Saturn 125,230,140 Operator's Manual
OPERATOR'S MANUAL
FURNACE MODELS: SATURN™ 140 and SATURN™ 230
MULTI-OIL FURNACES
with SATURN™ 125 BURNER
U.L. Listed Used Oil
Burning Appliance
#MH15393 (N)
U.L.-C Listed
#CMP217
PUBLICATION DATE: 6/13/11, Rev. 3 CLEAN BURN PART # 43224
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.
IMPORTANT FOR U.S. INSTALLATIONS: All installations must be made in accordance with state and local codes
which may differ from the information provided in this manual. Save these instructions for reference.
IMPORTANT FOR CANADIAN INSTALLATIONS: These instructions have been reviewed and accepted by
Underwriters' Laboratories of Canada as being appropriate for the installation of the ULC labelled products
identified herein. The use of these instructions for the installation of products NOT bearing the ULC label and
NOT identified herein may result in an unacceptable or hazardous installation.
IMPORTANT FOR CANADIAN INSTALLATIONS: The installation of this equipment is to be accomplished by
qualified personnel and in accordance with the regulation of authorities having jurisdiction and CSA Standard B 139,
Installation Code for Oil Burning Equipment.
WARRANTY INFORMATION
Clean Burn, LLC., MANUFACTURER, hereby warrants that MANUFACTURER's SaturnTM 140 and SaturnTM 230 furnace
models shall be free from defect in material and workmanship under normal use according to the provisions and limitations
herein set forth. MANUFACTURER warrants the heat exchanger/combustion chamber for three (3) years from the date of
purchase by the purchaser and pro rata thereafter according to the following schedule: (a) If the defect occurs during the
fourth year, customer pays 70% of parts, replacement or repair. (b) If the defect occurs during the fifth year, customer pays
80% of parts, replacement or repair. (c) If the defect occurs during the sixth year, customer pays 90% of parts, replacement or
repair. MANUFACTURER warrants all other Clean Burn components for a period of one (1) year from the date of purchase by
the purchaser.
LIMITATIONS:
The obligation of MANUFACTURER for breach of warranty shall be limited to products manufactured by MANUFACTURER (1) that are
installed, operated and maintained according to MANUFACTURER's instructions furnished and/or available to the purchaser upon
request; (2) that are installed according to all other applicable Federal, State and local codes or regulations; and (3) that the purchaser
substantiates were defective in material and workmanship notwithstanding that they were properly installed and correctly maintained as set
forth above and were not abused or misused.
The obligation of MANUFACTURER shall be limited to replacing or repairing the defective product, at the option of the
MANUFACTURER. MANUFACTURER shall not be responsible for any labor or costs of removal or reinstallation of its products and
shall not be liable for transportation costs to and from its plant in Lancaster, Pennsylvania.
Use of parts for modification or repair of the product or any component part thereof not authorized or manufactured by
MANUFACTURER specifically for such product shall void this warranty.
This warranty shall not apply to any damage to or defect in any of MANUFACTURER's products that is directly or indirectly caused by (1)
force majeure, Act of God or other accident not related to an inherent product defect; or (2) abuse, misuse or neglect of such product,
including any damage caused by improper assembly, installation, adjustment, service, maintenance or faulty instruction of the purchaser.
Other than as expressly set forth hereinabove, MANUFACTURER makes no other warranty, express or implied, with respect to any of
MANUFACTURER's products, including but not limited to any warranty of merchantability or fitness for a particular purpose.
And in no event shall MANUFACTURER be responsible for any incidental or consequential damages of any nature suffered by purchaser
or any other person or entity caused in whole or in part by any defect in any of MANUFACTURER's products. Any person or entity to
whom this warranty extends and who claims breach of warranty against MANUFACTURER must bring suit thereon within one year from
the date of occurrence of such breach of warranty or be forever barred from any and all legal or other remedies for such breach of warranty.
MANUFACTURER is not responsible for and hereby disclaims any undertaking, representation or warranty made by any dealer, distributor or other person that is inconsistent with or in any way more expansive than the provisions of this limited warranty.
This warranty grants specific legal rights and shall be read in conformity with applicable state law. In some jurisdictions, the applicable
law mandates warranty provisions that provide greater legal rights than those provided for herein. In such case, this limited warranty shall
be read to include such mandated provisions; and any provision herein that is prohibited or unenforceable in any such jurisdiction shall, as
to such jurisdiction, be ineffective to the extent of such prohibition or unenforceability without invalidating the remaining provisions and
without affecting the validity or enforceability of such provision in any other jurisdiction(s).
TRADEMARKS
The Clean Burn logo and Saturn logo are trademarks of Clean Burn, LLC. All other brand or product names mentioned are the
registered trademarks or trademarks of their respective owners.
COPYRIGHT
Copyright © 2011 Clean Burn, Inc. All rights reserved. No part of this publication may be reproduced, or distributed without
the prior written permission of Clean Burn, LLC. 4109 Capital Circle Dr, Janesville, WI 53546. Subject to change without notice.
TABLE OF CONTENTS
SECTION 1: INTRODUCTION.................................................................................... 1-1
Guide to this Manual........................................................................................................1-1
For Your Safety... ............................................................................................................. 1-2
Guidelines for Furnace Usage ...................................................................................1-4
Guidelines for Used Oil Tanks..................................................................................1-5
Safety Labels ............................................................................................................. 1-6
SECTION 2: UNPACKING ......................................................................................... 2-1
Removing the Shipping Crate..............................................................................................2-1
Unpacking and Inspecting All Components .........................................................................2-1
Furnace Component List .............................................................................................2-1
Warranty Registration.........................................................................................................2-2
SECTION 3: FURNACE ASSEMBLY......................................................................... 3-1
Understanding Assembly ................................................................................................. 3-1
Required Tools and Materials ......................................................................................3-1
Overview of Furnace Assembly ..........................................................................................3-2
Installing the Observation Port ............................................................................................3-3
Installing the Air Outlet Louvers ..........................................................................................3-3
Installing the Combustion Sleeve .........................................................................................3-5
Installing the Burner ............................................................................................................3-6
Checking the Burner Nozzle and Electrodes .................................................................3-6
Mounting the Burner on the Hinge Bracket ...................................................................3-7
Installing the Connector Block, Oil Line Tubing, and Air Line Tubing ...................................3-8
Installing the Connector Block on the Furnace Door .....................................................3-8
Installing the Oil Line Tubing ........................................................................................3-8
Installing the Air Line Tubing ........................................................................................3-9
Locking the Burner into Firing Position .........................................................................3-9
SECTION 4: FURNACE INSTALLATION .................................................................. 4-1
Understanding Installation ...................................................................................................4-1
Typical Installation Illustration ......................................................................................4-2
Selecting a Location ...........................................................................................................4-3
Guidelines for Selecting a Location...............................................................................4-3
Clearances for Installation ............................................................................................4-3
Mounting the Furnace.........................................................................................................4-4
Ceiling Mounting .........................................................................................................4-4
Raised Platform Mounting............................................................................................4-5
Floor Mounting ...........................................................................................................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
TABLE OF CONTENTS
SECTION 4: FURNACE INSTALLATION (continued)
Wiring the Furnace and Pump...........................................................................................4-12
Wiring to the Furnace ................................................................................................4-12
Wiring to the Metering Pump .....................................................................................4-12
Installing the Suction Oil Line Components........................................................................4-13
Installing the Pressure Relief Oil Line Back to the Tank .....................................................4-16
Installing the Pressure Oil Line Components ......................................................................4-17
Installing the Compressed Air Line....................................................................................4-17
Installing the Stack ...........................................................................................................4-18
Installing the Interior Stack.........................................................................................4-21
Installing the Barometric Damper ...............................................................................4-21
Installing the Stack Safety Switch For Canadian Installations.......................................4-22
Resetting the Stack Safety Switch ........................................................................4-23
Understanding the Function of the Stack Safety Switch .........................................4-23
Installing the Stack Penetration...................................................................................4-24
Installing the Exterior Stack........................................................................................4-24
Installing the Stack Cap .............................................................................................4-24
Installing the Optional Draft Inducer ...........................................................................4-24
Installing the Wall Thermostat ...........................................................................................4-26
Replacing the Wall Thermostat Batteries ....................................................................4-26
Inspecting the Furnace Installation.....................................................................................4-26
SECTION 5: METERING PUMP PRIMING ................................................................5-1
Understanding Metering Pump Priming .......................................................................... 5-1
Required Tools and Materials ................................................................................... 5-1
Priming the Metering Pump.................................................................................................5-2
Vacuum Testing the Oil Pump.............................................................................................5-4
SECTION 6: STARTING AND ADJUSTING THE BURNER ......................................6-1
Understanding Burner Startup and Adjustment ...............................................................6-1
Preparing the Burner for Startup ......................................................................................6-1
Starting the Burner .............................................................................................................6-2
Checking the Operation of the Fan/Blower Motor...............................................................6-4
SECTION 7: RESETTING THE OIL PRIMARY CONTROL .......................................7-1
Understanding the Oil Primary Control ...........................................................................7-1
Using the Reset Button .......................................................................................................7-1
The Blower/Fan Switch ......................................................................................................7-2
The High Temp Limit Switches ...........................................................................................7-2
Understanding the L-200 High Temp Limit Switches ....................................................7-2
Understanding the L-290 Auxiliary Auto Reset High Temp Limit Switch .......................7-2
TABLE OF CONTENTS
SECTION 8: ADJUSTING THE DRAFT OVER FIRE ................................................8-1
Understanding the Importance of Draft ...............................................................................8-1
Checking for Correct Draft Over Fire .................................................................................8-1
Adjusting the Barometric Damper .......................................................................................8-2
Solving Draft Over Fire Problems .......................................................................................8-2
Understanding the Effect of Exhaust Fans on Draft .......................................................8-3
Checking Draft Over Fire to Determine Severity of Backdraft ......................................8-3
Installing a Make-up Air Louver ..................................................................................8-5
SECTION 9: MAINTENANCE ....................................................................................9-1
Understanding Maintenance................................................................................................9-1
Periodic Burner Inspection .................................................................................................9-1
Cleaning the Canister Filter .................................................................................................9-2
Servicing the Metering Pump ..............................................................................................9-3
Cleaning the Check Valve / Screen .....................................................................................9-3
Cleaning the Tank ..............................................................................................................9-4
Cleaning Ash from the Furnace ...........................................................................................9-5
Annual Burner Tune-Up .....................................................................................................9-7
End of Season Maintenance ...............................................................................................9-7
Cleaning and Maintaining the Optional Draft Inducer ...........................................................9-7
SECTION 10: TROUBLESHOOTING ......................................................................10-1
Flow Chart ......................................................................................................................10-2
Troubleshooting Tables ....................................................................................................10-3
APPENDIX A
Detailed Furnace Specifications ......................................................................................... A-1
Burner Technical Specifications ......................................................................................... A-2
Furnace Dimensions .......................................................................................................... A-3
Burner Components .......................................................................................................... A-4
Removing the Nozzle for Cleaning.............................................................................A-11
Saturn™ 140 Cabinet Components ................................................................................. A-12
Saturn™ 230 Cabinet Components ................................................................................. A-14
Metering Pump Components ........................................................................................... A-16
APPENDIX B
Wiring Diagrams ............................................................................................................... B-1
Furnace Wiring Diagram ............................................................................................. B-1
Saturn™ 125 Burner Wiring Diagram ......................................................................... B-2
Ladder Schematic ...................................................................................................... B-3
Metering Pump Wiring Schematic ............................................................................... B-4
APPENDIX C
Furnace Service Record .................................................................................................... C-1
Operator's Manual: Models Saturn™ 140 & Saturn™ 230
SECTION 1: INTRODUCTION
Guide to this Manual
This manual contains all the information necessary to safely install and operate the Clean Burn furnace models
Saturn™ 140 and Saturn™ 230 . 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 your new
furnace involves five basic activities as outlined here:
• UNPACKING.................................................................................................... (Section 2)
• ASSEMBLY ...................................................................................................... (Section 3)
• INSTALLATION ............................................................................................. (Section 4)
• OPERATION
• Metering Pump Priming ...................................................................... (Section 5)
• Starting and Adjusting the Burner ..................................................... (Section 6)
• Resetting the Oil Primary Control...................................................... (Section 7)
• Adjusting the Draft............................................................................... (Section 8)
• MAINTENANCE ............................................................................................. (Section 9)
The manual also contains important and detailed
technical reference materials which are located at the
back of the manual in the Appendixes.
Please read all sections carefully--including the
important safety information found in this section-before beginning any installation/operation
procedures; doing so ensures your safety and the
optimal performance of your Clean Burn furnace.
WARNING!
STOP
YOUR SAFETY IS AT STAKE!
DO NOT INSTALL, OPERATE OR
MAINTAIN THIS EQUIPMENT
WITHOUT FIRST READING
AND UNDERSTANDING THE
OPERATOR'S MANUAL!
1-1
Operator's Manual: Models Saturn™ 140 & Saturn™ 230
For Your Safety...
For your safety, Clean Burn documentation contains the following types of safety statements (listed here
in order of increasing intensity). Note the safety key words printed in bold for each:
• 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 safety statement 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 furnace 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 furnace.
DANGER! DO NOT operate your furnace if excess oil, oil vapor or fumes have
accumulated in or near your furnace. As with any oil burning furnace, improper installation,
operation or maintenance may result in a 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 furnace. Instruct your personnel to never add hazardous
materials to your used oil.
1-2
Operator's Manual: Models Saturn™ 140 & Saturn™ 230
For Your Safety... (continued)
WARNING: Never alter or modify your furnace without prior written consent of
Clean Burn, LLC. Unauthorized modifications or alteration can adversely affect the proper,
safe operation of your furnace.
WARNING: The burner which is shipped with your Clean Burn furnace is to be used only
with your furnace according to the instructions provided in this manual. DO NOT use the
burner for any other purpose!
WARNING: The Best Operator is a Careful Operator! By using common sense,
observing general safety rules, and adhering to the precautions 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 in the U.S.
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 and the following standards:
NFPA 30 Flammable and Combustible Liquids Code
NFPA 30A Automotive and Marine Service Station Code
NFPA 31 Standard for the Installation of Oil Burning Equipment
NFPA 211 Chimneys, Fireplaces, Vents and Solid Fuel Burning Appliances
NFPA 88A Parking Structures
NFPA 88B Repair Garages
NFPA 70 National Electrical Code
The International Mechanical Code
The International Building Code
The International Fire Code
The International Fuel Gas Code
Likewise, the installation, operation, and maintenance of this equipment in Canada is to be
accomplished by qualified personnel and in compliance with the specifications in the
Clean Burn Operator's Manual and in accordance with the regulation of authorities having
jurisdiction and the following CSA Standards:
B139 Installation Code for Oil Burning Equipment
B140.0 General Requirements for Oil Burning Equipment
C22.1 Canadian Electrical Code, Part 1.
Failure to comply with these standards and requirements may result in equipment
damage, fire, explosion, personal injury and/or death.
1-3
Operator's Manual: Models Saturn™ 140 & Saturn™ 230
For Your Safety... (continued)
Guidelines for Furnace Usage
This furnace is listed for commercial and/or industrial use only; it is not listed for
residential use.
This furnace is listed with Underwriters Laboratory and Underwriters' Laboratories
of Canada to burn the following fuels:
• #2 fuel oil
• Used crankcase oil up to 50 SAE
• Used hydraulic oil
• Used transmission fluid (U.S.)
• #4 and #5 fuel oil (U.S.)
Make sure you comply with all EPA regulations concerning the use of your furnace.
EPA regulations require that:
• Your used oil is generated on-site. You may also accept used oil from
"do-it-yourself" oil changers.
• Hazardous wastes, such as chlorinated solvents, are NOT to be mixed
with your used oil.
• The 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 furnace in warm weather just to burn oil.
Contact your Clean Burn dealer for current EPA regulations.
If your furnace ever requires service, call your Clean Burn dealer. DO NOT allow
untrained, unauthorized personnel to service your furnace. Make sure that your
furnace receives annual preventative maintenance to ensure optimal performance.
1-4
Operator's Manual: Models Saturn™ 140 & Saturn™ 230
For Your Safety... (continued)
Guidelines for Used Oil Tanks
For the safe storage of used oil and the safety of
persons in the vicinity of the used oil supply tank,
ensure that your tank installation adheres to the
following safety guidelines:
• The tank installation must meet all
national and local codes. Consult your
local municipal authorities for more
information as necessary.
• Review and adhere to the safety
guidelines for used oil supply tanks
as stated in the WARNING shown.
• Ensure that the tank for your furnace
installation complies with all code and
safety requirements as stated here. If the
tank does not comply, DO NOT use it.
• If you do not have a copy of the tank
safety label pictured at right, please
contact your Clean Burn dealer for the
label, which is to be affixed directly on
your used oil supply tank.
1-5
Operator's Manual: Models Saturn™ 140 & Saturn™ 230
For Your Safety... (continued)
Safety Labels
Following are the locations and descriptions of all labels on your Clean Burn Saturn™ furnace. The following
illustrations show the location of labels on your furnace. Please note that some labels denote model number,
model description, etc. while others contain important safety messages.
Each Safety Label contains an important safety message starting with a key word as discussed earlier in
this section (e.g. ATTENTION, CAUTION, WARNING, DANGER). For your safety and the safe
operation of your furnace, review all labels and heed all safety messages as printed on the labels.
If any labels on your Clean Burn furnace ever become worn, lost or painted over, please call your Clean
Burn dealer for free replacements.
Saturn™ Furnace Cabinet Labels
Label Part # Description
42525 Saturn™ 140 Name Label
42526 Saturn™ 230 Name Label
42367 Furnace Safety Warning Label (Multiple Messages - Fire/Shock/Burn Hazards)
42527 Saturn™ 140 UL Data Label
42528 Saturn™ 230 UL Data Label
42358 UL Header Label
42457 Made in USA / Patent Pending Combination Label
42030 Furnace Electrical Shock Hazard Warning Label
42068 Fan Entanglement Hazard Warning Label (on top near fan)
1-6
Operator's Manual: Models Saturn™ 140 & Saturn™ 230
For Your Safety... (continued)
Saturn™ Furnace Cabinet Safety Labels
1-7
Operator's Manual: Models Saturn™ 140 & Saturn™ 230
For Your Safety... (continued)
Saturn™ Furnace Cabinet Safety Labels
LANCASTER, PENNSYLVANIA (USA)
MH15393
USED−OIL BURNING APPLIANCE
NO.
USED OIL−FIRED FURNACE
USED OIL−FIRED BOILER
For use with Integral Primary Safety Control
MULTI−OIL HEATING SYSTEM
FOR COMMERCIAL OR INDUSTRIAL USE ONLY.
CERTIFIED TO ELECTRICAL AND FUEL BURNING REQUIREMENTS ONLY.
1-8
13084
42358
Operator's Manual: Models Saturn™ 140 & Saturn™ 230
For Your Safety... (continued)
Saturn™ 125 Burner Labels
Label Part # Description
42000 Reset Warning Label
42004 Voltage / Moving Parts Warning Label
42005 Serviced-By Label
42023 Power / Pump Label
42235 Burner Warning Label
42457 Made In USA Label
42536 Saturn™ Series Logo Label
42537 Saturn™ Series Serial Number Plate
Saturn™ 125 Burner Safety Labels
1-9
Operator's Manual: Models Saturn™ 140 & Saturn™ 230
1-10
Operator's Manual: Models Saturn™ 140 & Saturn™ 230
SECTION 2: UNPACKING
Before assembling your furnace, you must accomplish the following activities described in this section:
• Removing the Shipping Crate
• Unpacking and Inspecting All Components
• Warranty Registration
Removing the Shipping Crate
NOTE: Remove the shipping crate prior to assembly and installation of the furnace. DO NOT use the
crate as a platform for furnace installation!
1. Carefully remove the top boards of the shipping crate. Then remove the front, back, and side
panels of the shipping crate.
2. Carefully lift the furnace off the shipping pallet with a fork lift.
ATTENTION: DO NOT attempt to slide the furnace cabinet out of the shipping crate--you may
damage the furnace cabinet.
Unpacking and Inspecting All Components
Following is an itemized list of all components you should have received in your Clean Burn furnace
shipment. Open all shipping containers and inspect all components according to the list. Immediately
notify the freight company and your Clean Burn dealer in case of shipping damage or shortage(s). Keep
all components together so you will have them as needed for furnace assembly and installation.
Furnace Component List
ONE SKID containing:
• Furnace cabinet
• Items packed inside furnace cabinet (combustion chamber):
NOTE: Please refer to the procedure on the following page to remove these items.
• Louvers
• Furnace Accessories (items below in one box):
• Canister Filter
• Vacuum Gauge
• Check Valve and Check Valve Screen
• Wall Thermostat
• Barometric Damper
• Connector Block
• Burner Oil Line and Air Line Components
• Assorted bolts/fittings for assembly/installation of furnace components
• Operator's Manual Literature Packet (includes Tank Safety Label)
ITEMS PACKED IN INDIVIDUAL BOXES:
• Burner
• Combustion Sleeve
• Metering Pump (includes Suction Oil Line Fittings Package)
NOTE: You may have received additional boxes or skids if you ordered optional accessories.
2-1
Operator's Manual: Models Saturn™ 140 & Saturn™ 230
Unpacking Items Packed Inside the Furnace
To unpack the items packed inside the furnace cabinet (in the combustion chamber), you will need to
open the combustion chamber door.
1. Remove the three nuts which hold the combustion chamber door closed. Set the nuts aside in a safe
place for later re-installation after the combustion sleeve has been installed (Section 3).
2. Carefully swing the combustion chamber door open. Remove and inspect the components packed
inside.
3. Leave the door unfastened (open) for assembly/installation procedures to be accomplished in the
next section.
I89085
Figure 2A - Accessing the Combustion Chamber
Warranty Registration
For proper warranty registration, Clean Burn requires that you fill out the provided warranty registration
card and return it within 30 days to:
CLEAN BURN WARRANTY REGISTRATION
Clean Burn, LLC.
4109 Capital Circle Drive
Janesville, WI 53546
2-2
Operator's Manual: Models Saturn™ 140 & Saturn™ 230
SECTION 3: FURNACE ASSEMBLY
Understanding Assembly
Assembling your Clean Burn Furnace includes the following steps:
(1) Installing the Observation Port
(2) Installing the Louvers
(3) Installing the Combustion Sleeve
(4) Installing the Burner
(5) Installing the Connector Block, Oil Line Tubing, and Air Line Tubing
Clean Burn recommends that you review all assembly procedures before proceeding, paying careful
attention to safety information statements.
Figure 3A on the following page provides a general overview of the furnace components and their
proper assembly.
Required Tools and Materials
The following tools are required for furnace assembly and should be gathered before starting any procedures:
• 9/16" open-end wrench
• Medium flat-blade screwdriver
• Medium adjustable wrench
• 1/4" nut driver attachment for drill
• 5/16" nut driver attachment for drill
• Variable speed drill
3-1
Operator's Manual: Models Saturn™ 140 & Saturn™ 230
"ALL THREAD" RODS
BURNER
MOUNTING
BRACKET
4
4
1
OBSERVATION
PORT
I89086-A
2
LOUVERS
CONNECTOR
BLOCK
COMBUSTION SLEEVE
3
INSTALL E D IN CHA MBER
ON 2" X 2" BLOCKS
5
Complete assembly of the furnace according to the following list of activities as illustrated above:
(1) Installing the Observation Port
(2) Installing the Louvers
(3) Installing the Combustion Sleeve
(4) Installing the Burner
(5) Installing the Connector Block, Oil Line Tubing, and Air Line Tubing
NOTE: Corresponding procedures provided in order in this section.
Figure 3A - Overview of Furnace Assembly
3-2
Operator's Manual: Models Saturn™ 140 & Saturn™ 230
Installing the Observation Port
CAUTION: To prevent serious personal injury, the observation port must be correctly installed
according to the following procedure. A properly installed observation port permits safe observation of
the flame during furnace operation. Be sure to follow all safety procedures as outlined in this manual when
observing the flame through the port.
1. Refer to Figure 3B.
2. Use a 1/4" nut driver to remove the two (2) self-tapping screws from the half-moon piece.
3. Position the half-moon piece and the faceplate on the observation port, and install the two
self-tapping screws.
4. Open the port and make sure the faceplate moves and closes freely. If the faceplate hangs up,
loosen the hex-head screws slightly until the faceplate closes correctly.
HALF−MOON
PIECE
FACE
PLATE
OBSERVATION
PORT
I89087
Figure 3B - Assembly of Observation Port
Installing the Air Outlet Louvers
Air Flow Discharge Installation Guidelines:
• It is very important to properly install the louvers to direct the flow of hot air away from the furnace. The
air flow may be directed front, back, or to either side depending on how the louvers are installed.
• Note that each furnace is supplied with four (4) louvers which may be installed all in the same direction
OR the louvers may be split for partial air discharge out either side or front to back.
• When determining the placement of the air discharge louvers, you also need to consider the required
clearances from combustibles as stated in Section 4 of this manual.
• DO NOT restrict the flow of the hot air from the furnace by keeping the louvers completely closed, or the
furnace may not operate properly.
3-3
Operator's Manual: Models Saturn™ 140 & Saturn™ 230
Installing the Air Outlet Louvers (continued)
ATTENTION: If the bottom clearance is less than 60 inches use a hot air diffuser as described under Floor
Mounting in Section 4.
1. Refer to Figures 3C. Determine the desired air flow discharge direction. Note that each furnace is
supplied with four (4) louvers.
2. Hold each louver against the base with the bend pointing down. Install the louvers in the desired
direction(s) with the self-tapping screws provided. Holes are pre-drilled in the furnace base to
accommodate installation of the louvers.
3. Rotate the louvers to help direct the hot air away from the furnace.
Figure 3C - Installing the Hot Air Discharge Louvers
CAUTION: The Saturn™ 140 and Saturn™ 230 are Unit Heater furnaces ONLY. DO NOT install
ductwork on these furnaces.
3-4
Operator's Manual: Models Saturn™ 140 & Saturn™ 230
Installing the Combustion Sleeve
Installing the Combustion Sleeve Inside the Combustion Chamber
ATTENTION: DO NOT fire your furnace without the Combustion Sleeve in place, or poor flame retention
will occur. Handle the Combustion Sleeve carefully to avoid damage.
1. Refer to Figure 3A and 3D to review the proper position of the Combustion Sleeve and 2" x 2"
mounting Blocks.
2. Swing open the clean-out door on the front of the furnace to gain access to the combustion chamber.
3. Refer to Figure 3D. Place the two (2) soft fiber board blocks (2" x 2" x 8") on the bottom of the
combustion chamber against the indicator tabs. The notch in the support blocks should fit over the front
flue plate.
4. Gently set the Combustion Sleeve on top of the two Blocks. The combustion sleeve needs to seat
firmly against the door insulation for proper combustion. Carefully position the Combustion Sleeve on
the blocks so that it extends out slightly beyond the door opening. The door will push the Combustion
Sleeve in place as it is closed.
COMBUSTION S LEEVE
SUPPORT BLOCK
LOCA TION INDICATOR TAB
I89090
NOTCH IN SUPPO RT BLOCK
OVER FRONT FLUE PLATE
TIGHT AGAINS T FRONT
DOOR INSULATION
Figure 3D - Installing the Combustion Sleeve
Closing the Furnace Door
1. After the Combustion Sleeve has been installed, close the furnace clean-out door.
2. If necessary, loosen the door hinges to allow the door to seal tight.
2. Tighten the three (3) lock-down nuts until all are snug.
3-5
Operator's Manual: Models Saturn™ 140 & Saturn™ 230
Installing the Burner
Checking the Burner Nozzle and Electrodes
NOTE: The burner nozzle is factory installed. Both furnace models use a Delavan 9-5 nozzle. The nozzle
size is indicated on the nozzle as shown in Figure 3E. Refer also to Appendix A at the back of the manual for
additional specifications/instructions on the burner nozzle.
ATTENTION: Check the electrode settings as specified in Figure 3E. The electrode settings must be correct
for your burner to operate properly.
BURNER NOZZLE
NOZZLE IS STAMPED EITHER 9−5
OR −5 ON FLAT OF NOZZLE HEAD
SIDE VIEW − AA
3/16" GAP BETWEEN
ELECTRODES & NOZZLE
3X
CRITICAL DIMENSION:
NOZZLE MUST BE 1/8"
AHEAD OF THE DISK.
NOZZLE MUST NOT BE
BEHIND THE DISK.
A
A
−
V
I
E
W
−
B
B
W
E
I
V
1/8"
SPARK
GAP
SIDE VIEW − BB
I88340
Figure 3E - Burner Nozzle and Electrode Specifications
3-6
Operator's Manual: Models Saturn™ 140 & Saturn™ 230
Installing the Burner (continued)
Mounting the Burner on the Hinge Bracket
ATTENTION: Burner tube components (e.g. electrodes and retention head) are factory set. Handle the
burner with extreme care so that burner components are not damaged.
1. Remove the nut from the mounting flange of the furnace cabinet, and set it aside for later use.
2. Lift the burner into position so that it is mounted on the hinge bracket on the furnace cabinet.
3. Carefully swing the burner so the retention head enters the throat of the furnace.
4. Check the clearance between the retention head and the furnace throat. There must be at least
1/8" clearance, so the retention head is not "bumped" as you swing the burner into firing
position.
NOTE: If the retention head "bumps" the furnace throat, adjust the hinge bracket bolts
as follows:
• While supporting the burner, slightly loosen the two (2) hinge bracket bolts.
• Carefully re-position the burner so it swings freely into its firing position.
• With the burner in its firing position, re-tighten the hinge bracket bolts.
3-7
Operator's Manual: Models Saturn™ 140 & Saturn™ 230
Installing the Connector Block, Oil Line Tubing, and Air Line Tubing
ATTENTION: DO NOT use teflon tape on any fittings. Teflon tape residues will plug vital burner
components and void your warranty.
Installing the Connector Block on the Furnace Door
1. Refer to Figure 3F.
2. Use the two (2) bolts to install the aluminum
connector block onto the furnace door.
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 furnace assembly.
ATTENTION: The connector block includes an
accumulator. The accumulator functions like a shock
absorber on the oil line to prevent pressure buildup and
protect vital burner components. It is important that the
connector block is installed as shown so that the accumulator
is in a vertical position to prevent sediment from settling in
the accumulator. Never operate your furnace without the
connector block and accumulator properly installed on the
furnace, or damage may occur to vital burner components.
Installing the Oil Line Tubing
ATTENTION: 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 red caps from the oil line
tubing.
2. Install the oil line tubing into the swival fitting on the
connector block.
3. Slightly bend the tubing as shown in Figure 3F, if required, to "line up" the oil line with the oil line fitting
on the burner. If necessary use a wrench to rotate the oil line fitting on the burner to line up the tubing.
4. If necessary, use a tubing cutter to cut the tubing to the proper length.
5. Make sure that the curl in the oil line is positioned so that the burner is able to swing open.
6. Install the oil line tubing and tighten the nuts on the compression fittings. DO NOT overtighten
these fittings to avoid damaging the ferrules.
Figure 3F - Installation of Connector
Block and Oil Line
3-8
Operator's Manual: Models Saturn™ 140 & Saturn™ 230
Installing the Connector Block, Oil Line Tubing, and Air Line Tubing
(continued)
Installing the Air Line Tubing
1. Remove and discard the red caps from the air line tubing.
2. Push the air line tubing into the push 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 the burner.
Locking the Burner into Firing Position
1. Swing the burner into firing position.
2. Install and tighten the lock-down 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.
NOTE: Be sure to properly align the plug when plugging it into the receptacle. See Fig 3G.
CONNECTOR PLUG
KEY IN PLUG
MUST ALIGN
WITH SLOT IN
RECEPTACLE
RECEPTACLE ON
TOP OF BURNER
I88641−B
Figure 3G - Detail of Burner Electric Receptacle
NOTE: Your furnace is now assembled and ready for installation. Install the furnace as
soon as possible so the burner and/or fan are not "bumped" or damaged. If you must
store the furnace for a period of time before installation, make sure it is located in a safe,
secure area.
3-9
Operator's Manual: Models Saturn™ 140 & Saturn™ 230
3-10
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