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 qualied 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
identied herein. The use of these instructions for the installation of products NOT bearing the ULC label and
NOT identied herein may result in an unacceptable or hazardous installation.
IMPORTANT FOR CANADIAN INSTALLATIONS: The installation of this equipment is to be accomplished by
qualied 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 modication or repair of the product or any component part thereof not authorized or manufactured by
MANUFACTURER specically 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 specic 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.
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:
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 clarication 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 specic 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 modications 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 onlywith 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 specic to the equipment,
you, the operator, can promote safe equipment operation. Failure to use common sense,
WARNING: The installation, operation, and maintenance of this equipment in the U.S. must be accomplished by qualied personnel and in compliance with the specications 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 qualied personnel and in compliance with the specications 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.
• 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 afxed 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 qualied 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)
UL
LISTED FUELS
INPUT
- GPH -
NO 2 OIL
2.516.07.0
USED CRANKCASE OIL
HYDRAULIC OIL
ATF
MAX.. DISCHARGE
AIR TEMP-F
2.5
2.516.0
220
FLUE DRAFT IN W.C.
CLEARANCE TO COMBUSTIBLE SURFACES: (INCHES)
POWER
2
1/6
1/10
400
1/3
1/3
CHIMNEY
REAR
VO LTSAMPS
208/230
120
120
120
120
120
18
TOP
1818
FRONT
60
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
24
BOTTOM
24
HZ
11.3/1160
3.2
1.4
3.3
3.9
3.5
60
60
60
60
60
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)
UL
LISTED FUELS
INPUT
- GPH -
NO 2 OIL
3.618.03.5
USED CRANKCASE OIL
HYDRAULIC OIL
ATF
MAX.. DISCHARGE
AIR TEMP-F
3.6
3.618.0
220
FLUE DRAFT IN W.C.
CLEARANCE TO COMBUSTIBLE SURFACES: (INCHES)
POWER
2
1/6
1/10
400
1/3
1/3
CHIMNEY
REAR
VO LTSAMPS
120
120
120
120
120
18
TOP
1818
FRONT
60
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
4.0
-.06
SIDES
24
BOTTOM
24
HZ
11.3/11208/230
3.2
1.4
3.3
3.9
3.5
60
60
60
60
60
60
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.
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
42175 - R1
CLEAN BURN LLC
JANESVILLE, WISCONSIN (USA)
MH15393
LISTED
USED-OIL BURNING APPLIANCEUSED 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 qualied 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
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
6
STABILIZER BRACKET
ON TOP OF FURNACE
AIR DISCHARGE
4
BURNER
MOUNT
4
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
1
ROTATION
3
ENERGY
RETENTION DISC
INSTALLED ON
BACK WALL OF
COMBUSTION
CHAMBER
BURNER
CONNECTOR
BLOCK
5
FRONT VIEW OF CABINET
AFTER ASSEMBLY
2
AIR DISCHARGE
STABILIZER BRACKETS
MOUNTING
BRACKET
BELOW
AIR OIL
FURNACE
6
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.
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 qualied 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
12
3
4
13
15
16
5
9
6
11
1
2
10
16
14
15
7
9
6
53
cm
8.5"
22
cm
46.5
18.5"
cm
11.5"
29
21"
cm
CB-3500 BLOWERCB-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
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 deect 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 Conguration
The CB-3500 and CB-5000 furnaces may be congured 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 efcient, 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 specied 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 specications; installation to be accomplished by
HVAC professionals ONLY.)
Be sure to adhere to the specied clearances as stated in Section 4 of this
manual.
Air Flow (CFM) and Static Pressure (SP) Specications
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 CFM5100 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 qualied 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 orice 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,itismandatorythatqualiedHVACpersonneldesignand
installtheductworksystemtotheCFMandSPspecicationsprovidedinthismanual. Establish correct duct
size according to the following specications 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 qualied 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 specications 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 specications 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
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