CLEAN BURN CB-200-CTB, CB-500-CTB, CB-350-CTB Operator's Manual

OPERATOR'S MANUAL

CLEAN BURN COIL TUBE BOILER MODELS:

CB-200-CTB COIL TUBE BOILER with CB-500-5W Burner & Metering Pump CB-350-CTB COIL TUBE BOILER with CB-551-5W Burner & Metering Pump

CB-500-CTB COIL TUBE BOILER with CB-551-H5-5W Burner & Metering Pump

230 V / 50 Hz

PUBLICATION DATE: 5/3/10, Rev. 7 CLEAN BURN PART #43186

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

reading and understanding the information provided in this manual. Installation and service must be accomplished by qualified personnel. Failure to follow all safety precautions and procedures as stated in this manual may result in property damage, serious personal injury or death.

Copyright © 2010 Clean Burn, Inc. All rights reserved. No part of this publication may be reproduced, or distributed without the prior written permission of Clean Burn, Inc. 34 Zimmerman Road, Leola, PA 17540, U.S.A. Subject to change without notice. The Clean Burn logo is a trademark of Clean Burn, Inc. All other brand or product names mentioned are the registered trademarks or trademarks of their respective owners.

I88729−B

DECLARATION OF CONFORMITY

Manufacturer: Clean Burn Inc.

34 Zimmerman Rd. Leola, PA USA

European Representative: TUV Rheinland North America

12 Commerce Rd. Newtown CT. 06470 USA

Equipment: CTB-350 #90192

CTB-200 #90201 CTB-500 #90227

EMC Competent Body: TÜV Rheinland Product Safety GmbH

Am Grauenstein D-51105 Köln

I hereby declare that the above named machinery complies with Essential Health and Safety Requirements of the Industrial Machinery Directive (IMD - 98/37/EEC) as amended, with the Low Voltage Directive (LVD – 73/23/EEC) as amended, and with the Electromagnetic Compatibility Directive (EMC – 89/336/EEC) as amended.

Safety Standard: EN 230: 1990 Monobloc Oil Burners – Safety, Control, and Regulation Devices and Safety Times. EN 292-1:1991 Safety of machinery - Basic concepts, general principles for design - Part 1 : Basic

terminology, methodology.

EN 292-2:1991+A1 Safety of machinery - Basic concepts, general principles for design - Part 2 : Technical

principles and specifications

EN 60204-1:2000 Safety of machinery. Electrical equipment of machines. General requirements.

EMC Standards:

EN 55014-1: 2000 Electromagnetic Compatibility – Requirements for Household Appliances, Electric

Tools, and Similar Apparatus. Part 1: Emission.

EN 55014-2: 2000 Electromagnetic Compatibility – Requirements for Household Appliances, Electric

Tools, and Similar Apparatus. Part 2: Immunity.

EN 50165: 1997 Electrical Equipment of Non-Electric Appliances for Household and Similar Purposes.

Safety Requirements.

Note: Above equipment is subject to an EMC Technical Construction File and Competent Body Certificate Number AV 72032554 0001.

________________________

3 May, 2010 Ryan D. Gamber

Engineering Manager

TABLE OF CONTENTS

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

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

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

Guidelines for CTB Usage ........................................................................................1-4

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

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

SECTION 2: UNPACKING & PRE-INSTALLATION CONSIDERATIONS ................. 2-1

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

Unpacking and Inspection................................................................................................2-1

CTB Component List .................................................................................................2-1

Pre-Installation Considerations ...........................................................................................2-2

Determining the CTB System Setup .............................................................................2-2

Selecting a Location ....................................................................................................2-2

SECTION 3: COIL TUBE BOILER ASSEMBLY ........................................................ 3-1

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

CTB (Single Boiler) Assembly ............................................................................................3-2

Installing the CTB on the Support Stand.......................................................................3-4

Dual-Stacked Boiler Assembly ...........................................................................................3-5

Assembling the Dual-Stacked Boiler ............................................................................3-5

Assembly for All Boilers .....................................................................................................3-8

Connecting the CTB ....................................................................................................3-8

Installing the Ceramic Sleeve........................................................................................3-9

Checking the Burner Nozzle and Electrodes ...............................................................3-11

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

Installing the Connector Block ...................................................................................3-12

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

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

Locking the Burner into Firing Position .......................................................................3-14

SECTION 4: COIL TUBE BOILER INSTALLATION .................................................. 4-1

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

Important Safety Guidelines .........................................................................................4-1

Typical Installation Diagrams........................................................................................4-3

Combustion Air Requirements .....................................................................................4-5

Oil Tank Installation Specifications......................................................................................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

Connecting Water to the Coil Tube Boiler.........................................................................4-12

Filling the CTB with Water ........................................................................................4-12

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

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

TABLE OF CONTENTS

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

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

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

Wiring the Coil Tube Boiler ..............................................................................................4-18

Wiring to the CTB .....................................................................................................4-18

Wiring to the Metering Pump .....................................................................................4-19

Wiring the Load Loop Circulator ...............................................................................4-19

Installing the Stack ...........................................................................................................4-20

Installing the Interior Stack.........................................................................................4-22

Installing the Barometric Damper ...............................................................................4-23

Installing the Optional Stack Safety Switch .................................................................4-24

Resetting the Stack Safety Switch ........................................................................4-25

Understanding the function of the Stack Safety Switch ..........................................4-25

Installing the Stack Penetration...................................................................................4-26

Installing the Exterior Stack........................................................................................4-26

Installing the Stack Cap .............................................................................................4-26

Installing the Draft Inducer ......................................................................................... 4-26

Installing the Wall Thermostat or Aquastat ........................................................................4-28

Replacing the Wall Thermostat Batteries ....................................................................4-28

Inspecting the CTB Installation .........................................................................................4-29

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

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

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

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

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

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

Understanding Burner Startup and Adjustment ............................................................... 6-1

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

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

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

SECTION 7: RESETTING THE OIL PRIMARY CONTROL .......................................7-1

Understanding the Danfoss Oil Primary Control ..................................................................7-1

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

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

Understanding the Importance of Draft ...............................................................................8-1

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

Understanding the Effect of Exhaust Fans on Draft .......................................................8-2

Checking Draft Over Fire to Determine Severity of Backdraft ......................................8-2

Adjusting Draft Over Fire with a Draft Inducer Installed ...............................................8-3

TABLE OF CONTENTS

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

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

Annual Preventative Maintenance & Burner Tune-up ..........................................................9-1

Cleaning the Canister Filter .................................................................................................9-2

Servicing the Metering Pump ..............................................................................................9-3

Cleaning the Check Valve / Screen .....................................................................................9-4

Cleaning Ash from the CTB................................................................................................9-5

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

End of Season Maintenance ...............................................................................................9-6

SECTION 10: THE CTB HYDRONIC SYSTEM .......................................................10-1

Understanding the CTB Hydronic System .........................................................................10-1

Special Safety Guidelines ...........................................................................................10-1

CTB System Function and Configuration....................................................................10-2

CTB Setup Options...................................................................................................10-4

Guidelines for CTB Setup and Operation ..........................................................................10-7

Guidelines for Preventing Oxygen Contamination ........................................................10-8

Guidelines for Initial Cleaning and Maintaining Water Quality ......................................10-8

Guidelines for CTB Operation ...................................................................................10-8

SECTION 11: TROUBLESHOOTING ......................................................................11-1

CTB Sequence of Operation ............................................................................................11-1

Flow Chart ......................................................................................................................11-2

Troubleshooting Tables ....................................................................................................11-3

APPENDIX A

Detailed CTB Specifications .............................................................................................. A-1

CTB Technical Specifications ..................................................................................... A-1

Burner Technical Specifications................................................................................... A-2

CTB Hydronic Specifications......................................................................................A-2

CTB Accessories and Parts Reference........................................................................A-3

CB-200-CTB Dimensions .......................................................................................... A-5

CB-350-CTB Dimensions .......................................................................................... A-6

CB-350-CTB Dual Stacked Boiler Dimensions ..........................................................A-7

CB-500-CTB Dimensions .......................................................................................... A-8

CB-500-CTB Dual Stacked Boiler Dimensions ..........................................................A-9

Burner Components ........................................................................................................ A-10

CB-500-CE 5W Series Burner Components ............................................................ A-10

CB-500-CE 5W and CB-551-CE 5W Preheater Block Assembly Detail ................. A-12

CB-551-H5 CE 5W Preheater Block Assembly Detail ............................................. A-14

Burner Electrode Specifications ................................................................................ A-16

Removing the Nozzle for Cleaning.............................................................................A-17

CB-200-CTB Components.............................................................................................A-18

CB-350-CTB Components.............................................................................................A-20

CB-500-CTB Components.............................................................................................A-22

APPENDIX B

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

Burner Wiring Diagram (CB-500-CE 5W and CB-551-CE 5W) ................................ B-1

Burner Wiring Diagram (CB-551-H5 CE 5W)............................................................ B-2

Control Box Wiring Diagram ...................................................................................... B-3

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

CTB Ladder Schematic..................................................................................................... B-5

APPENDIX C

Additional Installation and Maintenance Requirements (United Kingdom ONLY) ............... C-1

APPENDIX D

CTB Service Record.........................................................................................................D-1

TABLE OF CONTENTS

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

SECTION 1: INTRODUCTION

Guide to this Manual

This manual contains all the information necessary to safely install and operate the Clean Burn Coil Tube Boilers (CTB), Models CB-200-CTB, CB-350-CTB, and CB-500-CTB. Consult the Table of Contents for a detailed list of topics covered. You'll find 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 the Clean Burn CTB involves six basic activities as outlined here:

• UNPACKING & PRE-INSTALLATION CONSIDERATIONS ............................ (Section 2)

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

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

• OPERATION

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

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

• Resetting the Oil Primary Control...................................................... (Section 7)

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

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

• THE CTB HYDRONICS SYSTEM.....................................................................(Section 10)

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

WARNING!

Please read all sections carefully--including the following safety information--before beginning any installation/ operation procedures; doing so ensures your safety and the optimal performance of your Clean Burn Coil Tube Boiler.

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

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

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 clarification 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 specific precautions listed throughout the manual, the following general

precautions apply and must be heeded to ensure proper, safe boiler operation.

DANGER! DO NOT create a fire or explosion hazard by storing or using gasoline or other

flammable or explosive liquids or vapors near your boiler.

DANGER! DO NOT operate your CTB if excess oil, oil vapor or fumes have accumulated in or near your boiler. As with any oil burning appliance, improper installation, operation or maintenance may result in a fire 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 CTB. Instruct your personnel to never add hazardous materials to your used oil.

1-2

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

For Your Safety... (continued)

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

Clean Burn, Inc. Unauthorized modifications or alteration can adversely affect the proper,

safe operation of your boiler.

WARNING: The burner which is shipped with your Clean Burn CTB is to be used only

with your boiler according to the instructions provided in this manual. DO NOT use the

burner for any other purpose!

WARNING: For the safe installation and operation of the CTB, the boiler cannot be raised

above the floor level, suspended from the ceiling, installed on a raised platform, or placed over top

of any equipment, office space, parts room, etc. or installed in any other manner than directly on a

concrete floor.

WARNING: Electrical installation of the boiler is to be performed only by qualified

personnel (i.e. licensed electrician/engineer). Improper electrical installation can adversely

affect the proper, safe operation of the boiler and may cause serious personal injury/death.

WARNING: Install the boiler in an area away from the main shop traffic. It is essential for

personal safety that only manufacturer-trained, qualified personnel have access to operate

and maintain the boiler.

WARNING: DO NOT operate your boiler when the ambient temperature is above

35o C (95o F).

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

observing general safety rules, and adhering to the precautions specific 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 specific to the equipment may result in

equipment damage, fire, explosion, personal injury and/or death.

WARNING: The installation, operation, and maintenance of this equipment must be

accomplished by qualified personnel and in compliance with the specifications 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, fire and

electrical safety.

Failure to comply with these standards and requirements may result in equipment

damage, fire, explosion, personal injury and/or death.

1-3

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

For Your Safety... (continued)

Guidelines for Coil Tube Boiler Usage

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

• This boiler is designed to burn the following fuels:

• Used crankcase oil up to 50 SAE

• Used transmission fluid

• Used hydraulic oils

• #2, #4, and #5 fuel oils

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

• Make sure you comply with all environmental regulations concerning the use of your boiler. These 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 flue gases are vented to the outdoors with an appropriate stack.

• Your used oil is recycled as fuel for "heat recovery". DO NOT operate your boiler in warm weather just to burn oil.

Contact your Clean Burn dealer for current environmental regulations.

• If your CTB ever requires service, call your Clean Burn dealer. DO NOT allow untrained, unauthorized personnel to service your CTB. Make sure that your boiler receives annual preventative maintenance to ensure optimal performance.

1-4

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

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 boiler 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 affixed directly on your used oil supply tank.

1-5

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

For Your Safety... (continued)

Safety Labels

Following are the locations and descriptions of all labels on your CTB. The following illustrations show the location of ALL labels on your boiler. 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 CTB, review all labels and heed all safety messages as printed on the labels.

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

CTB Cabinet Labels Label Part # Description

42367 C.B. Safety Warning Label (multiple messages - fire/shock/burn hazards) 42457 Made in USA/Patent Pending Label 42027 Burn Hazard / Hazardous Voltage Warning Label 42308 Header Label 42481 CB-200-CTB CE Data Label 42306 CB-350-CTB CE Data Label 42503 CB-500-CTB CE Data Label 42030 Electrical Shock Hazard Warning Label 42421 CTB Hot Water Caution Label 42216 C.B. Logo Label - 22 cm x 11 cm (8.75" x 4.25") 42297 C.B. Logo Label - 51 cm x 20 cm (20" x 8") 42465 CB-200-CTB Model # Label 42286 CB-350-CTB Model # Label 42502 CB-500-CTB Model # Label

42367

42308

42481 42306 42503

42457

DATE CODE

1-6

AIR

OIL

I88785−B

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

CTB Cabinet Labels (continued)

42216 42497

42421

CTB Cabinet Safety Labels

Burn Hazard.

Fittings, piping, and boiler surface may be extremely hot. Pipes contain hot water. Do NOT touch without wearing protective gloves.

www.cleanburn.com

CB *** CTB

42216

42286

42465 42286 42502

1-7

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

For Your Safety... (continued)

CTB Cabinet Safety Labels (continued)

NO.

MULTI−OIL HEATING SYSTEM

FOR COMMERCIAL OR INDUSTRIAL USE ONLY.

42308

CTB−200−CE

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

3.8

MAXIMUM FUSE SIZE / WITH OPTIONS

14 2.7

18 4.0

POWER

1/20

1/10

400

1/6 230 1.10 50

1/10 230 .56 50

1/3

.96

1.24

230

220 1.5 50

230

2.5

3.4

4.0

SIDE

.40

.56

1.65

1.8

15/20

58.6

.17

.19

.17

.23

.28

−.06 (1.5MM)

7616122

FOR COMMERCIAL OR INDUSTRIAL USE ONLY.

42481

1-8

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

CTB Cabinet Safety Labels (continued)

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

CTB−500−CE

147.0

13.5

122

MAXIMUM FUSE SIZE / WITH OPTIONS

22 20

16 16

POWER

1/20

1/10

500

1/2 230 50

1/4

1/2

2.5

2.1

2.3

2.5

−.06 (1.5mm)

0.17

0.15

0.16

0.17

7616

1.1

1.5

1.4

1.1

SIDE

230

0.40

0.70

1.9

2.7

1.3

3.0

10.0

20.0

FOR COMMERCIAL OR INDUSTRIAL USE ONLY.

42503

1-9

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

For Your Safety... (continued)

CTB Burner Labels

Label Part # Description

42004 Burner Safety Warning Label (High Voltage/Moving Parts Hazard) 42235 Burner Safety Warning Label (Fire/Explosion Hazard - Burner Installation and Service) 42470 CB-500-CE-5W Burner Model/Serial Number 42483 CB-551-CE Burner Model/Serial Number 42508 CB-551-H5-CE Burner Model/Serial Number 42229 C.B. Logo/Burner Description Label 42482 Burner Safety Warning Label (Fire/Explosion Hazard - Reset Button) 42309 CE Mark Label 42023 Burner Power Label

CTB BurnerSafety Labels

42470 42483 42508

I88854−B

1-10

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

SECTION 2: UNPACKING & PRE-INSTALLATION

CONSIDERATIONS

Before assembling your coil tube boiler (CTB) , you must accomplish the following activities described in this section:

• Removing the Shipping Crate

• Unpacking and Inspecting All Components

• Warranty Registration

• Review the Pre-Installation Considerations

Removing the Shipping Crate

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

2. Remove the bolts holding the boiler on the shipping pallet.

3. Carefully lift the CTB off the shipping pallet with a fork lift.

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

Unpacking and Inspection

Following is an itemized list of all components you should have received in your Clean Burn Coil Tube Boiler 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 CTB assembly and installation.

Model CB-200-CTB, CB-350-CTB and CB-500-CTB Component List

• Coil Tube Boiler with factory-installed controls (including operating aquastat, high temperature cut-off, flow switch, relief valve, and check valve)

Components packed inside boiler:

• Ceramic combustion chamber sleeve

• Combustion chamber sleeve mounting stand

• Ceramic target (pre-mounted)

• Canister filter

• Vacuum gauge

• Check valve with screen (for tank)

• Boiler gauge

• Tube sealant

• Burner hook-up kit

• Barometric damper

• Burner

• Oil pump (metering pump)

• CTB base stand with hardware

• Draft Inducer

2-1

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Pre-Installation Considerations

The following information is critical to the proper installation of your Clean Burn Coil Tube Boiler system; read this section carefully before starting any other procedures.

Determining the CTB System Setup

Before installing the CTB, you must determine the following which relate to your installation:

(1) The type of oil storage tank you will be using (related information in Section 4)** (2) The positioning of your oil pump (related information in Section 4) (3) The appropriate size for your oil lines (related information in Section 4) (4) The electrical requirements for your CTB installation (related information in Section 4) (5) The type of hydronic installation you will be using (related information in Section 10)

**IMPORTANT NOTE: If you are installing an inside oil tank in the same room as the boiler, you must allow a 1.5 m (5 ft) minimum clearance between the tank and the boiler. The oil tank should be set and

installed in position BEFORE the boiler is installed.

Selecting a Location

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

• Installation in a dedicated boiler/mechanical room with a minimum fire rating of two (2) hours.

• Installation on a substantial, level, non-combustible concrete floor (minimum 10 cm / 4" thick).

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

• Safe, easy access for servicing.

• Adequate combustion air per national and local codes.

• Proper stack installation and materials.

WARNING: For the safe installation and operation of the CTB, the boiler cannot be raised

above the floor level, suspended from the ceiling, installed on a raised platform, or placed over top of any equipment, office space, parts room, etc. or installed in any other manner than directly on a concrete floor.

2-2

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Selecting a Location (continued)

Adhere to the following minimum clearances from combustible surfaces. Specifications are also

provided for servicing clearance. Be sure to check local codes which may differ from these

specifications. Refer to Figure 2A for a single CTB and Figure 2B for dual-stacked CTB boilers.

Fig. 2A and 2B Description Clearance from Combustibles Clearance for Service

A Above 46 cm (18") 46 cm (18")

B Front 61 cm (24") 122 cm (48")

C Stack 46 cm (18") 46 cm (18")

D Rear 15 cm (6") 102 cm (40")

E L.H. Side 15 cm (6") * 15 cm (6") *

F R.H. Side 76 cm (30") 76 cm (30")

G Bottom 15 cm (6") 15 cm (6")

* 91 cm (36") may be required

L.H. SIDE

R.H. SIDE

AIR OIL

Figure 2A - Single Boiler Minimum Installation Clearances

DRAFT

I88734−B

DRAFT

Figure 2B - Dual-Stacked Boilers Minimum Installation Clearances

AIR OIL

AIR

OIL

I88733−C

2-3

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

2-4

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

SECTION 3: COIL TUBE BOILER ASSEMBLY

Understanding Assembly

Assembling your Clean Burn Coil Tube Boiler (CTB) is a multi-step process. Note that some assembly

procedures apply only to certain CTB installations or configurations (i.e. single model or dual-stacked

boilers); the assembly procedures are outlined below as they appear in this section.

Be sure to refer to the appropriate instructions for your CTB configuration.

Single Boiler Assembly Only

• Installing the CTB on the Support Stand

Dual-Stacked Boiler Assembly Only

• Assembling the Dual-Stacked Boiler

Assembly For All Boilers

• Connecting the CTB

• Installing the Ceramic Sleeve

• Checking the Burner Nozzle and Electrodes

• Installing the Connector Block on the CTB Door

• Installing the Oil Line Tubing

• Installing the Air Line Tubing

• Locking the Burner into Firing Position

3-1

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Single Boiler Assembly

CB−350−CTB (230 V/50 Hz) SHOWN

DETAIL OF ITEM 21

17 16

CIRCULATOR

(USER SUPPLIED)

Figure 3A - Single Boiler Assembly Component Detail

I88747−C

3-2

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

CB‐350‐CTBCEPARTSLIST

NUMBER QTY PART # DESCRIPTION

31 1 90188 BASE

30 1 33529 COIL RELAY 240 VAC 30 A

29 1 33331 TERMINAL BLOCK

28 1 33340 TRANSFORMER 230V-24V

27 1 33328 RELAY DPDT

26 1 33352 RELAY DELAY

25 1 33486 TERMINAL BLOCK ASSEMBLY

24 1 33286 SWITCH DPDT

23 1 33338 AMBER LIGHT

22 1 27058 CONTROL BOX LID

21 1 12240 CONTROL BOX

20 1 33105 SNAP IN BUSHING

19 2 27158 L-BRACKET

18 1 33534 CONNECTOR CORD

17 1 31176 INSULATION – DOOR

16 1 11405 DOOR W.A.

15 1 21077 PORT LID

14 1 14084 ROPE GASKET

13 1 11583 BURNER MOUNT W.A.

12 1 11582 HINGE BRACKET W.A.

11 1 13141 ACCUMULATOR BLOCK ASSEMBLY

10 1 14272 UPPER PIPE ASSEMBLY

9 1 14293 CHECK VALVE AND PIPE ASSEMBLY

8 1 33330 GUAGE BOILER TEMP/PRESS

7 1 35048 RELIEF VALVE 3/4” MALE

6 1 35123 FLOW SWITCH TACO

5 1 28149 HIGH TEMP CUT-OFF

4 1 35079 COIL FLANGE 1-1/4”

3 1 28150 AQUASTAT

2 1 31166 INSULATION PANEL

1 1 11380 PANEL 350 REAR W.A.

PARTSTHATDIFFERONTHE CB‐200‐CTBCE

NO QTY PART # DESCRIPTION

31 1 90200 BASE

17 1 31216 INSULATION 200 DOOR

16 1 11540 DOOR W.A.

10 1 14307 UPPER PIPE ASSEMBLY

9 1 14298 CHECK VALV E AND PIPE A SSY

4 1 35116 COIL FLANGE 1” NPT

2 1 31215 INSULATION PANEL

1 1 11539 PANEL 200 REAR W.A.

Refractory Cylinder 21120 21140 21174 Refractory Cylinder Stand 27155 27190 27200

PARTSTHATDIFFERONTHE CB‐500‐CTBCE

NO QTY PART # DESCRIPTION

31 1 90206 BASE

17 1 31240 INSULATION 500 DOOR

16 1 11564 DOOR W.A.

10 1 14315 UPPER PIPE ASSEMBLY

9 1 14314 CHECK VALV E AND PIPE A SSY

4 1 35121 COIL FLANGE 1 ½ ” NPT

2 1 31239 INSULATION PANEL

1 1 11563 PANEL 500 REAR W.A.

200-CTB 350-CTB 500-CTB

3-3

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Single Boiler Assembly

Installing the CTB on the Support Stand

WARNING: Use extreme caution when moving and lifting the CTB (with a forklift) into

place on the support stand. One CTB can weigh up to 907 kg (2000 pounds). Clean Burn recommends placing safety blocking underneath the unit until it is properly installed and secured on the support stand.

Failure to follow these basic safety guidelines may result in serious personal injury and/or damage to the unit.

1. Refer to Figure 3A to become familiar with the components required for CTB assembly.

2. Assemble the CTB support stand as shown in Figure 3B, using the hardware provided.

3. Move the support stand into the approximate position where the CTB is to be installed, and place

blocks (approximately 25 cm /10 inches high) inside the stand to provide safety support for the

boiler.

4. Use a forklift to carefully lift the CTB into position over top of the support stand.

WARNING: Secure the boiler to the forklift prior to lifting to prevent possible equipment

damage or personal injury.

5. Lower the boiler down onto the safety blocks positioned inside the support stand.

6. Insert bolts (provided) into the keyhole slots in the boiler, and then lift the stand in position

against the bottom of the boiler.

7. Tighten the bolts to firmly attach the stand to the bottom of the boiler.

8. Carefully lift the assembled boiler (with stand) off the safety blocks and move the unit into place.

9. Proceed with the remainder of boiler assembly procedures marked for ALL CTB Models.

Figure 3B - Assembling the Support Stand

I88816-A

3-4

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Dual-Stacked Boiler Assembly

Assembling the Dual-Stacked Boiler

WARNING: Use extreme caution when moving and lifting one of the CTB's (with a forklift) into place on the support stand. One CTB can weigh up to 907 Kg (Weight of CB-500 with water).

Clean Burn recommends placing safety blocking underneath the unit until it is properly installed and secured on the support stand. Failure to follow these basic safety guidelines may result in serious personal injury

and/or damage to the unit.

1. Refer to Figures 3C and 3D. Move the support stand into the approximate position where the dualstacked boiler is to be installed, and place blocks (approximately 10 inches high) inside the stand to provide safety support for the boiler. NOTE: If the support stand has not been assembled, refer to Figure 3B. NOTE: Only use 19 cm (7 1/2") legs when stacking the boilers. Taller legs may be unstable.

2. Use a forklift to carefully lift one CTB into position over top of the support stand. WARNING: Secure the boiler to the forklift prior to lifting to prevent possible equipment damage or personal injury.

3. Lower the boiler down onto the safety blocks positioned inside the support stand.

4. Insert bolts (provided) into the keyhole slots in the boiler, and then lift the stand in position against the bottom of the boiler.

5. Tighten the bolts to firmly attach the stand to the bottom of the boiler.

6. Carefully lift the assembled boiler (with stand) off the safety blocks and move the unit into place for the rest of assembly. NOTE: This boiler will be referred to as the "bottom" boiler for the remainder of this procedure.

I88743−B

(Procedure continued on page 3-6)

Figure 3C - Dual-Stacked Boilers

(Completely Assembled)

3-5

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Dual-Stacked Boiler Assembly

"TOP" BOILER

(USER SUPPLIED)

ADAPTOR BRACKET

"BOTTOM" BOILER

(USER SUPPLIED)

Figure 3D - Dual-Stacked Boiler Assembly Detail

SUPPORT STAND

R B

I88737-C

3-6

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Dual-Stacked Boiler Assembly

Assembling the Dual-Stacked Boiler (continued)

7. Refer to Figures 3D and 3E. Assemble the adaptor bracket using the 1" x 3/8" bolts provided.

NOTE: The adaptor bracket is installed between the two boilers; it is fastened to the underside of the "top" boiler unit.

8. If you have not already done so, remove the pre-assembled hardware from the top of the "bottom" boiler. You will use this hardware to fasten the adaptor bracket.

9. Use a forklift to carefully lift the "top" boiler unit from underneath (see safety warning at the beginning

of this procedure).

10. Attach the adaptor bracket to the bottom of the boiler using the 1" x 3/8" carriage bolts provided. DO NOT completely tighten the bolts until the two units are assembled together. NOTE: The notches on the adaptor bracket are designed to fit around standard forklift forks.

11. After the bracket has been attached to the underside of the "top" boiler unit, move the "top" unit into position over the "bottom" unit.

12. Carefully lower the "top" boiler down onto the "bottom" boiler, watching for alignment of the bracket holes and the holes in the top of the boiler below.

13. Install the hardware through the lower set of holes in the adaptor bracket into the top of the "bottom" boiler while checking for proper alignment of the two units. Ensure that ALL hardware is securely tightened.

Figure 3E - Dual-Stacked Boiler Adaptor Bracket

I88465-A

3-7

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Assembly for ALL Boilers

Connecting the CTB

Refer to Figures 3A, 3C, and 3D. Connecting the boiler involves three activities:

• Supply Side Connections

• Return Side Connections

• Wiring

NOTE: If you are installing dual-stacked boilers, each boiler must be installed in the same manner according to the following guidelines for connections/wiring.

Supply Side Connections

• Install the temperature/pressure gauge into the first tee (the 1/2" tapping). Be sure to use

pipe dope on the threads of the gauge. Tighten the gauge into the tee.

• All other components on the supply side are factory installed and pre-wired for operation.

Return Side Connections Boiler circulator - (user-supplied) NOTE: Installation instructions are provided for both required and optional components.

• Mount the boiler circulator (user supplied) onto the flanged check valve assembly mounted on the

boiler. Place a gasket between the two flanges and tighten.

• Install the return piping assembly onto the other side of the circulator flange. Place a gasket

between the two flanges and tighten.

Wiring

• For each boiler, connect the wire from the CTB control box to the circulator. Refer to the

CTB wiring diagram in Appendix B as needed. If necessary, excess length may be trimmed from the circulator wires.

3-8

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Assembly for ALL Boilers

Installing the Ceramic Sleeve in the Boiler

NOTE: The ceramic target is factory-installed.

1. Refer to Figures 3F and 3G.

2. Swing open the clean-out door on the CTB front to gain access to the combustion chamber.

3. Install the stand for the ceramic sleeve as detailed in Figure 3F. Position the stand on the coils approximately 3" in from the door opening.

4. After the ceramic sleeve has been installed and positioned properly, close the clean-out door.

5. Tighten the four (4) nuts and washers in a criss-cross pattern until all are snug.

NOTE: The ceramic sleeve needs to seat firmly against the door insulation for proper combustion. Carefully position the ceramic sleeve on the stand so that it extends out slightly beyond the door opening, so that the door will push the ceramic sleeve in place as it is closed.

DOOR OPENING

SURFACE

CERAMIC SLEEVE

7.5 cm (3")

CERAMIC STAND

Figure 3F -Positioning of the Ceramic Stand and Ceramic Sleeve

I88463A

3-9

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Assembly for ALL Boilers

CERAMIC SLEEVE

I88124-B

CERAMIC STAND

Figure 3G - Ceramic Stand and Sleeve Installed in the Combustion Chamber

3-10

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Assembly for ALL Boilers

Checking the Burner Nozzle and Electrodes

NOTE: The burner nozzle is factory installed. Models CB-200-CTB and CB-350-CTB use a Delavan 9-5 nozzle. Model CB-500-CTB uses a 9-28 Delavan nozzle. The nozzle size is indicated on the nozzles as shown in Figure 3H. Refer also to Appendix A at the back of the manual for additional specifications on the burner nozzle.

ATTENTION: Check the electrode settings as specified in Figure 3H. The electrode settings must be correct for your burner to operate properly.

NOZZLE IS STAMPED 9−5 OR −5 ON FLAT OF NOZZLE HEAD

5 mm

(3/16")

NOZZLE

ELECTRODE

NOZZLE ADAPTER

3mm (1/8") SPARK GAP

OUTLINE OF RETENTION HEAD

3 mm (1/8")

Figure 3H - Burner Nozzle and Electrode Specifications

NOZZLE TO BE AHEAD OF RETENTION HEAD BY 3 mm (1/8")

3-11

I88757

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Assembly for ALL Boilers

Mounting the Burner on the Hinge Bracket

NOTE: The burner may have been mounted on the CTB at the factory. If this is the case, simply check the clearance between the retention head and the boiler to make sure the burner swings freely into firing position. If adjustments are necessary, follow the procedure below to adjust the hinge bracket bolts.

1. Remove the nut from the burner mounting flange on the boiler cabinet, and set it aside for later use.

2. Lift the burner into position and mount it on the hinge bracket of the boiler cabinet.

3. Carefully swing the burner and check the clearance between the retention head and the boiler throat. There must be at least 3 mm (1/8") clearance, so the retention head is not "bumped" as you swing the burner into firing position.

If the retention head "bumps" the boiler 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 firing position.

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

Installing the Connector Block on the CTB Door

1. Refer to Figure 3I on the next page.

2. Use the two (2) bolts to install the aluminum connector block onto the CTB cabinet.

3. Remove and discard the red caps and plugs from the fittings and ports on the connector block. DO NOT allow any dirt/debris to enter these components during CTB assembly.

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

accumulator properly installed on the boiler, or damage may occur to vital burner components.

ATTENTION: DO NOT use teflon tape or teflon pipe dope products on any fittings; teflon residue will plug vital burner components. Non-hardening pipe dope compounds are recommended.

3-12

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Assembly for ALL Boilers

Installing the Oil Line Tubing

OIL LINE

NOTE: DO NOT disassemble the compression fitting from the swivel fitting. To prevent leaks, the NPT threads of the compression fitting have been sealed with hydraulic sealant during assembly of the fittings at the factory.

1. Remove and discard the outer red protective

caps from the oil line tubing.

2. Loosely install the oil line tubing into the oil

line fitting on the burner.

3. Use a wrench to slightly rotate the oil line

fitting 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.

4. Make sure that the curl in the oil line is

positioned as shown in Figure 3I so that the burner can swing open correctly.

5. Install the oil line tubing and tighten the nuts

on the compression fittings. DO NOT overtighten these fittings to avoid damaging the ferrules.

CONNECTOR BLOCK

FRONT VIEW OF BOILER

OIL FITTING ON BURNER

AIR OIL

OIL LINE FITTING ON BURNER LINED UP WITH OIL LINE

OIL LINE

NOTE: You may also check the positioning of the oil line according to Figure 3J on the next page which provides a larger front view of the connector block assembly.

SWIVEL ASSEMBLY

CONNECTOR

BLOCK

SIDE VIEW OF BOILER

SHOWING OIL LINE INSTALLED

Figure 3I - Installation of

Connector Block and Oil Line

I88738A

3-13

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Assembly for ALL Boilers

AIR LINE FITTING ON BURNER

OIL LINE FITTING ON BURNER

AIR LINE

OIL LINE

AIR OIL

I88980

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

Installing the Air Line Tubing

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

2. Refer to Figure 3J. Push the air line tubing into the fitting on the connector block until the tubing bottoms out in the fitting.

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

Locking the Burner into Firing Position

1. Swing the burner into firing position.

2. Install and tighten the lock nut on the mounting plate bolt to secure the burner in its firing 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.

COMPRESSION / SWIVEL FITTING

CONNECTOR BLOCK INSTALLED ON BOILER

PLUG ON CAM LOCK CABLE

SLOT IN PLUG MUST ALIGN WITH SLOT IN RECEPTACLE

RECEPTACLE ON TOP OF BURNER

NOTE: Be sure to properly align the plug when plugging it into the receptacle. See Fig 3K.

I88354A

Figure 3K - Detail of Burner

Electric Receptacle

3-14

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

SECTION 4: COIL TUBE BOILER INSTALLATION

Understanding Installation

Installing your Clean Burn Coil Tube Boiler (CTB) is a multi-step process which includes:

(1) Oil Tank Installation Specifications (2) Installing the Metering Pump* (3) Connecting Water to the CTB (4) Installing the Oil Lines (5) Installing the Compressed Air Line (6) Wiring the CTB and Pump (7) Installing the Stack (8) Inspecting the Installation

*NOTE: This manual provides information for the installation of a metering pump with the CTB. If you ordered a J-pump, please also refer to the separate J-Pump Installation Manual included with your shipment.

Clean Burn recommends that you review all procedures before beginning installation, paying careful attention to safety information statements. Figures 4A / 4B provide a general overview of a typical

coil tube boiler installation and should be reviewed closely before proceeding.

WARNING: Improper installation can adversely affect the proper, safe operation of your CTB. It is

critical that your boiler installer reads and follows the instructions provided in this manual. Access to the boiler must be restricted; only trained, qualified personnel should be permitted to perform installation and operation procedures.

Important Safety Guidelines for Safe Installation

General installation of the appliance shall be in accordance with the manufacturer's literature, in addition to complying with the following:

BS5410 Code of Practice for Oil Firing

1997: Installation up to 45 KW output capacity for space heating and hot water supply purposes. 1998: Installation of 44 KW and above capacity for space heating, hot water and steam supply purposes. 1978: Installation for furnaces, kilns, ovens and other industrial purposes.

The Building Regulations:

England and Wales: Approved Document J: Heat Producing Appliances (1991).

Scotland: Technical standards for compliance with the Building Standard (Scotland) Regulations

1990, Part F: Heat Producing Installations and Storage of Liquid and Gaseous Fuels.

Northern Ireland: The Building Regulations (Northern Ireland) 1990. Technical Booklet L -

Heat Producing Appliances, July 1991.

Republic of Ireland: The Building Regulations of Ireland 1997, Part J: Heat Producing

Appliances.

Isle of Man, Jersey and Guernsey: The Building Bylaws - BS 7671: 1992 IEE Wiring

Regulations 16th Edition.

4-1

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Important Safety Guidelines for Safe Installation (continued)

The Environmental Protection Act 1990, Part 1: Processes prescribed for air pollution control by local enforcing authorities PG1/1 (95).

Secretary of State's Guidance: Waste Oil Burners, less than 0.4 MW net rated thermal input. November 1995 (Appendix A of OFTEC OFSA 103).

OFTEC Guidelines: Document OFG100 for externally serviced oil fired appliances.

Important Notes to the Electrician

WARNING: Electrical installation of the boiler is to be performed only by qualified personnel (i.e. licensed electrician/engineer). Improper electrical installation can adversely affect the proper, safe

operation of the boiler and may cause serious personal injury/death.

WARNING: Before completing any boiler wiring, refer to the wiring diagrams in Appendix B at the back of the manual. Carefully review the wiring assignments and colors, noting that the Clean

Burn wire colors may not be "standard" or familiar.

WARNING: High earth leakage current / earth connection is essential and must be established before connecting the main power supply.

WARNING: Low voltage terminals are only protected by basic insulation--caution is required.

CAUTION: Use only approved wire conduit and connectors when wiring the Clean Burn

boiler. An emergency stop device (i.e. "panic button") must be installed at ground level in the mains

cable to the boiler to ensure the safety of boiler operators and service personnel. The external disconnect device must employ a contact separation of 3mm in all poles; the external breaker must be an approved type.

CAUTION: The mains cable must be introduced into the control box using conduit connectors which provide adequate strain relief. The mains cable installation must be accomplished using suitably

rated and approved wiring (BASEC or HAR) or appropriate current-carrying capacity. The wires should have a minimum rating of 90 oC (194 oF).

NOTE: According to Clause 4A of 61000-3-11 (International Electrical Standard), the user must determine, in consultation with the supply authority, that the boiler is connected only to a supply with an impedance of

3.773 x 10-3 + 2.358 x 10-3 or less.

4-2

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Typical Installation Diagrams

"CLASS A" STACK CAP

WATERTIGHT ROOF FLASHING

"DEKTITE" FLASHING OR EQUIVALENT

ELECTRICAL THERMO CUT−OFF (OPTIONAL)

DEDICATED ELECTRICAL CIRCUIT 220 VOLT 15 AMP

(OPTIONAL) OIL THERMO CUT−OFF

20 cm (8") SINGLE WALL STACK MIN. 24 GAUGE

DRAFT

INDUCER

3 m (10’)

"CLASS A" STACK 1150 °C (2100 °F) ALL FUEL STACK

INSULATED STACK WITH A STAINLESS STEEL LINER

"CLASS A" KI T FOR INSTALLING "CLASS A" ST ACK THROUGH CEILING

PRESSURE OIL LINE INSTALLED TO CONNECTOR BLOCK ON BOILER

90 cm (3’)

OIL PUMP ELECTRICAL CIRCUIT

METERING PUMP

OIL FLOW

AIR & OIL

CONNECTIONS

AT CON NECTOR

BLOCK ON BOILER

COMPRESSED AIR LINE

CONTROL BOX

(ELECTRICAL

CONNECTION)

TEMP/PRESSURE

GAUGE

RETURN

FLOW SWITCH

RELIEF VALVE

HIGH LIMIT

W/RESET

FLUE COLLAR 20 cm DIA. (8")

6 mm (1/4") HOLE FOR CHECKING

DRAFT AT

DRAFT

BREACH

MAXIMUM 183 cm (6 FT)

THE PUMP MAY BE DECREASE

CAUTION: DO NOT EXCEED 183 cm (6 FT)

NOT PRIME AND/OR THE FLOW RATE FROM

VERTICAL SUCTION LIFT OR THE PUMP WILL

CLEAN−OUT TEE

CLEAN−OUT

Figure 4A - Typical Single Boiler Installation Diagram

EMERGENCY

VENT

945 LITER TANK (250 GALLONS)

CHECK VALVE

CHECK VALVE SCREEN

30 cm (1 FT)

SUCTION OIL LINE

VENT CAP

4-3

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Typical Installation Diagrams (continued)

"CLASS A" STACK CAP

30 cm (12")

ELECTRICAL THERMO CUT−OFF (OPTIONAL)

DEDICATED ELECTRICAL CIRCUIT 230 VOLT 15 AMP

(OPTIONAL)

OIL THERMO CUT−OFF

(OPTIONAL)

OIL THERMO CUT−OFF

AIR AND OIL CONNECTIONS AT CONNECTOR BLOCK ON BOILERS

COMPRESSED AIR LINE

OIL LINE

COMPRESSED

AIR LINE

230 VOLT 15 AMP

RETURN 1−1/2 NPT

SUPPLY 1−1/2 NPT

DRAFT

CLEAN−OUT TEE

"CLASS A" STACK

1150 °C (2100 °F) ALL FUEL STACK

INSULATED STACK WITH A STAINLESS STEEL LINER

WATERTIGHT ROOF FLASHING "DEKTITE" FLASHING OR EQUIVALENT

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

PRESSURE OIL LINES INSTALLED

TO CONNECTOR BLOCKS ON BOILERS

20 cm (8") SINGLE WALL STACK MIN. 24 GAUGE

CLEAN−OUT TEE

DRAFT

BAROMETRIC DAMPER

6mm (1/4") HOLE FOR

CHECKING DRAFT

AT BREACH

1.5m (5 FT) MIN

CLEAN−OUT

EMERGENCY

VENT

3 m (10’)

OIL PUMP ELECTRICAL CIRCUITS

OIL FLOW

SUCTION OIL LINE

945 LITER TANK

CHECK VALVE

CHECK VALVE SCREEN

(250 GALLONS)

90 cm (3’)

30 cm (12")

INLETGAUGE

INLET

GAUGE INLET

INLET

CANISTER FILTER

VENT CAP

Figure 4B - Typical Dual-Stacked Boiler Installation Diagram

(Two CB-350-CTB Boilers Shown)

4-4

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Combustion Air Requirements

The CTB system designer/installer must ensure that there is the proper amount of combustion air in the boiler/ mechanical room.

Refer to Figure 4C.

Combustion Air is the required amount of air that the equipment needs to permit the satisfactory combustion of oil, the proper venting of combustion gases, and to maintain a safe ambient temperature within the space at safe limits under normal conditions of use.

The following requirements should be followed for proper supply of combustion air:

Units located in confined spaces (units in a boiler room/mechanical room) must have two (2)

permanent openings, one near the top of the enclosure and one near the bottom of the enclosure

as follows:

1. If all of the air is taken directly from the outside of the building by use of vertical ducts each of the two openings must have a total free area of not less than 6.5 cm2 (1 in2) per 4,000 BTU/hr's, or 225 cm2 (35 in2) per gallon of oil, of the total appliance(s) input rating.

2. If all of the air is taken directly from the outside of the building by use of horizontal ducts each of the two openings must have a total free area of not less than 6.5 cm2 (1 in2) per 2,000 BTU/hr's, or 450 cm2 (70 in2) per gallon of oil, of the total appliance(s) input rating.

3. If all of the air is taken directly from inside of the building - each of the two openings must have a total free area of not less than 6.5 cm2 (1 in2) per 1,000 BTU/hr's, or 900 cm2 (140 in2) per gallon of oil, of the total appliances(s) input rating.

4-5

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

I88978

ABOVE FLOOR)

(ENDS 1 FOOT

INLET AIR DUCT

VENTILATION LOUVERS

(EACH END OF ATTIC)

AIR

OUTLET

AIR OILOILAIR OILAIR

DRAFT

AIR TAKEN FROM INSIDE THE BUILDING

APPLIANCES LOCATED IN CONFINED SPACES − ALL

OPENING

OUTLET AIR DUCT

INLET AIR DUCT

AIR TAKEN FROM OUTSIDE THE BUILDING

DRAFT

APPLIANCES LOCATED IN CONFINED SPACES − ALL

Figure 4C - Air for combustion and ventilation

OPENING

DRAFT

AIR TAKEN FROM INSIDE THE BUILDING

APPLIANCES LOCATED IN CONFINED SPACES − ALL

4-6

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Oil Tank Installation Specifications

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 specifications 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 affixed 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.

• Use a minimum 945 liter (250 gallon) tank. DO NOT use a 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.

• The tank must 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 and 4B.

• The tank must be vented to the outside of the building using iron or steel pipe and fittings with an approved vent cap.

• Carefully review the oil tank and pump installation details as shown in Figures 4A, 4B, and 4C, including the metering pump installation and specifications for the oil line installation. (Procedures for installing these components can be found in the following pages.)

IMPORTANT NOTE: If you are installing an inside oil tank in the same room as the boiler, you must allow a 1.5 m (5 foot) minimum clearance between the tank and the boiler. The oil tank should be set and installed in position BEFORE the boiler is installed.

4-7

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Oil Tank Installation Specifications (continued)

TANK VENT KITS AVAILABLE FROM CLEAN BURN: CB Part # 70380 − 4" Tank Vent Kit (2) elbows (2) 6" nipples (1) mushroom cap vent (1) emergency vent

MUSHROOM CAP VENT

STEEL PIPE (USER SUPPLIED)

FUNNEL WITH BALL VALVE

EMERGENCY VENT

PRESSURE RELIEF OIL LINE BACK TO THE TANK

PRESSURE LINE

PUMP

SUCTION LINE

ASSEMBLY

CHECK VALVE

FILTER SCREEN

CLEAN−OUT (TANK DRAIN)

Figure 4D - 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 4D. 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 50 mm (2") steel pipe (user-supplied) terminating outside with a proper vent cap as shown in Figure 4D. Consult local codes for information and requirements concerning the proper venting of oil storage tanks.

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

4-8

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Installing the Metering Pump

Preparing for Installation

Before starting installation of the metering pump, review Figures 4E, 4F, and 4G 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 boiler (note the specific gear motor part numbers shown in Figure 4F).

• Gather all required tools and materials as needed for installation; as indicated in the following procedures, some materials (e.g. fittings, 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 183 cm (6') TOTAL vertical lift AND 122 cm (4')

TOTAL horizontal lift.

Standard Mounting: Vertical Positioning

1. Refer to Figures 4E, 4F, and 4G. Note that the metering pump is shipped with the pump head already positioned for the standard 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.

Figure 4E - Standard (Recommended) Vertical Mounting of the Metering Pump

4-9

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

# PART # DESCRIPTION

2 see c hart 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 MIN I 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

Figure 4F - Metering Pump Component Detail

4-10

CLEAN BURN

MODEL

CB−1500 CB−2500 CB−3500

CB−5000 CB−200−CTB CB−350−CTB CB−500−CTB

GEARMOTOR

PART # 33425

33426 33427 33428 33530 33436 33571

I88728−F

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Alternate Mounting: Horizontal Positioning

ATTENTION: If the metering pump is to be mounted horizontally or on a bracket as shown in Figure 4G, 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 4F and 4G.

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 4G.

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.

RELIEFGAUGE

A2RA−7720

INLET

ROTATION

GAUGE

RELIEF

A2RA−7720

INLET

ROTATION

RECOMMENDED SETUP PUMP IS MOUNTED LEFT ON WALL

I88708−B

Figure 4G - Proper Positioning of Metering Pump Head

GAUGE

RELIEF

A2RA−7720

INLET

ROTATION

INLETINLET

ALTERNATE MOUNTING (NOT RECOMMENDED)

BLEED VALVE IS NOW CLOSE

TO THE WALL MAKING THE

BLEEDING DIFFICULT

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)

4-11

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Connecting Water to the Coil Tube Boiler

IMPORTANT NOTE! Detailed information on the installation and operation of the hydronics system is provided in Section 10 of this manual. The instructions provided here are abbreviated and serve only to indicate when these procedures should be performed; consult Section 10 for the detailed version.

1. Connect the desired header supply and return lines to the CTB.

2. Have the water trim installed by a certified hydronics technician. Heat exchangers must be used for domestic water heater installations.

3. For air separation and elimination, Clean Burn recommends the Enhanced Spiral-Type Air Separator which can be supplied by your local Clean Burn dealer. Installing an air separator helps ensure that air is purged from the boiler, which is necessary for optimal startup and operation of the burner.

4. The relief valve discharge must be piped to within four inches of the floor or to a floor drain. Be sure to allow for clearance to remove the back panel for servicing.

Filling the Coil Tube Boiler with Water

ATTENTION: It is necessary to fill the CTB with water prior to wiring and turning the CTB ON.

The boiler circulator bearings are water lubricated and should not be allowed to operate dry. Filling the CTB with water provides immediate lubrication of the bearings. Purging air from the water is also critical; doing so enables proper startup of the burner.

1. Fill the CTB with clean tap water. ATTENTION: To prevent damage to the CTB, DO NOT fill the boiler with water when the boiler is hot.

2. The pressure gauge should read 0.8 bar (12 psig). If a different operating pressure is needed, contact the Clean Burn Service Department for additional instructions.)

3. Refer to Section 10, The CTB Hydronic System, for additional information.

4-12

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Installing the Suction Oil Line Components

ATTENTION: It is critical that you adhere to the following specifications for suction oil line installation (oil line from the tank to the pump). If these specifications 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 fittings 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 4A, 4B, and 4F.

Suction line size is 1/2" (12.7 mm) diameter. Proper installation allows the suction oil line to be filled with used oil during initial priming.

• The suction oil line may NOT exceed 183 cm (6') TOTAL vertical lift AND 122 cm (4') TOTAL horizontal lift (which equals 6.0” hg maximum operating vacuum). To determine if your suction oil line will meet this specification for maximum operating vacuum, base the calculation for your installation on the following equivalents:

30 cm (1') vertical = 0.75” hg (vacuum) 122 cm (4') horizontal = 0.75” hg (vacuum)

NOTE: ALSO ADD 0.75" hg to the final sum to account for every oil filter, shut-off valve, and check valve on the suction side of the pump assembly. Sample calculation: 183 cm / 30 vertical cm feet x 0.75" = 4.50" hg AND

122 horizontal cm = 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 fitting. DO NOT use teflon tape or teflon pipe dope compounds; the teflon can flake off and cause damage to the pump head.

• The suction oil line must be 100% airtight for proper system functioning. Use only high-quality flare fittings for the copper tubing. DO NOT use compression fittings. DO NOT use any steel pipe unions. DO NOT use sweat copper pipe. These types of fittings 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 fittings (from the metering pump to the canister filter):

a. Refer to Figure 4F for a detailed look at the metering pump components and fittings. 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 fitting onto the nipple

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

e. Prepare the canister filter for installation:

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

Check the direction of the arrow for the proper flow.

• Install the 3/4" x 1/2" brass bushing into the inlet port of the canister filter.

4-13

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Installing the Suction Oil Line Components (continued)

(e.) Prepare the canister filter for installation (continued):

• Remove the plug from one of the 1/8" gauge ports in the canister filter 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" flare adapter into the other side of the ball valve.

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

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

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

• 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.

2. Install the suction oil line (from the the tank to the canister filter):

a. Refer to Figures 4A, 4B, and/or 4F. b. Prepare a piece of 1/2" O.D. copper tubing (user-supplied) which will function as the pick-up

line from the tank to the canister filter. This copper tubing must have the following specifications:

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

or fittings.

• 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 fitting is

marked "S" for suction and "R" for return.

d. Install the 1/2" MPT x 1/2" slip fitting into the "S" side of the 2" duplex slip-thru hex

bushing. e. Install the 1/4" MPT x 1/4" compression fitting 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 floor) to the 2"

opening that you are going to use for the supply oil line. Deduct 30 cm (12") from this

measurement and transfer this new measurement onto the 1/2" O.D. coppper tubing. h. Remove the locking nut and ferrel sleeve connector from the 1/2" slip fitting, and slide them

over the copper tubing. i. Slide the 1/2" O.D. copper tubing through the 1/2" slip fitting, 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" flare adapter into the 3/4" x 1/2" brass bushing.

4-14

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Installing the Suction Oil Line Components (continued)

(2.) Install the suction oil line (continued)):

m . Slide the 1/2" flare nut over the end of the 1/2" copper tubing, and flare the end of the tubing.

NOTE: Use a high-quality flaring tool (such as a Ridgid Flaring Tool) to ensure that all

flares are made properly (i.e. so they will be 100% airtight). n. Install the flared 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 fitting into the tank. q. Pull the 1/2" copper tubing back up through the slip fitting 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 fitting. 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 filter; use a spring bender over the oil line while

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

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

assembly at the canister filter). 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 4A/4B. 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 specified in this manual.

4-15

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Installing the Pressure Relief Oil Line Back to the Tank

ATTENTION: It is critical that you adhere to the following specifications 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 4A, 4B, and 4D.

• 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 fitting. DO NOT use teflon tape or teflon pipe dope compounds.

1. Refer to Figure 4H.

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 fitting 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 4D 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

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

4-16

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Installing the Pressure Oil Line Components

ATTENTION: It is critical that you adhere to the following specifications for pressure oil line installation (oil line from the pump to the boiler); if these specifications 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 30 meters (100') 9.5 mm (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.)

• If possible, the pressure oil line should 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 4A/4B, and 4H.

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

3. Install the fittings and components as shown in the related illustrations. Be sure to use Permatex #2 non-hardening gasket sealer to seal every threaded fitting. DO NOT use teflon tape or teflon pipe dope compounds.

Installing the Compressed Air Line

NOTE: Your air compressor system must supply air pressure to the boiler with the following requirements: 3.5 bar (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 boiler. Use minimum 1/4" O.D. copper tubing or equivalent for the compressed air line.

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

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

3.5 bar (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 flame 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

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Wiring the Coil Tube Boiler

WARNING: To avoid electrical shock, make sure that power to the CTB is turned OFF before connecting any wires. A licensed electrician should install all wiring to your furnace. All wiring must be

in accordance with national and local codes. Properly size all wires and use electrical conduit for all electrical lines. Specific wiring schematics are provided in Appendix B at the back of this manual. For safe and proper

operation of the boiler,

Wiring your boiler requires the installation of the following lines/circuits:

(1) A dedicated electrical line to the CTB (see IMPORTANT NOTE below) (2) A pump electrical circuit from the CTB to the oil pump (see IMPORTANT NOTE below) (3) A separate circuit for the load loop circulator

IMPORTANT NOTE: Separate, dedicated lines/circuits must be wired for each boiler in the dual-stacked unit.

Wiring to the Coil Tube Boiler

DO NOT alter factory installed wiring.

WARNING: A fuse-protected disconnect must be mounted in a readily accessible location for

the installation of the unit. This device can also be used for a disconnect in case of an emergency.

1. Install a dedicated electrical circuit to the electrical junction box on the CTB. Note that a

dual-stacked boiler will require two circuits. CAUTION: DO NOT tie into an existing circuit, or electrical overload may occur.

2. Wire the CTB according to the Wiring Schematic in Appendix B. Ensure that the ground wire is

attached to the GREEN ground screw on the boiler junction box.

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

ATTENTION: Incorrect voltage may damage the CTB components.

Total Amp Draw Per Burner & Circulator: 9.4 amps Load Circulator Ampacity: 2.5 amps (when wired through the CTB control box)

Model Voltage Breaker Qty. & Size* Phase Hertz

CB-200-CTB (single) 230 (1) @ 20 amps Single 50 CB-200-CTB (Dual-Stacked) 230 (2) @ 20 amps Single 50

CB-350-CTB (single) 230 (1) @ 20 amps Single 50 CB-350-CTB (Dual-Stacked) 230 (2) @ 20 amps Single 50

CB-500-CTB (single) 230 (1) @ 20 amps Single 50

*NOTE: Breaker size with optional equipment is 30 amps. When installing any optional equipment (e.g. air compressor), you must use a 30 amp breaker. Make sure a qualified electrician properly sizes and installs this electrical circuit. Note that minimum wire size with a 30 amp breaker is 10-gauge copper wire.

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

4-18

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Wiring to the Metering Pump

WARNING: DO NOT wire the oil pump directly into your building's electrical system. The oil 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 boiler and may result in a fire or explosion hazard.

1. Install the oil pump electrical circuit from the CTB to the oil pump location using approved electrical conduit (refer to Figures 4A/4B).

2. Wire the oil pump circuit according to the wiring schematic provided (Appendix B).

Wiring the Load Loop Circulator

NOTE: To reduce the amount of cold water returned to the boiler (and to protect the boiler from thermal shock), an optional circulator aquastat can be supplied by your Clean Burn Dealer.

1. Refer to the related information and illustrations in Section 10 and the CTB Wiring Diagram in Appendix B to locate and understand the wiring for the load loop circulator.

2. The cold water return in your CTB system installation should not be below 60 oC (140 oF).

NOTE: For installations where cold water return is a risk, Clean Burn recommends installation of a blending loop. If a blending loop is installed in your CTB system, the load loop circulator should be wired separately from the CTB control box. Refer to Section 10 for additional information.

4-19

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Installing the Stack

WARNING: Inappropriate stack materials or improper stack design/installation can adversely affect the proper, safe operation of your coil tube boiler.

Stack designs are generally classified as follows:

(1) "Class A" stack through the ceiling of the building (2) "Class A" stack through the sidewall and up the side of the building

Stack Design and Specifications

ATTENTION: The stack design must be single and dedicated for each unit (boiler) according to the following specifications. Failure to adhere to this rule may result in less than optimal system performance.

Figure 4H illustrates the through-the-ceiling stack design for a single boiler; this stack design is preferable and is more commonly used. Refer to Figure 4I for the dual-stacked boiler stack design. When designing your stack, adhere to the following specifications:

• Models CB-200-CTB and CB-350-CTB require 20 cm (8" I.D.) stack components.

• Model CB-500-CTB requires 25 cm (10" I.D.) stack components.

• Dual-stacked units require two (2) stack runs as single stacks.

• Ensure that the vertical stack height is at least 3m (10') PLUS 45 cm (1.5') for every fitting.

(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 fire. (Section 8 contains details on adjusting the draft.)

• Keep the horizontal stack run as short as possible; slant it upward at a minimum of 6 mm (1/4")

per 30 cm (12") 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 be located 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 resulting 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 concerning exhaust fans and proper make up air.

Stack components should be installed in the following order:

(1) Inside stack (the stack components from the coil tube boiler breach to within 457 mm / 18" of the

ceiling, roof, or sidewall of your building) (2) Barometric damper(s) (3) "Class A" stack penetration through the ceiling, roof, or sidewall (4) "Class A" stack on the exterior of the building (5) "Class A" stack cap

4-20

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

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

THE LAST STACK SECTION SHALL EXTEND

AT LEAST 90 cm (3’) HIGHER THAN ANY RIDGE, PARAPET WALL OR ROOF STRUCTURE WITHIN 3 m (10’) OF IT

3 m (10’)

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

DRAFT INDUCER

BAROMETRIC DAMPER

90 cm (3’)

WATERTIGHT ROOF FLASHING "DEKTITE" OR EQUIVALENT

3m (10’) MINIMUM VERTICAL

STACK HEIGHT OR EQUIVALENT

DRAFT SYSTEM TO MAINTAIN

−.02 W.C. DRAFT OVER FIRE

DRAFT

"CLASS A" INSULATED STACK

TRIPLE WALL ALL FUEL

STACK WITH A STAINLESS

STEEL LINER

20 cm (8") MINIMUM

SINGLE WALL STACK

MIN. 24 GAUGE

GALVANIZED

Figure 4H - Installation of "Class A" Stack Through Roof/Ceiling (Single Boiler)

I88742−C

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Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Installing the Stack (continued)

DAMPER

20 cm (8") STACK PIPE

82 cm (32 1/4") BETWEEN CENTERS (CB−200−CTB)

94 cm (37 1/8") BETWEEN CENTERS (CB−350−CTB)

20 cm (8") STACK PIPE

25 cm (10") BETWEEN CENTERS

I88744−C

Figure 4I - Detail of Dual-Stacked Boiler Stack Installation

Installing the Interior Stack

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

1. The stack can be installed from either side of the smoke hood breach. Install the 20 cm (8") smoke cap onto the unused smoke hood breach ring assembly.

2. Install a piece of the single-wall 24-gauge galvanized stack (minimum 45 cm (18") in length) onto the smoke hood breach.

3. Install an elbow or clean-out tee (with a smoke cap installed in the bottom) onto the extension piece from the boiler smoke hood breach.

4. Install a smoke pipe tee onto this elbow or clean-out tee (for the installation of the barometric damper). 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.

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Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Installing the Barometric Damper(s)

1. Refer to Figure 4J. Install a single wall tee (min. 24 gauge) on the first straight vertical or

horizontal stack section within 1 meter (40 inches) of the CTB breach. NOTE: This 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). ATTENTION: For Dual-Stacked CTB Units Only - You are required by code to install two dampers (provided) - one for each boiler. DO NOT attempt to substitute other types of dampers--they will not allow the unit to function properly and may void your warranty.

2. Install the barometric damper in the opening of the tee. Use a small spirit level to make sure that

it is properly level.

3. Install two self-tapping screws as shown in Figure 4J (i.e. one on each side of the barometric

damper) to hold the damper in place. DO NOT install a screw at the bottom of the barometric damper, or the flapper of the damper will not operate correctly.

NOTE: Specifications for adjusting the barometric damper for proper draft overfire are provided in Section 8 of this manual.

9" CLEAN BURN BAROMETRIC DAMPER WITH ADAPTOR IN

10" SINGLE WALL TEE

(FOR CB-500-CTB)

INSTALLED IN SINGLE WALL TEE

ADJUST THIS WEIGHT TO OBTAIN PROPER DRAFT

111

ADJUST THIS WEIGHT TO OBTAIN PROPER DRAFT

QTY

31198

31197

PART #

I88547

DAMPER PIPE ADAPTOR

9" BAROMETRIC DAMPER

DESCRIPTION

I885398" CLEAN BURN BAROMETRIC DAMPER

(FOR CB-200-CTB and CB-350-CTB)

Figure 4J - Installation of Barometric Damper

4-23

No QTY PART #

8" BAROMETRIC DAMPER3117011

DESCRIPTION

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Installing the Optional Stack Safety Switch

CAUTION: For your safety and the safe operation of your heating equipment, the stack switch must be installed by a qualified 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 1 meter (40 inches) of the breach. NOTE: The barometric damper must be installed so that it is level and the flapper 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 4K.

4. Drill a 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 flapper 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 4L. Install the wire so that it is secured away from any hot surfaces. NOTE: If a 24V thermostat is not used to activate the boiler, the stack safety switch is connected directly to the landings on top of the control box. Refer to Appendix B for the control box wiring diagram.

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 4K - Stack Safety Switch Installed on the Bar ometric Damper

I88964

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Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

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 fire, 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 flow 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 Specifications

Switching Voltage 24 volts Switch OPEN Temperature 180 oF Switch Type L180, normally closed, manual reset

WALL

THERMOSTAT

Figure 4L - Stack Safety Switch Wiring Diagram

CONTROL

BOX

STACK SAFETY SWITCH

(MOUNTED ON

BAROMETRIC DAMPER)

I88985

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Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Installing the Stack Penetration

WARNING: When running the stack through your ceiling, roof, or sidewall, you must use "Class A" 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 4H 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" double-wall insulated all-fuel stack components with a stainless steel liner.

• DO NOT use Class B Vent/double-wall stack components (i.e. for gas fired appliances only).

• DO NOT use Type L Vent/double-wall stack components (for approved fuel oil 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 4H as needed.

2. Follow the installation instructions provided by the stack manufacturer.

3. Install water-tight roof flashing around the penetration of the exterior stack.

NOTE: Clean Burn recommends the use of "Dektite" roof flashing (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 flow of stack gases which is essential for optimal burner performance.

1. Refer to Figure 4H as needed. Your stack cap should be classified 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 Field brand draft inducers have been tested for use on Clean Burn Equipment. 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 boiler and travel out of the stack. (See Figure 4M.)

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

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Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Installing the Draft Inducer (continued)

3 m (10’)

90 cm (3’)

3 m (10’) MINIMUM VERTICAL

STACK HEIGHT OR EQUIVALENT

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

(5’ − 8’)

1.5 m − 2.5 m

−.02 W.C. DRAFT

INDUCER

ADJUSTMENT

CHECK FOR

OVER FIRE

DRAFT

PLATE

SERVICEMAN ADJUSTS BAROMETRIC DAMPER TO OBTAIN −.02 W.C. DRAFT

DRAFT

OVERFIRE

AIR

DRAFT SYSTEM TO MAINTAIN

−.02 W.C. DRAFT OVER FIRE

OIL

I88981

Figure 4M - Installation of the Draft Inducer

WARNING: Turn OFF the main power to the boiler 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 breach where heat and ash will damage the inducer motor.

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Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Installing the Draft Inducer (continued)

1. Refer to Figure 4M. 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. You will adjust the draft plate later as part of Adjusting the Draft Overfire (Section 8).

Wiring the Draft Inducer for Normal Operation*

*(No exhaust fans in the building)

1. Wire the draft inducer according to the Wiring Diagram in the Burner Control Box and also provided in Appendix B at the back of this manual.

Installing the Wall Thermostat or Aquastat

IMPORTANT NOTE: A 24V wall thermostat is available separately from Clean Burn (i.e. it is not included with the CTB). If a 24V thermostat is used to activate the boiler, a qualified technician would need to remove the jumper from the external four landings on top of the black control box on the side of the boiler and use it to connect landings 5 and L1 on the internal terminal block. The 24V thermostat is then connected into the optional stack safety switch landing. Refer to Appendix B for the control box wiring diagram.

Refer to Appendix A in this manual for additional information on remote temperature sensing controls available from Clean Burn for your CTB system installation.

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 control box on the side of the boiler. DO NOT run the wiring to the primary control!

5. Mount the thermostat base 1.5 meters (60" to 66") from the floor 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.

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Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Inspecting the Coil Tube Boiler Installation

Following the completion of all installation activities described in this chapter, the CTB should be inspected by qualified personnel before firing. This ensures that your installation meets all applicable national and local codes and allows for any deficiencies in the installation to be corrected before CTB startup. Improper installation will void your warranty.

NOTE: Important! During the inspection, be sure to check the aquastat settings. Initial settings are listed here:

• Operating Aquastat 82

C (180 oF) minimum

• Hi-limit Aquastat (with manual reset) 115 oC (240 oF)

Refer to Section 6 for burner startup and final adjustments of the aquastat.

Any changes to these settings should be made only by a qualified hydronics technician. See Section 10, The CTB Hydronics System, for more information.

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Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

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Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

SECTION 5: METERING PUMP PRIMING

Understanding Metering Pump Priming

Preparing your Clean Burn boiler 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.

IMPORTANT NOTE FOR DUAL-STACKED UNITS: The priming procedures will have to be performed for one burner, and then repeated for the other burner (i.e. get one burner running first before attempting priming of the other burner.)

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 4 liters / one-gallon each)

• Permatex #2 non-hardening gasket sealer

• Adjustable Wrench

• Pipe Wrench

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Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

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 fill the oil line, canister filter, 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 on the pump two to three (2-3) full turns, and position a container to catch oil which will flow 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.

Figure 5A - Priming the Metering Pump

5-2

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Priming the Metering Pump (continued)

Activating the Pump NOTE: The coil tube boiler features a priming switch which is mounted on the left-hand side of

the electrical junction box on the front of the boiler 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 UP position. The pump should immediately start running.

OIL PUMP

PRIMING SWITCH

PRIMING LIGHT

AIR REGULATOR

OIL GAUGE

AIR GAUGE

COMPRESSED AIR LINE

Figure 5B - Detail of Burner Connections/Components

CONNECTOR BLOCK

OIL LINE

I88746−A

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Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Priming the Metering Pump (continued)

9. Run the pump until a solid stream of oil flows from the pump bleeder. This will bleed all air out of the suction line, oil filter 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 filled.

11. Close and tighten the bleeder on the pump.

12. Turn the priming switch to the DOWN position so that the pump stops running.

13. Disconnect the pressure oil ine from the burner and position a container to catch oil which will flow from the pressure oil ine during pump priming.

14. Turn the priming switch to the UP position. The pump should start running immediately .

15. Run the oil pump until the proper flow of oil has been established, and the oil line has been completely flushed out.

16. Turn the priming switch to the DOWN position so that the pump stops running.

17. Re-connect the oil line to the connector block.

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 fittings, 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 filter on systems equipped with a ball valve.

ATTENTION: For the pump to pull and hold vacuum, it is critical that all fittings are airtight. If any of these fittings are loose, the pump may not pull a vacuum or may lose the vacuum rapidly. It is also critical that all fittings in the suction line, including fittings on the canister filter, 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 flowing from the bleeder. DO NOT close the bleeder yet.

3. Refer to Figure 5A. Close the ball valve at the inlet to the canister filter. Observe the vacuum gauge. NOTE: The ball valve must have a stainless steel ball and should be pressure tested by the manufacturer to ensure that it does not leak. If the ball valve leaks, the vacuum test will not be accurate.

4. The vacuum should increase within 30 seconds to 15 inches of vacuum. When the vacuum gauge reads 15 inches of vacuum, first 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

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

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 five 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 five inches within the first minute, there is one or more leaks somewhere between the pump and the ball valve. Do the following:

• Wipe your finger 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 fittings from the pump to the ball valve. Properly seal all fittings with Permatex #2 non-hardening gasket sealer or equivalent. Check the condition of the o-ring on the canister filter and tighten the four canister filter 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

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

5-6

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

SECTION 6: STARTING AND ADJUSTING THE BURNER

Understanding Burner Startup and Adjustment

ATTENTION: Before starting the burner, you must fill the coil tube boiler with water. Refer to Section 10 in this manual for more information on the hydronics system. DO NOT bypass the CTB

controls to operate the burner!

FOR DUAL-STACKED UNITS ONLY: Clean Burn recommends that you complete burner startup and adjustment for one burner before starting the second burner.

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 Hydronics System for Burner Startup

The following procedure should be performed prior to burner startup to ensure that all key components of the hydronics system are functioning properly. Ensure that air is purged from the system. If the CTB circulator becomes air-bound, it will not produce sufficient flow to activate the flow switch, and the burner will not start properly.

1. Turn the load temperature controller (i.e. thermostat or aquastat) OFF.

2. Set the operating aquastat (on the CTB) at 82 oC (180 oF).

Preparing the Burner for Startup

1. If you have not already done so, disconnect one side of the jumper wire from the terminal block on top of the control box on the side of the boiler (this prevents the burner from running.) A wiring diagram is provided in Appendix B.

2. Turn the main power to the CTB ON (the green power light on the burner should be 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 sufficiently warm. The proving switch on the preheater block will not allow the burner to start until the block is at least 48 oC (120 oF).

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.

(Continued)

6-1

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Preparing the Burner for Startup (continued)

SLOT COVER INSTALLED

4. Refer to Figure 6A. Loosen the locking nut on the air regulator.

5. Turn the adjustment knob on the air regulator counterclockwise until 13 mm (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 first time, it is very important to turn the air regulator completely OFF as described.

6. Initial Adjustment of the

Combustion Air Band

Rotate the combustion air band to adjust it to the appropriate slot opening as listed in the following Initial Adjustment Charts. Use a ruler to accurately set the slot opening at the widest section of the slot.

AIR REGULATOR

LOCKING NUT

AIR GAUGE

OIL GAUGE

COMBUSTION

AIR BAND

Figure 6A - Component Detail of the

CB-500 Series Burner

WARNING: The combustion air band must be properly adjusted to ensure that the burner

ignites and burns correctly. DO NOT attempt to start the burner with the combustion air band

wide open or completely closed. The burner may not ignite correctly. Failure to heed this warning may result in a fire or explosion hazard.

IMPORTANT NOTE: This initial setting of the combustion air band will allow you to start the burner. You will fine tune the combustion air band further as described later in these instructions.

ATTENTION: The settings shown in the charts below are only initial adjustments. Final adjustments must be done by inspecting the flame 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-200-CTB

NOTE: Only Gearmotor part #33530 may be used with the CB-200-CTB.

Maximum Input = 59 KW (200,000 BTUH) @ 5.3 LPH (1.4 GPH) per CB-500-CE 5W Burner

Oil Type Oil Pressure/Flame Length Air Bar (PSI) Air Band Nozzle

#2 Fuel Oil* check flame length 0.8-1.1 (12-16) 10 mm (3/8") 9-5 Used Crankcase Oil check flame length 0.8-1.1 (12-16) 10 mm (3/8") 9-5 Used ATF check flame length 0.8-1.1 (12-16) 10 mm (3/8") 9-5 Used Hydraulic Oil check flame length 0.8-1.1 (12-16) 10 mm (3/8") 9-5 #4 and #5 Fuel Oils check flame length 0.8-1.1 (12-16) 10 mm (3/8") 9-5

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Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Preparing the Burner for Startup (continued)

Initial Adjustments for CB-350-CTB

NOTE:

Maximum Input = 103 KW (350,000 BTUH) @ 9.5 LPH (2.5 GPH) per CB-551-CE 5W Burner

Oil Type Oil Pressure/Flame Length Air Bar (PSI) Air Band Nozzle

#2 Fuel Oil* check flame length 0.8-1.1 (12-16) 12 mm (1/2") 9-5 Used Crankcase Oil check flame length 0.8-1.1 (12-16) 12 mm (1/2") 9-5 Used ATF check flame length 0.8-1.1 (12-16) 12 mm (1/2") 9-5 Used Hydraulic Oil check flame length 0.8-1.1 (12-16) 12 mm (1/2") 9-5 #4 and #5 Fuel Oils check flame length 0.8-1.1 (12-16) 12 mm (1/2") 9-5

Initial Adjustments for CB-500-CTB

NOTE:

Maximum Input = 146 KW (500,000 BTUH) @ 13 LPH (3.4 GPH) per CB-551-H5-CE 5W Burner

Oil Type Oil Pressure/Flame Length Air Bar (PSI) Air Band Nozzle

#2 Fuel Oil* check flame length 1 - 1.2 (14-18) 16 mm (5/8") 9-28 Used Crankcase Oil check flame length 1 - 1.2 (14-18) 16 mm (5/8") 9-28 Used ATF check flame length 1 - 1.2 (14-18) 16 mm (5/8") 9-28 Used Hydraulic Oil check flame length 1 - 1.2 (14-18) 16 mm (5/8") 9-28 #4 and #5 Fuel Oils check flame length 1 - 1.2 (14-18) 16 mm (5/8") 9-28

Only Gearmotor part # 33436 may be used with the CB-350-CTB.

Only Gearmotor part # 33571 may be used with the CB-500-CTB.

* 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. Re-connect the control wire. Turn the aquastat to call for heat (to start the burner).

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 (per the burner wiring diagram) is energized to 230VAC.

• Reset the hi-limit switch.

• If the flow switch is not closing, the circulator is air-locked. Air must be purged from the system.

• Verify that the prime switch (on the control box) is set to RUN (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 you burner.

3. Observing the Flame Length:

Visually inspect the flame length through the observation port. Refer to Figure 6B for an illustration of the desired flame length. The flame should extend no more than one-half of the way down the combustion chamber.

WHEN OPENING INSPECTION PORT

CAUTION

WARNING: The observation port gets hot as the burner fires. To avoid personal injury, always wear heavy work gloves and safety glasses when opening the port and viewing the flame.

PORT MAY BE HOT

PROTECT HANDS

WEAR SAFETY GOGGLES

KEEP FACE AWAY

OPEN PORT SLOWLY

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Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Starting the Burner (continued)

Correct Maximum Flame Adjustment (Proper Oil and Air Pressure)

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

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

Incorrect Flame Adjustment (Not Enough Combustion Air)

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

• Increase combustion air by opening the air band on the side of the burner.

Incorrect Flame Adjustment (Air Pressure too high)

• Ensure proper air pressure setting

Figure 6B - Flame Length Adjustment

4. Check the flame length after the burner has fired for 15 minutes.

5. Tighten the locking nuts on the air regulator.

I88372

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Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Starting the Burner (continued)

6. Checking for Proper CTB System Operation:

Observe the boiler temperature and water pressure.

7. After the burner stops running when the operating aquastat set temperature is reached, check the following:

• air has been purged from water lines

• water pressure is satisfactory (i.e. not greater than 1.5 bar (22 psi); normal pressure is

0.8 bar (12 psi)

• all system controls functioning properly

8. Reset the operating aquastat to the normal operating range; 82 - 93 6 and 7, observing the CTB operation.

9. Reset the load temperature controller (i.e. thermostat or aquastat) to the normal operating temperature.

10. As the CTB temperature drops, the burner will start running. Continue observing the CTB operation through several burner ON/OFF cycles to ensure proper system performance.

11. Fine Tuning the Combustion Air Band: NOTE: The initial setting of the combustion air band may require additional adjustment.

• Refer to Figure 6A to identify the combustion air band location on the burner.

• Observe the flame. The flame should be yellow-white with sharp tips and no "sparkles."

• If the flame is orange in color or the flame length is too long, the oil you are burning requires MORE combustion air. OPEN the air band 3 mm (1/8") to 6 mm (1/4"), and re-check the flame for the proper characteristics.

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

12. Checking for a Smokeless Burn:

Check for a smokeless burn by observing the stack while the burner is running. If you see any smoke, repeat the previous steps for setting the combustion air band and adjusting the air regulator. After adjusting the combustion air band, re-check the flame length. NOTE: Check for a smokeless burn periodically (as you do the flame 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 fire should be -0.02 to -0.04 inch w.c.

• Adjust for a smoke spot of a trace to 2

• For the CB-500-CTB adjust for a CO2 reading of 12.5 to 14% or an O2 reading of 2 to 4%

• For the CB-350-CTB adjust for a CO2 reading of 12 to 13.5% or an O2 reading of 4 to 7%

• For the CB-200-CTB adjust for a CO2 reading of 10.5 to 12.5% or an O2 reading of 3 to 5%

• Cad cell reading of 200 to 500 ohms

C (180 - 200 oF) and repeat steps

NOTE: On the CB-200-CTB the flame can not be observed through the inspection door. The CB-200-CTB must be adjusted with instruments for proper combustion. Obtain the above settings by adjusting the air band 10 mm (3/8") to 13 mm (1/2"). The metering pump will deliver a constant oil flow and set the flame length.

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Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

6-6

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

SECTION 7: RESETTING THE OIL PRIMARY CONTROL

Understanding the Danfoss Oil Primary Control

The oil primary control will shut the oil pump and oil solenoid off when it detects flame-out during burner operation. The oil primary control will then wait approximately 15 seconds (while the burner motor, air solenoid, and transformer are energized) and attempt to re-ignite the burner (recycle mode). If the burner does not re-ignite, the control will shut the burner off on safety lock-out. The following procedure explains what should be done when this occurs. It is very important that you follow these instructions precisely when

resetting the safety on the primary control and restarting the burner.

Resetting the Danfoss Oil Primary Control

DANGER! DO NOT reset the oil primary control if oil mist is present in the combustion

chamber or when the combustion chamber is hot! DO NOT operate your CTB if excess oil, oil vapor or fumes have accumulated in or near your boiler. As with any oil burning appliance, improper operation may result in a fire or explosion hazard.

1. Refer to Figure 7A.

2. Allow 5 to 10 minutes for all fuel mist to exhaust from the combustion chamber.

3. If the combustion chamber is hot, allow the boiler to cool for at least 30 minutes. DO NOT

push the reset button.

4. When you are sure that all fuel mist has cleared and the boiler has cooled, push in and hold the

reset button for three seconds, then release. This will reset the control at any time during its operation.

5. If the burner will not restart, call your Clean Burn dealer immediately.

I88853A

Figure 7A - Danfoss Oil Primary Control

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Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

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Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

SECTION 8: ADJUSTING THE DRAFT OVER FIRE

Understanding the Importance of Draft

Draft in the Coil Tube Boiler is created as the hot combustion gases rise up the stack, creating a negative pressure inside the stack and the boiler. This negative pressure is measured as inches of water column (W.C.) of draft. A proper draft overfire of -.02 w.c. is essential so that all combustion products travel away from the burner, down the combustion chamber, through the boiler flues and up the stack.

Checking for Correct Draft Over Fire

NOTE: The CTB is equipped with an observation/draft reading port to check draft over fire. A qualified serviceman with proper equipment must adjust your CTB 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.

2. Adjust the barometric damper to achieve

the required draft over fire of -0.02 w.c.

(water column).

3. Record the reading in the Maintenance

Record located in the Appendixes.

4. If correct draft over fire cannot be achieved,

contact your Clean Burn dealer

immediately.

ATTENTION: Only operate your CTB

with a draft over fire of -0.02 w.c. Poor

draft results in back pressure and poor

burner performance. DO NOT operate your

CTB with a draft over fire greater than

-0.04 w.c.; an abnormally high stack

temperature may result from a draft over fire

that is too high.

ATTENTION: Backdraft must be resolved or your boiler will not operate correctly!

Under backdraft conditions, draft overfire 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.

I88257

Figure 8A - Checking for Proper

Draft Over Fire

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Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Checking for Correct Draft Over Fire (continued)

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.)

• Boiler flues are plugged with ash. (See Section 9.)

• Improper seal on clean-out door on back panel. (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.)

If there is insufficient make-up air, the exhaust fan will suck air and combustion gases down the coil tube boiler stack and create backdraft in the boiler. After the burner is shut down, the backdraft may suck the residual heat out of the combustion chamber and into the burner causing damage to the burner. Even if the exhaust fan is on another level of the building or in another room away from the boiler, the exhaust fan will still create backdraft at the boiler.

Checking Draft Overfire 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.

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 coil tube boiler and adjust the barometric damper so that the draft overfire is -.02 w.c.

3. Check the draft overfire again. Now have someone start the exhaust fans.

4. Note how much the draft overfire has changed. ATTENTION: If the draft overfire changed towards positive, it is mandatory that make-up air is provided to the building or severe damage to the boiler and burner will occur. If the draft overfire remained constant at -.02 w.c., there is sufficient make-up air entering the building, and the exhaust fan is not adversely affecting the draft.

CAUTION: Under no circumstances should the equipment room ever be under a negative pressure. Look for exhaust fans, compressors, air handling units, or anything else that may take air

away from the boiler. Also look for chemical fumes, solvents, refrigerants, etc. that may be in use around the boiler and cause damage to it.

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Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Adjusting Draft Over Fire with A Draft Inducer Installed

NOTE: The draft inducer is purposely sized to create a generous draft. When adjusting the barometric damper, you will find that the flapper 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 fire.

2. Adjust the barometric damper to obtain -0.02 w.c. draft over fire. 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.

8-3

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

8-4

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

SECTION 9: MAINTENANCE

Understanding Maintenance

Maintaining your Clean Burn CTB is an important activity which includes several periodic maintenance activities and an annual burner tune-up...all are necessary to keep your boiler running in peak condition.

WARNING: Failure to maintain and/or improper servicing by unqualified personnel may adversely affect the proper, safe operation of your coil tube boiler, may reduce the service

life of your boiler, and may void your warranty.

The following chart summarizes all the maintenance activities which should be performed on the CTB at the intervals indicated. Instructions/procedures for these activities are included in this chapter.

Maintenance Activity Interval

Cleaning the canister filter 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 oil tank At least once a year Cleaning out ash (CB-200-CTB)* Approx. every 750 hrs. per burner hour meter Cleaning out ash (CB-350-CTB)* Approx. every 1000 hrs. per burner hour meter Cleaning out ash (CB-500-CTB)* Approx. every 1000 hrs. per burner hour meter Checking boiler water condition Periodically by qualified water treatment company Annual burner tune-up At least once a year

*It is very important to clean the ash from the CTB on schedule. Normal use of the boiler requires clean-out at least twice during the heating season. Heavy, around-the-clock usage requires more frequent clean-out (e.g. one month of continual running of the boiler is 720 hours).

NOTE: IMPORTANT! Record all maintenance activities in the Maintenance Record provided in the Appendixes.

Annual Preventative Maintenance and Burner Tune-up

The Clean Burn CTB requires annual preventative maintenance. The burner also requires an annual tune-up to keep it running in peak condition. The burner tune-up should be performed by a qualified Clean Burn service technician who has the necessary parts and expertise.

Contact your local Clean Burn dealer to schedule the annual maintenance for your boiler. Various levels of service are provided to fit your particular need. This work is usually performed during the warm-weather months to prepare the boiler for the next heating season.

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Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Cleaning the Canister Filter

ATTENTION: Never operate the oil pump with more than 10" HG of vacuum on the vacuum gauge. High vacuum on the suction side of the pump separates air from the oil (cavitation) and will cause the burner to shut down.

The following protective gear should be worn when cleaning the filter:

• Rubber gloves • Safety goggles

1. Close the ball valve adjacent to the filter.

2. Position a container under the filter.

3. Unscrew the four bolts, remove the canister bowl, and filter element. Now pour the oil into the container.

4. Clean the filter element and the bowl in a parts washer.

5. Referring to Figure 9A, check the condition of the O-rings. Replace any that are cracked or worn.

6. Ensure that the canister filter is 100% airtight by firmly tightening the four bolts.

7. 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

I88716−C

Figure 9A - Canister Filter Component Detail

9-2

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Servicing the Metering Pump

1. Refer to Figure 9B.

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.

Figure 9B - Servicing the Metering Pump

9-3

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Cleaning the Check Valve / Screen

This procedure applies to coil tube boiler 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 9C. Remove the one-piece suction oil line from the tank.

2. Remove the check valve and screen. Clean these components in a parts washer.

3. Check the operation of the check valve. The valve must seat so it is airtight to hold pump prime.

4. Re-assemble and re-install the components. Apply Permatex #2 non-hardening gasket sealer or equivalent to the threaded fittings. 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

METERING PUMP

EMERGENCY

VENT VALVE

CLEAN OUT

SUCTION OIL LINE

VENT CAP

945 LITER TANK (250 GALLONS)

CHECK VALVE

CHECK VALVE SCREEN

I88717−C

Figure 9C - Check Valve Detail

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Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Cleaning the Ash from the Coil Tube Boiler

ATTENTION: Your CTB may require frequent clean out of the ash due to contaminants in the oil or heavy use. As ash accumulates, CTB heat output declines, and the stack temperature rises. 3 mm (1/8") of ash has the insulating capacity of 2.5 cm (1") of fiberglass insulation and reduces heat transfer significantly. Never allow more than 6 mm (1/4") of ash to accumulate in the combustion chamber heat exchanger flues or stack.

The following protective gear should be worn when cleaning the ash:

• Respirator for fine particles • Rubber gloves

• Safety goggles • Protective clothing

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

sufficiently. Shop air should be turned OFF and disconnected. Allow at least one hour for the ceramics to cool.

2. Clean the ash from the combustion chamber (see Figure 9D):

a. If the air and oil lines must be disconnected to open the clean out door:

1. Bleed-down pressure on the air and oil lines by slightly loosening the fittings at the bottom of the connector block.

2. With air and oil pressure completely bled off, disconnect the air and oil pressure lines from the bottom of the connector block. NOTE: Cover these lines to keep dirt from entering the air/oil supply.

b. Remove the lock nuts on the clean-out door. c. Carefully swing open the clean-out door to expose the coiled heat exchanger, flue passages,

and the combustion chamber.

d. Remove the two ceramic sleeve half-pieces from the combustion chamber, and remove the

supporting ceramic stand pieces.

e. Use a wire or bristle brush to thoroughly clean out the ash from the combustion chamber and

flue passages.

f. While cleaning out the combustion chamber, also check the burner retention head and throat.

Carefully clean these elements.

I88123-A

Figure 9D - Accessing the Combustion Chamber for Cleaning

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 and target wall. DO NOT bump or bend burner components while cleaning the combustion chamber.

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Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Cleaning the Ash (continued)

(2.) h. Thoroughly vacuum any remaining ash residue from the flue passages. A long wand on the

hose of your shop vac is helpful in reaching all the way back.

i. Inspect the combustion chamber and its components to ensure that it is in good condition.

Inspect the inside of the clean-out door and target wall. Make sure the refractory material on the inside of the door is in good condition, and the door seals tightly when closed. If the door does not seal tightly, replace any damaged components.

3. 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 clean-out tee or elbow, then vacuum out. d. Disconnect the stack from the CTB breach. e. Thoroughly vacuum out the back of the boiler, including the boiler breach (through the

breach). If desired, the back panel can be removed for cleaning.

ATTENTION: When handling the front door and rear panel, be careful that you do not damage the insulation seal surfaces. Two technicians may be required to remove and install the rear panel safely. The panel weighs approximately 39 Kg (85 lbs).

4. Reassemble the boiler components (ceramic stand, ceramic sleeve, back panel, etc.) If necessary, refer to Section 3 for additional Assembly information.

5. Close the clean-out door, install and tighten the washer and nuts. Make sure that the clean-out door and rear panel close and seal properly. Reconnect all disconnected lines (oil and air) 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 pertinent instructions.

Cleaning the Oil Tank

DO NOT allow water, sludge, or other debris to accumulate in your oil supply tank to the point that non-combustible or harmful materials are drawn into the pump or burner.

Drain water and sludge from the bottom of your tank at least once a year, and more frequently with water accumulation.

End of Season Maintenance

Turn main power to your coil tube boiler OFF at the end of the heating season. Environmental regulations allow your used oil to be burned only for "heat recovery." DO NOT operate your boiler during warm weather just to burn oil. Contact your local Clean Burn dealer to schedule your annual burner tune-up. Allow only

trained, authorized service personnel to service your burner.

In the "off" season after the boiler has been cleaned, spray the combustion chamber with a light coat of oil to reduce corrosion caused by moisture in the air.

NOTE: If the CTB is not used during the cold-weather months, it must be protected to prevent damage from freezing temperatures.

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Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

SECTION 10: THE CTB HYDRONIC SYSTEM

Understanding the CTB Hydronic System

The Clean Burn Coil Tube Boiler (CTB) is designed to function as a low-mass boiler (i.e. it will not maintain boiler water temperature when there is no call for heat). Low-mass boilers require that a sufficient, constant flow of water be maintained through the coil in order to: (a) remove the heat from the boiler when the burner is firing AND (b) prevent the flow switch from shutting off the burner.

IMPORTANT NOTE: When designing the system layout and application for your CTB, keep in mind that it is NOT suitable for open systems. The Clean Burn CTB has been designed to operate as a closed loop boiler system. Potable water heating (i.e. for domestic or washing purposes) can be accomplished by incorporating a heat exchanger into the system.

Special Safety Guidelines for the Design and Installation of Hydronic Systems

Adhere to the following Safety Guidelines when designing and setting up the CTB hydronics system:

• The CTB must be installed on non-combustible flooring.

• The CTB must be installed in accordance with national, state, and local plumbing, heating, and electrical codes and the regulations of the serving utilities which may differ from this manual. Authorities having jurisdiction should be consulted before installations are made. In all cases, reference should be made to all aplicable standards.

• The heating system must be designed by a competent hydronics contractor, and only persons knowledgeable in the layout and installation of hydronic heating systems should install this boiler.

• The boiler must be connected to an approved chimney in good condition. Serious property damage could result if the boiler is connected to a dirty or inadequate chimney. The interior of the chimney flue must be inspected periodically through the heating season for any obstructions. A clean and unobstructed chimney flue is necessary to allow noxious fumes that could cause serious injury to vent safely and will contribute toward maintaining the boiler's efficiency.

• It is the responsibility of the installing contractor to see that all controls are correctly installed and are operating properly when the installation is completed.

• To ensure optimum performance, qualified personnel must perform proper and timely maintenance on the CTB according to the procedures provided in Section 9 of this manual.

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Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

CTB System Function and Configuration

Water Flow and Temperature

The Clean Burn Coil Tube Boiler design requires continuous water flow through the boiler heat exchanger to ensure proper system operation. The boiler circulator must be capable of developing sufficient (head) pressure to overcome the resistance of the boiler plus the circulating system at the required flow rate. If the water flow through the boiler is too low, the flow switch will not allow the burner to operate. (Refer to Appendix A, as needed, for CTB system specifications.)

Heating systems using zone valves, zone pumps, or three-way valves may experience reduced water flow through the boiler. This condition can cause excessive water temperature rise and unstable boiler operation. The normal temperature rise across the boiler is 11 oC(20 oF). Minimum operating temperature for the CTB is 71 oC (160 oF). To avoid condensation, the return water temperature should not fall below 60 oC (140 oF).

System Pressure

The Clean Burn CTB is designed to operate in closed, pressurized hydronic systems. Certain levels of pressure are required for proper system operation--a minimum of 0.8 bar (12 PSI) should be maintained on the system where the boiler supply water temperature is 93 oC (200 oF) or less. If a higher working pressure is required, contact the Clean Burn Service Department for proper pressure requirements.

Sample System Configuration: Primary/Secondary Pumping System

A sample hydronic system setup using Clean Burn Coil Tube Boilers is shown in Figure 10A. This system, a Primary/Secondary Pumping System, allows for many special hydronic requirements (e.g. water return temperatures below the normal 60 oC (140 oF), variable flow zones, multiple zones, multi-temperature systems, and/or multiple boilers) and provides maximum flexibility while maintaining optimal system functioning. A critical advantage of this type of system is that it dramatically

reduces the danger of thermal shock to the boiler.

In a Primary/Secondary Pumping System (as shown in Figure 10A), the primary loop circulator runs when any of the zones call for heat. In some system setups, the circulator may run continuously during the heating season. The circulator pushes hot water past the zone tees; any of the secondary zone pumps can draw hot water out of the first tee (as though the tee were a boiler). Each zone then returns cooler water through the second tee where it mixes with the hot water being pushed through by the primary loop circulator. The close positioning of the two zone tees is crucial to the operation of the system; the tees must be at least 15 cm (6") but not more than 31 cm (12") apart. This allows for circulators of different flow rates to be used in the same system while maintaining proper flow and functioning.

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Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

WATER

COLD

CIRCULATOR

CONCEPTUAL SCHEMATIC:

THE DESIGNER MUST DETERMINE IF IT WILL WORK

WITHIN THE SYSTEM AND ENSURE COMPLIANCE

PRIMARY LOOP

WITH EXISTING CODES

AIR SEPARATOR

ENHANCED TYPE

WATER

HEATER

INDIRECT

ERGOMAX

DOMESTIC

HOT WATER

COLD

SUPPLY WATER

VALVEEXPANSION

FILL

WITH MULTIPLE OR SINGLE BOILERS

PRIMARY/SECONDARY SYSTEM

TANK

I88759−A

SECONDARY LOOPS

HYDRONIC

UNIT HEATER

CB 350 CTB

BASEBOARD ZONE

NO MORE THAN 30 cm (12") APART

TANK

EXPANSION

3−WAY MIXING

VALVE

OR TEMPERING

CB 350 CTB

Figure 10A - Sample Primary/Secondary Hydronic System Diagram

PURGING VALVE

RADIANT FLOOR LOOP

LOOP

PRIMARY

OPTIONAL

FLOOR LOOP

IS USED IN THE RADIANT

REQUIRED IF ANTIFREEZE

CIRCULATOR MAY BE

HEAT EXCHANGER AND

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Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

CTB Setup Options

When designing and setting up the CTB Hydronic System, please be aware of the following options and special setup requirements:

(1) The boiler circulator (which you may have ordered from Clean Burn for your CTB system) is sized to ensure a flow of water through the coil tube ONLY; it is NOT sized to be used as a system

circulator. An additional circulator must be installed to flow water through the system and to the boiler.

(2) In low load conditions, Clean Burn recommends the installation of a larger storage tank next to the CTB to extend the run time and to reduce the occurrence of short cycling. Position the tank close to the boiler to reduce the required connective piping as shown in sample configuration, Figure 10B.

(3) If hot water is required in the system installation for washing or other related activities, Clean Burn offers Ergomax Heat Exchangers/Storage Tanks in 182, 273, and 450 liter sizes (48, 72, and 119 gallon sizes). Contact your local Clean Burn representative for additional details on these CTB system components. Refer to Figure 10C for a sample system configuration using an Ergomax Heat Exchanger. This configuration is ideal for installations requiring pressure washing, car/truck washing, etc. The Ergomax unit works well with a CTB because it stores boiler water in the tank and acts as a buffer (tempering) tank while enabling reduction of short cycling.

10-4

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

SYSTEM

SUPPLY

SYSTEM

RETURN

SYSTEM SUPPLY

CIRCULATOR

TANK

STORAGE

(BOILER WATER)

COLD

WATER

I88748−B

FILL VALVE

AIR ELIMINATOR

AIR SEPARATOR

ENHANCED TYPE

ISOLATION VALVE

USER SUPPLIED BOILER CIRCULATOR

PURGE VALVE

Figure 10B - Model CB-350-CTB with Additional Larger Storage Tank

CONCEPTUAL SCHEMATIC:

WILL WORK WITHIN THE SYSTEM AND

ENSURE COMPLIANCE WITH EXISTING CODES

THE DESIGNER MUST DETERMINE IF THIS SYSTEM

10-5

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

WATER

INLET

I88749−B

HOT WATER

OUTLET

ERGOMAX

WATER HEATER

HEAT EXCHANGER

COLD

WATER

FILL VALVE

AIR ELIMINATOR

AIR SEPARATOR

ENHANCED TYPE

ISOLATION VALVE

USER SUPPLIED BOILER CIRCULATOR

PURGE VALVE

Figure 10C - CB-350-CTB with Ergomax Indirect Water Heater

CONCEPTUAL SCHEMATIC:

WILL WORK WITHIN THE SYSTEM AND

ENSURE COMPLIANCE WITH EXISTING CODES

THE DESIGNER MUST DETERMINE IF THIS SYSTEM

10-6

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Guidelines for CTB Setup and Operation

1. Refer to the appropriate illustration in this section for your CTB system configuration, as well as Figures 4A/4B in the Installation chapter.

2. Connect the supply and return piping to the heating system. (Additional information in Section 4). CAUTION: Hot water pipes shall have clearances of at least 13 mm (1/2") from all combustible surfaces. For additional technical reference material, see I=B=R Installation and Piping Guide No. 200.

3. The relief valve must be installed with the spindle in the vertical position. The relief valve discharge pipe must be extended to within four inches of the floor or to a drain.

4. To reduce the amount of cold water returned to the boiler (and to protect the boiler from thermal shock), a return blend loop should be utilized.

5. Fill the entire heating system with water and vent air from the system according to the following instructions: (a) Close the isolation valve in the boiler supply piping. (b) Isolate all circuits by closing the zone valves or balancing valves. (c) Attach a hose to the purge valve located just below the isolation valve in the boiler supply

piping. NOTE: Ensure that the end of the hose drains into a bucket located in a drain area or

outside. (d) Starting with one circuit, open the first zone valve ONLY. (e) Open the purge valve. (f) Open the fill valve (the make-up water line should be located on the system side of the

isolation valve in the boiler supply piping.) (g) Allow water to overflow from the bucket until discharge from the hose is bubble-free.

ATTENTION: Air in the hose may cause the hose to "jump" and water to spray out;

ensure that the area (and equipment nearby) is protected from any possible water damage. (h) Open the zone valve to the second zone to be purged, then close the first. Repeat this step

until all zones have been purged, but always have one zone open. At completion, open all

zone valves. (i) Close the purge valve, continue filling the system until the pressure gauge reads 0.8 bar (12 psi).

Close the fill valve.

NOTE: If the make-up water line is equipped with a pressure reducing valve, the system

will automatically fill to 0.8 bar (12 psi). (j) Open the isolation valve in the boiler supply piping. (k) Remove the hose from the purge valve. ( l) As soon as the boiler is filled, heat the water in the boiler to 82

water.

C (180 oF) to de-aerate the

10-7

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Guidelines for Preventing Oxygen Contamination

ATTENTION: Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and can lead to boiler failure (and void warranty). Causes of oxygen contamination include:

• Addition of excessive make-up water as a result of system leaks

• Absorption through open tanks and fittings

• Oxygen permeable material in the distribution system

To ensure optimal CTB maintenance and operation, follow these recommendations to eliminate damaging oxygen contamination:

• Repair system leaks to eliminate the need for the addition of make-up water

• Eliminate open tanks from the system

• Eliminate and/or repair leaky fittings

• Use non-permeable materials in the distribution system

• Isolate the boiler from the water heater system (i.e. wash and potable waters) by installing a heat exchanger.

Guidelines for Initial Cleaning of the Hydronics System and Maintaining Water Quality

• Clean the boiler with an alkaline cleaner (e.g. soda ash or detergent) as recommended by a qualified water treatment company. NOTE: This is necessary to remove oil or other coatings from the tube surfaces. These protective coatings are commonly applied to new tubes to prevent rusting during storage/ transit and will cause corrosion if left on the tubes during operation of the boiler.

• After cleaning the boiler, drain the system in a manner and to a location that hot water can be discharged safely.

• Remove plugs from all available locations, and wash the water side of the boiler as thoroughly as possible using a high-pressure water stream.

• Refill the system with fresh water.

• Test the pH of the water in the system. The pH should be higher than 8.5 but lower than 9.5. Add appropriate boiler water treatment compounds as recommended by your qualified water treatment company (if necessary) to bring the pH within the specified range.

• Heat the water in the boiler to 82 oC (180 oF) to de-aerate the water.

Guidelines for CTB Operation

After proper and safe CTB boiler setup and installation has been accomplished, CTB operation proceeds as follows:

(a) Refer to Section 6 for instructions on starting the CTB. (b) Following burner startup, set the operating control dial at 82 - 93 oC (180 - 200 oF).

ATTENTION: If, during normal operation, it is necessary to add water to your system more than once a year, consult a qualified service technician to check your system for leaks. A leaky system will increase the volume of make-up water supplied to the boiler which can significantly shorten the life of the boiler and cause damage to the boiler.

10-8

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

SECTION 1 1: TROUBLESHOOTING

The following charts and tables are provided for reference in troubleshooting any difficulties encountered in boiler operation and adjustment.

• The Flow Chart outlines the proper sequence of events in boiler operation -- use this

chart to help diagnose where a problem may be occurring.

• More specific troubleshooting information is provided in the Troubleshooting Tables following the flow chart. Each table lists a Problem, Possible Cause, and Possible

Action(s) to fix the problem.

The CTB sequence of operation is summarized as follows:

(1) A call for heat by the thermostat energizes the DPDT relay which in turn energizes the

circulator delay relay and the boiler loop circulator to establish a flow of water through the coil.

(2) The flow switch closes. The power then continues from the flow switch through the high limit

aquastat, through the operating aquastat, and then to the burner.

(3) If the burner ignites within approximately 15 seconds and the photo unit sees a flame, the burner

will continue to operate until the call for heat is satisfied or the setting of the operating aquastat is reached.

(4) If the thermostat is not satisfied, but the temperature setting of the operating aquastat is

reached, the burner will stop until the return water drops the water temperature in the boiler (re-closing the operating aquastat and turning the burner back on).

(5) The boiler loop circulator will operate as long as the thermostat is calling for heat. (6) The boiler loop circulator circuit includes a delay relay that keeps the circulator operating

approximately ten minutes after the call for heat is satisfied.

11-1

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

Delay Relay

are energized

and the Boiler

Loop Circulator

closes

is energized

DPDT Relay

control is

energized

the oil primary

Wall thermostat or

aquastat calls for heat.

Flow Swith

Burner ignites.

and 210 µA indicating

Oil primary control receives

photo current between 50 µA

Oil primary control checks for

photo current less than 5 µA

chamber (NO FLAME)

indicating dark in the combustion

Oil primary control relay closes.

Burner ignition sequence begins.

proper ignition.

or aquastat is satisfied.

until the wall thermostat

Burner continues to run

opens and the burner

Primary control relay

shuts off.

FLOW CHART

230 V / 50 Hz

200 / 350 / 500 CTB

I88984A

INITIAL START-UP

BURNER PRE-IGNITION SEQUENCE

and DPDT relay circuit opens.

Wall thermostat or aquastat is satisfied

Yellow indicator

oil solenoid.

Pump circuit opens

When block temperature reaches 49 °C

and sends power to the oil primary control.

(120 °F) , the F120 proving switch closes

heater element and heats the block.

Preheater thermostat activates block

switch closes.

primary control receives power when the flow

F120 proving switch remains closed and oil

Air sensing switch closes

as it receives more than

NORMAL BURNER OPERATION

BURNER IGNITION SEQUENCE

heater element and maintains

60 °C (140 °F) block temperature.

Preheater thermostat cycles block

Air regulator adjusted to

INITIAL START-UP

0.7 bar (10 psi) of air

proper air pressure.

oil pump.

light ON.

Pump circ uit starts

pressure.

for proper combustion air.

Combustion air band adjusted

INITIAL START-UP

Hour meter starts.

Air sensing switch

centrifugal switch.

receives power from

BOILER HEATING SEQUENCE

sends power to air sensing

switch.

Centrifugal switch closes and

to heated area.

Hot water delivered

BOILER COOL DOWN SEQUENCE

stops running.

Boiler loop circulator

The Delay Relay keeps the boiler loop

circulator operating approximately ten

minutes after the call for heat is satisfied.

cut-off

and low water

Main power ON

sending power to

centrifugal switch

plugged in.

Green indicator

Burner cable

light ON.

Operating Aquastat senses water

temperature rise as the burner fires.

Air solenoid

electrode gap.

(15 sec.) spark at

providing interupted

14,000 volt igniter starts,

opens.

Burner motor starts and

reaches full rpm.

to drive latent heat from the CTB.

Boiler loop circulator continues to run

11-2

CLEAN BURN CB-200-CTB, CB-500-CTB, CB-350-CTB Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual