CB-200 350 500 CTB BOOK

CB-200 350 500 CTB BOOK
OPERATOR'S MANUAL
CLEAN BURN MODELS:
CB-200-CTB COIL TUBE BOILER with CB-525-S2 Burner & Metering Pump
CB-350-CTB COIL TUBE BOILER with CB-551-H3 Burner & Metering Pump
CB-500-CTB COIL TUBE BOILER with CB-551-H5 Burner & Metering Pump
USED-OIL BURNING
APPLIANCE
#MH15393 (N)
LISTED
USED OIL-FIRED
FURNACE
I88460-C
PUBLICATION DATE: 07/16/13, Rev. 13
Manufactured & Tested
to meet ASME Section IV
CLEAN BURN PART #43146
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: 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 products shall be free from defect in
material and workmanship under normal use according to the provisions and limitations herein set forth. MANUFACTURER
warrants the burner and Coil Tube Boiler for a period of one (1) year from the date of purchase by the original purchaser. The
steel coil tube section of the boiler only shall carry a limited warranty for a period of five (5) years from the date of purchase
by the original purchaser.
LIMITATIONS:
The obligation of MANUFACTURER for breach of warranty shall be limited to products manufactured by MANUFACTURER (1) that are
installed, operated and maintained according to MANUFACTURER's instructions furnished and/or available to the purchaser upon request;
(2) that are installed according to all other applicable Federal, State and local codes or regulations; and (3) that the purchaser substantiates
were defective in material and workmanship notwithstanding that they were properly installed and correctly maintained as set forth above
and were not abused or misused.
The 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 at 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 is a trademark of Clean Burn, LLC. All other brand or product names mentioned are the registered
trademarks or trademarks of their respective owners.
COPYRIGHT
Copyright © 2010 Clean Burn, LLC. All rights reserved. No part of this publication may be reproduced, or distributed without the prior written permission of Clean Burn, LLC. 4109 Capital Circle, Janesville WI 53546. Subject to change without
notice.
TABLE OF CONTENTS
SECTION 1: INTRODUCTION............................................................................................................. 1-1
Guide to this Manual...................................................................................................................... 1-1
For Your Safety............................................................................................................................... 1-2
Guidelines for 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
Warranty Registration..................................................................................................................... 2-2
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
Single Boiler Assembly Component Detail........... ....................................................................... 3-2
Single Boiler Assembly.................................................................................................................. 3-4
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............................................................................................................. 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
Typical Installation Diagrams................................................................................................. 4-2
Combustion Air Requirements................................................................................................ 4-4
Oil Tank Installation Specifications................................................................................................ 4-6
Installing the Tank Vent and Emergency Vent........................................................................ 4-7
Installing the Metering Pump......................................................................................................... 4-8
Preparing for Installation........................................................................................................ 4-8
Standard Mounting: Vertical Positioning................................................................................ 4-8
Alternate Mounting: Horizontal Positioning......................................................................... 4-10
Connecting Water to the Coil Tube Boiler....................................................................................4-11
Filling the CTB with Water....................................................................................................4-11
Installing the Suction Oil Line Components................................................................................ 4-12
TABLE OF CONTENTS
SECTION 4: CTB INSTALLATION (continued)............................................................................
Installing the Pressure Relief Oil Line Back to the Tank............................................................. 4-15
Installing the Pressure Oil Line Components............................................................................... 4-16
Installing the Compressed Air Line.............................................................................................. 4-16
Wiring the Coil Tube Boiler......................................................................................................... 4-17
Wiring to the Oil Pump................................................................................................................ 4-18
Wiring the Load Loop Circulator................................................................................................. 4-18
Installing the Stack....................................................................................................................... 4-19
Installing the Interior Stack................................................................................................... 4-20
Installing the Barometric Damper......................................................................................... 4-21
Installing the Stack Safety Switch For Canadian Installations............................................. 4-23
Resetting the Stack Safety Switch.................................................................................. 4-24
Understanding the Function of the Stack Safety Switch................................................ 4-24
Installing the Stack Penetration............................................................................................. 4-25
Installing the Exterior Stack.................................................................................................. 4-25
Installing the Stack Cap........................................................................................................ 4-25
Installing the Draft Inducer.......................................................................................................... 4-25
Installing the Wall Thermostat...................................................................................................... 4-27
Replacing the Wall Thermostat Batteries.............................................................................. 4-27
Inspecting the CTB Installation.................................................................................................... 4-28
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 Oil Primary Control......................................................................................... 7-1
Resetting the Oil Primary Control (CB-200-CTB)........................................................................ 7-1
Resetting the Oil Primary Control (CB-350-CTB and CB-500-CTB)........................................... 7-2
Primary Control Operation/Troubleshooting Guide (CB-350-CTB and CB-500-CTB)................ 7-4
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
Combustion Air Requirements................................................................................................ 8-3
Adjusting Draft Over Fire With A Draft Inducer Installed............................................................. 8-3
Air for Combustion and Ventilation............................................................................................... 8-4
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.............................................................................................................. 9-3
Cleaning Ash from the CTB........................................................................................................... 9-4
Cleaning the Oil Tank..................................................................................................................... 9-6
End of Season Maintenance........................................................................................................... 9-6
Cleaning and Maintaining the Draft Inducer.................................................................................. 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
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
CTB Dimensions.................................................................................................................... A-4
Single Boiler Assembly Component Detail......................................................................... A-10
Burner Components............................................................................................................. A-12
CB-525-S2 (CB-200-CTB)...................... ..................................................................... A-12
CB-551-H3 (CB-350-CTB)........................................................................................... A-14
CB-551-H5 (CB-500-CTB)........................................................................................... A-18
Removing the Nozzle for cleaning................................................................................ A-23
CB-200-CTB Components................................................................................................... A-24
CB-350-CTB Components................................................................................................... A-26
CB-500-CTB Components................................................................................................... A-28
Metering Pump Components............................................................................................... A-30
APPENDIX B
Wiring Diagrams............................................................................................................................B-1
CTB Sequence of Operation...................................................................................................B-4
CTB Ladder Schematic...........................................................................................................B-5
Metering Pump Wiring Schematic..........................................................................................B-6
CAD Cell Oil Primary Control Data Sheets...........................................................................B-7
TABLE OF CONTENTS
APPENDIX C
CTB Service Record.......................................................................................................................C-1
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
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), Model 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
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
For Your Safety... (continued)
WARNING: Never alter or modify your CTB without prior written consent of
Clean Burn, LLC. 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: 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 and the following standards:
ASME Section IV Boiler Code for Pressure Vessels
ASME CSD-1 Controls and Safety Devices for Automatically Fired Boilers
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 70National Electrical Code
NFPA 88AParking Structures
NFPA 88BRepair Garages
NFPA 211 Chimneys, Fireplaces, Vents and Solid Fuel Burning Appliances
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
B140.7.2 Oil-Fired Steam and Hot Water Boilers for Commercial and Industrial Use
B214 Installation Code for Hydronic Heating Systems
C22.1Canadian 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
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
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 listed with Underwriters Laboratory (UL) to burn the following fuels:
• Used crankcase oil up to 50 SAE
• Used transmission fluid (for U.S.)
• 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 EPA regulations concerning the use of your boiler.
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 boiler in
warm weather just to burn oil.
Contact your Clean Burn dealer for current EPA 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
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.
WARNING
Fire and explosion hazards
To prevent serious injury or death:
ONLY place these listed substances in
this used-oil supply tank:
• Used crankcase oil
• Used automatic transmission fluid
• Used hydraulic oil
• #2 fuel oil
Do NOT place flammable or corrosive
substances such as gasoline, chlorinated
oils, solvents, paint thinners, or any other
unsafe substances in this used-oil supply tank.
Do NOT weld or allow open flame within
35 feet of this used-oil supply tank.
Tank installation MUST comply with NFPA
30 and 31 Fire Codes, including the following
requirements:
• Tank must be listed to UL 80 or UL 142.
• Tank must be vented to outside.
• Emergency vent or explosion relief must
be installed on tank.
• Inside fill allowed only with funnel including 1/4
turn-to-close fall valve, which must be
closed after filling.
• All other openings must be plugged
• All oil lines must be constructed of copper,
steel, or brass components. Do NOT use
rubber or plastic tubing or piping, or any other
inappropriate material.
Follow all instructions
for tank installation in
Operator's Manual.
42366 Rev. 2
1-5
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
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
200-CTB 350-CTB 500-CTB
42367 42367 42367 42457 42457 42457 42027 42027 42027 42358 42358 42358 42464 42288 42496 42030 42030 42030 42421 42421 42421 42216 42497 42497 42465 42286 42493 Description
C.B. Safety Warning Label
(multiple messages - fire/shock/burn hazards)
Made in USA / Patent Pending Combination Label
Burn Hazard / Hazardous Voltage Warning Label
UL Header Label
CTB Data Label
Electrical Shock Hazard Warning Label
CTB Hot Water Caution Label
C.B. Logo Label
CTB Model # Label
42457
42027
42367
42263
42288
42464
42496
AIR
OIL
I88568-C
1-6
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
CTB Cabinet Labels (continued)
42216
42497
42465
42286
42493
www.cleanburn.com
MODEL
42216
CB *** CTB
42286
42421
CAUTION
Burn Hazard.
Fittings, piping,
and boiler surface
may be extremely hot.
Pipes contain hot water.
DO NOT touch
without wearing
protective gloves.
I88567-D
CTB Cabinet Safety Labels
WARNING
WARNING
Fire, explosion and burn hazards:
Hazardous voltage.
Maintain clearances from
combustibles as listed on unit.
ONLY burn used crankcase
oil, automatic transmission
fluid, hydraulic oil, or #2 fuel
oil. NEVER burn any other
substances in this unit.
To prevent serious injury, shut OFF main
power to unit before removing cover.
Line voltage is present on most
subbase terminals when power is ON.
If the furnace is not wired correctly.
fire, shock or damage could result.
• ONLY a qualified electrician should wire
this furnace.
• ONLY use copper conductors.
Hot gases and ash may be released when
inspection port is opened.
• Wear safety goggles and hand protection
when opening inspection port.
• Keep face away and open port slowly.
42030 Rev. 2
WARNING
To avoid possible injury, death, or
equipment damage, read and
understand operator's manuals and
all safety precautions before
installing, operating, or servicing this
equipment.
42367 Rev. 2
Burn Hazard.
Hazardous Voltage.
Burner may fire at any time.
Disconnect burner power cord
before swinging open burner
or clean-out door.
42027 Rev. 2
1-7
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
For Your Safety... (continued)
CTB Cabinet Safety Labels (continued)
CLEAN BURN LLC
CAUTION
JANESVILLE, WISCONSIN (USA)
MH15393
Burn Hazard.
LISTED
USED-OIL BURNING APPLIANCE
Fittings, piping, and boiler
surface may be extremely
hot.
NO.
13084
MULTI-OIL HEATING SYSTEM
Pipes contain hot water.
INSTALL AND USE ONLY IN ACCORDANCE WITH THE
MFR’S INSTALLATION AND OPERATING INSTRUCTIONS.
Do NOT touch without
wearing protective gloves.
FOR COMMERCIAL OR INDUSTRIAL USE ONLY.
AUTHORITIES HAVING JURISDICTION SHOULD
BE CONSULTED PRIOR TO INSTALLATION.
CERTIFIED TO ELECTRICAL AND FUEL BURNING REQUIREMENTS ONLY.
42421
MODEL NO.
MODEL NO.
CB-200 CTB
INPUT RATING W/NO 2 FUEL OIL (BTU/HR)
INPUT RATING W/NO 2 FUEL OIL (BTU/HR)
ATOM AIR
PRESSURE
OIL
PRESSURE
LISTED FUELS
- GPH 1.4
- PSIG 14.0
- PSIG 2.5
NO 2 OIL
USED CRANKCASE OIL
1.4
14.0
2.7
HYDRAULIC OIL
1.4
14.0
2.5
ATF
1.4
18.0
NO 4 OIL
1.4
NO 5 OIL
1.4
NO 2 OIL
TOP
18
CHIMNEY
48
REAR
ATOM AIR
PRESSURE
OIL
PRESSURE
- GPH 2.5
- PSIG 16.0
- PSIG 6.0
USED CRANKCASE OIL
2.5
16.0
7.0
HYDRAULIC OIL
2.5
16.0
7.0
3.4
ATF
2.5
18.0
7.0
18.0
4.0
NO 4 OIL
2.5
20.0
9.5
18.0
4.0
NO 5 OIL
2.5
20.0
9.5
-.06
FLUE DRAFT IN W.C.
INSTALL ON NONCOMBUSTIBLE FLOOR
MINIMUM CLEARANCE TO COMBUSTIBLE SURFACES (IN.)
CLEARANCES MAY BE INCREASED FOR SERVICE
18
6
350000
UL
INPUT
FLUE DRAFT IN W.C.
INSTALL ON NONCOMBUSTIBLE FLOOR
MINIMUM CLEARANCE TO COMBUSTIBLE SURFACES (IN.)
CLEARANCES MAY BE INCREASED FOR SERVICE
FRONT
42358
CB-350 CTB
200000
UL
INPUT
LISTED FUELS
USED OIL-FIRED FURNACE
USED OIL-FIRED BOILER
For use with Integral Primary Safety Control
6
SIDE
PLUMBING SIDE
30
TOP
18
CHIMNEY
FRONT
48
REAR
18
6
SIDE
PLUMBING SIDE
-.06
6
30
OIL PUMP MOTOR HP.
POWER
1/20
VOLTS
120
AMPS
.75
HZ
60
OIL PUMP MOTOR HP.
POWER
1/20
VOLTS
120
AMPS
.75
HZ
60
BURNER MOTOR HP.
1/10
120
1.4
60
BURNER MOTOR HP.
1/10
120
1.4
60
BURNER HEATER WATTS
400
120
3.3
60
BURNER HEATER WATTS
400
120
3.3
60
CIRCULATOR BOILER (OPT)
1/6
120
2.1
60
CIRCULATOR BOILER (OPT)
2/5
120
4.7
60
120
3.0
60
DRAFT INDUCER HP.
1/10
120
1.1
60
1/2
120
5.8
60
CIRCULATOR LOAD (OPT) MAX.
DRAFT INDUCER HP.
1/10
120
1.1
60
AIR COMPRESS. (OPT) HP.
AIR COMPRESS. (OPT) HP.
1/3
120
4.0
60
TOTAL CIRCUIT AMPACITY
TOTAL CIRCUIT AMPACITY
MAXIMUM FUSE SIZE / WITH OPTIONS
12.0
MAXIMUM FUSE SIZE / WITH OPTIONS
17
20/30
15/20
BURNER REQUIRES A MINIMUM AIR SOURCE OF 2 S.C.F.M. AT 25 P.S.I.
INSTALL AND USE ONLY IN ACCORDANCE WITH THE MFR’S
INSTALLATION AND OPERATING INSTRUCTIONS. FOR COMMERCIAL
OR INDUSTRIAL USE ONLY.
BURNER REQUIRES A MINIMUM AIR SOURCE OF 2 S.C.F.M. AT 25 P.S.I.
INSTALL AND USE ONLY IN ACCORDANCE WITH THE MFR’S
INSTALLATION AND OPERATING INSTRUCTIONS. FOR COMMERCIAL
OR INDUSTRIAL USE ONLY.
AUTHORITIES HAVING JURISDICTION SHOULD
BE CONSULTED PRIOR TO INSTALLATION
AUTHORITIES HAVING JURISDICTION SHOULD
BE CONSULTED PRIOR TO INSTALLATION
42288- R1
42464 - R1
1-8
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
For Your Safety... (continued)
CTB Cabinet Safety Labels (continued)
MODEL NO.
NOTICE!
CB-500 CTB
500000
INPUT RATING W/NO 2 FUEL OIL (BTU/HR)
UL
INPUT
ATOM AIR
PRESSURE
OIL
PRESSURE
- GPH 3.57
- PSIG 18.0
- PSIG 2.1
USED CRANKCASE OIL
3.57
18.0
3.0
HYDRAULIC OIL
3.57
24.0
2.5
ATF
3.57
22.0
2.7
NO 4 OIL
3.57
18.0
3.0
NO 5 OIL
3.57
18.0
3.0
LISTED FUELS
PLUMBING ASSEMBLY IS SHIPPED DRY FIT ONLY.
NO 2 OIL
DO NOT INSTALL UNTIL PLUMBING COMPONENTS ARE
RE-ASSEMBLED WITH PROPER THREAD SEALANT.
I42325
FLUE DRAFT IN W.C.
INSTALL ON NONCOMBUSTIBLE FLOOR
MINIMUM CLEARANCE TO COMBUSTIBLE SURFACES (IN.)
CLEARANCES MAY BE INCREASED FOR SERVICE
TOP
18
CHIMNEY
FRONT
48
REAR
18
6
SIDE
PLUMBING SIDE
-.06
6
30
OIL PUMP MOTOR HP.
POWER
1/20
VOLTS
120
AMPS
.75
HZ
60
BURNER MOTOR HP.
1/10
120
1.4
60
BURNER HEATER WATTS
500
120
4.2
60
CIRCULATOR BOILER (OPT)
1/2
120
5.0
60
DRAFT INDUCER HP
1/3
120
3.9
60
AIR COMPRESS. (OPT) HP.
1/2
120
5.8
60
21.0
TOTAL CIRCUIT AMPACITY
30
MAXIMUM FUSE SIZE / WITH OPTIONS
BURNER REQUIRES A MINIMUM AIR SOURCE OF 2 S.C.F.M. AT 25 P.S.I.
INSTALL AND USE ONLY IN ACCORDANCE WITH THE MFR’S
INSTALLATION AND OPERATING INSTRUCTIONS. FOR COMMERCIAL
OR INDUSTRIAL USE ONLY.
AUTHORITIES HAVING JURISDICTION SHOULD
BE CONSULTED PRIOR TO INSTALLATION
42496 - R1
CTB Burner Safety Labels
WARNING
Fire and explosion hazard.
This burner is to be installed ONLY on
Clean Burn products.
Only a qualified technician may maintain
and service this burner.
42235 Rev. 2
1-9
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
For Your Safety... (continued)
CTB BurnerSafety Labels (continued)
WARNING
WARNING
Hazardous high voltage
and moving parts hazard.
Fire and explosion hazard.
Do NOT press reset button until
you read and understand Reset
Procedures in Operator's Manual.
To avoid electric shock and injury
from moving parts. turn power OFF
before opening cover.
42000 Rev. 2
42004 Rev. 2
CTB Burner Labels
200-CTB
350-CTB 500-CTB
42005
42005
42005
42004
42004
42004
42235
42235
42235
42321
42337
42494
42229
42229
42229
42000
42000
42000
42023
42023
42023
Description
Sold/Serviced By Label
Burner Safety Warning Label
(High Voltage/Moving Parts Hazard)
Burner Safety Warning Label
(Fire/Explosion Hazard - Burner Installation and Service)
Burner Model # Label
C.B. Logo/Burner Description Label
Burner Safety Warning Label
(Fire/Explosion Hazard - Reset Button)
Burner Power Label
TOPVIEW
FRONT VIEW
42321
42337
42494
42005
42004
42229
42235
42321
42337
42494
42000
42229
42023
I88722-B
1-10
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
For Your Safety... (continued)
Metering Pump Labels
200-CTB
350-CTB 42284
42466
42284
42420
500-CTB
42284
42495
Description
Metering Pump Wiring Diagram
Model Number / Warning
66 0
4
42 242 95
4 24
4
4
8
22
4
GA
UG
E
RE
INL
LIE
ET
F
RO
TA
TIO
N
I88966-A
1-11
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
1-12
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
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.
2.
3.
Carefully remove the top boards of the shipping crate. Then remove the front, back, and side panels.
Remove the bolts holding the boiler on the shipping pallet.
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.
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
•Low water cut-off
•Tube sealant
•Burner hook-up kit
•Barometric damper
•Burner
• Oil 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
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
Janesville, WI 53546
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 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.
Selecting a Location
The location you select for your CTB must allow the following:
•
•
•
•
•
Installation on a substantial, level, non-combustible concrete floor (minimum 4" thick).
Proper clearances from combustibles (Figure 2A/2B). Verify according to your local safety codes.
Safe, easy access for servicing (Figure 2A/2B).
Adequate combustion air per ASME CSD-1, NFPA 31, and local codes (Reference Section 8).
Proper stack installation and materials (Reference Section 4).
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
Selecting a Location (continued)
Adhere to the following minimum clearances from combustible surfaces. Specifications are also provided for
servicing clearance. Be sure to check state and local codes which may differ from these specifications. Refer
to pages A4 through A7 for boiler dimensions.
Fig. 2A/2B Description Clearance from Combustibles
Clearance for Service
AAbove
18"
18"
BFront
24"
48"
CStack
18"
18"
DRear
6"
40"
E L.H. Side
6"
6"
F R.H. Side
30"
30"
GBottom
6"
6"
C
C
A
BAROMETRIC DRAFT CONTROL
MOR E
DRAFT
LE S S
E
L.H. SIDE
AIR
OIL
G
F
B
R.H. SIDE
D
I88682-C
Figure 2A - Single Boiler Minimum Installation Clearances
C
A
C
C
F
E
BAROMETRIC DRAFT CONTROL
L.H. SIDE
MOR E
DRAFT
LE S S
AIR
OIL
B
AIR
OIL
D
G
I88683-C
Figure 2B - Dual-Stacked Boilers Minimum Installation Clearances
2-3
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
2-4
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
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
NOTE: PLUMBING ASSEMBLY IS SHIPPED DRY FIT ONLY. DO NOT INSTALL UNTIL
PLUMBING COMPONENTS ARE RE-ASSEMBLED WITH PROPER THREAD SEALANT.
3-1
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Single Boiler Assembly
DETAIL OF ITEM 24
1
2
33
CB-350-CTB
SHOWN
5
32
9
6
31
4
10
27
30
28
8
29
26
23
25
22
7
24
21
14
20
19
3
18
17
13
16
12
15
11
(USER
SUPPLIED)
34
(option)
I88121-F
Figure 3A - Single Boiler Assembly Component Detail
3-2
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
NUMBER
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
NO
34
22
21
20
14
13
12
11
9
4
2
1
QTY
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
CB-350-CTB PARTS LIST
PART #
DESCRIPTION
90188
BOILER STAND (optional)
33331
TERMINAL BLOCK
33327
TRANSFORMER 120V-24V
33328
RELAY DPDT
33352
RELAY DELAY
33486
TERMINAL BLOCK ASSEMBLY
33286
SWITCH DPDT
33168
AMBER LIGHT
27058
CONTROL BOX LID
12240
CONTROL BOX 120 AC
33105
SNAP IN BUSHING
27158
L-BRACKET
33546
CONNECTOR CORD
31176
INSULATION – DOOR
11405
DOOR W.A.
21077
PORT LID
14084
ROPE GASKET
11583
BURNER MOUNT W.A.
11582
HINGE BRACKET W.A.
13141
ACCUMULATOR BLOCK ASSEMBLY
14272
UPPER PIPE ASSEMBLY
35061
1-1/2” FLANGE
35078
CIRCULATOR PL36 115V 60Hz
14293
CHECK VALVE AND PIPE ASSEMBLY
13110
LOW WATER CUT-OFF
14274
LOW WATER PIPE ASSEMBLY
33330
GUAGE BOILER TEMP/PRESS
35048
RELIEF VALVE 3/4” MALE
35123
FLOW SWITCH TACO
28149
HIGH TEMP CUT-OFF
35079
COIL FLANGE 1-1/4”
28150
AQUASTAT
31166
INSULATION PANEL
11380
PANEL 350 REAR W.A.
PARTS THAT DIFFER ON THE CB-200-CTB
QTY PART # DESCRIPTION
1
90200 BOILER STAND (optional)
1
33508 CONNECTOR CORD
1
31216 INSULATION 200 DOOR
1
11540 DOOR W.A.
1
14300 UPPER PIPE ASSEMBLY
1
35079 1-1/4” FLANGE
1
11095 CIRCULATOR TACO 0011 115 V
1
14298 CHECK VALVE AND PIPE ASSY
1
14299 LOW WATER PIPE ASSEMBLY
1
35116 COIL FLANGE 1” NPT
1
31215 INSULATION PANEL
1
11539 PANEL 200 REAR W.A.
NO
34
22
21
20
14
13
12
11
9
4
2
1
PARTS THAT DIFFER ON THE CB-500-CTB
QTY PART # DESCRIPTION
1
90206 BOILER STAND (optional)
1
33546 CONNECTOR CORD
1
31240 INSULATION 500 DOOR
1
11564 DOOR W.A.
1
14315 UPPER PIPE ASSEMBLY
1
35120 FLANGE 2” SET
1
35130 CIRCULATOR TACO 2400-50/2 115V
1
14314 CHECK VALVE AND PIPE ASSY
1
14313 LOW WATER PIPE ASSEMBLY
1
35121 FLANGE 1-1/2” SET
1
31239 INSULATION PANEL
1
11563 PANEL 500 REAR W.A.
200-CTB350-CTB500-CTB
Refractory Cylinder
Refractory Cylinder Stand
21120
27155
3-3
21140
27190
21174
27200
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
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 2000 pounds (approximate). 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.
2.
3.
4.
Refer to Figure 3A to become familiar with the components required for CTB assembly.
Assemble the CTB support stand as shown in Figure 3B, using the hardware provided.
Move the support stand into the approximate position where the CTB is to be installed,
and place blocks (approximately 10 inches high) inside the stand to provide safety support for theboiler.
Use a forklift to carefully lift the CTB into position over top of the support stand.
5.
6.
7.
8.
9.
Lower the boiler down onto the safety blocks positioned inside the support stand.
Insert bolts (provided) into the keyhole slots in the boiler, and then lift the stand in position
against the bottom of the boiler.
Tighten the bolts to firmly attach the stand to the bottom of the boiler.
Carefully lift the assembled boiler (with stand) off the safety blocks and move the unit into place.
Proceed with the remainder of boiler assembly procedures marked for ALL CTB Models.
WARNING: Secure the boiler to the forklift prior to lifting to prevent possible equipment
damage or personal injury.
NOTE: When assembling the support
stand, ensure that the channel brackets
are aligned as shown; fasten the shorter
brackets at the innermost set of holes.
I88816-A
Figure 3B - Assembling the Support Stand
3-4
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
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 2000 pounds (approximate). 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.
ATTENTION: Dual-stacked units may be installed in several combinations: two CB-200-CTB boilers, two CB350-CTB boilers, two CB-500-CTB boilers, or any combination of two models with the larger unit on the bottom.
For optimal system functioning and to prevent system damage, each boiler must be installed/piped individually as
shown in Figure 3C.
1.
Refer to Figures 3C and 3D. Move the support stand into the approximate position where the
dual-stacked 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 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.
(Procedure continued on page 3-6)
I88688-C
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
Dual-Stacked Boiler Assembly
"TOP" BOILER
(USER SUPPLIED)
ADAPTOR
BRACKET
"BOTTOM" BOILER
(USER SUPPLIED)
SUPPORT STAND
REMOVE EXTRA FLANGES FROM
BOILER TO INSTALL PLUMBING
I88671-B
Figure 3D - Dual-Stacked Boiler Assembly Detail
3-6
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
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.
NOTE: When stacking a CB-200-CTB on top of a CB-350-CTB use an additional set of side channels turned
180 degrees to help distribute the load around the fork lift notches. This will require lifting the "top" boiler unit
from the front rather than the side. Install the front channel into the adaptor bracket after the "top" unit is set on
the "bottom" unit.
I88465-A
Figure 3E - Dual-Stacked Boiler Adaptor Bracket
3-7
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
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. Each boiler must be protected with its own low water cut-off
and MUST be piped individually (i.e. piping dual-stacked units together with a single supply or return line is
strictly PROHIBITED).
NOTE: PLUMBING ASSEMBLY IS SHIPPED DRY FIT ONLY. DO NOT INSTALL UNTIL PLUMBING
COMPONENTS ARE RE-ASSEMBLED WITH PROPER THREAD SEALANT.
Supply Side Connections
• Install the pre-assembled low water cut-off onto the supply piping flange.
• Place a flange gasket between the two flanges, and tighten the bolts to secure this part.
• 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.
• Install the probe of the low water cut-off into the upper tee, using pipe dope on the threads of
the probe. Tighten into the tee.
• Install the low water cut-off control onto the probe and secure.
• Connect the wiring harness from the CTB control box to the low water cut-off. Refer to the
CTB wiring diagram in Appendix B at the back of this manual.
Return Side Connections
• Mount the boiler circulator 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.
• Isolation valves must be installed on supply and return plumbing connections.
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
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
3"
SLEEVE STAND
I88463A
Figure 3F -Positioning of the Sleeve Stand and Ceramic Sleeve
3-9
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Assembly for ALL Boilers
CERAMIC
SLEEVE
SLEEVE
STAND
I88124-B
Figure 3G - Sleeve 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
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 OR
9-28 OR -28 ON FLAT
OF NOZZLE HEAD
NOZZLE
ELECRODE
NOZZLE ADAPTER
101.00
3/16"
SPARK GAP
OUTLINE OF RETENTION HEAD
3/16"
142.47
1/8"
90.00
NOZZLE TO BE AHEAD OF
RETENTION HEAD BY 1/8"
I88144-A
Figure 3H - Burner Nozzle and Electrode Specifications
3-11
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
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 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.
2.
3.
Refer to Figure 3I on the next page.
Use the two (2) bolts to install the aluminum connector block onto the CTB cabinet.
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
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.
2.
3.
4.
5.
Remove and discard the outer red protective
caps from the oil line tubing.
Loosely install the oil line tubing into the oil
line fitting on the burner.
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.
Make sure that the curl in the oil line is
positioned as shown in Figure 3I so that the
burner can swing open correctly.
Install the oil line tubing and tighten the nuts
on the compression fittings. DO NOT
overtighten these fittings to avoid damaging
the ferrules.
OIL FITTING
ON BURNER
CONNECTOR BLOCK
AIR
OIL
FRONT VIEW OF BOILER
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
I88108A
Figure 3I - Installation of
Connector Block and Oil Line
3-13
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Assembly for ALL Boilers
AIR LINE FITTING
ON BURNER
OIL LINE FITTING
ON BURNER
AIR LINE
OIL LINE
AIR
OIL
COMPRESSION /
SWIVEL FITTING
CONNECTOR BLOCK
INSTALLED ON BOILER
I88112-B
Figure 3J - Installation of Connector Block, Oil Line and Air Line (Front View)
Installing the Air Line Tubing
1.
2.
3.
Remove and discard the outer red protective caps from the air
line tubing.
Refer to Figure 3J. Push the air line tubing into the swivel
fitting on the connector block until
the tubing bottoms out in the fitting.
Repeat this procedure to connect the air line tubing to the
air line fitting on the side of the burner.
C77005
PLUG ON CAM LOCK
CABLE
Locking the Burner into Firing Position
1.
2.
3.
4.
Swing the burner into firing position.
Install and tighten the lock nut on the mounting
plate bolt to secure the burner in its firing position.
Plug the burner electrical cable into the receptacle on the
top of the burner housing.
Tighten the locking ring to secure the electrical cable.
NOTE: Be sure to properly align the plug when plugging it into the
receptacle. See Fig 3K.
3-14
SLOT IN PLUG
MUST ALIGN WITH
SLOT IN RECEPTACLE
RECEPTACLE ON TOP
OF BURNER
Figure 3K - Detail of Burner
Electric Receptacle
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
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
(5) Installing the Compressed Air Line
(2) Installing the Metering Pump*
(6) Wiring the CTB and Pump
(3) Connecting Water to the CTB
(7) Installing the Stack
(4) Installing the Oil Lines
(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: 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 and the following standards:
ASME Section IV Boiler Code for Pressure Vessels
ASME CSD-1 Controls and Safety Devices for Automatically Fired Boilers
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 70National Electrical Code
NFPA 88AParking Structures
NFPA 88BRepair Garages
NFPA 211 Chimneys, Fireplaces, Vents and Solid Fuel Burning Appliances
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
B140.7.2 Oil-Fired Steam and Hot Water Boilers for Commercial and Industrial Use B214 Installation Code for Hydronic Heating Systems
C22.1Canadian Electrical Code, Part 1.
Failure to comply with these standards and requirements may result in equipment damage, fire, explosion,
personal injury and/or death.
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.
4-1
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Typical Installation Diagrams
3 FT
"CLASS A" STACK CAP
10 FT
"CLASS A" STACK
2100 DEGREE 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
ELECTRICAL THERMO CUT-OFF (OPTIONAL)
DEDICATED ELECTRICAL CIRCUIT
110 VOLT 20 AMP
OIL PUMP ELECTRICAL CIRCUIT
PRESSURE OIL LINE INSTALLED
TO CONNECTOR BLOCK ON BOILER
OIL FLOW
8 INCH SINGLE
WALL STACK
MIN. 24 GAUGE
DRAFT
INDUCER
METERING
PUMP
(OPTIONAL)
OIL THERMO
CUT-OFF
CONTROL BOX
(ELECTRICAL
CONNECTION)
LOW WATER
CUT-OFF
BAROMETRIC
DAMPER
FLOW SWITCH
RELIEF
VALVE
TEMP/PRESSURE
GAUGE
HIGH LIMIT
AIR & OIL
CONNECTIONS
AT CONNECTOR
BLOCK ON BOILER
USER SUPPLIED
BOILER LOOP
CIRCULATOR
OPERATING
AQUASTAT
EMERGENCY
VENT
BAROMETRIC DRAFT CONTROL
MO R E
DRAFT
LE SS
W/RESET
FLUE
COLLAR
8" DIA.
FUNNEL WITH
BALL VALVE
SUCTION
OIL LINE
VENT
CAP
1/4" HOLE FOR
CHECKING DRAFT
AT BREACH
250 GAL TANK
5 FT MIN
RETURN
FLANGE SET
1-1/2 NPT
CHECK VALVE
CLEAN-OUT TEE
COMPRESSED AIR LINE
CHECK VALVE SCREEN
CLEAN-OUT
I88679-C
Figure 4A - Typical Single Boiler Installation Diagram
(CB-350-CTB Shown)
4-2
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
1 FT
Typical Installation Diagrams (continued)
3 FT
"CLASS A"
STACK CAP
"CLASS A" STACK
2100 DEGREE ALL FUEL STACK
INSULATED STACK WITH A
STAINLESS STEEL LINER
10 FT
WATERTIGHT ROOF FLASHING
"DEKTITE" FLASHING OR
EQUIVALENT
"CLASS A" KIT FOR INSTALLING
"CLASS A" STACK THROUGH CEILING
ELECTRICAL THERMO CUT-OFF (OPTIONAL)
DEDICATED ELECTRICAL CIRCUIT
110 VOLT 20 AMP
OIL PUMPS ELECTRICAL CIRCUIT
PRESSURE OIL LINES INSTALLED
TO CONNECTOR BLOCKS ON BOILERS
SUPPLY
1-1/2 NPT
ELECTRICAL
CONNECTIONS
GAUGE
RELIEF
A2RA-7720
INLET
ROTATION
OIL FLOW
BAROMETRIC DRAFT CONTROL
BAROMETRIC DRAFT CONTROL
MOR E
MOR E
DRAFT
DRAFT
LE S S
RETURN
FLANGE SET
1-1/2 NPT
EMERGENCY
VENT
OIL LINE
CLEAN-OUT TEE
COMPRESSED
AIR LINE
6 ft MAX
1/4" HOLE FOR CHECKING
DRAFT AT BREACH
SUPPLY
1-1/2 NPT
(OPTIONAL)
OIL THERMO
CUT-OFF
BAROMETRIC DAMPER
LE S S
SUCTION OIL LINE
(OPTIONAL)
OIL THERMO
CUT-OFF
FUNNEL WITH
BALL VALVE
SUCTION OIL LINE
GAUGE
RELIEF
A2RA-7720
INLET
ROTATION
VENT
CAP
CANISTER
FILTER
8 INCH SINGLE
WALL STACK
MIN. 24 GAUGE
110 VOLT 20 AMP
250 GAL TANK
5 FT MIN
RETURN
FLANGE SET
1-1/2 NPT
CHECK VALVE
AIR AND OIL CONNECTIONS
CONNECTOR BLOCK ON BOILERS
COMPRESSED AIR LINE
CHECK VALVE SCREEN
CLEAN-OUT
CLEAN-OUT TEE
I88726-C
Figure 4B - Typical Dual-Stacked Boiler Installation Diagram
(Two CB-350-CTB Boilers Shown)
4-3
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
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.
NFPA 31 requires the following for 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 1 square inch per 4,000 BTU/hr (35 square inches per gallon of oil) of the total appliance(s) input rating (NFPA 31, Section 5.4.2.2).
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 1 square inch per 2,000 BTU/hr (70 square inches per gallon of oil) of the total appliance(s) input rating (NFPA 31, Section 5.4.2.2).
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 1 square inch per 1,000 BTU/hr (140 square inches per gallon of oil) of the total appliances(s) input rating (NFPA 31 Section 5.4.1).
4-4
4-5
AIR
OIL
OPENING
AIR
OIL
INLET AIR DUCT
APPLIANCES LOCATED IN CONFINED SPACES ALL AIR TAKEN FROM INSIDE THE BUILDING
Figure 4C - Air for combustion and ventilation
APPLIANCES LOCATED IN CONFINED SPACES ALL AIR TAKEN FROM OUTSIDE THE BUILDING
AIR
OIL
OUTLET
AIR
APPLIANCES LOCATED IN CONFINED SPACES ALL AIR TAKEN FROM INSIDE THE BUILDING
LES S
MOR E
DRAFT
LE S S
LE S S
BAROMETRIC DRAFT CONTROL
MOR E
DRAFT
MOR E
BAROMETRIC DRAFT CONTROL
OUTLET AIR DUCT
DRAFT
BAROMETRIC DRAFT CONTROL
OPENING
I88978
INLET AIR DUCT
(ENDS 1 FOOT
ABOVE FLOOR)
VENTILATION LOUVERS
(EACH END OF ATTIC)
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
WARNING
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.
• The tank must be listed to UL 80, UL 142,
or equivalent standard.
• Use a minimum 250-gallon tank.
DO NOT use a 55-gallon drum as a
substitute for an appropriate tank. The
tank must be large enough to allow water,
sludge, etc. to settle out of the used oil.
• Single wall tanks should have a manual shut-
off type valve on the side of the tank to allow the water, sludge, etc. to be drained from the bottom of the tank.
•All unused openings in the tank must be
plugged or capped off.
• For optimal system functioning, Clean Burn
recommends inside tank installations as shown in Figures 4A and 4B.
• Some codes require the tank to 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 4D, including the metering pump
installation and specifications for the oil
line installation. (Procedures for installing
these components can be found in the
following pages.)
Fire and explosion hazards
To prevent serious injury or death:
ONLY place these listed substances in
this used-oil supply tank:
• Used crankcase oil
• Used automatic transmission fluid
• Used hydraulic oil
• #2 fuel oil
Do NOT place flammable or corrosive
substances such as gasoline, chlorinated
oils, solvents, paint thinners, or any other
unsafe substances in this used-oil supply tank.
Do NOT weld or allow open flame within
35 feet of this used-oil supply tank.
Tank installation MUST comply with NFPA
30 and 31 Fire Codes, including the following
requirements:
• Tank must be listed to UL 80 or UL 142.
• Tank must be vented to outside.
• Emergency vent or explosion relief must
be installed on tank.
• Inside fill allowed only with funnel including 1/4
turn-to-close fall valve, which must be
closed after filling.
• All other openings must be plugged
• All oil lines must be constructed of copper,
steel, or brass components. Do NOT use
rubber or plastic tubing or piping, or any other
inappropriate material.
Follow all instructions
for tank installation in
Operator's Manual.
42366 Rev. 2
IMPORTANT NOTE: If you are installing an inside oil tank in the same room as the boiler, you must allow a
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.
4-6
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Oil Tank Installation Specifications (continued)
TANK VENT KITS AVAILABLE FROM CLEAN BURN
Example Oil Tank Install Diagram
PRESSURE
RELIEF OIL
LINE BACK TO
THE TANK
PRESSURE
LINE
F
RELIE
PUMP
E
GAUG
MUSHROOM
CAP VENT
N
ROTATIO
INLET
STEEL PIPE
(USER SUPPLIED)
SUCTION LINE
ASSEMBLY
FUNNEL WITH
BALL VALVE
EMERGENCY
VENT
CHECK
VALVE
FILTER
SCREEN
K
6
36
42
OIL
CLEAN-OUT
(TANK DRAIN)
N
A
T
E
AG
R
STO
I88669-H
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 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.
4-7
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
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 6 feet TOTAL vertical lift AND 4 feet TOTAL
horizontal lift.
Standard Mounting: Vertical Positioning
1.
2.
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.
Use the appropriate type of bolts and washers (user-supplied) to securely mount the metering
pump to the appropriate wall in your building at a distance from the tank that complies with the
suction oil line requirements.
I88727-B
1/8" OUTLET
GA
UG
E
RE
INL
LIE
ET
F
RO
TA
TIO
N
INLET
BLEEDER VALVE
Figure 4E - Standard (Recommended) Vertical Mounting of the Metering Pump
4-8
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
DESCRIPTION
SUPPLY
TO BURNER
CAPACITOR - GEARMOTOR
GEARMOTOR
MOUNT - METER PUMP
1/8 NPT X 1/4 TUBE COMPRESSION FITTING
1/4 COPPER OR ALUM. TUBING
3/8 OR 1/2 TUBE FLARE NUT
3/8 OR 1/2 COPPER OR ALUM. TUBING
1/8 M NPT X 3/8 OR 1/2 FLARE
MINI BALL VALVE 1/8 MNPT X 1/8 FNPT
METER PUMP
1/4" X 3" NIPPLE
1/4" STREET ELBOW
1/4" X 3/4" BRASS BUSHING
VACUUM GAUGE
CANISTER FILTER- LENZ
1/2" x 3/4" BUSHING, BRASS
1/2" X 5" NIPPLE
1/2" STREET TEE, BRASS
1/2" HEX NIPPLE
1/2" BALL VALVE
1/4" NPT x 1/4" TUBING FITTING
1/4" x 1/2" BUSHING
1/2" NPT x 1/2" TUBING FLARE ADAPTER
1/2" LONG NUT
1/2" NPT x 1/2" TUBING SLIP ADAPTER
2" x 1/2" x 1/2" NPT DUPLEX HEX BUSHING
3/4" CHECK VALVE
3/4" CHECK VALVE SCREEN
1/2" PIPE CAP
RETURN
TO TANK
6
5
7
4
8
3
2
9
10
GA
UG
E
A2
R
RA ELIEF
T -7
72
0
INLE
RO
TAT
ION
29
11
1
13
16
12
T
17
IN
33363
see chart
11322
32037
N/A
N/A
N/A
N/A
32526
32475
32467
32210
32336
32123
32127
32430
32446
32429
32137
32142
32062
32443
32141
32140
32139
32442
32021
32061
32445
OU
# PART #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
14
18
PACKAGED WITH
CLEAN BURN
EQUIPMENT
15
19
20
23
24
21
22
25
26
SINGLE PIECE OF
COPPER TUBING
(USER SUPPLIED)
24
23
16
27
PACKAGED WITH
CLEAN BURN
EQUIPMENT
28
CLEAN BURN
MODEL
CB-140
CB-230
CB-1750
CB-2500
CB-3250
CB-3500
CB-5000
CB-200-CTB
CB-350-CTB
CB-500-CTB
GEARMOTOR
PART #
33291
33293
33353
33354
33572
33355
33356
33507
33295
33558
I89052-C
Figure 4F - Metering Pump Component Detail
4-9
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
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.
2.
3.
4.
5.
Refer to Figures 4F and 4G.
Remove the two pump mounting bolts. The coupling is keyed and does not have set screws.
Rotate the pump head 180 degrees to the horizontal position as shown in Figure 4G.
Re-install and tighten the two pump mounting bolts.
Use the appropriate type of bolts and washers (user-supplied) to securely mount the metering
pump to the mounting bracket, which is to be installed on the appropriate wall in your building at a
distance from the tank that complies with the suction oil line requirements.
ATTENTION !
THE PUMP HEAD MUST BE POSITIONED SO THE GAUGE
ARROW POINTS UP OR THE PUMP WILL NOT PRIME
GAUGE
RELIEF
A2RA-7720
INLET
ROTATION
GAUGE
RELIEF
A2RA-7720
INLET
GAUGE
GAUGE
RELIEF
RELIEF
A2RA-7720
A2RA-7720
INLET
INLET
ROTATION
ROTATION
ROTATION
INLET
RECOMMENDED SETUP
PUMP IS MOUNTED
LEFT ON WALL
INLET
INLET
ALTERNATE MOUNTING
(NOT RECOMMENDED)
BLEED VALVE IS NOW CLOSE
TO THE WALL MAKING THE
BLEEDING DIFFICULT
I88708-B
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)
Figure 4G - Proper Positioning of Metering Pump Head
4-10
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
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.
NOTE: PLUMBING ASSEMBLY IS SHIPPED DRY FIT ONLY. DO NOT INSTALL UNTIL PLUMBING
COMPONENTS ARE RE-ASSEMBLED WITH PROPER THREAD SEALANT.
1.
2.
3.
4.
Connect the desired header supply and return lines to the CTB.
Have the water trim installed by a certified hydronics technician according to the ASME
Section IV Boiler Code. Heat exchangers must be used for domestic water heater installations.
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.
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.
2.
3.
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.
The pressure gauge should read 20 psig. (If a different operating pressure is needed, contact the
Clean Burn Service Department for additional instructions.)
Refer to Section 10, The CTB Hydronic System, for additional information.
4-11
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
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" diameter. Proper installation allows the suction oil line to be filled
with used oil during initial priming.
• The suction oil line may NOT exceed 6 feet TOTAL vertical lift AND 4 feet TOTAL
horizontal lift (which equals 6.0” hg maximum operating vacuum). To determine if your
suction oil line will meet this specification for maximum operating vacuum, base the calculation for
your installation on the following equivalents:
(1) vertical foot
= 0.75” hg (vacuum)
(4) horizontal feet
= 0.75” hg (vacuum)
NOTE: ALSO ADD 0.75" hg to the final sum to account for every oil filter, shut-off valve, and check valve on the suction side of the pump assembly.
Sample calculation: (6) vertical feet x 0.75" = 4.50" hg AND (4) horizontal feet = 0.75" hg
4.50" hg + 0.75" hg + 0.75" hg = 6.00" hg vacuum
• The metering pump must be installed with a 3/4" check valve and screen at the end of the
suction oil line, or the pump will not maintain its prime.
•Use Permatex #2 non-hardening gasket sealer on every threaded 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.
4-12
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
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 12" (305mm) 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.
4-13
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
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, and 4D.
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.
4-14
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
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.
2.
3.
4.
Refer to Figure 4H.
Remove the plug from the relief port on top of the metering pump head.
Install the 1/8 NPT x 1/4 tube compression fitting in the relief port on top of the metering pump head.
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
2
3
4
5
6
7
METERING PUMP HEAD (7720)
MINI BALL VALVE 1/8 MNPT X 1/8 FNPT
1/8 MNPT X 3/8 OR 1/2 FLARE
3/8 OR 1/2 COPPER OR ALUM. TUBING
3/8 OR 1/2 TUBE FLARE NUT
1/4 COPPER OR ALUM. TUBING
1/8 MNPT X 1/4 TUBE COMP. FITTING
32475
32526
INSTALLER SUPPLIED
INSTALLER SUPPLIED
INSTALLER SUPPLIED
INSTALLER SUPPLIED
32037
SUPPLY
TO BURNER
RETURN
TO TANK
5
6
4
7
3
2
1
GA
UG
A2
E
R
R ELIEF
INL A
ET -7
72
0
RH
RO
TA
TIO
N
I89004-D
Figure 4H - Pressure Relief Oil Line Back to the Tank
4-15
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
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 100 feet 3/8" O.D. copper or aluminum 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 4F.
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: 25
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.
2.
3.
4.
Run a compressed air line from your shop air to the burner on the boiler. Use minimum 1/4"
O.D. copper tubing or equivalent for the compressed air line.
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.
Install a pressure regulator (additional to the burner air regulator) in the air line, and set it at 50 psi.
ATTENTION: DO NOT feed full shop air pressure to the burner or damage to burner
components may occur.
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.
4-16
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Wiring the Coil Tube Boiler
WARNING: To avoid electrical shock, make sure that power to the CTB is turned OFF before
connecting any wires. All wiring must be in accordance with the National Electrical Code and local
codes. Properly size all wires and use Greenfield or Thin-wall Conduit for all electrical lines. Refer to Figures
4A/4B at the beginning of this chapter for the Clean Burn recommended typical CTB
installation. Specific wiring schematics are provided in Appendix B at the back of this manual.
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
1.
Install a dedicated electrical circuit to the electrical junction box on the CTB. Note that a
dual-stacked boiler will require two circuits, each with a single pole, single throw breaker.
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. Refer to NFPA-70 for wire size and
distances.
3.
Check for correct voltage at the CTB and refer to the following chart. Incorrect voltage may
damage the CTB components.
ModelVoltage
Breaker Qty. & Size*
Phase
Hertz
CB-200-CTB (single)
Dual-Stacked (200-CTB)
110/120
110/120
(1) @ 15 amps
(2) @ 15 amps
Single
Single
60
60
CB-350-CTB (single)
Dual-Stacked (350-CTB)
110/120
110/120
(1) @ 20 amps
(2) @ 20 amps
Single
Single
60
60
CB-500-CTB (single)
Dual-Stacked (500-CTB)
110/120
110/120
(1) @ 20 amps
(2) @ 20 amps
Single
Single
60
60
*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. Refer to NFPA-70 for wire size and distances.
CAUTION: DO NOT turn on main power until instructed to do so.
4-17
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Wiring to the Oil Pump
ATTENTION: 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.
1.
Install the oil pump electrical circuit from the CTB to the oil pump location (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 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.
4-18
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
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
Figure 4I illustrates the through-the-ceiling stack design for a single boiler; this stack design is
preferable and is more commonly used. Refer to Figure 4J for the dual-stacked boiler stack design.
When designing your stack, adhere to the following specifications:
• Models CB-200-CTB and CB-350-CTB single boilers require 8" I.D. stack components.
• Model CB-500-CTB single boilers require 10" I.D. stack components.
• Models CB-200-CTB and CB-350-CTB dual-stacked units require 8" I.D. stack components run
as two (2) individual stacks.
• Model CB-500-CTB dual-stacked units require 10" I.D. stack components run as two (2)
individual stacks.
•
Ensure that the vertical stack height is at least 10 feet. 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 1/4" per
foot of run.
•
Keep the stack design simple. Complicated stacks (with long runs and many turns) reduce
draft and result in poor burner performance. Your stack may include only one 90 degree
turn. All other stack turns must be at 45 degrees or less to ensure optimal draft and burner
performance.
NOTE: If you plan to use an existing masonry chimney, the chimney must be lined and 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 resultant vacuum in the building will draw combustion products back into the burner. This back
draft causes poor burner performance and may damage vital burner
components. Refer to Section 8 in this manual for additional information 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 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
4-19
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
"CLASS A" STACK CAP
NON-RESTRICTIVE TYPE TO ALLOW
FREE FLOW OF TH STACK GASES
THE LAST STACK SECTION SHALL
EXTEND AT LEAST 3 FEET ABOVE
THE HIGHEST POINT. AT WHICH IT
COMES IN CONTACT WITH THE ROOF.
AND AT LEAST 3 FEET HIGHER THAN
ANY RIDGE, PARAPET WALL OR ROOF
STRUCTURE WITHIN 10 FEET OF IT
"CLASS A" UL 103HT STACK
DOUBLE WALL INSULATED
ALL FUEL,STACK WITH A
A STAINLESS STEEL LINER
3 FEET
WATERTIGHT
ROOF
FLASHING
"DEKTITE" OR
EQUIVALENT
10 FEET
"CLASS A" KIT FOR INSTALLING
"CLASS A" STACK THROUGH CEILING
DRAFT
INDUCER
10 FT MINIMUM VERTICAL
STACK HEIGHT OR EQUIVALENT
DRAFT SYSTEM TO MAINTAIN
-.02 W.C. DRAFT OVER FIRE
BAROMETRIC
DAMPER
BAROMETRIC DRAFT CONTROL
MOR E
DRAFT
LE S S
8 INCH MINIMUM
SINGLE WALL STACK
MIN. 24 GAUGE
GALVANIZED
I88681-C
Figure 4I - Installation of "Class A" Stack Through Roof/Ceiling (Single Boiler)
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.
2.
The stack can be installed from either side of the smoke hood breach. Install the 8" smoke cap
onto the unused smoke hood breach ring assembly.
Install a piece of the single-wall 24-gauge galvanized stack (minimum 18" in length) onto the
smoke hood breach.
4-20
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Installing the Stack (continued)
DAMPER
8"
32 1/4" BETWEEN
CENTERS (CB-200-CTB)
37 1/8" BETWEEN
CENTERS (CB-350-CTB)
8"
10" BETWEEN
OPENING CENTERS
I88672-A
Figure 4J - Detail of Dual-Stacked Boiler Stack Installation
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.
Installing the Barometric Damper(s)
1.
Refer to Figure 4K. Install a single wall tee (min. 24 gauge) on the first straight vertical or
horizontal stack section within three feet 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; 10" single wall tee - CB# 70180).
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.
4-21
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Installing the Stack (continued)
2.
3.
3.
For CB-500-CTB ONLY: Install the 9"-to-10" pipe adapter in the opening of the tee as shown in
Figure 4K.
Install the barometric damper in the opening of the tee (or pipe adapter for CB-500-CTB). Use a small
spirit level to make sure that it is properly level.
Install two self-tapping screws as shown in Figure 4K (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.
I88547
9" CLEAN BURN BAROMETRIC
DAMPER WITH ADAPTOR IN
10" SINGLE WALL TEE
ADJUST THIS WEIGHT TO
OBTAIN PROPER DRAFT
2
1
(FOR CB-500-CTB)
2
1
31198
DAMPER PIPE ADAPTOR
1
1
31197
9" BAROMETRIC DAMPER
No QTY PART #
DESCRIPTION
I88539
8" CLEAN BURN BAROMETRIC DAMPER
INSTALLED IN SINGLE WALL TEE
ADJUST THIS WEIGHT TO
OBTAIN PROPER DRAFT
1
1
(FOR CB-200-CTB and CB-350-CTB)
1
31170
No QTY PART #
Figure 4K - Installation of Barometric Damper
4-22
8" BAROMETRIC DAMPER
DESCRIPTION
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Installing the Stack Safety Switch For Canadian Installations
NOTE: CSA Standards require that all heating equipment must be installed with a stack safety switch. If your
heating equipment is being installed in Canada, follow the instructions listed below.
CAUTION: For your safety and the safe operation of your heating equipment, the stack switch must
be installed by a 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 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 4L.
4.
Drill a 1/8” pilot hole for the mounting screw, and mount the stack safety switch using the mounting
screw supplied with the switch.
NOTE: The mounting screw must not interfere with the free movement of the 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 4M. Install the wire so
that it is secured away from any hot surfaces.
6.
When the heating equipment installation is completed, follow the instructions in the Operator’s
Manual, Sections 5 and 6 to prime the pump and start/adjust the burner.
7.
Follow instructions in the Operator’s Manual, Section 8 to check the draft; this is crucial for the
proper, safe operation of the heating equipment.
I88964
Figure 4L - Stack Safety Switch Installed on the Barometric Damper
4-23
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
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.
2.
3.
Before resetting the stack safety switch, check the stack to make sure it is clear of any obstructions.
Remove the cover from the stack safety switch, and push the small button in the middle of the switch.
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 TypeL180, normally closed, manual reset
WALL
THERMOSTAT
T T F F
OIL
PRIMARY
CONTROL
BOX
STACK
SAFETY
SWITCH
(MOUNTED ON
BAROMETRIC DAMPER)
I88976
Figure 4M - Stack Safety Switch Wiring Diagram
4-24
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Installing the Stack Penetration
WARNING: When running the stack through your ceiling, roof, or sidewall, you must use
Class A/UL103 HT double-wall insulated all-fuel stack components with a stainless steel liner.
DO NOT run single-wall stack through your ceiling, roof or sidewall.
1.
2.
Refer to Figure 4I as needed.
Follow the installation instructions provided by the stack manufacturer.
Installing the Exterior Stack
ATTENTION: All exterior stack pieces must be Class A/UL103 HT double-wall insulated all-fuel stack
components with a stainless steel liner.
• DO NOT use Class B 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 4I 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/UL103 HT stack cap ensures the free flow of stack gases which is
essential for optimal burner performance.
1.
2.
Refer to Figure 4I as needed. Your stack cap should be classified as: Class A/UL103 HT
non-restrictive, all-fuel type.
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 4N.)
Proper sizing, installation, and adjustment of the draft inducer are critical for optimal draft inducer operation.
4-25
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Installing the Draft Inducer (continued)
NOTE: Lubricate the motor as recommended
by the Draft Inducer manufacturer.
3 FEET
10 FEET
NOTE: INSTALL DRAFT INDUCER IN LAST
SECTION OF VERTICAL STACK TO POSITION
DRAFT INDUCER AWAY FROM BOILER
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 BOILER
BREACH
10 FT MINIMUM VERTICAL
STACK HEIGHT OR EQUIVALENT
DRAFT SYSTEM TO MAINTAIN
-.02 W.C. DRAFT OVER FIRE
DRAFT
INDUCER
DRAFT
ADJUSTMENT
PLATE
BAROMETRIC DRAFT CONTROL
SERVICEMAN ADJUSTS
BAROMETRIC DAMPER TO
OBTAIN -.02 W.C. DRAFT
OVERFIRE
MOR E
DRAFT
5 FEET - 8 FEET
LE S S
CHECK FOR
-.02 W.C. DRAFT
OVER FIRE
AIR
OIL
I88968-B
Figure 4N - 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.
4-26
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Installing the Draft Inducer (continued)
1.
2.
Refer to Figure 4N. Follow the instructions included with the draft inducer to mount the draft
inducer on the section of single-wall vertical stack.
Position the draft plate all the way out so that it does not reduce the draft produced by the draft
inducer. Follow directions in Section 8 (Adjusting the Draft Overfire) to set the proper draft.
Wiring the Draft Inducer for Normal Operation*
*(No exhaust fans in the building)
1.
Wire the draft inducer according to the 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: The wall thermostat is available separately from Clean Burn (i.e. it is not included with
the CTB). 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.
Run two wire, 18-gauge (minimum) thermostat cable from the B1/B2 terminals of the control box on the
side of the boiler to the T/T terminals of the primary control on the burner.
ATTENTION: NEVER jump between T/T terminals on the burner control box or the primary control
without removing one of the wires. Failure to remove one of the wires will burn out the heat anticipator
on the thermostat and will cause the thermostat to fail.
6.
Mount the thermostat base 60" to 66" from the floor using the hardware provided.
7.
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.
2.
3.
Proper battery level is indicated by the room temperature being displayed on the LCD screen.
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.
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.
4-27
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
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 Aquastat180 oF (minimum)
• Hi-limit Aquastat (with manual reset)
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.
4-28
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
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 one-gallon)
• Permatex #2 non-hardening gasket sealer
• Adjustable Wrench
• Pipe Wrench
5-1
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
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.
2.
3.
4.
5.
6.
7.
Refer to Figure 5A.
Remove the 1/4" NPT plug from the side of the pump head, and set it aside.
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.
Apply Permatex #2 non-hardening gasket sealer to the threads of the plug (removed from the
pump head). Re-install the plug and tighten.
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.
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.
Close the mini ball valve at the outlet port of the pump head.
ATTENTION: Verify that the relief oil line is installed back to the tank before closing the mini ball
valve. Closing the mini ball valve will cause the internal pump relief valve to open.
TO BURNER
RETURN TO TANK
MINI BALL
VALVE
1/2" BRASS
CAP
1/2" BRASS
NIPPLE
GEARMOTOR
1/4" PLUG
PUMP
BLEEDER VALVE
BALL VALVE
VACUUM GAUGE
CANISTER
FILTER
TO TANK
SUCTION
LINE
Figure 5A - Priming the Metering Pump
5-2
I88756-C
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Priming the Metering Pump (continued)
8.
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 hydraunics side 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
THERMOSTAT TERMINAL
BURNER
TERMINAL
PRIMING LIGHT
AIR
REGULATOR
OIL
GAUGE
AIR
GAUGE
CONNECTOR BLOCK
COMPRESSED AIR LINE
OIL LINE
Figure 5B - Detail of Burner Connections/Components
5-3
I88130-B
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
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
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
5-6
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
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.
2.
Turn the load temperature controller (i.e. thermostat or aquastat) OFF.
Set the operating aquastat (on the CTB) at 180 to 200 oF.
Preparing the Burner for Startup
1.
2.
3.
If you have not already done so, disconnect one wire from the terminal block at the "thermostat"
connection. (This prevents the burner from running.) A wiring diagram is provided in
Appendix B.
Turn the main power to the CTB ON (the green power light on the burner should be ON).
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 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
Preparing the Burner for Startup
(continued)
4.
Refer to Figure 6A. Loosen the
locking nut on the air regulator.
5.
Turn the adjustment knob on the air regulator counterclockwise
until 1/2" of the threads on the
knob are exposed. DO NOT
back the knob all the way out.
NOTE: The air gauge will not
show any pressure until the burner
starts. Before starting the burner
for the 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
Chart. Use a ruler to accurately
set the slot opening at the widest
section of the slot.
WARNING: The combustion air
SLOT COVER INSTALLED
AIR REGULATOR
LOCKING NUT
AIR GAUGE
OIL GAUGE
COMBUSTION
AIR BAND
I88725
Figure 6A - Component Detail of the CB-551-H3 Burner
(CB-525-S2 Burner is similar)
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 chart 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 #33507 may be used with the CB-200-CTB.
Maximum Input = 200,000 BTUH @ 1.4 GPH per CB 525-S2 Burner
Oil Type #2 Fuel Oil*
Used Crankcase Oil Used ATF
Used Hydraulic Oil #4 and #5 Fuel Oils Oil PSI / Flame Length check flame length check flame length check flame length check flame length check flame length 6-2
Air PSI
14
14
18
14
18
Air Band 3/8" - 1/2" 3/8" - 1/2" 3/8" - 1/2" 3/8" - 1/2" 3/8" - 1/2" Nozzle
9-5
9-5
9-5
9-5
9-5
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Preparing the Burner for Startup (continued)
Initial Adjustments for CB-350-CTB
NOTE: Only Gearmotor part #33295 may be used with the CB-350-CTB.
Maximum Input = 350,000 BTUH @ 2.5 GPH per CB 551-H3 Burner
Oil Type Oil PSI / Flame Length Air PSI Air Band #2 Fuel Oil* check flame length 12-16 1/2" Used Crankcase Oil check flame length 12-16 1/2" Used ATF check flame length 12-16 1/2" Used Hydraulic Oil check flame length 12-16 1/2" #4 and #5 Fuel Oils check flame length 12-16 1/2" Initial Adjustments for CB-500-CTB
NOTE: Only Gearmotor part #33558 may be used with the CB-500-CTB.
Maximum Input = 500,000 BTUH @ 3.57 GPH per CB 551-H5 Burner
Oil Type Oil PSI / Flame Length Air PSI Air Band #2 Fuel Oil* check flame length 18 1/2" Used Crankcase Oil check flame length 18 1/2" Used ATF check flame length 22 1/2" Used Hydraulic Oil check flame length 24 1/2" #4 and #5 Fuel Oils check flame length 18 1/2" * 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.
Nozzle
9-5
9-5
9-5
9-5
9-5
Nozzle
9-28
9-28
9-28
9-28
9-28
Starting the Burner
1.
Re-connect the control wire. Turn the aquastat to call for heat (to start the burner).
NOTE: The CB-350-CTB and CB-500-CTB burner oil primary controls include alarm contacts which
will close should the burner fail to start. 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 115VAC.
• 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
WHEN OPENING INSPECTION PORT
no more than one-half of the way down the chamber.
PORT MAY BE HOT
WARNING: The observation port gets hot as the
PROTECT HANDS
burner fires. To avoid personal injury, always wear heavy
WEAR
SAFETY GOGGLES
work gloves and safety glasses when opening the port and viewing
KEEP
FACE AWAY
the flame. CAUTION
OPEN PORT SLOWLY
6-3
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
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.
I88372
Incorrect Flame Adjustment
(Air Pressure too high)
• Ensure proper air pressure setting
I88372
I88372
Figure 6B - Flame Length Adjustment
4.
5.
Check the flame length after the burner has fired for 15 minutes.
Tighten the locking nuts on the air regulator.
6-4
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
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 22 psi; normal pressure is 12 psi)
• all system controls functioning properly
8.
Reset the operating aquastat to the normal operating range (180-200 oF) and repeat steps 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 1/8" to 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 -.02 inch w.c. to -.04 inch w.c.
• Adjust for a smoke spot of a trace to 1
• 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
NOTE: On the CB-200-CTB, the flame cannot be observed through the inspection door. The CB200-CTB must be adjusted with instruments for proper combustion. Obtain the above settings
by adjusting the air band 3/8" to 1/2". The metering pump will deliver a constant oil flow and set the
flame length accordingly.
6-5
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
6-6
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
SECTION 7: RESETTING THE OIL PRIMARY CONTROL
Understanding the Oil Primary Control (CB-200-CTB)
( See Appendix B for additional information )
The oil primary control will go into safety lockout and
shut the burner off when it detects flame-out during
burner operation. The following procedure explains
what should be done when this occurs.
It is very important that you follow these
instructions precisely when resetting the safety
on the primary control and restarting the burner.
AMBER LED
GREEN LED
RED LED
Resetting the Oil Primary Control
(CB-525-S2 Burner)
DANGER! DO NOT push the reset button
more than once! DO NOT push the reset
button if oil mist is present in the combustion chamber
or when the combustion chamber is hot! DO NOT
operate your boiler 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.
RESET BUTTON
T T F F
ALARM
AMB GRN
RED
CAD CELL
WIRES
WIRES RUN UNDER
SMALL CENTER GAP
C77008
Figure 7A - Oil Primary Control for CB-200-CTB
1. Refer to Figure 7A.
2. Check the combustion chamber for fuel mist by
shining a flashlight through the observation port.
If you see fog (fuel mist) in the chamber, DO NOT
push the reset button.
3. If the combustion chamber is hot, allow the
furnace to cool for at least 30 minutes. DO NOT
push the reset button.
4. When you are sure all mist has been cleared from
the chamber and the combustion chamber is cool,
depress the red button on the primary control for
2 seconds, then release. Reset the control ONCE
ONLY.
5. If the burner will not restart, call your Clean Burn
dealer immediately.
WARNING
Fire and explosion hazard.
Do NOT press reset button until
you read and understand Reset
Procedures in Operator's Manual.
42000 Rev. 2
ATTENTION: It is very important that
the "F" and "T" terminals of the Oil
Primary Control are wired exactly as
shown in Figure 7A.
NEVER connect jumper wires to these
terminals or severe damage may occur to
the Oil Primary Control.
7-1
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Understanding the Oil Primary Control (CB-350-CTB and CB-500-CTB)
( See Appendix B for additional information )
NOTE: This is a new control featuring the ability to activate a remote alarm in case of lock-out or
latch-up.
The oil primary control will go into safety lock-out and shut the burner off when it detects flame-out during burner
operation. The oil primary control will then wait approximately one minute 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. The following
procedure explains what should be done when this occurs. It is very
important that you follow these instructions precisely when resetting the safety on the primary control and
restarting the burner.
Resetting the Oil Primary Control (CB-551-H3 and CB-551-H5 Burners)
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 unit, improper operation
may result in a fire or explosion hazard.
Refer to Figure 7B.
Check the combustion chamber for fuel mist by shining a flashlight through the observation port.
If you see fog (fuel mist) in the chamber, DO NOT push the reset button.
If the combustion chamber is hot, allow the boiler to cool for at least 30 minutes. DO NOT
push the reset button.
When you are sure that all fuel mist has cleared and the boiler has cooled, push in and hold the
reset button for one second, then release. This will reset the control at any time during its operation.
WARNING
AMBER LED
GREEN LED
RED LED
ALARM
AMB GRN
RESET BUTTON
T T F F
1.
2.
3.
4.
Fire and explosion hazard.
Do NOT press reset button until
you read and understand Reset
Procedures in Operator's Manual.
42000 Rev. 2
RED
CAD CELL
WIRES
WIRES RUN UNDER
SMALL CENTER GAP
C77008
Figure 7B - Oil Primary Control For
CB-350-CTB and CB-500-CTB
7-2
ATTENTION: It is very
important that the "F" and
"T" terminals of the Oil
Primary Control are wired exactly
as shown in Figure 7B. NEVER
connect jumper wires to these
terminals or severe damage may
occur to the Oil Primary Control.
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Resetting the Oil Primary Control (continued)
5.
Set the load temperature controller to call for heat.
NOTE: Main power should be ON and all hand-operated oil line valves open. When the call
for heat is detected, the oil primary control will perform a 5 second self-test which is indicated
by a "solid on" amber LED. After the self-test, the amber LED will turn OFF, and the burner will
start.
6.
If flame is not established within 15 seconds (TFI-Try For Ignition), lock-out will occur.
Lock-out is indicated by a "solid on" red LED and closure of the alarm contacts (see NOTE
below). To reset the control, repeat step 4.
7.
Latch-up occurs if the control locks-out and is reset three times during a call for heat. Latch-up
is indicated by "solid on" red and amber LEDs.
8.
To reset the control from a latch-up condition:
9.
10.
11.
12.
WARNING: Only a qualified service technician should attempt to reset the control after
latch-up. The problem that caused the repeated burner lockouts must be corrected before
returning the burner to normal operation.
• Push in and hold the reset button for 10 seconds. The amber LED will begin to flash.
• After the LED begins flashing, continue holding the reset button for 20 seconds. The LEDs will
turn off. Release the reset button and the control will restart (releasing the button before the leds
turn off will cause the control to remain in latch-up)
NOTICE: The 50200 control will not reset from lockout or latch-up if power is interrupted.
When the load temperature controller opens, the burner motor turns off within 1.2 seconds.
If flame is lost during a normal run (after TFI), the burner motor turns off after 1.2 seconds. A
65-second recycle period begins, indicated by a blinking red LED. The control will restart
automatically after the recycle period.
Power loss during a normal run will cause the burner to safely shut down and begin a normal TFI
when power is restored.
If the burner will not restart at all (after having attempted oil primary control reset), contact your
Clean Burn dealer immediately.
NOTE: The oil primary control on the CB-551-H3 and CB-551-H5 Burners provides an extra set of dry contacts
to accommodate an externally-mounted horn, siren, bell, or other alarm device. The contacts close when the
control goes into either lock-out or latch-up mode. Because these are dry contacts, power must be supplied from
an external source. The contacts are rated for 24 VAC or DC at 2 amps.
7-3
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
7-4
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
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's are 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.
I88257
Figure 8A - Checking for Proper
Draft Over Fire
Severe backdraft will force heat back against the burner and result in heat damage to the cad cell and
transformer.
8-1
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
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 (voiding the
warranty). 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.
8-2
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
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.
2.
Use a draft gauge to check draft over fire.
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
8-4
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
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 Cleaning the canister filter Servicing the metering pump Cleaning the check valve/screen Cleaning water/sludge out of oil tank Cleaning out ash (CB-200-CTB)* Cleaning out ash (CB-350-CTB)* Cleaning out ash (CB-500-CTB)* Cleaning / Maintaining the Draft Inducer Checking boiler water condition Annual burner tune-up Interval
Before vacuum gauge reads 10" HG of vacuum
At least once a year
At least once a year
At least once a year
Approx. every 750 hrs. per burner hour meter
Approx. every 1000 hrs. per burner hour meter
Approx. every 1000 hrs. per burner hour meter
At least once a year
Periodically by qualified water treatment company
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.
9-1
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
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.
2.
3.
4.
5.
6.
7.
Close the ball valve adjacent to the filter.
Position a container under the filter.
Unscrew the four bolts, remove the canister bowl, and filter element. Now pour the oil intothe container.
Clean the filter element and the bowl in a parts washer.
Referring to Figure 9A, check the condition of the O-rings. Replace any that are cracked or worn.
Ensure that the canister filter is 100% airtight by firmly tightening the four bolts.
Open the ball valve. Refer to Sections 5 and 6 for instructions on priming the pump and starting
the burner.
FILTER HEAD
VACUUM/PRESURE GAUGE
INSTALL IN 1/8" PORT
ELEMENT "O" RING
(IN GROOVE ON TOP
OF FILTER ELEMENT)
FILTER
ELEMENT
BOWL "O" RING
FITS IN GROOVE
IN TOP OF CANISTER
BOWL
USE A RATCHET WRENCH WITH
A 6" EXTENSION AND 3/16" "ALLEN"
SOCKET TO REMOVE THE FOUR
"ALLEN" SCREWS
CANISTER BOWL
DRAIN PLUG
I88281-A
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
Servicing the Metering Pump
1.
2.
3.
4.
5.
6.
Refer to Figure 9B.
Remove the pump head cover (part 1).
Remove the screen (part 2) and wash it.
Remove and discard the used gasket (part 3).
Install a new gasket (Clean Burn Part #32422).
Replace the screen and pump head cover.
3
2
1
GA
UG
E
A2
PART No 32422
RA
INL
ET
RE
LIE
-7
F
72
RO
TAT
IO
0
PART No 32423
N
I88332-A
Figure 9B - Servicing the Metering Pump
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.
9-3
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
TO BURNER
METERING PUMP
FUNNEL WITH
BALL VALVE
EMERGENCY
VENT
CLEANOUT
VENT
CAP
SUCTION
OIL LINE
OIL STORAGE TANK
CHECK VALVE
CHECK VALVE SCREEN
12"
I88670-F
Figure 9C - Check Valve Detail
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. 1/8" of ash has the insulating
capacity of one inch of fiberglass insulation and reduces heat transfer significantly. Never allow more than 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.
9-4
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
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 ceramic sleeve from the combustion chamber, and remove the supporting stand.
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.
g. 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.
h. 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 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.
I88123-A
Figure 9D - Accessing the Combustion Chamber for Cleaning
9-5
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Cleaning the Ash (continued)
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 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. EPA 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.
Cleaning and Maintaining the Draft Inducer
The Draft Inducer will require periodic maintenance to ensure that the fan blades do not accumulate excessive ash
which can create vibration, noise, and motor wear.
1.
2.
3.
4.
Ensure that power has been turned OFF, and all "hot" components have been allowed to cool
sufficiently.
Disconnect the wires from the draft inducer and remove it from the stack penetration.
Clean the fan blades with a scraper and wire brush.
Oil the draft inducer motor according to the manufacturer's recommendations.
9-6
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
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 an ASME Section IV Boiler (i.e. 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 the following standards:
(1) Current Edition of American National Standard ANSI/NFPA 31, "Installation of Oil Burning
Equipment" for clearances between boiler, vent connector and combustible material.
(2) Current Edition of American National Standard ANSI/NFPA 211, "Chimneys, Fireplaces,
Vents, and Solid Fuel Burning Appliances" for chimney requirements, type of venting material
and clearances between vent connector pipe and combustible materials.
(3) Current Edition of American Society of Mechanical Engineers ASME CSD-1, "Controls and
Safety Devices for Automatically Fired Boilers" for assembly and operation of controls and safety
devices.
• 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.
10-1
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
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 GPM. 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 20 oF. Minimum operating temperature for the CTB is 180 oF. To avoid
condensation, the return water temperature should not fall below 140 oF.
Boiler Mixing Valve 140 oF
Provided with the boiler plumbing is a 140 oF Mixing Valve set up to blend cold water return from the system to
maintain a proper temperature (above 140 oF) for the “Non-condensing” design of the CTB. For optimal boiler
operation with the Mixing Valve, and when burning used oils, it is recommended to run the boiler “hot” (180 oF
to 200 oF). Therefore the operating aquastat setting should be no less than 180 oF. The high limit aquastat
factory recommended setting is 220-240 oF.
The 140 oF Mixing Valve must be installed according to Figure 10B or 10C and must be as close as possible to
the suction side of the boiler circulator. This allows the by-pass loop to function properly. When starting the
boiler from cold (room temperature) the boiler water temperature will be able to come up above 140 oF within 5
to 7 minutes (variance caused by unit settings and type of fuel). As the boiler temperature rises above 160 oF the
Mixing Valve will modulate and allow more system return water to be mixed into the boiler therefore supplying
more hot water to the zones.
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 12 PSI should be maintained on the system where the
boiler supply water temperature is 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 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.
10-2
PRIMARY
LOOP
OPTIONAL
HEAT EXCHANGER AND
CIRCULATOR MAY BE
REQUIRED IF ANTIFREEZE
IS USED IN THE RADIANT
FLOOR LOOP
RADIANT FLOOR LOOP
PURGING VALVE
10-3
NO MORE THAN 12" APART
CTB
BASEBOARD ZONE
SECONDARY LOOPS
COLD
SUPPLY WATER
DOMESTIC
HOT WATER
FILL
VALVE
PRIMARY LOOP
CIRCULATOR
COLD
WATER
PRIMARY/SECONDARY SYSTEM
WITH MULTIPLE OR SINGLE BOILERS
I88673
EXPANSION
TANK
AIR SEPARATOR
ENHANCED TYPE
ERGOMAX
INDIRECT
WATER
HEATER
Figure 10A - Sample Primary/Secondary Hydronic System Diagram
CB 350 CTB
CB 200 CTB
EXPANSION
TANK
3-WAY MIXING
OR TEMPERING
VALVE
HYDRONIC
UNIT HEATER
CONCEPTUAL SCHEMATIC:
THE DESIGNER MUST DETERMINE IF IT WILL
WORK WITHIN THE SYSTEM AND ENSURE
COMPLIANCE WITH EXISTING CODES
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
CTB System Function and Configuration (continued)
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 6" but not more than 12" apart.
This allows for circulators of different flow rates to be used in the same system while maintaining proper flow and
functioning.
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. The boiler
circulator must be installed according to Figures 10B and 10C, after the mixing valve. 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 various 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
CONCEPTUAL SCHEMATIC:
WILL WORK WITHIN THE SYSTEM AND
ENSURE COMPLIANCE WITH EXISTING CODES
THE DESIGNER MUST DETERMINE IF THIS SYSTEM
LOW WATER
CUT-OFF
10-5
FILL VALVE
AIR SEPARATOR
ENHANCED TYPE
AIR ELIMINATOR
COLD
WATER
Figure 10B - CTB with Additional Larger Storage Tank
USER SUPPLIED BOILER CIRCULATOR
PURGE VALVE
ISOLATION VALVE
(BOILER WATER)
STORAGE
TANK
I88676-B
SYSTEM
SUPPLY
SYSTEM SUPPLY
CIRCULATOR
SYSTEM
RETURN
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
CONCEPTUAL SCHEMATIC:
ENSURE COMPLIANCE WITH EXISTING CODES
WILL WORK WITHIN THE SYSTEM AND
THE DESIGNER MUST DETERMINE IF THIS SYSTEM
LOW WATER
CUT-OFF
10-6
FILL VALVE
AIR SEPARATOR
ENHANCED TYPE
AIR ELIMINATOR
COLD
WATER
Figure 10C - CTB with Ergomax Indirect Water Heater
USER SUPPLIED BOILER CIRCULATOR
PURGE VALVE
ISOLATION VALVE
ERGOMAX
HEAT EXCHANGER
WATER HEATER
I88674-B
WATER
INLET
HOT WATER
OUTLET
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
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 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 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 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 180 oF to de-aerate the water.
10-7
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
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 180 oF to de-aerate the water.
Guidelines for CTB Operation
After proper and safe CTB burner 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 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
SECTION 11: 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 charts. Each table lists a Problem, Possible Cause, and Possible
Action(s) to fix the problem.
11-1
11-2
Boiler loop circulator continues to run
to drive latent heat from the CTB.
Air sensing switch
receives power from
centrifugal switch.
The Delay Relay keeps the boiler loop
circulator operating approximately ten
minutes after the call for heat is satisfied.
BOILER COOL DOWN SEQUENCE
Hot water delivered
to heated area.
BOILER HEATING SEQUENCE
Centrifugal switch closes and
sends power to air sensing
switch.
INITIAL START-UP
Combustion air band adjusted
for proper combustion air.
Air sensing switch closes
as it receives more than
10 psi of air pressure.
BURNER IGNITION SEQUENCE
Boiler loop circulator
stops running.
Delay Relay
and the Boiler
Loop Circulator
are energized
Primary control relay
opens and the burner
shuts off.
Burner continues to run
until the wall thermostat
or aquastat is satisfied.
Oil primary control
receives <500 ohm signal
from cad cell indicating
proper ignition.
Burner ignites.
Oil primary control relay closes.
Burner ignition sequence begins.
Oil primary control checks for
2000+ ohms from cad cell
indicating dark in the combustion
chamber (NO FLAME)
Flow Swith
closes
T-T circuit on
the oil primary
control is closed
DPDT Relay
is energized
FLOW CHART
200/350/500 CTB
120 V / 60 Hz
Wall thermostat or
aquastat calls for heat.
Wall thermostat or aquastat is satisfied
and DPDT relay circuit opens.
Hour meter starts.
Yellow indicator
light ON.
Pump circuit starts
oil pump.
Pump circuit opens
oil solenoid.
F120 proving switch remains closed and oil
primary control receives power when the flow
switch closes.
NORMAL BURNER OPERATION
Preheater thermostat cycles block
heater element and maintains block
temperature.
When block temperature reaches 120 °F , the
F120 proving switch closes which will allow
power to be sent to the oil primary control.
INITIAL START-UP
BURNER PRE-IGNITION SEQUENCE
Preheater thermostat activates block
heater element and heats the block.
INITIAL START-UP
Air regulator adjusted to
proper psi of air pressure.
Operating Aquastat senses water
temperature rise as the burner fires.
Burner motor starts and
reaches full rpm.
Air solenoid
opens.
14,000 volt igniter starts,
providing interrupted
ignition (approx. 45 sec.
of spark at electrode gap)
Green indicator
light ON.
Burner cable
plugged in.
Main power ON
sending power to
centrifugal switch
and low water
cut-off
I88963-A
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
PROBLEM
POSSIBLE CAUSE(S)
POSSIBLE ACTION(S)
Burner won’t run at all and
Green power light is NOT ON.
1. Circuit breaker/main switch open.
2. Fuse/breaker blown.
1. Close circuit breaker/switch.
2. Electrician should check out
electrical system.
3. Check burner cable.
3. Burner cable is damaged or not
plugged in properly.
Burner won’t run at all and
Green power light is ON.
1. Oil primary control has shut down
on safety reset.
2. Wall thermostat is not operating.
3. Heater block is not heating up.
4. F-120 proving switch has not
closed.
5. Oil primary control terminals are
not wired correctly.
6. Oil primary control is damaged.
7. The flow switch, operating
aquastat, or high limit switch has
opened.
11-3
1. Follow the directions in Section 7
to reset the oil primary control.
2. Check the wall thermostat and
thermostat cable.
3. Feel the back of the burner; it
should be 140 degrees F. If the
heater block is NOT HOT: (a) Wait
15 minutes for the heater block
to heat up and re-check the back
of the burner, and (b) Check the
block heater thermostat and block
heater element. Refer to the wiring
diagram and ladder schematic in
Appendix B.
4. If the block is HOT: (a) Check
the red wire at the F-120 proving
switch for power. If there is NO
power at the red wire, refer to
the wiring diagram and ladder
schematic in Appendix B to
troubleshoot the circuit that
provides power to the proving
switch. (b) If there is power at the
red wire at the proving switch,
check for power at the black wire.
If there is NO power at the black
wire, replace the F-120 proving
switch.
5. Check the oil primary control:
(a) Check that the “F” terminals
are NOT jumped. (b) Check that
the two yellow cad cell wires are
connected to the “F” terminals.
(c) Check that the two thermostat
wires are connected to the “T”
terminals.
6. Replace oil primary control: (a)
Check voltage – it must be 115
volts.
7. Test the switches for power. Note
that power should be indicated on
both sides of the switch.
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
PROBLEM
POSSIBLE CAUSE(S)
Burner ignites, but will not stay
1. There is a fuel delivery problem.
running and Burner shuts off on reset
within 15 seconds.
2. The cad cell is dirty.
3. Cad cell wires are loose.
4. Cad cell / cad cell wires are
damaged.
5. The primary control is not
receiving the proper ohm signal
from the cad cell.
POSSIBLE ACTION(S)
1. Follow the procedures listed in the
next problem.
2. Clean and check the condition of
the cad cell and cad cell wires.
3. Check that the yellow wires are
connected properly at the “F”
terminals on the oil primary
control.
4. Replace the cad cell and cad
cell wires. If the cad cell is heat
damaged: (a) Clean your boiler,
including the combustion
chamber, flues and stack. Refer
to instructions in Section 9. (b)
Check for backdraft caused by
exhaust fans in your building.
Follow instructions in Section 8.
5. Disconnect the yellow wires from
the “F” terminals. Start the burner
and check the ohm reading from
the cad cell. You have 10 seconds
to perform this test before the
burner shuts off on reset. Refer to
Section 7 to reset the oil primary
control. If the ohm reading is
above 500 ohms: (a) Check the
position of the cad cell; the cad
cell must “look” straight through
the central hole in the retention
head. (b) Check the position of
the retention head according to
Appendix A.
Burner ignites and runs properly,
1. There is air in the suction oil line
1. Follow the procedures in Section 5
but the burner shuts off on reset
due to leaks at the fittings
to vacuum test the pump. Reinstall
periodically (e.g. the burner goes off
and properly seal the suction line
on reset during the night and requires
fittings to eliminate air leaks.
resetting in the morning).
2. There is air trapped in a high point 2. Follow instructions in Section 4
in the pressure oil line.
to bleed the air out of the pressure
oil line.
11-4
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
PROBLEM
POSSIBLE CAUSE(S)
POSSIBLE ACTION(S)
Burner ignites and Burner shuts off
on reset sometime later during the
day or night.
1. There is air in the fuel supply.
1. Prime the pump. If the pump
will not prime or there is air in
the oil stream from the pump
bleeder, follow the steps in the next
problem (“Pump will not prime.”)
2. Check for proper ohm signal.
Follow the procedures in the
previous problem (top, page 11-4
3. Follow the instructions in Section
5 to adjust the air regulator for
proper air pressure. DO NOT turn
the air compressor off while the
boiler is operating. If you turn the
air compressor off at night, turn
the wall thermostat or aquastat
OFF so the burner will not run.
4. DO NOT shut off power to the
boiler overnight, or the heater
block will cool down, and the
burner will not re-start the next
morning. To turn the boiler “off ”
overnight, turn the wall thermostat
or aquastat OFF. The heater block
will stay hot.
5. If oil residues have built up on
the electrodes and retention head,
follow the instructions in Section 8
to check for proper draft over fire.
Clean the electrodes and retention
head.
2. The primary control is not
receiving the proper ohm signal
from the cad cell.
3. There is insufficient air pressure.
4. The heater block is cold.
5. The electrodes are fouled.
11-5
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
PROBLEM
POSSIBLE CAUSE(S)
Pump will not prime and Pump
motor is running.
1. There is a leak(s) in the suction
line.
2.
3.
4.
5.
6.
7.
8.
POSSIBLE ACTION(S)
1. Follow the specifications in Section
4 to make sure the suction line
is installed properly and that all
fittings are 100% airtight.
The pump is not installed so it will 2. Make sure the pump head is filled
with oil prior to starting the pump.
fill with oil during the priming
See Section 5.
process.
3. Follow the procedure in Section
The pump gears are dry.
5 to fill the oil line and prime the
pump.
4. With the pump not running, wipe
The pump seal is damaged.
your finger along the bottom of the
cylinder at the pump shaft. If there
is oil at the pump shaft, the seal is
damaged. Replace the pump, or
replace the seal.
NOTE: Some oils will expand as
they warm up. Because there is
a check valve in the suction line,
the expanding oil may build up
pressure and damage the oil seal.
Install a mini-accumulator in the
1/8” port of the canister filter to
prevent the pressure build-up.
5. Open the ball valve on the suction
The ball valve is closed.
line.
6. Refer to Section 9 to clean the
The canister filter is dirty.
canister filter.
7. Refer to Section 9 to clean the
The check valve is dirty.
check valve.
The pump is damaged or worn out. 8. Replace the pump.
11-6
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
PROBLEM
POSSIBLE CAUSE(S)
POSSIBLE ACTION(S)
Pump will not prime and Pump
motor is
NOT running.
1. There is NO power on the pump
circuit from the burner.
1. Start the burner and adjust the
air pressure regulator to 15 PSI.
(a) If the amber “pump” light on
the burner comes ON, the pump
circuit on the burner has activated
properly. Refer to the wiring
diagram and ladder schematic in
Appendix B to troubleshoot the
pump circuit from the burner to
the pump. (b) If the amber “pump”
light on the burner does NOT
come ON, there is a problem with
pump circuit in the burner. With
the burner running, check for
power at the brown wire on the
air pressure switch. If there is NO
power at the brown wire, replace
the burner motor. If there is power
at the brown wire, replace the air
sensing switch.
2. (a) The pump motor is too hot
the internal thermal protection
switch shut the motor off. Wait
for the motor to cool down; the
thermal switch will automatically
reset. Check voltage and amperage
draw of the pump motor. Call
your dealer if the problem persists.
(b) The coupling is not adjusted
properly, keeping the shafts of the
motor and pump from turning
freely. Re-position the coupling so
that both shafts turn freely. (c) The
shaft on the motor or oil pump will
not turn freely. If you can’t turn the
shafts, replace the faulty part(s).
2. The pump motor has shut offon
thermal overload.
11-7
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
11-8
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
APPENDIX A
Detailed Coil Tube Boiler Specifications
CTB Technical Specifications
Model
BTUH Input
Listed Fuels:
• #2 Fuel Oil
• Used Crankcase Oil
• Used ATF
• Used Hydraulic Oil
• #4, #5 Fuel Oils
Water Volume
(gallons)
Cabinet Dimensions
(LxWxH)
Overall Length
(with burner/breach)
Approximate Weight
Mounting
Electrical Requirements
(VAC @ 60 Hz)
Circuit Breaker
Approximate Amp Draw
Max. Oil Consumption
Oil Pump
Oil Pump Motor
Pump Motor Rotation
Canister Filter
Stack Size
Approx. Air Compressor
Requirements
CB-200-CTB
CB-350-CTB
CB-500-CTB
200,000*
350,000*
500,000*
1.4
2.5
3.57
5 gal.
12 gal.
20.6 gal.
40 x 29 x 29.5”
56 x 34 x 34.5”
66.38 x 40 x 42”
59”
74”
86.13”
677 lbs. (dry)
1240 lbs. (dry)
1600 lbs. (dry)
Non-Combustible
Floor
115
Non-Combustible
Floor
115
Non-Combustible
Floor
115
15 amps**
20 amps**
20 amps**
9
10
12
1.4 GPH
2.5 GPH
3.57 GPH
Suntec
A2RA-7720
Bison Gear Motor
1/20 HP
CCW shaft end
Suntec
A2RA-7720
Bison Gear Motor
1/20 HP
CCW shaft end
Suntec
A2RA-7720
Bison Gear Motor
1/20 HP
CCW shaft end
Lenz
DH 750-100
8”
Lenz
DH 750-100
8”
Lenz
DH 750-100
10”
2.0 CFM
@ 25 PSI
2.5 CFM
@ 25 PSI
2.5 CFM
@ 25 PSI
*Nominal values; actual values will vary depending on installation.
** With optional accessories, 30 amps may be required.
A-1
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Burner Technical Specifications
Model
CB-200-CTB
CB-350-CTB
CB-500-CTB
Burner
CB-525-S2
CB-551-H3
CB-551-H5
Ignition Transformer
Carlin
14,000 Volts
Carlin
14,000 Volts
Carlin
14,000 Volts
Nozzle
Delavan 9-5
Delavan 9-5
Delavan 9-28
1/10 HP 3000 rpm
w/ Centrifugal Switch)
1/10 HP 3000 rpm
w/ Centrifugal Switch)
1/10 HP 3000 rpm
w/ Centrifugal Switch)
CCW shaft end
CCW shaft end
CCW shaft end
2.0 CFM
@25 PSI
2.5 CFM
@25 PSI
2.5 CFM
@25 PSI
Carlin Oil
Primary 402
w/ Interrupted Ignition)
Carlin Oil
Primary 502
w/ Interrupted Ignition)
Carlin Oil
Primary 502
w/ Interrupted Ignition)
Heater Element in
Preheater Block
400 Watts
400 Watts
500 Watts
Air Pressure Switch
MPL 808
MPL 808
MPL 808
Heater Thermostat
140 oF
140 oF
160 oF
Burner Motor
Burner Motor Rotation
Compressed Air
Requirements
Oil Primary Control
CB-200-CTB Hydronic Specifications
NOTE: These specifications apply for each CTB unit or coil.
• Water flow through the boiler: • Coil Dry Weight: 189 lbs.
15 GPM at 20 -22 ft. of head (pressure)
• System operating pressure: 12 to 22 psi
•20 oF temperature rise (DT)
• Standard relief valve setting: 30 psi
• ASME coil length: 112 ft. long, 1" diameter steel • Relief valve capacity: 550 MBH
tubing made to Sch. 40 pipe size
• Heating surface: 38.7 sq. ft.
• Coil Volume: 5 Gallons
• Factory Recommended Boiler Circulator:
TACO 0011
CB-350-CTB Hydronic Specifications
NOTE: These specifications apply for each CTB unit or coil.
• Water flow through the boiler:
•
25 GPM at 18-20 ft. of head (pressure)
•
•20 oF temperature rise (DT)
•
• ASME coil length: 158 ft. long, 1-1/4" diameter
•
steel tubing made to Sch. 40 pipe size
•
• Coil Volume: 12.3 Gallons
•
Coil Dry Weight: 359 lbs.
System operating pressure: 12 to 22 psi
Standard relief valve setting: 30 psi
Relief valve capacity: 710 MBH
Heating surface: 68 sq. ft.
Factory Recommended Boiler Circulator:
B&G PL36
B&G PL55 (over 20 ft. of head)
NOTE: These specifications apply for each CTB unit or coil.
• Water flow through the boiler:
•
37 GPM at 22 ft. of head (pressure)
•
•20 oF temperature rise (DT)
•
• ASME coil length: 195 ft. long, 1-1/2" diameter
•
steel tubing made to Sch. 40 pipe size
•
• Coil Volume: 20.63 Gallons
•
Coil Dry Weight: 530 lbs.
System operating pressure: 12 to 22 psi
Standard relief valve setting: 30 psi
Relief valve capacity: 970 MBH
Heating surface: 97 sq. ft.
Factory Recommended Boiler Circulator:
TACO 2400-50/2
CB-500-CTB Hydronic Specifications
A-2
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
CTB Accessories and Parts Reference
C.B. Part #
Description
500-CTB 350-CTB 200-CTB
11578 90187 90199
Boiler Stacking Adapter Kit
90206 90188 90200
Boiler Stand (base)
11095
Circulator, TACO 0011, 115VAC
35078
Circulator, B&G PL-36, 115VAC
35112
Circulator, B&G PL-55, 115VAC
35130
Circulator, TACO 2400-50/2 115VAC
35080 35080
B&G Circulator Flange Gasket O-Ring
35134
TACO Circulator 500 Flange Gasket O-Ring
35116
Flange, 1" NPT
35061
Flange, 1-1/2 NPT
35079 35079
Flange, 1-1/4 NPT
35120
TACO Flange, 500 2" NPT Set
35121
TACO Flange, 500 1-1/2" NPT Set
35053 35053
Flange Gasket, 3-hole
35125
500 Flange Gasket, 3-hole
28150 28150 28150
Operating Aquastat, L4006A
35110 35110 35110
Electronic Low Water Cut-Off with Probe, 750P-MT-120
35111 35111 35111
Probe (only) for Low Water Cut-Off
28149 28149 28149
High Temperature Cut-off, L4006H
35123 35123 35123
Taco Flow Switch (without paddle)
35124 35124 35124
Stainless Steel Paddle for Taco Flow Switch (sized to fit)
35117
Stainless Steel Paddle for M&M Flow Switch (sized to fit)
333303333033330
Temp-Pressure Boiler Gauge
35136 35135 35048
Relief Valve, 30 PSI
35049 35049 35049
Well Immersion, 3/4" NPT
Ergomax Indirect Water Heater (Heat Exchangers)*
*Contact the CB Parts/Service Department for help in specifying the appropriate model.
35113 E23
35096 E24
35097 E44
35098 E45
35099 E65
35100 E109
35107
35108
Air Separator, EAS - 1-1/2 Air Separator, EAS -2 Remote Temperature Controls
33557 Wall Thermostat
A-3
(1-1/2" piping with air vent)
(2" piping with air vent)
A-4
*
2.75
29.25
* 7.5 OR 11.75 LEG LENGTH
29
8.0
AIR
4.0
OIL
SUPPLY
1-1/4 NPT
BOTH SIDES
36
5.75
5.12
FRONT
SERVICE
CLEARANCE
48
12.5
AIR & OIL
CONNECTOR
BLOCK
CONTROL BOX
(ELECTRICAL
CONNECTION)
20
19.25
USER SUPPLIED
BOILER LOOP
CIRCULATOR
39.5
OPERATING
AQUASTAT
TEMP/PRESSURE
GAUGE
W/RESET
HIGH LIMIT
40
REAR
SERVICE
CLEARANCE
I88846-D
5.5
4.8
FLUE
COLLAR
8" DIA.
RELIEF
VALVE
FLOW SWITCH
RETURN
1-1/4 NPT
LOW WATER
CUT-OFF
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
CTB Dimensions
Figure A1 - Model CB-200-CTB Dimensions (Single Boiler)
A-5
34.25
* 7.5 OR 11.75 LEG LENGTH
I88677-C
*
34.5
6.5
AIR
OIL
SUPPLY
1-1/2 NPT
5
BOTH SIDES
5
36
6.0
FRONT
SERVICE
CLEARANCE
48
12.5
AIR & OIL
CONNECTOR
BLOCK
CONTROL BOX
(ELECTRICAL
CONNECTION)
21.50
USER SUPPLIED
BOILER LOOP
CIRCULATOR
34.75
OPERATING
AQUASTAT
TEMP/PRESSURE
GAUGE
56
LOW WATER
CUT-OFF
RETURN
FLANGE SET
1-1/2 NPT
5.5
REAR
SERVICE
CLEARANCE
40
5.0
W/RESET
HIGH LIMIT
FLUE
COLLAR
8" DIA.
RELIEF
VALVE
FLOW SWITCH
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
CTB Dimensions
Figure A2 - Model CB-350-CTB Dimensions (Single Boiler)
A-6
34.25
AIR
Figure A4 - Dual-Stacked Boiler Dimensions (Two CB-350-CTB Boilers)
I88678-C
* USE ONLY 7.5" LEG LENGTH WHEN
STACKING BOILERS
*7.5
79.50
AIR
OIL
OIL
SUPPLY
1-1/2 NPT
5
5
BOTH SIDES
36
13.5
48.5
SUPPLY
1-1/2 NPT
86.0
FRONT
SERVICE
CLEARANCE
48
12.5
AIR & OIL
CONNECTOR
BLOCK
CONTROL BOX
(ELECTRICAL
CONNECTION)
21.50
34.75
USER SUPPLIED
BOILER LOOP
CIRCULATOR
OPERATING
AQUASTAT
USER SUPPLIED
BOILER LOOP
CIRCULATOR
OPERATING
AQUASTAT
TEMP/PRESSURE
GAUGE
LOW WATER
CUT-OFF
56
RETURN
FLANGE SET
1-1/2 NPT
RETURN
FLANGE SET
1-1/2 NPT
RELIEF
VALVE
FLOW SWITCH
40
12
REAR
SERVICE
CLEARANCE
5.5
FLUE
COLLAR
8" DIA.
48
W/RESET
HIGH LIMIT
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
CTB Dimensions
A-7
Figure A3 - Model CB-500-CTB Dimensions
3
39.75
AIR
OIL
* 7.5 OR 11.75 LEG LENGTH
FOR A 7.8 OR 12.1 STAND HEIGHT
I88967-C
*
41.75
6.1
36
7.75
BOTH SIDES
10.25
3.75
6
SUPPLY
2" NPT
FRONT
SERVICE
CLEARANCE
48
12.5
AIR & OIL
CONNECTOR
BLOCK
CONTROL BOX
(ELECTRICAL
CONNECTION)
23
16.1
44.5
USER SUPPLIED
BOILER LOOP
CIRCULATOR
OPERATING
AQUASTAT
TEMP/PRESSURE
GAUGE
66.5
LOW WATER
CUT-OFF
RETURN
FLANGE SET
2" NPT
W/RESET
HIGH LIMIT
6.75
40
REAR
SERVICE
CLEARANCE
6.44
FLUE
COLLAR
10" DIA.
RELIEF
VALVE
FLOW SWITCH
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
CTB Dimensions
A-8
39.75
AIR
AIR
Figure A4 - Dual-Stacked Boiler Dimensions (Two CB-500-CTB Boilers)
I88979-B
* USE ONLY 7.5" LEG LENGTH WHEN
STACKING BOILERS
*7.8
94.75
3
OIL
OIL
SUPPLY
2 NPT
10.25
3.75
BOTH SIDES
36
15.5
60.75
SUPPLY
2 NPT
101
FRONT
SERVICE
CLEARANCE
48
12.5
AIR & OIL
CONNECTOR
BLOCK
CONTROL BOX
(ELECTRICAL
CONNECTION)
23
44.5
USER SUPPLIED
BOILER LOOP
CIRCULATOR
OPERATING
AQUASTAT
USER SUPPLIED
BOILER LOOP
CIRCULATOR
OPERATING
AQUASTAT
TEMP/PRESSURE
GAUGE
66.5
LOW WATER
CUT-OFF
RETURN
FLANGE SET
2" NPT
RETURN
FLANGE SET
2" NPT
RELIEF
VALVE
FLOW SWITCH
40
12
REAR
SERVICE
CLEARANCE
6.75
59.75
FLUE
COLLAR
10" DIA.
W/RESET
HIGH LIMIT
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
CTB Dimensions
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
A-9
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Single Boiler Assembly
DETAIL OF ITEM 24
1
2
33
CB-350-CTB
SHOWN
5
32
9
6
31
4
10
27
30
28
8
29
26
23
25
22
7
24
21
14
20
19
3
18
17
13
16
12
15
11
(USER
SUPPLIED)
34
(option)
I88121-F
Figure A5 - Single Boiler Assembly Component Detail
A-10
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
NUMBER
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
NO
34
22
21
20
14
13
12
11
9
4
2
1
QTY
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
CB-350-CTB PARTS LIST
PART #
DESCRIPTION
90188
BASE
33331
TERMINAL BLOCK
33327
TRANSFORMER 120V-24V
33328
RELAY DPDT
33352
RELAY DELAY
33486
TERMINAL BLOCK ASSEMBLY
33286
SWITCH DPDT
33168
AMBER LIGHT
27058
CONTROL BOX LID
12240
CONTROL BOX 120 AC
33105
SNAP IN BUSHING
27158
L-BRACKET
33546
CONNECTOR CORD
31176
INSULATION – DOOR
11405
DOOR W.A.
21077
PORT LID
14084
ROPE GASKET
11583
BURNER MOUNT W.A.
11582
HINGE BRACKET W.A.
13141
ACCUMULATOR BLOCK ASSEMBLY
14272
UPPER PIPE ASSEMBLY
35061
1-1/2” FLANGE
35078
CIRCULATOR PL36 115V 60Hz
14293
CHECK VALVE AND PIPE ASSEMBLY
13110
LOW WATER CUT-OFF
14274
LOW WATER PIPE ASSEMBLY
33330
GUAGE BOILER TEMP/PRESS
35048
RELIEF VALVE 3/4” MALE
35123
FLOW SWITCH TACO
28149
HIGH TEMP CUT-OFF
35079
COIL FLANGE 1-1/4”
28150
AQUASTAT
31166
INSULATION PANEL
11380
PANEL 350 REAR W.A.
PARTS THAT DIFFER ON THE CB-200-CTB
QTY PART # DESCRIPTION
1
90200 BASE
1
33508 CONNECTOR CORD
1
31216 INSULATION 200 DOOR
1
11540 DOOR W.A.
1
14300 UPPER PIPE ASSEMBLY
1
35079 1-1/4” FLANGE
1
11095 CIRCULATOR TACO 0011 115 V
1
14298 CHECK VALVE AND PIPE ASSY
1
14299 LOW WATER PIPE ASSEMBLY
1
35116 COIL FLANGE 1” NPT
1
31215 INSULATION PANEL
1
11539 PANEL 200 REAR W.A.
NO
34
22
21
20
14
13
12
11
9
4
2
1
PARTS THAT DIFFER ON THE CB-500-CTB
QTY PART # DESCRIPTION
1
90206 BASE
1
33546 CONNECTOR CORD
1
31240 INSULATION 500 DOOR
1
11564 DOOR W.A.
1
14315 UPPER PIPE ASSEMBLY
1
35120 FLANGE 2” SET
1
35130 CIRCULATOR TACO 2400-50/2 115V
1
14314 CHECK VALVE AND PIPE ASSY
1
14313 LOW WATER PIPE ASSEMBLY
1
35121 FLANGE 1-1/2” SET
1
31239 INSULATION PANEL
1
11563 PANEL 500 REAR W.A.
200-CTB350-CTB500-CTB
Refractory Cylinder
Refractory Cylinder Stand
21120
27155
A-11
21140
27190
21174
27200
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Burner Components CB-200-CTB
26
24
4
3
22
23
SEE ILLUSTRATION
I88543 FOR PART
NUMBERS
5
21
1
25
2
170
20
160
150
130
120
110
140
1
2
4
5
6
7
8
9
10
11
12
13
6
19
7
5
4
6
3
7
8
OIL
2
9
18
10
11
12
1
0
psi
13
14
15
8
20
30
AIR
10
40
0
50
psi
60
9
10
11
12
13
17
14
15
BURNER CB - 525 - S2
16
I88234-C
Figure A6 - CB-525-S2 Burner Component Detail (CB-200-CTB)
A-12
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Burner Components CB-200-CTB((continued)
Item# Clean Burn Part# Component Description
1
26103
AIR INTAKE OUTER PLATE
2
11359
AIR INTAKE INNER PLATE
3
33400
CARLIN PRIMARY CONTROL (W/ INTERRUPTED IGNITION)
4
33335
ISOLATOR (OPTIONAL)
5
33189
CARLIN IGNITER (TRANSFORMER)
6
33116
CAD CELL
711243TRANSFORMER PLATE
8
32178
OIL GAUGE 0-15 PSI
9
32235
FEMALE ELBOW (3/16 T x 1/8 NPT)
10
32179
AIR GAUGE 0-60 PSI
11
32253
FEMALE ELBOW (1/8 TP x 1/8 NPT)
12
33297
HOUR METER (60 Hz)
13
33169
GREEN LIGHT (POWER)
14
33168
AMBER LIGHT (PUMP)
15
31113
FAN SQUIRREL CAGE
16
26044
MOTOR MOUNT PLATE
17
33175
BLOWER MOTOR
18
26053
RIGHT SIDE COVER
19
11335
HOUSING (INCLUDES ITEM 23)
20
13148
HEATER BLOCK ASSEMBLY
21
11265
COVER-HINGED
22
SEE NOTE
NOZZLE ADAPTER ASSEMBLY
23
11334
HINGE MOUNTING PLATE
24
33149
CONNECTOR RECEPTACLE
25
33508
CONNECTOR CORD (CB-200-CTB)
26
26052
LATCH BRACKET
27
11308
RETENTION HEAD
A-13
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Burner Components CB-350-CTB
24
4
3
22
26
23
SEE ILLUSTRATION
I88543 FOR PARTS
NUMBER.
5
21
1
25
2
170
20
160
150
130
120
110
140
1
2
4
5
6
7
8
9
10
11
12
13
6
19
7
5
4
6
3
7
8
OIL
2
9
18
10
11
12
1
0
psi
13
14
15
8
20
30
AIR
10
0
40
50
psi
60
9
10
11
12
13
17
14
15
16
BURNER
CB - 551 - H3
I88239-B
Figure A7 - CB-551-H3 Burner Component Detail (CB-350-CTB)
A-14
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Burner Components CB-350-CTB (continued)
Item# C. B. Part# Component Description
1 26103 Air Intake Outer Plate
2 11359 Air Intake Inner Plate
3 33610 Electronic Primary Control (w/ Interrupted Ignition)
4 33189 Carlin Igniter (Transformer)
5 33116 Cad Cell
6 11243 Transformer Plate
7 32178 Oil Gauge, 0-15 psi
8 32235 Female Elbow, 3/16T x 1/8 NPT
9 32179 Air Gauge, 0-60 psi
10 32253 Female Elbow, 1/8TP x 1/8 NPT
11 33297 Hour Meter, 60 Hz
12 33169 Green Light (Power)
13 33168 Amber Light (Pump)
1431113Fan Squirrel Cage
15 26044 Motor Mounting Plate
16 33175 Blower Motor
17 14085 Right Side Cover
18 11335 Housing (includes item 23)
1913148Heater Block Assembly
20 11265 Cover, Hinged
21 SEE NOTE Nozzle Adapter Assembly
2211334Hinged Mounting Plate
2314088Connector Receptacle
24 33546 Connector Cord (CB-350/500 CTB)
25 26052 Latch Bracket
26 11376 Retention Head
A-15
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Burner Components (continued)
30
(8)
31
58
57
32
(8)
56
1
3
9
34
35
59
52
36
51
37
27
39
12
6
(4) 17
41
46
26
(2)
10
45
40
48
(2)
29
38
60
49
11
7
54
50
5
8
33
53
4
2
55
42
43
28
25
44
0
17
0
16
0
15
0
0
0
13
0
12
11
14
47
15
14
1
2
3
4
5
6
7
46
13
24
8
9
10
11
12
13
16
19
17
18
21 (2)
23
20
22
Figure A8 - Preheater Block and Electrode Assembly Component Detail
CB-525-S2 and CB-551-H3 Burners (CB-200-CTB and CB-350-CTB)
A-16
I88543-A
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Item# C.B. Part# Qty. Component Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60*
34169
33183
34165
32000
13150
32007
33298
33381
33418
32199
32050
32189
32043
54020
32201
33247
34036
26059
33057
26090
32190
32202
32201
33173
33041
32325
54020
33011
32359
14090
34148
34114
34147
34022
32306
32226
32364
32227
32360
32361
32223
32222
32221
32362
13142
32308
32309
33311
33312
33313
33314
33315
33316
33317
33318
33319
33320
33321
32322
26107
1
1
1
1
1
1
1
1
1
1
2
2
1
1
2
1
4
1
1
1
2
1
1
1
1
1
1
1
1
1
8
8
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
1
ELECTRODE SCREW - 10-32 x 3/4
SINGLE PIECE ELECTRODE
WASHER
9 - 5 NOZZLE
NOZZLE ADAPTOR
PLUG - 1/8 NPT
140 WATTS HEATER
INSULATED CAP CRIMP CONNECTOR
THERMOSTAT L-130
PLUG - 1/16 NPT
SWIVEL FITTING
HEX NIPPLE - 1/8 NPT x 1-1/2
MALE CONNECTOR - 3/16T x 1/8 NPT
3/16 COPPER TUBING(OIL GAUGE LINE)
MACH. SCREW PHILLIPS HD. 6-32 x 3/8 Z
TERMINAL BLOCK
MACH. SCREW PHILLIPS HD. 6-32 x 1/4 Z
TERMINAL BLOCK BRACKET
AIR PRESSURE SWITCH
HEATER BLOCK
HEX NIPPLE - 1/8 NPT x 2
FEMALE ELBOW (FOR 1/4" AIR LINE)
FEMALE ELBOW (FOR 3/8" OIL LINE)
PRE-HEATER ELEMENT - 400 WATTS
PROVING SWITCH (NORMALLY OPEN)
MALE ELBOW 1/8 x 1/8 NPT (FOR AIR GAUGE LINE)
3/16 COPPER TUBING(OIL GAUGE LINE)
HEATER BLOCK THERMOSTAT(NORMALLY CLOSED)
REGULATOR SURFACE MOUNT
REGULATOR LOCK PLATE
REGULATOR MOUNTING SCREW
LOCK WASHER #8 Z
REGULATOR THREADED STEM
HEX NU T - 10-32 Z
BONNET
DIAPHRAM RING
CAP AND BALL ASSEMBLY
COMPRESSION SPRING
DIAPHRAM
BRASS POPPET SEAT
POPPET ‘O” RING
POPPET VALVE
POPPET SPRING
BASE
REGULATOR KIT COMPONENTS
REGULATOR OUTER “O” RING
REGULATOR INNER “O” RING
SOLENOID INNER “O” RING
SOLENOID OUTER “O” RING
MANIFOLD MOUNT SOLENOID BODY
BODY “O” RING
PLUNGER ASSEMBLY
PLUNGER GUIDE ASSEMBLY
FLUX PLATE
WASHER SEAL
COIL
COIL HOUSING
NUT
AIR/OIL SOLENOID ASSEMBLY
REG. SQUARE CAP*
*NOTE: When the CTB is used with a metering pump, the oil regulator must be removed from the burner and replaced with the square
cap.
A-17
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Burner Components CB-500-CTB
24
4
3
22
26
23
SEE ILLUSTRATION
I88975 FOR PART
NUMBERS
5
21
27
1
25
2
170
20
160
150
130
120
110
140
1
2
4
5
6
7
8
9
10
11
12
13
6
19
7
5
4
6
3
7
8
OIL
2
9
18
10
11
12
1
0
psi
13
14
15
8
20
30
AIR
10
0
40
50
psi
60
9
10
12
13
17
11
14
15
16
BURNER
CB - 551 - H5
I88969-B
Figure A9 - CB-551-H5 Burner Component Detail (CB-500-CTB)
A-18
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Burner Components CB-500-CTB (continued)
Item# C. B. Part# Component Description
1 11585 Air Intake Outer Plate
2 11584 Air Intake Inner Plate
3 33610 Electronic Primary Control (w/ Interrupted Ignition)
4 33189 Carlin Igniter (Transformer)
5 33116 Cad Cell
6 11243 Transformer Plate
7 32178 Oil Gauge, 0-15 psi
8 32235 Female Elbow, 3/16T x 1/8 NPT
9 32179 Air Gauge, 0-60 psi
10 32253 Female Elbow, 1/8TP x 1/8 NPT
11 33297 Hour Meter, 60 Hz
12 33169 Green Light (Power)
13 33168 Amber Light (Pump)
1431113Fan Squirrel Cage
15 26044 Motor Mounting Plate
16 33175 Blower Motor
17 14085 Right Side Cover
18 11335 Housing (includes item 23)
1913179Heater Block Assembly
20 11265 Cover, Hinged
21 SEE NOTE Nozzle Adapter Assembly
2211334Hinged Mounting Plate
2314088Connector Receptacle
24 33546 Connector Cord (CB-350/500 CTB)
25 26052 Latch Bracket
26 11376 Retention Head
27 34417 Wing Nut 5/16
Note: When installing the blower and motor into the burner housing, the blower wheel needs to be adjusted to reduce the air gap between the side and the wheel to a maximum of 3/32" (.09375")
A-19
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
CB-551-H5 Heater Block
30
(8)
31
58
57
32
(8)
56
1
3
9
34
35
59
52
36
51
37
27
39
40
48
(2)
10
42
43
12
6
25
44
28
15
14
1
2
3
4
5
6
7
47
46
13
24
8
9
10
11
12
45
41
46
26
(2)
29
38
60
49
11
7
54
50
5
8
33
53
4
2
55
13
16
19
17
18
21 (2)
23
20
22
I88975-A
Figure A10 - Preheater Block and Electrode Assembly Component Detail
CB-551-H5 Burner (CB-500-CTB)
A-20
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Item# C.B. Part# Qty. Component Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60*
34169
33183
34165
32006
13150
32007
33298
33381
33418
32199
32050
32189
32043
54020
32201
33247
34036
26059
33057
26126
32190
32202
32201
33334
33041
32325
54020
33561
32359
14090
34148
34114
34147
34022
32306
32226
32364
32227
32360
32361
32223
32222
32221
32362
13142
32308
32309
33311
33312
33313
33314
33315
33316
33317
33318
33319
33320
33321
32322
26107
1
1
1
1
1
1
1
1
1
1
2
2
1
1
2
1
4
1
1
1
2
1
1
1
1
1
1
1
1
1
8
8
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
1
ELECTRODE SCREW - 10-32 x 3/4
SINGLE PIECE ELECTRODE
WASHER
9 - 28 NOZZLE
NOZZLE ADAPTOR
PLUG - 1/8 NPT
140 WATTS HEATER
INSULATED CAP CRIMP CONNECTOR
THERMOSTAT L-130
PLUG - 1/16 NPT
SWIVEL FITTING
HEX NIPPLE - 1/8 NPT x 1-1/2
MALE CONNECTOR - 3/16T x 1/8 NPT
3/16 COPPER TUBING(OIL GAUGE LINE)
MACH. SCREW PHILLIPS HD. 6-32 x 3/8 Z
TERMINAL BLOCK
MACH. SCREW PHILLIPS HD. 6-32 x 1/4 Z
TERMINAL BLOCK BRACKET
AIR PRESSURE SWITCH
HEATER BLOCK
HEX NIPPLE - 1/8 NPT x 2
FEMALE ELBOW (FOR 1/4" AIR LINE)
FEMALE ELBOW (FOR 3/8" OIL LINE)
PRE-HEATER ELEMENT - 500 WATTS
PROVING SWITCH (NORMALLY OPEN)
MALE ELBOW 1/8 x 1/8 NPT (FOR AIR GAUGE LINE)
3/16 COPPER TUBING(OIL GAUGE LINE)
HEATER BLOCK THERMOSTAT(L160)
REGULATOR SURFACE MOUNT
REGULATOR LOCK PLATE
REGULATOR MOUNTING SCREW
LOCK WASHER #8 Z
REGULATOR THREADED STEM
HEX NU T - 10-32 Z
BONNET
DIAPHRAM RING
CAP AND BALL ASSEMBLY
COMPRESSION SPRING
DIAPHRAM
BRASS POPPET SEAT
POPPET ‘O” RING
POPPET VALVE
POPPET SPRING
BASE
REGULATOR KIT COMPONENTS
REGULATOR OUTER “O” RING
REGULATOR INNER “O” RING
SOLENOID INNER “O” RING
SOLENOID OUTER “O” RING
MANIFOLD MOUNT SOLENOID BODY
BODY “O” RING
PLUNGER ASSEMBLY
PLUNGER GUIDE ASSEMBLY
FLUX PLATE
WASHER SEAL
COIL
COIL HOUSING
NUT
AIR/OIL SOLENOID ASSEMBLY
REG. SQUARE CAP*
*NOTE: When the CTB is used with a metering pump, the oil regulator must be removed from the burner and replaced with the square
cap.
A-21
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Burner Components (continued)
NOZZLE IS STAMPED
9-5 OR -5 OR
9-28 OR -28 ON FLAT
OF NOZZLE HEAD
NOZZLE
ELECRODE
NOZZLE ADAPTER
101.00
3/16"
SPARK GAP
OUTLINE OF RETENTION HEAD
3/16"
142.47
1/8"
90.00
NOZZLE TO BE AHEAD OF
RETENTION HEAD BY 1/8"
I88144-A
ATTENTION: Make sure the electrodes are adjusted to the specifications in these diagrams. Correct
clearances must be maintained to avoid stray arcing. The minimum clearance to any ground source is
3/16". Stray arcing results in a weak spark, late burner ignition, and transformer failure.
NOTE: Clean Burn recommends the use of a special tool (CB Part# 70306) to set the retension head.
The burner electrodes should be replaced annually to maintain proper burner performance.
•
•
Install the electrodes according to the setting and specifications in these diagrams.
Use the shank of a 1/8" drill bit as a feeler gauge to set the spark gap at 1/8".
Figure A11 - Burner Electrode Specifications
A-22
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Burner Components (continued)
ModelNozzle Size
CB-200-CTB Delavan 9-5
CB-350-CTB Delavan 9-5
CB-500-CTB Delavan 9-28
DISTRIBUTOR
HEAD
NOZZLE SIZE IS
STAMPED ON
FLAT OF
NOZZLE HEAD
ORIFICE
STEM
O-RING
I88378
Removing the Nozzle for Cleaning:
NOTE: Due to swivel fittings on the air and oil lines, it is not necessary to disconnect these lines when
swinging the burner open.
1.
Remove the lock-down nut on the mounting flange bolt.
2.
Disconnect the burner power cable.
3.
Carefully swing the burner open to its maintenance position.
4.
Remove the nozzle from the nozzle adapter with a 5/8" socket.
Cleaning the Nozzle:
1.
Unscrew the stem from the nozzle head.
2.
Spray WD-40 or equivalent through the orifice to thoroughly remove any blockage.
CAUTION: DO NOT damage or deform the nozzle orifice; DO NOT use a torch tip
cleaner or other inappropriate device to clean the orifice. If the blockage is a "tarry"
material or a hard, black material, call your Clean Burn dealer for service.
3.
Flush all components with WD-40 to remove oil residues.
4.
Reassemble the nozzle components. When tightening the stem, just barely "snug" it down.
DO NOT overtighten.
5.
Check the O-ring on the nozzle stem. Replace the O-ring if it is in the least bit cut or
deformed.
6.
Lubricate the O-ring on the nozzle stem with a couple of drops of new motor oil, then re
install the nozzle.
7.
Check the electrodes for proper gap and clearances.
8.
Re-install the burner and adjust for optimal performance as necessary.
NOTE: If the nozzle plugs within a few days after cleaning, call your Clean Burn Dealer for service.
Figure A12 - Cleaning the Nozzle
A-23
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
CB-200-CTB
55
50
53
54
70
61
69
7
56
62
60
52
63
10
57
58
50
51
64
49
48
68
67
66
65
8
47
46
59
52
16
42
6
71
41
5
72
40
73
39
45
74
75
38
44
43
76
37
36
35
34
33
77
32
78
79
80
31
30
1
2
3
29
4
28
12
5
13
27
26
25
24
23
6
17
14
22
21
6
20
19
18
7
8
15
16
11
9
10
I88961-B
A-24
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Item# Part# Component Description
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
27139 70470 12240 14298 35053 35079 35052 35118 35115 35051 35065 27148 21057 90200 27136 27189 27144 27147 27146 11537 27133 27155 21056 11540 11582 14061 34120 11583 11325 34118 34009 31216 21120 27138 27131 27150 27149 27123 11538 33508 27158 27140 14335 35138 35139 35147 35141 35119 35124 35066 35048 35049 28149 35123 35110 35057 33330 28150 35146 11549 33145 33168 33486 33286 33352 33328 33327 33131 27109 33331 54013 27143 27134 31264 11154 31215 11539 35116 27132 27129 27803 JACKET RH SIDE 200
MIXING VALVE 140F & FLEX PIPE KIT 200-CTB
CONTROL BOX 120 V A
PIPE & CHECK VALVE 1 1/4 A
GASKET FLANGE
FLANGE 1-1/4 NPT; BLACK
NIPPLE 1 1/4 X 2 BLK
NIPPLE 1 1/4 X 3 BLK
SWING CHECK VALVE 1 1/4 NPT
TEE 1 1/4 X 3/4 X 1 1/4 BLK
BOILER DRAIN 3/4 NPT
SHIELD RET TUBE
HINGE BRACKET
BOILER STAND 200 CTB (optional)
BASE 200 CTB
SEAL PLATE STAMPED 200
SEAL PLATE FRONT OUTER
BRACKET HINGE 200 CTB
FILLER FRONT TUBE
BASE 200 CTB WA
RING BURNER END
STAND REFACY CYL 200 CTB
HINGE BRACKET
DOOR 200 CTB WA
HINGE BRKT 3DEG BURNER WA
HOOK-UP KIT - 200,350,2800
5/16-18 X 2 3/4 CARR BOLT S.S.
BURNER MOUNT 3 DEG WA
INSPECTION DOOR A
5/16-18 X 3/4 HEX HEAD TAP SCREW
3/8-16 HEX SERR FLANGE NUT PLT
INSULATION 200 FRONT DOOR
REFRACTORY CYL 10 X 14
JACKET LH SIDE 200
BAFFLE LH 200
LINER PROTECTOR
LINER TOP CRADLE
BRACKET 350 HINGE
CRADLE TOP WA
CORD 43" CONN PLUG
BRACKET BURNER CORD
JACKET TOP 200
MIXING VALVE VTC511 & T-STAT 140F A.
THERMOSTAT 160F/60C FOR VTC511
THERMOSTATIC BYPASS VALVE VTC511 1-1/4"
METAL FLEX HOSE 1 1/4" - 16"
CROSS 1 1/4 NPT BLK
1 1/4 X 1 1/4 X 1 TEE BLK
PADDLE TACO FLOW SW
TEE 1 1/4 X 1 1/4 X 3/4 BLK
RELIEF VALVE 3/4 M
WELL 3/4 NPT X 1 1/2 EXT (INS)
AQUASTAT 100-240F HIGH LIMIT
FLOW SWITCH; TACO
LOW WATER CUT-OFF CONTROL UNIT
BUSHING 3/4 X 1/2 BLK
GAUGE BOILER, TEMP-PRESSURE
AQUASTAT 100-200F OPERATING
BUSHING 1 1/4" - 3/4" BLK
BOILER STACK ADAPTOR 200CTB (optional)
SCREW LUG
AMBER LIGHT
TERMINAL BLK A; DIN-RAIL SCREW
SWITCH DPDT ON-ON
RELAY DELAY
RELAY DPDT
TRANSFORMER 24-120V
KNOCK-OUT SEAL/PLUG
BOX JUNCTION A
TERMINAL BLOCK (4 POST) CTB
ROPE-FIBERGLASS HD 250 W/ADH
SEAL PLATE REAR OUTER
RING TOP STACK END
ENERGY RETENTION DISC, 2-BOLT (W/HDWR)
TARGET (REFRAC) DISC ASSY
INSULATION 200 REAR PANEL
PANEL REAR 200 CTB WA
FLANGE 1 NPT
BAFFLE RH 200
RING BOTTOM STACK END
COIL 1" TUBE 22.5 T 200CTB
75.
76.
77.
78.
79.
80.
Item# •
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
A-25
Part# Component Description
11420 11550 14301 14302 14304 70427 31170 31217 31218 31219 31220 34162 42027 42030 42216 42217 42231 42261 42421 44052 42464 43146 54013 54104 14302
BURNER CB-525-S2 ASSEMBLY
BOILER 200 CTB CABINET A
PUMP METERING CB 200 CTB A
BOLT HOLE FIBERGLASS TAPE A
ACCESSORIES 200 CTB GP
DUCT CAP ROUND 8" - 24 GA.
DAMPER 8"
INSULATION STRIP 200 TOP
INSULATION STRIP 200 BOT FRT
INSULATION STRIP 200 BOT CENTR
INSULATION STRIP 200 BOT REAR
STOVE CEMENT - HIGH TEMP
LABEL - WARNING - BURN/VOLTAGE
LABEL - VOLTAGE WARNING
LABEL - LOGO - SMALL
LABEL - AIR OIL
LABEL - PRIME PUMP/RUN BURNER
LABEL - THRMOSTAT/BURNER
LABEL - BOILER WARNING
SCHEM CB 350 CTB (Wiring Diagram)
LABEL UL DATA CB 200 CTB
OPERATORS MANUAL CB 200/350/500 CTB
ROPE-FIBERGLASS HD 250 W/ADH
HYDRAULIC / PNEUMATIC SEALANT
FIBERGLASS BOLT HOLE TYPE 4 PER
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
CB-350-CTB
56
57
53
65
66
6
74
67
59
58
60
8
6
68
9
53
8
61
55
54
64
52
69
51
54
70
50
71
49
73
72
75
48
16
62
76
43
47
77
42
5
78
41
63
79
80
40
13
39
46
81
45
44
13
83
38
35
32
36
37
82
34
33
1
2
3
5
4
31
6
7
11
30
12
18
29
28
27
26
25
24
23
8
13
14
22
21
20
17
19
I88962-B
A-26
16
15
10
9
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Item# Part# Component Description
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
27093 12240 70471 14293 35053 35061 35081 35069 35082 35065 90188 21057 35079 27084 11373 27186 54013 27188 27193 27191 27086 27190 31176 21056 11405 11582 14061 34118 34120 11583 11325 34009 21140 27050 27087 27090 27802 27115 27123 11374 33546 27158 27095 14335 35138 35139 35148 35149 35140 35068 35084 35124 35083 35049 28149 35135 35123 35110 35057 33330 35145 28150 35118 90187 33131 33286 33168 33486 33145 33352 33328 33327 27109 33331 27187 27089 34150 31264 11154 31166 11380 34067 27037 27088 JACKET R.H. SIDE
CONTROL BOX 120 V A
MIXING VALVE 140F & FLEX PIPE KIT 350-CTB
CHECK AND DRAIN 350 PIPE A
GASKET FLANGE
FLANGE 1 1/2 NPT, BLACK
SWING CHECK 1 1/2
NIPPLE 1 1/2 X 2 BLK
TEE 1 1/2 X 3/4 X 1 1/2 BLK
BOILER DRAIN 3/4 NPT
BOILER STAND 350 (option only)
HINGE BRACKET
FLANGE 1-1/4 NPT; BLACK
BASE CTB
BASE CTB WA
SEAL PLATE STAMPED 350
ROPE-FIBERGLASS HD 250 W/ADH
SEAL PLATE FLAT FRONT 350
BRACKET HINGE 500
FILLER FRONT TUBE 350 CTB
RING BURNER END
STAND REFRACTORY 1 Pc 350
INSULATION 350 DOOR
HINGE BRACKET
DOOR WA
HINGE BRKT 3DEG BURNER WA
HOOK-UP KIT - 200,350,2800
5/16 - 18 X 3/4 HEX HEAD TAP SCREW
5/16-18 X 2 3/4 CARR BOLT S.S.
BURNER MOUNT 3 DEG WA
INSPECTION DOOR A
3/8-16 HEX SERR FLANGE NUT PLT
REFRACTORY CYL (1 Pc. 350)
JACKET L.H. SIDE
BAFFLE RH
LINER COMBUSTION CHAMBER
COIL 1 1/4 PIPE 26.5T
LINER PROTECTOR
BRACKET 350 HINGE
COVER TOP WA
CONN CORD 4-WIRE 51"
BRACKET BURNER CORD
JACKET TOP CTB
MIXING VALVE VTC511 & T-STAT 140F A.
THERMOSTAT 160F/60C FOR VTC511
THERMOSTATIC BYPASS VALVE VTC511 1-1/4"
METAL FLEX HOSE 1 1/4" - 24"
BUSHING 1 1/2" - 1 1/4" BLK
CROSS 1 1/2 NPT BLK
NIPPLE 1 1/2 X 6 BLK
TEE 1 1/2 X 1 1/2 X 1 BLK
PADDLE TACO FLOW SW
TEE 1 1/2 X 1 1/2 X 3/4 BLACK
WELL 3/4 NPT X 1 1/2 EXT (INS)
AQUASTAT 100-240F HIGH LIMIT
RELIEF VALVEl ; 30 PSI; (for CB-350-CTB)
FLOW SWITCH; TACO
LOW WATER CUT-OFF CONTROL UNIT
BUSHING 3/4 X 1/2 BLK
GAUGE BOILER, TEMP-PRESSURE
BUSHING 1 1/2" - 3/4" BLK
AQUASTAT 100-200F OPERATING
NIPPLE 1 1/4 X 3 BLK
BOILER STACKING ADAPTOR 350 (option only)
KNOCK-OUT SEAL/PLUG
SWITCH DPDT ON-ON
AMBER LIGHT
TERMINAL BLK A; DIN-RAIL SCREW
SCREW LUG
RELAY DELAY
RELAY DPDT
TRANSFORMER 24-120V
BOX JUNCTION A
TERMINAL BLOCK (4 POST) CTB
SEAL PLATE FLAT REAR 350
RING TOP STACK END
3/8-16 X 4 HHCS 18-8
ENERGY RETENTION DISC, 2-BOLT (W/HDWR)
TARGET (REFRAC) DISC ASSY
INSULATION PANEL
PANEL REAR 350 WA
3/8-16 FIN HEX NUT 18-8 S.S.
RING STACK END
BAFFLE LH
79.
80.
81.
82.
83.
Item# •
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
A-27
Part# Component Description
11369 11412 14201 28148 70427 31242 31163 31164 31168 31169 31170 31241 34162 42027 42030 42216 42217 42231 42286 42261 42292 42366 42367 42421 43146 44052 54104 54013
14184
CB 551 H3 BURNER A
DOOR 350 A.
ACCESSORIES 350 GP
CTB 350 CABINET ASSEMBLY
DUCT CAP ROUND 8" - 24 GA.
INSULATION 18.38 X 55 1/2 CTR FRONT
INSULATION STRIP 3.06 X 55.50 TOP FRONT
INSULATION TOP 48 X 51
INSULATION STRIP 21 5/8 X 55 1/2 CTR REAR
INSULATION STRIP 5 5/16 X 55 1/2 BOT REAR
DAMPER 8"
INSULATION STRIP 7.63 x 55.5 BOT FRT
STOVE CEMENT - HIGH TEMP
LABEL - WARNING - BURN/VOLTAGE
LABEL - VOLTAGE WARNING
LABEL - LOGO - SMALL
LABEL - AIR OIL
LABEL - PRIME PUMP/RUN BURNER
LABEL - IDENT CB-350 CTB
LABEL - THRMOSTAT/BURNER
LABEL - CTB WIRING CTB-200/350/500
LABEL - TANK WARNING
LABEL - FURNACE WARNING
LABEL - BOILER WARNING
OPERATORS MANUAL CB 200/350/500 CTB
SCHEM CB 350 CTB
HYDRAULIC / PNEUMATIOC SEALANT
ROPE FG HD 250 W/ADH 8'
FIBERGLASS BOH HOLE TAPE 4 PER
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
CB-500-CTB
56
57
6
53
65
66
74
67
59
58
60
53
8
68
9
8
6
61
55
54
64
52
69
51
54
70
50
71
49
73
72
75
48
16
47
62
76
43
77
42
78
41
79
63
45
80
40
46
84
44
81
39
13
13
5
83
38
35
32
36
37
82
34
33
1
2
3
5
4
31
6
7
11
30
12
18
29
28
27
26
25
24
23
8
13
14
22
21
20
17
19
I88997-C
A-28
16
15
10
9
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Item# Part# Component Description
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
27172 70472 12240 14314 35125 35120 35126 35128 35133 35065 90206 21057 35121 27170 11572 27178 54013 27177 11581 27179 27166 27200 31240 21056 11564 11582 14103 34118 34120 11583 11325 34009 21174 27171 27163 27181 27804 27180 11596 11562 33546 27158 27173 14335 35138 35139 35148 35143 35142 35127 35132 35124 35131 35049 28149 35136 35123 35110 35057 33330 35144 28150 35150 11578 33131 33286 33168 33486 33145 33352 33328 27109 33331 27176 27167 34150 31264 11154 31239 11563 34067 27165 27164 35149 JACKET RH SIDE 500
MIXING VALVE 140F & FLEX PIPE KIT 500-CTB
CONTROL BOX 120 V A
CHECK AND DRAIN 500 PIPE A
GASKET FLANGE 2"
FLANGE 500 2" NPT
CHECK VALVE 2" NPT SWING; Type WCV
NIPPLE 2 X 2 1/2" SCH 40 BLK
TEE 2 X 3/4 X 2 NPT BLK
BOILER DRAIN 3/4 NPT
BOILER STAND 500 A (optional)
HINGE BRACKET
FLANGE 500 1 1/2" NPT
BASE 500
BASE 500 CTB WA
SEAL PLATE STAMPED 500
ROPE-FIBERGLASS HD 250 W/ADH
SEAL PLATE FLAT FRONT
HINGE BRKT DOOR LOWER WA
FILLER PLATE 500
RING BURNER END 500
STAND REFACTORY CYL 500 CTB
INSULATION FRONT DOOR 500
HINGE BRACKET
DOOR FRONT 500 WA
HINGE BRKT 3DEG BURNER WA
CB-5000 HOOK-UP A
5/16 - 18 X 3/4 HEX HEAD TAP SCREW
5/16-18 X 2 3/4 CARR BOLT S.S.
BURNER MOUNT 3 DEG WA
INSPECTION DOOR A
3/8-16 HEX SERR FLANGE NUT PLT
REFRACTORY CYL 12.63 X 20
JACKET LH SIDE 500
BAFFLE LH 500
LINER COMBR CHM TOP 500
COIL 1.50 TUBE 28.5 T 500CTB
LINER PROTECTOR 500
BRACKET 500 UPPER HINGE WA
COVER TOP 500 CTB WA
CONN CORD 4-WIRE 51"
BRACKET BURNER CORD
JACKET TOP 500
MIXING VALVE VTC511 & T-STAT 140F A.
THERMOSTAT 160F/60C FOR VTC511
THERMOSTATIC BYPASS VALVE VTC511 1-1/4"
METAL FLEX HOSE 1 1/4" - 24"
BUSHING 2" - 1 1/4" BLK
CROSS 2"NPT BLK
NIPPLE 2 X 6 SCH 40 BLK
TEE 2 X 2 X 1 NPT BLK
PADDLE TACO FLOW SW
TEE 2 X 2 X 3/4 NPT BLK
WELL 3/4 NPT X 1 1/2 EXT (INS)
AQUASTAT 100-240F HIGH LIMIT
RELIEF VALVE; 30 PSI; (for CB-500-CTB)
FLOW SWITCH; TACO
LOW WATER CUT-OFF CONTROL UNIT
BUSHING 3/4 X 1/2 BLK
GAUGE BOILER, TEMP-PRESSURE
BUSHING 2" - 3/4" BLK
AQUASTAT 100-200F OPERATING
NIPPLE 1 1/4" - 14" BLK
BOILER STACKING ADAPT 500 CTB A (optional)
KNOCK-OUT SEAL/PLUG
SWITCH DPDT ON-ON
AMBER LIGHT
TERMINAL BLK A; DIN-RAIL SCREW
SCREW LUG
RELAY DELAY
RELAY DPDT
33327 TRANSFORMER 24-120V
BOX JUNCTION A
TERMINAL BLOCK (4 POST) CTB
SEAL PLATE FLAT REAR
RING TOP STACK END
3/8-16 X 4 HHCS 18-8
ENERGY RETENTION DISC, 2-BOLT (W/HDWR)
TARGET (REFRAC) DISC ASSY
INSULATION DOOR REAR 500
DOOR REAR BREECH 500 CTB WA
3/8-16 FIN HEX NUT 18-8 S.S.
RING BOT STACK END 500
BAFFLE RH 500
BUSHING 1 1/4 - 1 1/2 NPT
79.
80.
81.
82.
83.
84.
Item# •
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
A-29
Part# Component Description
11565 11567 11580 14317 70428 31197 31245 31246 31247 31248 34162 35137 42027 42030 42217 42231 42261 42292 42366 42367 42457 42421 42493 42497 43146 44052 54104 70469 70477 54013
14346
CTB 500 BOILER CABINET ASSMBLY
DOOR FRONT 500 A
CB-551-H5 BURNER A
ACCESSORIES 500 CTB GP
DUCT CAP ROUND 10" - 24 GA.
DAMPER 9" ASSEMBLY
INSUL. 62.0 X 48.0 BLANKET TOP
INSUL. 14.31X 62.0 BLANKET TOP FRT
INSUL. 24.0 X 66.0 BLANKET BOT CTR
INSUL. 7.50 X 66.0 BLANKET BOT FRT + REAR
STOVE CEMENT - HIGH TEMP
NIPPLE 3/4 X 2 NPT SCH40 BRASS
LABEL - WARNING - BURN/VOLTAGE
LABEL - VOLTAGE WARNING
LABEL - AIR OIL
LABEL - PRIME PUMP/RUN BURNER
LABEL - THRMOSTAT/BURNER
LABEL - CTB WIRING CTB-200/350/500
LABEL - TANK WARNING
LABEL - FURNACE WARNING
LABEL-MADE IN USA/PAT PENDING
LABEL - BOILER WARNING
LABEL IDENT CB 500 CTB
LABEL - LOGO - LARGE; 8" x 20"
OPERATORS MANUAL CTB
SCHEM CB 350 CTB (Wi ring Diagram)
HYDRAULIC / PNEUMATIC SEALANT
500 CTB BARE CABINET
SEAL KIT FOR TACO 2400-50/2 CIRCULATOR
ROPE FIG HD 250 W/ADH 8'
FIBERGLASS BOLT HOLE TAPE 4 PER
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Metering Pump Components
SUPPLY
TO BURNER
3
RETURN
TO TANK
6
5
7
2
4
8
9
10
GA
UG
E
IN
LE
RE
LIE
T
F
1
RO
TA
TIO
N
29
11
31
13
17
30
16
12
T
OU
GA
UG
E
A2
RA
INL
ET
R.H
-7
IN
. RO
INL
ET
71
TA
TIO
N
0
14
18
PACKAGED WITH
CLEAN BURN
EQUIPMENT
15
19
20
23
24
24
21
SINGLE PIECE OF
COPPER TUBING
(USER SUPPLIED)
22
23
16
25
27
26
PACKAGED WITH
CLEAN BURN
EQUIPMENT
28
I88952-C
A-30
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Item# Part# Component Description
1.
2.
33363 33507 33295 33558 11322 32037 N/A 1/4 N/A 3/8 N/A 3/8 N/A 1/8 32526 32475 32467 32210 32336 32123 32127 32430 32446 32429 32137 32142 32062 32443 32141 32140 32139 32442 32021 32061 32445 32423 32422 CAPACITOR
GEAR MOTOR CB 200 CTB
GEAR MOTOR CB 350 CTB
GEAR MOTOR CB 500 CTB
MOUNT METER PUMP A
1/8 NPT X 1/4 TUBE COMPRESSION FITTING
COPPER OR ALUMINUM TUBING
OR 1/2 TUBE FLARE NUT
OR 1/2 COPPER FOR ALUMINUM TUBING
M NPT X 3/8 OR 1/2 FLARE
MINI BALL VALVE 1/8 MNPT X 1/8 FNPT
PUMP-METERED OIL
NIPPLE 1/4 NPT X 3 ROUND BRASS
ST EL 90 1/4F-1/4M NPT
BUSHING 3/4 X 1/4 BR.
GAUGE (LENZ)
CANISTER FILTER
BUSHING 3/4" X 1/2"
NIPPLE 1/2 X 5"-BRASS
TEE 1/2" BRANCH
EXTERNAL PIPE ADAPTER
BALL VALVE 1/2 NPT
MALE CONNECTOR 1/4 TUBE
BUSHING 1/4 X 1/2" BRASS
FLARED TUB.TO PIPE STRAIGHT
LONG NUT 1/2
TUBE TO PIPE MALE STRAIGHT
BUSHING DUPLEX SLIP THRU
CHECK VALVE
CHECK VALVE SCREEN 3/4"
PIPE CAP 1/2"-BRASS
SCREEN PUMP (M PUMP)
GASKET COVER (M PUMP)
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
Item# •
A-31
Part# Component Description
13176 SUCTION FITTINGS PACKAGE
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
A-32
140 WATTS NOZZLE HEATER
WALL
THERMOSTAT
NOZZLE
TEMP.SW.
RED
BLACK
BLACK
RED
AIR
SOLENOID
OIL
SOLENOID
CAD CELL
YELLOW
TRANS-
OIL
PRIMARY
FORMER
BLUE
BLUE
BLACK
140
F F T T
Figure B1 -CB-525-S2 Burner Wiring Diagram (CB-200-CTB)
BLACK
ORANGE
MOTOR
BURNER
WHITE
WHITE
JUMPERS
WHITE
1 2 3 4 5 6 7 8 9 10 11 12 13
GREEN
GREEN
LIGHT
CENTRIFICAL
SWITCH
B-1
YELLOW
BLACK
I88249-C
CAPACITOR
AMBER
LIGHT
PREHEATER THERMOSTAT
BLACK
METER
HOUR
BLUE
WHITE
AIR
SWITCH
N.O.
(OPTIONAL)
COMPRESSOR
AIR
BLOCK HEATER 400 WATTS
TO RELEASE OR INSTALL A WIRE, CAREFULLY PUSH THE
BLADE OF THE SCREWDRIVER INTO THE RELEASE SLOT
ON THE TERMINAL STRIP UNTIL YOU FEEL THE JAWS "SNAP"
WIDE OPEN. LEAVE THE BLADE IN THE RELEASE SLOT TO
REMOVE OR INSTALL A WIRE. TO RELEASE THE JAWS,
CAREFULLY PULL THE BLADE OF THE SCREWDRIVER
FROM THE RELEASE SLOT.
NOTE: WHEN RELEASING OR INSTALLING WIRES ON THE
TERMINAL STRIP USE THE SMALL SCREWDRIVER SUPPLIED
WITH THE BURNER TO RELEASE THE TERMINAL JAWS.
TO LOCATE THE SCREWDRIVER, OPEN THE HINGED ACCESS
PLATE ON THE TOP OF THE BURNER. THE SCREWDRIVER
IS CLIPPED TO THE INSIDE OF THE BURNER HOUSING
ON THE RIGHT.
BLACK
BLACK
RED
PROVING SWITCH 120° N.O.
BLACK
CONNECTOR (FACE)
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
APPENDIX B
Wiring Diagrams
NOZZLE HEATER
YELLOW
CAD CELL
YELLOW
(OPTIONAL)
ALARM
BOILER
CONTROL
BOX
NOZZLE
TEMP.SW.
RED
RED
AIR
SOLENOID
OIL
PRIMARY
FORMER
TRANS-
BLACK
BLACK
BLUE
BLACK
BLUE
ORANGE
MOTOR
BURNER
WHITE
WHITE
JUMPERS
WHITE
1 2 3 4 5 6 7 8 9 10 11 12 13
GREEN
BLACK
AMBER
LIGHT
OIL
SOLENOID
GREEN
LIGHT
CENTRIFICAL
SWITCH
CONNECTOR (FACE)
METER
HOUR
AIR
SWITCH
N.O.
AIR
COMPRESSOR
(OPTIONAL)
CB-551-H3
CB-551-H5
BURNERS
BLACK
WHITE
BLUE
BLOCK HEATER
TEMPATURE
SWITCH
RED
PROVING SWITCH 120° N.O.
BLOCK HEATER
BLACK
I42305
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Wiring Diagrams (continued)
T T F F ALARM
Figure B2 - CB-551-H3 and CB551-H5 Burner Wiring Diagram (CB-350-CTB and CB-500-CTB)
B-2
B-3
Figure B3 - Coil Tube Boiler Wiring Diagram (Control Box)
5
PRIME
SWITCH
6
1
4
*12060VACHz
RUN
5
6
2
3
BLK
4
1
GRND
L2 NEUT (WHT)
L1 HOT (BLK)
PRIME
POWER IN
3
2
PRIME
LIGHT
*
5
4
L2
L2
L1
L1
INDUCER
* DRAFT
(MAX. 6 AMPS)
BLK
BLK
PUR
PUR
OIL PUMP
PUR
**
GRN
RED
WHT
BLK
TO BURNER
THERMOSTAT
OR AQUASTAT
BLK
PUR
WHT
BLU
1
3
B
T
A
RED
2
4
6
5
F
F
T
T
ALARM
BLK
RED
1
4
ORG
WHT
RED
RED
RED
RED
TRANSFORMER
24 VOLT
**OPTIONAL
DPDT RELAY
CONNECTION AT
*MAKE
TIME OF INSTALLATION
DELAY RELAY
1
3
WHT
YEL
PRIMARY
BLK
BLK
BLK
WHT
CIRCULATOR
* BOILER
LOOP
WHT
4
6
RED
BLK
THERMOSTAT BURNER
BLU
*
RED
BURNER
3
5
NC
COM
2
I42292
PROBE IN PIPE
P
LOW WATER
CUT-OFF
SWITCH
TACO
SWITCH
FLOW
HI LIMIT
OPERATING
AQUASTAT
120 V / 60 Hz
CB 200 CTB
CB 350 CTB
CB 500 CTB
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Wiring Diagrams (continued)
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
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 low water cut-off "proves" the water level inside the boiler and allows the flow switch to
close. 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 cad cell sees 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.
B-4
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
H
N
115 VOLTS 60 Hz
NOTE 1:
TDR TIMER CONTACT
CLOSES INSTANTANEOUSLY
WHEN RELAY IS ENERGIZED
(TRIGGERED BY CR1) AND
OPENS 10 MINUTES AFTER
CR1 IS DE-ENERGIZED
A
SEE NOTE 2
OPERATING
AQUASTAT
HI LIMIT
RUN - PRIME
LO WATER
CUT - OFF
FLOW
SWITCH
5
1
3
4
PRIMING
P
2
OIL PUMP
MOTOR
PROBE
M2
NOTE 2:
DPDT TOGGLE SWITCH
ON BOILER CABINET
TOGGLE DOWN: BURNER
TOGGLE UP: PRIME PUMP
BOILER CIRC. MOTOR
M1
DRAFT INDUCER
NOTE 3:
24 VAC
CB-350-CTB and CB-500-CTB
PRIMARY CONTROL IS
SHOWN. CB-200-CTB
PRIMARY CONTROL
IS SIMILAR WITH NO
ALARM.
- CONNECTION TO
CUSTOMER POWER
SEE NOTE 1
GRN
RD
WHT
BK
WHT
GRN
A
B TD
R T
THERMOSTAT
CR
1
T
T
DOUBLE POLE RELAY
BK
RD
PROVING SWITCH
120°
- CONNECTION AT
TERMINAL BLOCK
OUTSIDE BOILER
CONTROL BOX
B
T1
T2
LOW VOLTAGE
ALARM
CONTACT
CAD
CELL
BLK
B
F1
F2
WHT
OIL PRIMARY CONTROL
ORG
IGNITION TRANSF.
BL
SEE NOTE 3
AIR SOL.
SPARK GAP
AIR COMPRESSOR
(OPTIONAL)
BURNER MOTOR
M3
AIR PRESSURE
OIL SOL.
PUMP ON
CENTRIFUGAL SWITCH
N. C. HELD OPEN
A
ACTUATED BY BURNER MOTOR
HOUR METER
L-130 NOZZLE THERMOSTAT
140 WATTS NOZZLE HEATER
L-140 BLOCK THERMOSTAT
140°
400 WATTS BLOCK HEATER
POWER ON
G
I44087
Figure B4 - Coil Tube Boiler Ladder Schematic
B-5
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Wiring Diagrams (continued)
ENCLOSED J-BOX
GROUND
N
GR
BLUE
BLK
L 2 (WHT)
*
BLK
BLK
CAP.
D
RE
L 1 (BLK)
* 115 V 60 HZ POWER FROM OIL PUMP CIRCUIT
(SEE FURNACE SCHEMATIC)
Figure B4 - Metering Pump Wiring Schematic
B-6
I44040
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Understanding the Oil Primary Control (CB-200-CTB)
Model 40200 / 42230 Cad Cell Oil Primary Control Data Sheet
Model 40200/ 42230 CAD Cell Oil
Primary Control Data Sheet
• Oil pump bleed assist up to 1 min.
C77009
• Thermostat/aquastat compatible
• Improved SMC Technology
zero bleed voltage during standby
• Serviceman Reset Protection
• Works well with generators
Latch-up after 3 consecutive lockouts
Insensitive to frequency changes
• Diagnostic LED’s
• Flame Stabilize
• 15-second TFI/ 30-second TFI
Power input (from limit circuit)
120 VAC, 60 HZ, 10 VA
Storage temperature limits
Motor load
10 FLA/ 60 LRA
Thermostat anticipator current
0.1 A, AC
Ignitor load
120 VAC, 60 HZ, 500 VA
Cad cell resistance
R < 1500 OHMS
Operating temperature limits
+32°F to +140°F
Agencies
UL recognized (US & Canada)
-40°F to +185°F
Installing and wiring
Warning —
1. Always disconnect power source before wiring to avoid electrical shock or damage to the control. All wiring must comply with applicable codes and
ordinances.
2. Thermostat terminals (T–T) provide a current source. Never apply external power to these terminals under any circumstances.
Mounting
• The control may be mounted on a 4” x 4” junction box in any convenient location on the burner, furnace or wall. The location must not exceed the ambient
temperature limit, 140°F.
Wiring
• Wiring must comply with local and national electrical codes, and with the wiring diagram.
L2
L2
LIMIT IN
Field checks
120V, 60 HZ
1. Safety timing (TFI) test — Remove one cad cell wire (F-F). Start burner.
The control should lockout within the TFI time limit. Replace cad cell wire.
2. Flame failure test
as described on the reverse side of this Data sheet. The control should recycle (restart after 65 seconds).
3. If control does not operate as described, check the wiring.
LINE
HEATER
L2
MOTOR
10FLA
60LRA
IGNITOR
500VA
VALVE
Model 40200/42230 diagnostic LED’s
Start-up & operation
Do not start the burner if the combustion chamber
contains oil or oil vapor.
– Amber OFF
– Amber ON
– Amber FLASHING
– Green OFF
– Green ON
– Green FLASHING
– Red OFF
– Red ON
– Red FLASHING
The amber LED
every 3 to 4 seconds & green LED will be on
or blinking.
Power ON
Open all manual oil line valves. Close the line switch.
Self-test 1
The control performs a “boot-up” test to verify internal operation each time power is applied to the black wire. The amber LED turns
on and the test continues for about 5 seconds. If the test fails, the control turns the amber LED off and repeats this test sequence
until successful.
Stand-by
(No call for heat) If Self-test 1 is successful, amber LED turns off and control waits for heat call.
Call for heat Set thermostat and limit to call for heat. Thermostat circuit must be closed and power coming to black wire from limit circuit.
Self-test 2
If a failure occurs in this self-check, the control won’t start and the amber LED blinks 1 second on, 4 seconds off, until serviced or the
problem clears. These failures include CAD cell seeing light, internal fault, or line voltage <90V. See service section.
Burner on
After the self-test, amber LED turns off. The ignitor starts, followed 2 seconds later by the motor.
B-7
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Understanding the Oil Primary Control (CB-200-CTB) Cont.
Model 40200 / 42230 Cad Cell Oil Primary Control Data Sheet
C77010
Start-up & operation continued...
Pump Prime To enter pump prime: 1. Start a CFH cycle. During Pre-Ignition or Pre-Purge, press Reset until motor turns off (10 seconds), then
in Pump Prime, release Reset button.
Optional Pump Prime notes: 1) If lost, press Reset for 1 second and release, then if the control is not in Pump Prime, restart the se-
Reset button is pressed.
TFI
Run
The burn
Lockout
lockout occurs. The control turns the red LED on
constant, and closes the alarm contact.
To Reset
Push in and hold reset button for 2 seconds, then release.
Latch-up
If the control locks out 3 times during a single call for heat, latch-up occurs. The control turns on both the amber and red LED’s constant. You must use the special procedure below to reset the control after latch-up.
repeated burner lockouts must be corrected before returning the burner to normal operation.
the control will restart (releasing the button before the LED’s turn off will cause the control to remain in latch-up).
The 40200 & 42230 controls will retain lockout or latch-up if power is interrupted.
Flame failure
Stand-by
f
Recycle: Control waits for 65 seconds (with
Control remains in stand-by mode until limit circuit sends power to the black wire and thermostat circuit closes (call for heat).
Service & Troubleshooting
•
Burner (control) will not come on
No power to control
• Check limit circuit to the control (at least 102 VAC).
• Check all electrical connections.
Internal fault: CAD cell, and line voltage OK, the issue may be
an internal fault . Replace the control.
Check for:
• CAD cell is defective. Replace.
•
Control is in lockout
• Red LED will be on. Press the reset button for 2 seconds.
CAD cell seeing light
• Green LED on, and amber LED blinking 1 second on, 4 seconds
off. Remove one yellow lead from FF terminals. If the amber LED
If the amber LED goes OFF, the control is OK, and;
• light is leaking into the burner housing, OR
• CAD cell is defective, OR
• there is a problem with the CAD cell wiring or holder.
• If appliance was recently shut down, CAD cell may see residual
hot spots in chamber.
To troubleshoot:
• Attach multimeter to monitor CAD cell resistance. Dark
resistance should be over 50K ohms, and room light resis-
•
.
Replace cell if necessary, or reinstall and close the burner
housing.
Check for stray light by measuring the CAD cell resistance
looking into the inactive combustion chamber. It should read
at least 50 KOHMS.
Other no start problems
If the CAD cell is OK, and the amber LED still blinks 1 second on, 4
seconds off, the other possible failures include:
•
on, 1/2 second off, 1 second on, 3 seconds off, then repeats).
Check line voltage.
B-8
•
•
•
-
check for proper air band setting and draft.
Control locks out at end of TFI (
red LED on)
Check for:
•
• Shorted electrodes- inspect for cracked porcelain and replace
as needed.
• Poor spark- check electrode spacing and condition per burner
manual. Replace or realign if necessary.
• Nozzle clogged- replace nozzle.
•
• Ignitor module defective- replace if no spark.
• CAD cell defective
• Oil valve (if used) stuck in closed position.
• Check wiring connections.
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Understanding the Oil Primary Control (CB-350-CTB & CB-500-CTB)
Model 50200 Cad Cell Oil Primary Control Data Sheet
Model 50200 CAD Cell Oil
Primary Control Data Sheet
• Interrupted duty ignition
C77011
• Thermostat/aquastat compatible
• SMC Technology
• Pump Prime
• Serviceman Reset Protection
Latch-up after 3 consecutive lockouts
• Alarm contacts
• Diagnostic LED’s
• 15-second TFI/30-second TFI
Power input (from limit circuit)
120 VAC, 60 HZ, 9VA
Storage temperature limits
Motor load
10 FLA/ 60 LRA
Thermostat anticipator current
0.1 A, AC
Ignitor load
120 VAC, 60 HZ, 500 VA
Cad cell resistance
R < 1500 OHMS
Alarm contacts
24 V, AC/DC, 2A
Agencies
UL recognized (US & Canada)
Operating temperature limits
+32°F to +140°F
-40°F to +185°F
Installing and wiring
Warning —
1. Always disconnect power source before wiring to avoid electrical shock or damage to the control. All wiring must comply with applicable codes and
ordinances.
2. Thermostat terminals (T–T) provide a current source. Never apply external power to these terminals under any circumstances.
alarm systems such as Carlin Secure Heat™.
3. Alarm terminals provide a 24 VAC/VDC-rated dry contact, suitable for use with
Mounting
• The control may be mounted on a 4” x 4” junction box in any convenient location on the burner, furnace or wall. The location must not exceed the ambient
temperature limit, 140°F.
Wiring
• Wiring must comply with local and national electrical codes, and with the wiring diagram.
L2
L2
L2
LIMIT IN
LINE
MOTOR IGNITOR
VALVE
Field checks
120V, 60 HZ
10FLA
500VA
HEAT60LRA
1. Safety timing (TFI) test — Remove one cad cell wire (F-F). Start burner.
ER
The control should lockout within the TFI time limit. Replace cad cell wire.
is established (after TFI period), close the oil supply hand valve. This will cause a
failure sequence
2. Flame failure test — Start burner. After
as described on the reverse side of this Data sheet. The control should recycle (restart after 65 seconds).
3. If control does not operate as described, check the wiring.
Model 50200 diagnostic LED’s
Start-up & operation
Do not start the burner if the combustion chamber
contains oil or oil vapor.
– Amber OFF
– Amber ON
– Amber FLASHING
– Green OFF
– Green ON
– Green FLASHING
– Red OFF
– Red ON
– Red FLASHING
Per UL requirements, the control will not turn on if the cad cell senses
during the self-test. If the cad cell sees light
at
The amber LED
the beginning of a cycle, the control will remain in self-test mode until the cad cell no longer senses light
every 3 to 4 seconds and green LED will be on or blinking.
will blink momentarily
Power ON
Open all manual oil line valves. Close the line switch. (If Red LED turns on constant
Self-test 1
The control performs a “boot-up” test to verify internal operation each time power is applied to the black wire. The amber LED turns
on and the test continues for about 5 seconds. If the test fails, the control turns the amber LED off and repeats this test sequence
until successful.
Stand-by
Thermostat circuit open and/or limit circuit open) If Self-test 1 is successful, amber LED turns off and control waits for thermostat
circuit to close and a limit input.
, control is in lockout. See below to reset.)
Call for heat Set thermostat to call for heat. Thermostat circuit must be closed and black wire must receive power from the limit circuit.
Self-test 2
If a failure occurs in this self-check, the control won’t start and the amber LED blinks 1 second on, 4 seconds off, until serviced or the
problem clears. These failures include CAD cell seeing light, internal failure, or line voltage <90V. See service section.
Burner on
After the self-test, amber LED turns off. The ignitor starts, followed 2 seconds later by the motor.
B-9
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Understanding the Oil Primary Control (CB-350-CTB & CB-500-CTB) Cont.
Model 50200 Cad Cell Oil Primary Control Data Sheet
C77012
Start-up & operation continued...
Pump Prime To enter pump prime: 1. Start a CFH cycle. During Pre-Ignition or Pre-Purge, press Reset until motor turns off (10 seconds), then
You are
release the button. When motor turns back on, within 5 seconds, press the Reset button until the amber LED starts to
in Pump Prime, release Reset button.
Optional Pump Prime notes: 1) If lost, press Reset for 1 second and release, then if the control is not in Pump Prime, restart the sequence. 2) If Reset is released before end of
10 seconds, the control returns to Standby and restarts another CFH cycle. 3) If
reset is not pressed the second time, a normal CFH cycle will continue. 4) If motor and igniter are on and amber LED is
the
is detected, or 60 seconds has elapsed, or loss of TT or Limit, or
control is in Pump Prime. 5) Pump Prime will exit standby if
Reset button is pressed.
TFI
The cad cell must sense
within the TFI time limit (trial for ignition). After CAD cell senses
seconds.
stabilization period).
Run
The burner continues
Lockout
If cad cell does not sense
within the TFI time limit after the burner starts, lockout occurs. The control turns the red LED on
constant, and closes the alarm contact.
To Reset
Push in and hold reset button for 1 second, then release.
Latch-up
If the control locks out 3 times during a single call for heat, latch-up occurs. The control turns on both the amber and red LED’s
constant. You must use the special procedure below to reset the control after latch-up.
during call for heat if the CAD cell is sensing
the ignitor stays on another 10
Only the green LED is on during normal running.
Reset after latch-up- only a
service technician should attempt to reset the control after latchup. The problem that caused the
repeated burner lockouts must be corrected before returning the burner to normal operation.
Push in and hold the reset button for 10 seconds. The amber LED will begin to
After the LED begins
continue holding the reset button for 20 seconds. The LED’s will turn off. Release the reset button and
the control will restart (releasing the button before the LED’s turn off will cause the control to remain in latch-up).
The 50200 control will not reset from lockout or latch-up if power is interrupted.
Flame failure If the CAD cell loses
signal during operation (after the TFI), the red LED
The burner shuts off within 2 seconds.
Recycle: Control waits for 65 seconds (with red LED
then begins again at Self-test. Red LED goes off .
End cycle
Set thermostat (or aquastat) to stop call for heat. The burner shuts off within 2 seconds after end of call for heat.
Stand-by
Control remains in stand-by mode until limit circuit sends power to the black wire and thermostat circuit closes (call for heat).
Service & Troubleshooting
Check for:
• CAD cell is defective. Replace.
• Air leaking into oil line causing
out- check oil line
connections and
gasket.
• Defective nozzle causing
to be erratic- change nozzle.
• Excessive
or draft causing
to leave burner headcheck for proper air band setting and draft.
• Excessive back pressure causing
to be erratic- check
appliance and
for sooting/plugging.
Burner (control) will not come on
No power to control
• Check limit circuit to the control (at least 102 VAC).
• Check all electrical connections.
Control is in lockout
• Red LED will be on. Press the reset button for 1 second.
• If the control returns immediately to lockout, the Safety Monitoring Circuit may have detected an internal control problem.
Replace the control.
Control locks out after TFI (
CAD cell seeing light
• Green LED on, and amber LED blinking 1 second on, 4 seconds
test
off. Remove one yellow lead from FF terminals, and the
plug. If the amber LED remains
the control is defective.
If the amber LED goes OFF, the control is OK, and;
• light is leaking into the burner housing, OR
• CAD cell is defective, OR
• there is a problem with the CAD cell wiring or holder.
• If appliance was recently shut down, CAD cell may see residual
hot spots in chamber.
To troubleshoot:
• Attach multimeter to monitor CAD cell resistance. Dark
resistance should be over 50K ohms, and room light resistance (control
open) should be at most 10K ohms
Replace cell if necessary, or reinstall and close the burner
housing.
• Check for stray light by measuring the CAD cell resistance
looking into the inactive combustion chamber. It should read
at least 50 KOHMS.
B-10
red LED on)
Check for:
lines.
• No oil to burner- check oil supply,
• Shorted electrodes- inspect for cracked porcelain and replace
as needed.
• Poor spark- check electrode spacing and condition per burner
manual. Replace or realign if necessary.
• Nozzle clogged- replace nozzle.
too high- check air band setting.
• Ignitor module defective- replace if no spark.
• CAD cell defective
• Oil valve (if used) stuck in closed position.
• Check wiring connections.
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
Boiler Service Record
APPENDIX C
Boiler Purchased:
Date __________
From (name/phone)________________________________
Boiler Installed:
Date __________
By (name/phone)__________________________________
Boiler Inspected:
Date __________
By (name/phone)__________________________________
Note: Refer to Section 9 for Maintenance Instructions
Draft Readings
Service Record
(Date / Draft)
(Date / Initials of Technician)
Burner Stack
Canister Metering Check Valve Chamber Stack
Oil Tank
Filter
Pump and Screen & Flues
*A.P.M. is Annual Preventative Maintenance on the Burner (Burner Tune-up)
C-1
A.P.M.*
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB
C-2
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