CLEAN BURN CB-3500, CB-5000 Operator's Manual

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OPERATOR'S MANUAL

CLEAN BURN MULTI-OIL FURNACE MODELS:

CB-3500 with CB-525-S2 BURNER CB-5000 with CB-550-S2 BURNER

ENERGY SYSTEMS

www.cleanburn.com

USED-OIL BURNING

APPLIANCE

#MH15393 (N)

LISTED

I88798-C

PUBLICATION DATE: 05/12/14, Rev. 14 CLEAN BURN PART #43144

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.

USED OIL-FIRED

FURNACE

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 Blower Components ................................................................................................ 3-4

Installing the Blower (CB-5000 ONLY) ................................................................................ 3-4

Installing the Motor on the Blower ........................................................................................ 3-4

Wiring the Blower Motor ....................................................................................................... 3-4

Installing the Motor Pulley, Blower Pulley, and V-Belt ......................................................... 3-6

Installing the Belt Guard and the Blower Guard .................................................................... 3-7

Installing the Hot Air Discharge Components ............................................................................... 3-8

Determining the Air Discharge Conguration ....................................................................... 3-8

UNIT HEATERS: Installing the Air Discharge Louver Assembly ....................................... 3-9

CENTRAL FURNACES: Installing Ductwork .................................................................. 3-10

Installing the Energy Retention Disc ........................................................................................... 3-10

Installing the Energy Retention Disc in the Combustion Chamber ..................................... 3-10

Closing the Furnace Door .................................................................................................... 3-10

Installing the Burner .....................................................................................................................3-11

Checking the Burner Nozzle and Electrodes 3-11

Mounting the Burner on the Hinge Bracket ......................................................................... 3-12

Installing the Connector Block, Oil Line Tubing, and Air Line Tubing...................................... 3-13

Installing the Connector Block on the Furnace Door .......................................................... 3-13

Installing the Oil Line Tubing .............................................................................................. 3-13

Installing the Air Line Tubing .............................................................................................. 3-14

Locking the Burner into Firing Position .............................................................................. 3-15

Installing the Mounting and Stabilizer Brackets ......................................................................... 3-15

Installing the Brackets on the Furnace Cabinet ................................................................... 3-15

TABLE OF CONTENTS

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

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

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

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

Installing the Interior Stack .................................................................................................. 4-19

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 Function of 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 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

TABLE OF CONTENTS

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 ............................................................................... 6-5

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

Understanding the Fan Switches and Hi-Limits ............................................................................ 7-2

The Blower/Fan Switch ................................................................................................................. 7-2

The Fan Limit Control ................................................................................................................... 7-3

The Auxiliary Hi-Temp Limit Switch ........................................................................................... 7-4

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

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

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

Adjusting Draft Overre on Furnaces with Draft Inducers ........................................................... 8-2

Solving Draft Overre Problems ................................................................................................... 8-3

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

Cleaning and Maintaining the Draft Inducer ................................................................................. 9-9

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

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

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

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

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

TABLE OF CONTENTS

APPENDIX A

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

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

Furnace Dimensions .................................................................................................................... A-3

Burner Components ...................................................................................................................... A-6

Removing the Nozzle for cleaning ...................................................................................... A-13

CB-3500 Furnace Components .................................................................................................. A-14

CB-3500 Blower Components ................................................................................................... A-16

CB-5000 Furnace Components .................................................................................................. A-18

CB-5000 Blower Components ................................................................................................... A-20

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

APPENDIX B

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

Furnace Wiring Diagram ........................................................................................................B-1

Burner Wiring Diagram .................................................................................................................B-2

Ladder Schematic ...................................................................................................................B-3

Metering Pump Wiring Schematic .........................................................................................B-4

Cad Cell Oil Primary Details .........................................................................................................B-5

APPENDIX C

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

Operator's Manual: Models CB-3500 & CB-5000

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-3500 and CB-5000. 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 questions 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-3500 & CB-5000

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-3500 & CB-5000

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.

1-3

Operator's Manual: Models CB-3500 & CB-5000

For Your Safety... (continued)

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

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-3500 & CB-5000

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-3500 & CB-5000

For Your Safety... (continued)

Safety Labels

Following are the locations and descriptions of all labels on your CB-3500 or CB-5000 furnace. 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

42146

AIR OIL

I88799-B

42367

42358

42174 42175

SERIAL #

42030

42457

42027

42144/42145

CB-3500/CB-5000 Furnace Cabinet Labels

Label Part # Description

42030 Furnace Electrical Shock Hazard Warning Label (several locations) 42457 Made in USA / Patent Pending Combination Label 42027 Furnace Burn Hazard/Hazardous Voltage Warning Label 42367 Furnace Safety Warning Label (Multiple Messages - Fire/Shock/Burn Hazards) 42358 UL / ULC Header Label 42174 Data Label - CB-3500 42175 Data Label - CB-5000 42497 Clean Burn Logo Label (not shown - positioned on side of unit) 42144 Model CB-3500 Label 42145 Model CB-5000 Label 42146 220V Label 42068 Furnace Blower/Fan Entanglement Hazard Warning Label

(not shown - positioned on top of unit near blower)

1-6

Operator's Manual: Models CB-3500 & CB-5000

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-3500 & CB-5000

For Your Safety... (continued)

CB-3500/CB-5000 Furnace Cabinet Safety Labels

MODEL NO.

CB-3500

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

LISTED FUELS

INPUT

- GPH -

NO 2 OIL

2.5 16.0 7.0

USED CRANKCASE OIL

HYDRAULIC OIL

ATF

MAX.. DISCHARGE

AIR TEMP-F

2.5

2.5 16.0

220

FLUE DRAFT IN W.C.

CLEARANCE TO COMBUSTIBLE SURFACES: (INCHES)

POWER

1/6

1/10

400

1/3

CHIMNEY

REAR

VO LTS AMPS

208/230

120

TOP

18 18

FRONT

BLOWER MOTOR HP.

OIL PUMP MOTOR HP.

BURNER MOTOR HP.

BURNER HEATER WAT TS

DRAFT IND. (OPT) HP

AIR COMPRESS. (OPT) HP.

TOTAL CIRCUIT AMPACITY W/BLOWER (UNIT HEATER)

MAXIMUM FUSE SIZE

TOTAL CIRCUIT AMPACITY W/BLOWER (CENTRAL FURNACE)

MAXIMUM FUSE SIZE

350000

ATOM AIR PRESSURE

OIL

PRESSURE

- PSIG - - PSIG -

9.516.02.5

16.0

8.0

8.5

.06

SIDES

BOTTOM

11.3/11 60

3.2

1.4

3.3

3.9

3.5

26.6/26.3

35/35

26.6/26.3

35/35

MODEL NO.

CB-5000

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

LISTED FUELS

INPUT

- GPH -

NO 2 OIL

3.6 18.0 3.5

USED CRANKCASE OIL

HYDRAULIC OIL

ATF

MAX.. DISCHARGE

AIR TEMP-F

3.6

3.6 18.0

220

FLUE DRAFT IN W.C.

CLEARANCE TO COMBUSTIBLE SURFACES: (INCHES)

POWER

1/6

1/10

400

1/3

CHIMNEY

REAR

VO LTS AMPS

120

TOP

18 18

FRONT

BLOWER MOTOR HP.

OIL PUMP MOTOR HP.

BURNER MOTOR HP.

BURNER HEATER WAT TS

DRAFT IND. (OPT) HP

AIR COMPRESS. (OPT) HP.

TOTAL CIRCUIT AMPACITY W/BLOWER (UNIT HEATER)

MAXIMUM FUSE SIZE

TOTAL CIRCUIT AMPACITY W/BLOWER (CENTRAL FURNACE)

MAXIMUM FUSE SIZE

500000

ATOM AIR PRESSURE

OIL

PRESSURE

- PSIG - - PSIG -

4.518.03.6

18.0

4.0

-.06

SIDES

BOTTOM

11.3/11208/230

3.2

1.4

3.3

3.9

3.5

26.6/26.3

35/35

26.6/26.3

35/35

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

42174 - R1

Clean Burn Energy Systems

4109 Capital Circle

Janesville, Wisconsin 53546

1-800-331-0183

www.cleanburn.com

Serial No. CB-XXXX-XXXXX

Model No. CB-XXXX

AUTHORITIES HAVING JURISDICTION SHOULD

BE CONSULTED PRIOR TO INSTALLATION

42175 - 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

1-8

Operator's Manual: Models CB-3500 & CB-5000

For Your Safety... (continued)

CB-3500/CB-5000 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 CB-525-S2 Burner Model/Serial Number Label 42322 CB-550-S2 Burner Model/Serial Number Label 42197 Made in USA / Patent Pending Combination Label

(not shown - positioned on side of burner)

42229 Logo/Burner Description Label 42023 Burner Power Label

CB-3500/CB-5000 BurnerSafety Labels

42005

42004

42000

42235

42321 42322

42229

42023

I88800-B

WARNING

Hazardous high voltage and moving parts hazard.

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

42004 Rev. 2

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.

WARNING

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

42000 Rev. 2

WARNING

42235 Rev. 2

1-9

Operator's Manual: Models CB-3500 & CB-5000

1-10

Operator's Manual: Models CB-3500 & CB-5000

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

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

panels.

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.

NOTE: DO NOT remove the squirrel cage blower from the furnace cabinet. (The blower is installed in nal position for Model CB3500; it will require additional installation for Model CB5000.)

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 (CB-3500 and CB-5000)

ONE SKID containing:

• Furnace cabinet Components packed on top of furnace cabinet:

• Burner • Air discharge

• Blower • Draft inducer (CB-5000 only)

• Oil pump: Metering Pump OR J-Pump

- includes suction oil line ttings package

Components packed inside furnace cabinet:

• Energy Retention Disc • Blower assembly components

• 2 HP Blower motor • Canister lter

• Vacuum gauge • Check valve / check valve screen

• Wall thermostat • Barometric damper

• Connector block • Burner oil line and air line components

• Operator's Manual literature packet

- includes tank safety label

• Assorted bolts/ttings, Assembly parts, Mounting components

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

2-1

Operator's Manual: Models CB-3500 & CB-5000

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 Energy Retention Disc 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

CLEAN-OUT BREACH

CLEAN-OUT CAP

COMBUSTION CHAMBER

FURNACE FLUE

I88293-A

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

Clean Burn, LLC.

4109 Capital Circle

Janesville, WI 53546

2-2

Operator's Manual: Models CB-3500 & CB-5000

SECTION 3: FURNACE ASSEMBLY

Understanding Assembly

Assembling your Clean Burn Furnace is a six-step process which includes: (1) Installing the Blower Components (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 (6) Installing the Mounting and Stabilizer Brackets

Clean Burn recommends that you review all assembly procedures before proceeding, paying careful attention to safety information statements. Please note that some assembly procedures apply only to certain furnace models. Figures 3A and 3B on the following pages provide a general overview of the furnace components and their proper assembly and how the unit should look following proper assembly.

Required Tools and Materials

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

• Variable-speed drill

• 1/4" hex-nut driver attachment for drill

• 5/16" hex-nut driver attachment for drill

• Set of open-end wrenches (3/8" - 5/8")

• Medium adjustable wrench

• Medium straight-blade screwdriver

3-1

JUNCTION BOX

FAN LIMIT

BURNER

CABLE

Operator's Manual: Models CB-3500 & CB-5000

'ALL THREAD' ROD

STABILIZER BRACKET ON TOP OF FURNACE

AIR DISCHARGE

BURNER

MOUNT

THROAT

FURNACE DOOR

FRONT VIEW OF CABINET

PRIOR TO ASSEMBLY

NOTE: BLOWER MUST BE INSTALLED WITH BULGE ON BLOWER FACING BACK OF FURNACE. MAKE SURE BLOWER WHEEL ROTATION IS CLOCKWISE AS SHOWN

NOTE: LOOP ON ENERGY RETENTION DISC HOOKS OVER MOUNTING BRACKET ON BACK WALL OF COMBUSTION CHAMBER

ROTATION

ENERGY RETENTION DISC INSTALLED ON BACK WALL OF COMBUSTION CHAMBER

BURNER

CONNECTOR

BLOCK

FRONT VIEW OF CABINET

AFTER ASSEMBLY

AIR DISCHARGE

STABILIZER BRACKETS

MOUNTING

BRACKET

BELOW

AIR OIL

FURNACE

SIDE VIEW OF CABINET

Figure 3A - Overview of Furnace Assembly

Complete assembly of the CB-3500/CB-5000 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 Energy Retention Disc (4) Installing the Burner (5) Installing the Connector Block, Oil Line Tubing, and Air Line Tubing (6) Installing the Mounting and Stabilizer Brackets NOTE: Corresponding procedures provided in order in this section.

FURNACE BREACH

MOUNTING BRACKETS INSTALLED

3-2

ON FURNACE CABINET BASE

I88801-C

Operator's Manual: Models CB-3500 & CB-5000

STABILIZER

BRACKETS

MOUNTING

BRACKETS

I88288-B

Figure 3B - Three-dimensional View - Furnace Completely Assembled

with Louver Assembly for Unit Heater Application

NOTE: This gure shows the mounting/stabilizer brackets in place for

a ceiling mounting installation. If your furnace will be oor

or platform mounted, the brackets are not needed.

3-3

Operator's Manual: Models CB-3500 & CB-5000

Installing the Blower Components

NOTE: The blower is installed in nal position on the CB-3500 cabinet. The blower for the CB-5000

requires additional installation as described in the following procedure.

Installing the Blower (Model CB-5000 ONLY)

NOTE: For proper air ow through the furnace, the blower must be positioned so the bulge on the blower faces toward the rear of the furnace as illustrated in Figures 3A, 3B, and 3D.

1. Remove the hex-head screws, which hold the blower in the shipping position.

2. Carefully slide the blower rearward on the cabinet into position against the blower inlet lip.

3. Use self-tapping screws to install the angle support at the back of the blower to complete the

blower inlet lip.

4. Install at least three (3) self-tapping screws to each side of the blower inlet to safely support the

blower.

Installing the Motor on the Blower

1. Refer to Figures 3C and 3D.

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

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 3C.

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 lower holes in the motor mounting plate and motor. Tighten the nuts to hold the motor rmly in position.

Wiring the Blower Motor

WARNING: To avoid electrical shock, make sure the main power to the furnace is turned OFF before wiring the blower motor.

1. Refer to the Furnace Wiring Diagram provided in Appendix B at the back of this manual.

2. Install the electrical cable between the electrical junction box on the front of the furnace and the

electrical access on the blower motor.

3. Connect the wires in the junction box according to the Furnace Wiring Diagram (Appendix B).

NOTE: The blower motor is rated for 208-230 volts, single phase. Make sure the proper electrical circuit to the

furnace has been provided by a qualied electrician as shown in the Furnace Wiring Diagram.

3-4

Operator's Manual: Models CB-3500 & CB-5000

BLOWER ASSEMBLY PARTS LIST

1 NUT 2 NUT 3 2 HP MOTOR 4 MOTOR PULLEY 5 MOTOR MOUNTING PLATE 6 BOLT 7 MOTOR TENSIONING BRACKET 8 BLOWER PULLEY 9 SELF-TAPPING BOLT 10 V-BELT 11 MOTOR MOUNTING BRACKET 12 SQUARE HEAD BOLT 13 MOTOR BUSHING (7/8" HUB) 14 BLOWER BUSHING (1" HUB) 15 LOCKWASHER 16 CAPSCREWS

8.5"

46.5

18.5"

11.5"

21"

CB-3500 BLOWER CB-5000 BLOWER

NOTE: The brackets must be installed at the correct position on the side of the blower as shown here.

Note the measurements provided which should aid your positioning of the brackets.

Figure 3C - Expanded View of Blower Assembly

DETAIL OF BRACKET INSTALLATION

I88876-A

3-5

Operator's Manual: Models CB-3500 & CB-5000

Installing the Blower Components (continued)

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

MODEL CB-3500

1 BLOWER PULLEY (31225) 2 BLOWER BUSHING - 1" HUB (31226) 3 MOTOR PULLEY (31223) 4 MOTOR BUSHING - 7/8" HUB (31238) 5 LOCKWASHERS 6 CAPSCREWS

MODEL CB-5000

1 BLOWER PULLEY (31225) 2 BLOWER BUSHING - 1" HUB (31226) 3 MOTOR PULLEY (31227) 4 MOTOR BUSHING - 7/8" HUB (31238) 5 LOCKWASHERS 6 CAPSCREWS

I88878-B

Figure 3D - Blower Pulley and Motor Pulley Parts List

1. Review the contents of the Blower Pulley and Motor Pulley as shown in Figure 3D. 2 Refer to Figure 3D. 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 wedging will split the bushing.

MOTOR BRACKET

I88877

TENSION BRACKET

Figure 3E - Blower Assembly Installed on Furnace Cabinet

3-6

Operator's Manual: Models CB-3500 & CB-5000

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

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.

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 3E).

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 Belt Guard and the 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.

2. Install the belt guard and blower guard

as shown.

BLOWER

GUARD

BELT GUARD

I88802-B

Figure 3F - Installing the Belt and Blower Guards

3-7

Operator's Manual: Models CB-3500 & CB-5000

Installing the Hot Air Discharge Components

Determining the Air Discharge Conguration

The CB-3500 and CB-5000 furnaces may be congured for use as EITHER a Unit Heater or a Central Furnace as

described below.

(1) Unit Heater Furnace with blower for FREE AIR applications. HOT AIR DISCHARGE: Louver assembly (components supplied)

NOTE: If the peak of your shop roof/ceiling is 14 feet or higher, install industrial-size ceiling fans to aid in efcient, even heat distribution. A minimum of one Clean Burn 56" Blade Industrial Ceiling Fan (C.B. part# 70003) or equivalent is recommended for each 2000 square feet of shop space.

Be sure to adhere to the specied clearances as stated in Section 4 of this

manual.

(2) Central Furnace Furnace with blower for DUCTING applications from .25 to .40 static pressure.*

HOT AIR DISCHARGE: Ductwork (Refer to the following chart for the proper air discharge/ducting specications; installation to be accomplished by HVAC professionals ONLY.)

Be sure to adhere to the specied clearances as stated in Section 4 of this

manual.

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

CB-3500

Air Discharge Louvers

Mounted on Furnace

Duct Free**

4200 CFM

CB-5000

Air Discharge Louvers

Mounted on Furnace

Duct Free**

5500 CFM

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.**

5200 CFM 5100 CFM

Air Discharge Louvers Removed

Ductwork Installed on Furnace

0.40 Inches of W.C.**

3900 CFM4000 CFM

Air Discharge Louvers Removed

Ductwork Installed on Furnace

0.40 Inches of W.C.**

C77003

*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.

3-8

Operator's Manual: Models CB-3500 & CB-5000

UNIT HEATER APPLICATIONS: Installing the Air Discharge Louver Assembly

The body of the air discharge louver assembly is shipped assembled and is packed on top of the furnace cabinet. The louvers, nuts and bolts, which must be assembled separately, are packed inside the combustion chamber.

It is very important to install the air discharge to direct the ow of the hot air from the furnace as desired for your application. As you will note from Figure 3G, the air discharge may be installed facing forward (as shown) or rotated 90 degrees to the left or right. Additionally, the louvers may be installed horizontally or vertically to direct the ow of the heated air.

1. Position the body of the air discharge as desired over the hot air outlet on the furnace (i.e. facing forward, right, or left). ATTENTION: KEEP THE ORIFICE PLATE IN PLACE (as shown in Figure 3G) when installing the louver assembly. The orice plate is necessary for proper air ow from the furnace.

2. Use the 12 self-tapping screws to securely attach the body of the louver assembly to the furnace cabinet.

3. Install the louvers in the desired position (i.e. horizontally or vertically) using the bolts and locking nuts

provided. ATTENTION: DO NOT restrict the ow of hot air from the furnace by closing the louvers, or damage to the furnace and/or blower motor may occur.

ORIFICE

PLATE

AIR DISCHARGE WITH LOUVERS MOUNTED HORIZONTALLY

AIR DISCHARGE WITH LOUVERS MOUNTED VERTICALLY

STABILIZER BRACKET

MOUNTING

BRACKET

Figure 3G - Installation of the Hot Air Discharge Louver Assembly

I88291-B

3-9

Operator's Manual: Models CB-3500 & CB-5000

CENTRAL FURNACE APPLICATIONS: Installing Ductwork

If you plan to install ductwork on your furnace,itismandatorythatqualiedHVACpersonneldesignand installtheductworksystemtotheCFMandSPspecicationsprovidedinthismanual. Establish correct duct

size according to the following specications and use radial bends or turning vanes to allow for proper air ow.

Sizing the Ductwork:

• For Model CB-3500, the outlet on the air discharge is 20" x 20". The main duct (CB-3500)

must initially maintain an outlet size of 20" x 20".

• For Model CB-5000, the outlet on the air discharge is 24" x 24". The main duct (CB-5000) must initially maintain an outlet size of 24" x 24".

Additionally, to ensure proper air ow from the furnace and to prevent damage to related furnace components, adhere to the following guidelines for installing ductwork with your CB-3500 or CB-5000 central furnace

application.

Installation Guidelines for Ductwork:

• It is essential that qualied HVAC personnel properly design the ductwork for your

furnace and determine the static pressure for your ducting application; ATTENTION: Failure to adhere to the static pressure and CFM specications provided in this manual may result in damage to the blower motor.

• The ductwork should be installed directly over the opening in the top of the furnace cabinet (i.e. where the louver assembly would be installed for free air applications.)

• THE ORIFICE PLATE MUST BE REMOVED for all ductwork applications.

• Existing ductwork at your installation site may NOT be appropriate or meet the specications for

your furnace installation.

Installing the Energy Retention Disc

Installing the Energy Retention Disc in 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 damage.

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.

3-10

Operator's Manual: Models CB-3500 & CB-5000

Installing the Burner

Checking the Burner Nozzle and Electrodes

NOTE: The burner nozzle is factory installed. Model CB-3500 uses a Delavan 9-5 nozzle. Model CB-5000 uses a Delavan 9-11 nozzle. The nozzle size is indicated on the nozzle head as shown in Figure 3H.

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

NOTE: Check the electrode settings as specied in Figure 3H. 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 3H - Burner Nozzle and Electrode Specications

3-11

Operator's Manual: Models CB-3500 & CB-5000

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.

3-12

Operator's Manual: Models CB-3500 & CB-5000

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

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

your warranty.

Installing the Connector Block on the Furnace Door

OIL LINE

1. Refer to Figure 3I.

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

OIL FITTING ON BURNER

block onto the furnace door.

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

CONNECTOR BLOCK

AIR OIL

the accumulator is in a vertical position to prevent sediment from settling in the accumulator. Never operate your furnace without

FRONT VIEW OF FURNACE

the connector block and accumulator properly installed on the furnace, or damage may occur to vital burner components.

Installing the Oil Line Tubing

OIL LINE FITTING ON BURNER LINED UP WITH OIL LINE

ATTENTION: DO NOT disassemble the compression tting

OIL LINE

from the swivel tting. To prevent leaks, the NPT threads of the compression tting have been sealed with hydraulic sealant during assembly of the ttings at the factory.

SWIVEL

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

tubing.

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

ASSEMBLY

CONNECTOR BLOCK

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 3I, if required, to "line up" the oil line.

SIDE VIEW OF FURNACE

SHOWING OIL LINE INSTALLED

Figure 3I - Installation of

Connector Block and Oil Line

I88341-A

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.

(procedure continued on next page)

3-13

Operator's Manual: Models CB-3500 & CB-5000

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 3I 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 3J, 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 3J. 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.

CONNECTOR BLOCK

WITH ACCUMULATOR

INSTALLED ON

FURNACE CABINET

AIR OIL

AIR LINE FITTING ON BURNER

OIL LINE FITTING ON BURNER

AIR LINE

OIL LINE

COMPRESSION FITTING

I88357-A

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

SWIVEL FITTING

3-14

Operator's Manual: Models CB-3500 & CB-5000

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 3K.

CONNECTOR PLUG

KEY IN PLUG MUST ALIGN WITH SLOT IN RECEPTACLE

RECEPTACLE ON TOP OF BURNER

I88641-B

Figure 3K - Detail of Burner

Electric Receptacle

Installing the Mounting and Stabilizer Brackets

Installing the Brackets on the Furnace Cabinet (For Ceiling Mounting Only)

NOTE: If you are ceiling mounting your furnace, it is critical that the mounting and stabilizer brackets be installed as described below.

The mounting brackets must be attached to the furnace base to allow ceiling installation of the furnace using "all-thread" rods. See Figures 3A/3B.

The weight of the furnace must be supported by the mounting brackets. The stabilizer brackets are installed on

the top of the furnace to properly align the "all-thread" rods. The stabilizer brackets will not support the furnace.

1. Refer to Figures 3A and 3B.

2. Install both mounting brackets (1" channel) on the base of the furnace using the four (4) bolts supplied.

3. Install the two (2) stabilizer brackets on the top of the furnace using self-tapping screws.

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.

3-15

Operator's Manual: Models CB-3500 & CB-5000

3-16

Operator's Manual: Models CB-3500 & CB-5000

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:

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 NFPA88A 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.

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-3500 & CB-5000

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 '

DEDICATED ELECTRIC CIRCUIT

ELECTRICAL

SERVICE

THERMOSTAT CABLE

"2 WIRE" MIN. 18 GA.

THERMOSTAT

24 VOLT WALL

COMPRESSED AIR LINE

INSTALLED TO ALUMINUM

CONNECTOR BLOCK

EMERGENCY

VENT VALVE

MAXIMUM 6 FEET

AIR OIL

PRESSURE OIL LINE

SUCTION

OIL LINE

BALL

VALVE

FOR MORE DRAFT

WEIGHT

TURN

1/4" HOLE FOR SETTING DRAFT AT BREACH

OIL PUMP ELECTRICAL CIRCUIT

VENT

CAP

10 FT. MIN. VERTICAL STACK HEIGHT

FROM THE PUMP MAY DECREASE

CAUTION: DO NOT EXCEED 6 FEET

VERTICAL SUCTION LIFT OR THE PUMP

WILL NOT PRIME AND/OR THE FLOW RATE

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

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

Figure 4A - Typical CB-3500/5000 Furnace Installation

4-2

OIL

STORAGE

TANK

I88359-F

Operator's Manual: Models CB-3500 & CB-5000

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 CB-3500/CB-5000

INSTALLATIONS

WARNING: National codes require

• TOP (above blower) ......................... 2"

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

• SIDES ............................................ 24"

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

• REAR ............................................ 18"

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

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

**Where applicable

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.

18"

REAR

18"

CHIMNEY

CONNECTOR

MINIMUM CLEARANCES

CB-3500 / CB-5000 FURNACES

TOP

24"

SIDES

60"

FRONT

BOTTOM

24"

Figure 4B - Clearances from Combustibles

4-3

I88803-A

Operator's Manual: Models CB-3500 & CB-5000

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.

"CLASS A" STACK CAP NON-RESTRICTIVE TYPE TO ALLOW FREE FLOW OF THE STACK GASES

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

10 FT. (3 M)

"CLASS A" KIT FOR INSTALLING "CLASS A" STACK

THROUGH CEILING

3 FT. (90 cm)

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

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

WATERTIGHT ROOF FLASHING: CLEAN BURN RECOMMENDS "DEKTITE" FLASHING FOR A WATERTIGHT SEAL

SINGLE WALL STACK

FOR MORE DRAFT

WEIGHT

TURN

'CLASS A' STACK COMPONENTS

INSULATED STACK WITH A STAINLESS STEEL LINER

TO MAINTAIN PROPER DRAFT OVERFIRE

10 FT. (3 M) MINIMUM VERTICAL STACK HEIGHT

Figure 4C - Ceiling Mounting Installation Overview

1/4" HOLE FOR

SETTING DRAFT.

ADJUST BAROMETRIC DAMPER FOR

-.04 W.C. DRAFT

AT BREECH

AIR OIL

BAROMETRIC DAMPER MUST BE INSTALLED SO IT IS FACING

AWAY FROM THE FAN TO PREVENT EXHAUST GASES FROM BEING SUCKED OUT

OF THE DAMPER OPENING

MIN. 24 GAUGE

SINGLE WALL STACK

I88805-C

4-4

Operator's Manual: Models CB-3500 & CB-5000

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.

CAUTION: If you are installing your furnace

in an area with a combustible oor (e.g. over the top of a parts room or on a mezzanine), you must construct a non-combustible oor as shown in Figure 4E. Refer to NFPA-31 or CSA-B-139.

Constructing A Non-Combustible Floor

AIR OIL

TO FURNACE. REFER TO NFPA 88-B.

8 FEET (2.5 METER) MINIMUM FROM FLOOR

I88804-B

Figure 4D - Furnace Installed on

Raised Platform

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-3500 measures 58" long x 35" wide. 58" + 12" + 12" = 82" long 35" + 12" + 12" = 59" 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.

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.

4-5

Operator's Manual: Models CB-3500 & CB-5000

Constructing A Non-Combustible Floor (continued)

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 LIP FOR OIL CONTAINMENT

4 INCHES (MIN.) TALL CINDER BLOCK

1 PIECE MIN. 24 GA STEEL

2 PIECES 5/8" SHEETROCK

COMBUSTIBLE MATERIAL

AIR OIL

MIN. 12"

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

Figure 4E - Furnace Installed on Non-Combustible Floor

MIN. 12"

I88806-B

4-6

Operator's Manual: Models CB-3500 & CB-5000

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 municipal 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 is also supplied with the metering pump and oil line installation

procedures (following in Section 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-3500 & CB-5000

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-3500 & CB-5000

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-3500 & CB-5000

# 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-3500 & CB-5000

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. Re-install 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

GAUGE

A2RA-7720

INLET

ROTATION ROTATION

RELIEF

INLETINLET

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

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-3500 & CB-5000

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 electrical junction box on the furnace. Refer to NFPA-70 for wire size and distances

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

2. Wire the furnace according to the Wiring Schematic, Figure B1, 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.

Model Voltage Breaker Size* Circuit Hertz

CB-3500 208/240 30/30 amps Dedicated 60 CB-3500 (w/Options) 208/240 35/35 amps* Dedicated 60 CB-5000 208/240 30/30 amps Dedicated 60 CB-5000 (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-3500 & CB-5000

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 and screen 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.

• 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.

4-13

Operator's Manual: Models CB-3500 & CB-5000

Installing the Suction Oil Line Components (continued)

(1.) (e.) Prepare the canister lter for installation (continued):

• 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.

FOR MORE DRAFT

WEIGHT

TURN

COMPRESSED AIR LINE

MAXIMUM 6 FT (183 cm)

THE PUMP MAY DECREASE

NOT PRIME AND/OR THE FLOW RATE FROM

VERTICAL SUCTION LIFT OR THE PUMP WILL

CAUTION: DO NOT EXCEED 6 FT (183 cm)

CLEAN-OUT

FUNNEL

WITH BALL VALVE

EMERGENCY VENT RELIEF

AIR OIL

OIL FLOW

PRESSURE OIL LINE

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

CHECK VALVE SCREEN

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

BALL VALVE

SUCTION LINE

INSTALL SLIP FITTING

TO HOLD TUBING

IN PLACE

CANISTER FILTER IN SUCTION LINE

OIL PUMP ELECTRICAL CIRCUIT

VENT

CAP

I88807-E

Figure 4J - Oil Line Installation Overview

4-14

Operator's Manual: Models CB-3500 & CB-5000

2. Install the suction oil line (fromthethetanktothecanisterlter): a. Refer to Figures 4H and 4J. 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 Figures 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-3500 & CB-5000

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 4F, and 4J.

• 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

GAUGE

A2RA-7720

INLET

RETURN

TO TANK

RELIEF

R H ROTATION

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

I89004-D

4-16

Operator's Manual: Models CB-3500 & CB-5000

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 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 -- for Model CB-3500 use minimum 1/4" O.D. copper tubing or equivalent; for Model CB-5000, use 3/8" O.D.

copper tubing or equivalent.

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-3500 & CB-5000

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:

• Model CB-3500 requires minimum 8" I.D. stack components. Model CB-5000 requires minimum 10" I.D. stack components.

• Ensure that the vertical stack height is atleast10feetPLUS1.5feet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 (stack components from furnace breach to within 18" of ceiling, roof, or sidewall of

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 (6) Draft Inducer (standard component for Model CB-5000; optional accessory for Model CB-3500)

4-18

Operator's Manual: Models CB-3500 & CB-5000

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.

"CLASS A" STACK CAP NON-RESTRICTIVE TYPE TO ALLOW FREE FLOW OF THE STACK GASES

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

10 FT. (3 M)

"CLASS A" KIT FOR INSTALLING "CLASS A" STACK THROUGH CEILING

3 FT. (90 cm)

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

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

WATERTIGHT ROOF FLASHING: CLEAN BURN RECOMMENDS "DEKTITE" FLASHING FOR A WATERTIGHT SEAL

SINGLE WALL STACK

FOR MORE DRAFT

WEIGHT

TURN

'CLASS A' STACK COMPONENTS

INSULATED STACK WITH A STAINLESS STEEL LINER

TO MAINTAIN PROPER DRAFT OVERFIRE

10 FT. (3 M) MINIMUM VERTICAL STACK HEIGHT

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

1/4" HOLE FOR

SETTING DRAFT. ADJUST BAROMETRIC DAMPER FOR

-.04 W.C. DRAFT AT BREECH

AIR OIL

BAROMETRIC DAMPER MUST BE INSTALLED SO IT IS FACING

AWAY FROM THE FAN TO PREVENT EXHAUST GASES FROM BEING SUCKED OUT OF THE DAMPER OPENING

MIN. 24 GAUGE

SINGLE WALL STACK

I88805-C

4-19

Operator's Manual: Models CB-3500 & CB-5000

"CLASS A" STACK CAP NON-RESTRICTIVE TYPE TO ALLOW FREE FLOW OF THE STACK GASES

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

SINGLE WALL STACK MIN. 24 GAUGE

BAROMETRIC DAMPER

"CLASS A" STACK PENETRATION AND

CLEAN-OUT TEE

10 FT. (3 M)

3 FT. (90 cm)

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

10 FT. (3 M) MINIMUM VERTICAL STACK HEIGHT

"CLASS A" STACK COMPONENTS

INSULATED STACK WITH A STAINLESS STEEL LINER

I88365-B

FOR MORE DRAFT

TURN

WEIGHT

AIR OIL

Installing the Stack (continued)

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

4-20

Operator's Manual: Models CB-3500 & CB-5000

Installing the Barometric Damper

1. Refer to the stack installation drawing, 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 for CB-3500; 10" single wall tee CB#70180 for CB-5000).

2. For CB-5000 ONLY: Install the 9"-to-10" pipe adapter in the opening of the tee as shown in

Figure 4N.

3. Install the barometric damper in the opening of the tee (or pipe adapter for CB-5000 furnaces). Use a

small spirit level to make sure that it is properly level.

4. Install two self-tapping screws (i.e. one on each side of the barometric damper) to hold the damper in

place as shown in Figures 4N and 4O . 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.

9" CLEAN BURN BAROMETRIC DAMPER WITH ADAPTOR IN

10" SINGLE WALL TEE

ADJUST THIS WEIGHT TO OBTAIN PROPER DRAFT

DAMPER PIPE ADAPTOR

9" BAROMETRIC DAMPER

DESCRIPTION

(FOR CB-5000)

31198

31197

PART #

QTY

Figure 4N - Installation of 9" Barometric Damper for Model CB-5000 Furnaces

8" CLEAN BURN BAROMETRIC DAMPER INSTALLED IN SINGLE WALL TEE

ADJUST THIS WEIGHT TO OBTAIN PROPER DRAFT

I88547

I88539

(FOR CB-3500)

Figure 4O - Installation of 8" Barometric Damper for Model CB-3500 Furnaces

4-21

8" BAROMETRIC DAMPER

31170

QTY

PART #

DESCRIPTION

Operator's Manual: Models CB-3500 & CB-5000

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 4P.

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 4Q. 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 4P - Stack Safety Switch Installed on the Barometric Damper

I88964

4-22

Operator's Manual: Models CB-3500 & CB-5000

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

FF T T

OIL

PRIMARY

Figure 4Q - Stack Safety Switch Wiring Diagram

STACK SAFETY SWITCH

(MOUNTED ON

BAROMETRIC DAMPER)

4-23

I88965

Operator's Manual: Models CB-3500 & CB-5000

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 Draft Inducer

ATTENTION: The draft inducer, Field brand model DI-3, is standard equipment for CB-5000 furnaces and must be installed to ensure proper draft. The Field brand model DI-2 is available as optional equipment for the CB-3500 furnace. The Field brand draft inducers have 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 4R.)

Propersizing,installation,andadjustmentofthedraftinducerarecriticalforoptimaldraftinduceroperation.

4-24

Operator's Manual: Models CB-3500 & CB-5000

Installing the Draft Inducer (continued)

Note: Lubricate the motor as recommended by the Draft Inducer manufacturer.

"CLASS A" STACK

NOTE: INSTALL DRAFT INDUCER IN LAST SECTION OF VERTICAL STACK TO POSITION DRAFT INDUCER AWAY FROM FURNACE BREACH SO THAT 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 BREACH

CHECK FOR

5 FEET - 8 FEET

(1.5 METERS - 2.5 METERS)

-.02 W.C. DRAFT OVERFIRE

CLEAN-OUT CAP INSTALLED ON L.H. FURNACE BREACH

Figure 4R - Installation of the Draft Inducer

DRAFT

INDUCER

DRAFT

ADJUSTMENT

PLATE

FOR MORE DRAFT

WEIGHT

TURN

AIR OIL

SERVICEMAN ADJUSTS BAROMETRIC DAMPER TO OBTAIN -.02 W.C. DRAFT OVERFIRE

I88366-B

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-3500 & CB-5000

Installing the Draft Inducer (continued)

1. Refer to Figure 4R. 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 directions 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)

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-3500 & CB-5000

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-3500 & CB-5000

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-3500 & CB-5000

Priming the Metering Pump (continued)

8. Activating the Pump NOTE: The CB-3500 and CB-5000 furnaces feature a priming switch which is mounted on the

left-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 / orange indicator light is ON): 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 LIGHT

OIL PUMP PRIMING SWITCH

I88808-D

Figure 5B - Locating the Pump Priming Switch

5-3

Operator's Manual: Models CB-3500 & CB-5000

Priming the Metering Pump (continued)

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 5 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.

5-4

Operator's Manual: Models CB-3500 & CB-5000

Vacuum Testing the Oil Pump (continued)

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-3500 & CB-5000

5-6

Operator's Manual: Models CB-3500 & CB-5000

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 or 6B (depending on your burner model) 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. 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.

OIL GAUGE

(continued on next page)

AIR REGULATOR

LOCKING NUT

COVER PLATE

AIR GAUGE

COMBUSTION

AIR BAND

I88583

Figure 6A - Component Detail of the CB-525-S2 Burner for

CB-3500 Furnaces

6-1

Operator's Manual: Models CB-3500 & CB-5000

Preparing the Burner for Startup (continued)

6. Initial Adjustment of the Combustion Air Band for CB-3500 Furnaces: 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. Failure to heed this warning may result in re or explosion hazard.

• Refer to Figure 6A to locate the combustion air band. Note that the CB-525-S2 burner has an adjustable combustion air band.

• Rotate the combustion air band to adjust it to the appropriate slot opening as listed in the

Initial Adjustment Charts on the next page Use a ruler to accurately set the slot opening at the widest section of the slot.

7. Initial Adjustment of the Air Intake for CB-5000 Furnaces: WARNING: The air intake must be properly adjusted to ensure that the burner ignites and burns correctly. DO NOT attempt to start the burner with the air intake wide open or completely

closed. Failure to heed this warning may result in re or explosion hazard.

• Refer to Figure 6B to locate the air intake. Note that the CB-550-S2 burner has an adjustable air intake with a locking wing nut.

• Loosen the wing nut and OPEN the air intake by rotating the disk (CCW) to the appropriate

slot opening as listed in the following Initial Adjustment Charts on the next page.

• Tighten the wing nut to lock the air intake in place.

WING NUT

AIR REGULATOR

LOCKING NUTS

OIL REGULATOR

AIR GAUGE

OIL GAUGE

AIR INTAKE OPENING

I88227-A

Figure 6B - Component Detail of the CB-550-S2 Burner for CB-5000 Furnaces

6-2

Operator's Manual: Models CB-3500 & CB-5000

Preparing the Burner for Startup (continued)

ATTENTION: The settings shown in the charts below are only initial adjustments. Finaladjustmentsmustbe donebyinspectingtheamelengthaccordingtotheillustrationsprovidedonthefollowingpage.

NOTE: Theoilpressureisautomaticallyadjustedbythemeteringpump.

Initial Adjustments for CB-3500 Maximum Input = 350,000 BTUH @ 2.5 GPH with CB525-S2 Burner Oil Type Oil PSI / Flame Length Air PSI Air Band Nozzle

#4 and #5 Fuel Oils 6.5 & checkamelength 12-18 3/4" 9-5 Used Crankcase Oil 7.0 & checkamelength 12-18 3/4" 9-5 Used ATF 7.0 & checkamelength 12-18 3/4" 9-5 Used Hydraulic Oil 7.0 & checkamelength 12-18 3/4" 9-5

#2 Fuel Oil* 6.5 & checkamelength 12-18 3/4" 9-5

Initial Adjustments for CB-5000 Maximum Input = 500,000 BTUH @ 3.6 GPH with CB550-S2 Burner

Oil Type Oil PSI / Flame Length Air PSI Air Band Nozzle #2 Fuel Oil* 3.5 & checkamelength 12-18 1/4" 9-11

#4 and #5 Fuel Oils 3.5 & checkamelength 12-18 1/4" 9-11 Used Crankcase Oil 3.8 & checkamelength 12-18 1/4" 9-11 Used ATF 3.8 & checkamelength 12-18 1/4" 9-11 Used Hydraulic Oil 3.8 & checkamelength 12-18 1/4" 9-11

*If you are burning light viscosity oils such as #2 fuel oil, it may be necessary to install a smaller nozzle. Call

your Clean Burn dealer for more information.

Starting the Burner

1. Adjust the thermostat setting above room temperature to start the burner.

NOTE: If the burner refuses to start, review the Preparing the Burner for Startup procedure. If, after repeating this procedure, the burner still refuses to start, check the following system components for proper functioning:

• Verify that the red wire as shown in the Burner Wiring Diagram (Appendix B) is energized

to115VAC.

• Verify that the prime switch (on the control box) is set to RUN (i.e. DOWN position).

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.

(Starting the Burner procedure continued on the next page)

6-3

Operator's Manual: Models CB-3500 & CB-5000

Starting the Burner (continued)

3. Observing the Flame Length: Visually inspect the ame length through the observation port. Refer to Figure 6C 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.

Correct Maximum Flame Adjustment (Proper Oil and Air Pressure with correct supply of Combustion Air):

• Flame goes half of the way down the combustion chamber.

• Flame does not touch back or walls of combustion chamber.

CAUTION

WHEN OPENING INSPECTION PORT

PORT MAY BE HOT

PROTECT HANDS

WEAR SAFETY GOGGLES

KEEP FACE AWAY

OPEN PORT SLOWLY

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

Figure 6C - Flame Length Adjustment

4. Check the ame length after the burner has red for 15 minutes.

5. Tighten the locking nuts on the air regulator.

6. Fine Tuning the Combustion Air Band for CB-3500 Furnaces: 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 re-check the ame

for the proper characteristics.

• Re-check the ame after ve minutes. You should see a yellow-white ame with sharp tips and no "sparkles", and the ame should extend half of the way down the combustion

chamber.

6-4

Operator's Manual: Models CB-3500 & CB-5000

Starting the Burner (continued)

7. Fine Tuning the Air Intake for CB-5000 Furnaces:

• Refer to Figure 6B to identify the air intake location on the burner.

• Observe the ame.

• If you see "sparkles" in the ame, or the ame is orange in color, the oil you are burning

requires MORE combustion air. Rotate the locking tab DOWN and OPEN the air intake

1/16" to 1/8", and re-check the ame--you should see a yellow-white ame with no

"sparkles."

• Re-check the ame after ve minutes--the ame should still be yellow-white with no

"sparkles."

• Rotate the locking tab UP to lock the air intake in place.

8. 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 or air intake and adjusting the air regulator. After adjusting the combustion air band or air intake, 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 12% or an O2 reading of 4 to 8%

• Cad cell reading of 200 to 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 information on the fan limit control.

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 limit control 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 limit control will then shut off the blower motor.

CAUTION: If the blower motor does not operate as described, immediately shut down your furnace and contact your Clean Burn dealer.

6-5

Operator's Manual: Models CB-3500 & CB-5000

6-6

Operator's Manual: Models CB-3500 & CB-5000

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.

• If the burner will not restart, review the information provided in this section on the functioning of the

Fan Switches and the Hi-Temp Limit Switches.

• If the burner still will not restart, contact your Clean Burn Distributor for immediate service.

The Oil Primary Control

AMBER LED

GRNAMB

RED

GREEN LED

RED LED

CAD CELL

WIRES

WIRES RUN UNDER

SMALL CENTER GAP

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.

RESET BUTTON

ALARM

F FTT

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 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.

C77008

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.

42000 Rev. 2

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.

7-1

Operator's Manual: Models CB-3500 & CB-5000

Understanding the Fan Switches and Hi-Limits on the CB-3500/CB-5000 Furnaces

The CB-3500 and CB-5000 furnaces feature redundant fan switches and redundant limit switches. The two fan switches enable efcient working of the fan/blower for both unit heater and central furnace applications. The two limit switches serve to protect the furnace from damage due to overheating. Review the following specics on

each of the switches/controls to understand their operation; refer to the Furnace Wiring Diagrams in Appendix B at the back of this manual to review the installation of these switches.

The Blower/Fan Switch

The CB-3500/CB-5000 furnaces feature an F-180 blower/fan switch (normally open) which is surface-mounted at the front of the combustion chamber as shown in 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 switch closes and sends power to the blower motor relay to turn ON the blower. When the wall thermostat

is satised and the burner shuts off, the blower/fan continues to run until the switch senses that the combustion

chamber has cooled down. The switch then opens and shuts off the blower/fan.

AIR DISCHARGE

ACCESS

PLATE

CB-3500/5000 FURNACE WITH CLEAN-OUT DOOR OPEN TO SHOW HEAT EXCHANGER

33288 L-290 HI-TEMP SWITCH

33230 FAN SWITCH

ORIFICE PLATE

DETAIL OF HI-TEMP SWITCH AND FAN SWITCH INSTALLED ON FRONT HEADER OF FURNACE

I88328-A

Figure 7B - Locating the F-180 Fan Switch amd the L-290 Hi-Temp Limit Switch

7-2

Operator's Manual: Models CB-3500 & CB-5000

The Fan Limit Control

Understanding the Operation of the Fan Limit Control

The fan limit control, which is a probe style control, senses air temperature within the furnace cabinet. This control contains two switches: the fan switch and the limit switch. This control is especially important for the functioning of the fan with ducted applications.

Fan Switch: The fan switch is normally open and provides power to the fan (or blower). When the fan limit control senses "Fan On" temperature, the fan switch closes and starts the fan (or blower). When the wall thermostat is satised and the burner shuts off, the fan continues to run until the fan limit control senses the "Fan Off" temperature. At this temperature, the fan switch opens and shuts off the fan (or blower).

NOTE: The fan limit control has a white fan switch button. Make sure the white button is pulled OUT for

automatic (normal) operation. When the button is pushed in (manual setting), the fan will run continuously.

Limit Switch: The limit switch is normally closed and provides power to the oil primary control on

the burner. If the fan limit control senses 200

degrees F, the limit switch opens and shuts off power to the oil primary control and the burner

stops running. The fan (or blower) continues to run. Once the fan limit control senses 170 degrees

F, the limit switch automatically resets and restarts the burner. ATTENTION: It is very important to avoid cycling the burner on hi limit as described above. If the hi limit activates, immediately check and

readjust burner settings.

ATTENTION: DO NOT change the fan limit

settings from the specied settings, or severe

damage to the furnace cabinet may occur.

Setting the Pointers on the Fan Limit Control Dial

1. Turn OFF main power to the furnace.

2. Remove the fan limit control cover.

3. While holding the dial securely in place

with your thumb, move the pointer to the desired setting.

ATTENTION: DO NOT rotate the dial when setting the pointers; doing so will severely damage

the control.

FAN OFF

(LEFT POINTER)

LOAD

FAN

LINE

CAUTION

DO NOT ROTATE

HOLD DIAL WHEN SETTING

POINTERS

100

FAN ON

(MIDDLE POINTER)

CAUTION

DO NOT ROTATE

HOLD DIAL WHEN SETTING

POINTERS

100

250

200

150

25050

200

150

LIMIT (RIGHT POINTER)

LOAD

LIMIT

LINE

TO RELEASE WIRE, PUSH SCREWDRIVER IN AND PULL WIRE OUT

Fan Limit Control Settings: CB-3500/CB-5000

Fan Off: 100 Fan On: 120 Limit: 210

BRASS

JUMPER

BL/WHT

ORANGE WIRE (CONNECT TO BLOWER MOTOR RELAY )

BLACK

I89038

Figure 7C - Fan Limit Control Components

7-3

RED WIRE (CONNECT TO LIMIT)

Operator's Manual: Models CB-3500 & CB-5000

The Auxiliary Hi-Temp Limit Switch

The CB-3500 and CB-5000 furnaces are equipped with an auxiliary L-290 high temperature limit switch which is mounted on a bracket at the front of the combustion chamber as shown in Figure 7B. This switch senses the build-up of heat within the combustion chamber beyond the fan limit control setting and is designed to protect the

furnace from damage due to overheating.

Understanding the Function of the Auxiliary L-290 Auto-Reset Hi-Temp Limit Switch

If the temperature of the combustion chamber has exceeded the range of the fan limit control, the auxiliary

L-290 auto-reset hi-temp limit switch opens and shuts off power to the primary control on the burner, and the burner shuts down. After the combustion chamber has sufciently cooled, the L-290 switch will automatically reset, and allow the burner to re-start.

The L-290 hi-temp limit switch will open and shut down the burner if any of the following conditions exists:

• If the fan/blower has stopped running for any reason during furnace operation, the heat

in the furnace may cause the L-290 hi-temp limit switch to open. Ensure that the fan/blower is

functioning properly.

• The fan limit control is not functioning properly. If the fan limit control has malfunctioned,

the L-290 could cycle on/off repeatedly. If this occurs, contact your Clean Burn Distributor

immediately for service.

• The furnace is overring. Review the directions in Section 6 in the Operator’s Manual 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 of the Operator’s

Manual.

ATTENTION: It is very important to determine the reason for the opening of the L-290 switch 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.

7-4

Operator's Manual: Models CB-3500 & CB-5000

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-3500 & CB-5000

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

Adjusting Draft Over Fire on Furnaces with Draft Inducers

(CB-5000 Standard; CB-3500 Optional)

NOTE: The draft inducer is purposely sized to create a generous draft. When adjusting the barometric damper, you will nd that the apper is open most of the time. This allows the draft inducer to suck cool air through the

damper to protect the inducer motor from heat damage.

1. Use a draft gauge to check draft over re.

2. Adjust the barometric damper to obtain -0.02 w.c. draft over re. If you still have too much draft, adjust the draft plate on the draft inducer. Move the plate in 1/4" to reduce the draft. Recheck

the draft reading.

8-2

Operator's Manual: Models CB-3500 & CB-5000

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.

• 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.

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-3500 & CB-5000

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 FINAL 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

BACKDRAFT

DRAFT

LESS

PROPER DRAFT

EXHUST FAN CREATES BACKDRAFT IN STACK AND SUCKS COMBUSTION GASES DOWN THE STACK AND BACK INTO THE FURNACE

BACKDRAFT CREATED BY EXHAUST FAN

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

RISING HOT COMBUSTION GASES PRODUCE PROPER DRAFT

DRAFT

LESS

Corresponding Draft Over Fire measurement should be -.02 to -.04 WC

8-4

COMBUSTION AIR

TO BURNER

I88809-A

Operator's Manual: Models CB-3500 & CB-5000

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 ft. wide x 9 in. high

• Round off to 12 ft. wide x 1 ft. high

• Convert to square feet (in this case it equals 12 ft2)

• Multiply by 1.1 correction factor (12 ft2 x 1.1 = 13.2 ft2)

• Multiply by free area factor (13.2 ft2 x 1.25 = 16.5 ft2)

• Refer to sizing chart (following page) - required grill size would be (1) 54 in2 grill

8-5

Operator's Manual: Models CB-3500 & CB-5000

Installing a Make-up Air Louver (continued)

Calculated Opening Size

(square feet)

Required Louver/Grill Size

(inches) From 0.000 to 0.569 10 X 10 From 0.570 to 0.900 12 X 12 From 0.901 to 1.556 16 X 16 From 1.557 to 2.070 18 X 18 From 2.071 to 2.574 20 X 20 From 2.575 to 3.408 24 X 24 From 3.409 to 5.133 30 X 30 From 5.134 to 7.696 36 X 36 From 7.697 to 9.883 42 X 42

From 9.884 to 13.299 48 X 48 From 13.300 to 16.683 54 X 54 From 16.684 to 21.152 60 X 60

C77004

Installing the Make-up Air Louver

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-3500 & CB-5000

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 per the burner hour meter*

Cleaning / Maintaining the Draft Inducer At least once a year

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 the Appendixes.

9-1

Operator's Manual: Models CB-3500 & CB-5000

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 variations, clean the canister lter and check

WHEN OPENING INSPECTION PORT

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 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.

CAUTION

PORT MAY BE HOT

PROTECT HANDS

WEAR SAFETY GOGGLES

KEEP FACE AWAY

OPEN PORT SLOWLY

LOCKING NUT

AIR GAUGE

OIL GAUGE

AIR REGULATOR

COVER PLATE

COMBUSTION

AIR BAND

Figure 9A - Component Detail of the CB-525-S2 Burner (CB-550-S2 is similar)

I88583

9-2

Operator's Manual: Models CB-3500 & CB-5000

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. Open the ball valve. 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-3500 & CB-5000

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

RELIEF

PART No 32422

PART No 32423

I88332-A

Figure 9C - Servicing the Metering Pump

9-4

Operator's Manual: Models CB-3500 & CB-5000

Cleaning the Check Valve

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 lter. 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-3500 & CB-5000

Cleaning the Tank

DO NOT allow water, sludge, or other debris to accumulate in your oil supply tank to the point that non-combus-

tible 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-3500 & CB-5000

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

BREACH

CLEAN-OUT CAP

Figure 9E - Accessing the Combustion Chamber for Cleaning

9-7

COMBUSTION CHAMBER

FURNACE FLUE

CLEAN-OUT DOOR

I88293-A

Operator's Manual: Models CB-3500 & CB-5000

Cleaning the Ash (continued)

1. Ensure that power has been turned OFF, and all "hot" components have been allowed to cool sufciently.

Carefully remove the Energy Retention Disc with a long handle or pipe. Lightly vacuum off the Energy Retention Disc.

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.

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-3500 & CB-5000

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.

Cleaning and Maintaining the 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.

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. This will prevent

the oil from being "cooked" in the pre-heater block when it is not in use. Failure to do so may result in carbon build up in the burner preheater block which will block oil ow.

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.

9-9

Operator's Manual: Models CB-3500 & CB-5000

9-10

Operator's Manual: Models CB-3500 & CB-5000

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-3500 & CB-5000

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.

Pump circuit opens

Burner ignites.

oil solenoid.

Pump circuit starts

from cad cell indicating

Oil primary control

receives <500 ohm signal

proper ignition.

Yellow indicator

oil pump.

light ON.

Hour meter starts.

until the wall thermostat

is satisfied.

Burner continues to run

Primary control relay

Wall thermostat is

shuts off.

opens and the burner

satisfied and T

circuit opens.

Warm air delivered

to heated area.

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.

Centrifugal switch closes and

for proper combustion air.

Combustion air band adjusted

INITIAL START-UP

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-3500 & CB-5000

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-3500 & CB-5000

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.

Operator's Manual: Models CB-3500 & CB-5000

PROBLEM POSSIBLE CAUSE(S) POSSIBLE ACTION(S)

Burner ignites and Burner shuts o on reset sometime later during the day or night.

1. ere is air in the fuel supply.

2. e primary control is not receiving the proper ohm signal from the cad cell.

3. ere is insucient air pressure.

4. e heater block is cold.

5. e electrodes are fouled.

1. Prime the pump. If the pump will not prime or there is air in the oil stream from the pump bleeder, follow the steps in the next problem (“Pump will not prime.”)

2. Check for proper ohm signal. Follow the procedures in the previous problem (top, page 10-4)

3. Follow the instructions in Section 5 to adjust the air regulator for proper air pressure. DO NOT turn the air compressor o while the furnace is operating. If you turn the air compressor o at night, turn the wall thermostat to OFF so the burner will not run.

4. DO NOT shut o power to the furnace overnight, or the heater block will cool down, and the burner will not re-start the next morning. To turn the furnace “o” overnight, turn the wall thermostat to OFF. e heater block will stay hot.

5. If oil residues have built up on the electrodes and retention head, follow the instructions in Section 8 to check for proper dra overre. Clean the electrodes and retention head as shown in Appendix A.

10-5

Operator's Manual: Models CB-3500 & CB-5000

PROBLEM POSSIBLE CAUSE(S) POSSIBLE ACTION(S)

Pump will not prime and Pump motor is running.

1. ere is a leak(s) in the suction line.

2. e pump is not installed so it will ll with oil during the priming process.

3. e pump gears are dry.

4. e pump seal is damaged.

5. e ball valve is closed.

6. e canister lter is dirty.

7. e check valve is dirty.

8. e pump is damaged or worn out.

1. Follow the specications in Section 4 to make sure the suction line is installed properly and that all ttings are 100% airtight.

2. Make sure the pump head is lled with oil prior to starting the pump. See Section 5.

3. Follow the procedure in Section 5 to ll the oil line and prime the pump.

4. With the pump not running, wipe your nger along the bottom of the cylinder at the pump sha. If there is oil at the pump sha, the seal is damaged. Replace the pump, or replace the seal. NOTE: Some oils will expand as they warm up. Because there is a check valve in the suction line, the expanding oil may build up pressure and damage the oil seal. Install a mini-accumulator in the 1/8” port of the canister lter to prevent the pressure build-up.

5. Open the ball valve on the suction line.

6. Refer to Section 9 to clean the canister lter.

7. Refer to Section 9 to clean the check valve.

8. Replace the pump

10-6

CLEAN BURN CB-3500, CB-5000 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual