procedures in this manual.

As you follow the directions in this manual, you'll discover that assembling and operating your new

furnace involves ve basic activities as outlined here:

• UNPACKING ..................................................................................................... (Section 2)

• ASSEMBLY ........................................................................................................ (Section 3)

• INSTALLATION .............................................................................................. (Section 4)

• OPERATION

• Metering Pump Priming ........................................................................ (Section 5)

• Starting and Adjusting the Burner ....................................................... (Section 6)

• Resetting the Furnace and Burner ....................................................... (Section 7)

• Adjusting the Draft ............................................................................... (Section 8)

• MAINTENANCE .............................................................................................. (Section 9)

The manual also contains important and detailed technical reference materials which are located at the back of the manual in the Appendixes.

Please read all sections carefully--including the important safety information found in this section--before beginning any installation/operation procedures; doing so ensures your safety and the optimal performance of your Clean Burn furnace.

WARNING!

STOP

YOUR SAFETY IS AT STAKE!

DO NOT INSTALL, OPERATE OR

MAINTAIN THIS EQUIPMENT

WITHOUT FIRST READING

AND UNDERSTANDING THE

OPERATOR'S MANUAL!

1-1

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

For Your Safety...

For your safety, Clean Burn documentation contains the following types of safety statements (listed here in order of increasing intensity):

• NOTE: A clarication of previous information or additional pertinent information.

• ATTENTION: A safety statement indicating that potential equipment damage may occur if instructions are not followed.

CAUTION: A safety statement that reminds of safety practices or directs attention to unsafe

practices which could result in personal injury if proper precautions are not taken.

WARNING: A strong safetystatement indicating that a hazard exists which can result in injury or death if proper precautions are not taken.

DANGER! The utmost levels of safety must be observed; an extreme hazard exists which would result in high probability of death or irreparable serious personal injury if proper

precautions are not taken.

In addition to observing the specic precautions listed throughout the manual, the following general precautions apply and must be heeded to ensure proper, safe furnace operation.

DANGER! DO NOT create a re or explosion hazard by storing or using gasoline or other ammable or explosive liquids or vapors near your furnace.

DANGER! DO NOT operate your furnace if excess oil, oil vapor or fumes have accumulated in or near your furnace. As with any oil burning furnace, improper installation,

operation or maintenance may result in a re or explosion hazard.

WARNING: DO NOT add inappropriate or hazardous materials to your used oil, such as:

• Anti-freeze

• Carburetor cleaner

• Paint thinner

• Parts washer solvents

• Gasoline

• Oil additives

• Any other inappropriate/hazardous

material

WARNING: Burning chlorinated materials (chlorinated solvents and oils) is illegal, will severely damage your heat exchanger, immediately void your warranty, and adversely affect the proper, safe operation of your furnace. Instruct your personnel to never add hazardous materials to your used oil.

1-2

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

For Your Safety... (continued)

WARNING: Never alter or modify your furnace without prior written consent of

Clean Burn, LLC. Unauthorized modications or alteration can adversely affect the proper,

safe operation of your furnace.

WARNING: The burner which is shipped with your Clean Burn furnace is to be used only with your furnace according to the instructions provided in this manual. DO NOT use the burner for any other purpose!

WARNING: The Best Operator is a Careful Operator! By using common sense,

observing general safety rules, and adhering to the precautions specic to the equipment,

you, the operator, can promote safe equipment operation. Failure to use common sense,

  observegeneralsafetyrules,andadheretotheprecautionsspecictotheequipmentmay   resultinequipmentdamage,re,explosion,personalinjuryand/ordeath.

WARNING: The installation, operation, and maintenance of this equipment in the U.S. must be accomplished by qualied personnel and in compliance with the specications in the

Clean Burn Operator's Manual and with all national, state, and local codes or authorities

having jurisdiction over environmental control, building inspection and fuel, re and

electrical safety and the following standards:

NFPA 30 Flammable and Combustible Liquids Code NFPA 30A Automotive and Marine Service Station Code NFPA 31 Standard for the Installation of Oil Burning Equipment NFPA 211 Chimneys, Fireplaces, Vents and Solid Fuel Burning Appliances NFPA 88A Parking Structures NFPA 88B Repair Garages NFPA 70 National Electrical Code

The International Mechanical Code The International Building Code The International Fire Code

The International Fuel Gas Code

Likewise, the installation, operation, and maintenance of this equipment in Canada is to be

accomplished by qualied personnel and in compliance with the specications in the

Clean Burn Operator's Manual and in accordance with the regulation of authorities having

jurisdiction and the following CSA Standards: B139 - Installation Code for Oil Burning Equipment; B140.0 - General Requirements for Oil Burning Equipment; and C22.1 Canadian Electrical Code, Part 1.

Failuretocomplywiththesestandardsandrequirementsmayresultinequipment   damage,re,explosion,personalinjuryand/ordeath.

1-3

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

For Your Safety... (continued)

Guidelines for Furnace Usage

• This furnace is listed for commercial and/or industrial use only; it is not listed for residential use.

• This furnace is listed with Underwriters Laboratory (UL) and Underwriters' Laboratories of Canada (ULC) to burn the following fuels:

• Used crankcase oil up to 50 SAE

• Used transmission uid (for U.S.)

• Used hydraulic oils

• #2 fuel oil

• #4 fuel oil

• #5 fuel oil

NOTE: Used oils may contain other substances, including gasoline, that may hinder performance.

• Make sure you comply with all EPA regulations concerning the use of your furnace. EPA regulations require that:

• Your used oil is generated on-site. You may also accept used oil from "do-it-yourself" oil changers.

• Hazardous wastes, such as chlorinated solvents, are NOT to be mixed with your

used oil.

• The ue gases are vented to the outdoors with an appropriate stack.

• Your used oil is recycled as fuel for "heat recovery". DO NOT operate your furnace

in warm weather just to burn oil.

Contact your Clean Burn dealer for current EPA regulations.

• If your furnace ever requires service, call your Clean Burn dealer. DO NOT allow

untrained, unauthorized personnel to service your furnace. Make sure that your furnace

receives annual preventative maintenance to ensure optimal performance.

1-4

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

For Your Safety... (continued)

Guidelines for Used Oil Tanks

For the safe storage of used oil and the safety of persons in the vicinity of the used oil supply tank, ensure that your tank installation adheres to the following safety guidelines:

• The tank installation must meet all national and local codes. Consult your local municipal authorities for more information as necessary.

• Review and adhere to the safety

guidelines for used oil supply tanks as stated in the WARNING shown.

• Ensure that the tank for your furnace installation complies with all code and safety requirements as stated here. If the tank does not comply, DO NOT use it.

• If you do not have a copy of the tank safety label pictured at right, please contact your Clean Burn dealer for the

label, which is to be afxed directly on

your used oil supply tank.

WARNING

Fire and explosion hazards To prevent serious injury or death:

ONLY place these listed substances in this used-oil supply tank:

• Used crankcase oil

• Used automatic transmission uid

• Used hydraulic oil

• #2 fuel oil Do NOT place ammable or corrosive substances such as gasoline, chlorinated oils, solvents, paint thinners, or any other unsafe substances in this used-oil supply tank.

Do NOT weld or allow open ame within 35 feet of this used-oil supply tank.

Tank installation MUST comply with NFPA 30 and 31 Fire Codes, including the following requirements:

• Tank must be listed to UL 80 or UL 142.

• Tank must be vented to outside.

• Emergency vent or explosion relief must be installed on tank.

• Inside ll allowed only with funnel including 1/4 turn-to-close fall valve, which must be closed after lling.

• All other openings must be plugged

• All oil lines must be constructed of copper, steel, or brass components. Do NOT use rubber or plastic tubing or piping, or any other inappropriate material.

Follow all instructions for tank installation in Operator's Manual.

42366 Rev. 2

1-5

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

For Your Safety... (continued)

Safety Labels

Following are the locations and descriptions of all labels on your furnace cabinet. The following illustrations show the location of ALL labels on your furnace. Please note that some labels denote model number, model description, etc. while others contain important safety messages.

Each Safety Label contains an important safety message starting with a key word as discussed earlier

in this section (e.g. ATTENTION, CAUTION, WARNING, DANGER). For your safety and the safe

operation of your furnace, review all labels and heed all safety messages as printed on the labels.

If any labels on your Clean Burn furnace ever become worn, lost or painted over, please call your Clean Burn dealer for free replacements.

42030

42027

42358

42462

42457

42355 42514

DAT E CODE

42367

42461/42333/42513

Furnace Cabinet Labels

Label Part # Description

42030 Furnace Electrical Shock Hazard Warning Label (several locations) 42027 Furnace Burn Hazard/Hazardous Voltage Warning Label 42358 UL Data Label 42462 UL Header Label - CB-1750 42355 UL Header Label - CB-2500 42514 UL Header Label - CB-3250 42457 Made in USA / Pat Pending Combination Label 42461 Model CB-1750 Label 42333 Model CB-2500 Label 42513 Model CB-3250 Label 42367 Furnace Safety Warning Label (Multiple Messages - Fire/Shock/Burn Hazards) 42068 Furnace Blower/Fan Entanglement Hazard Warning Label (near blower)

AIR OIL

I88793-C

1-6

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

For Your Safety... (continued)

Furnace Cabinet Safety Labels

WARNING

Hazardous voltage.

To prevent serious injury, shut OFF main power to unit before removing cover.

Line voltage is present on most subbase terminals when power is ON. If the furnace is not wired correctly. re, shock or damage could result.

•

ONLY a qualied electrician should wire this furnace. ONLY use copper conductors.

•

42030 Rev. 2

WARNING

Burn Hazard. Hazardous Voltage.

Burner may re at any time. Disconnect burner power cord before swinging open burner or clean-out door.

42027 Rev. 2

WARNING

Fire, explosion and burn hazards:

Maintain clearances from combustibles as listed on unit. ONLY burn used crankcase oil, automatic transmission uid, hydraulic oil, or #2 fuel oil. NEVER burn any other substances in this unit.

Hot gases and ash may be released when inspection port is opened.

Wear safety goggles and hand protection

•

when opening inspection port. Keep face away and open port slowly.

•

To avoid possible injury, death, or equipment damage, read and understand operator's manuals and all safety precautions before installing, operating, or servicing this equipment.

42367 Rev. 2

WARNING

Entanglement and cutting hazard.

Blower can start at any time. Turn power OFF before servicing. Do NOT operate without guard in place.

42068 Rev. 2

1-7

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

For Your Safety... (continued)

Furnace Cabinet Safety Labels

MODEL NO.

CB-1750

INPUT RATING W/NO 2 FUEL OIL (BTU/HR)

LISTED FUELS

INPUT

- GPH -

NO 2 OIL

1.15 15.0 1.5

USED CRANKCASE OIL

HYDRAULIC OIL

ATF

NO 4 OIL

NO 5 OIL

MAX.. DISCHARGE

AIR TEMP-F

1.17

1.17 16.0

1.17 15.0 2.1

1.17 16.0 2.1

200

CLEARANCE TO COMBUSTIBLE SURFACES: (INCHES)

TOP

FRONT

BOTTOM

FAN MOTOR HP.

OIL PUMP MOTOR HP.

BURNER MOTOR HP.

BURNER HEATER WAT TS

DRAFT IND. (OPT ) HP

AIR COMPRESS. (OPT) HP.

REAR FROM

W/LOUVERS

POWER

3/4

1/20

1/10

400

1/3

CHIMNEY

BLOWER

BOTTOM

VO LTS AMPS

TOTAL CIRCUIT AMPACITY W/BLOWER

MAXIMUM FUSE SIZE

ULC

INPUT

- GPH -

ATOM AIR PRESSURE

- PSIG - - PSIG -

1.15

1.17

15.0

N/A 2.1

1.17

FLUE DRAFT IN W.C.

SIDE

HEATED AIR

DISCHARGE SIDE

120

11.0 60

0.75

1.4

3.3

3.9

3.5

170000

OIL

PRESSURE

2.115.01.17

2.1

-0.04

MODEL NO.

CB-2501

INPUT RATING W/NO 2 FUEL OIL (BTU/HR)

LISTED FUELS

INPUT

- GPH -

NO 2 OIL

1.7 18.0 3.5

USED CRANKCASE OIL

HYDRAULIC OIL

ATF

NO 4 OIL

NO 5 OIL

MAX.. DISCHARGE

AIR TEMP-F

1.7

1.7 18.0

1.7 18.0 4.0

1.7 18.0 5.0

200

CLEARANCE TO COMBUSTIBLE SURFACES: (INCHES)

TOP

FRONT

FAN MOTOR HP.

OIL PUMP MOTOR HP.

BURNER MOTOR HP.

BURNER HEATER WAT TS

DRAFT IND. (OPT ) HP

AIR COMPRESS. (OPT) HP.

REAR FROM

POWER

1/20

1/10

400

1/3

CHIMNEY

BLOWER

BOTTOM

VO LTS AMPS

TOTAL CIRCUIT AMPACITY W/BLOWER

MAXIMUM FUSE SIZE

ULC

INPUT

- GPH -

ATOM AIR PRESSURE

- PSIG - - PSIG -

1.7

16.0

N/A 4.0

1.7

FLUE DRAFT IN W.C.

SIDE

HEATED AIR

DISCHARGE SIDE

120

14.0 60

0.75

1.4

3.3

3.9

3.5

250000

OIL

PRESSURE

4.016.01.7

4.0

-0.04

BURNER REQUIRES A MINIMUM AIR SOURCE OF 2 S.C.F.M. AT 25 P.S.I. THIS APPLIANCE IS NOT TO BE USED WITH AIR FILTERS AND SHALL INCORPORATE NO PROVISIONS FOR MOUNTING AIR FILTERS. INSTALL AND USE ONLY IN ACCORDANCE WITH THE MFR’S INSTALLATION AND OPERATING INSTRUCTIONS. FOR COMMERCIAL OR INDUSTRIAL USE ONLY.

AUTHORITIES HAVING JURISDICTION SHOULD

BE CONSULTED PRIOR TO INSTALLATION

42462 - R1

1-8

AUTHORITIES HAVING JURISDICTION SHOULD

BE CONSULTED PRIOR TO INSTALLATION

42355 - R1

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

For Your Safety... (continued)

Furnace Cabinet Safety Labels

MODEL NO.

CB-3250

INPUT RATING W/NO 2 FUEL OIL (BTU/HR)

LISTED FUELS

INPUT

- GPH -

NO 2 OIL

2.1 16.0 5.0

USED CRANKCASE OIL

HYDRAULIC OIL

ATF

NO 4 OIL

NO 5 OIL

MAX.. DISCHARGE

AIR TEMP-F

2.1

2.1 16.0

200

CLEARANCE TO COMBUSTIBLE SURFACES: (INCHES)

TOP

FRONT

BOTTOM

BLOWER MOTOR HP.

OIL PUMP MOTOR HP.

BURNER MOTOR HP.

BURNER HEATER WAT TS

DRAFT IND. (OPT ) HP

AIR COMPRESS. (OPT) HP.

REAR FROM

DISCHARGE

POWER

1/6

1/10

400

1/3

CHIMNEY

BLOWER

BOTTOM

VO LTS AMPS

120/208/230

TOTAL CIRCUIT AMPACITY W/BLOWER

MAXIMUM FUSE SIZE

ULC

INPUT

- GPH -

ATOM AIR PRESSURE

- PSIG - - PSIG -

2.1

16.0

N/A

2.1 6.0

2.1 6.3

FLUE DRAFT IN W.C.

UNIT HEATER AIR

DISCHARGE SIDE

CENTRAL FURNACE

DISCHARGE SIDE

22/11.3/11 60

120

3.2

1.4

3.3

3.9

3.5

37.3/26.6/26.3

50/35/35

SIDE

300000

OIL

PRESSURE

6.016.02.1

6.0

-0.04

AUTHORITIES HAVING JURISDICTION SHOULD

BE CONSULTED PRIOR TO INSTALLATION

42514 - R1

CLEAN BURN LLC

JANESVILLE, WISCONSIN (USA)

MH15393

LISTED

USED-OIL BURNING APPLIANCE USED OIL-FIRED FURNACE

NO.

MULTI-OIL HEATING SYSTEM

INSTALL AND USE ONLY IN ACCORDANCE WITH THE MFR’S INSTALLATION AND OPERATING INSTRUCTIONS.

FOR COMMERCIAL OR INDUSTRIAL USE ONLY.

AUTHORITIES HAVING JURISDICTION SHOULD

BE CONSULTED PRIOR TO INSTALLATION.

CERTIFIED TO ELECTRICAL AND FUEL BURNING REQUIREMENTS ONLY.

USED OIL-FIRED BOILER

For use with Integral Primary Safety Control

13084

42358

1-9

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

525 BURNER

For Your Safety... (continued)

CB-525-S2 Burner Labels

Label Part # Description

42005 Sold and Serviced By Label 42004 Burner Safety Warning Label (High Voltage/Moving Parts Hazards) 42000 Burner Safety Warning Label (Fire/Explosion Hazard - Reset Button) 42235 Burner Safety Warning Label (Fire/Explosion Hazard Burner Installation and Service) 42321 Burner Model/Serial Number Label 42229 Logo/Burner Description Label 42023 Burner Power Label 42457 Made in USA / Pat Pending Combination Label (on side)

CB-525-S2 BurnerSafety Labels

42005

42004

42000

42235

42321

42229

42023

I88603-B

WARNING

Hazardous high voltage and moving parts hazard.

To avoid electric shock and injury from moving parts. turn power OFF before opening cover.

WARNING

Fire and explosion hazard. Do NOT press reset button until you read and understand Reset Procedures in Operator's Manual.

42000 Rev. 2

42004 Rev. 2

WARNING

Fire and explosion hazard.

This burner is to be installed ONLY on Clean Burn products. Only a qualied technician may maintain and service this burner.

42235 Rev. 2

1-10

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

SECTION 2: UNPACKING

Before assembling your furnace, you must accomplish the following activities described in this section:

• Removing the Shipping Crate

• Unpacking and Inspecting All Components

• Warranty Registration

Removing the Shipping Crate

NOTE: Remove the shipping crate prior to assembly and installation of the furnace. DO NOT use the crate as a platform for furnace installation!

1. Carefully remove the top boards of the shipping crate. Then remove the front, back, and side

panels of the shipping crate.

2. Carefully lift the furnace off the shipping pallet with a fork lift.

ATTENTION: DO NOT attempt to slide the furnace cabinet out of the shipping crate--you may damage the furnace cabinet.

Unpacking and Inspecting All Components

Following is an itemized list of all components you should have received in your Clean Burn furnace

shipment. Open all shipping containers and inspect all components according to the list. Immediately

notify the freight company and your Clean Burn dealer in case of shipping damage or shortage(s). Keep

all components together so you will have them as needed for furnace assembly and installation.

Furnace Component List

ONE SKID containing:

• Furnace cabinet

• Items packed inside furnace cabinet (combustion chamber): NOTE: Please refer to the procedure on the following page to remove these items.

• Target

• Hot air discharge assembly components plus hardware

• Furnace Accessories (items below in one box):

• Canister Filter

• Vacuum Gauge

• Check Valve and Check Valve Screen

• Wall Thermostat

• Barometric Damper

• Connector Block

• Burner Oil Line and Air Line Components

• Assorted bolts/ttings for assembly/installation of furnace components

• Operator's Manual Literature Packet (includes Tank Safety Label)

ITEMS PACKED IN INDIVIDUAL BOXES:

• Burner

• Blower Assembly

• Metering Pump (includes Suction Oil Line Fittings Package)

NOTE: You may have received additional boxes or skids if you ordered optional accessories.

2-1

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Unpacking Items Packed Inside the Furnace

To unpack the items packed inside the furnace cabinet (in the combustion chamber), you will need to

open the combustion chamber door.

1. Remove the four nuts and washers which hold the combustion chamber door closed. Set the nuts and washers aside in a safe place for later re-installation after the target has been installed (Section 3).

2. Carefully swing the combustion chamber door open. Remove and inspect the components

packed inside.

3. Leave the door unfastened (open) for assembly/installation procedures to be accomplished in the

next section.

CLEAN-OUT DOOR

Figure 2A - Accessing the Combustion Chamber

Warranty Registration

For proper warranty registration, Clean Burn requires that you ll out the provided warranty registration

card and return it within 30 days to:

CLEAN BURN WARRANTY REGISTRATION

COMBUSTION CHAMBER

I88436-A

Clean Burn, LLC.

4109 Capital Circle,

Janesville, WI 53546

2-2

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

SECTION 3: FURNACE ASSEMBLY

Understanding Assembly

Assembling your Clean Burn Furnace includes the following steps:

(1) Installing the Blower Assembly (2) Installing the Hot Air Discharge Components (3) Installing the Energy Retention Disc (4) Installing the Burner (5) Installing the Connector Block, Oil Line Tubing, and Air Line Tubing

Clean Burn recommends that you review all assembly procedures before proceeding, paying careful attention to safety information statements.

Figure 3A on the following page provides a general overview of the furnace components and their proper assembly.

Required Tools and Materials

The following tools are required for furnace assembly and should be gathered before starting any procedures:

• 9/16" open-end wrench

• Medium at-blade screwdriver

• Medium adjustable wrench

• 1/4" nut driver attachment for drill

• 5/16" nut driver attachment for drill

• Variable speed drill

3-1

JUNCTION BOX

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

"ALL THREAD" RODS

COUPLINGS FOR "ALL THREAD" RODS

BURNER MOUNTING BRACKET

BURNER CABLE

PUMP PRIMING SWITCH

R.H. FURNACE

THROAT

FURNACE DOOR

NOTE: LOOP ON ENERGY RETENTION

DISC HOOKS OVER MOUNTING BRACKET ON BACK WALL OF COMBUSTION CHAMBER

BREECH

LH FURNACE BREECH WITH CLEAN-OUT

AIR OIL

ENERGY

FURNACE BREECH

RETENTION DISC INSTALLED ON BACK WALL OF COMBUSTION CHAMBER

HOT AIR DISCHARGE

NOTICE THE VARIOUS MOUNTING CHOICES FOR THE LOUVERS

IT IS OK TO OPEN OR RESTRICT THE LOUVERS AS NEEDED, AND THEN

TO TURN THOSE CONFIGURATIONS IN ANY OF FOUR DIRECTIONS

Complete assembly of the furnace according to the following list of activities as illustrated above: (1) Installing the Blower Assembly (2) Installing the Hot Air Discharge Components (3) Installing the Target (4) Installing the Burner (5) Installing the Connector Block, Oil Line Tubing, and Air Line Tubing NOTE: Corresponding procedures provided in order in this section.

Figure 3A - Overview of Furnace Assembly

I88437-C

3-2

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Installing the CB-1750 and CB-2500 Blower Assembly

1. Refer to Figures 3B and 3C.

2. Remove the blower stabilizer brackets as shown in Figure 3B. (These braces, which are installed

at the factory, are designed to keep the blower in proper position during shipping. Note that

these braces are provided on CB-2500 blower assemblies ONLY; CB-1750 blower assemblies do not require these special shipping braces.)

3. Position the blower over the opening in the back of the furnace cabinet by sliding the blower into the mounting angle brackets. Note that the mounting brackets may be loosened for adjustment,

as needed. The blower should be centered over the opening.

4. Fasten the blower to the brackets with self-tapping screws (provided). Drive the screws into the

blower housing through the holes in the mounting angle brackets. There are four holes along each side and across the top of the bracket to fasten the blower to the furnace cabinet.

5. Install the blower safety guards as shown. WARNING: To avoid serious personal injury, be sure to install both pieces of the blower guard

around the blower prior to operating the furnace. NEVER operate the furnace without all safety shields/guards in place! ATTENTION: The air ow is changed when the guards are not in place which may result in damage to the blower motor. NOTE: For proper air ow through the furnace cabinet the blower must be positioned so that

the bulge on the blower faces down as illustrated in Figures 3A, 3B, and 3C.

IMPORTANT!!:

REMOVE SHIPPING BRACES

ATTACH BLOWER TO FURNACE ATTACH SHIELDS/GUARDS TO BLOWER (1 ON EACH SIDE)

X 2

Figure 3B - Installing the Blower Assembly (CB-1750 and CB-2500)

I88691-D

3-3

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

I88438-D

Installing the CB-1750 and CB-2500 Blower Assembly (continued)

L2 L1

Note capacitor location on blower.

CB-1750 is shown; CB-2500

capacitor is mounted on the opposite side of the blower.

Figure 3C - Blower Installed on Furnace Cabinet (CB-1750 and CB-2500)

Wiring the CB-1750 and CB-2500 Blower Motor

WARNING: Make sure the main power to the furnace is turned OFF before wiring the blower motor. NOTE: Wiring schematics are provided in Figures 3D and 3E and in Appendix B at the back of the manual.

1. After the blower has been secured to the back of the furnace cabinet, install the electrical conduit with the blower motor leads into the 4" x 6" rear junction box on the top of the furnace cabinet as shown in Figure 3C.

2. For CB-1750 furnaces (see Figure 3D):

• Connect the power lead coming from the blower assembly to the 4" x 6" electrical box

mounted on the rear of the furnace cabinet.

• Connect the black (power) motor lead wire to the connector block terminal with the black (power) wire from the front electrical box.

• Connect the white (neutral) motor lead wire to the connector block terminal with the white (neutral) wire from the front electrical box.

3. For CB-2500 furnaces (see Figure 3E):

• Connect the power lead coming from the blower assembly to the 4" x 6" electrical box

mounted on the rear of the furnace cabinet.

• Connect the black (power) motor lead wire to the T1 terminal of the contactor.

• Connect the white (neutral) motor lead wire to the T2 terminal of the contactor.

3-4

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Installing the CB-1750 and CB-2500 Blower Assembly (continued)

REAR JUNCTION BOX

BLOWER MOTOR

WHITE

BLACK

WHITE

BLACK

POWER IN

I42425

Figure 3D - Detail of Blower Motor Wiring for CB-1750

WHITE

SPADE

(MALE TO FEMALE)

(FLEX CONDUIT)

WHITE

REAR JUNCTION BOX

(UNDER LUG SCREW)

POWER IN FLEX CONDUIT

(UNDER LUG SCREW)

I42423

Figure 3E - Detail of Blower Motor Wiring for CB-2500

WHITE

BLACK

ORANGE

3-5

WHT

BLK

BLOWER

MOTOR

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Installing the CB-3250 Blower Assembly

Mounting the CB-3250 Blower

1. Refer to Figures 3F and 3G.

2. Position the blower over the opening in the back of the furnace cabinet by sliding the blower into

the mounting angle brackets. The top of the blower is slid over the lip on the back of the furnace. The mounting screws on top will go through the blower and anchor into the thicker lip pretruding

from the back of the furnace cabinet. Check for proper positioning by referring to Figure 3G.

3. Fasten the blower to the brackets with self-tapping screws (provided).

NOTE: There are three holes for fastening the blower along each side of the bracket, as well as three across the top.

Installing the CB-3250 Motor on the Blower

1. Refer to Figures 3F and 3G.

2. Use self-tapping bolts to install the motor mounting bracket on the blower according to the dimensions provided in Figure 3F.

3. Slide the two (2) square-head bolts upside-down in the channel of the motor mounting bracket.

4. Install the motor mounting plate on the mounting bracket using the two bolts in the channel to

hold the plate in position. DO NOT install the nuts on the bolts yet. Make sure the plate is ush

with the side of the blower.

5. Use a self-tapping bolt to install the motor tensioning bracket on the blower according to the dimensions provided in Figure 3F.

6. Lift up on the end of the motor mounting plate until the hole in the side of the plate is aligned

with the slot in the motor tensioning bracket. Push a bolt through the slot and install a nut

loosely just to hold the plate in position. DO NOT tighten the nut yet.

7. Lift the motor into position on the motor mounting plate using the two bolts in the channel to hold the motor in place. Now loosely install the nuts on the two (2) bolts.

8. Slide the motor into position so the face of the motor is ush with the side of the blower. Now

tighten the nuts.

9. Install the additional two (2) bolts and nuts through the upper holes in the motor mounting plate and motor. Tighten the nuts to hold the motor rmly in position.

Wiring the CB-3250 Blower Motor

WARNING: Make sure the main power to the furnace is turned OFF before wiring the blower motor. NOTE: Wiring schematics are provided in Figure H and Appendix B at the back of the manual.

1. After the blower has been secured to the back of the furnace cabinet, screw the electrical conduit

with the blower motor leads into the motor housing.

2. Determine the voltage being supplied to the unit. Follow the correct wiring diagram in Figure H for either 115 Volts or 230 Volts. Connect the wire ends with the terminals to the motor. Refer to

the wiring diagram on the motor to ensure that the motor is wired for proper voltage and CW rotation facing the shaft.

3. Install the electrical conduit with the blower motor leads into the 4" x 6" rear junction box on top of the furnace cabinet as shown in Figure 3G. Refer to Figure 3H for the proper wiring diagram.

3-6

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

BLOWER ASSEMBLY PARTS LIST

1 NUT

(4) 1

2 MOTOR 3 MOTOR PULLEY 4 SHEAVE BUSHING 7/8” 5 MOTOR MOUNTING PLATE 6 BOLT 7 SQUARE HEAD BOLT 8 BLOWER GUARD 9 MOTOR MOUNTING BRACKET 10 BLOWER 11 MOTOR TENSIONING BRACKET 12 SELF TAPPING SCREW 13 BLOWER PULLEY 14 SHEAVE BUSHING 1" 15 BELT 16 BELT GUARD

CB-3250 BLOWER

DETAIL OF BRACKET INSTALLATION NOTE: The brackets must be

installed at the correct position on the side of the blower as shown here to allow the belt guard to mount properly.

18 1/4"

3/4"

8 1/2"

I89022

Figure 3F - Blower Assembly Parts Detail (CB-3250)

3-7

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Installing the CB-3250 Blower Assembly (continued)

I89021

Figure 3G - Blower Installed on Furnace Cabinet (CB-3250)

Installing the CB-3250 Motor Pulley, Blower Pulley, and V-Belt

1. Review the contents of the Blower Pulley and Motor Pulley as shown in Figure 3F. 2 Refer to Figure 3F. Place the blower pulley over and onto the blower shaft as far as possible

with large bore end of taper outward.

3. Insert the blower key into the bushing. (If the key is deformed and does not t into place, le the key to the proper size or replace it with a new key).

4. Slide the bushing (with key inserted) onto the shaft so the tapered end will engage into the

pulley.

NOTE: If bushing does not slide freely on shaft, wedge a screwdriver blade into the saw cut

at the ange OD to open the bore of the bushing. CAUTION: Excessive force may split the

bushing.

5. Align drilled holes in bushing ange with tapped holes in the pulley. Use the capscrews

and washers provided with the bushing package to fasten the pulley on to the bushing. DO NOT

COMPLETELY TIGHTEN THE SCREWS AT THIS POINT! Make sure you can still slide the bushing and pulley for future alignment with the motor pulley. (Additional information is available in the “Bushing Instruction Sheet” provided with each bushing)

6. Install the motor pulley following steps 1 through 5.

3-8

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

115

VOLTS

FLEX

CONDUIT

GROUND

COMMON / NEUTRAL

HOT LEG

WHITE

BLACK

ORANGE

115 VOLTS AC

2 L

1 L

CONTACTOR HAS A

110 - 120 VOLT AC COIL

CONNECT 2 HP BLOWER MOTOR

ACCORDING TO THE LABEL SUPPLIED WITH

THE MOTOR FOR CW ROTATION FACING

THE SHAFT AND 115 VOLTS

2 T

1 T

GREEN

BLOWER

MOTOR

230

VOLTS

FLEX

CONDUIT

I89031

COMMON / NEUTRAL

HOT LEG

WHITE

BLACK

GROUND

ORANGE

230 VOLTS AC

2 L

1 L

CONTACTOR HAS A

110 - 120 VOLT AC COIL

CONNECT 2 HP BLOWER MOTOR

ACCORDING TO THE LABEL SUPPLIED WITH

THE MOTOR FOR CW ROTATION FACING

THE SHAFT AND 230 VOLTS

2 T

1 T

GREEN

BLOWER

MOTOR

Figure 3H - Detail of Blower Motor Wiring for CB-3250

3-9

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Installing the CB-3250 Motor Pulley, Blower Pulley, and V-Belt (continued)

7. Align the motor pulley with the blower pulley.

a. Place the blower bushing ½ inch from the end of the shaft and tighten the capscrews securely

(9 Ft. - Lbs. if using a torque wrench). b. Place a level or straight edge at onto the two most outer edges of the blower pulley.

c. Place the motor pulley and bushing about ¼ inch away from the straight edge.

d. Start tightening the screws on the motor bushing. As the screws are tightened, the motor pulley will approach the straight edge. TIGHTEN THE CAPSCREWS SECURELY (9 Ft. Lbs. if using a torque wrench).

e. Four points of the two pulleys should be touching the straight edge. If they don’t make full contact, loosen the screws on the motor bushing and realign it so both pulleys are on the same plane.

8. Place the belt on the pulleys, starting with the motor pulley and feeding it onto the blower pulley.

9. Tighten the belt (Refer to Figure 3G).

a. Raise the motor bracket and at the same time tighten the nut on the tension bracket.

b. DO NOT over tighten the belt. Leave about 1inch of slack (when pushing on the top of the belt, it should deect about 1 inch).

Installing the CB-3250 Belt Guard and Blower Guard

WARNING: To prevent serious personal injury, DO NOT operate the furnace without the belt

and blower guards in place.

1. Refer to Figure 3F and 3G.

2. Install the belt guard and blower guard as shown.

Determining the Air Discharge Conguration

Before proceeding with the assembly of your furnace, it is important to determine the conguration of the air discharge for your furnace. There are three congurations to consider:

(1) Unit Heater Furnace with blower assembly for free air applications. Follow the instructions (provided in this section) to install the blower

assembly and air discharge components. Be sure to adhere to the proper

       speciedclearancesforUnitHeaterCongurationsasstatedin

Section 4 of this manual.

(2) Central Furnace (A) Furnace with blower assembly for ducting applications with .25 or less static pressure.*

Follow the instructions to install the blower assembly and air discharge components, and refer to the following chart for the proper air discharge

and ducting specications. Besuretoadheretotheproperspecied        clearancesforCentralFurnaceCongurationsasstatedinSection4of

this manual.

(3) Central Furnace (B) Furnace with blower assembly for ducting applications from .25 to .40 static pressure.*

Follow the instructions to install the blower assembly, and refer to the

following chart for the proper air discharge and ducting specications.

BesuretoadheretotheproperspeciedclearancesforCentralFurnace        CongurationsasstatedinSection4ofthismanual.

3-10

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Determining the Air Discharge Conguration (continued)

Static Pressure (SP) and Air Flow (CFM) Specications

CB-1750

Air Discharge Louvers

Mounted on Furnace

Duct Free**

1625 CFM

CB-2500

Air Discharge Louvers

Mounted on Furnace

Duct Free**

2700 CFM

CB-3250

Air Discharge Louvers

Mounted on Furnace

Duct Free**

Air Discharge Louvers Mounted on Furnace

(Fully Open - Ductwork Installed Over Top)*

0.25 Inches of W.C.**

Air Discharge Louvers Mounted on Furnace

(Fully Open - Ductwork Installed Over Top)*

0.25 Inches of W.C.**

2500 CFM

Air Discharge Louvers Removed

Ductwork Installed on Furnace

0.25 Inches of W.C.**

Air Discharge Louvers Removed

Ductwork Installed on Furnace

0.30 Inches of W.C.**

MFC 0041MFC 0051

Air Discharge Louvers Removed

Ductwork Installed on Furnace

0.40 Inches of W.C.**

2400 CFM

Air Discharge Louvers Removed

Ductwork Installed on Furnace

0.40 Inches of W.C.**

3300 CFM

3150 CFM

2900 CFM

C77001

*NOTE: The open louvers function as an orice plate for the lower static pressure installations.

**ATTENTION: A qualied electrician must check the blower motor amperage during operation of the furnace to ensure that motor amperage does not exceed 85% of the maximum amperage on the motor label. DO NOT operate the blower motor above 85% of maximum amperage or motor damage may occur.

IMPORTANT NOTE: ItisessentialthatqualiedHVACpersonnelproperlydesigntheductwork for your furnace and determine the static pressure for your ducting application. Note that existing

ductwork at your installation site may not be appropriate or meet the specications for this

furnace installation. For static pressure readings as shown in the chart above, the ductwork should be installed directly over the opening in the SIDE of the furnace cabinet (i.e. where the louver panels would be installed for free air applications.) ForCentralFurnaceapplications,ductwork

may NOT be installed over the bottom opening.

3-11

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Installing the Hot Air Discharge Components

It is very important to properly install the hot air discharge components (louvers and blank cover panels) to direct the ow of air from the furnace. As you will note from Figures 3I and 3J, the air discharge panels are to be installed on the side(s) and/or bottom of the furnace. Theairowmaybedirected

down,front,orback,dependinguponhowthelouversandcoverpanelsareinstalled.

IMPORTANT NOTE FOR CENTRAL FURNACE APPLICATIONS:

• For ducting applications of .25 static pressure, install the louvers as described in the following procedure, and then install the ductwork over top of the fully open louvers.

• For ducting applications of .30 (CB-1750) or .40 (CB-2500 and CB-3250) static pressure, DO NOT install the louvers. The ductwork should be installed directly over the desired air discharge openings on the side of the furnace cabinet.

• Ductwork must be installed over side opening(s) ONLY. Ductwork may NOT be installed over the bottom air discharge opening.

1. Refer to Figures 3I and 3J. Determine the desired air ow discharge pattern. Note that each furnace is supplied with (2) louver sections and (4) blank cover panels. Air discharge openings are: (1) on each side of the furnace, and (1) on the bottom of the furnace.

2. Install the louver panels in the desired location(s) with the self-tapping screws provided. Holes are pre-drilled in the furnace cabinet to accommodate installation of the panels.

Air Flow Discharge Installation Guidelines:

• When determining the

placement of the air discharge louvers, you also need to consider the required clearances from combustibles as stated in Section 4 of this manual.

• Note that each furnace model supplied with (2) louver sections which may be installed together on one side or the bottom as shown here OR the louvers may be split for partial air discharge on each side and/or bottom as shown in

Figure 3J.

NOTE: Bottom louver installation

applies to Unit Heater furnaces ONLY. Ductwork for Central Furnace applications may NOT be installed over the bottom opening.

Figure 3I - Hot Air Discharge Components (Louvers/Blank Covers) Installed on Furnace

I88439-C

3-12

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Installing the Hot Air Discharge Components (continued)

3. Adjust the louvers for the desired air ow direction. ATTENTION: DO NOT restrict the ow of the hot air from the furnace by closing the louvers,

or the furnace will not operate properly.

4. Install the blank covers over the remaining air discharge opening(s) on the furnace cabinet.

Louvers split between two side openings, showing left and right side views of same furnace

NOTE: When louver panels are "split" between two sides, make sure the louvers are installed

Louvers split between left side and bottom openings, showing left and right side views of same furnace

NOTE: When louver panels are "split" between a side and the bottom, make sure the bottom louvers

Louvers split between right side and bottom openings, showing left and right side views of same furnace

in the upper half of each side air discharge opening as shown here.

are installed in the forward half of the bottom air discharge opening as shown here.

Figure 3J - Sample Split Louver Installations for Partial Air Discharge on Sides and/or Bottom

I88537

3-13

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Installing the Energy Retention Disc

Installing the Energy Retention Disc at the Back of the Combustion Chamber

ATTENTION: DO NOT re your furnace without the Energy Retention Disc in place, or combustion

chamber damage will occur. Handle the Energy Retention Disc carefully to avoid damaging it.

1. Refer to Figure 3A to review the proper positioning of the Energy Retention Disc.

2. Swing open the clean-out door on the front of the furnace to gain access to the combustion

chamber.

3. Use a long rod to support the Energy Retention Disc as you guide it into position on the back of the combustion chamber. The loop on the back of the Energy Retention Disc ts over the hook

located on the back of the combustion chamber.

Closing the Furnace Door

1. After the Energy Retention Disc has been installed, close the furnace clean-out door.

2. Tighten the four (4) lock-down nuts in a criss-cross pattern until all are snug.

3-14

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Installing the Burner

Checking the Burner Nozzle and Electrodes

NOTE: The burner nozzle is factory installed. All furnace models (CB-1750, CB-2500, and CB-3250) use a Delavan 9-5 nozzle. The nozzle size is indicated on the nozzle as shown in Figure 3K. Refer also

to Appendix A at the back of the manual for additional specications/instructions on the burner nozzle.

ATTENTION: Check the electrode settings as specied in Figure 3K. The electrode settings must be

correct for your burner to operate properly.

BURNER NOZZLE

NOZZLE IS STAMPED WITH SIZE

ON FLAT OF NOZZLE HEAD

VIEW - BB

SIDE VIEW - AA

3/16" GAP BETWEEN

ELECTRODES & NOZZLE

VIEW - AA

CRITICAL DIMENSION: NOZZLE MUST BE 1/8"

AHEAD OF THE DISK.

NOZZLE MUST NOT BE

BEHIND THE DISK.

1/8"

SPARK

GAP

FRONT VIEW - BB

I88647

Figure 3K - Burner Nozzle and Electrode Specications

3-15

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Installing the Burner (continued)

Mounting the Burner on the Hinge Bracket

ATTENTION: Burner tube components (e.g. electrodes and retention head) are factory set. Handle the

burner with extreme care so that burner components are not damaged.

1. Remove the nut from the mounting ange of the furnace cabinet, and set it aside for later use.

2. Lift the burner into position so that it is mounted on the hinge bracket on the furnace cabinet.

3. Carefully swing the burner so the retention head enters the throat of the furnace.

4. Check the clearance between the retention head and the furnace throat. There must be at least

 1/8"clearance,sotheretentionheadisnot"bumped"asyouswingtheburnerintoring

position.

NOTE: If the retention head "bumps" the furnace throat, adjust the hinge bracket bolts as follows:

• While supporting the burner, slightly loosen the two (2) hinge bracket bolts.

• Carefully re-position the burner so it swings freely into its ring position.

• With the burner in its ring position, re-tighten the hinge bracket bolts.

3-16

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Installing the Connector Block, Oil Line Tubing, and Air Line Tubing

ATTENTION: DO NOT use teon tape on any ttings. Teon tape residues will plug vital burner

components and void your warranty.

Installing the Connector Block on the Furnace Door

1. Refer to Figure 3L.

2. Use the two (2) bolts to install the aluminum

connector block onto the furnace cabinet.

3. Remove and discard the red caps and plugs from the ttings and ports on the connector block. DO NOT

allow any dirt/debris to enter these components during furnace assembly.

ATTENTION: The connector block includes an accumulator. The accumulator functions like a shock absorber on the oil line to prevent pressure buildup and protect vital burner components. It is important that the connector block is installed as shown so that the accumulator is in a vertical position to prevent sediment from settling in the accumulator. Never operate your furnace without the

connectorblockandaccumulatorproperlyinstalledonthe

furnace, or damage may occur to vital burner components.

CONNECTOR BLOCK

FRONT VIEW OF FURNACE

OIL LINE

OIL FITTING ON BURNER

AIR OIL

OIL LINE FITTING ON BURNER LINED UP WITH OIL LINE

OIL LINE

Installing the Oil Line Tubing

SWIVEL

ATTENTION: DO NOT disassemble the compression

tting from the swivel tting. To prevent leaks, the NPT

ASSEMBLY

CONNECTOR BLOCK

threads of the compression tting have been sealed with hydraulic sealant during assembly of the ttings at the

factory.

SIDE VIEW OF FURNACE

SHOWING OIL LINE INSTALLED

I88341-A

Figure 3L - Installation of Connector

Block and Oil Line

1. Remove and discard the red caps from the oil line tubing.

2. Loosely install the oil line tubing into the oil line tting on the burner.

3. Use a wrench to slightly rotate the oil line tting on the burner counterclockwise so the tubing lines up with the swivel assembly. Slightly bend the tubing as shown in Figure 3L, if required,

to "line up" the oil line.

4. If necessary, use a tubing cutter to cut the tubing to the proper length. ATTENTION: Due to adjustment of the burner hinge bracket, the oil line tubing may need to

be cut to t properly. DO NOT lift up on the burner when installing the oil line tubing to

compensate for oil line tubing that is too long. This will place the weight of the burner on the

swivel tting and result in leaks at the swivel tting seal.

3-17

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Installing the Connector Block, Oil Line Tubing, and Air Line Tubing (continued)

Installing the Oil Line Tubing (continued)

5. Make sure that the curl in the oil line is positioned as shown in Figure 3L so that the burner can

swing open correctly.

6. Install the oil line tubing and tighten the nuts on the compression ttings. DO NOT overtighten these ttings to avoid damaging the ferrules.

NOTE: You may also check the positioning of the oil line according to Figure 3M which provides a

larger front view of the connector block assembly.

Installing the Air Line Tubing

1. Remove and discard the red caps from the air line tubing.

2. Refer to Figure 3M. Push the air line tubing into the swivel tting on the connector block until the tubing bottoms out in the tting.

3. Repeat this procedure to connect the air line tubing to the air line tting on the side of the burner.

I88440-A

PUMP PRIMING SWITCH

AIR LINE FITTING

ON BURNER

OIL LINE FITTING

ON BURNER

AIR LINE

OIL LINE

COMPRESSION /

SWIVEL FITTING

AIR OIL

CONNECTOR BLOCK

INSTALLED ON FURNACE CABINET

Figure 3M - Installation of Connector Block, Oil Line and Air Line (Front View)

3-18

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Locking the Burner into Firing Position

1. Swing the burner into ring position.

2. Install and tighten the lock-down nut on the mounting plate bolt to secure the burner in its ring position.

3. Plug the burner electrical cable into the receptacle on the

top of the burner housing.

4. Tighten the locking ring to secure the electrical cable.

NOTE: Be sure to properly align the plug when plugging it into

the receptacle. See Fig 3N.

CONNECTOR PLUG

KEY IN PLUG MUST ALIGN WITH SLOT IN RECEPTACLE

RECEPTACLE ON

TOP OF BURNER

I88641-B

Figure 3N - Detail of Burner

Electric Receptacle

NOTE: Your furnace is now assembled and ready for installation. Install the furnace as

soon as possible so the burner and/or blower are not "bumped" or damaged. If you must store the furnace for a period of time before installation, make sure it is located in a safe, secure area.

3-19

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

3-20

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

SECTION 4: FURNACE INSTALLATION

Understanding Installation

Installing your Clean Burn furnace is a multi-step process which includes: (1) Selecting a Location (2) Mounting the Furnace (3) Oil Tank Installation Specications (review) (4) Installing the Metering Pump (5) Wiring the Furnace and Pump (6) Installing the Oil Lines (7) Installing the Compressed Air Line (8) Installing the Stack (9) Installing the Wall Thermostat (10) Inspecting the Installation

Clean Burn recommends that you review all procedures before beginning installation, paying careful attention to safety information statements. Figure 4A provides a general overview of a typical furnace installation and should be reviewed closely before proceeding.

WARNING: The installation, operation, and maintenance of this equipment in the U.S.

must be accomplished by qualied personnel and in compliance with the specications in the

Clean Burn Operator's Manual and with all national, state, and local codes or authorities having

jurisdiction over environmental control, building inspection and fuel, re and electrical safety and the

following standards:

The International Mechanical Code The International Building Code The International Fire Code

The International Fuel Gas Code

Likewise, the installation, operation, and maintenance of this equipment in Canada is to be

accomplished by qualied personnel and in compliance with the specications in the Clean Burn Operator's Manual and in accordance with the regulation of authorities having jurisdiction and the following CSA Standards: B139 - Installation Code for Oil Burning Equipment; B140.0 - General Requirements for Oil Burning Equipment; and C22.1 - Canadian Electrical Code, Part 1.

Failuretocomplywiththesestandardsandrequirementsmayresultinequipmentdamage,re, explosion,personalinjuryand/ordeath.

WARNING: Improper installation can adversely affect the proper, safe operation of your furnace. It is critical that your furnace installer reads and follows the instructions provided in this manual.

4-1

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

WARNING: When installing your furnace,

adhere to the minimum clearances from combustible surfaces as stated in Section 4.

These clearances also provide adequate

space for servicing. Failure to maintain proper clearances may result in fire, explosion, personal injury, or death.

10 FT.

3 FT.

DEDICATED ELECTRIC CIRCUIT

24 VOLT WALL THERMOSTAT

ELECTRIC SERVICE

THERMOSTAT CABLE

"2 WIRE" MIN 18 GA.

8 FT. MIN. FROM FLOOR TO FURNACE IFTHERE IS A POTENTIAL FOR

GASOLINE FUMES IN YOUR SHOP. CHECK LOCAL CODES AND NFPA 88-B

CONNECTOR BLOCK

MAXIMUM 6 FT.

SUCTION LIFT OR THE PUMP WILL NOT

CAUTION: DO NOT EXCEED 6 FT VERTICAL

COMPRESSED AIR LINE

EMERGENCY

VENT VALVE

THE PUMP MAY DECREASE

PRIME AND/OR THE FLOW RATE FROM

1/4" HOLE FOR SETTING DRAFT. ADJUST BAROMETRIC DAMPER FOR -.04" W.C. DRAFT AT BREECH

AIR OIL

PRESSURE OIL LINE

OIL PUMP ELECTRICAL CIRCUIT

SUCTION OIL LINE

BALL VALVE

OIL

STORAGE

TANK

EVERY FITTING TO MAINTAIN PROPER DRAFT OVERFIRE

VENT

CAP

10 FT. MINIMUM VERTICAL STACK HEIGHT PLUS 1 FT. FOR

CLEANOUT

WITH DRAIN

Figure 4A - Typical CB-1750/2500/3250 Furnace Installation

1 FT.

I88555-G

4-2

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Selecting a Location

Guidelines for Selecting a Location

The location you select for your furnace must allow the following:

• Unobstructed, even heat distribution.

• Safe, easy access for servicing.

• Unobstructed passage for shop vehicles and equipment.

• Proper clearances from combustibles. Verify according to your local safety codes.

• Adequate combustion air per local codes.

• Proper stack installation.

WARNING: Adhere to the following minimum clearances from combustible surfaces and

to provide adequate clearance for servicing (also refer to Figure 4B for visual reference); failure to maintain proper clearances may result in re, explosion, personal injury or death.

CLEARANCES FOR UNIT HEATER INSTALLATION WITH SIDE AIR DISCHARGE

• TOP (of furnace) .............................. 12"

• FRONT (burner) ............................... 60"

• SIDE with Air Discharge ................... 60"

• OTHER SIDE ................................... 18"

• CHIMNEY CONNECTOR ................ 18"

• REAR (from blower) ......................... 2"

• BOTTOM .......................................... 24"

REAR 2"

CB-140 / CB-1750 / CB-2500 / CB-3250 FURNACES

MINIMUM DISTANCES

TOP

12"

18" OTHER SIDE

(WITHOUT AIR DISCHARGE)

CLEARANCES FOR UNIT HEATER INSTALLATION WITH BOTTOM AIR DISCHARGE

• TOP (of furnace) .............................. 12"

• FRONT (burner) ............................... 60"

• SIDE (with or without stack) ............. 18"

• CHIMNEY CONNECTOR ................ 18"

• REAR (from blower) ......................... 2"

• BOTTOM (CB-1750) ........................ 38"

• BOTTOM (CB-2500 and CB-3250) .. 60"

CLEARANCES FOR CENTRAL FURNACE INSTALLATION

• TOP (of furnace) .............................. 12"

• FRONT (burner) ............................... 60"

• SIDE without stack ........................... 18"

• CHIMNEY CONNECTOR ................ 18"

• REAR (from blower) ......................... 2"

• BOTTOM .......................................... 24"

• WARM AIR DUCTS within 3ft. ........ 6"

18" CHIMNEY CONNECTOR

60" AIR DISCHARGE SIDE

96 " BOTTOM - IF THERE IS POTENTIAL

FOR GASOLINE FUMES

24 " BOTTOM - IF THERE IS NO POTENTIAL

FOR GASOLINE FUMES

Figure 4B - Clearances from Combustibles

WARNING: Codes may require

that your furnace is mounted a

minimum of eight (8) feet off the ground when

installing the furnace in a repair facility. Refer

to NFPA-88B, Standard for Repair Garages, Chapter 3, Hazards, Sec. 3-2.3.1.

60" FRONT

I88600-E

4-3

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Mounting the Furnace

After selecting a safe and appropriate location for your furnace, construct the mounting system as

required by the location and the following specications.

Ceiling Mounting

WARNING: To prevent serious personal injury, ensure that your furnace mounting system can

safely bear the suspended weight of the furnace and allow safe servicing of furnace components.

Use adequately sized square tubing or angle iron bridged across sufcient structural members to safely

support the furnace.

1. Refer to Figure 4C.

2. Follow the instructions as provided in the diagram.

3. Use a spirit level to make sure the cabinet is level side to side and front to back.

CEILING MOUNTING SYSTEM

WARNING! USE MINIMUM 2-1/2 X 2-1/2 X 1/4" ANGLE

IRON BEAMS, BRIDGED ACROSS SUFFICIENT

STRUCTURAL MEMBERS TO SAFELY

SUPPORT FURNACE

(4) 5/8 "ALL THREAD" SUPPORT RODS

THREAD SUPPORT RODS TO COUPLING NUTS IN FURNACE CABINET

WARNING! MAKE SURE TO USE LOCKNUTS WHEN FASTENING THE RODS TO THE COUPLING NUTS

ANGLE IRON SUPPORT

BEAMS

CB-525-S2

BURNER

CONNECTOR

BLOCK

DOUBLE NUTS

AIR OIL

R. H. FURNACE BREECH

I88446-E

Figure 4C - Ceiling Mounting Installation Overview

4-4

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Mounting the Furnace (continued)

Raised Platform Mounting

WARNING: To prevent serious personal

injury, make sure the platform is designed

to safely bear the weight of the furnace and allow safe servicing of furnace components. The platform

must be constructed of non-combustible materials (e.g. steel) and must be securely anchored to an adjacent wall.

1. Refer to Figure 4D, and follow the

instructions as provided in the diagram.

Floor Mounting

WARNING: To prevent serious personal

injury, make sure the oor can safely bear the

weight of the furnace.

AIR OIL

8 FEET MINIMUM FROM FLOOR TO

CAUTION: If you are installing your furnace

FURNACE CABINET IF THERE IS POTENTIAL

FOR GASOLINE FUMES. REFER TO NFPA 88-B.

in an area with a combustible oor (e.g. over the top of a parts room or on a mezzanine) and the bottom of the furnace is less than 24" above the oor,

I88447-C

you must construct a non-combustible oor as shown in Figure 4E. Refer to NFPA-31 or CSA-B-139.

Figure 4D - Furnace Installed on

Raised Platform

NOTE: If the bottom of the unit is more than 24" above the oor, a support stand can be constructed

out of square tubing or angle iron adequately sized to safely support the weight of the furnace. A minimum stand height of 30" is recommended to allow for easy ash cleanout and servicing of the

heating equipment.

NOTE: Make sure that blank cover panels are installed over the bottom air discharge opening to allow

safe oor mounting.

Constructing a non-combustible oor

1. Determine the size of oor you will need to construct:

• Measure the width and length of the cabinet of the furnace.

• Add 12" (minimum) to all sides of the cabinet to achieve the total measurement for the non-combustible oor. EXAMPLE: The CB-1750 measures 55" long x 27" wide. 55" + 12" + 12" = 79" long 27" + 12" + 12" = 51" wide

2. Refer to Figure 4E. Install two (2) pieces of 5/8" sheet rock on top of the combustible material (wooden oor, wooden beams, etc.) The sheet rock must be cut to the size of the total non-combustible oor area.

4-5

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Constructing a Non-Combustible Floor (continued)

3. Place a sheet of 24-gauge (minimum) galvanized sheet metal on top of the 5/8" sheet rock;

the sheet metal must cover the sheet rock completely.

4. Place 4" thick (minimum) hollow masonry block, end to end, on top of the 24-gauge sheet metal

to make a solid foundation. Be sure to add center cross blocking to safely and adequately support the furnace.

5. Place a 24-gauge sheet metal pan with a 1" containment lip on top of the masonry blocks. This

will provide containment of any oil that may be spilled while working on the furnace.

6. Position the furnace on top of the sheet metal pan; make sure you maintain the extra 12"

minimum clearance on all sides of the cabinet.

7. Ensure that the installation adheres to all clearances from combustibles as stated at the beginning of Section 4 in this manual.

8. After positioning the furnace cabinet on the sheet metal pan, install 2" tall (minimum) cinder blocks (4) under each corner of the furnace to elevate the cabinet off the sheet metal pan to allow clearance for installation of ttings on the connector block.

MIN. 24 GA STEEL PAN WITH MIN. 1 INCH (2.5 CM) LIP FOR OIL CONTAINMENT

8 INCHES (20 CM) TALL CINDER BLOCK

MIN. 24 GA STEEL

FIREGUARD SHEETROCK OR EQUIVALENT

COMBUSTIBLE MATERIAL

MIN. 18" (46 CM)

MIN. 2" (5 CM) TALL MASONRY BLOCKS TO ALLOW CLEARENCE FO INSTALLATION OF FITTINGS ON THE CONNECTOR BLOCK

AIR OIL

Figure 4E - Furnace Installed on Non-Combustible Floor

MIN. 18" (46 CM)

I88462-B

4-6

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Oil Tank Installation Specications

Ensure that your tank installation adheres to the following safety guidelines as stated here and in Section 1 of this manual.

The tank safety label (shown at right) also summarizes these important specications for tank

installation and usage. If you do not have a copy of this label, please contact your Clean Burn dealer for

a copy, which is to be afxed directly to your used

oil supply tank.

• The tank installation must meet all

national and local codes. Consult your

local authorities for more information as necessary.

• The tank must be listed to UL 80, UL 142, or

equivalent standard.

• Use a minimum 250-gallon tank DO NOT

use a 55-gallon drum as a substitute for an

appropriate tank. The tank must be large enough to allow water, sludge, etc. to settle out of the used oil.

• Single wall tanks should have a manual

shut-off type valve on the side of the tank to allow the water, sludge, etc. to be drained from the bottom of the tank.

• All unused openings in the tank must be plugged or capped off.

• For optimal system functioning, Clean Burn Recommends inside tank installations as shown in Figures 4A, 4F, and 4J.

• Some codes require the tank to be vented to the outside of the building using iron or steel

pipe and ttings with an approved vent cap.

• Carefully review the oil tank and pump installation details as shown in Figures 4A, 4F, and 4J. Pertinent information also supplied with the metering pump and oil line

installation procedures (following in Sec. 4).

• Ensure that the oil supply tank is properly maintained; refer to Section 9 in this manual

for related procedures.

WARNING

Fire and explosion hazards To prevent serious injury or death:

ONLY place these listed substances in this used-oil supply tank:

• Used crankcase oil

• Used automatic transmission uid

• Used hydraulic oil

• #2 fuel oil Do NOT place ammable or corrosive substances such as gasoline, chlorinated oils, solvents, paint thinners, or any other unsafe substances in this used-oil supply tank.

Do NOT weld or allow open ame within 35 feet of this used-oil supply tank.

Tank installation MUST comply with NFPA 30 and 31 Fire Codes, including the following requirements:

• Tank must be listed to UL 80 or UL 142.

• Tank must be vented to outside.

• Emergency vent or explosion relief must be installed on tank.

• Inside ll allowed only with funnel including 1/4 turn-to-close fall valve, which must be closed after lling.

• All other openings must be plugged

• All oil lines must be constructed of copper, steel, or brass components. Do NOT use rubber or plastic tubing or piping, or any other inappropriate material.

Follow all instructions for tank installation in Operator's Manual.

42366 Rev. 2

ATTENTION: For outside tank installations and/or tanks larger than 500 gallons, contact your

local Clean Burn Distributor for installation recommendations and specications.

4-7

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Oil Tank Installation Specications (continued)

TANK VENT KITS AVAILABLE FROM CLEAN BURN

Example Oil Tank Install Diagram

PRESSURE

PRESSURE RELIEF OIL LINE BACK TO THE TANK

MUSHROOM CAP VENT

STEEL PIPE (USER SUPPLIED)

FUNNEL WITH BALL VALVE

EMERGENCY VENT

LINE

RELIEF

GAUGE

ROTATION

INLET

PUMP

SUCTION LINE

ASSEMBLY

CHECK VALVE

FILTER SCREEN

42366

OIL STORAGE TANK

CLEAN-OUT (TANK DRAIN)

Figure 4F - Typical Metering Pump Installation with Inside Tank

Installing the Tank Vent and Emergency Vent

Some codes require that you install a tank vent (to the outside) and an emergency vent for your tank

as shown in Figure 4F. Tank Vent Kits are available from Clean Burn; contact your local Clean Burn dealer to order. Be sure to check your local codes for any additional tank installation requirements, and adhere to the following installation guidelines:

• Install a length of minimum 2" steel pipe (user-supplied) terminating outside with a proper

vent cap as shown in Figure 4F. Consult local codes for information and requirements concerning the proper venting of oil storage tanks.

• Install an emergency vent as shown in Figure 4F. Contact your tank manufacturer for information concerning the proper emergency vent for your tank.

I88669-H

4-8

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Installing the Metering Pump

Preparing for Installation

Before starting installation of the metering pump, review Figures 4G, 4H, and 4I to become familiar

with the metering pump components. You will also need to accomplish the following activities:

• Verify that you have the proper metering pump for your furnace (note the specic gear motor part numbers shown in Figure 4H).

• Gather all required tools and materials as needed for installation; as indicated in the following procedures, some materials (e.g. ttings, tubing) are to be user-supplied.

• Standard mounting is vertical mounting on a wall; this pump installation is recommended. Alternate mounting is horizontal mounting on a bracket. Be sure to carefully follow the appropriate procedures/diagrams for pump mounting.

• For optimal metering pump functioning, mount the pump at a distance from the oil tank that will comply with the following requirements: The suction oil line may NOT exceed 6 feet TOTAL vertical lift AND 4 feet TOTAL

horizontal lift.

Standard Mounting: Vertical Positioning

1. Refer to Figures 4G, 4H, and 4I. Note that the metering pump is shipped with the pump head

already positioned for vertical wall mounting.

2. Use the appropriate type of bolts and washers (user-supplied) to securely mount the metering

pump to the appropriate wall in your building at a distance from the tank that complies with the suction oil line requirements.

I88727-B

1/8" OUTLET

GAUGE

RELIEF

INLET

ROTATION

Figure 4G - Vertical Mounting of the Metering Pump

BLEEDER VALVEINLET

4-9

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

# PART # DESCRIPTION

1 33363 CAPACITOR - GEARMOTOR

2 see chart GEARMOTOR 3 11322 MOUNT - METER PUMP 4 32037 1/8 NPT X 1/4 TUBE COMPRESSION FITTING 5 N/A 1/4 COPPER OR ALUM. TUBING

6 N/A 3/8 OR 1/2 TUBE FLARE NUT

7 N/A 3/8 OR 1/2 COPPER OR ALUM. TUBING

8 N/A 1/8 M NPT X 3/8 OR 1/2 FLARE

9 32526 MINI BALL VALVE 1/8 MNPT X 1/8 FNPT 10 32475 METER PUMP 11 32467 1/4" X 3" NIPPLE 12 32210 1/4" STREET ELBOW 13 32336 1/4" X 3/4" BRASS BUSHING 14 32123 VACUUM GAUGE 15 32127 CANISTER FILTER- LENZ 16 32430 1/2" x 3/4" BUSHING, BRASS 17 32446 1/2" X 5" NIPPLE 18 32429 1/2" STREET TEE, BRASS 19 32137 1/2" HEX NIPPLE 20 32142 1/2" BALL VALVE 21 32062 1/4" NPT x 1/4" TUBING FITTING 22 32443 1/4" x 1/2" BUSHING 23 32141 1/2" NPT x 1/2" TUBING FLARE ADAPTER 24 32140 1/2" LONG NUT 25 32139 1/2" NPT x 1/2" TUBING SLIP ADAPTER 26 32442 2" x 1/2" x 1/2" NPT DUPLEX HEX BUSHING 27 32021 3/4" CHECK VALVE 28 32061 3/4" CHECK VALVE SCREEN 29 32445 1/2" PIPE CAP

TO BURNER

SUPPLY

OUT

GAUGE

A2RA-7720

INLET

ROTATION

RELIEF

RETURN

TO TANK

PACKAGED WITH

CLEAN BURN

EQUIPMENT

SINGLE PIECE OF COPPER TUBING (USER SUPPLIED)

PACKAGED WITH CLEAN BURN EQUIPMENT

CLEAN BURN

MODEL

CB-230

CB-2500 CB-3250 33572

CB-5000

CB-500-CTB 33558

GEARMOTOR

PART #

33291CB-140 33293 33353CB-1750 33354

33355CB-3500 33356 33507CB-200-CTB 33295CB-350-CTB

I89052-C

Figure 4H - Metering Pump Component Detail

4-10

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Installing the Metering Pump (continued)

Alternate Mounting: Horizontal Positioning

ATTENTION: If the metering pump is to be mounted horizontally or on a bracket as shown in Figure 4I, the pump head must be rotated counterclockwise so that it is aligned in a horizontal position.

The gauge arrow on the pump head must point up, or the pump will not prime.

1. Refer to Figures 4H and 4I.

2. Remove the two pump mounting bolts. The coupling is keyed and does not have set screws.

3. Rotate the pump head 180 degrees to the horizontal position as shown in Figure 4I.

4. Reinstall and tighten the two pump mounting bolts.

5. Use the appropriate type of bolts and washers (user-supplied) to securely mount the metering

pump to the mounting bracket, which is to be installed on the appropriate wall in your building at a distance from the tank that complies with the suction oil line requirements.

ATTENTION !

THE PUMP HEAD MUST BE POSITIONED SO THE GAUGE ARROW POINTS UP OR THE PUMP WILL NOT PRIME

GAUGE

RELIEF

A2RA-7720

INLET

RECOMMENDED SETUP PUMP IS MOUNTED LEFT ON WALL

I88708-B

ALTERNATE MOUNTING

(NOT RECOMMENDED)

BLEED VALVE IS NOW CLOSE

TO THE WALL MAKING THE

BLEEDING DIFFICULT

INLETINLET

GAUGE

RELIEF

A2RA-7720

INLET

ROTATION ROTATION

A2RA-7720

INLET

GAUGE RELIEF

A2RA-7720

INLET

ROTATION

INLET

NON-STANDARD SETUP PUMP HEAD HAS BEEN ROTATED 90° CCW FOR HORIZONTAL MOUNTING

(THE 1/4" STREET ELBOW AND 1/4" X 3" NIPPLE CHANGE PLACES IN THE PLUMBING SEQUENCE)

RELIEFGAUGE

ROTATION

Figure 4I - Proper Positioning of Metering Pump Head

4-11

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Wiring the Furnace and Pump

WARNING: To avoid electrical shock, make sure that power to the furnace is turned OFF

before connecting any wires. A licensed electrician should install all wiring to your furnace. All wiring

must be in accordance with the National Uniform Electrical Code and local codes. Properly size all wires and use

electrical conduit for all electrical lines.

Wiring your furnace involves the installation of two lines:

(1) A dedicated electrical line to the furnace (2) A pump electrical circuit from the furnace to the metering pump Necessary wiring specications are provided in this section and in the Wiring Schematics located in

Appendix B at the back of the manual.

Wiring to the Furnace

1. Install a dedicated electrical circuit to the BURNER junction box on the CB-1750 / 2500 and to the BLOWER junction box on the CB-3250. Refer to NFPA-70 for wire size and distances.

2. Wire the furnace according to the Wiring Schematic in Appendix B. Ensure that the ground

 wireisattachedtotheGREENgroundscrewonthefurnacejunctionbox.

3. Check for correct voltage at the furnace, and refer to the following chart.

ATTENTION: Incorrect voltage will severely damage the blower motor/furnace components.

DO NOT operate your furnace on any non-specication power system.

WARNING: DO NOT tie into an existing circuit, or electrical overload may occur.

Model Voltage Breaker Size Circuit Hertz

CB-1750 110/120 20 amps Dedicated 60 CB-1750 (w/Options) 110/120 30 amps* Dedicated 60 CB-2500 110/120 30 amps Dedicated 60 CB-3250 208/240 30/30 amps Dedicated 60 CB-3250 (w/Options) 208/240 35/35 amps* Dedicated 60

*NOTE: When installing any optional equipment (e.g. air compressor or draft inducer), please refer to the "w/Options" breaker size above. Make sure a qualied electrician properly sizes and

installs this electrical circuit. Refer to NFPA-70 for wire size and distances.

4. DO NOT turn on main power until instructed to do so.

Wiring to the Metering Pump

WARNING: DO NOT wire the pump directly into your building's electrical system. The pump

must be activated (receive power) from the burner via the pump electrical circuit. DO NOT wire

the pump directly to a wall outlet so that it runs continuously; this will seriously damage your metering

pump and/or furnace and may result in a re or explosion hazard.

1. Install the pump electrical circuit from the furnace to the metering pump location.

2. Wire the pump circuit according to the Metering Pump Wiring Schematic in Appendix B at the

back of this manual.

4-12

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Installing the Suction Oil Line Components

ATTENTION: It is critical that you adhere to the following specications for suction oil line

installation (oillinefromthetanktothepump). If these specications are not met, the metering pump will not function correctly and the burner will shut down on reset. The majority of service problems with the metering pump are caused by leaks at ttings in the suction oil line; these problems are eliminated by ensuring a 100% airtight suction oil line which slants up to the pump.

All suction oil line components must be installed as shown in Figures 4H and 4J. Suction line size is 1/2" diameter. Proper installation allows the suction oil line to be lled with used oil during initial

priming.

The suction oil line may NOT exceed 6 feet TOTAL vertical lift and 4 feet total horizontal lift

(which equals 6.0” hg maximum operating vacuum). To determine if your suction oil line will meet this specication for maximum operating vacuum, base the calculation for your installation on the following

equivalents:

(1) vertical foot = 0.75” hg (vacuum) (4) horizontal feet = 0.75” hg (vacuum)

NOTE: ALSO ADD 0.75" hg to the nal sum to account for every oil lter, shut-off valve, and check valve on the suction side of the pump assembly.

Sample calculation: (6) vertical feet x 0.75" = 4.50" hg AND (4) horizontal feet = 0.75" hg

4.50" hg + 0.75" hg + 0.75" hg = 6.00 " hg vacuum

The metering pump must be installed with a 3/4" check valve at the end of the suction oil line, or the pump will not maintain its prime.

Use Permatex #2 non-hardening gasket sealer on every threaded tting. DO NOT use teon tape or

teon pipe dope compounds; the teon can ake off and cause damage to the pump head.

The suction oil line must be 100% airtight for proper system functioning. Use only high-quality are ttings for the copper tubing. DO NOT use compression ttings. DO NOT use any steel pipe unions. DO NOT use sweat copper pipe. These types of ttings cause air leaks in the suction oil line and will require re-installation.

The suction oil line must slant up to the pump; any high spots will trap air and will not allow the pump to prime.

1. Assemble the suction oil line ttings (fromthemeteringpumptothecanisterlter): a. Refer to Figure 4H for a detailed look at the metering pump components and ttings. b. Remove the plug from the 1/4" inlet port of the pump. c. Install the 1/4" x 3" brass nipple into the 1/4" inlet port on the pump. d. Install the 1/4" brass street elbow onto the 3" brass nipple; turn the tting onto the nipple

until it is tight and faces away from the pump mounting plate.

e. Prepare the canister lter for installation:

• Install the 3/4" x 1/4" brass hex bushing into the outlet port of the canister lter.

Checkthedirectionofthearrowfortheproperow.

• Install the 3/4" x 1/2" brass bushing into the inlet port of the canister lter. (1.) (e.) Prepare the canister lter for installation (continued):

4-13

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Installing the Suction Oil Line Components (continued)

• Remove the plug from one of the 1/8" gauge ports in the canister lter and install the vacuum gauge. Seal the threads of the gauge with Permatex #2 non-hardening gasket

sealer.

• Install the 1/2" threaded pipe adapter into one side of the 1/2" ball valve.

• Install the 1/2" MPT x 1/2" are adapter into the other side of the ball valve.

• Install this assembly into one side of the 1/2" brass tee.

• Install the assembled 1/2" tee into the 3/4" x 1/2" brass bushing, which is installed in the inlet port of the canister lter. Make sure that the 1/2" are adapter is pointing

down.

• Install the canister lter assembly onto the 1/4" brass street elbow as shown in Figure 4H. The canister lter must be installed with the arrow pointing towards the pump (direction of oil ow).

• Install the 1/2" x 5" brass nipple into the top side of the 1/2" brass tee assembly.

• Loosely install the 1/2" brass cap onto this nipple. DO NOT tighten the cap at this

time.

MAXIMUM 6 FT

PRIME AND/OR THE FLOW RATE FROM

SUCTION LIFT OR THE PUMP WILL NOT

CAUTION: DO NOT EXCEED 6 FT VERTICAL

COMPRESSED AIR LINE

THE PUMP MAY DECREASE

CLEAN-OUT

CONNECTOR BLOCK

WITH BALL VALVE

EMERGENCY VENT RELIEF

AIR OIL

OIL FLOW

FUNNEL

CONTINUOUS PIECE OF COPPER TUBING INSIDE TANK: 1/2" O.D.

CHECK VALVE

CHECK VALVE SCREEN

CHECK VALVE IS MINIMUM 12 INCHES OFF TANK BOTTOM TO CREATE SLUDGE TRAP

PRESSURE OIL LINE

BALL VALVE

RADIAL BEND MADE WITH TUBING BENDER

SUCTION LINE

INSTALL SLIP FITTING TO HOLD TUBING

IN PLACE

1 FT.

CANISTER FILTER

IN SUCTION LINE

OIL PUMP ELECTRICAL CIRCUIT

VENT

CAP

I88777-E

Figure 4J - Oil Line Installation Overview

4-14

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

2. Install the suction oil line (fromthethetanktothecanisterlter):

a. Refer to Figures 4H and 4J. b. Prepare a piece of 1/2" O.D. copper tubing (user-supplied) which will function as the pick-

up line from the tank to the canister lter. This copper tubing must have the following specications:

• The tube must be one continuous piece of 1/2" O.D. copper tubing with no kinks or ttings.

• The tube is to slant up from the tank to the pump with no loops or high points to trap air.

c. Locate the 2" MPT x 1/2" FPT x 1/2" FPT duplex, slip-thru hex bushing (which will eventually

be installed into one of the 2" openings on the tank). Notethatthettingismarked"S"for

suction and "R" for return.

d. Install the 1/2" MPT x 1/2" slip tting into the "S" side of the 2" duplex slip-thru hex bushing. e. Install the 1/4" MPT x 1/4" compression tting into the 1/2" x 1/4" brass bushing. f. Install the 1/2" x 1/4" brass bushing into the "R" side of the 2" duplex slip-thru hex bushing. g. Measure the height of the oil tank (from the bottom of the tank, NOT the oor) to the 2" opening

that you are going to use for the supply oil line. Deduct 12" (305mm) from this measurement and transfer this new measurement onto the 1/2" O.D. copper tubing.

h. Remove the locking nut and ferrel sleeve connector from the 1/2" slip tting, and slide them over

the copper tubing.

i. Slide the 1/2" O.D. copper tubing through the 1/2" slip tting, which is installed in the "S" side

of the 2" hex bushing.

j. Install the screen into one side of the 3/4" check valve (making sure the arrow is pointing away

from the screen assembly).

k. Install the 3/4" x 1/2" brass bushing into the 3/4" check valve. l. Install the 1/2" MPT x 1/2" are adapter into the 3/4" x 1/2" brass bushing. m. Slide the 1/2" are nut over the end of the 1/2" copper tubing, and are the end of the tubing.

NOTE: Use a high-quality aring tool (such as a Ridgid Flaring Tool) to ensure that all ares are made properly (i.e. so they will be 100% airtight).

n. Install the ared oil line and nut onto the assembled check valve/screen and tighten. o. Pick up the assembled oil line, and carefully guide the end of the tubing with the check valve

through the 2" tank opening.

p. Apply Permatex #2 non-hardening gasket sealer (or equivalent) to the threads of the 2" duplex

slip-thru tank bushing, and tighten this tting into the tank.

q. Pull the 1/2" copper tubing back up through the slip tting until you see the mark that you put

on the tubing earlier. Holding the tubing with one hand, push the ferrel sleeve connector and

locking nut down the tubing, then tighten onto the 1/2" slip tting. The oil line is now installed

in the correct position off of the bottom of the tank.

r. Carefully bend the oil line up to the canister lter; use a spring bender over the oil line while

bending the tubing to prevent kinks in the oil line. Allowing for the are nut, cut off the excess

tubing.

s. Install the 1/2" are nut onto the tubing, and are the end of the tubing. t. Install the end of the tubing with the are nut onto the 1/2" are adapter (on the ball valve

assembly at the canister lter).

u. Install a vent from the tank to the outside of the building according to code. The tank must be

properly vented to allow air to enter the tank as oil is pumped out and to safely vent fumes to the

outside. See Figure 4J.

v. Install plugs in all other tank openings as required by code. w. Inspect the installation. For proper suction oil line operation, make sure all components are

installed and positioned as specied in this manual.

4-15

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Installing the Pressure Relief Oil Line Back to the Tank

ATTENTION: It is critical that you adhere to the following specications for plumbing the pressure

relief back to the tank.

The metering pump requires the installation of a pressure relief oil line back to the tank that you are

pulling oil from as shown in Figures 4H, 4J, and 4K.

• The pressure relief will open and relieve pressure if there is a restriction in the pressure oil

line, clogged nozzle, etc.

Be sure to use Permatex #2 non-hardening gasket sealer to seal every threaded tting. DO NOT use teon tape or teon pipe dope compounds.

1. Refer to Figure 4K.

2. Remove the plug from the relief port on top of the metering pump head.

3. Install the 1/8 NPT x 1/4 tube compression tting in the relief port on top of the metering pump

head.

4. Install 1/4" O.D. copper tubing (user-supplied) from the pressure relief port back to the oil tank.

Refer to Figure 4J as needed.

# PART # DESCRIPTION

1 32475 METERING PUMP HEAD (7720) 2 32526 MINI BALL VALVE 1/8 MNPT X 1/8 FNPT 3 INSTALLER SUPPLIED 1/8 MNPT X 3/8 OR 1/2 FLARE 4 INSTALLER SUPPLIED 3/8 OR 1/2 COPPER OR ALUM. TUBING 5 INSTALLER SUPPLIED 3/8 OR 1/2 TUBE FLARE NUT 6 INSTALLER SUPPLIED 1/4 COPPER OR ALUM. TUBING 7 32037 1/8 MNPT X 1/4 TUBE COMP. FITTING

SUPPLY

TO BURNER

RETURN

TO TANK

Figure 4K - Pressure Relief Oil Line Back to the Tank

GAUGE

A2RA-7720

RELIEF

INLET

R H ROTATION

4-16

I89004-D

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Installing the Pressure Oil Line Components

ATTENTION: It is critical that you adhere to the following specications for pressure oil line installation (oil line from the pump to the furnace); if these specications are not met, the metering

pump will not function correctly and the burner will shut down on reset.

• The parameters for pressure oil line installation are: Length of Pressure Line Line Size

Up to 100 feet 3/8" O.D. copper tubing (Please note that some installations will allow for a greater pressure line length. Contact your Authorized Clean Burn Distributor for more information.)

• The pressure oil line must slant up to the burner with no loops or high points to trap air.

• Local codes may require the installation of an in-line "Fire-O-Matic" safety valve. Be sure to check all appropriate codes to ensure compliance.

1. Refer to Figures 4H, 4J, and 4K.

2. Make sure you have purchased all the necessary ttings to complete the installation correctly.

3. Install the ttings and components as shown in the related illustrations. Be sure to use Permatex #2 non-hardening gasket sealer to seal every threaded tting. DO NOT use teon tape or teon

pipe dope compounds.

Installing the Compressed Air Line

NOTE: Your air compressor system must supply air pressure to the furnace with the following minimum requirements: 50 psi and water trap or dryer. If you do not have shop air, an optional air compressor is available. Contact your local Clean Burn dealer for more information.

1. Run a compressed air line from your shop air to the connector block on the furnace. Use minimum 1/4" O.D. copper tubing or equivalent for the compressed air line.

2. Install an easily accessible shut-off valve in the air line so the burner can be serviced without

shutting off the shop air in your service area.

3. If necessary, install a pressure regulator (additional to the burner air regulator) in the air line, and set it at 50 psi.

ATTENTION: DO NOT feed full shop air pressure to the burner or damage to burner components may occur.

4. Install a water trap or extractor/dryer in the air line with an automatic drain so compressed air

(rather than water) is supplied to the burner.

ATTENTION: Water must not be fed to the burner, or the ame will be extinguished and the burner will shut down. Be sure to drain water from your compressor tank on a regular basis to keep water out of the air line.

4-17

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Installing the Stack

WARNING: Inappropriate stack materials or improper stack design/installation can adversely affect the proper, safe operation of your furnace. Contact your Clean Burn dealer to purchase the proper stack components for your furnace.

Stack designs are generally classied as follows: (1) "Class A" stack through the ceiling of the building (refer to Figure 4L) (2) "Class A" stack through the sidewall and up the side of the building (refer to Figure 4M)

Stack Design and Specications

ATTENTION: Thestackdesignmustbesingle and dedicated for each unit (furnace) according to thefollowingspecications. A single stack serving more than one unit MUST be engineered/certied

for that specic installation (ref. NFPA 211, 3.3.39 and 10.2.1; NFPA 31 6.5.16-18). Failure to adhere to

this rule may result in less than optimal system performance.

Figures 4L and 4M illustrate recommended stack designs. Choose the stack design which is appropriate

for your furnace installation and review all specications provided in the corresponding drawing. When designing your stack, adhere to the following specications:

• Models CB-1750, CB-2500 and CB-3250 require minimum 8" I.D. stack components.

• Ensure that the vertical stack height is atleast10feetPLUSonefootforeverytting (e.g. 45 degree, 90 degree, or T) in the stack run. If needed, increase the vertical length of the

stack or install a draft inducer to obtain -.02" W.C. draft over re. (Section 8 contains details on adjusting the draft.)

• Keep the horizontal stack run as short as possible; slant it upward at a minimum of 1/4" per foot of run.

• Keep the stack design simple. Complicated stacks (with long runs and many turns) reduce draft and result in poor burner performance. Your stack may include only one 90 degree

turn. All other stack turns must be at 45 degrees or less to ensure optimal draft and burner

performance. NOTE: If you plan to use an existing masonry chimney, the chimney must be lined and inside the building. Exterior masonry chimneys chill the stack gases and result in poor draft and poor burner performance.

ATTENTION: If you have an exhaust fan(s) in your shop, itiscriticalthatyouhaveadequate makeupair(sourceoffreshairtoreplacethestaleairexhaustedbythefan). When an exhaust fan is

run without adequate make up air, the resultant vacuum in the building will draw combustion products back into the burner. This back draft causes poor burner performance and may damage vital burner

components. Refer to Section 8 in this manual for additional information.

Stack components should be installed in the following order:

(1) Inside stack (the stack components from the furnace breach to within 18" of the ceiling, roof, or sidewall of your building) (2) Barometric damper (3) "Class A" stack penetration through the ceiling, roof, or sidewall (4) "Class A" stack on the exterior of the building (5) "Class A" stack cap

4-18

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Installing the Stack (continued)

"CLASS A" STACK CAP - NON-RESTRICTIVE TYPE TO ALLOW

FREE FLOW OF THE STACK GASES

NOTE: THE LAST STACK SECTION SHALL EXTEND AT LEAST 90 cm (3') HIGHER THAN ANY RIDGE, PARAPET, WALL OR ROOF STRUCTURE WITHIN 3 m (10') OF IT.

3 m (10')

"CLASS A" KIT FOR

INSTALLING "CLASS A" STACK THROUGH CEILING

-0.02 W.C. DRAFT OVERFIRE IS ESSENTIAL FOR PROPER FURNACE OPERATION. SEE SECTION 8

CLEAN OUT CAP

AIR OIL

90 cm (3')

STACK SIZE:

MIN. 20 cm (8")

6 mm (1/4") HOLE FOR SETTING DRAFT. ADJUST BAROMETRIC DAMPER FOR -.04 W.C. DRAFT AT BREECH

WARNING! ENSURE PROPER CLEARANCES BETWEEN STACK COMPONENTS AND COMBUSTIBLES PER ALL APPLICABLE CODES.

WARNING! MAKE SURE TO INSTALL THE PROPER ROOF SUPPORT SYSTEM TO SAFELY SUPPORT THE STACK

WATERTIGHT ROOF FLASHING

ATTENTION:

BAROMETRIC DAMPER MUST BE INSTALLED SO

IT IS FACING AWAY FROM THE BLOWER TO PREVENT EXHAUST GASES FROM

BEING SUCKED OUT OF THE

DAMPER OPENING

"CLASS A" STACK COMPONENTS

SINGLE WALL STACK

I88449-C

INSULATED STACK WITH A STAINLESS STEEL LINER

EVERY FITTING TO MAINTAIN PROPER DRAFT OVERFIRE

3m (10') MIN. VERTICAL STACK HEIGHT PLUS 30 cm (1') FOR

MIN. 24 GAUGE

Figure 4L - Installation of "Class A" Stack Through Roof/Ceiling

4-19

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Installing the Stack (continued)

WARNING! ENSURE PROPER CLEARANCES BETWEEN STACK COMPONENTS AND COMBUSTIBLES PER ALL APPLICABLE CODES.

NOTE: THE LAST STACK SECTION SHALL EXTEND AT LEAST 3 FEET HIGHER THAN ANY RIDGE, PARAPET, WALL OR ROOF STRUCTURE WITHIN 10 FEET OF IT.

"CLASS A" STACK CAP - NON-RESTRICTIVE TYPE TO ALLOW

FREE FLOW OF THE STACK GASES

10 FT.

WARNING! MAKE SURE TO INSTALL

THE PROPER WALL SUPPORT SYSTEM

TO SAFELY SUPPORT THE STACK

1/4" HOLE FOR SETTING DRAFT. ADJUST BAROMETRIC DAMPER FOR -.04 W.C. DRAFT AT BREECH

"CLASS A" STACK PENETRATION AND CLEAN-OUT TEE

3 FT.

"CLASS A" STACK COMPONENTS

STACK SIZE MIN. 8"

10 FT. MINIMUM VERTICAL STACK HEIGHTPLUS 1 FT.

FOR EVERY FITTING TO MAINTAIN PROPER DRAFT OVERFIRE

INSULATED STACK WITH A STAINLESS STEEL LINER

-0.02 W.C. DRAFT OVERFIRE IS ESSENTIAL FOR PROPER FURNACE OPERATION. SEE SECTION 8

BAROMETRIC DAMPER

DRAFT

AIR OIL

SINGLE WALL STACK

MIN. 24 GAUGE

I88450-D

Figure 4M - Installation of "Class A" Stack Through Sidewall

4-20

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Installing the Interior Stack

WARNING: Single wall stack components may be used only for those portions of the stack which are located inside your building and away from any re/burn hazards.

1. Install the single wall stack with proper clearances from combustibles. Also ensure that the stack

is located a safe distance from all shop personnel.

2. Install an elbow at the junction of the horizontal and vertical stack components to allow for easy

cleaning of the stack. ATTENTION: Avoid additional 90-degree turns in the stack. Each additional 90-degree turn

slows down stack gases, creates back-pressure, and results in repeated burner shutdown and unnecessary service calls. All other turns in the stack should be at a 45-degree (or smaller) angle. NOTE: IMPORTANTforCanadianInstallations - Local codes may require the installation of a clean-out tee.

Installing the Barometric Damper

1. Refer to Figure 4L. Install a single wall tee (min. 24 gauge) after the 90 degree elbow in the straight vertical stack section within three to ve feet of the furnace breach. For horizontal stack runs (as shown in Figure 4M), install the tee after the rst straight section of pipe.

NOTE: The tee is required to support the barometric damper. You must purchase this tee when

you purchase your stack materials (8" single wall tee - CB#70174).

2. Refer to Figure 4N. Install the barometric damper in the opening of the tee. Use a small spirit

level to make sure that it is properly level.

3. Install two self-tapping screws as shown in Figure 4N (i.e. one on each side of the barometric damper) to hold the damper in place. DO NOT install a screw at the bottom of the barometric damper, or the apper of the damper will not operate correctly.

NOTE: Specications for adjusting the barometric damper for proper draft overre are provided in Section 8 of this manual.

8" CLEAN BURN BAROMETRIC DAMPER INSTALLED IN SINGLE WALL TEE

Figure 4N - Installation of Barometric Damper

4-21

ADJUST THIS WEIGHT TO OBTAIN PROPER DRAFT

PART #

QTY

31170

I88539

8" BAROMETRIC DAMPER

DESCRIPTION

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Installing the Stack Safety Switch For Canadian Installations

NOTE: CSA Standards require that all heating equipment must be installed with a stack safety switch.

If your heating equipment is being installed in Canada, follow the instructions listed below.

CAUTION: For your safety and the safe operation of your heating equipment, the stack switch

must be installed by a qualied installer in accordance with the installation instructions provided

here. Wiring must be accomplished in accordance with all applicable codes. Failure to adhere to these

safety recommendations may result in serious personal injury and/or equipment damage.

1. Follow the instructions in the Operator’s Manual, Section 4 to install a proper stack, including the barometric damper which must be installed within 40 inches of the breach. NOTE: The barometric damper must be installed so that it is level and the apper moves freely.

2. Ensure that main power to the heating equipment is turned OFF.

3. Position the stack safety switch over the lip of the barometric damper as shown in Figure 4O.

4. Drill a 1/8” pilot hole for the mounting screw, and mount the stack safety switch using the

mounting screw supplied with the switch. NOTE: The mounting screw must not interfere with the free movement of the apper on the barometric damper.

5. Install the wall thermostat according to the instructions provided in the Operator’s Manual, Section 4. Wire the wall thermostat and stack safety switch in series as shown in Figure 4P.

Install the wire so that it is secured away from any hot surfaces.

6. When the heating equipment installation is completed, follow the instructions in the Operator’s Manual, Sections 5 and 6 to prime the pump and start/adjust the burner.

7. Follow instructions in the Operator’s Manual, Section 8 to check the draft; this is crucial for the proper, safe operation of the heating equipment.

Figure 4O - Stack Safety Switch Installed on the Barometric Damper

I88964

4-22

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Resetting the Stack Safety Switch

WARNING: BURN HAZARD! To prevent serious personal injury, be sure to allow ample

time, at least 30 minutes, for the stack, barometric damper, and switch to cool down before

attempting to access and service these components. It is crucial to identify the cause of the stack

obstruction (e.g. heavy snowfall) and correct it before resetting the stack safety switch and re-starting

the burner. DO NOT operate the heating equipment with an obstructed stack; failure to correct an

obstructed stack may result in re, explosion, and/or burn hazards causing serious personal injury or

death.

NOTE: In locations where heavy snowfall occurs, it is critical that the stack remain unobstructed by snow. For safe heating equipment operation, be sure to keep the area surrounding the stack clear of snow.

1. Before resetting the stack safety switch, check the stack to make sure it is clear of any obstructions.

2. Remove the cover from the stack safety switch, and push the small button in the middle of the switch.

3. Pushing the stack safety switch reset button will re-establish the thermostat circuit, and the burner will start (assuming the wall thermostat is calling for heat).

Understanding the Function of the Stack Safety Switch

The Stack Safety Switch monitors the temperature at the barometric damper on the stack and is designed to

detect the obstruction of the free ow of stack gases from the heating equipment and shut down the burner. Obstruction of the stack results in the “spillage” of stack gases from the barometric damper, which heats up the

switch. The switch then opens, disconnecting the thermostat circuit to the burner, and the burner shuts off.

Stack Safety Switch Specications

Switching Voltage 24 volts Switch OPEN Temperature 180 degrees F Switch Type L180, normally closed, manual reset

WALL

THERMOSTAT

T T

OIL

PRIMARY

Figure 4P - Stack Safety Switch Wiring Diagram

STACK SAFETY SWITCH

(MOUNTED ON

BAROMETRIC DAMPER)

4-23

I88965

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Installing the Stack Penetration

WARNING: When running the stack through your ceiling, roof, or sidewall, you must use Class A/UL 103 HT double-wall insulated all-fuel stack components with a stainless steel

liner. DO NOT run single-wall stack through your ceiling, roof or sidewall. NEVER locate a stack joint inside walls or in a joist spacer. Ensure proper clearances from combustibles per all applicable codes.

1. Refer to Figure 4L/4M as needed.

2. Follow the installation instructions provided by the stack manufacturer.

Installing the Exterior Stack

ATTENTION: All exterior stack pieces must be Class A/UL103 HT double-wall insulated all-fuel stack

components with a stainless steel liner.

• DO NOT use Class B or BW Vent/double-wall stack components (for gas red appliances only).

• DO NOT use Type L Vent/double-wall stack components (for approved fuel oil appliances only).

• DO NOT use black stack pipe (for solid fuel burning appliances only).

• DO NOT use single-wall stack for your exterior stack. Single-wall exterior stack chills the stack

gases and results in poor draft and poor burner performance.

1. Refer to Figure 4L/4M as needed.

2. Follow the installation instructions provided by the stack manufacturer.

3. Install water-tight roof ashing around the penetration of the exterior stack. NOTE: Clean Burn recommends the use of "Dektite" roof ashing (or equivalent) which ensures a water-tight seal when installed properly. Contact your local Clean Burn dealer for details.

Installing the Stack Cap

NOTE: Proper installation of a "Class A" stack cap ensures the free ow of stack gases which is

essential for optimal burner performance.

1. Refer to Figure 4L/4M as needed. Your stack cap should be classied as: "Class A" non-restrictive, all-fuel type.

2. Install the stack cap according to the manufacturer's instructions.

Installing the Optional Draft Inducer

ATTENTION: The draft inducer, Field brand model DI-2, is optional equipment and may be installed

to ensure proper draft. The Field brand draft inducer has been tested for use on Clean Burn furnaces. DO NOT use other models or brands of draft inducers.

Understanding the Importance of the Draft Inducer

The draft inducer is designed to aid in the removal of the natural draft created by the appliance to vent the combustion gases to the outside of the building. As the paddle wheel turns, a negative pressure is maintained within the stack so that the combustion gases can leave the furnace and travel out of the

stack. (See Figure 4Q.) Propersizing,installation,andadjustmentofthedraftinducerarecriticalfor

optimal draft inducer operation.

4-24

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Installing the Optional Draft Inducer (continued)

NOTE: Lubricate the motor as recommended by the Draft Inducer manufacturer.

OPTIONAL DRAFT INDUCER

"CLASS A" STACK

NOTE: INSTALL DRAFT INDUCER IN LAST SECTION OF VERTICAL STACK TO POSITION DRAFT INDUCER AWAY FROM FURNACE BREECH SO THE MOTOR DOES NOT

OVERHEAT. THIS ALSO REDUCES ASH ACCUMULATION IN THE DRAFT INDUCER.

DO NOT MOUNT THE DRAFT INDUCER IN THE HORIZONTAL STACK NEAR THE FURNACE BREECH.

5 FEET - 8 FEET

(1.5 METERS - 2.5 METERS)

CHECK FOR

-0.02 W.C. DRAFT OVERFIRE FURNACE OPERATION.

CLEAN-OUT CAP INSTALLED ON L.H. FURNACE BREECH

CONNECTOR BLOCK

DRAFT ADJUSTMENT PLATE

AIR OIL

SINGLE WALL

24 GAUGE INTERIOR STACK

SERVICEMAN ADJUSTS BAROMETRIC DAMPER TO OBTAIN -.02 W. C. DRAFT OVERFIRE

I88451-C

Figure 4Q - Installation of the Optional Draft Inducer

WARNING: Turn OFF the main power to the furnace before proceeding with the installation of

the draft inducer.

ATTENTION: It is very important to install the draft inducer on a vertical section of stack to isolate

the inducer from excessive heat and ash buildup. Never install the draft inducer on a horizontal section

of stack close to the furnace breach where heat and ash will damage the inducer motor.

4-25

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Installing the Optional Draft Inducer (continued)

1. Refer to Figure 4Q. Follow the instructions included with the draft inducer to mount the draft inducer on the section of single-wall vertical stack.

2. Position the draft plate all the way out so that it does not reduce the draft produced by the draft

inducer. Follow instructions in Section 8 (Adjusting the Draft Overre) to set the proper draft.

Wiring the Draft Inducer for Normal Operation*

*(No exhaust fans in the building. Read pages 8-3 to 8-6 if exhaust fans are present.)

1. Wire the draft inducer according to the Furnace Wiring Diagram provided in Appendix B at the

back of this manual.

Installing the Wall Thermostat

1. Select a location for the thermostat on an interior wall away from any hot or cold drafts.

2. Remove the top cover from the thermostat by pushing gently on the latch at the top center of the body. (Hold the thermostat base in one hand, and grasp the body with the other hand; push in on the latch with your thumb, and pull the cover away from the base.)

ATTENTION: DO NOT use a screwdriver to pry the cover off the base, or damage may occur.

3. Remove the green paper insert and the black plastic battery isolator from the battery section of the

thermostat.

4. Refer to the Burner Wiring Diagram in Appendix B at the back of this manual. Run two wire,

18-gauge (minimum) thermostat cable from the terminals on the back of the thermostat base to the T/T

terminals of the primary control on the burner. ATTENTION: NEVER jump between T/T terminals on the primary control without removing one of the wires. Failure to remove one of the wires will burn out the heat anticipator on the thermostat and will cause the thermostat to fail.

5. Mount the thermostat base 60" to 66" from the oor using the hardware provided.

6. Reassemble the thermostat body onto the base. (Align the hinges at the bottom of the cover with the slots at the bottom of the base, and swing the cover up into place.)

Replacing the Wall Thermostat Batteries

1. Proper battery level is indicated by the room temperature being displayed on the LCD screen.

2. When the battery level becomes low, a battery icon along with the word "REPLACE" will be displayed in

the lower left corner of the LCD screen. Replace the batteries to ensure proper operation, following the previous instructions on the thermostat disassembly procedure.

3. If the batteries are not replaced, the display will slowly become dim and not display any information.

The thermostat will eventually not function. If this happens, replace the batteries immediately.

Inspecting the Furnace Installation

Following completion of all installation activities described in this chapter, the furnace should be

inspected by qualied personnel before ring. This ensures that your installation meets all applicable national and local codes and allows for any deciencies to be corrected before furnace startup. Improper installation may void

your warranty.

4-26

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

SECTION 5: METERING PUMP PRIMING

Understanding Metering Pump Priming

Preparing your Clean Burn furnace for operation begins with priming the metering pump. The procedures in this section must be performed in sequence without interruption to properly prime the pump.

Required Tools and Materials

The following tools and materials are required for oil pump priming and should be gathered before starting any procedures:

• 3/8" open-end wrench

• 5/8" open-end wrench

• Rags

• Two containers (minimum one-gallon)

• Permatex #2 non-hardening gasket sealer

• Adjustable Wrench

• Pipe Wrench

5-1

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Priming the Metering Pump

ATTENTION: The priming process must be done precisely as described in this procedure to ensure that all air is thoroughly bled from the system. Failure to bleed all air from the system will result in

repeated burner shutdowns on reset.

1. Refer to Figure 5A.

2. Remove the 1/4" NPT plug from the side of the pump head, and set it aside.

3. Remove the 1/2" brass cap from the 1/2" brass nipple. Place a funnel in the opening. Slowly pour used oil into the funnel until oil comes out of the side of the pump head; this will ll the oil line, canister lter, and pump head with oil.

ATTENTION: NEVER run the pump head dry (i.e. without oil in the pump head); doing so will severely damage the pump.

4. Apply Permatex #2 non-hardening gasket sealer to the threads of the plug (removed from the pump head). Re-install the plug and tighten.

5. Apply Permatex #2 non-hardening gasket sealer to the threads of the 1/2" brass nipple. Re-install the 1/2" brass cap on the brass nipple and tighten.

6. Open the bleeder valve on the pump two to three (2-3) full turns, and position a container to catch oil which will ow from the bleeder during pump priming.

7. Close the mini ball valve at the outlet port of the pump head.

ATTENTION: Verify that the relief oil line is installed back to the tank before closing the mini ball valve. Closing the mini ball valve will cause the internal pump relief valve to open.

TO BURNER

1/2" BRASS

CAP

1/2" BRASS

NIPPLE

BALL VALVE

RETURN TO TANK

GEARMOTOR

MINI BALL VALVE

1/4" PLUG

PUMP

BLEEDER VALVE

VACUUM GAUGE

CANISTER FILTER

TO TANK

Figure 5A - Priming the Metering Pump

SUCTION LINE

I88756-C

5-2

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Priming the Metering Pump (continued)

8. Activating the Pump NOTE: The CB-1750/2500/3250 furnaces feature a priming switch which is mounted on the

right-hand side of the electrical junction box on the front of the furnace cabinet. The priming switch has

two positions:

• PRIME (switch is in the UP position): This is used only for pump priming. When the switch is in the UP position, the pump circuit is activated for priming. The pump will continue to run as long

as the switch is in this position. The oil primary control circuit is de-activated so the burner cannot

run while the switch is in the UP position.

• BURNER (switch is in the DOWN position): This is used for normal burner operation. When the switch is in the DOWN position, the burner controls the operation of the pump. The pump will only run while the burner is running.

a. Refer to Figure 5B to locate the priming switch. b. Turn the priming switch to the prime (UP) position. The pump should immediately start running.

OIL PUMP

PRIMING

SWITCH

Figure 5B - Locating the Pump Priming Switch

I89121

5-3

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

9. Run the pump until a solid stream of oil ows from the pump bleeder. This will bleed all air out of the suction line, oil lter and pump head.

ATTENTION: For the metering pump to operate correctly, it is very important that the system is entirely full of oil and all air is bled out. The burner will shut down if there is any air in the system.

10. Open the mini ball valve at the outlet port of the pump head to allow the pressure oil line to be lled.

11. Close and tighten the bleeder on the pump.

12. Turn the priming switch to the burner (DOWN) position so that the pump stops running.

13. Disconnect the pressure oil line from the burner and position a container to catch oil which will ow

from the pressure oil line during pump priming.

14. Turn the priming switch to the prime (UP) position. The pump should start running immediately .

15. Run the oil pump until the proper ow of oil has been established, and the oil line has been completely ushed out.

16. Turn the priming switch to the burner (DOWN) position so that the pump stops running.

17. Re-connect the oil line to the burner.

Vacuum Testing the Oil Pump

Vacuum testing the oil pump is a very accurate way to determine the following:

• The condition of the pump -- the ability of the pump to pull a vacuum and suck oil from the tank.

• The condition of the ttings, gaskets and seals from the ball valve to the pump -- these

components must all be airtight to avoid suction leaks.

The following procedure provides instructions for vacuum testing the pump and canister lter on

systems equipped with a ball valve.

ATTENTION: For the pump to pull and hold vacuum, it is critical that all ttings are airtight. If any of these ttings are loose, the pump may not pull a vacuum or may lose the vacuum rapidly. It is also critical that all ttings in the suction line, including ttings on the canister lter, are 100% airtight.

1. Follow the instructions to prime the pump (previous procedure).

NOTE: The pump will not pull a vacuum if the pump is dry. There must be oil in the gears of the pump before the pump can pull a vacuum.

2. With the pump running, open the bleeder two to three full turns, and make sure that oil is owing

from the bleeder. DO NOT close the bleeder yet.

3. Refer to Figure 5A. Close the ball valve at the inlet to the canister lter. Observe the vacuum gauge.

NOTE: The ball valve must have a stainless steel ball and should be pressure tested by the manufacturer to ensure that it does not leak. If the ball valve leaks, the vacuum test will not be accurate.

4. The vacuum should increase within 30 seconds to 15 inches of vacuum. When the vacuum gauge reads 15 inches of vacuum, rst close and tighten the bleeder, then turn the pump off and close the mini ball

valve at the outlet port of the pump. Observe the vacuum gauge. NOTE: If the pump will not pull at least 15 inches of vacuum, there is a very serious suction leak, or the pump is damaged.Vacuum Testing the Oil Pump (continued)

5-4

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

5. If there are no suction leaks, the system will hold vacuum. NOTE: It is acceptable for the vacuum to drop one to ve inches within one minute as the seal in the pump seats. The vacuum should then hold steady for 15 minutes.

ATTENTION: If the vacuum dropsmorethanonetoveincheswithintherstminute, there is one or more leaks somewhere between the pump and the ball valve. Do the following:

• Wipe your nger along the cylinder at the shaft of the pump. If there is oil here, the pump

seal is damaged. Replace the pump.

• Disassemble and clean all the ttings from the pump to the ball valve. Properly seal all ttings with Permatex #2 non-hardening gasket sealer or equivalent. Check the condition of the o-ring on the canister lter and tighten the four canister lter bolts in a crisscross pattern.

• Repeat the procedure to vacuum test the system to ensure that the system is air tight.

6. Follow the instructions to prime the metering pump after a vacuum test has been performed.

5-5

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

5-6

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

SECTION 6: STARTING AND ADJUSTING THE BURNER

Understanding Burner Startup and Adjustment

Starting and adjusting the burner involves a series of separate procedures which must be accomplished

in sequence without interruption. Review all the procedures before attempting burner startup and

adjustment, paying careful attention to safety information statements.

Preparing the Burner for Startup

1. Turn the switch on the wall thermostat OFF.

NOTE: If your thermostat does not have an OFF setting, disconnect one thermostat wire so the burner will not run.

2. Turn the main power to the furnace ON.

3. Wait at least 15 minutes until the preheater block is thoroughly warmed up. (Feel the back of the burner box to make sure the preheater is sufciently warm. The proving switch on the preheater

block will not allow the burner to start until the block

is hot.)

NOTE: The preheater block will remain warm as long as power is supplied to the burner. If the main power supply is ever turned OFF,

you must wait at least 15

minutes until the preheater block is thoroughly warm before starting the burner.

4. Refer to Figure 6A to locate

the air regulator. Loosen the locking nut on the air regulator.

5. Turn the adjustment knob

on the air regulator

counterclockwise until 1/2"

of the threads on the knob are exposed. DO NOT back the knob all the way out.

OIL GAUGE

AIR REGULATOR

LOCKING NUT

COVER PLATE

AIR GAUGE

COMBUSTION

AIR BAND

I88583

Figure 6A - Component Detail of the CB-525-S2 Burner

6-1

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Preparing the Burner for Startup (continued)

NOTE: The air gauge will not show any pressure until the burner starts. Before starting the

burner for the rst time, it is very important to turn the air regulator completely OFF as

described.

6. Initial Adjustment of the Combustion Air Band:

WARNING: The combustion air band must be properly adjusted to ensure that the burner ignites and burns correctly. DO NOT attempt to start the burner with the combustion air band wide open or completely closed. The burner may not ignite correctly. Failure to heed this warning may result in a

re or explosion hazard.

• Refer to Figure 6A to locate the combustion air band.

• Rotate the combustion air band to adjust it to the appropriate initial slot opening as listed

in the following Initial Adjustment Charts. Use a ruler to accurately set the slot opening at the widest section of the slot. This initial setting of the combustion air band will allow you to

start the burner. You will ne tune the combustion air band further as described later in these

instructions.

ATTENTION: The settings shown in the charts below are only initial adjustments. Finaladjustments mustbedonebyinspectingtheameaccordingtotheillustrationsprovidedonthefollowingpage.

NOTE: Theoilpressureisautomaticallyadjustedbythemeteringpump.Theapproximateoilpres- sure range during initial startup is 1 to 4 psi for Model CB-1750, 4 to 7 psi for Model CB-2500 and 5 to 8 psi for Model CB-3250.

Initial Adjustments for CB-1750

Maximum Input = 175,000 BTUH @ 1.2 GPH with CB525-S2 Burner

Oil Type Oil PSI / Flame Length Air PSI Air Band Nozzle #2 Fuel Oil*  checkamelength 12-16 3/8" 9-5

Used Crankcase Oil  checkamelength 12-16 3/8" 9-5 Used ATF*  checkamelength 12-16 3/8" 9-5 Used Hydraulic Oil*  checkamelength 12-16 3/8" 9-5

#4 and #5 Fuel Oils checkamelength 12-16 3/8" 9-5

Initial Adjustments for CB-2500 Maximum Input = 250,000 BTUH @ 1.7 GPH with CB525-S2 Burner

Oil Type Oil PSI / Flame Length Air PSI Air Band Nozzle

Used Crankcase Oil  checkamelength 12-18 1/2" 9-5 Used ATF*  checkamelength 12-18 1/2" 9-5 Used Hydraulic Oil*  checkamelength 12-18 1/2" 9-5

#4 and #5 Fuel Oils checkamelength 12-18 1/2" 9-5

Initial Adjustments for CB-3250 Maximum Input = 300,000 BTUH @ 2.1 GPH with CB525-S2 Burner

#2 Fuel Oil*  checkamelength 12-18 1/2" 9-5

Oil Type Oil PSI / Flame Length Air PSI Air Band Nozzle #2 Fuel Oil*  checkamelength 12-18 7/8" 9-5

Used Crankcase Oil  checkamelength 12-18 7/8" 9-5 Used ATF*  checkamelength 12-18 7/8" 9-5 Used Hydraulic Oil*  checkamelength 12-18 7/8" 9-5

#4 and #5 Fuel Oils checkamelength 12-18 7/8" 9-5

*If you are burning light viscosity oils, it may be necessary to install a smaller nozzle. Call your local Clean Burn

Distributor for more information.

6-2

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Starting the Burner

1. Adjust the thermostat setting above room temperature to start the burner.

2. Adjusting the Air Regulator:

As soon as the burner starts running, turn the knob on the air regulator clockwise to achieve proper operating air pressure. Refer to the Initial Adjustment Charts. NOTE: If the safety reset on the primary control is activated and the burner stops running, see

Section 7 for further instructions on restarting your burner.

3. Observing the Flame Length: Visually inspect the ame length through the observation port. Refer to Figure 6B for an illustration of the desired ame length. The ame should extend no more than one-half of the way down the combustion

chamber. WARNING: The observation port gets hot as the

burner res. To avoid personal injury, always wear

heavy work gloves and safety glasses when opening the

port and viewing the ame.

WHEN OPENING INSPECTION PORT

CAUTION

PORT MAY BE HOT

PROTECT HANDS

WEAR SAFETY GOGGLES

KEEP FACE AWAY

OPEN PORT SLOWLY

Correct Maximum Flame Adjustment (Proper Oil and Air Pressure):

• Flame goes half of the way down the combustion chamber.

• Flame does not touch back or walls of combustion chamber.

Incorrect Flame Adjustment (Not Enough Combustion Air):

• Flame must not touch back or walls of combustion chamber.

• Increase combustion air by opening the

air band on the side of the burner.

Incorrect Flame Adjustment (Air Pressure Too High):

• Ensure proper air pressure setting.

I88372

4. Check the ame length after the burner has red for 15 minutes.

5. Tighten the locking nut on the air regulator.

Figure 6B - Flame Length Adjustment

6-3

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Starting the Burner (continued)

6. Fine Tuning the Combustion Air Band: NOTE: The initial setting of the combustion air band may require additional adjustment.

• Refer to Figure 6A to identify the combustion air band location on the burner.

• Observe the ame. The ame should be yellow-white with sharp tips and no "sparkles."

• If the ame is orange in color or the ame length is too long, the oil you are burning requires MORE combustion air. OPEN the air band 1/8" to 1/4", and recheck the ame for the proper characteristics.

• Recheck the ame after ve minutes. You should see a yellow-white ame with sharp tips and no "sparkles", and the ame should extend half the way down the combustion

chamber.

7. Checking for a Smokeless Burn:

Check for a smokeless burn by observing the stack while the burner is running. If you see any

smoke, repeat the previous steps for setting the combustion air band and adjusting the air regulator. After adjusting the combustion air band, re-check the ame length. NOTE: Check for a smokeless burn periodically (as you do the ame length). Immediately readjust the burner if you ever see smoke coming from the stack. Smoke indicates improper air/ fuel adjustment.

NOTE: When using instruments to adjust the burner for a smokeless burn, the following readings should be achieved:

• Draft over re should be -.02 inch w.c.

• Adjust for a smoke spot of a trace to 2

• Adjust for a CO2 reading of 8 to 10% or an O2 reading of 7 to 9%

• Cad cell reading below 500 ohms

Checking the Operation of the Blower Motor

NOTE: It is important to verify that the blower motor operates correctly to ensure that the fan limit control is properly cycling the blower motor as described below. Also refer to Appendix A at the back of the manual for additional pertinent information.

1. Start the burner and adjust it as described previously in this section.

2. The blower motor will not start until the burner has been running for 5 to 15 minutes to heat up

the combustion chamber and heat exchanger. At this point, the fan fan switch will activate the blower motor.

3. Once the blower motor has activated, turn the burner off by turning the wall thermostat to OFF.

4. With the burner off, the blower motor should continue to run for 5 to 10 minutes until the

combustion chamber is cooled down. The fan switch will then shut off the motor.

WARNING: If the blower motor does not operate as described, immediately shut down

your furnace to avoid potential equipment damage and/or re hazard. Contact your local Clean

Burn Distributor immediately.

6-4

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

SECTION 7: RESETTING THE FURNACE AND BURNER

( See Appendix B for additional information )

Understanding Furnace/Burner Shutdowns

When troubleshooting furnace/burner shutdown situations, Clean Burn recommends the following sequence of actions:

• Follow the procedure for Resetting the Oil Primary Control provided in this section.

• Review the material on the following page about the safety switches to determine if the furnace is shut down on high limit.

• If the burner still will not restart, contact your Clean Burn Distributor for immediate service.

The Oil Primary Control

The oil primary control will go into safety lockout

and shut the burner off when it detects ame-out

during burner operation. The following procedure explains what should be done when this occurs.

It is very important that you follow these instructions precisely when resetting the safety on the primary control and restarting the burner.

Resetting the Oil Primary Control

DANGER! DO NOT push the reset button more than once! DO NOT push the reset button if oil mist is present in the combustion chamber or when the combustion

C77008

chamber is hot! DO NOT operate your furnace if excess oil, oil vapor or fumes have accumulated in or near your furnace. As with any oil burning furnace, improper operation may result in a

re or explosion hazard.

1. Refer to Figure 7A.

2. Check the combustion chamber for fuel mist by shining a ashlight through the observation port. If you see fog (fuel mist) in the chamber, DO NOT

push the reset button.

3. If the combustion chamber is hot, allow the furnace to cool for at least 30 minutes. DO NOT push the

reset button.

4. When you are sure all mist has been cleared from the chamber and the combustion chamber is cool, depress the red button on the primary control for

2 seconds, then release. Reset the control ONCE

ONLY.

5. If the burner will not restart, call your Clean Burn dealer immediately.

AMBER LED GREEN LED RED LED

GRNAMB

RED

CAD CELL

WIRES

WIRES RUN UNDER

SMALL CENTER GAP

RESET BUTTON

ALARM

F FTT

Figure 7A - Oil Primary Control

WARNING

Fire and explosion hazard. Do NOT press reset button until you read and understand Reset Procedures in Operator's Manual.

ATTENTION: Never touch a jumper wire from an "F" terminal to a "T" terminal on the oil primary control. This will severely damage your primary control.

42000 Rev. 2

7-1

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

The Blower Switch

The CB-1750/2500/3250 furnaces feature an F-180 blower/fan switch (normally open) which is surface mounted at the front of the combustion chamber (see Figure 7B). The blower/fan switch senses the temperature of the combustion chamber as the burner is ring. When the combustion chamber reaches the proper temperature, the blower/fan switch closes and sends power to the blower motor (CB-1750) or relay (CB-2500/3250) to turn ON the blower motor. When the wall thermostat is satised and the

burner shuts off, the blower continues to run until the switch senses that the combustion chamber has cooled down. The switch then opens and shuts off the blower motor.

The Hi-Temp Limit Switches

These furnaces also feature two high temperature limit switches which are mounted on a bracket at the front of

the combustion chamber as shown in Figure 7B. The switches sense the build-up of heat within the combustion

chamber and are designed to protect the furnace from damage due to overheating. The limit switches are wired in

series, and both are auto-resetting.

Understanding the Function of the L-200 Hi-Temp Limit Switch

If the temperature of the combustion chamber is too hot, the L-200 hi-temp limit switch opens and shuts off power

to the primary control on the burner, and the burner shuts off. The blower continues to run to cool down the

furnace. After the combustion chamber has cooled down, the L-200 hi-temp limit switch will automatically reset

and allow the burner to restart.

ATTENTION: If the L-200 hi-temp limit switch is opening repeatedly, the burner MUST be readjusted according to the instructions in Section 6 to correct the overheating problem, or serious damage to the furnace may occur.

The L-200 hi-temp limit switch will open and shut down the burner if any of the following conditions exists:

• The furnace is over ring. Review the directions in Section 6 to properly adjust the burner.

• Improper ductwork is installed on the furnace (applicable only if your furnace is

operating as a central furnace). Ductwork must be installed by qualied HVAC personnel according to industry standards and the specications provided in Section 3.

Understanding the Function of the L-290 Auxiliary Auto-Reset Hi-Temp Limit Switch

The L-290 auxiliary auto-reset high temperature limit switch is a back-up safety switch for the L-200 hi-temp

limit switch.

Both the L-200 and L-290 auxiliary hi-temp limit switches will open and shut down the burner if:

• the blower has stopped running for any reason during furnace operation, the heat in the furnace will cause the limit switches to open. Ensure that the blower is functioning properly.

ATTENTION: It is very important to determine the reason for the opening of the limit switches and take steps to correct the cause; failure to do so may result in serious overheating and damage to the heat exchanger of the furnace. Additionally,iftheburnerisrapidly cycling on/off, contact your Clean Burn Distributor immediately; failure to address this situation may result in serious damage to the furnace.

7-2

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

The Hi-Temp Limit Switches (continued)

CLEAN-OUT BREECH

CLEAN-OUT CAP

RED & TAN WIRE LINKS THE 2 SWITCHES IN SERIES

(33390) L-200 HI LIMIT NC

RED & TAN WIRE TO BURNER

COMBUSTION

CHAMBER

33288 L-290 HI LIMIT AUXILIARY

SWITCH (AUTO RESET)

(33230) F-180

SURFACE MOUNT

FAN SWITCH

BLACK & TAN WIRE

FROM TERMINAL BLOCK

RED & TAN WIRE FROM TERMINAL BLOCK

BLACK AND TAN WIRE TO TERMINAL BLOCK

Figure 7B - Locating the Hi-Temp Limit Switches

I88162-D

7-3

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

7-4

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

SECTION 8: ADJUSTING THE DRAFT OVERFIRE

Understanding the Importance of Draft

Draft in the furnace is created as the hot combustion gases rise up the stack, creating a negative pressure

inside the stack and the furnace. This negative pressure is measured as inches of water column (W.C.) of draft. A proper draft overre of -.02 to -.04 w.c. is essential so that all combustion products travel away from the burner, down the combustion chamber, through the furnace ues and up the stack.

Checking for Correct Draft Overre

WARNING: Correct draft overre is

essential for the proper and safe operation of your furnace.

Your furnace is equipped with an observation/

draft reading port to check draft overre. A

qualiedservicemanwithproperequipment

must check/adjust your furnace for proper draft.

Contact your Clean Burn dealer for this service.

1. Insert the probe of the draft gauge

instrument into the draft reading port in the observation port as shown in

Figure 8A.

NOTE: Follow the directions with the

draft gauge to use your specic type of

gauge.

2. Note the draft overre reading on the draft

gauge. ATTENTION: The draft reading should

be in the -.02 to -.04 w.c. range. Poor draft (i.e. -.01 to +.08) results in back

pressure in the furnace and poor burner

performance. Too much draft overre (i.e. greater than -.04) sucks the heat from

the furnace and results in abnormally high stack temperature.

I88257

Figure 8A - Checking for Proper

Draft Overre

8-1

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Adjusting the Barometric Damper

NOTE: If the draft overre is not in the -.02 to -.04 w.c. range, it is necessary to adjust the barometric

damper.

1. Before starting the burner, turn the weight on the apper COUNTERCLOCKWISE until the apper remains closed. This will

provide maximum draft for the furnace.

2. Follow the directions in Section 6 to start and adjust the burner.

3. With the burner running, check the draft overre with a draft gauge.

4. As shown in Figure 8B, adjust the weight on the apper to obtain a consistent

-.02 w.c. draft overre. Turn the weight COUNTERCLOCKWISE to increase draft (i.e. draft increases as the apper closes). Turn the weight CLOCKWISE to decrease draft (i.e. draft decreases as the apper opens).

5. Tighten the locking nut to securely hold

the weight in position.

ADJUST THIS WEIGHT TO OBTAIN PROPER

TO OBTAIN PROPER DRAFT OVERFIRE

I88572

Figure 8B - Adjustment of Barometric Damper

Solving Draft Overre Problems

WARNING! If you cannot achieve proper draft overre, do not operate your furnace!

Contact your Clean Burn dealer for assistance.

ATTENTION: Backdraft must be resolved or your furnace will not operate correctly!

Under backdraft conditions, draft overre readings will show positive pressure in the combustion

chamber. Backdraftmeans that oil spray, combustion products, and heat are blown back against the burner. Backdraft results in oil-fouled retention heads and electrodes. Severe backdraft will force heat back against the burner and result in heat damage to the cad cell and transformer.

Backdraft is caused by the following conditions:

• Poor draft caused by improper stack design. (See Section 4.)

• Poor draft caused by improper adjustment of the barometric damper. (See Above)

• Incorrect combustion air band setting on the burner. (See Section 6.)

• Furnace ues are plugged with ash. (See Section 9.)

• Exhaust fans in your building are sucking gases down the stack. (See following pages)

8-2

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Understanding the Effect of Exhaust Fans on Draft

Any type of exhaust fan, paint booth, or exhaust system in a building will create negative pressure in the

building unless there is a source of make-up air (i.e. fresh air which enters the building and replaces the air removed by the exhaust fans.) Refer to Figure 8C on the following page.

If there is insufcient make-up air, the exhaust fan will suck air and combustion gases down the furnace

stack and create backdraft in the furnace. Even if the exhaust fan is on another level of the building or in another room away from the furnace, the exhaust fan will still create backdraft at the furnace.

Checking Draft Overre to Determine Severity of Backdraft

The following procedure is an accurate method of determining how much backdraft is created by the exhaust fans. Once this is determined, you can select the correct method for resolving the backdraft.

Refer to Figure 8C on the following page as needed.

1. Turn off ALL exhaust fans and close ALL doors and windows in the building (any open door or

window will allow make-up air to enter the building and will negate the test).

2. Start the furnace and adjust the barometric damper so that the draft overre is -.02 w.c.

3. Check the draft overre again. Now have someone start the exhaust fans.

4. Note how much the draft overre has changed.

ATTENTION: If the draft overre changed towards positive, it is mandatory that make-up air is provided to the building or severe damage to the furnace and burner will occur (voiding the warranty). If the draft overre remained constant at -.02 w.c., there is sufcient make-up air

entering the building, and the exhaust fan is not adversely affecting the draft.

8-3

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

EXHUST FAN CREATES BACKDRAFT IN STACK

BACKDRAFT

AND SUCKS COMBUSTION GASES DOWN THE

STACK AND BACK INTO THE FURNACE

BACKDRAFT CREATED BY EXHAUST FAN

Special Note to Service Personnel

To arrive at proper draft measurements be sure that all fans within the building are running while adjusting the draft

to nal levels!

DRAFT OVERFIRE OF -.02 TO -.04 W.C.

MEANS COMBUSTION GASES

ARE FLOWING AWAY FROM THE

BURNER,THROUGH THE FURNACE

FLUES AND UP THE STACK

DRAFT

LESS

PROPER DRAFT

RISING HOT COMBUSTION GASES PRODUCE PROPER DRAFT

BACKDRAFT

The Smart Use For Used Oil

OIL SPRAY AND HEAT IS FORCED BACK AGAINST THE BURNER AND RESULTS IN OIL FOULED ELECTRODES

AND RETENTION HEAD.

SEVERE BACKDRAFT WILL HEAT AND DAMAGE THE CAD CELL AND THE

TRANSFORMER.

SERVICEMAN ADJUST

BAROMETRIC DAMPER TO OBTAIN -.04 TO -.06 W.C. DRAFT AT STACK

Figure 8C - Proper Draft vs. Backdraft

DRAFT

LESS

Corresponding Draft Over Fire

measurement should be -.02 to -.04 WC

8-4

The Smart Use For Used Oil

COMBUSTION AIR

TO BURNER

I88452-C

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Installing a Make-up Air Louver

Exhaust Fans and Make-up Air Louvers

When exhaust fans are operated in tight buildings, there is little or no source of fresh air to replace the air

removed from the building by the exhaust fan. This results in negative pressure (vacuum) in the building which

creates severe backdraft problems at the furnace.

Properly sized make-up air louvers are designed to allow adequate fresh air to enter the building during operation

of the exhaust fans. The louvers automatically open under the vacuum created by the exhaust fans. The louvers

open just enough to provide the correct CFM of fresh air. The louvers automatically close when the exhaust fans

are turned off.

Sizing the Make-up Air Louver

IMPORTANT NOTE: When using louvers and grills, and the actual free area of the louver or grill is not known,

it is understood that wooden louvers/grills will have a free area of 25%, while metal louvers/grills will have a free area of 75%. ("Free area" translates into the actual space allowing air to ow through.)

Procedure 1: (a) Determine the CFM rating of the exhaust fan. This information should be stamped on

a label on the exhaust fan. Make sure to add up the total CFM if more than one exhaust fan exists in the building.

(b) Select the correct size of make-up air louver to provide the required CFM of fresh air.

If you cannot determine the CFM rating of the exhaust fan, use the following procedure.

Procedure 2: (a) Count the total number of exhaust fans in the building. (b) Close all of the doors and windows in the building except for one overhead garage door. (c) Start the furnace and allow it to run for 15 minutes to bring it up to temperature. (d) Set the draft-over-re for -.02" to -.04" W.C. (e) Turn ON all of the exhaust fans in the building. (f) Now close the opened overhead garage door slowly, just until the draft gauge moves down into a positive (+) draft reading; as soon as it reaches this point, STOP the door at that

position.

(g) Slowly open the door back up, just until the draft reading comes back up to the -.02" to -.04 W.C. (h) Measure the size of the door opening, rounding this measurement off to the next largest

even foot.

Example of Calculations for Sizing Make-up Air Louver

Measured door opening: 12' wide x 9" high

• Round off to 12' wide x 1' high

• Convert to square feet (in this case, equals 12 square feet)

• Multiply by 1.1 correction factor (12 sq. ft. x 1.1 = 13.20 sq. ft.)

• Multiply by free area factor (13.20 sq. ft. x 1.25 = 16.50 sq. ft.)

• Refer to sizing chart (following page) - required grill size would be (1) 54" square grill

8-5

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Installing a Make-up Air Louver (continued)

Calculated Opening Size

From 0.000 to 0.569

From 0.570 to 0.900

From 0.901 to 1.556

From 1.557 to 2.070

From 2.071 to 2.574

From 2.575 to 3.408

From 3.409 to 5.133

From 5.134 to 7.696

From 7.697 to 9.883

From 9.884 to 13.299

From 13.300 to 16.683

From 13.684 to 21.152

Installing the Make-up Air Louver

(Square Feet)

Required Louver / Grill Size

(Inches)

10 x 10

12 x 12

16 x 16

18 x 18

20 x 20

24 x 24

30 x 30

36 x 36

42 x 42

48 x 48

54 x 54

60 x 60

C77002

All louvers and grills, regardless of the material from which they are made, must be FIXED in the OPEN position

OR be interlocked with the appliance so that they will open automatically during the operation of the appliance. The interlock must be placed on the driven member.

NOTE: It is very important to follow these instructions carefully to ensure proper performance of the louver.

1. The louver must not be close to the furnace. The fresh air should travel at least 40 to 50 feet before

reaching the furnace, so the air warms up. The furnace will not heat well if it is receiving cold return air.

2. The louver must be high in the sidewall of the building so the cold fresh air does not blow across the oor level and chill the service personnel.

3. The louver should be installed in the opposite wall from the location of the exhaust fan. This

will quickly vent diesel exhaust from the top of the building and reduce the amount of run time for the exhaust fan.

8-6

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

SECTION 9: MAINTENANCE

Understanding Maintenance

Servicing your Clean Burn furnace in a timely manner is very important to keep your furnace running in peak condition. Just as an automobile requires periodic maintenance such as oil changes, engine tune-

ups, etc. your Clean Burn furnace also requires regularly scheduled service.

WARNING: Failuretomaintainand/orimproperservicingbyunqualiedpersonnelmay adversely affect the proper, safe operation of your furnace, may reduce the service life of your furnace, and may void your warranty.

The following chart summarizes all the service intervals which are required to maintain your furnace. Service instructions/procedures for these activities are included in this chapter.

Maintenance Activity Interval Periodic Burner Inspection Monthly

Cleaning the canister lter Before vacuum gauge reads 10" HG of vacuum Servicing the metering pump At least once a year

Cleaning the check valve/screen At least once a year Cleaning water/sludge out of tank At least once a year

Cleaning out ash Approx. 700 hours as indicated on the burner hour meter* Annual burner tune-up At least once a year

*It is very important to clean ash from the furnace on schedule. Normal use of the furnace requires

clean-out at least twice during the heating season. Heavy, around-the-clock usage requires more frequent clean-out. For instance, one month of continual running of the furnace is 720 hours (24 hours x 30 days = 720 hours).

NOTE: IMPORTANT! Record all maintenance activities in the Maintenance Record provided in Appendix C.

9-1

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Periodic Burner Inspection

Following initial start up of the burner, you should inspect the operation of the burner periodically--ideally on a monthly basis. Doing so ensures that the system is functioning efciently and safely.

Follow these guidelines for inspecting the operation of the burner:

• Visually inspect the ame length through the observation port; the ame should extend no more than one-half of

the way down the combustion chamber.

• If the ame is diminishing or displays wide

WHEN OPENING INSPECTION PORT

CAUTION

variations, clean the canister lter and check valve/screen (procedures provided in this section).

• If the ame is ring too strongly (i.e. ame touches back and/or side walls of the combustion chamber), check the air pressure setting (see following

PORT MAY BE HOT

PROTECT HANDS

WEAR SAFETY GOGGLES

KEEP FACE AWAY

OPEN PORT SLOWLY

guideline).

• Check the air pressure by observing the air gauge; proper air pressure settings are provided in

Section 6. DO NOT overre the burner; doing so on a continual basis will damage the furnace.

• Check the combustion air band setting for the proper opening and clean away any dust/debris as necessary. Note that the air band should NEVER be set fully open or closed.

• Check the draft over re reading as specied in Section 8.

LOCKING NUT

AIR GAUGE

OIL GAUGE

AIR REGULATOR

COVER PLATE

COMBUSTION

Figure 9A - Component Detail of the CB-525-S2 Burner

AIR BAND

I88583

9-2

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Cleaning the Canister Filter

ATTENTION: Never operate your furnace with more than 10" HG of vacuum on the suction side of

the pump. High vacuum separates air from the oil and results in erratic burner operation.

The following protective gear should be worn when cleaning the lter:

• Rubber gloves

• Safety goggles

1. Close the ball valve adjacent to the lter.

2. Position a container under the lter.

3. Unscrew the four bolts to drain the oil from the canister.

4. Remove the canister bowl.

5. Clean the screen and the bowl in a parts washer.

6. Referring to Figure 9B, examine the lter components as you reassemble them.

7. Check the condition of the O-rings. Replace any that are cracked or worn.

8. Ensure that the canister lter is 100% airtight by rmly tightening the four bolts.

9. After the pump head screen is serviced as well (page 9-4) open the ball valve and refer to Sections 5 and 6 for instructions on priming the pump and starting the burner.

USE A RATCHET WRENCH WITH A 6" EXTENSION AND 3/16" "ALLEN" SOCKET TO REMOVE THE FOUR "ALLEN" SCREWS

TO BURNER

RETURN BACK

TO TANK

I88259-C

Figure 9B - Canister Filter Component Detail

9-3

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Servicing the Metering Pump

1. Refer to Figure 9C.

2. Remove the pump head cover (part 1).

3. Remove the screen (part 2) and wash it.

4. Remove and discard the used gasket (part 3).

5. Install a new gasket (Clean Burn Part #32422).

6. Replace the screen and pump head cover.

GAUGE

A2RA - 7720

INLET

ROTATION

PART No 32422

RELIEF

PART No 32423

I88332-A

Figure 9C - Servicing the Metering Pump

9-4

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Cleaning the Check Valve And Check Valve Screen

This procedure applies to furnace installations with inside and outside tanks. The following protective gear should be worn when cleaning the check valve/screen:

• Rubber gloves

• Safety goggles

1. Refer to Figure 9D. Remove the one-piece suction oil line from the tank.

2. Remove the check valve and screen. Clean these components in a parts washer.

3. Check the operation of the check valve. The valve must seat so it is airtight to hold pump prime.

4. Re-assemble and re-install the components. Apply Permatex #2 non-hardening gasket sealer or equivalent to the threaded ttings. Firmly tighten all connections so the suction line is 100%

airtight.

5. Follow pump priming instructions in Section 5 to re-establish prime.

TO BURNER

EMERGENCY

VENT

CLEANOUT

FUNNEL WITH

BALL VALVE

OIL STORAGE TANK

CHECK VALVE

METERING PUMP

SUCTION

OIL LINE

VENT

CAP

CHECK VALVE SCREEN

12"

I88670-F

Figure 9D - Check Valve Detail

9-5

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Cleaning the Tank

DO NOT allow water, sludge, or other debris to accumulate in your oil supply tank to the point that non-

combustible or harmful materials are drawn into the pump or burner.

Drain water and sludge from the bottom of your tank at least once a year, and more frequently with water accumulation.

NOTE: If your used oil tank has not been cleaned on a regular basis, a considerable amount of sludge, etc. may have accumulated on the bottom of the tank. Under these circumstances, it is advisable for you to hire your used oil hauler to pump the tank. Make sure the tank is pumped to the bottom to remove

all sludge, etc. from the tank (your used oil hauler may charge an additional fee for this type of service).

The best time to pump the used oil tank is at the end of the heating season when the tank is low. This

allows sufcient time to rell the tank with used oil (generated by your company over the summer months) so that you have adequate fuel for the heating season.

9-6

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Cleaning Ash from the Furnace

NOTE: The maintenance interval for cleaning ash from the furnace is approximately 700 hours of operation as indicated on the hour meter on the burner (refer to the servicing intervals at the beginning of this chapter). Be sure to clean the ash from your furnace at least twice during the heating season.

Yourfurnacemayrequiremorefrequentcleanoutoftheashduetocontaminantsintheoilorheavy

use. As ash accumulates, furnace heat output declines, and the stack temperature rises. 1/8" of ash has the insulating capacity of one inch of berglass insulation and reduces heat transfer signicantly. Never

allowmorethan1/4"ofashtoaccumulateinthecombustionchamber,heatexchangerues,or stack.

CAUTION: Be aware that used oils may contain heavy metallic compounds or foreign materials. When burned, these compounds are deposited within the furnace, necessitating careful cleaning. The following protective gear should be worn when cleaning the ash:

• Respirator for ne particles (a dust mask is not acceptable)

• Rubber gloves • Safety goggles • Protective clothing

CAUTION: Make sure you use a sturdy ladder or scaffolding for safe access to ceiling-hung

furnaces. When cleaning the furnace, static electricity may build up in the shop vac hose. If this

occurs, use #12 copper wire wrapped around the hose with the other end connected to the furnace (or other ground source) to eliminate the static.

CLEAN-OUT BREECH

CLEAN-OUT CAP

COMBUSTION CHAMBER

Figure 9E - Accessing the Combustion Chamber for Cleaning

CLEAN-OUT DOOR

I88563-C

9-7

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Cleaning the Ash (continued)

1. Ensure that power has been turned OFF, and all "hot" components have been allowed to cool sufciently. (Allow at least one hour for the Energy Retention Disc to cool.)

2. Clean the ash from the stack components:

a. Brush accumulated ash from the stack cap. b. Lightly tap the stack components to loosen the ash. c. Allow ash and dust to settle in the elbow on the stack. NOTE: It is not necessary to remove the stack to clean it. You will vacuum ash from the stack elbow as you clean out the back of the furnace as described below.

d. Remove the clean-out cap from the unused furnace breach.

e. Thoroughly vacuum out the back of the furnace, including the stack elbow, through the

clean-out breach. A long wand on the hose of your shop vac is helpful in reaching all the

way through the back of the furnace to the stack elbow.

3. Clean the ash from the combustion chamber (see Figure 9E): a. Bleed down pressure on the air and oil lines by slightly loosening the ttings at the bottom of

the connector block. NOTE: Turn off the shut-off on the air pressure line. b. With air and oil pressure completely bled off, disconnect the air and oil pressure lines from the bottom of the connector block. NOTE: Cover the lines to keep dirt from entering the air / oil supply.

c. Remove the lock-down nuts on the clean-out door. d. Carefully swing open the clean-out door to expose the heat exchanger ues and the

combustion chamber. Carefully remove the Energy Retention Disc with a long handle or pipe. Lightly vacuum the Energy Retention Disc.

e. Check the color of the ash--it should be light gray or tan.

ATTENTION: White ash indicates excessive air pressure. Black ash or soot indicates lack

of combustion air. If these conditions exist, call your Clean Burn dealer. DO NOT overre your furnace by turning up the compressed air. Overring will damage the combustion

chamber and heat exchanger and will void your warranty.

f. Vacuum the ash from the combustion chamber and the ues.

ATTENTION: When cleaning the combustion chamber, ensure that you do not gouge or

damage the refractory material on the inside of the clean-out door. NOTE: Avoid "packing" the ash in the tubes by rst vacuuming the ues before pushing the ue brush down the ues. DO NOT bump or bend burner components while cleaning the

combustion chamber.

g. Use a ue brush to thoroughly clean the ues. h. Thoroughly vacuum any remaining ash residue from the ues. Make sure the back (at the breach) is still clean. i. Check the ues for rust.

ATTENTION: The presence of rust in the ues indicates that chlorinated materials are being burned. Burning chlorinated materials will severely damage your heat exchanger and void your warranty. Contact your Clean Burn dealer for instructions to test your oil for

chlorine contamination before ring your furnace. j. Inspect the inside of the clean-out door. Make sure the refractory material on the inside of the clean-out door is in good condition and the clean-out door seals tightly when closed. If

the door does not seal tightly, replace any damaged components.

9-8

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

Cleaning the Ash (continued)

k. Re-install the furnace components: Swing the clean-out door shut; install and tighten the lock-down nuts so that the door seals properly. Re-install the air and oil lines on the bottom

of the connector block. NOTE: You may need to bleed air from the oil line before starting the burner. See Section 5 for the pertinent instructions.

Annual Burner Tune-up

Your Clean Burn furnace requires annual periodic maintenance. The burner requires an annual tune-up

--similar to an automotive tune-up--to keep it running in peak condition. The burner tune-up should be

performedbyaqualiedCleanBurnservicetechnicianwhohasthenecessarypartsandexpertise.

Contact your local Clean Burn dealer to schedule the annual periodic maintenance which is usually

(preferably) performed during warm weather to prepare the furnace for the next heating season. Various levels of service are provided to t your particular need.

End of Season Maintenance

ATTENTION: Turn main power to your furnace OFF at the end of the heating season. EPA regulations allow your used oil to be burned only for "heat recovery." DO NOT operate your furnace

during warm weather just to burn oil, or severe damage to the combustion chamber/heat exchanger may

occur.

Contact your local Clean Burn dealer to schedule your annual burner tune-up. Allow only trained, authorized service personnel to service your burner.

Cleaning and Maintaining the Optional Draft Inducer

The Draft Inducer will require periodic maintenance to ensure that the fan blades do not accumulate excessive ash which can create vibration, noise, and motor wear.

1. Ensure that power has been turned OFF, and all "hot" components have been allowed to cool sufciently.

2. Disconnect the wires from the draft inducer and remove it from the stack penetration.

3. Clean the fan blades with a scraper and wire brush.

4. Oil the draft inducer motor according to the manufacturer's recommendations.

9-9

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

9-10

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

SECTION 10: TROUBLESHOOTING

The following charts and tables are provided for reference in troubleshooting any difculties encountered in furnace operation and adjustment.

• The Flow Chart outlines the proper sequence of events in furnace operation -- use this chart to help diagnose where a problem may be occurring.

• More specic troubleshooting information is provided in the Troubleshooting Tables following the ow charts. Each table lists a Problem, Possible Cause, and Possible Action(s) to x the problem.

10-1

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

I88792-B

Wall thermostat calls for heat and

closes 24V thermostat.

2000+ ohms from cad cell

chamber (NO FLAME)

Oil primary control checks for

indicating dark in the combustion

When block temperature reaches 120 °F , the

to the oil primary control.

F120 proving switch closes and sends power

F120 proving switch remains closed and oil

primary control has power.

Oil primary control relay closes.

Burner ignition sequence begins.

oil solenoid.

Pump circuit opens

Burner ignites.

oil pump.

Pump circuit starts

from cad cell indicating

Oil primary control

receives <500 ohm signal

proper ignition.

Yellow indicator

light ON.

Burner continues to run

Hour meter starts.

until the wall thermostat

is satisfied.

opens and the burner

Primary control relay

Wall thermostat is

satisfied and T

Warm air delivered

to heated area.

shuts off.

circuit opens.

CB-1750/2500/3250

FLOW CHART

115 V / 60 Hz

230 V / 60 Hz

CB-3250

INITIAL START-UP

BURNER PRE-IGNITION SEQUENCE

temperature.

heater element and maintains 140 °F block

Preheater thermostat cycles 400 watt block

plugged in.

Burner cable

sending power to

switches.

and both high limit

centrifugal switch

Main power ON

heater element and heats the block to 140 °F.

Preheater thermostat activates 400 watt block

NORMAL BURNER OPERATION

BURNER IGNITION SEQUENCE

Green indicator

light ON.

Air sensing switch closes

as it receives more than

10 psi of air pressure.

Air regulator adjusted to

proper psi of air pressure.

INITIAL START-UP

Air solenoid

of spark at electrode gap)

providing interrupted

ignition (approx. 45 sec.

14,000 volt igniter starts,

opens.

Air sensing switch

centrifugal switch.

receives power from

sends power to air sensing

switch.

for proper combustion air.

Combustion air band adjusted

INITIAL START-UP

Centrifugal switch closes and

reaches full rpm.

Burner motor starts and

Blower switch sends power

FURNACE HEATING SEQUENCE

Blower switch senses ON

Blower switch on combustion

to motor (CB-1750) or relay

(CB-2500 / 3250), and

blower starts.

FURNACE COOL DOWN SEQUENCE

temperature (180 °F) and

Blower switch closes.

chamber senses temperature

rise as the burner fires.

Blower stops running.

temperature (160 °F) and

Blower switch senses OFF

Blower switch opens.

to drive latent heat from

the heat exchanger.

Blower continues to run

10-2

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

PROBLEM POSSIBLE CAUSE(S) POSSIBLE ACTION(S)

Burner won’t run at all and Green power light is NOT ON.

Burner won’t run at all and Green power light is ON.

1. Circuit breaker/main switch open.

2. Fuse/breaker blown.

3. Burner cable is damaged or not plugged in properly.

1. Oil primary control has shut down on safety reset.

2. Wall thermostat is not operating.

3. Heater block is not heating up.

4. F-120 proving switch has not closed.

5. Oil primary control terminals are not wired correctly.

6. Oil primary control is damaged.

7. e L-200 or L-290 limit switches have opened.

1. Close circuit breaker/switch.

2. Electrician should check out electrical system.

3. Check burner cable.

1. Follow the directions in Section 7 to reset the oil primary control.

2. Check the wall thermostat and thermostat cable.

3. Feel the back of the burner; it should be 140 degrees F. If the heater block is NOT HOT: (a) Wait 15 minutes for the heater block to heat up and re-check the back of the burner, and (b) Check the block heater thermostat and block heater element. Refer to the wiring diagram and ladder schematic in Appendix B.

4. If the block is HOT: (a) Check the red wire at the F-120 proving switch for power. If there is NO power at the red wire, refer to the wiring diagram and ladder schematic in Appendix B to troubleshoot the circuit that provides power to the proving switch. (b) If there is power at the red wire at the proving switch, check for power at the black wire. If there is NO power at the black wire, replace the F-120 proving switch.

5. Check the oil primary control: (a) Check that the “F” terminals are NOT jumped. (b) Check that the two yellow cad cell wires are connected to the “F” terminals. (c) Check that the two thermostat wires are connected to the “T” terminals.

6. Replace oil primary control: (a) Check voltage – it must be 115 volts.

7. Test the switch for power. Note that power should be indicated on both sides of the switch. See Section 7.

10-3

Operator's Manual: Models CB-1750, CB-2500 & CB-3250

PROBLEM POSSIBLE CAUSE(S) POSSIBLE ACTION(S)

Burner ignites, but will not stay running and Burner shuts o on reset within 15 seconds.

1. ere is a fuel delivery problem.

2. e cad cell is dirty.

3. Cad cell wires are loose.

4. Cad cell / cad cell wires are damaged.

5. e primary control is not receiving the proper ohm signal from the cad cell.

1. Follow the procedures listed in the next problem.

2. Clean and check the condition of the cad cell and cad cell wires.

3. Check that the yellow wires are connected properly at the “F” terminals on the oil primary control.

4. Replace the cad cell and cad cell wires. If the cad cell is heat damaged: (a) Clean your furnace, including the combustion chamber, ues and stack. Refer to instructions in Section 9. (b) Check for backdra caused by exhaust fans in your building. Follow instructions in Section 8.

5. Disconnect the yellow wires from the “F” terminals. Start the burner and check the ohm reading from the cad cell. You have 10 seconds to perform this test before the burner shuts o on reset. Refer to Section 7 to reset the oil primary control. If the ohm reading is above 500 ohms: (a) Check the position of the cad cell; the cad cell must “look” straight through the central hole in the retention head. (b) Check the position of the retention head according to Appendix A

Burner ignites and runs properly, but the burner shuts o on reset periodically (e.g. the burner goes o on reset during the night and requires resetting in the morning).

1. ere is air in the suction oil line due to leaks at the ttings.

2. ere is air trapped in a high point in the pressure oil line

10-4

1. Follow the procedures in Section 5 to vacuum test the pump. Reinstall and properly seal the suction line ttings to eliminate air leaks.

2. Bleed the air out of the pressure oil line.

CLEAN BURN CB-1750, CB-2500, CB-3250, CB 140 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual