CLEAN BURN CB-2500, CB 140, CB-3250, CB-1750 User manual

CLEAN BURN CB-2500, CB 140, CB-3250, CB-1750 User manual
OPERATOR'S MANUAL
CLEAN BURN MODELS: CB-1750, CB-2500, and CB-3250
MULTI-OIL FURNACES
with CB-525-S2 BURNER
USED-OIL BURNING
APPLIANCE
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FOR YOUR SAFETY -
LISTED
DO NOT STORE GASOLINE
OR OTHER FLAMMABLE VAPORS AND LIQUIDS
IN THE VICINITY OF THIS OR ANY APPLIANCE !!
I88435-D
PUBLICATION DATE: 07/16/13, Rev. 13
USED OIL-FIRED
FURNACE
CLEAN BURN PART # 43195
WARNING: DO NOT assemble, install, operate, or maintain this equipment without first
reading and understanding the information provided in this manual. Installation and
service must be accomplished by qualified personnel. Failure to follow all safety precautions
and procedures as stated in this manual may result in property damage, serious personal injury
or death.
IMPORTANT FOR U.S. INSTALLATIONS: All installations must be made in accordance with state and local codes
which may differ from the information provided in this manual. Save these instructions for reference.
IMPORTANT FOR CANADIAN INSTALLATIONS: These instructions have been reviewed and accepted by
Underwriters' Laboratories of Canada as being appropriate for the installation of the ULC labelled products
identified herein. The use of these instructions for the installation of products NOT bearing the ULC label and
NOT identified herein may result in an unacceptable or hazardous installation.
IMPORTANT FOR CANADIAN INSTALLATIONS: The installation of this equipment is to be accomplished by
qualified personnel and in accordance with the regulation of authorities having jurisdiction and CSA Standard B 139,
Installation Code for Oil Burning Equipment.
CLEAN BURN
WASTE OIL FURNACE
WARRANTY INFORMATION
Clean Burn, LLC, MANUFACTURER, hereby warrants that MANUFACTURER’s products shall be free from defect in
material and workmanship under normal use according to the provisions and limitations herein set forth.
MANUFACTURER warrants the heat exchanger/combustion chamber for a period of ten (10) years or 15,000 hours,
whichever comes first), from the date of purchase by the original purchaser, as follows:
If the defect occurs within the first ten (10 years or 15,000 hours, whichever comes first), Clean Burn will replace or repair
the heat exchanger/combustion chamber.
MANUFACTURER warrants all other Clean Burn component parts, including the energy retention disk, for a period of
one (1) year from the date of purchase by the original purchaser.
LIMITATIONS:
The obligation of MANUFACTURER for breach of warranty shall be limited to products manufactured by
MANUFACTURER, (1) that are installed, operated and maintained according to MANUFACTURER’s instructions furnished
and/or available to the purchaser upon request; (2) that are installed according to all other applicable Federal, State and local
codes or regulations; and (3) that the purchaser substantiates were defective in material and workmanship notwithstanding
that they were properly installed and correctly maintained as set forth above and were not abused or misused. The
MANUFACTURER may request service records or require photos of the installation or defect.
The obligation of MANUFACTURER shall be limited to replacing or repairing the defective product, at the option of the
MANUFACTURER. MANUFACTURER shall not be responsible for any labor or costs or removal or reinstallation of its
products and shall not be liable for transportation costs to and from its plant at Janesville, Wisconsin.
Use of parts for 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.
Warranty (continued)
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 © 2013 Clean Burn, LLC. All rights reserved. No part of this publication may be reproduced, or distributed
without the prior written permission of Clean Burn, LLC. 4109 Capital Circle, Janesville, WI 53546. Subject to change
without notice.
TABLE OF CONTENTS
SECTION 1: INTRODUCTION............................................................................................................. 1-1
Guide to this Manual...................................................................................................................... 1-1
For Your Safety............................................................................................................................... 1-2
Guidelines for Furnace Usage................................................................................................. 1-4
Guidelines for Used Oil Tanks................................................................................................ 1-5
Safety Labels........................................................................................................................... 1-6
SECTION 2: UNPACKING.................................................................................................................... 2-1
Removing the Shipping Crate........................................................................................................ 2-1
Unpacking and Inspecting All Components................................................................................... 2-1
Furnace Component List ........................................................................................................ 2-1
Unpacking Items Packed Inside the Furnace.2-2
Warranty Registration..................................................................................................................... 2-2
SECTION 3: FURNACE ASSEMBLY................................................................................................. 3-1
Understanding Assembly................................................................................................................ 3-1
Required Tools and Materials................................................................................................. 3-1
Installing the CB-1750 and CB-2500 Blower Assembly............................................................... 3-3
Wiring the CB-1750 and CB-2500 Blower Motor ................................................................. 3-4
Installing the CB-3250 Blower Assembly...................................................................................... 3-6
Mounting the CB-3250 Blower............................................................................................... 3-6
Installing the CB-3250 Blower Motor on the Blower............................................................. 3-6
Wiring the CB-3250 Blower Motor ....................................................................................... 3-6
Installing the Motor Pulley, Blower Pulley, and V-Belt.......................................................... 3-8
Installing the Belt Guard and Blower Guard........................................................................ 3-10
Determining the Air Discharge Configuration............................................................................. 3-10
Installing the Hot Air Discharge Components.............................................................................. 3-12
Installing the Energy Retention Disc............................................................................................ 3-14
Installing the Energy Retention Disc on the Combustion Chamber..................................... 3-14
Closing the Furnace Door..................................................................................................... 3-14
Installing the Burner..................................................................................................................... 3-15
Checking the Burner Nozzle and Electrodes........................................................................ 3-15
Mounting the Burner on the Hinge Bracket.......................................................................... 3-16
Installing the Connector Block, Oil Line Tubing, and Air Line Tubing...................................... 3-17
Installing the Connector Block on the Furnace Door........................................................... 3-17
Installing the Oil Line Tubing............................................................................................... 3-17
Installing the Air Line Tubing............................................................................................... 3-18
Locking the Burner into Firing Position............................................................................... 3-19
SECTION 4: FURNACE INSTALLATION.......................................................................................... 4-1
Understanding Installation............................................................................................................. 4-1
Selecting a Location....................................................................................................................... 4-3
Guidelines for Selecting a Location........................................................................................ 4-3
Mounting the Furnace.................................................................................................................... 4-4
Ceiling Mounting.................................................................................................................... 4-4
Raised Platform Mounting...................................................................................................... 4-5
Floor Mounting....................................................................................................................... 4-5
Oil Tank Installation Specifications................................................................................................ 4-7
Installing the Tank Vent and Emergency Vent........................................................................ 4-8
Installing the Metering Pump......................................................................................................... 4-9
TABLE OF CONTENTS
Preparing for Installation........................................................................................................ 4-9
Standard Mounting: Vertical Positioning................................................................................ 4-9
SECTION 4: FURNACE INSTALLATION (continued)..........................................................................
Alternate Mounting: Horizontal Positioning.................................................................................4-11
Wiring the Furnace and Pump...................................................................................................... 4-12
Wiring to the Furnace............................................................................................................ 4-12
Wiring to the Metering Pump............................................................................................... 4-12
Installing the Suction Oil Line Components................................................................................ 4-13
Installing the Pressure Relief Oil Line Back to the Tank............................................................. 4-16
Installing the Pressure Oil Line Components............................................................................... 4-17
Installing the Compressed Air Line.............................................................................................. 4-17
Installing the Stack....................................................................................................................... 4-18
Stack Design and Specifications........................................................................................... 4-18
Installing the Interior Stack................................................................................................... 4-21
Installing the Barometric Damper......................................................................................... 4-21
Installing the Stack Safety Switch For Canadian Installations............................................. 4-22
Resetting the Stack Safety Switch.................................................................................. 4-23
Understanding the Stack Safety Switch.......................................................................... 4-23
Installing the Stack Penetration............................................................................................. 4-24
Installing the Exterior Stack.................................................................................................. 4-24
Installing the Stack Cap........................................................................................................ 4-24
Installing the Optional Draft Inducer.................................................................................... 4-24
Installing the Wall Thermostat...................................................................................................... 4-26
Replacing the Wall Thermostat Batteries.............................................................................. 4-26
Inspecting the Furnace Installation............................................................................................... 4-26
SECTION 5: METERING PUMP PRIMING............................................................................... 5-1
Understanding Metering Pump Priming......................................................................................... 5-1
Required Tools and Materials................................................................................................. 5-1
Priming the Metering Pump........................................................................................................... 5-2
Vacuum Testing the Oil Pump........................................................................................................ 5-4
SECTION 6: STARTING AND ADJUSTING THE BURNER.................................................... 6-1
Understanding Burner Startup and Adjustment.6-1
Preparing the Burner for Startup.................................................................................................... 6-1
Starting the Burner......................................................................................................................... 6-3
Checking the Operation of the Blower Motor .............................................................................. 6-4
SECTION 7: RESETTING THE FURNACE AND BURNER..................................................... 7-1
Understanding Furnace/Burner Shutdowns.................................................................................... 7-1
The Oil Primary Control................................................................................................................. 7-1
Resetting the Oil Primary Control.......................................................................................... 7-1
The Blower Switch......................................................................................................................... 7-2
The Hi-Temp Limit Switches......................................................................................................... 7-2
Understanding the L-200 Hi-Temp Limit Switch................................................................... 7-2
Understanding the L-290 Auxiliary Auto Reset Hi-Temp Limit Switch................................ 7-2
SECTION 8: ADJUSTING THE DRAFT OVER FIRE............................................................... 8-1
Checking for Correct Draft Over Fire............................................................................................ 8-1
Adjusting the Barometric Damper................................................................................................. 8-2
TABLE OF CONTENTS
SECTION 8: FURNACE INSTALLATION (continued)..........................................................................
Solving Draft Overfire Problems............................................................................................ 8-2
Understanding the Effect of Exhaust Fans on Draft............................................................... 8-3
Checking Draft Overfire to Determine Severity of Backdraft................................................ 8-3
Installing a Make-up Air Louver............................................................................................. 8-5
SECTION 9: MAINTENANCE................................................................................................... 9-1
Understanding Maintenance........................................................................................................... 9-1
Periodic Burner Inspection............................................................................................................. 9-2
Cleaning the Canister Filter............................................................................................................ 9-3
Servicing the Metering Pump......................................................................................................... 9-4
Cleaning the Check Valve.............................................................................................................. 9-5
Cleaning the Tank........................................................................................................................... 9-6
Cleaning Ash from the Furnace...................................................................................................... 9-7
Annual Burner Tune-up.................................................................................................................. 9-9
End of Season Maintenance........................................................................................................... 9-9
Cleaning and Maintaining the Optional draft Inducer.................................................................... 9-9
SECTION 10: TROUBLESHOOTING..................................................................................... 10-1
Flow Chart.................................................................................................................................... 10-2
Troubleshooting Tables................................................................................................................ 10-3
APPENDIX A
Furnace Technical Specifications.................................................................................................. A-1
Burner Technical Specifications.................................................................................................... A-2
Furnace Dimensions ..................................................................................................................... A-2
Burner Components....................................................................................................................... A-4
Removing the Nozzle for cleaning......................................................................................... A-9
CB-1750 Furnace Components................................................................................................... A-10
CB-1750 Blower Components.................................................................................................... A-12
CB-2500 Furnace Components................................................................................................... A-14
CB-2500 Blower Components.................................................................................................... A-16
CB-3250 Furnace Components................................................................................................... A-18
CB-3250 Blower Components.................................................................................................... A-20
Metering Pump Components....................................................................................................... A-22
APPENDIX B
Wiring Diagrams............................................................................................................................B-1
CB-1750 Furnace Wiring Diagram.........................................................................................B-1
CB-2500 Furnace Wiring Diagram.........................................................................................B-2
CB-3250 Furnace Wiring Diagram (115 Volts)......................................................................B-3
CB-3250 Furnace Wiring Diagram (230 Volts)......................................................................B-4
Burner Wiring Diagram..........................................................................................................B-5
CB-1750 Ladder Schematic....................................................................................................B-6
CB-2500 Ladder Schematic....................................................................................................B-7
CB-3250 Ladder Schematic (115 Volts).................................................................................B-8
CB-3250 Ladder Schematic (230 Volts).................................................................................B-9
Metering Pump Wiring Schematic........................................................................................B-10
CAD Cell Oil Primary Control Data Sheets.........................................................................B-11
TABLE OF CONTENTS
APPENDIX C
Furnace Service Record..................................................................................................................C-1
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
SECTION 1: INTRODUCTION
Guide to this Manual
This manual contains all the information necessary to safely install and operate the Clean Burn Furnace
Models CB-1750, CB-2500 and CB-3250. Consult the Table of Contents for a detailed list of topics
covered. You'll find this manual's step-by-step procedures easy to follow and understand. Should questions arise, please contact your Clean Burn dealer before starting any of the procedures in this manual.
As you follow the directions in this manual, you'll discover that assembling and operating your new
furnace involves five basic activities as outlined here:
•
UNPACKING...................................................................................................... (Section 2)
•
ASSEMBLY......................................................................................................... (Section 3)
•
INSTALLATION ............................................................................................... (Section 4)
•OPERATION
•Metering Pump Priming......................................................................... (Section 5)
•Starting and Adjusting the Burner........................................................ (Section 6)
• Resetting the Furnace and Burner........................................................ (Section 7)
• Adjusting the Draft ................................................................................ (Section 8)
•MAINTENANCE ............................................................................................... (Section 9)
The manual also contains important and detailed technical
reference materials which are located at the back of the
manual in the Appendixes.
WARNING!
Please read all sections carefully--including the important
safety information found in this section--before beginning
any installation/operation procedures; doing so ensures
your safety and the optimal performance of your Clean
Burn furnace.
STOP
YOUR SAFETY IS AT STAKE!
DO NOT INSTALL, OPERATE OR
MAINTAIN THIS EQUIPMENT
WITHOUT FIRST READING
AND UNDERSTANDING THE
OPERATOR'S MANUAL!
1-1
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
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 furnace operation.
DANGER! DO NOT create a fire or explosion hazard by storing or using gasoline or other
flammable or explosive liquids or vapors near your furnace.
DANGER! DO NOT operate your furnace if excess oil, oil vapor or fumes have
accumulated in or near your furnace. As with any oil burning furnace, improper installation,
operation or maintenance may result in a fire or explosion hazard.
WARNING: DO NOT add inappropriate or hazardous materials to your used oil, such as:
• Anti-freeze
• Carburetor cleaner
• Paint thinner
• Parts washer solvents
• Gasoline
• Oil additives
• Any other inappropriate/hazardous
material
WARNING: Burning chlorinated materials (chlorinated solvents and oils) is illegal, will
severely damage your heat exchanger, immediately void your warranty, and adversely affect
the proper, safe operation of your furnace. Instruct your personnel to never add hazardous
materials to your used oil.
1-2
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
For Your Safety... (continued)
WARNING: Never alter or modify your furnace without prior written consent of
Clean Burn, LLC. Unauthorized modifications or alteration can adversely affect the proper,
safe operation of your furnace.
WARNING: The burner which is shipped with your Clean Burn furnace is to be used only
with your furnace according to the instructions provided in this manual. DO NOT use the
burner for any other purpose!
WARNING: The Best Operator is a Careful Operator! By using common sense,
observing general safety rules, and adhering to the precautions specific to the equipment,
you, the operator, can promote safe equipment operation. Failure to use common sense,
observe general safety rules, and adhere to the precautions specific to the equipment may
result in equipment damage, fire, explosion, personal injury and/or death.
WARNING: The installation, operation, and maintenance of this equipment in the U.S.
must be accomplished by qualified personnel and in compliance with the specifications in the
Clean Burn Operator's Manual and with all national, state, and local codes or authorities
having jurisdiction over environmental control, building inspection and fuel, fire and
electrical safety and the following standards:
NFPA 30 Flammable and Combustible Liquids Code
NFPA 30A Automotive and Marine Service Station Code
NFPA 31 Standard for the Installation of Oil Burning Equipment
NFPA 211 Chimneys, Fireplaces, Vents and Solid Fuel Burning Appliances
NFPA 88A Parking Structures
NFPA 88B Repair Garages
NFPA 70 National Electrical Code
The International Mechanical Code
The International Building Code
The International Fire Code
The International Fuel Gas Code
Likewise, the installation, operation, and maintenance of this equipment in Canada is to be
accomplished by qualified personnel and in compliance with the specifications in the
Clean Burn Operator's Manual and in accordance with the regulation of authorities having
jurisdiction and the following CSA Standards: B139 - Installation Code for Oil Burning
Equipment; B140.0 - General Requirements for Oil Burning Equipment; and C22.1 Canadian Electrical Code, Part 1.
Failure to comply with these standards and requirements may result in equipment
damage, fire, explosion, personal injury and/or death.
1-3
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
For Your Safety... (continued)
Guidelines for Furnace Usage
• This furnace is listed for commercial and/or industrial use only; it is not listed for residential
use.
• This furnace is listed with Underwriters Laboratory (UL) and Underwriters' Laboratories of
Canada (ULC) to burn the following fuels:
• Used crankcase oil up to 50 SAE
• Used transmission fluid (for U.S.)
• Used hydraulic oils
• #2 fuel oil
• #4 fuel oil
• #5 fuel oil
NOTE: Used oils may contain other substances, including gasoline, that may hinder
performance.
• Make sure you comply with all EPA regulations concerning the use of your furnace. EPA
regulations require that:
• Your used oil is generated on-site. You may also accept used oil from
"do-it-yourself" oil changers.
• Hazardous wastes, such as chlorinated solvents, are NOT to be mixed with your
used oil.
• The flue gases are vented to the outdoors with an appropriate stack.
• Your used oil is recycled as fuel for "heat recovery". DO NOT operate your furnace
in warm weather just to burn oil.
Contact your Clean Burn dealer for current EPA regulations.
• If your furnace ever requires service, call your Clean Burn dealer. DO NOT allow
untrained, unauthorized personnel to service your furnace. Make sure that your furnace
receives annual preventative maintenance to ensure optimal performance.
1-4
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
For Your Safety... (continued)
WARNING
Guidelines for Used Oil Tanks
For the safe storage of used oil and the safety of
persons in the vicinity of the used oil supply tank,
ensure that your tank installation adheres to the
following safety guidelines:
•
The tank installation must meet all
national and local codes. Consult your
local municipal authorities for more
information as necessary.
•
Review and adhere to the safety
guidelines for used oil supply tanks
as stated in the WARNING shown.
• Ensure that the tank for your furnace
installation complies with all code and
safety requirements as stated here. If the
tank does not comply, DO NOT use it.
• If you do not have a copy of the tank
safety label pictured at right, please
contact your Clean Burn dealer for the
label, which is to be affixed directly on
your used oil supply tank.
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
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
For Your Safety... (continued)
Safety Labels
Following are the locations and descriptions of all labels on your furnace cabinet. The following
illustrations show the location of ALL labels on your furnace. Please note that some labels denote model
number, model description, etc. while others contain important safety messages.
Each Safety Label contains an important safety message starting with a key word as discussed earlier
in this section (e.g. ATTENTION, CAUTION, WARNING, DANGER). For your safety and the safe
operation of your furnace, review all labels and heed all safety messages as printed on the labels.
If any labels on your Clean Burn furnace ever become worn, lost or painted over, please call your Clean
Burn dealer for free replacements.
42030
42027
42358 42462
42355
42514
42457
DATE
CODE
42367
42461/42333/42513
Furnace Cabinet Labels
Label Part #
42030
42027
42358
42462
42355
42514
42457
42461
42333
42513
42367
42068
AIR
OIL
I88793-C
Description
Furnace Electrical Shock Hazard Warning Label (several locations)
Furnace Burn Hazard/Hazardous Voltage Warning Label
UL Data Label
UL Header Label - CB-1750
UL Header Label - CB-2500
UL Header Label - CB-3250
Made in USA / Pat Pending Combination Label
Model CB-1750 Label
Model CB-2500 Label
Model CB-3250 Label
Furnace Safety Warning Label (Multiple Messages - Fire/Shock/Burn Hazards)
Furnace Blower/Fan Entanglement Hazard Warning Label (near blower)
1-6
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
For Your Safety... (continued)
Furnace 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.
42030 Rev. 2
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.
WARNING
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
To avoid possible injury, death, or
equipment damage, read and
understand operator's manuals and
all safety precautions before
installing, operating, or servicing this
equipment.
42367 Rev. 2
WARNING
Entanglement and cutting hazard.
Blower can start at any time.
Turn power OFF before servicing.
Do NOT operate without guard in place.
42068 Rev. 2
1-7
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
For Your Safety... (continued)
Furnace Cabinet Safety Labels
MODEL NO.
MODEL NO.
CB-1750
INPUT RATING W/NO 2 FUEL OIL (BTU/HR)
INPUT RATING W/NO 2 FUEL OIL (BTU/HR)
LISTED FUELS
UL
INPUT
ULC
INPUT
ATOM AIR
PRESSURE
OIL
PRESSURE
- GPH 1.15
- GPH 1.15
- PSIG 15.0
- PSIG 1.5
USED CRANKCASE OIL
1.17
1.17
15.0
2.1
HYDRAULIC OIL
1.17
1.17
15.0
2.1
LISTED FUELS
NO 2 OIL
CB-2501
170000
250000
UL
INPUT
ULC
INPUT
ATOM AIR
PRESSURE
OIL
PRESSURE
- GPH 1.7
- GPH 1.7
- PSIG 18.0
- PSIG 3.5
USED CRANKCASE OIL
1.7
1.7
16.0
4.0
HYDRAULIC OIL
1.7
1.7
16.0
4.0
NO 2 OIL
ATF
1.17
N/A
16.0
2.1
ATF
1.7
N/A
18.0
4.0
NO 4 OIL
1.17
1.17
15.0
2.1
NO 4 OIL
1.7
1.7
18.0
4.0
NO 5 OIL
1.17
1.17
16.0
2.1
NO 5 OIL
1.7
1.7
18.0
5.0
MAX.. DISCHARGE
AIR TEMP-F
200
FLUE DRAFT IN W.C.
MAX.. DISCHARGE
AIR TEMP-F
200
FLUE DRAFT IN W.C.
-0.04
CLEARANCE TO COMBUSTIBLE SURFACES: (INCHES)
TOP
FRONT
BOTTOM
18
12
CHIMNEY
60
REAR FROM
BLOWER
2
24
BOTTOM
W/LOUVERS
38
SIDE
HEATED AIR
DISCHARGE SIDE
CLEARANCE TO COMBUSTIBLE SURFACES: (INCHES)
18
TOP
60
FRONT
12
CHIMNEY
60
REAR FROM
BLOWER
BOTTOM
POWER
VOLTS
AMPS
HZ
3/4
120
11.0
60
FAN MOTOR HP.
OIL PUMP MOTOR HP.
1/20
120
0.75
60
FAN MOTOR HP.
-0.04
SIDE
18
HEATED AIR
DISCHARGE SIDE
60
18
2
24
POWER
VOLTS
AMPS
1
120
14.0
60
OIL PUMP MOTOR HP.
1/20
120
0.75
60
60
HZ
BURNER MOTOR HP.
1/10
120
1.4
60
BURNER MOTOR HP.
1/10
120
1.4
BURNER HEATER WATTS
400
120
3.3
60
BURNER HEATER WATTS
400
120
3.3
60
DRAFT IND. (OPT) HP
1/3
120
3.9
60
DRAFT IND. (OPT) HP
1/3
120
3.9
60
AIR COMPRESS. (OPT) HP.
1/3
120
3.5
60
AIR COMPRESS. (OPT) HP.
1/3
120
3.5
60
TOTAL CIRCUIT AMPACITY W/BLOWER
24
TOTAL CIRCUIT AMPACITY W/BLOWER
27
MAXIMUM FUSE SIZE
30
MAXIMUM FUSE SIZE
30
BURNER REQUIRES A MINIMUM AIR SOURCE OF 2 S.C.F.M. AT 25 P.S.I.
THIS APPLIANCE IS NOT TO BE USED WITH AIR FILTERS AND SHALL
INCORPORATE NO PROVISIONS FOR MOUNTING AIR FILTERS. INSTALL
AND USE ONLY IN ACCORDANCE WITH THE MFR’S INSTALLATION AND
OPERATING INSTRUCTIONS. FOR COMMERCIAL OR INDUSTRIAL USE
ONLY.
BURNER REQUIRES A MINIMUM AIR SOURCE OF 2 S.C.F.M. AT 25 P.S.I.
THIS APPLIANCE IS NOT TO BE USED WITH AIR FILTERS AND SHALL
INCORPORATE NO PROVISIONS FOR MOUNTING AIR FILTERS. INSTALL
AND USE ONLY IN ACCORDANCE WITH THE MFR’S INSTALLATION AND
OPERATING INSTRUCTIONS. FOR COMMERCIAL OR INDUSTRIAL USE
ONLY.
AUTHORITIES HAVING JURISDICTION SHOULD
BE CONSULTED PRIOR TO INSTALLATION
AUTHORITIES HAVING JURISDICTION SHOULD
BE CONSULTED PRIOR TO INSTALLATION
42462 - R1
42355 - R1
1-8
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
For Your Safety... (continued)
Furnace Cabinet Safety Labels
MODEL NO.
CB-3250
300000
INPUT RATING W/NO 2 FUEL OIL (BTU/HR)
UL
INPUT
ULC
INPUT
ATOM AIR
PRESSURE
OIL
PRESSURE
- GPH 2.1
- GPH 2.1
- PSIG 16.0
- PSIG 5.0
USED CRANKCASE OIL
2.1
2.1
16.0
6.0
HYDRAULIC OIL
2.1
2.1
16.0
6.0
ATF
2.1
N/A
16.0
6.0
NO 4 OIL
2.1
2.1
16.0
6.0
NO 5 OIL
2.1
2.1
16.0
6.3
MAX.. DISCHARGE
AIR TEMP-F
200
FLUE DRAFT IN W.C.
LISTED FUELS
NO 2 OIL
-0.04
CLEARANCE TO COMBUSTIBLE SURFACES: (INCHES)
TOP
FRONT
BOTTOM
12
CHIMNEY
60
REAR FROM
BLOWER
24
BOTTOM
DISCHARGE
SIDE
18
UNIT HEATER AIR
DISCHARGE SIDE
60
CENTRAL FURNACE
DISCHARGE SIDE
18
18
2
60
POWER
VOLTS
AMPS
HZ
BLOWER MOTOR HP.
2
120/208/230
22/11.3/11
60
OIL PUMP MOTOR HP.
1/6
120
3.2
60
BURNER MOTOR HP.
1/10
120
1.4
60
BURNER HEATER WATTS
400
120
3.3
60
DRAFT IND. (OPT) HP
1/3
120
3.9
60
AIR COMPRESS. (OPT) HP.
1/3
120
3.5
60
37.3/26.6/26.3
TOTAL CIRCUIT AMPACITY W/BLOWER
50/35/35
MAXIMUM FUSE SIZE
BURNER REQUIRES A MINIMUM AIR SOURCE OF 2 S.C.F.M. AT 25 P.S.I.
THIS APPLIANCE IS NOT TO BE USED WITH AIR FILTERS AND SHALL
INCORPORATE NO PROVISIONS FOR MOUNTING AIR FILTERS. INSTALL
AND USE ONLY IN ACCORDANCE WITH THE MFR’S INSTALLATION AND
OPERATING INSTRUCTIONS. FOR COMMERCIAL OR INDUSTRIAL USE
ONLY.
AUTHORITIES HAVING JURISDICTION SHOULD
BE CONSULTED PRIOR TO INSTALLATION
42514 - R1
CLEAN BURN LLC
JANESVILLE, WISCONSIN (USA)
MH15393
LISTED
USED-OIL BURNING APPLIANCE
USED OIL-FIRED FURNACE
USED OIL-FIRED BOILER
For use with Integral Primary Safety Control
NO.
13084
MULTI-OIL HEATING SYSTEM
INSTALL AND USE ONLY IN ACCORDANCE WITH THE
MFR’S INSTALLATION AND OPERATING INSTRUCTIONS.
FOR COMMERCIAL OR INDUSTRIAL USE ONLY.
AUTHORITIES HAVING JURISDICTION SHOULD
BE CONSULTED PRIOR TO INSTALLATION.
CERTIFIED TO ELECTRICAL AND FUEL BURNING REQUIREMENTS ONLY.
1-9
42358
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
For Your Safety... (continued)
525 BURNER
CB-525-S2 Burner Labels
Label
Part # Description
42005 Sold and Serviced By Label
42004 Burner Safety Warning Label
(High Voltage/Moving Parts Hazards)
42000 Burner Safety Warning Label
(Fire/Explosion Hazard - Reset Button)
42235 Burner Safety Warning Label
(Fire/Explosion Hazard Burner Installation and Service)
42321 Burner Model/Serial Number Label
42229 Logo/Burner Description Label
42023 Burner Power Label
42457 Made in USA / Pat Pending
Combination Label (on side)
42005
42235
42004
42321
42229
42023
42000
CB-525-S2 BurnerSafety Labels
I88603-B
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
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
1-10
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
SECTION 2: UNPACKING
Before assembling your furnace, you must accomplish the following activities described in this section:
• Removing the Shipping Crate
• Unpacking and Inspecting All Components
• Warranty Registration
Removing the Shipping Crate
NOTE: Remove the shipping crate prior to assembly and installation of the furnace. DO NOT use the
crate as a platform for furnace installation!
1.
Carefully remove the top boards of the shipping crate. Then remove the front, back, and side
panels of the shipping crate.
2.
Carefully lift the furnace off the shipping pallet with a fork lift.
ATTENTION: DO NOT attempt to slide the furnace cabinet out of the shipping crate--you may
damage the furnace cabinet.
Unpacking and Inspecting All Components
Following is an itemized list of all components you should have received in your Clean Burn furnace
shipment. Open all shipping containers and inspect all components according to the list. Immediately
notify the freight company and your Clean Burn dealer in case of shipping damage or shortage(s). Keep
all components together so you will have them as needed for furnace assembly and installation.
Furnace Component List
ONE SKID containing:
• Furnace cabinet
• Items packed inside furnace cabinet (combustion chamber):
NOTE: Please refer to the procedure on the following page to remove these items.
•Target
• Hot air discharge assembly components plus hardware
• Furnace Accessories (items below in one box):
• Canister Filter
• Vacuum Gauge
• Check Valve and Check Valve Screen
• Wall Thermostat
• Barometric Damper
• Connector Block
• Burner Oil Line and Air Line Components
• Assorted bolts/fittings for assembly/installation of furnace components
• Operator's Manual Literature Packet (includes Tank Safety Label)
ITEMS PACKED IN INDIVIDUAL BOXES:
• Burner
• Blower Assembly
• Metering Pump (includes Suction Oil Line Fittings Package)
NOTE: You may have received additional boxes or skids if you ordered optional accessories.
2-1
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Unpacking Items Packed Inside the Furnace
To unpack the items packed inside the furnace cabinet (in the combustion chamber), you will need to
open the combustion chamber door.
1.
2.
3.
Remove the four nuts and washers which hold the combustion chamber door closed. Set the nuts
and washers aside in a safe place for later re-installation after the target has been installed
(Section 3).
Carefully swing the combustion chamber door open. Remove and inspect the components
packed inside.
Leave the door unfastened (open) for assembly/installation procedures to be accomplished in the
next section.
CLEAN-OUT DOOR
COMBUSTION CHAMBER
I88436-A
Figure 2A - Accessing the Combustion Chamber
Warranty Registration
For proper warranty registration, Clean Burn requires that you fill out the provided warranty registration
card and return it within 30 days to:
CLEAN BURN WARRANTY REGISTRATION
Clean Burn, LLC.
4109 Capital Circle,
Janesville, WI 53546
2-2
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
SECTION 3: FURNACE ASSEMBLY
Understanding Assembly
Assembling your Clean Burn Furnace includes the following steps:
(1) Installing the Blower Assembly
(2) Installing the Hot Air Discharge Components
(3) Installing the Energy Retention Disc
(4) Installing the Burner
(5) Installing the Connector Block, Oil Line Tubing, and Air Line Tubing
Clean Burn recommends that you review all assembly procedures before proceeding, paying careful
attention to safety information statements.
Figure 3A on the following page provides a general overview of the furnace components and their
proper assembly.
Required Tools and Materials
The following tools are required for furnace assembly and should be gathered before starting any
procedures:
•
•
•
•
•
•
9/16" open-end wrench
Medium flat-blade screwdriver
Medium adjustable wrench
1/4" nut driver attachment for drill
5/16" nut driver attachment for drill
Variable speed drill
3-1
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
"ALL THREAD" RODS
PUMP PRIMING
SWITCH
JUNCTION
BOX
COUPLINGS FOR
"ALL THREAD" RODS
BURNER
CABLE
4
BURNER
MOUNTING
BRACKET
4
R.H.
FURNACE
BREECH
THROAT
FURNACE DOOR
AIR
OIL
5
LH FURNACE
BREECH WITH
CLEAN-OUT
1
NOTE: LOOP ON ENERGY RETENTION
DISC HOOKS OVER MOUNTING
BRACKET ON BACK WALL OF
COMBUSTION CHAMBER
3
ENERGY
RETENTION DISC
INSTALLED ON
BACK WALL OF
COMBUSTION
CHAMBER
2
HOT AIR DISCHARGE
FURNACE BREECH
NOTICE THE VARIOUS MOUNTING CHOICES FOR THE LOUVERS
IT IS OK TO OPEN OR RESTRICT THE LOUVERS AS NEEDED, AND THEN
TO TURN THOSE CONFIGURATIONS IN ANY OF FOUR DIRECTIONS
I88437-C
Complete assembly of the furnace according to the following list of activities as illustrated above:
(1) Installing the Blower Assembly
(2) Installing the Hot Air Discharge Components
(3) Installing the Target
(4) Installing the Burner
(5) Installing the Connector Block, Oil Line Tubing, and Air Line Tubing
NOTE: Corresponding procedures provided in order in this section.
Figure 3A - Overview of Furnace Assembly
3-2
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Installing the CB-1750 and CB-2500 Blower Assembly
1.
Refer to Figures 3B and 3C.
2.
Remove the blower stabilizer brackets as shown in Figure 3B. (These braces, which are installed
at the factory, are designed to keep the blower in proper position during shipping. Note that
these braces are provided on CB-2500 blower assemblies ONLY; CB-1750 blower assemblies do
not require these special shipping braces.)
3.
Position the blower over the opening in the back of the furnace cabinet by sliding the blower into
the mounting angle brackets. Note that the mounting brackets may be loosened for adjustment,
as needed. The blower should be centered over the opening.
4.
Fasten the blower to the brackets with self-tapping screws (provided). Drive the screws into the
blower housing through the holes in the mounting angle brackets. There are four holes along
each side and across the top of the bracket to fasten the blower to the furnace cabinet.
5.
Install the blower safety guards as shown.
WARNING: To avoid serious personal injury, be sure to install both pieces of the blower guard
around the blower prior to operating the furnace. NEVER operate the furnace without all safety
shields/guards in place!
ATTENTION: The air flow is changed when the guards are not in place which may result in
damage to the blower motor.
NOTE: For proper air flow through the furnace cabinet the blower must be positioned so that
the bulge on the blower faces down as illustrated in Figures 3A, 3B, and 3C.
IMPORTANT!!:
1 REMOVE SHIPPING BRACES
2 ATTACH BLOWER TO FURNACE
3 ATTACH SHIELDS/GUARDS TO BLOWER (1 ON EACH SIDE)
X2
I88691-D
Figure 3B - Installing the Blower Assembly (CB-1750 and CB-2500)
3-3
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Installing the CB-1750 and CB-2500 Blower Assembly (continued)
L2
L1
Note capacitor location on blower.
CB-1750 is shown; CB-2500
capacitor is mounted on the opposite
side of the blower.
I88438-D
Figure 3C - Blower Installed on Furnace Cabinet (CB-1750 and CB-2500)
Wiring the CB-1750 and CB-2500 Blower Motor
WARNING: Make sure the main power to the furnace is turned OFF before wiring the blower
motor.
NOTE: Wiring schematics are provided in Figures 3D and 3E and in Appendix B at the back of
the manual.
1.
After the blower has been secured to the back of the furnace cabinet, install the electrical conduit
with the blower motor leads into the 4" x 6" rear junction box on the top of the furnace cabinet as shown in Figure 3C.
2.
For CB-1750 furnaces (see Figure 3D):
• Connect the power lead coming from the blower assembly to the 4" x 6" electrical box
mounted on the rear of the furnace cabinet.
• Connect the black (power) motor lead wire to the connector block terminal with the black
(power) wire from the front electrical box.
• Connect the white (neutral) motor lead wire to the connector block terminal with the
white (neutral) wire from the front electrical box.
For CB-2500 furnaces (see Figure 3E):
3.
• Connect the power lead coming from the blower assembly to the 4" x 6" electrical box
mounted on the rear of the furnace cabinet.
• Connect the black (power) motor lead wire to the T1 terminal of the contactor.
• Connect the white (neutral) motor lead wire to the T2 terminal of the contactor.
3-4
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Installing the CB-1750 and CB-2500 Blower Assembly (continued)
REAR
JUNCTION
BOX
WHITE
BLACK
BLACK
BLACK
WHITE
BLOWER
MOTOR
WHITE
POWER IN
(FLEX CONDUIT)
I42425
Figure 3D - Detail of Blower Motor Wiring for CB-1750
REAR
JUNCTION
BOX
WHITE
SPADE
(MALE TO FEMALE)
WHT
WHITE
(UNDER LUG SCREW)
POWER
IN
FLEX
CONDUIT
L2
BLACK
(UNDER LUG SCREW)
BLOWER
MOTOR
T2
BLK
L1
T1
ORANGE
I42423
Figure 3E - Detail of Blower Motor Wiring for CB-2500
3-5
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Installing the CB-3250 Blower Assembly
Mounting the CB-3250 Blower
1.
2.
3.
Refer to Figures 3F and 3G.
Position the blower over the opening in the back of the furnace cabinet by sliding the blower into
the mounting angle brackets. The top of the blower is slid over the lip on the back of the furnace.
The mounting screws on top will go through the blower and anchor into the thicker lip pretruding
from the back of the furnace cabinet. Check for proper positioning by referring to Figure 3G.
Fasten the blower to the brackets with self-tapping screws (provided).
NOTE: There are three holes for fastening the blower along each side of the bracket, as well as
three across the top.
Installing the CB-3250 Motor on the Blower
1.
2.
3.
4.
5.
6.
7.
8.
9.
Refer to Figures 3F and 3G.
Use self-tapping bolts to install the motor mounting bracket on the blower according to the
dimensions provided in Figure 3F.
Slide the two (2) square-head bolts upside-down in the channel of the motor mounting bracket.
Install the motor mounting plate on the mounting bracket using the two bolts in the channel to
hold the plate in position. DO NOT install the nuts on the bolts yet. Make sure the plate is flush
with the side of the blower.
Use a self-tapping bolt to install the motor tensioning bracket on the blower according to the
dimensions provided in Figure 3F.
Lift up on the end of the motor mounting plate until the hole in the side of the plate is aligned
with the slot in the motor tensioning bracket. Push a bolt through the slot and install a nut
loosely just to hold the plate in position. DO NOT tighten the nut yet.
Lift the motor into position on the motor mounting plate using the two bolts in the channel to
hold the motor in place. Now loosely install the nuts on the two (2) bolts.
Slide the motor into position so the face of the motor is flush with the side of the blower. Now
tighten the nuts.
Install the additional two (2) bolts and nuts through the upper holes in the motor mounting plate
and motor. Tighten the nuts to hold the motor firmly in position.
Wiring the CB-3250 Blower Motor
WARNING: Make sure the main power to the furnace is turned OFF before wiring the blower
motor.
NOTE: Wiring schematics are provided in Figure H and Appendix B at the back of the manual.
1.
2.
3.
After the blower has been secured to the back of the furnace cabinet, screw the electrical conduit
with the blower motor leads into the motor housing.
Determine the voltage being supplied to the unit. Follow the correct wiring diagram in Figure H
for either 115 Volts or 230 Volts. Connect the wire ends with the terminals to the motor. Refer to
the wiring diagram on the motor to ensure that the motor is wired for proper voltage and CW
rotation facing the shaft.
Install the electrical conduit with the blower motor leads into the 4" x 6" rear junction box on top
of the furnace cabinet as shown in Figure 3G. Refer to Figure 3H for the proper wiring diagram.
3-6
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
BLOWER ASSEMBLY PARTS LIST
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
(4) 1
3
4
2
1
6
5
8
11
NUT
MOTOR
MOTOR PULLEY
SHEAVE BUSHING 7/8”
MOTOR MOUNTING PLATE
BOLT
SQUARE HEAD BOLT
BLOWER GUARD
MOTOR MOUNTING BRACKET
BLOWER
MOTOR TENSIONING BRACKET
SELF TAPPING SCREW
BLOWER PULLEY
SHEAVE BUSHING 1"
BELT
BELT GUARD
6
7
12
9
13
10
14
15
16
18 1/4"
3/4"
4"
8 1/2"
CB-3250 BLOWER
DETAIL OF BRACKET INSTALLATION
NOTE: The brackets must be
installed at the correct position on
the side of the blower as shown
here to allow the belt guard to
mount properly.
I89022
Figure 3F - Blower Assembly Parts Detail (CB-3250)
3-7
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Installing the CB-3250 Blower Assembly (continued)
I89021
Figure 3G - Blower Installed on Furnace Cabinet (CB-3250)
Installing the CB-3250 Motor Pulley, Blower Pulley, and V-Belt
1.
Review the contents of the Blower Pulley and Motor Pulley as shown in Figure 3F.
2
Refer to Figure 3F. Place the blower pulley over and onto the blower shaft as far as possible
with large bore end of taper outward.
3.
Insert the blower key into the bushing. (If the key is deformed and does not fit into place, file the
key to the proper size or replace it with a new key).
4.
Slide the bushing (with key inserted) onto the shaft so the tapered end will engage into the
pulley.
NOTE: If bushing does not slide freely on shaft, wedge a screwdriver blade into the saw cut
at the flange OD to open the bore of the bushing. CAUTION: Excessive force may split the
bushing.
5.
6.
Align drilled holes in bushing flange with tapped holes in the pulley. Use the capscrews
and washers provided with the bushing package to fasten the pulley on to the bushing. DO NOT
COMPLETELY TIGHTEN THE SCREWS AT THIS POINT! Make sure you can still slide the
bushing and pulley for future alignment with the motor pulley. (Additional information is
available in the “Bushing Instruction Sheet” provided with each bushing)
Install the motor pulley following steps 1 through 5.
3-8
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
GROUND
BLACK
GREEN
FLEX
CONDUIT
T2
WHITE
T1
HOT LEG
L2
115 VOLTS AC
COMMON / NEUTRAL
L1
115
VOLTS
IN
ORANGE
BLOWER
MOTOR
CONTACTOR HAS A
110 - 120 VOLT AC COIL
CONNECT 2 HP BLOWER MOTOR
ACCORDING TO THE LABEL SUPPLIED WITH
THE MOTOR FOR CW ROTATION FACING
THE SHAFT AND 115 VOLTS
GROUND
BLACK
GREEN
FLEX
CONDUIT
T2
WHITE
230 VOLTS AC
T1
HOT LEG
HOT LEG
L2
COMMON / NEUTRAL
L1
230
VOLTS
IN
ORANGE
CONTACTOR HAS A
110 - 120 VOLT AC COIL
CONNECT 2 HP BLOWER MOTOR
ACCORDING TO THE LABEL SUPPLIED WITH
THE MOTOR FOR CW ROTATION FACING
THE SHAFT AND 230 VOLTS
I89031
Figure 3H - Detail of Blower Motor Wiring for CB-3250
3-9
BLOWER
MOTOR
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Installing the CB-3250 Motor Pulley, Blower Pulley, and V-Belt (continued)
7.
Align the motor pulley with the blower pulley.
a. Place the blower bushing ½ inch from the end of the shaft and tighten the capscrews securely
(9 Ft. - Lbs. if using a torque wrench).
b. Place a level or straight edge flat onto the two most outer edges of the blower pulley.
c. Place the motor pulley and bushing about ¼ inch away from the straight edge.
d. Start tightening the screws on the motor bushing. As the screws are tightened, the motor
pulley will approach the straight edge. TIGHTEN THE CAPSCREWS SECURELY (9 Ft. Lbs. if using a torque wrench).
e. Four points of the two pulleys should be touching the straight edge. If they don’t make full
contact, loosen the screws on the motor bushing and realign it so both pulleys are on the
same plane.
8.
Place the belt on the pulleys, starting with the motor pulley and feeding it onto the blower pulley.
Tighten the belt (Refer to Figure 3G).
9.
a. Raise the motor bracket and at the same time tighten the nut on the tension bracket.
b. DO NOT over tighten the belt. Leave about 1inch of slack (when pushing on the top of the belt, it should deflect about 1 inch).
Installing the CB-3250 Belt Guard and Blower Guard
WARNING: To prevent serious personal injury, DO NOT operate the furnace without the belt
and blower guards in place.
1.
Refer to Figure 3F and 3G.
2.
Install the belt guard and blower guard as shown.
Determining the Air Discharge Configuration
Before proceeding with the assembly of your furnace, it is important to determine the configuration of
the air discharge for your furnace. There are three configurations to consider:
(1) Unit Heater Furnace with blower assembly for free air applications.
Follow the instructions (provided in this section) to install the blower
assembly and air discharge components. Be sure to adhere to the proper
specified clearances for Unit Heater Configurations as stated in
Section 4 of this manual.
(2) Central Furnace (A) Furnace with blower assembly for ducting applications with .25 or less
static pressure.*
Follow the instructions to install the blower assembly and air discharge
components, and refer to the following chart for the proper air discharge
and ducting specifications. Be sure to adhere to the proper specified
clearances for Central Furnace Configurations as stated in Section 4 of
this manual.
(3) Central Furnace (B) Furnace with blower assembly for ducting applications from .25 to .40
static pressure.*
Follow the instructions to install the blower assembly, and refer to the
following chart for the proper air discharge and ducting specifications.
Be sure to adhere to the proper specified clearances for Central Furnace
Configurations as stated in Section 4 of this manual.
3-10
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Determining the Air Discharge Configuration (continued)
Static Pressure (SP) and Air Flow (CFM) Specifications
CB-1750
Air Discharge Louvers
Mounted on Furnace
Air Discharge Louvers Mounted on Furnace
(Fully Open - Ductwork Installed Over Top)*
Air Discharge Louvers Removed
Ductwork Installed on Furnace
Duct Free**
0.25 Inches of W.C.**
0.30 Inches of W.C.**
1625 CFM
1500 CFM
1400 CFM
Air Discharge Louvers
Mounted on Furnace
Air Discharge Louvers Mounted on Furnace
(Fully Open - Ductwork Installed Over Top)*
Air Discharge Louvers Removed
Ductwork Installed on Furnace
Duct Free**
0.25 Inches of W.C.**
0.40 Inches of W.C.**
2700 CFM
2500 CFM
2400 CFM
Air Discharge Louvers
Mounted on Furnace
Air Discharge Louvers Removed
Ductwork Installed on Furnace
Air Discharge Louvers Removed
Ductwork Installed on Furnace
Duct Free**
0.25 Inches of W.C.**
0.40 Inches of W.C.**
3300 CFM
3150 CFM
2900 CFM
CB-2500
CB-3250
C77001
*NOTE: The open louvers function as an orifice plate for the lower static pressure installations.
**ATTENTION: A qualified electrician must check the blower motor amperage during operation of the furnace to ensure
that motor amperage does not exceed 85% of the maximum amperage on the motor label. DO NOT operate the blower motor
above 85% of maximum amperage or motor damage may occur.
IMPORTANT NOTE: It is essential that qualified HVAC personnel properly design the ductwork
for your furnace and determine the static pressure for your ducting application. Note that existing
ductwork at your installation site may not be appropriate or meet the specifications for this
furnace installation. For static pressure readings as shown in the chart above, the ductwork
should be installed directly over the opening in the SIDE of the furnace cabinet (i.e. where the louver panels would be installed for free air applications.) For Central Furnace applications, ductwork
may NOT be installed over the bottom opening.
3-11
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Installing the Hot Air Discharge Components
It is very important to properly install the hot air discharge components (louvers and blank cover panels)
to direct the flow of air from the furnace. As you will note from Figures 3I and 3J, the air discharge
panels are to be installed on the side(s) and/or bottom of the furnace. The air flow may be directed
down, front, or back, depending upon how the louvers and cover panels are installed.
IMPORTANT NOTE FOR CENTRAL FURNACE APPLICATIONS:
•
For ducting applications of .25 static pressure, install the louvers as described in
the following procedure, and then install the ductwork over top of the fully open louvers.
•
For ducting applications of .30 (CB-1750) or .40 (CB-2500 and CB-3250) static pressure,
DO NOT install the louvers. The ductwork should be installed directly over the desired air
discharge openings on the side of the furnace cabinet.
•
Ductwork must be installed over side opening(s) ONLY. Ductwork may NOT be
installed over the bottom air discharge opening.
1.
2.
Refer to Figures 3I and 3J. Determine the desired air flow discharge pattern. Note that each
furnace is supplied with (2) louver sections and (4) blank cover panels.
Air discharge openings are: (1) on each side of the furnace, and (1) on the bottom of the furnace.
Install the louver panels in the desired location(s) with the self-tapping screws provided. Holes
are pre-drilled in the furnace cabinet to accommodate installation of the panels.
Air Flow Discharge Installation
Guidelines:
• When determining the
placement of the air discharge
louvers, you also need to consider
the required clearances from
combustibles as stated in
Section 4 of this manual.
• Note that each furnace model
supplied with (2) louver sections
which may be installed together
on one side or the bottom as
shown here OR the louvers may be
split for partial air discharge on each
side and/or bottom as shown in
Figure 3J.
NOTE: Bottom louver installation
applies to Unit Heater furnaces ONLY.
Ductwork for Central Furnace applications
may NOT be installed over the bottom
opening.
I88439-C
Figure 3I - Hot Air Discharge Components (Louvers/Blank Covers) Installed on Furnace
3-12
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Installing the Hot Air Discharge Components (continued)
3.
Adjust the louvers for the desired air flow direction.
ATTENTION: DO NOT restrict the flow of the hot air from the furnace by closing the louvers,
or the furnace will not operate properly.
4.
Install the blank covers over the remaining air discharge opening(s) on the furnace cabinet.
Louvers split between two side openings, showing left and right side views of same furnace
NOTE: When louver panels are "split" between two sides, make sure the louvers are installed
in the upper half of each side air discharge opening as shown here.
Louvers split between left side and bottom openings, showing left and right side views of same furnace
NOTE: When louver panels are "split" between a side and the bottom, make sure the bottom louvers
are installed in the forward half of the bottom air discharge opening as shown here.
Louvers split between right side and bottom openings, showing left and right side views of same furnace
I88537
Figure 3J - Sample Split Louver Installations for Partial Air Discharge on Sides and/or Bottom
3-13
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Installing the Energy Retention Disc
Installing the Energy Retention Disc at the Back of the Combustion Chamber
ATTENTION: DO NOT fire your furnace without the Energy Retention Disc in place, or combustion
chamber damage will occur. Handle the Energy Retention Disc carefully to avoid damaging it.
1.
Refer to Figure 3A to review the proper positioning of the Energy Retention Disc.
2.
Swing open the clean-out door on the front of the furnace to gain access to the combustion
chamber.
3.
Use a long rod to support the Energy Retention Disc as you guide it into position on the back of
the combustion chamber. The loop on the back of the Energy Retention Disc fits over the hook
located on the back of the combustion chamber.
Closing the Furnace Door
1.
2.
After the Energy Retention Disc has been installed, close the furnace clean-out door.
Tighten the four (4) lock-down nuts in a criss-cross pattern until all are snug.
3-14
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Installing the Burner
Checking the Burner Nozzle and Electrodes
NOTE: The burner nozzle is factory installed. All furnace models (CB-1750, CB-2500, and CB-3250)
use a Delavan 9-5 nozzle. The nozzle size is indicated on the nozzle as shown in Figure 3K. Refer also
to Appendix A at the back of the manual for additional specifications/instructions on the burner nozzle.
ATTENTION: Check the electrode settings as specified in Figure 3K. The electrode settings must be
correct for your burner to operate properly.
BURNER NOZZLE
NOZZLE IS STAMPED WITH SIZE
ON FLAT OF NOZZLE HEAD
SIDE VIEW - AA
3/16" GAP BETWEEN
ELECTRODES & NOZZLE
3X
CRITICAL DIMENSION:
NOZZLE MUST BE 1/8"
AHEAD OF THE DISK.
NOZZLE MUST NOT BE
BEHIND THE DISK.
VIE
W
-B
VIE
W
A
-A
B
1/8"
SPARK
GAP
FRONT VIEW - BB
I88647
Figure 3K - Burner Nozzle and Electrode Specifications
3-15
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Installing the Burner (continued)
Mounting the Burner on the Hinge Bracket
ATTENTION: Burner tube components (e.g. electrodes and retention head) are factory set. Handle the
burner with extreme care so that burner components are not damaged.
1.
Remove the nut from the mounting flange of the furnace cabinet, and set it aside for later use.
2.
Lift the burner into position so that it is mounted on the hinge bracket on the furnace cabinet.
3.
Carefully swing the burner so the retention head enters the throat of the furnace.
4.
Check the clearance between the retention head and the furnace throat. There must be at least
1/8" clearance, so the retention head is not "bumped" as you swing the burner into firing
position.
NOTE: If the retention head "bumps" the furnace throat, adjust the hinge bracket bolts
as follows:
• While supporting the burner, slightly loosen the two (2) hinge bracket bolts.
• Carefully re-position the burner so it swings freely into its firing position.
• With the burner in its firing position, re-tighten the hinge bracket bolts.
3-16
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Installing the Connector Block, Oil Line Tubing, and Air Line Tubing
ATTENTION: DO NOT use teflon tape on any fittings. Teflon tape residues will plug vital burner
components and void your warranty.
OIL LINE
Installing the Connector Block on the Furnace Door
1.
2.
3.
OIL FITTING
ON BURNER
Refer to Figure 3L.
Use the two (2) bolts to install the aluminum
connector block onto the furnace 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 furnace assembly.
ATTENTION: The connector block includes an
accumulator. The accumulator functions like a shock
absorber on the oil line to prevent pressure buildup and
protect vital burner components. It is important that the
connector block is installed as shown so that the accumulator
is in a vertical position to prevent sediment from settling in
the accumulator. Never operate your furnace without the
connector block and accumulator properly installed on the
furnace, or damage may occur to vital burner components.
CONNECTOR BLOCK
AIR
OIL
FRONT VIEW OF FURNACE
OIL LINE FITTING
ON BURNER LINED
UP WITH OIL LINE
OIL LINE
Installing the Oil Line Tubing
ATTENTION: DO NOT disassemble the compression
fitting from the swivel fitting. To prevent leaks, the NPT
threads of the compression fitting have been sealed with
hydraulic sealant during assembly of the fittings at the
factory.
SWIVEL
ASSEMBLY
CONNECTOR
BLOCK
SIDE VIEW OF FURNACE
SHOWING OIL LINE INSTALLED
I88341-A
Figure 3L - Installation of Connector
Block and Oil Line
1.
2.
3.
4.
Remove and discard the red 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 3L, if required,
to "line up" the oil line.
If necessary, use a tubing cutter to cut the tubing to the proper length.
ATTENTION: Due to adjustment of the burner hinge bracket, the oil line tubing may need to
be cut to fit properly. DO NOT lift up on the burner when installing the oil line tubing to
compensate for oil line tubing that is too long. This will place the weight of the burner on the
swivel fitting and result in leaks at the swivel fitting seal.
3-17
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Installing the Connector Block, Oil Line Tubing, and Air Line Tubing
(continued)
Installing the Oil Line Tubing (continued)
5.
6.
Make sure that the curl in the oil line is positioned as shown in Figure 3L 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.
NOTE: You may also check the positioning of the oil line according to Figure 3M which provides a
larger front view of the connector block assembly.
Installing the Air Line Tubing
1.
2.
3.
Remove and discard the red caps from the air line tubing.
Refer to Figure 3M. 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.
PUMP PRIMING SWITCH
AIR LINE FITTING
ON BURNER
OIL LINE FITTING
ON BURNER
AIR LINE
OIL LINE
COMPRESSION /
SWIVEL FITTING
AIR
OIL
CONNECTOR BLOCK
INSTALLED ON
FURNACE CABINET
I88440-A
Figure 3M - Installation of Connector Block, Oil Line and Air Line (Front View)
3-18
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Locking the Burner into Firing Position
1.
2.
3.
4.
Swing the burner into firing position.
Install and tighten the lock-down 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.
CONNECTOR PLUG
NOTE: Be sure to properly align the plug when plugging it into
the receptacle. See Fig 3N.
KEY IN PLUG
MUST ALIGN
WITH SLOT IN
RECEPTACLE
RECEPTACLE ON
TOP OF BURNER
I88641-B
Figure 3N - Detail of Burner
Electric Receptacle
NOTE: Your furnace is now assembled and ready for installation. Install the furnace as
soon as possible so the burner and/or blower are not "bumped" or damaged. If you must
store the furnace for a period of time before installation, make sure it is located in a safe,
secure area.
3-19
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
3-20
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
SECTION 4: FURNACE INSTALLATION
Understanding Installation
Installing your Clean Burn furnace is a multi-step process which includes:
(1) Selecting a Location
(2) Mounting the Furnace
(3) Oil Tank Installation Specifications (review)
(4) Installing the Metering Pump
(5) Wiring the Furnace and Pump
(6) Installing the Oil Lines
(7) Installing the Compressed Air Line
(8) Installing the Stack
(9) Installing the Wall Thermostat
(10) Inspecting the Installation
Clean Burn recommends that you review all procedures before beginning installation, paying careful
attention to safety information statements. Figure 4A provides a general overview of a typical furnace
installation and should be reviewed closely before proceeding.
WARNING: The installation, operation, and maintenance of this equipment in the U.S.
must be accomplished by qualified personnel and in compliance with the specifications in the
Clean Burn Operator's Manual and with all national, state, and local codes or authorities having
jurisdiction over environmental control, building inspection and fuel, fire and electrical safety and the
following standards:
NFPA 30 Flammable and Combustible Liquids Code
NFPA 30A Automotive and Marine Service Station Code
NFPA 31 Standard for the Installation of Oil Burning Equipment
NFPA 211 Chimneys, Fireplaces, Vents and Solid Fuel Burning Appliances
NFPA 88A Parking Structures
NFPA 88B Repair Garages
NFPA 70 National Electrical Code
The International Mechanical Code
The International Building Code
The International Fire Code
The International Fuel Gas Code
Likewise, the installation, operation, and maintenance of this equipment in Canada is to be
accomplished by qualified personnel and in compliance with the specifications in the Clean Burn
Operator's Manual and in accordance with the regulation of authorities having jurisdiction and the
following CSA Standards: B139 - Installation Code for Oil Burning Equipment; B140.0 - General
Requirements for Oil Burning Equipment; and C22.1 - Canadian Electrical Code, Part 1.
Failure to comply with these standards and requirements may result in equipment damage, fire,
explosion, personal injury and/or death.
WARNING: Improper installation can adversely affect the proper, safe operation of your
furnace. It is critical that your furnace installer reads and follows the instructions provided in
this manual.
4-1
WARNING: When installing your furnace,
adhere to the minimum clearances from
combustible surfaces as stated in Section 4.
These clearances also provide adequate
space for servicing. Failure to maintain
proper clearances may result in fire,
explosion, personal injury, or death.
3 FT.
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
EVERY FITTING TO MAINTAIN PROPER DRAFT OVERFIRE
10 FT. MINIMUM VERTICAL STACK HEIGHT PLUS 1 FT. FOR
10 FT.
MAXIMUM 6 FT.
ELECTRIC SERVICE
OIL PUMP ELECTRICAL CIRCUIT
AIR
COMPRESSED AIR LINE
CAUTION: DO NOT EXCEED 6 FT VERTICAL
SUCTION LIFT OR THE PUMP WILL NOT
PRIME AND/OR THE FLOW RATE FROM
THE PUMP MAY DECREASE
24 VOLT WALL
THERMOSTAT
8 FT. MIN. FROM FLOOR TO FURNACE IFTHERE IS A POTENTIAL FOR
GASOLINE FUMES IN YOUR SHOP. CHECK LOCAL CODES AND NFPA 88-B
CONNECTOR BLOCK
"2 WIRE" MIN 18 GA.
THERMOSTAT CABLE
DEDICATED ELECTRIC CIRCUIT
1/4" HOLE FOR
SETTING DRAFT.
ADJUST BAROMETRIC
DAMPER FOR -.04" W.C.
DRAFT AT BREECH
OIL
PRESSURE OIL LINE
SUCTION
OIL LINE
BALL VALVE
VENT
CAP
EMERGENCY
VENT VALVE
OIL
STORAGE
TANK
CLEANOUT
WITH DRAIN
1 FT.
I88555-G
Figure 4A - Typical CB-1750/2500/3250 Furnace Installation
4-2
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Selecting a Location
Guidelines for Selecting a Location
The location you select for your furnace must allow the following:
• Unobstructed, even heat distribution.
• Safe, easy access for servicing.
• Unobstructed passage for shop vehicles and equipment.
• Proper clearances from combustibles. Verify according to your local safety codes.
• Adequate combustion air per local codes.
• Proper stack installation.
WARNING: Adhere to the following minimum clearances from combustible surfaces and
to provide adequate clearance for servicing (also refer to Figure 4B for visual reference); failure
to maintain proper clearances may result in fire, explosion, personal injury or death.
CLEARANCES FOR UNIT HEATER
INSTALLATION WITH
SIDE AIR DISCHARGE
MINIMUM DISTANCES
CB-140 / CB-1750 / CB-2500 / CB-3250 FURNACES
REAR
2"
TOP
12"
• TOP (of furnace)............................... 12"
• FRONT (burner)................................ 60"
• SIDE with Air Discharge.................... 60"
• OTHER SIDE.................................... 18"
• CHIMNEY CONNECTOR................. 18"
• REAR (from blower).......................... 2"
•BOTTOM........................................... 24"
CLEARANCES FOR UNIT HEATER
INSTALLATION WITH
BOTTOM AIR DISCHARGE
•
•
•
•
•
•
•
TOP (of furnace)............................... 12"
FRONT (burner)................................ 60"
SIDE (with or without stack).............. 18"
CHIMNEY CONNECTOR................. 18"
REAR (from blower).......................... 2"
BOTTOM (CB-1750)......................... 38"
BOTTOM (CB-2500 and CB-3250)... 60"
CLEARANCES FOR CENTRAL FURNACE
INSTALLATION
• TOP (of furnace)............................... 12"
• FRONT (burner)................................ 60"
• SIDE without stack............................ 18"
• CHIMNEY CONNECTOR................. 18"
• REAR (from blower).......................... 2"
•BOTTOM........................................... 24"
• WARM AIR DUCTS within 3ft.......... 6"
18"
OTHER SIDE
(WITHOUT AIR
DISCHARGE)
18"
CHIMNEY
CONNECTOR
60"
AIR
DISCHARGE
SIDE
60"
FRONT
96 " BOTTOM - IF THERE IS POTENTIAL
FOR GASOLINE FUMES
24 " BOTTOM - IF THERE IS NO POTENTIAL
FOR GASOLINE FUMES
I88600-E
Figure 4B - Clearances from Combustibles
WARNING: Codes mayrequire
that your furnace is mounted a
minimum of eight (8) feet off the ground when
installing the furnace in a repair facility. Refer
to NFPA-88B, Standard for Repair Garages,
Chapter 3, Hazards, Sec. 3-2.3.1.
4-3
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Mounting the Furnace
After selecting a safe and appropriate location for your furnace, construct the mounting system as
required by the location and the following specifications.
Ceiling Mounting
WARNING: To prevent serious personal injury, ensure that your furnace mounting system can
safely bear the suspended weight of the furnace and allow safe servicing of furnace components.
Use adequately sized square tubing or angle iron bridged across sufficient structural members to safely
support the furnace.
1.
2.
3.
Refer to Figure 4C.
Follow the instructions as provided in the diagram.
Use a spirit level to make sure the cabinet is level side to side and front to back.
CEILING MOUNTING SYSTEM
WARNING! USE MINIMUM 2-1/2 X 2-1/2 X 1/4" ANGLE
IRON BEAMS, BRIDGED ACROSS SUFFICIENT
ANGLE IRON SUPPORT
STRUCTURAL MEMBERS TO SAFELY
SUPPORT FURNACE
BEAMS
DOUBLE NUTS
(4) 5/8 "ALL THREAD" SUPPORT RODS
THREAD SUPPORT RODS TO COUPLING
NUTS IN FURNACE CABINET
WARNING! MAKE SURE TO USE LOCKNUTS
WHEN FASTENING THE RODS TO THE
COUPLING NUTS
R. H.
FURNACE
BREECH
CB-525-S2
BURNER
CONNECTOR
BLOCK
AIR
OIL
I88446-E
Figure 4C - Ceiling Mounting Installation Overview
4-4
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Mounting the Furnace (continued)
Raised Platform Mounting
WARNING: To prevent serious personal
injury, make sure the platform is designed
to safely bear the weight of the furnace and allow
safe servicing of furnace components. The platform
must be constructed of non-combustible materials
(e.g. steel) and must be securely anchored to an
adjacent wall.
Refer to Figure 4D, and follow the
instructions as provided in the diagram.
Floor Mounting
WARNING: To prevent serious personal
injury, make sure the floor can safely bear the
weight of the furnace.
CAUTION: If you are installing your furnace
in an area with a combustible floor (e.g. over
the top of a parts room or on a mezzanine) and the
bottom of the furnace is less than 24" above the floor,
you must construct a non-combustible floor as shown
in Figure 4E. Refer to NFPA-31 or CSA-B-139.
OIL
8 FEET MINIMUM FROM FLOOR TO
FURNACE CABINET IF THERE IS POTENTIAL
FOR GASOLINE FUMES. REFER TO NFPA 88-B.
1.
AIR
I88447-C
Figure 4D - Furnace Installed on
Raised Platform
NOTE: If the bottom of the unit is more than 24" above the floor, a support stand can be constructed
out of square tubing or angle iron adequately sized to safely support the weight of the furnace. A
minimum stand height of 30" is recommended to allow for easy ash cleanout and servicing of the
heating equipment.
NOTE: Make sure that blank cover panels are installed over the bottom air discharge opening to allow
safe floor mounting.
Constructing a non-combustible floor
Determine the size of floor you will need to construct:
1.
• Measure the width and length of the cabinet of the furnace.
• Add 12" (minimum) to all sides of the cabinet to achieve the total measurement for the
non-combustible floor.
EXAMPLE: The CB-1750 measures 55" long x 27" wide.
55" + 12" + 12" = 79" long
27" + 12" + 12" = 51" wide
2.
Refer to Figure 4E. Install two (2) pieces of 5/8" sheet rock on top of the combustible material
(wooden floor, wooden beams, etc.) The sheet rock must be cut to the size of the total
non-combustible floor area.
4-5
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Constructing a Non-Combustible Floor (continued)
3.
4.
5.
6.
7.
8.
Place a sheet of 24-gauge (minimum) galvanized sheet metal on top of the 5/8" sheet rock;
the sheet metal must cover the sheet rock completely.
Place 4" thick (minimum) hollow masonry block, end to end, on top of the 24-gauge sheet metal
to make a solid foundation. Be sure to add center cross blocking to safely and adequately
support the furnace.
Place a 24-gauge sheet metal pan with a 1" containment lip on top of the masonry blocks. This
will provide containment of any oil that may be spilled while working on the furnace.
Position the furnace on top of the sheet metal pan; make sure you maintain the extra 12"
minimum clearance on all sides of the cabinet.
Ensure that the installation adheres to all clearances from combustibles as stated at the beginning
of Section 4 in this manual.
After positioning the furnace cabinet on the sheet metal pan, install 2" tall (minimum) cinder
blocks (4) under each corner of the furnace to elevate the cabinet off the sheet metal pan to
allow clearance for installation of fittings on the connector block.
MIN. 24 GA STEEL
PAN WITH MIN. 1 INCH
(2.5 CM) LIP FOR
OIL CONTAINMENT
AIR
MIN. 18" (46 CM)
OIL
MIN. 18" (46 CM)
8 INCHES (20 CM)
TALL CINDER BLOCK
MIN. 24 GA STEEL
FIREGUARD SHEETROCK
OR EQUIVALENT
COMBUSTIBLE MATERIAL
MIN. 2" (5 CM) TALL MASONRY BLOCKS TO
ALLOW CLEARENCE FO INSTALLATION OF
FITTINGS ON THE CONNECTOR BLOCK
Figure 4E - Furnace Installed on Non-Combustible Floor
4-6
I88462-B
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Oil Tank Installation Specifications
WARNING
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 authorities for more information as
necessary.
• The tank must be listed to UL 80, UL 142, or
equivalent standard.
• Use a minimum 250-gallon tank DO NOT
use a 55-gallon drum as a substitute for an
appropriate tank. The tank must be large
enough to allow water, sludge, etc. to settle
out of the used oil.
• Single wall tanks should have a manual
shut-off type valve on the side of the tank
to allow the water, sludge, etc. to be drained
from the bottom of the tank.
• All unused openings in the tank must be
plugged or capped off.
• For optimal system functioning, Clean Burn
Recommends inside tank installations as
shown in Figures 4A, 4F, and 4J.
• Some codes require the tank to be vented to
the outside of the building using iron or steel
pipe and fittings with an approved vent cap.
• Carefully review the oil tank and pump
installation details as shown in Figures
4A, 4F, and 4J. Pertinent information also
supplied with the metering pump and oil line
installation procedures (following in Sec. 4).
• Ensure that the oil supply tank is properly
maintained; refer to Section 9 in this manual
for related procedures.
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
ATTENTION: For outside tank installations and/or tanks larger than 500 gallons, contact your
local Clean Burn Distributor for installation recommendations and specifications.
4-7
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
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
PUMP
F
RELIE
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 4F - Typical Metering Pump Installation with Inside Tank
Installing the Tank Vent and Emergency Vent
Some codes require that you install a tank vent (to the outside) and an emergency vent for your tank
as shown in Figure 4F. Tank Vent Kits are available from Clean Burn; contact your local Clean Burn
dealer to order. Be sure to check your local codes for any additional tank installation requirements, and
adhere to the following installation guidelines:
• Install a length of minimum 2" steel pipe (user-supplied) terminating outside with a proper
vent cap as shown in Figure 4F. Consult local codes for information and requirements
concerning the proper venting of oil storage tanks.
• Install an emergency vent as shown in Figure 4F. Contact your tank manufacturer for
information concerning the proper emergency vent for your tank.
4-8
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Installing the Metering Pump
Preparing for Installation
Before starting installation of the metering pump, review Figures 4G, 4H, and 4I to become familiar
with the metering pump components. You will also need to accomplish the following activities:
• Verify that you have the proper metering pump for your furnace (note the specific gear motor
part numbers shown in Figure 4H).
• Gather all required tools and materials as needed for installation; as indicated in the
following procedures, some materials (e.g. 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 4G, 4H, and 4I. Note that the metering pump is shipped with the pump head
already positioned for 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 4G - Vertical Mounting of the Metering Pump
4-9
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
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 4H - Metering Pump Component Detail
4-10
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Installing the Metering Pump (continued)
Alternate Mounting: Horizontal Positioning
ATTENTION: If the metering pump is to be mounted horizontally or on a bracket as shown in
Figure 4I, the pump head must be rotated counterclockwise so that it is aligned in a horizontal position.
The gauge arrow on the pump head must point up, or the pump will not prime.
1.
2.
3.
4.
5.
Refer to Figures 4H and 4I.
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 4I.
Reinstall 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
INLET
INLET
RECOMMENDED SETUP
PUMP IS MOUNTED
LEFT ON WALL
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 4I - Proper Positioning of Metering Pump Head
4-11
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Wiring the Furnace and Pump
WARNING: To avoid electrical shock, make sure that power to the furnace is turned OFF
before connecting any wires. A licensed electrician should install all wiring to your furnace. All wiring
must be in accordance with the National Uniform Electrical Code and local codes. Properly size all wires and use
electrical conduit for all electrical lines.
Wiring your furnace involves the installation of two lines:
(1) A dedicated electrical line to the furnace
(2) A pump electrical circuit from the furnace to the metering pump
Necessary wiring specifications are provided in this section and in the Wiring Schematics located in
Appendix B at the back of the manual.
Wiring to the Furnace
1.
Install a dedicated electrical circuit to the BURNER
junction box on the CB-1750 / 2500 and to the
BLOWER junction box on the CB-3250.
Refer to NFPA-70 for wire size and distances.
2.
Wire the furnace according to the Wiring Schematic in Appendix B. Ensure that the ground
wire is attached to the GREEN ground screw on the furnace junction box.
3.
Check for correct voltage at the furnace, and refer to the following chart.
ATTENTION: Incorrect voltage will severely damage the blower motor/furnace components.
DO NOT operate your furnace on any non-specification power system.
Model
Voltage
Breaker Size CB-1750
110/120
20 amps
CB-1750 (w/Options) 110/120
30 amps
CB-2500
110/120
30 amps*
CB-3250
110/120 or 220/240
30/20 amps*
*NOTE: When installing any optional equipment (e.g. air compressor or draft inducer), you do
not need to "upgrade" the breaker size. The breaker size listed above should be sufficient.
Make sure a qualified electrician properly sizes and installs this electrical circuit. Refer to
NFPA-70 for wire size for distances
4.
DO NOT turn on main power until instructed to do so.
WARNING: DO NOT
tie into an existing
circuit, or electrical overload
may occur.
Circuit
Dedicated
Dedicated
Dedicated
Dedicated
Hertz
60
60
60
60
Wiring to the Metering Pump
WARNING: DO NOT wire the pump directly into your building's electrical system. The pump
must be activated (receive power) from the burner via the pump electrical circuit. DO NOT wire
the pump directly to a wall outlet so that it runs continuously; this will seriously damage your metering
pump and/or furnace and may result in a fire or explosion hazard.
1.
2.
Install the pump electrical circuit from the furnace to the metering pump location.
Wire the pump circuit according to the Metering Pump Wiring Schematic in Appendix B at the
back of this manual.
4-12
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
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 4H and 4J. 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 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 4H 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.
(1.) (e.)Prepare the canister filter for installation (continued):
4-13
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Installing the Suction Oil Line Components (continued)
AIR
OIL
OIL FLOW
CONNECTOR BLOCK
CAUTION: DO NOT EXCEED 6 FT VERTICAL
SUCTION LIFT OR THE PUMP WILL NOT
PRIME AND/OR THE FLOW RATE FROM
THE PUMP MAY DECREASE
COMPRESSED AIR LINE
MAXIMUM 6 FT
OIL PUMP ELECTRICAL CIRCUIT
• 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
4H. 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.
PRESSURE OIL LINE
FUNNEL
WITH BALL VALVE
BALL VALVE
RADIAL BEND MADE
WITH TUBING BENDER
CANISTER FILTER
IN SUCTION LINE
VENT
CAP
SUCTION
LINE
EMERGENCY
VENT RELIEF
CONTINUOUS PIECE
OF COPPER TUBING
INSIDE TANK: 1/2" O.D.
INSTALL SLIP FITTING
TO HOLD TUBING
IN PLACE
CHECK VALVE
CLEAN-OUT
CHECK VALVE SCREEN
CHECK VALVE IS MINIMUM 12 INCHES OFF
TANK BOTTOM TO CREATE SLUDGE TRAP
1 FT.
Figure 4J - Oil Line Installation Overview
4-14
I88777-E
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
2.
Install the suction oil line (from the the tank to the canister filter):
a. Refer to Figures 4H and 4J.
b. Prepare a piece of 1/2" O.D. copper tubing (user-supplied) which will function as the pickup 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. copper 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.
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 Figure 4J.
v. Install plugs in all other tank openings as required by code.
w. Inspect the installation. For proper suction oil line operation, make sure all components are
installed and positioned as specified in this manual.
4-15
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
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 4H, 4J, and 4K.
• The pressure relief will open and relieve pressure if there is a restriction in the pressure oil
line, clogged nozzle, etc.
Be sure to use Permatex #2 non-hardening gasket sealer to seal every threaded fitting. DO NOT use
teflon tape or teflon pipe dope compounds.
1.
Refer to Figure 4K.
2.
Remove the plug from the relief port on top of the metering pump head.
3.
Install the 1/8 NPT x 1/4 tube compression fitting in the relief port on top of the metering pump
head.
4.
Install 1/4" O.D. copper tubing (user-supplied) from the pressure relief port back to the oil tank.
Refer to Figure 4J 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
RA ELIEF
ET -7
72
0
INL
RH
RO
TA
TIO
N
I89004-D
Figure 4K - Pressure Relief Oil Line Back to the Tank
4-16
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
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 furnace); 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 LineLine Size
Up to 100 feet 3/8" O.D. copper tubing
(Please note that some installations will allow for a greater pressure line length. Contact
your Authorized Clean Burn Distributor for more information.)
•
The pressure oil line must slant up to the burner with no loops or high points to trap air.
• Local codes may require the installation of an in-line "Fire-O-Matic" safety valve.
Be sure to check all appropriate codes to ensure compliance.
1.
2.
3.
Refer to Figures 4H, 4J, and 4K.
Make sure you have purchased all the necessary fittings to complete the installation correctly.
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 furnace with the following
minimum requirements: 50 psi and water trap or dryer. If you do not have shop air, an optional air
compressor is available. Contact your local Clean Burn dealer for more information.
1.
Run a compressed air line from your shop air to the connector block on the furnace. Use
minimum 1/4" O.D. copper tubing or equivalent for the compressed air line.
2.
Install an easily accessible shut-off valve in the air line so the burner can be serviced without
shutting off the shop air in your service area.
3.
If necessary, install a pressure regulator (additional to the burner air regulator) in the air line, and
set it at 50 psi.
ATTENTION: DO NOT feed full shop air pressure to the burner or damage to burner
components may occur.
4.
Install a water trap or extractor/dryer in the air line with an automatic drain so compressed air
(rather than water) is supplied to the burner.
ATTENTION: Water must not be fed to the burner, or the flame will be extinguished and the
burner will shut down. Be sure to drain water from your compressor tank on a regular basis to
keep water out of the air line.
4-17
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Installing the Stack
WARNING: Inappropriate stack materials or improper stack design/installation can adversely
affect the proper, safe operation of your furnace. Contact your Clean Burn dealer to purchase the
proper stack components for your furnace.
Stack designs are generally classified as follows:
(1) "Class A" stack through the ceiling of the building (refer to Figure 4L)
(2) "Class A" stack through the sidewall and up the side of the building (refer to Figure 4M)
Stack Design and Specifications
ATTENTION: The stack design must be single and dedicated for each unit (furnace) according to
the following specifications. A single stack serving more than one unit MUST be engineered/certified
for that specific installation (ref. NFPA 211, 3.3.39 and 10.2.1; NFPA 31 6.5.16-18). Failure to adhere to
this rule may result in less than optimal system performance.
Figures 4L and 4M illustrate recommended stack designs. Choose the stack design which is appropriate
for your furnace installation and review all specifications provided in the corresponding drawing. When
designing your stack, adhere to the following specifications:
• Models CB-1750, CB-2500 and CB-3250 require minimum 8" I.D. stack components.
•
Ensure that the vertical stack height is at least 10 feet PLUS one foot for every fitting (e.g.
45 degree, 90 degree, or T) in the stack run. If needed, increase the vertical length of the
stack or install a draft inducer to obtain -.02" W.C. draft over fire. (Section 8 contains details
on adjusting the draft.)
•
Keep the horizontal stack run as short as possible; slant it upward at a minimum of 1/4" per
foot of run.
•
Keep the stack design simple. Complicated stacks (with long runs and many turns) reduce
draft and result in poor burner performance. Your stack may include only one 90 degree
turn. All other stack turns must be at 45 degrees or less to ensure optimal draft and burner
performance.
NOTE: If you plan to use an existing masonry chimney, the chimney must be lined and inside the
building. Exterior masonry chimneys chill the stack gases and result in poor draft and poor burner
performance.
ATTENTION: If you have an exhaust fan(s) in your shop, it is critical that you have adequate
make up air (source of fresh air to replace the stale air exhausted by the fan). When an exhaust fan is
run without adequate make up air, the resultant vacuum in the building will draw combustion products
back into the burner. This back draft causes poor burner performance and may damage vital burner
components. Refer to Section 8 in this manual for additional information.
Stack components should be installed in the following order:
(1)Inside stack (the stack components from the furnace breach to within 18" of the ceiling, roof,
or sidewall of your building)
(2)Barometric damper
(3)"Class A" stack penetration through the ceiling, roof, or sidewall
(4)"Class A" stack on the exterior of the building
(5)"Class A" stack cap
4-18
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Installing the Stack (continued)
WARNING! MAKE SURE TO INSTALL
THE PROPER ROOF SUPPORT
SYSTEM TO SAFELY SUPPORT THE
STACK
3 m (10')
WATERTIGHT
ROOF FLASHING
"CLASS A" KIT FOR
INSTALLING "CLASS A" STACK
THROUGH CEILING
6 mm (1/4") HOLE FOR
SETTING DRAFT.
ADJUST BAROMETRIC
DAMPER FOR -.04 W.C.
DRAFT AT BREECH
-0.02 W.C. DRAFT OVERFIRE
IS ESSENTIAL FOR PROPER
FURNACE OPERATION.
SEE SECTION 8
CLEAN OUT CAP
ATTENTION:
BAROMETRIC DAMPER
MUST BE INSTALLED SO
IT IS FACING AWAY FROM
THE BLOWER TO PREVENT
EXHAUST GASES FROM
BEING SUCKED OUT OF THE
DAMPER OPENING
AIR
SINGLE WALL STACK
MIN. 24 GAUGE
STACK SIZE:
MIN. 20 cm (8")
OIL
I88449-C
Figure 4L - Installation of "Class A" Stack Through Roof/Ceiling
4-19
3m (10') MIN. VERTICAL STACK HEIGHT PLUS 30 cm (1') FOR
EVERY FITTING TO MAINTAIN PROPER DRAFT OVERFIRE
WARNING! ENSURE PROPER
CLEARANCES BETWEEN STACK
COMPONENTS AND COMBUSTIBLES
PER ALL APPLICABLE CODES.
90 cm (3')
NOTE: THE LAST STACK SECTION SHALL EXTEND AT LEAST
90 cm (3') HIGHER THAN ANY RIDGE, PARAPET, WALL OR ROOF
STRUCTURE WITHIN 3 m (10') OF IT.
"CLASS A" STACK COMPONENTS
INSULATED STACK WITH A STAINLESS STEEL LINER
"CLASS A" STACK CAP - NON-RESTRICTIVE TYPE
TO ALLOW FREE FLOW OF THE STACK GASES
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Installing the Stack (continued)
WARNING! ENSURE PROPER
CLEARANCES BETWEEN STACK
COMPONENTS AND COMBUSTIBLES
PER ALL APPLICABLE CODES.
"CLASS A" STACK CAP - NON-RESTRICTIVE TYPE
TO ALLOW FREE FLOW OF THE STACK GASES
WARNING! MAKE SURE TO INSTALL
THE PROPER WALL SUPPORT SYSTEM
TO SAFELY SUPPORT THE STACK
"CLASS A" STACK
PENETRATION AND
CLEAN-OUT TEE
1/4" HOLE FOR
SETTING DRAFT.
ADJUST BAROMETRIC
DAMPER FOR -.04 W.C.
DRAFT AT BREECH
-0.02 W.C. DRAFT OVERFIRE
IS ESSENTIAL FOR PROPER
FURNACE OPERATION.
SEE SECTION 8
STACK
SIZE
MIN.
8"
BAROMETRIC DAMPER
MO
RE
DRAFT
L E SS
AIR
OIL
SINGLE WALL STACK
MIN. 24 GAUGE
I88450-D
Figure 4M - Installation of "Class A" Stack Through Sidewall
4-20
"CLASS A" STACK COMPONENTS
INSULATED STACK WITH A STAINLESS STEEL LINER
10 FT.
10 FT. MINIMUM VERTICAL STACK HEIGHTPLUS 1 FT.
FOR EVERY FITTING TO MAINTAIN PROPER DRAFT OVERFIRE
3 FT.
NOTE: THE LAST STACK SECTION SHALL EXTEND AT LEAST
3 FEET HIGHER THAN ANY RIDGE, PARAPET, WALL OR ROOF
STRUCTURE WITHIN 10 FEET OF IT.
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Installing the Interior Stack
WARNING: Single wall stack components may be used only for those portions of the stack
which are located inside your building and away from any fire/burn hazards.
1.
2.
Install the single wall stack with proper clearances from combustibles. Also ensure that the stack
is located a safe distance from all shop personnel.
Install an elbow at the junction of the horizontal and vertical stack components to allow for easy
cleaning of the stack.
ATTENTION: Avoid additional 90-degree turns in the stack. Each additional 90-degree turn
slows down stack gases, creates back-pressure, and results in repeated burner shutdown and
unnecessary service calls. All other turns in the stack should be at a 45-degree (or smaller) angle.
NOTE: IMPORTANT for Canadian Installations - Local codes may require the installation of
a clean-out tee.
Installing the Barometric Damper
1.
Refer to Figure 4L. Install a single wall tee (min. 24 gauge) after the 90 degree elbow in the
straight vertical stack section within three to five feet of the furnace breach. For horizontal stack
runs (as shown in Figure 4M), install the tee after the first straight section of pipe.
NOTE: The tee is required to support the barometric damper. You must purchase this tee when
you purchase your stack materials (8" single wall tee - CB#70174).
2.
Refer to Figure 4N. Install the barometric damper in the opening of the tee. Use a small spirit
level to make sure that it is properly level.
3.
Install two self-tapping screws as shown in Figure 4N (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.
I88539
8" CLEAN BURN BAROMETRIC DAMPER
INSTALLED IN SINGLE WALL TEE
ADJUST THIS WEIGHT TO
OBTAIN PROPER DRAFT
1
1
1
31170
No QTY PART #
Figure 4N - Installation of Barometric Damper
4-21
8" BAROMETRIC DAMPER
DESCRIPTION
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
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.
2.
3.
4.
5.
6.
7.
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.
Ensure that main power to the heating equipment is turned OFF.
Position the stack safety switch over the lip of the barometric damper as shown in Figure 4O.
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.
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 4P.
Install the wire so that it is secured away from any hot surfaces.
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.
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 4O - Stack Safety Switch Installed on the Barometric Damper
4-22
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
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
Switch OPEN Temperature
Switch Type
24 volts
180 degrees F
L180, normally closed, manual reset
WALL
THERMOSTAT
F F T T
OIL
PRIMARY
STACK
SAFETY
SWITCH
(MOUNTED ON
BAROMETRIC DAMPER)
I88965
Figure 4P - Stack Safety Switch Wiring Diagram
4-23
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Installing the Stack Penetration
WARNING: When running the stack through your ceiling, roof, or sidewall, you must use
Class A/UL 103 HT double-wall insulated all-fuel stack components with a stainless steel
liner. DO NOT run single-wall stack through your ceiling, roof or sidewall. NEVER locate a stack joint
inside walls or in a joist spacer. Ensure proper clearances from combustibles per all applicable codes.
1.
2.
Refer to Figure 4L/4M 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 or BW Vent/double-wall stack components (for gas fired appliances only).
• DO NOT use Type L Vent/double-wall stack components (for approved fuel oil appliances only).
• DO NOT use black stack pipe (for solid fuel burning appliances only).
• DO NOT use single-wall stack for your exterior stack. Single-wall exterior stack chills the stack
gases and results in poor draft and poor burner performance.
1.
2.
3.
Refer to Figure 4L/4M as needed.
Follow the installation instructions provided by the stack manufacturer.
Install water-tight roof flashing around the penetration of the exterior stack.
NOTE: Clean Burn recommends the use of "Dektite" roof flashing (or equivalent) which ensures a
water-tight seal when installed properly. Contact your local Clean Burn dealer for details.
Installing the Stack Cap
NOTE: Proper installation of a "Class A" stack cap ensures the free flow of stack gases which is
essential for optimal burner performance.
1.
2.
Refer to Figure 4L/4M as needed. Your stack cap should be classified as: "Class A" non-restrictive,
all-fuel type.
Install the stack cap according to the manufacturer's instructions.
Installing the Optional Draft Inducer
ATTENTION: The draft inducer, Field brand model DI-2, is optional equipment and may be installed
to ensure proper draft. The Field brand draft inducer has been tested for use on Clean Burn furnaces.
DO NOT use other models or brands of draft inducers.
Understanding the Importance of the Draft Inducer
The draft inducer is designed to aid in the removal of the natural draft created by the appliance to vent
the combustion gases to the outside of the building. As the paddle wheel turns, a negative pressure is
maintained within the stack so that the combustion gases can leave the furnace and travel out of the
stack. (See Figure 4Q.) Proper sizing, installation, and adjustment of the draft inducer are critical for
optimal draft inducer operation.
4-24
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Installing the Optional Draft Inducer (continued)
NOTE: Lubricate the motor as recommended by the
Draft Inducer manufacturer.
"CLASS A" STACK
5 FEET - 8 FEET
(1.5 METERS - 2.5 METERS)
NOTE: INSTALL DRAFT INDUCER IN LAST
SECTION OF VERTICAL STACK TO POSITION
DRAFT INDUCER AWAY FROM FURNACE
BREECH SO THE MOTOR DOES NOT
OVERHEAT. THIS ALSO REDUCES ASH
ACCUMULATION IN THE DRAFT INDUCER.
DRAFT
ADJUSTMENT
PLATE
DO NOT MOUNT THE DRAFT INDUCER IN THE
HORIZONTAL STACK NEAR THE FURNACE
BREECH.
SINGLE WALL
24 GAUGE INTERIOR STACK
OPTIONAL
DRAFT INDUCER
CHECK FOR
-0.02 W.C. DRAFT
OVERFIRE
FURNACE OPERATION.
SERVICEMAN ADJUSTS
BAROMETRIC DAMPER TO
OBTAIN -.02 W. C. DRAFT
OVERFIRE
CLEAN-OUT CAP
INSTALLED ON L.H.
FURNACE BREECH
CONNECTOR BLOCK
AIR
OIL
I88451-C
Figure 4Q - Installation of the Optional Draft Inducer
WARNING: Turn OFF the main power to the furnace before proceeding with the installation of
the draft inducer.
ATTENTION: It is very important to install the draft inducer on a vertical section of stack to isolate
the inducer from excessive heat and ash buildup. Never install the draft inducer on a horizontal section
of stack close to the furnace breach where heat and ash will damage the inducer motor.
4-25
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Installing the Optional Draft Inducer (continued)
1.
2.
Refer to Figure 4Q. 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 instructions 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. Read pages 8-3 to 8-6 if exhaust fans are present.)
1.
Wire the draft inducer according to the Furnace Wiring Diagram provided in Appendix B at the
back of this manual.
Installing the Wall Thermostat
1.
Select a location for the thermostat on an interior wall away from any hot or cold drafts.
2.
Remove the top cover from the thermostat by pushing gently on the latch at the top center of the
body. (Hold the thermostat base in one hand, and grasp the body with the other hand; push in on the
latch with your thumb, and pull the cover away from the base.)
ATTENTION: DO NOT use a screwdriver to pry the cover off the base, or damage may occur.
3.
Remove the green paper insert and the black plastic battery isolator from the battery section of the
thermostat.
4.
Refer to the Burner Wiring Diagram in Appendix B at the back of this manual. Run two wire,
18-gauge (minimum) thermostat cable from the terminals on the back of the thermostat base to the T/T
terminals of the primary control on the burner.
ATTENTION: NEVER jump between T/T terminals on the primary control without removing
one of the wires. Failure to remove one of the wires will burn out the heat anticipator on the
thermostat and will cause the thermostat to fail.
5.
Mount the thermostat base 60" to 66" from the floor using the hardware provided.
6.
Reassemble the thermostat body onto the base. (Align the hinges at the bottom of the cover with the slots
at the bottom of the base, and swing the cover up into place.)
Replacing the Wall Thermostat Batteries
1.
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.
Inspecting the Furnace Installation
Following completion of all installation activities described in this chapter, the furnace 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 to be corrected before furnace startup. Improper installation may void
your warranty.
4-26
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
SECTION 5: METERING PUMP PRIMING
Understanding Metering Pump Priming
Preparing your Clean Burn furnace for operation begins with priming the metering pump. The
procedures in this section must be performed in sequence without interruption to properly prime the
pump.
Required Tools and Materials
The following tools and materials are required for oil pump priming and should be gathered before
starting any procedures:
• 3/8" open-end wrench
• 5/8" open-end wrench
•Rags
• Two containers (minimum one-gallon)
• Permatex #2 non-hardening gasket sealer
• Adjustable Wrench
• Pipe Wrench
5-1
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
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 valve 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
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Priming the Metering Pump (continued)
8.
Activating the Pump
NOTE: The CB-1750/2500/3250 furnaces feature a priming switch which is mounted on the
right-hand side of the electrical junction box on the front of the furnace cabinet. The priming switch has
two positions:
•
PRIME (switch is in the UP position): This is used only for pump priming. When the switch is in the UP position, the pump circuit is activated for priming. The pump will continue to run as long as the switch is in this position. The oil primary control circuit is de-activated so the burner cannot run while the switch is in the UP position.
•
BURNER (switch is in the DOWN position): This is used for normal burner operation.
When the switch is in the DOWN position, the burner controls the operation of the pump.
The pump will only run while the burner is running.
a. Refer to Figure 5B to locate the priming switch.
b. Turn the priming switch to the prime (UP) position. The pump should immediately start running.
OIL PUMP
PRIMING
SWITCH
I89121
Figure 5B - Locating the Pump Priming Switch
5-3
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
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.
Close and tighten the bleeder on the pump.
11.
12.
Turn the priming switch to the burner (DOWN) position so that the pump stops running.
13.
Disconnect the pressure oil line from the burner and position a container to catch oil which will flow
from the pressure oil line during pump priming.
14.
Turn the priming switch to the prime (UP) position. The pump should start running immediately .
Run the oil pump until the proper flow of oil has been established, and the oil line has been completely
15.
flushed out.
Turn the priming switch to the burner (DOWN) position so that the pump stops running.
16.
17.
Re-connect the oil line to the burner.
Vacuum Testing the Oil Pump
Vacuum testing the oil pump is a very accurate way to determine the following:
• The condition of the pump -- the ability of the pump to pull a vacuum and suck oil from the tank.
• The condition of the 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.Vacuum Testing the Oil Pump (continued)
5-4
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
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:
•
•
•
6.
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.
Follow the instructions to prime the metering pump after a vacuum test has been performed.
5-5
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
5-6
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
SECTION 6: STARTING AND ADJUSTING THE BURNER
Understanding Burner Startup and Adjustment
Starting and adjusting the burner involves a series of separate procedures which must be accomplished
in sequence without interruption. Review all the procedures before attempting burner startup and
adjustment, paying careful attention to safety information statements.
Preparing the Burner for Startup
1.
2.
3.
4.
5.
Turn the switch on the wall thermostat OFF.
NOTE: If your thermostat does not have an OFF setting, disconnect one thermostat wire so
the burner will not run.
Turn the main power to the furnace 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
AIR REGULATOR
is hot.)
NOTE: The preheater block
will remain warm as long as
power is supplied to the
burner. If the main power
supply is ever turned OFF,
LOCKING NUT
you must wait at least 15
minutes until the preheater
COVER PLATE
block is thoroughly warm
before starting the burner.
Refer to Figure 6A to locate
the air regulator.
Loosen the locking nut on
the air regulator.
Turn the adjustment knob
on the air regulator
counterclockwise until 1/2"
AIR GAUGE
of the threads on the knob
are exposed. DO NOT back
OIL GAUGE
the knob all the way out.
COMBUSTION
AIR BAND
I88583
Figure 6A - Component Detail of the CB-525-S2 Burner
6-1
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Preparing the Burner for Startup (continued)
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:
WARNING: The combustion air band must be properly adjusted to ensure that the burner
ignites and burns correctly. DO NOT attempt to start the burner with the combustion air band wide open
or completely closed. The burner may not ignite correctly. Failure to heed this warning may result in a
fire or explosion hazard.
• Refer to Figure 6A to locate the combustion air band.
• Rotate the combustion air band to adjust it to the appropriate initial slot opening as listed
in the following Initial Adjustment Charts. Use a ruler to accurately set the slot opening at
the widest section of the slot. This initial setting of the combustion air band will allow you to
start the burner. You will fine tune the combustion air band further as described later in these
instructions.
ATTENTION: The settings shown in the charts below are only initial adjustments. Final adjustments
must be done by inspecting the flame according to the illustrations provided on the following page.
NOTE: The oil pressure is automatically adjusted by the metering pump. The approximate oil pressure range during initial startup is 1 to 4 psi for Model CB-1750, 4 to 7 psi for Model
CB-2500 and 5 to 8 psi for Model CB-3250.
Initial Adjustments for CB-1750
Maximum Input = 175,000 BTUH @ 1.2 GPH with CB525-S2 Burner
#2 Fuel Oil*
Used Crankcase Oil
Used ATF*
Used Hydraulic Oil*
#4 and #5 Fuel Oils
Initial Adjustments for CB-2500
Maximum Input = 250,000 BTUH @ 1.7 GPH with CB525-S2 Burner
Oil Type
Oil PSI / Flame Length
check flame length
check flame length
check flame length check flame length check flame length Oil PSI / Flame Length
Air PSI
Air Band
Nozzle
12-16
12-16
12-16
12-16
12-16
3/8"
3/8"
3/8"
3/8"
3/8"
9-5
9-5
9-5
9-5
9-5
Oil Type
#2 Fuel Oil*
Used Crankcase Oil
Used ATF*
Used Hydraulic Oil*
#4 and #5 Fuel Oils
Initial Adjustments for CB-3250
Maximum Input = 300,000 BTUH @ 2.1 GPH with CB525-S2 Burner
check flame length
check flame length
check flame length check flame length check flame length Oil PSI / Flame Length
Air PSI
Air Band
Nozzle
12-18
12-18
12-18
12-18
12-18
1/2"
1/2"
1/2"
1/2"
1/2"
9-5
9-5
9-5
9-5
9-5
Oil Type
#2 Fuel Oil*
Used Crankcase Oil
Used ATF*
Used Hydraulic Oil*
#4 and #5 Fuel Oils
*If you are burning light viscosity oils, it may be necessary to install a smaller nozzle. Call your local Clean Burn
Distributor for more information.
check flame length
check flame length
check flame length check flame length check flame length 6-2
Air PSI
Air Band
Nozzle
12-18
12-18
12-18
12-18
12-18
7/8"
7/8"
7/8"
7/8"
7/8"
9-5
9-5
9-5
9-5
9-5
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Starting the Burner
1.
2.
Adjust the thermostat setting above room temperature to start the burner.
Adjusting the Air Regulator:
As soon as the burner starts running, turn the knob on the air regulator clockwise to achieve
proper operating air pressure. Refer to the Initial Adjustment Charts.
NOTE: If the safety reset on the primary control is activated and the burner stops running, see
Section 7 for further instructions on restarting your burner.
3.
Observing the Flame Length:
Visually inspect the flame length through the
observation port. Refer to Figure 6B for an illustration
of the desired flame length. The flame should extend
no more than one-half of the way down the combustion
chamber.
WARNING: The observation port gets hot as the
burner fires. To avoid personal injury, always wear
heavy work gloves and safety glasses when opening the
port and viewing the flame. CAUTION
WHEN OPENING INSPECTION PORT
PORT MAY BE HOT
PROTECT HANDS
WEAR SAFETY GOGGLES
KEEP FACE AWAY
OPEN PORT SLOWLY
Correct Maximum Flame Adjustment
(Proper Oil and Air Pressure):
• Flame goes half of the way down the
combustion chamber.
• Flame does not touch back or walls of
combustion chamber.
Incorrect Flame Adjustment
(Not Enough Combustion Air):
• Flame must not touch back or walls of
combustion chamber.
•
Increase combustion air by opening the
air band on the side of the burner.
Incorrect Flame Adjustment
(Air Pressure Too High):
• Ensure proper air pressure setting.
I88372
I88372
I88372
Figure 6B - Flame Length Adjustment
4.
5.
Check the flame length after the burner has fired for 15 minutes.
Tighten the locking nut on the air regulator.
6-3
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Starting the Burner (continued)
6.
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
recheck the flame for the proper characteristics.
• Recheck the flame after five minutes. You should see a yellow-white flame with sharp
tips and no "sparkles", and the flame should extend half the way down the combustion
chamber.
7.
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.
• Adjust for a smoke spot of a trace to 2
• Adjust for a CO2 reading of 8 to 10% or an O2 reading of 7 to 9%
• Cad cell reading below 500 ohms
Checking the Operation of the Blower Motor
NOTE: It is important to verify that the blower motor operates correctly to ensure that the fan limit
control is properly cycling the blower motor as described below. Also refer to Appendix A at the back of
the manual for additional pertinent information.
1.
2.
3.
4.
Start the burner and adjust it as described previously in this section.
The blower motor will not start until the burner has been running for 5 to 15 minutes to heat up
the combustion chamber and heat exchanger. At this point, the fan fan switch will activate the
blower motor.
Once the blower motor has activated, turn the burner off by turning the wall thermostat to OFF.
With the burner off, the blower motor should continue to run for 5 to 10 minutes until the
combustion chamber is cooled down. The fan switch will then shut off the motor.
WARNING: If the blower motor does not operate as described, immediately shut down
your furnace to avoid potential equipment damage and/or fire hazard. Contact your local Clean
Burn Distributor immediately.
6-4
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
SECTION 7: RESETTING THE FURNACE AND BURNER
( See Appendix B for additional information )
Understanding Furnace/Burner Shutdowns
When troubleshooting furnace/burner shutdown situations, Clean Burn recommends the following
sequence of actions:
• Follow the procedure for Resetting the Oil Primary Control provided in this section.
• Review the material on the following page about the safety switches to determine if the
furnace is shut down on high limit.
• If the burner still will not restart, contact your Clean Burn Distributor for immediate service.
The Oil Primary Control
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
RESET BUTTON
Resetting the Oil Primary Control
DANGER! DO NOT push the reset
button more than once! DO NOT push
the reset button if oil mist is present in the
combustion chamber or when the combustion
chamber is hot! DO NOT operate your furnace if
excess oil, oil vapor or fumes have accumulated in
or near your furnace. As with any oil burning
furnace, improper operation may result in a
fire or explosion hazard.
1.
2.
3.
4.
5.
T T F F
ALARM
AMB GRN
RED
CAD CELL
WIRES
WIRES RUN UNDER
SMALL CENTER GAP
C77008
Figure 7A - Oil Primary Control
Refer to Figure 7A.
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 furnace
to cool for at least 30 minutes. DO NOT push the
reset button.
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.
If the burner will not restart, call your Clean Burn
dealer immediately.
7-1
WARNING
Fire and explosion hazard.
Do NOT press reset button until
you read and understand Reset
Procedures in Operator's Manual.
42000 Rev. 2
ATTENTION: Never touch a
jumper wire from an "F" terminal
to a "T" terminal on the oil primary
control. This will severely damage
your primary control.
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
The Blower Switch
The CB-1750/2500/3250 furnaces feature an F-180 blower/fan switch (normally open) which is surface
mounted at the front of the combustion chamber (see Figure 7B). The blower/fan switch senses the
temperature of the combustion chamber as the burner is firing. When the combustion chamber reaches
the proper temperature, the blower/fan switch closes and sends power to the blower motor (CB-1750)
or relay (CB-2500/3250) to turn ON the blower motor. When the wall thermostat is satisfied and the
burner shuts off, the blower continues to run until the switch senses that the combustion chamber has
cooled down. The switch then opens and shuts off the blower motor.
The Hi-Temp Limit Switches
These furnaces also feature two high temperature limit switches which are mounted on a bracket at the front of
the combustion chamber as shown in Figure 7B. The switches sense the build-up of heat within the combustion
chamber and are designed to protect the furnace from damage due to overheating. The limit switches are wired in
series, and both are auto-resetting.
Understanding the Function of the L-200 Hi-Temp Limit Switch
If the temperature of the combustion chamber is too hot, the L-200 hi-temp limit switch opens and shuts off power
to the primary control on the burner, and the burner shuts off. The blower continues to run to cool down the
furnace. After the combustion chamber has cooled down, the L-200 hi-temp limit switch will automatically reset
and allow the burner to restart.
ATTENTION: If the L-200 hi-temp limit switch is opening repeatedly, the burner MUST be readjusted
according to the instructions in Section 6 to correct the overheating problem, or serious damage to the furnace
may occur.
The L-200 hi-temp limit switch will open and shut down the burner if any of the following conditions exists:
•
The furnace is over firing. Review the directions in Section 6 to properly adjust the burner.
•
Improper ductwork is installed on the furnace (applicable only if your furnace is
operating as a central furnace). Ductwork must be installed by qualified HVAC personnel
according to industry standards and the specifications provided in Section 3.
Understanding the Function of the L-290 Auxiliary Auto-Reset Hi-Temp Limit Switch
The L-290 auxiliary auto-reset high temperature limit switch is a back-up safety switch for the L-200 hi-temp
limit switch.
Both the L-200 and L-290 auxiliary hi-temp limit switches will open and shut down the burner if:
•
the blower has stopped running for any reason during furnace operation, the heat
in the furnace will cause the limit switches to open. Ensure that the blower is functioning properly.
ATTENTION: It is very important to determine the reason for the opening of the limit switches and take steps
to correct the cause; failure to do so may result in serious overheating and damage to the heat exchanger of the
furnace. Additionally, if the burner is rapidly cycling on/off, contact your Clean Burn Distributor immediately;
failure to address this situation may result in serious damage to the furnace.
7-2
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
The Hi-Temp Limit Switches (continued)
CLEAN-OUT
BREECH
COMBUSTION
CHAMBER
CLEAN-OUT CAP
33288 L-290 HI LIMIT AUXILIARY
SWITCH (AUTO RESET)
(33230) F-180
SURFACE MOUNT
FAN SWITCH
BLACK & TAN WIRE
FROM TERMINAL BLOCK
RED & TAN WIRE LINKS THE 2
SWITCHES IN SERIES
(33390) L-200
HI LIMIT NC
RED & TAN WIRE
TO BURNER
RED & TAN WIRE
FROM TERMINAL
BLOCK
BLACK AND TAN WIRE
TO TERMINAL BLOCK
I88162-D
Figure 7B - Locating the Hi-Temp Limit Switches
7-3
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
7-4
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
SECTION 8: ADJUSTING THE DRAFT OVERFIRE
Understanding the Importance of Draft
Draft in the furnace is created as the hot combustion gases rise up the stack, creating a negative pressure
inside the stack and the furnace. This negative pressure is measured as inches of water column (W.C.) of
draft. A proper draft overfire of -.02 to -.04 w.c. is essential so that all combustion products travel away
from the burner, down the combustion chamber, through the furnace flues and up the stack.
Checking for Correct Draft Overfire
WARNING: Correct draft overfire is
essential for the proper and safe operation
of your furnace.
Your furnace is equipped with an observation/
draft reading port to check draft overfire. A
qualified serviceman with proper equipment
must check/adjust your furnace for proper draft.
Contact your Clean Burn dealer for this service.
1.
Insert the probe of the draft gauge
instrument into the draft reading port in
the observation port as shown in
Figure 8A.
NOTE: Follow the directions with the
draft gauge to use your specific type of
gauge.
2.
Note the draft overfire reading on the draft
gauge.
ATTENTION: The draft reading should
be in the -.02 to -.04 w.c. range. Poor
draft (i.e. -.01 to +.08) results in back
pressure in the furnace and poor burner
performance. Too much draft overfire
(i.e. greater than -.04) sucks the heat from
the furnace and results in abnormally high stack temperature.
8-1
I88257
Figure 8A - Checking for Proper
Draft Overfire
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Adjusting the Barometric Damper
NOTE: If the draft overfire is not in the -.02 to -.04 w.c. range, it is necessary to adjust the barometric
damper.
1.
2.
3.
4.
5.
Before starting the burner, turn the weight
on the flapper COUNTERCLOCKWISE
until the flapper remains closed. This will
ADJUST THIS WEIGHT
provide maximum draft for the furnace.
Follow the directions in Section 6 to start TO OBTAIN PROPER
DRAFT OVERFIRE
and adjust the burner.
With the burner running, check the draft
overfire with a draft gauge.
As shown in Figure 8B, adjust the weight
on the flapper to obtain a consistent
-.02 w.c. draft overfire. Turn the weight
COUNTERCLOCKWISE to increase draft
(i.e. draft increases as the flapper closes).
Turn the weight CLOCKWISE to decrease
draft (i.e. draft decreases as the flapper
I88572
opens).
Tighten the locking nut to securely hold
Figure 8B - Adjustment of Barometric Damper
the weight in position.
Solving Draft Overfire Problems
WARNING! If you cannot achieve proper draft overfire, do not operate your furnace!
Contact your Clean Burn dealer for assistance.
ATTENTION: Backdraft must be resolved or your furnace will not operate correctly!
Under backdraft conditions, draft overfire readings will show positive pressure in the combustion
chamber. Backdraft means that oil spray, combustion products, and heat are blown back against the
burner. Backdraft results in oil-fouled retention heads and electrodes. Severe backdraft will force heat
back against the burner and result in heat damage to the cad cell and transformer.
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. (See Above)
• Incorrect combustion air band setting on the burner. (See Section 6.)
• Furnace flues are plugged with ash. (See Section 9.)
• Exhaust fans in your building are sucking gases down the stack. (See following pages)
8-2
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Understanding the Effect of Exhaust Fans on Draft
Any type of exhaust fan, paint booth, or exhaust system in a building will create negative pressure in the
building unless there is a source of make-up air (i.e. fresh air which enters the building and replaces the
air removed by the exhaust fans.) Refer to Figure 8C on the following page.
If there is insufficient make-up air, the exhaust fan will suck air and combustion gases down the furnace
stack and create backdraft in the furnace. Even if the exhaust fan is on another level of the building or in
another room away from the furnace, the exhaust fan will still create backdraft at the furnace.
Checking Draft 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.
Refer to Figure 8C on the following page as needed.
1.
Turn off ALL exhaust fans and close ALL doors and windows in the building (any open door or
window will allow make-up air to enter the building and will negate the test).
2.
Start the furnace and adjust the barometric damper so that the draft 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 furnace 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.
8-3
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
EXHUST FAN CREATES BACKDRAFT IN STACK
AND SUCKS COMBUSTION GASES DOWN THE
STACK AND BACK INTO THE FURNACE
BACKDRAFT
BACKDRAFT CREATED
BY EXHAUST FAN
BA
CK
DR
DRAFT
LESS
MORE
Special Note to
Service Personnel
AF
T
The
To arrive at proper
draft measurements
be sure that all fans
within the building
are running while
adjusting the draft
to final levels!
Smar
t Use
For
Used
Oil
OIL SPRAY AND HEAT IS FORCED
BACK AGAINST THE BURNER AND
RESULTS IN OIL FOULED ELECTRODES
AND RETENTION HEAD.
SEVERE BACKDRAFT WILL HEAT AND
DAMAGE THE CAD CELL AND THE
TRANSFORMER.
PROPER DRAFT
DRAFT OVERFIRE OF -.02 TO -.04 W.C.
MEANS COMBUSTION GASES
ARE FLOWING AWAY FROM THE
RISING HOT
COMBUSTION
GASES PRODUCE
PROPER DRAFT
DRAFT
LESS
SERVICEMAN ADJUST
BAROMETRIC DAMPER
TO OBTAIN -.04 TO -.06 W.C.
DRAFT AT STACK
MORE
BURNER,THROUGH THE FURNACE
FLUES AND UP THE STACK
The
Smar
t Use
For
Used
Corresponding Draft Over Fire
measurement should be -.02 to -.04 WC
Oil
COMBUSTION AIR
TO BURNER
I88452-C
Figure 8C - Proper Draft vs. Backdraft
8-4
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Installing a Make-up Air Louver
Exhaust Fans and Make-up Air Louvers
When exhaust fans are operated in tight buildings, there is little or no source of fresh air to replace the air
removed from the building by the exhaust fan. This results in negative pressure (vacuum) in the building which
creates severe backdraft problems at the furnace.
Properly sized make-up air louvers are designed to allow adequate fresh air to enter the building during operation
of the exhaust fans. The louvers automatically open under the vacuum created by the exhaust fans. The louvers
open just enough to provide the correct CFM of fresh air. The louvers automatically close when the exhaust fans
are turned off.
Sizing the Make-up Air Louver
IMPORTANT NOTE: When using louvers and grills, and the actual free area of the louver or grill is not known,
it is understood that wooden louvers/grills will have a free area of 25%, while metal louvers/grills will have a free
area of 75%. ("Free area" translates into the actual space allowing air to flow through.)
Procedure 1: (a) Determine the CFM rating of the exhaust fan. This information should be stamped on
a label on the exhaust fan. Make sure to add up the total CFM if more than one
exhaust fan exists in the building.
(b) Select the correct size of make-up air louver to provide the required CFM of fresh air.
If you cannot determine the CFM rating of the exhaust fan, use the following procedure.
Procedure 2: (a) Count the total number of exhaust fans in the building.
(b) Close all of the doors and windows in the building except for one overhead garage door.
(c) Start the furnace and allow it to run for 15 minutes to bring it up to temperature.
(d) Set the draft-over-fire for -.02" to -.04" W.C.
(e) Turn ON all of the exhaust fans in the building.
(f) Now close the opened overhead garage door slowly, just until the draft gauge moves down
into a positive (+) draft reading; as soon as it reaches this point, STOP the door at that
position.
(g) Slowly open the door back up, just until the draft reading comes back up to the -.02"
to -.04 W.C.
(h) Measure the size of the door opening, rounding this measurement off to the next largest
even foot.
Example of Calculations for Sizing Make-up Air Louver
Measured door opening: 12' wide x 9" high
• Round off to 12' wide x 1' high
• Convert to square feet (in this case, equals 12 square feet)
• Multiply by 1.1 correction factor (12 sq. ft. x 1.1 = 13.20 sq. ft.)
• Multiply by free area factor (13.20 sq. ft. x 1.25 = 16.50 sq. ft.)
• Refer to sizing chart (following page) - required grill size would be (1) 54" square grill
8-5
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Installing a Make-up Air Louver (continued)
Calculated Opening Size
(Square Feet)
Required Louver / Grill Size
(Inches)
From 0.000 to 0.569
10 x 10
From 0.570 to 0.900
12 x 12
From 0.901 to 1.556
16 x 16
From 1.557 to 2.070
18 x 18
From 2.071 to 2.574
20 x 20
From 2.575 to 3.408
24 x 24
From 3.409 to 5.133
30 x 30
From 5.134 to 7.696
36 x 36
From 7.697 to 9.883
42 x 42
From 9.884 to 13.299
48 x 48
From 13.300 to 16.683
54 x 54
From 13.684 to 21.152
60 x 60
C77002
Installing the Make-up Air Louver
All louvers and grills, regardless of the material from which they are made, must be FIXED in the OPEN position
OR be interlocked with the appliance so that they will open automatically during the operation of the appliance.
The interlock must be placed on the driven member.
NOTE: It is very important to follow these instructions carefully to ensure proper performance of the louver.
1.
2.
3.
The louver must not be close to the furnace. The fresh air should travel at least 40 to 50 feet before
reaching the furnace, so the air warms up. The furnace will not heat well if it is receiving cold return air.
The louver must be high in the sidewall of the building so the cold fresh air does not blow across the
floor level and chill the service personnel.
The louver should be installed in the opposite wall from the location of the exhaust fan. This
will quickly vent diesel exhaust from the top of the building and reduce the amount of run time
for the exhaust fan.
8-6
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
SECTION 9: MAINTENANCE
Understanding Maintenance
Servicing your Clean Burn furnace in a timely manner is very important to keep your furnace running in
peak condition. Just as an automobile requires periodic maintenance such as oil changes, engine tuneups, etc. your Clean Burn furnace also requires regularly scheduled service.
WARNING: Failure to maintain and/or improper servicing by unqualified personnel may
adversely affect the proper, safe operation of your furnace, may reduce the service life of your
furnace, and may void your warranty.
The following chart summarizes all the service intervals which are required to maintain your furnace.
Service instructions/procedures for these activities are included in this chapter.
Maintenance Activity
Periodic Burner Inspection
Cleaning the canister filter
Servicing the metering pump
Cleaning the check valve/screen
Cleaning water/sludge out of tank
Cleaning out ash
Annual burner tune-up
Interval
Monthly
Before vacuum gauge reads 10" HG of vacuum
At least once a year
At least once a year
At least once a year
Approx. 700 hours as indicated on the burner hour meter*
At least once a year
*It is very important to clean ash from the furnace on schedule. Normal use of the furnace requires
clean-out at least twice during the heating season. Heavy, around-the-clock usage requires more
frequent clean-out. For instance, one month of continual running of the furnace is 720 hours (24 hours x
30 days = 720 hours).
NOTE: IMPORTANT! Record all maintenance activities in the Maintenance Record provided in
Appendix C.
9-1
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Periodic Burner Inspection
Following initial start up of the burner, you should inspect the operation of the burner periodically--ideally on a
monthly basis. Doing so ensures that the system is functioning efficiently and safely.
Follow these guidelines for inspecting the operation of the burner:
• Visually inspect the flame length through the observation
port; the flame should extend no more than one-half of
the way down the combustion chamber.
• If the flame is diminishing or displays wide
WHEN OPENING INSPECTION PORT
variations, clean the canister filter and check
PORT MAY BE HOT
valve/screen (procedures provided in this
PROTECT HANDS
section).
WEAR
SAFETY GOGGLES
• If the flame is firing too strongly (i.e. flame touches
KEEP
FACE AWAY
back and/or side walls of the combustion chamber),
OPEN PORT SLOWLY
check the air pressure setting (see following
guideline).
• Check the air pressure by observing the air gauge; proper air pressure settings are provided in
Section 6. DO NOT overfire the burner; doing so on a continual basis will damage the furnace.
• Check the combustion air band setting for the proper opening and clean away any dust/debris as
necessary. Note that the air band should NEVER be set fully open or closed.
• Check the draft over fire reading as specified in Section 8.
CAUTION
AIR REGULATOR
LOCKING NUT
COVER PLATE
AIR GAUGE
OIL GAUGE
COMBUSTION
AIR BAND
I88583
Figure 9A - Component Detail of the CB-525-S2 Burner
9-2
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Cleaning the Canister Filter
ATTENTION: Never operate your furnace with more than 10" HG of vacuum on the suction side of
the pump. High vacuum separates air from the oil and results in erratic burner operation.
The following protective gear should be worn when cleaning the filter:
• Rubber gloves
• Safety goggles
1.
2.
3.
4.
5.
6.
7.
8.
9.
Close the ball valve adjacent to the filter.
Position a container under the filter.
Unscrew the four bolts to drain the oil from the canister.
Remove the canister bowl.
Clean the screen and the bowl in a parts washer.
Referring to Figure 9B, examine the filter components as you reassemble them.
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.
After the pump head screen is serviced as well (page 9-4) open the ball valve and refer to
Sections 5 and 6 for instructions on priming the pump and starting the burner.
TO BURNER
RETURN BACK
TO TANK
USE A RATCHET WRENCH WITH A 6" EXTENSION
AND 3/16" "ALLEN" SOCKET TO REMOVE THE
FOUR "ALLEN" SCREWS
I88259-C
Figure 9B - Canister Filter Component Detail
9-3
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Servicing the Metering Pump
1.
2.
3.
4.
5.
6.
Refer to Figure 9C.
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
N
0
PART No 32423
I88332-A
Figure 9C - Servicing the Metering Pump
9-4
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Cleaning the Check Valve And Check Valve Screen
This procedure applies to furnace installations with inside and outside tanks. The following protective
gear should be worn when cleaning the check valve/screen:
• Rubber gloves
• Safety goggles
1.
Refer to Figure 9D. Remove the one-piece suction oil line from the tank.
2.
Remove the check valve and screen. Clean these components in a parts washer.
3.
Check the operation of the check valve. The valve must seat so it is airtight to hold pump prime.
4.
Re-assemble and re-install the components. Apply Permatex #2 non-hardening gasket sealer or
equivalent to the threaded fittings. Firmly tighten all connections so the suction line is 100%
airtight.
5.
Follow pump priming instructions in Section 5 to re-establish prime.
TO BURNER
METERING PUMP
FUNNEL WITH
BALL VALVE
SUCTION
OIL LINE
EMERGENCY
VENT
CLEANOUT
VENT
CAP
OIL STORAGE TANK
CHECK VALVE
CHECK VALVE SCREEN
12"
I88670-F
Figure 9D - Check Valve Detail
9-5
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Cleaning the Tank
DO NOT allow water, sludge, or other debris to accumulate in your oil supply tank to the point that noncombustible or harmful materials are drawn into the pump or burner.
Drain water and sludge from the bottom of your tank at least once a year, and more frequently with
water accumulation.
NOTE: If your used oil tank has not been cleaned on a regular basis, a considerable amount of sludge,
etc. may have accumulated on the bottom of the tank. Under these circumstances, it is advisable for you
to hire your used oil hauler to pump the tank. Make sure the tank is pumped to the bottom to remove
all sludge, etc. from the tank (your used oil hauler may charge an additional fee for this type of service).
The best time to pump the used oil tank is at the end of the heating season when the tank is low. This
allows sufficient time to refill the tank with used oil (generated by your company over the summer
months) so that you have adequate fuel for the heating season.
9-6
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Cleaning Ash from the Furnace
NOTE: The maintenance interval for cleaning ash from the furnace is approximately 700 hours of
operation as indicated on the hour meter on the burner (refer to the servicing intervals at the beginning
of this chapter). Be sure to clean the ash from your furnace at least twice during the heating season.
Your furnace may require more frequent clean out of the ash due to contaminants in the oil or heavy
use. As ash accumulates, furnace heat output declines, and the stack temperature rises. 1/8" of ash has
the insulating capacity of one inch of 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.
CAUTION: Be aware that used oils may contain heavy metallic compounds or foreign
materials. When burned, these compounds are deposited within the furnace, necessitating
careful cleaning. The following protective gear should be worn when cleaning the ash:
• Respirator for fine particles (a dust mask is not acceptable)
• Rubber gloves • Safety goggles • Protective clothing
CAUTION: Make sure you use a sturdy ladder or scaffolding for safe access to ceiling-hung
furnaces. When cleaning the furnace, static electricity may build up in the shop vac hose. If this
occurs, use #12 copper wire wrapped around the hose with the other end connected to the furnace
(or other ground source) to eliminate the static.
CLEAN-OUT DOOR
CLEAN-OUT
BREECH
CLEAN-OUT CAP
COMBUSTION CHAMBER
I88563-C
Figure 9E - Accessing the Combustion Chamber for Cleaning
9-7
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Cleaning the Ash (continued)
1.
Ensure that power has been turned OFF, and all "hot" components have been allowed to cool
sufficiently. (Allow at least one hour for the Energy Retention Disc to cool.)
2.
Clean the ash from the stack components:
a. Brush accumulated ash from the stack cap.
b. Lightly tap the stack components to loosen the ash.
c. Allow ash and dust to settle in the elbow on the stack.
NOTE: It is not necessary to remove the stack to clean it. You will vacuum ash from the
stack elbow as you clean out the back of the furnace as described below.
d. Remove the clean-out cap from the unused furnace breach.
e. Thoroughly vacuum out the back of the furnace, including the stack elbow, through the
clean-out breach. A long wand on the hose of your shop vac is helpful in reaching all the
way through the back of the furnace to the stack elbow.
3.
Clean the ash from the combustion chamber (see Figure 9E):
a. Bleed down pressure on the air and oil lines by slightly loosening the fittings at the bottom of
the connector block.
NOTE: Turn off the shut-off on the air pressure line.
b. With air and oil pressure completely bled off, disconnect the air and oil pressure lines from
the bottom of the connector block.
NOTE: Cover the lines to keep dirt from entering the air / oil supply.
c. Remove the lock-down nuts on the clean-out door.
d. Carefully swing open the clean-out door to expose the heat exchanger flues and the
combustion chamber. Carefully remove the Energy Retention Disc with a long handle or
pipe. Lightly vacuum the Energy Retention Disc.
e. Check the color of the ash--it should be light gray or tan.
ATTENTION: White ash indicates excessive air pressure. Black ash or soot indicates lack
of combustion air. If these conditions exist, call your Clean Burn dealer. DO NOT overfire
your furnace by turning up the compressed air. Overfiring will damage the combustion
chamber and heat exchanger and will void your warranty.
f. Vacuum the ash from the combustion chamber and the flues.
ATTENTION: When cleaning the combustion chamber, ensure that you do not gouge or
damage the refractory material on the inside of the clean-out door.
NOTE: Avoid "packing" the ash in the tubes by first vacuuming the flues before pushing
the flue brush down the flues. DO NOT bump or bend burner components while cleaning the
combustion chamber.
g. Use a flue brush to thoroughly clean the flues.
h. Thoroughly vacuum any remaining ash residue from the flues. Make sure the back (at the
breach) is still clean.
i. Check the flues for rust.
ATTENTION: The presence of rust in the flues indicates that chlorinated materials are
being burned. Burning chlorinated materials will severely damage your heat exchanger and
void your warranty. Contact your Clean Burn dealer for instructions to test your oil for
chlorine contamination before firing your furnace.
j. Inspect the inside of the clean-out door. Make sure the refractory material on the inside of
the clean-out door is in good condition and the clean-out door seals tightly when closed. If
the door does not seal tightly, replace any damaged components.
9-8
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Cleaning the Ash (continued)
k. Re-install the furnace components: Swing the clean-out door shut; install and tighten the
lock-down nuts so that the door seals properly. Re-install the air and oil lines on the bottom
of the connector block.
NOTE: You may need to bleed air from the oil line before starting the burner. See Section 5
for the pertinent instructions.
Annual Burner Tune-up
Your Clean Burn furnace requires annual periodic maintenance. The burner requires an annual tune-up
--similar to an automotive tune-up--to keep it running in peak condition. The burner tune-up should be
performed by a qualified Clean Burn service technician who has the necessary parts and expertise.
Contact your local Clean Burn dealer to schedule the annual periodic maintenance which is usually
(preferably) performed during warm weather to prepare the furnace for the next heating season. Various
levels of service are provided to fit your particular need.
End of Season Maintenance
ATTENTION: Turn main power to your furnace OFF at the end of the heating season. EPA
regulations allow your used oil to be burned only for "heat recovery." DO NOT operate your furnace
during warm weather just to burn oil, or severe damage to the combustion chamber/heat exchanger may
occur.
Contact your local Clean Burn dealer to schedule your annual burner tune-up. Allow only trained,
authorized service personnel to service your burner.
Cleaning and Maintaining the Optional 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.
9-9
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
9-10
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
SECTION 10: TROUBLESHOOTING
The following charts and tables are provided for reference in troubleshooting any difficulties
encountered in furnace operation and adjustment.
•The Flow Chart outlines the proper sequence of events in furnace operation -- use this
chart to help diagnose where a problem may be occurring.
• More 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.
10-1
10-2
Blower continues to run
to drive latent heat from
the heat exchanger.
Blower switch on combustion
chamber senses 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 both high limit
switches.
Air sensing switch
receives power from
centrifugal switch.
Blower switch sends power
to motor (CB-1750) or relay
(CB-2500 / 3250), and
blower starts.
Blower switch senses OFF
temperature (160 °F) and
Blower switch opens.
Blower stops running.
FURNACE COOL DOWN SEQUENCE
Blower switch senses ON
temperature (180 °F) and
Blower switch closes.
FURNACE 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
INITIAL START-UP
Air regulator adjusted to
proper psi of air pressure.
FLOW CHART
CB-3250
230 V / 60 Hz
Warm air delivered
to heated area.
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 has power.
When block temperature reaches 120 °F , the
F120 proving switch closes and sends power
to the oil primary control.
NORMAL BURNER OPERATION
Preheater thermostat cycles 400 watt block
heater element and maintains 140 °F block
temperature.
Preheater thermostat activates 400 watt block
heater element and heats the block to 140 °F.
INITIAL START-UP
BURNER PRE-IGNITION SEQUENCE
Primary control relay
opens and the burner
shuts off.
I88792-B
FLOW CHART
CB-1750/2500/3250
115 V / 60 Hz
Wall thermostat is
satisfied and T
circuit opens.
Burner continues to run
until the wall thermostat
is satisfied.
Oil primary control
receives <500 ohm signal
from cad cell indicating
proper ignition.
Burner ignites.
Burner ignition sequence begins.
Oil primary control relay closes.
Oil primary control checks for
2000+ ohms from cad cell
indicating dark in the combustion
chamber (NO FLAME)
Wall thermostat calls for heat and
closes 24V thermostat.
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
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 L-200 or L-290 limit switches
have opened.
10-3
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 switch for power. Note
that power should be indicated
on both sides of the switch. See
Section 7.
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
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 furnace,
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
1. Follow the procedures in Section 5
Burner ignites and runs properly,
1. There is air in the suction oil line
due to leaks at the fittings.
to vacuum test the pump. Reinstall
but the burner shuts off on reset
and properly seal the suction line
periodically (e.g. the burner goes off
fittings to eliminate air leaks.
on reset during the night and requires
2. There is air trapped in a high point 2. Bleed the air out of the pressure
resetting in the morning).
in the pressure oil line
oil line.
10-4
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
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 10-4)
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
furnace is operating. If you turn
the air compressor off at night,
turn the wall thermostat to OFF so
the burner will not run.
4. DO NOT shut off power to the
furnace overnight, or the heater
block will cool down, and the
burner will not re-start the next
morning. To turn the furnace “off ”
overnight, turn the wall thermostat
to 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 overfire.
Clean the electrodes and retention
head as shown in Appendix A.
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.
10-5
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
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
fill with oil during the priming
with oil prior to starting the pump.
process.
See Section 5.
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.
The check valve is dirty.
7. Refer to Section 9 to clean the
check valve.
The pump is damaged or worn out. 8. Replace the pump
10-6
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
PROBLEM
POSSIBLE CAUSE(S)
Pump will not prime and Pump motor is
NOT running.
1.
There is NO power on the pump
circuit from the burner.
1.
2.
The pump motor has shut off on
thermal overload
2.
1.
Blower motor circuit is wired
incorrectly.
1.
2.
For CB-2500/3250 ONLY: Blower relay 2.
is stuck in the closed position
1.
The blower motor is not wired
correctly.
1.
2.
3.
The fan / blower switch is defective.
The blower motor has overheated and
shut down on thermal reset.
2.
3.
4.
For CB-2500/3250 ONLY: blower relay
won’t close
4.
Blower motor runs all the time.
Blower motor will not run.
10-7
POSSIBLE ACTION(S)
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.
(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).
Refer to wiring diagram and
ladder schematic in Appendix B to
troubleshoot the blower circuit.
Test the blower motor contactor. If
it will not open when the power is
turned OFF, replace the contactor
Check the fan motor wiring Refer
to the wiring diagram and ladder
schematic in Appendix B. Follow
the directions in Section 6 to test for
proper blower operation. If the blower
does not operate, shut OFF power to
the furnace and call your Clean Burn
dealer for service.
Replace the fan / blower switch.
The blower 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 blower
motor. Call your dealer if the problem
persists.
Test the blower motor contactor.
Check for proper voltage at the L1/L2
lugs. Check the orange wire on thecoil
for 110 volts. Replace if needed.
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
10-8
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
APPENDIX A
Detailed Furnace Specifications
Furnace Technical Specifications
FURNACE MODEL
CB-1750
CB-2500
CB-3250
BTUH Input
175,000*
@ 1.2 GPH
250,000*
@ 1.7 GPH
300,000*
@ 2.1 GPH
Listed Fuels:
#2, #4, #5 Fuel Oils
Used Crankcase Oil
Used ATF (for U.S.)
Used Hydraulic Oil
#2, #4, #5 Fuel Oils
Used Crankcase Oil
Used ATF (for U.S.)
Used Hydraulic Oil
#2, #4, #5 Fuel Oils
Used Crankcase Oil
Used ATF (for U.S.)
Used Hydraulic Oil
52 x 26.5 x 26.5
72 x 26.5 x 26.5
81 x 28.25 x 28.25
83.25 x 29.25 x 31.5
103.25 x 29.25 x 31.5
121 x 31.25 x 35
406 lbs.
509 lbs.
641 lbs.
Cabinet Dimensions
(LxWxH) inches
Furnace Dimensions
w/ fan, Burner, and Louvers
(LxWxH) inches
Approximate Weight
(complete furnace system – uncrated)
Mounting (NFPA-31)
Electrical Requirements
(VAC @ 60 Hz)
1) Ceiling hung
1) Ceiling hung
2) Raised platform
2) Raised platform
3) non-combustible platform 3) non-combustible platform
1) Ceiling hung
2) Raised platform
3) non-combustible platform
115
115
115
230
Circuit Breaker
20 amps
30 amps (w/options)
30 amps
50 amps @ 115 Volts
35 amps @ 208/230 Volts
Wall Thermostat
24 volt
24 volt
24 volt
Suntec
A2RA-7720
Suntec
A2RA-7720
Suntec
A2RA-7720
Bison Gear Motor
1/20 HP
Bison Gear Motor
1/20 HP
Bison Gear Motor
1/20 HP
CCW shaft end
CCW shaft end
CCW shaft end
Lenz
DH 750-100
Lenz
DH 750-100
Lenz
DH 750-100
8”
8”
8”
Blower Motor HP
¾ HP
1 HP
2 HP
Blower Wheel Size
10 5/8” diameter
10 5/8” wide
12” diameter
11” wide
15” diameter
15” wide
Blower/Fan Switch
F180
F180
F180
Hi-Temp Limit Switch
L200
L200
L200
Auxiliary Hi-Temp Switch
L290 (Auto-Reset)
L290 (Auto-Reset)
L290 (Auto-Reset)
Approx. Air Compressor
Requirements
2.0 CFM
@ 25 PSI
2.5 CFM
@ 25 PSI
2.5 CFM
@ 25 PSI
Oil Pump
Oil Pump Motor
Pump Motor Rotation
Canister Filter
Stack Size
* Nominal values; actual values may vary depending on installation.
A-1
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Burner Technical Specifications
Burner
CB-525-S2
Ignition Transformer
Carlin Transformer 14,000 Volts
Nozzle
Delavan 9-5
Burner Motor
1/10 HP 3200 RPM
with centrifugal switch
Burner Motor Rotation
CCW shaft end
CB-1750
2.0 CFM
@25 PSI
Compressed Air Requirements
CB2500 / 3250
2.5 CFM
@25 PSI
Oil Primary Control
Carlin Oil Primary Control
(W/ Interupted Ignition)
Heater Element in Preheater Block
400 Watts
Air Pressure Switch
MPL 808
Setting for Preheater Thermostat
140 ºF
Furnace Dimensions
CB-1750
NOTE:
MEASUREMENT FROM BOLT CENTER
TO BOLT CENTER IS 51-1/8"
51 1/8
18 1/2
18 3/4
31
13
6 1/2
3/4
26 1/2
4 3/8
TOP VIEW
8 1/2
261/2
12
4
12
12
7 1/4
AIR
SIDE VIEW
16 1/2
261/2
52 1/8
OIL
FRONT VIEW
83
I88454-D
A-2
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Furnace Dimensions (continued)
CB-2500
NOTE:
MEASUREMENT FROM BOLT CENTER
TO BOLT CENTER IS 69"
3/4
69
21
18 3/4
31
14 1/2
2 3/4
26 1/2
TOP VIEW
12 1/2
2 5/8
12
6
4
26 1/2
12
12
7 1/4
SIDE VIEW
19 1/8
FRONT VIEW
70
26 1/2
103 1/4
I89024-B
CB-3250
NOTE:
MEASUREMENT FROM BOLT CENTER
TO BOLT CENTER IS 79-1/2"
79 1/2
28
3/4
33 3/4
18 1/2
4 3/4
20
28 1/4
TOP VIEW
6
2 5/8
15 1/2
3
15 1/2
28 1/4
8 3/4
7
SIDE VIEW
22
FRONT VIEW
81
28 1/4
121
I89025-A
A-3
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Burner Components (CB-525-S2)
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
12
13
17
11
14
15
BURNER CB - 525 - S2
16
I88234-C
Figure A1 - CB-525-S2 Burner Component Detail
A-4
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Burner Components (CB-525-S2) (continued)
Item#
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.
Clean Burn Part# Qty.
Component Description
261031AIR INTAKE OUTER PLATE
113591AIR INTAKE INNER PLATE
33400
1
CARLIN PRIMARY CONTROL (w/ INTERRUPTED IGNITION)
331891CARLIN IGNITER (TRANSFORMER)
331161CAD CELL
112431TRANSFORMER PLATE
321781OIL GAUGE 0-15 PSI
32235
1
FEMALE ELBOW (3/16 T x 1/8 NPT)
321791AIR GAUGE 0-60 PSI
32253
1
FEMALE ELBOW (1/8 TP x 1/8 NPT)
332971HOUR METER (60 Hz)
331691GREEN LIGHT (POWER)
331681AMBER LIGHT (PUMP)
311131FAN SQUIRREL CAGE
260441MOTOR MOUNT PLATE
331751BLOWER MOTOR
260531RIGHT SIDE COVER
113351HOUSING (INCLUDES ITEM 23)
131481HEATER BLOCK ASSEMBLY
112651COVER-HINGED
SEE NOTE ON DRAWING
NOZZLE ADAPTER ASSEMBLY
11334
1
HINGE MOUNTING PLATE
331491CONNECTOR RECEPTACLE
333361CONNECTOR PLUG
260521LATCH BRACKET
113081RETENTION HEAD
A-5
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Burner Components (continued)
30
(8)
31
58
57
32
(8)
56
1
3
9
34
35
59
52
36
51
37
27
39
40
48
(2)
12
6
(4) 17
45
41
46
26
(2)
10
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 A2 - Preheater Block Assembly Component Detail
A-6
I88543-A
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Burner Components (continued)
Item#
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
C.B. Part#
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
Qty.
Component Description
1 ELECTRODE SCREW - 10-32 x 3/4
1 SINGLE PIECE ELECTRODE
1WASHER
1 9 - 5 NOZZLE
1 NOZZLE ADAPTOR
1 PLUG - 1/8 NPT
1 140 WATTS HEATER
1 INSULATED CAP CRIMP CONNECTOR
1 THERMOSTAT L-130
1 PLUG - 1/16 NPT
2 SWIVEL FITTING
2 HEX NIPPLE - 1/8 NPT x 1-1/2
1 MALE CONNECTOR - 3/16T x 1/8 NPT
1 3/16 COPPER TUBING(OIL GAUGE LINE)
2 MACH. SCREW PHILLIPS HD. 6-32 x 3/8 Z
1 TERMINAL BLOCK
4 MACH. SCREW PHILLIPS HD. 6-32 x 1/4 Z
1 TERMINAL BLOCK BRACKET
1 AIR PRESSURE SWITCH
1 HEATER BLOCK
2 HEX NIPPLE - 1/8 NPT x 2
1 FEMALE ELBOW (FOR 1/4" AIR LINE)
1 FEMALE ELBOW (FOR 3/8" OIL LINE)
1 PRE-HEATER ELEMENT (400 WATTS)
1 PROVING SWITCH (NORMALLY OPEN)
1 MALE ELBOW 1/8 x 1/8 NPT (FOR AIR GAUGE LINE)
1 3/16 COPPER TUBING(OIL GAUGE LINE)
1 HEATER BLOCK THERMOSTAT(NORMALLY CLOSED)
1 REGULATOR SURFACE MOUNT
1 REGULATOR LOCK PLATE
8 REGULATOR MOUNTING SCREW
8 LOCK WASHER #8 Z
2 REGULATOR THREADED STEM
2 HEX NU T - 10-32 Z
2BONNET
2 DIAPHRAM RING
2 CAP AND BALL ASSEMBLY
2 COMPRESSION SPRING
2DIAPHRAM
2 BRASS POPPET SEAT
2 POPPET ‘O” RING
2 POPPET VALVE
2 POPPET SPRING
2BASE
2 REGULATOR KIT COMPONENTS
2 REGULATOR OUTER “O” RING
2 REGULATOR INNER “O” RING
2 SOLENOID INNER “O” RING
2 SOLENOID OUTER “O” RING
2 MANIFOLD MOUNT SOLENOID BODY
2 BODY “O” RING
2 PLUNGER ASSEMBLY
2 PLUNGER GUIDE ASSEMBLY
2 FLUX PLATE
2 WASHER SEAL
2COIL
2 COIL HOUSING
2NUT
2 AIR/OIL SOLENOID ASSEMBLY
1 REG. SQUARE CAP
A-7
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Burner Components (continued)
INSTALLATION OF THE SPINNER RETENTION HEAD
THE SPINNER RETENTION HEAD FITS INSIDE THE BURNER TUBE AND
REQUIRES (3) SELF-TAPPING SCREWS. IT IS VERY IMPORTANT THAT
THE SPINNER HEAD IS NOT TIPPED FROM SIDE TO SIDE OR FROM
TOP TO BOTTOM.
3X
VIE
W
IEW
V
A-A
B-B
USE PROVIDED SCREWDRIVER AS
WEDGE TO HOLD THE SPINNER
RETENTION HEAD IN POSITION. THEN
TIGHTEN THE THREE SCREWS TO
LOCK THE HEAD IN POSITION.
3/16" GAP
BETWEEN
ELECTRODES &
NOZZLE
CRITICAL DIMENSION:
NOZZLE MUST BE 1/8"
AHEAD OF THE DISK.
NOZZLE MUST NOT BE
BEHIND THE DISK.
1/8" SPARK
GAP
SIDE VIEW A-A
SIDE VIEW B-B
I88377
Figure A3 - Burner Electrode Specifications with Spinner Retention Head
A-8
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Burner Components (continued)
ModelNozzle Size
CB-1750 Delavan 9-5
CB-2500 Delavan 9-5
CB-3250 Delavan 9-5
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
reinstall the nozzle.
7.
Check the electrodes for proper gap and clearances. (Figure A3)
8.
Re-install the burner and adjust for optimal performance as described in Section 6.
NOTE: If the nozzle plugs within a few days after cleaning, call your Clean Burn Dealer for
service.
Figure A4 - Cleaning the Nozzle
A-9
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
CABINET
CB-1750
66
65
32
(# 11536)
71
31
70
64
63
30
29
28
62
59
58
31
32
61
60
DETAIL C
67
69
DETAIL A
DETAIL B
C
68
27
DETAIL D
72
46
48
47
33
26
49
34
54
B
45
53
55
52
44
50
51
56
73
A
57
15
43
42
41
40
39
38
2
18
37
19
36
20
21
35
D
25
24
23
22
1
3
17
16
13
15
14
12
4
11
10
9
21
8
I88953-C
A-10
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
ITEM#
PART#
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.
31091 21010 29083 11475 34054 29069 29070 34028 29045 29112 29088 31232 29056 29095 29115 29059 34179 34121 21039 31183 34118 34095 21056 34119 14230 34051 32311 32039 13119 13125 32304 32303 32245 21101 11033 34120 21076 11325 11143 34009 29044 29113 29082 29084 33336 21184 33142 12249 29090 29114 23091 11485 34007 29094 29093 11553 29096 33230 29068 34004 33288 33390 34050 33131 21183 33286 33267 33273 33486 21164
33468 21165 21007 DUCT CAP ROUND 8"
STACK PIPE FLASH RING
SHROUD RIGHT
LOUVER ASSEMBLY (2)
1/4-20 X 1/2 HEX FLANGE SCREW
ANGLE LVR CB-1750 / 2500
LOUVER
5/16-18 X 3/4 SERR HEX FLANG
HINGE
SIDE SHIELD LFT (CB-1750,2500)
PLATE (STATIC) AIR FLOW
ENERGY RETENTION DISC
COMB CHAMBER
BASE
COVER DISCHARGE CLOSURE PANEL
FRAME FRONT
3/8-16 X 3 HHCS GR-5
5/16-18 TOP LOCK NUT S.S.
.438 X 1.5 X .135 FLAT WASHER
INSULATION
5/16-18 X 3/4 HEX WASHER HEAD
3/8-16 STOVER L/N GR-B CAD/WAX
HINGE BRACKET
3/8-16 X 3 HHCS GR-2 ZINC
HOOK-UP KIT CB-1750/2500/3250
5/16-18 X 1 1/2 HHCS GR-2 ZINC
ACCUMULATOR
ADAPT 1/4 OD X 1/8 P
AIR LINE A
OIL LINE A
NUT - LONG
SLEEVE
SWIVEL 1/4NPTM,1/4NPTF
CONNECTOR BLOCK
HINGE BRACKET W A
5/16-18 X 2 3/4 CARR BOLT S.S.
PORT CAP
INSPECTION DOOR A
BURNER MOUNT W A
3/8-16 HEX SERR FLANGE NUT PLT
DOOR CB-1750/2500/3250
SIDE SHIELD RT. (CB-1750,2500)
SHROUD LEFT
SHROUD TOP
CONNECTOR PLUG
LID E-BOX
CLAMP 3/8 FLEX CONDUIT or 1/4
FLEX CONDUIT R.W. 3/8 X 43"
SWITCH COVER
TOP HEAT SHIELD (CB-1750)
FLUE TUBE CB-1750
FURNACE WELD ASSY CB-1750
5/8-11 X 2 1/8 ROD COUPLNG NUT
ANGLE BLOWER SHORT
ANGLE BLOWER LONG
SHROUD BACK CB-1750 (PAINTED)
SEAL STACK RING
FAN SWITCH - SURFACE MOUNT 180
BRACKET TEMP HI LIMIT
#8 X 1/2 WASHER HEAD TEK SCREW
AUXIL HI LIMIT-AUTO RESET 290
SWITCH TEMP (HL)
8/32 X 3/8 SLTD IND HEX TYPE-F
KNOCK-OUT SEAL/PLUG
E-BOX FOR PRIME SWITCH
SWITCH DPDT ON-ON
CONNECTOR (ID Screw In Type)
CONNECTOR 90 DEG. SNAP-TITE
TERMINAL BLOCK A (SCREW)
E-BOX 6 X 4 X 3 .
TERMINAL BLOCK (2 CIRCUIT)
LID E-BOX 6 X 4 X 3 .
STACK PIPE FLANGE
ITEM#
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
A-11
PART#
Description
14084 34162 70416 12159 14246 14297 21065 29086 29087 42027 42030 42038 42045 42068 42197 42216 42358 42367 42461 42462 42424 42425 43163 43195 11536 FIBERGLASS ROPE A
STOVE CEMENT - HIGH TEMP
STAINLESS TARGET SERVICE KIT
BLOWER MOTOR ASSEMBLY
BLOWER CB-1750 DD
PUMP MTR CB-1750
TARGET HANGER
FLUE PLATE FRONT
FLUE PLATE BACK
LABEL - WARNING - BURN/VOLTAGE
LABEL - VOLTAGE WARNING
LABEL COPPER CONDUCTORS
LABEL - MADE IN USA - 2X3
LABEL - TANGLE / CUTTING
LABEL - PAT PEND
LABEL-LOGO-ENG'D LIKE NO OTHER
LABEL - UL/ULC HEADER LABEL
LABEL - FURNACE WARNING
LABEL IDENT - CB 1750
LABEL-UL DATA FOR CB-1750
LABEL CB-1750 SCHEMATIC (FRNT)
LABEL CB-1750 SCHEMATIC (REAR)
CAUTION INSTRUCTION SHEET
OPERATORS MAN CB-1750/2500/3250
FURNACE CABINET CB-1750
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
BLOWER ASSEMBLY
CB-1750
2
8
9
10
1
11
12
7
6
5
4
3
2
1
I88954
A-12
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
ITEM#
PART#
Description
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
34116 31191 31204 31199 33142 33470 33000 33422 33419 33454 34159
33448 33055 43205 14246 10 X 5/8 HEX WASHER HEAD TEK Z
GUARD DD BLOWER
BRACKET KIT - 3/4 HP MOTOR EA
BLOWER DD 1750 10-10A
CLAMP 3/8 FLEX CONDUIT or 1/4
FLEX CONDUIT R.W. 3/8 x 19"
CONNECTOR 90 DEG. THRD & NUT
CAPACTR BONNET (RUBBER CAP)
CAPACTR RUN 370-V 10-Mfd
CAPACTR STRAP-Hold Down Clamp
1/4 X 3/4 SLOTTED IND HEX
MOTOR 3/4 HP
WIRE PROTECTOR (anti-short)
INSTRUCTION SHEET CB-1750
BLOWER CB-1750 ASSEMBLY
A-13
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
CABINET
CB-2500
32
( # 11471 )
31
74
66
67
65
73
68
30
69
29
28
64
31
27
59
60
61
63
62
32
26
DETAIL A
70
71
DETAIL B
25
DETAIL C
72
33
C
DETAIL D
75
49
50
48
47
51
52
53
54
56
55
B
76
46
45
44
57
15
43
A
42
57
41
39
58
40
39
38
1
2
18
37
3
D
36
4
20
35
34
24
23
22
21
20
19
17
16
15
14
13
A-14
12
11
10
9
I88955-B
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
ITEM#
PART#
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.
31091 21010 29066 11475 29070 29069 34124 34054 34028 29045 29112 31232 29056 29061 29115 29059 34179 34121 21039 34118 34095 21056 34119 14230 34051 21101 32039 32311 13119 13125 32304 32303 32245 11033 34120 11143 11325 21076 34009 29044 31183 29113 29065 29067 29090 33336 21184 33142 34004 33545 23079 29133 11554 29072 34007 29073 29096 34191 33230 34004 29068 33288 33390 33486 33131 33547 33286 33267 33469 21183 33273 34050 21164 33207 21165 21007 DUCT CAP ROUND 8"
STACK PIPE FLASH RING
SHROUD RIGHT
LOUVER ASSEMBLY (2)
LOUVER
ANGLE LVR CB-1750 / 2500
1/4-20 NUT
1/4-20 X 1/2 HEX FLANGE SCREW
5/16-18 X 3/4 SERR HEX FLANG
HINGE
SIDE SHIELD LFT (CB-1750,2500)
ENERGY RETENTION DISC
COMB CHAMBER
BASE
COVER DISCHARGE CLOSURE PANEL
FRAME FRONT
3/8-16 X 3 HHCS GR-5
5/16-18 TOP LOCK NUT S.S.
.438 X 1.5 X .135 FLAT WASHER
5/16-18 X 3/4 HEX WASHER HEAD
3/8-16 STOVER L/N GR-B CAD/WAX
HINGE BRACKET
3/8-16 X 3 HHCS GR-2 ZINC
HOOK-UP KIT CB-1750/2500/3250
5/16-18 X 1 1/2 HHCS GR-2 ZINC
CONNECTOR BLOCK
ADAPT 1/4 OD X 1/8 P
ACCUMULATOR
AIR LINE A
OIL LINE A
NUT - LONG
SLEEVE
SWIVEL 1/4NPTM,1/4NPTF
HINGE BRACKET W A
5/16-18 X 2 3/4 CARR BOLT S.S.
BURNER MOUNT W A
INSPECTION DOOR A
PORT CAP
3/8-16 HEX SERR FLANGE NUT PLT
DOOR CB-1750/2500/3250
INSULATION
SIDE SHIELD RT. (CB-1750,2500)
SHROUD LEFT
SHROUD TOP
SWITCH COVER
CONNECTOR PLUG
LID E-BOX
CLAMP 3/8 FLEX CONDUIT or 1/4
#8 X 1/2 WASHER HEAD TEK SCREW
FLEX CONDUIT (RW) 1/2" x 65"
FLUE TUBE CB2500
REAR CHAMBER WA 2500
SHROUD BACK CB-2500 (PAINTED)
ANGLE BLOWER SHORT
5/8-11 X 2 1/8 ROD COUPLNG NUT
ANGLE BLOWER LONG
SEAL STACK RING
3/8-16 X 3/4 CARRIAGE BOLT
FAN SWITCH - SURFACE MOUNT 180
#8 X 1/2 WASHER HEAD TEK SCREW
BRACKET TEMP HI LIMIT
AUXIL HI LIMIT-AUTO RESET 290
SWITCH TEMP (HL)
TERMINAL BLOCK A (SCREW)
KNOCK-OUT SEAL/PLUG
CONNECTOR 1/2” (ID Screw In Type)
SWITCH DPDT ON-ON
CONNECTOR 3/8” (ID Screw In Type)
FLEX CONDUIT R.W. 3/8 x 5"
E-BOX FOR PRIME SWITCH
CONNECTOR 90 DEG. SNAP-TITE
8/32 X 3/8 SLTD IND HEX TYPE-F
E-BOX 6 X 4 X 3 3/4
CONTACTOR 120V
LID E-BOX 6 X 4 X 3 3/4
STACK PIPE FLANGE
ITEM#
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
A-15
PART#
Description
14084 11471 11473 11499 14168 14245 29057 29060 34162 42027 42030 42038 42045 42068 42137 42216 42217 42333 42355 42358 42366 42367 42422 42423 43195 54014 FIBERGLASS ROPE A
FURN CAB CB-2500
ACCESSORY GROUP
DISCHARGE HOT AIR A
METER PUMP CB-2500
BLOWER - CB 2500 DD
FLUE PLATE FRONT
FLUE PLATE BACK
STOVE CEMENT - HIGH TEMP
LABEL - WARNING - BURN/VOLTAGE
LABEL - VOLTAGE WARNING
LABEL COPPER CONDUCTORS
LABEL - MADE IN USA - 2X3
LABEL - TANGLE / CUTTING
LABEL - DATE CODE
LABEL-LOGO-ENG'D LIKE NO OTHER
LABEL - AIR OIL
LABEL CB-2500
LABEL (CB-2500 UL DATA)
LABEL - UL/ULC HEADER LABEL
LABEL - TANK WARNING
LABEL - FURNACE WARNING EA
LABEL CB-2500 SCHEMATIC (FRNT)
LABEL CB-2500 SCHEMATIC (REAR)
OPERATORS MAN CB-1750/2500/3250
FIBERGLASS ROPE 3/4 W/AD
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
BLOWER ASSEMBLY
CB-2500
7
15
14
13
12
11
10
9
7
1
2
3
4
5
7
1
6
8
I88956
A-16
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
ITEM#
PART#
Description
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
31191 31189 12057 33055 33450 11482 34116 34035 34159 34009 33416 33422 33414 33142 33000 14245 42365 43163 GUARD DD BLOWER
BLOWER CB-2500
FLEX CONDUIT RW 3/8 X 23
WIRE PROTECTOR (anti-short)
MOTOR 1 HP
MOTOR MOUNT WELD
10 X 5/8 HEX WASHER HEAD TEK Z
CB 3/8-16 X 1.25 G5 Z
1/4 X 3/4 SLOTTED IND HEX
3/8-16 HEX SERR FLANGE NUT PLT
CAPACTR STRAP-Hold Down Clamp
CAPACTR BONNET (RUBBER CAP)
CAPACTR RUN 370-V 30-Mfd
CLAMP 3/8 FLEX CONDUIT or 1/4
CONNECTOR 90 DEG. THRD & NUT
BLOWER CB-2500 DD ASSEMBLY
LABEL (TO REMOVE SHPING BRKT)
CAUTION INSTRUCTION SHEET
A-17
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
CABINET
CB-3250
53
#11595
52
29
56
57
51
58
28
59
55
27
26
28
60
54
DETAIL B
63
50
DETAIL A
25
61
29
64
49
24
30
31
DETAIL C
62
32
48
47
46
65
66
67
68
B
45
69
70
44
71
41
40
72
43
42
73
13
A
39
38
16
37
36
1
2
3
35
C
18
34
33
4
16
11
19
19
23
22
21
20
17
15
14
13
12
10
A-18
9
8
I89028-B
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
ITEM#
PART#
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.
31091 21010 29165 11609 34054 29188 29168 34028 29167 29176 31232 29159 29169 29158 34179 21039 31183 34119 34118 34095 21056 11033 14230 21101 32039 13119 13125 32304 32303 32245 32311 34051 34120 34009 11325 21076 11143 29044 29175 29164 29177 29182 29181 29166 33336 21184 29090 33545 29064 33230 29068 33288 33390 34050 33486 33547 33286 33267 33469 21183 33273 21164 21165 33182 29178 34007 11618 29161 24082 29160 23092 21007 29102 DUCT CAP ROUND 8"
STACK PIPE FLASH RING
SHROUD RIGHT
LOUVER ASSEMBLY (2)
1/4-20 X 1/2 HEX FLANGE SCREW
ANGLE LVR
LOUVER
5/16-18 X 3/4 SERR HEX FLANG
HINGE BENT BRACKET
SIDE SHIELD RIGHT (CB-3250)
ENERGY RETENTION DISC
BASE
COVER DISCHARGE CLOSURE PANEL
FRAME FRONT
3/8-16 X 3 HHCS GR-5
.438 X 1.5 X .135 FLAT WASHER
INSULATION
3/8-16 X 3 HHCS GR-2 ZINC
5/16-18 X 3/4 HEX WASHER HEAD
3/8-16 STOVER L/N GR-B CAD/WAX
HINGE BRACKET
HINGE BRACKET W A
HOOK-UP KIT CB-1750/2500/3250
CONNECTOR BLOCK
ADAPT 1/4 OD X 1/8 P
AIR LINE A
OIL LINE A
NUT - LONG
SLEEVE
SWIVEL 1/4NPTM,1/4NPTF
ACCUMULATOR
5/16-18 X 1 1/2 HHCS GR-2 ZINC
5/16-18 X 2 3/4 CARR BOLT S.S.
3/8-16 HEX SERR FLANGE NUT PLT
INSPECTION DOOR A
PORT CAP
BURNER MOUNT W A
DOOR CB-1750/2500/3250
SIDE SHIELD LEFT (CB-3250)
SHROUD LEFT
INNER TOP SHIELD
TARGET STOP
TARGET HANGER
SHROUD TOP
CONNECTOR PLUG
LID E-BOX
SWITCH COVER
FLEX CONDUIT (RW) 1/2" x 65"
FAN SWITCH MOUNTING PLATE
FAN SWITCH - SURFACE MOUNT 180
BRACKET TEMP HI LIMIT
AUXIL HI LIMIT-AUTO RESET 290
SWITCH TEMP (HL)
8/32 X 3/8 SLTD IND HEX TYPE-F
TERMINAL BLOCK A (SCREW)
CONNECTOR 1/2" (ID Screw In Type)
SWITCH DPDT ON-ON
CONNECTOR 3/8” (ID Screw In Type)
FLEX CONDUIT R.W. 3/8 x 5"
E-BOX FOR PRIME SWITCH
CONNECTOR 90 DEG. SNAP-TITE
E-BOX 6 X 4 X 3 ¾
LID E-BOX 6 X 4 X 3 3/4
CONTACTOR 120V – 2 POLE
AIR SCOOP
5/8-11 X 2 1/8 ROD COUPLNG NUT
REAR FRAME 3250 (PAINTED)
HEADER COVER 3250
ANGLE BLOWER
FLUE PLATE REAR 3250
FLUE TUBE CB-3250
STACK PIPE FLANGE
SEAL STACK RING
ITEM#
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
A-19
PART#
Description
33572 31084 29157 34162 42027 42030 42038 42045 42068 42137 42216 42217 42513 42514 42358 42366 42367 42516 42517 42518 43195 54014 METER PUMP CB-3250
BLOWER - CB 3250
FLUE PLATE COMBUSTION CHAMBER
STOVE CEMENT - HIGH TEMP
LABEL - WARNING - BURN/VOLTAGE
LABEL - VOLTAGE WARNING
LABEL COPPER CONDUCTORS
LABEL - MADE IN USA - 2X3
LABEL - TANGLE / CUTTING
LABEL - DATE CODE
LABEL-LOGO-ENG'D LIKE NO OTHER
LABEL - AIR OIL
LABEL CB-3250
LABEL (CB-3250 UL DATA)
LABEL - UL/ULC HEADER LABEL
LABEL - TANK WARNING
LABEL - FURNACE WARNING EA
LABEL CB-3250 SCHEMATIC (FRNT)
LABEL CB-3250 SCH. 115 V (REAR)
LABEL CB-3250 SCH. 230 V (REAR)
OPERATORS MAN CB-1750/2500/3250
FIBERGLASS ROPE 3/4 W/AD
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
BLOWER ASSEMBLY
CB-3250
17
16
18
3
19
15
20
21
22
14
13
12
11
2
10
9
8
7
6
5
4
3
2
1
I89023
A-20
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
ITEM#
PART#
Description
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
11125 34116 34214 31226 31225 210131 31192 31194 31084 31228 31187 34290 24087 34072 33533 210129 31223 31238 25046 34328 34159 31229 BELT GUARD ASSY
10 X 5/8 HEX WASHER HEAD TEK Z
1/4-20 X 1 HHCS GR-5 ZINC
SHEAVE BUSHING 1"
BLOWER PULLEY 3250/3500/5000
KEY 1/4 X 1 1/4
REPLACEMENT BEARING PACKAGE
1" SHAFT W/KEYWAY (15")
BLOWER
BLOWER WIRE GUARD 3250/3500/5000
MOTOR MOUNT BRACKET
5/16-18 X 3/4 SQUARE HEAD
MOTOR MOUNT
5/16-18 STOVER TOP LOCK NUT
BLOWER MOTOR 2HP RESILIENT MOUNT
KEY SQ. 3/16 X 1
MOTOR PULLEY 3250/3500 BLOWER
SHEAVE BUSHING 7/8"
ANGLE FRONT
5/16-18 X 3/4 HEX HEAD FLANGE
1/4 X 3/4 SLOTTED IND HEX
BLOWER BELT 3250/3500 - A-BELT
A-21
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
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-22
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
ITEM#
PART#
Description
1.
2.
33363 33353 33354 33572 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 32423 32422 CAPACITOR
GEAR MOTOR CB-1750
GEAR MOTOR CB-2500
GEAR MOTOR CB-3250
MOUNT METER PUMP A
1/8 NPT X 1/4 TUBE COMPRESSION FITTING
1/4 COPPER OR ALUMINUM TUBING
3/8 OR 1/2 TUBE FLARE NUT
3/8 0R 1/2 COPPER OR ALUMINUM TUBING
1/8 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-23
PART#
Description
33297 21182 13176 HOUR METER (60 Hz)
MTR PUMP COVER FOR HOUR METER
SUCTION FITTINGS PACKAGE
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
A-24
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
APPENDIX B
Wiring Diagrams
CB-1750
BLOWER
MOTOR
CAP
WHITE
WHITE
BLACK
BLACK
(OPTIONAL)
DRAFT
INDUCER
Ref. 42425
TO
BLOWER
WHITE
BLK
GRND
POWER IN
120 VAC
WHITE
L1
L2
HOT (BLK)
L1
L1
L2
L2
3
4
5
NEUT (WHT)
WHITE
BLACK
2
5
3
6
PRIME
PUMP
RUN
BURNER
WHT
PURPLE
RED
Blk / Wht HT
Blk / Wht HT
Ref. 42424
R/W HT
AUX.
AUTO
HIGH
LIMIT
4
GRN
BLK
Red / Wht HT
OIL
PUMP
Red / Wht HT
BLACK
1
FAN
SWITCH
(TEMP)
HIGH
LIMIT
(TEMP)
ON CONTROL
BRACKET
SURFACE
MOUNTED
BLK
RED
WHT
GRN
CONNECTOR
FACE
I88685-H
Figure B1 - CB-1750 Furnace Wiring Diagram
B-1
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Wiring Diagrams (continued)
CB-2500
WHITE
SPADE
(MALE TO FEMALE)
WHT
WHITE
(UNDER LUG SCREW)
L2
T2
L1
T1
BLOWER
MOTOR
BLACK
(OPTIONAL)
BLK
(UNDER LUG SCREW)
DRAFT
INDUCER
ORG
CAP
Ref. 42423
TO BLOWER
(FLEX CONDUIT)
WHITE
ORG
BLK
GRND
POWER IN
120 VAC
WHITE
L1
L2
HOT (BLK)
L1
L1
L2
L2
3
4
5
NEUT (WHT)
WHITE
BLACK
2
5
3
6
PRIME
PUMP
RUN
BURNER
WHT
PURPLE
RED
Blk / Wht HT
Blk / Wht HT
Ref. 42422
R/W HT
AUX.
AUTO
HIGH
LIMIT
4
GRN
BLK
Red / Wht HT
OIL
PUMP
Red / Wht HT
BLACK
1
HIGH
LIMIT
(TEMP)
ON CONTROL
BRACKET
FAN
SWITCH
(TEMP)
SURFACE
MOUNTED
Figure B2 - CB-2500 Furnace Wiring Diagram
B-2
BLK
RED
WHT
GRN
CONNECTOR
FACE
I88461-F
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Wiring Diagrams (continued)
CB-3250 (115 VOLTS)
GROUND
COMMON / NEUTRAL
HOT LEG
GREEN
T2
BLACK
T1
WHITE
L2
115 VOLTS AC
L1
115
VOLTS
IN
ORANGE
BLOWER
MOTOR
CONTACTOR HAS A
110 - 120 VOLT
AC COIL
CONNECT 2 HP BLOWER MOTOR
ACCORDING TO THE LABEL SUPPLIED
WITH
THE MOTOR FOR CW ROTATION FACING
THE SHAFT AND 115 VOLTS
Ref. 42517
TO BLOWER (FLEX CONDUIT)
ORANGE
BLACK
WHITE
(OPTIONAL)
ORG
BLK
WHITE
DRAFT
INDUCER
BLACK
L1
L1
L2
L2
3
4
5
WHITE
WHITE
Red / Wht HT
OIL
PUMP
Red / Wht HT
BLACK
I89026-A
4
2
5
3
6
PRIME
PUMP
RUN
BURNER
GRN
BLK
WHT
PURPLE
RED
Blk / Wht HT
Blk / Wht HT
Ref. 42516
R/W HT
AUX.
AUTO
HIGH
LIMIT
1
HIGH
LIMIT
(TEMP)
ON CONTROL
BRACKET
BLK
RED
FAN
SWITCH
(TEMP)
SURFACE
MOUNTED
Figure B3 - CB-3250 Furnace Wiring Diagram (115 Volts)
B-3
WHT
GRN
CONNECTOR
FACE
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Wiring Diagrams (continued)
CB-3250 (230 VOLTS)
GROUND
COMMON / NEUTRAL
HOT LEG
HOT LEG
GREEN
T2
BLACK
T1
WHITE
L2
230 VOLTS AC
L1
230
VOLTS
IN
ORANGE
BLOWER
MOTOR
CONTACTOR HAS A
110 - 120 VOLT
AC COIL
CONNECT 2 HP BLOWER MOTOR
ACCORDING TO THE LABEL SUPPLIED
WITH
THE MOTOR FOR CW ROTATION FACING
THE SHAFT AND 230 VOLTS
Ref. 42518
TO BLOWER (FLEX CONDUIT)
ORANGE
BLACK
WHITE
(OPTIONAL)
ORG
BLK
WHITE
DRAFT
INDUCER
BLACK
L1
L1
L2
L2
3
4
5
WHITE
WHITE
Red / Wht HT
OIL
PUMP
Red / Wht HT
BLACK
I89027-A
4
2
5
3
6
PRIME
PUMP
RUN
BURNER
GRN
BLK
WHT
PURPLE
RED
Blk / Wht HT
Blk / Wht HT
Ref. 42516
R/W HT
AUX.
AUTO
HIGH
LIMIT
1
HIGH
LIMIT
(TEMP)
ON CONTROL
BRACKET
BLK
RED
FAN
SWITCH
(TEMP)
SURFACE
MOUNTED
Figure B4 - CB-3250 Furnace Wiring Diagram (230 Volts)
B-4
WHT
GRN
CONNECTOR
FACE
140 WATTS NOZZLE HEATER
WALL
THERMOSTAT
NOZZLE
TEMP.SW.
RED
BLACK
BLACK
RED
AIR
SOLENOID
OIL
SOLENOID
CAD CELL
YELLOW
TRANS-
Figure B5 - Burner Wiring Diagram
OIL
PRIMARY
FORMER
BLUE
BLUE
BLACK
140
F F T T
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-5
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)
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Wiring Diagrams (continued)
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
MODEL CB-1750 - UH/CF
DRAWING : I44080
OPTIONAL SERVICE
DISCONNECT SWITCH
HOT
NEUTRAL
BLOWER SWITCH
(METAL SURFACE; 33230)
BLOWER MOTOR
M1
SECONDARY TEMP SWITCH N/C
(ON METAL SURFACE:33288)
BURNER PRIME
OIL PUMP MOTOR
M2
GRN
RD
WHT
BK
WHT
BK
GRN
RD
PUMP PRIME SWITCH
F
U
R
N
A
C
E
DRAFT INDUCER MOTOR
(OPTIONAL)
24 VOLTS
OPERATING
AQUASTAT
CAD
CELL
PROVING SWITCH
120°
BK
OR
- CONNECTION TO
CUSTOMER POWER
BL
AIR SOL.
F
F
T
OIL
PRIMARY
CONTROL
T
WHT
IGNITION TRANSF.
SPARK GAP
AIR COMPRESSOR (OPTIONAL)
BURNER MOTOR
M3
AIR PRESSURE
OIL SOL.
A
CENTRIFUGAL SWITCH
N. C. HELD OPEN
ACTUATED BY BURNER MOTOR
PUMP ON
HOUR METER
BLOCK THERMOSTAT
140°
400 WATTS BLOCK HEATER
NOZZLE ADAPTOR THERMOSTAT
130°
140 WATTS NOZZLE HEATER
POWER ON
G
B-6
B
U
R
N
E
R
Figure B6 - Ladder Schematic for CB-1750
HI LIMIT TEMP SWITCH N/C
(ON METAL SURFACE:33390)
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
MODEL CB-2501-UH/CF
DRAWING : I44076
OPTIONAL SERVICE
DISCONNECT SWITCH
HOT
NEUTRAL
SINGLE POLE RELAY
BLOWER SWITCH
(METAL SURFACE; 33230)
110 V COIL
M C
R 1
BLOWER MOTOR
SECONDARY TEMP SWITCH N/C
(ON METAL SURFACE:33288)
HI LIMIT TEMP SWITCH N/C
(ON METAL SURFACE:33390)
- CONNECTION AT
RELAY TERMINAL
INSIDE FURNACE
JUNCTION BOX
(6 X 6 INCHES)
BURNER PRIME
OIL PUMP MOTOR
M2
GRN
RD
WHT
BK
WHT
BK
GRN
RD
F
U
R
N
A
C
E
DRAFT INDUCER MOTOR
(OPTIONAL)
24 VOLTS
OPERATING
AQUASTAT
CAD
CELL
PROVING SWITCH
120°
BK
OR
- CONNECTION TO
CUSTOMER POWER
BL
AIR SOL.
F
F
T
OIL
PRIMARY
CONTROL
T
WHT
IGNITION TRANSF.
SPARK GAP
AIR COMPRESSOR (OPTIONAL)
BURNER MOTOR
M3
AIR PRESSURE
OIL SOL.
A
CENTRIFUGAL SWITCH
N. C. HELD OPEN
ACTUATED BY BURNER MOTOR
PUMP ON
HOUR METER
BLOCK THERMOSTAT
140°
400 WATTS BLOCK HEATER
NOZZLE ADAPTOR THERMOSTAT
130°
140 WATTS NOZZLE HEATER
POWER ON
G
B-7
B
U
R
N
E
R
Figure B7 - Ladder Schematic for CB-2500
M1
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
DRAWING : I44123
MODEL CB-3250-UH/CF
OPTIONAL SERVICE
115 VOLTS / 60 Hz
DISCONNECT SWITCH
N
L1
BLOWER MOTOR
(WIRED FOR 115 V)
M1
110 VOLTS COIL
M C
R 1
HI LIMIT TEMP SWITCH N/C
(ON METAL SURFACE:33390)
SECONDARY TEMP SWITCH N/C
(ON METAL SURFACE:33288)
DOUBLE POLE RELAY
BURNER PRIME
OIL PUMP MOTOR
- CONNECTION AT
RELAY TERMINAL
INSIDE FURNACE
JUNCTION BOX
(6 X 6 INCHES)
F
U
R
N
A
C
E
M2
GRN
RD
WHT
BK
WHT
BK
GRN
RD
PUMP PRIME SWITCH
DRAFT INDUCER MOTOR
(OPTIONAL)
24 VOLTS
OPERATING
AQUASTAT
CAD
CELL
PROVING SWITCH
120°
BK
OR
- CONNECTION TO
CUSTOMER POWER
BL
AIR SOL.
F
F
T
OIL
PRIMARY
CONTROL
T
WHT
IGNITION TRANSF.
SPARK GAP
AIR COMPRESSOR (OPTIONAL)
BURNER MOTOR
M3
AIR PRESSURE
OIL SOL.
A
CENTRIFUGAL SWITCH
N. C. HELD OPEN
ACTUATED BY BURNER MOTOR
PUMP ON
HOUR METER
BLOCK THERMOSTAT
140°
400 WATTS BLOCK HEATER
NOZZLE ADAPTOR THERMOSTAT
130°
140 WATTS NOZZLE HEATER
POWER ON
G
B-8
B
U
R
N
E
R
Figure B8 - Ladder Schematic for CB-3250 (115 Volts)
BLOWER SWITCH
(METAL SURFACE; 33230)
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
DRAWING : I44122
MODEL CB-3250-UH/CF
OPTIONAL SERVICE
230 VOLTS / 60 Hz
DISCONNECT SWITCH
N
L2
L1
BLOWER MOTOR
(WIRED FOR 230 V)
M1
110 VOLTS COIL
M C
R 1
HI LIMIT TEMP SWITCH N/C
(ON METAL SURFACE:33390)
SECONDARY TEMP SWITCH N/C
(ON METAL SURFACE:33288)
DOUBLE POLE RELAY
BURNER PRIME
- CONNECTION AT
RELAY TERMINAL
INSIDE FURNACE
JUNCTION BOX
(6 X 6 INCHES)
OIL PUMP MOTOR
F
U
R
N
A
C
E
M2
GRN
RD
WHT
BK
WHT
BK
GRN
RD
PUMP PRIME SWITCH
DRAFT INDUCER MOTOR
(OPTIONAL)
24 VOLTS
OPERATING
AQUASTAT
CAD
CELL
PROVING SWITCH
120°
BK
OR
- CONNECTION TO
CUSTOMER POWER
BL
AIR SOL.
F
F
T
OIL
PRIMARY
CONTROL
T
WHT
IGNITION TRANSF.
SPARK GAP
AIR COMPRESSOR (OPTIONAL)
BURNER MOTOR
M3
AIR PRESSURE
OIL SOL.
A
CENTRIFUGAL SWITCH
N. C. HELD OPEN
ACTUATED BY BURNER MOTOR
PUMP ON
HOUR METER
BLOCK THERMOSTAT
140°
400 WATTS BLOCK HEATER
NOZZLE ADAPTOR THERMOSTAT
130°
140 WATTS NOZZLE HEATER
POWER ON
G
B-9
B
U
R
N
E
R
Figure B9 - Ladder Schematic for CB-3250 (230 Volts)
BLOWER SWITCH
(METAL SURFACE; 33230)
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
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 B10 - Metering Pump Wiring Schematic
B-10
I44040
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Understanding the Oil Primary Control
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-11
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Understanding the Oil Primary Control (continued)
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-12
•
•
•
-
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.
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
Furnace Service Record
APPENDIX C
Furnace Purchased:
Date __________ From (name/phone)________________________________
Furnace Installed:
Date __________ By (name/phone)__________________________________
Furnace 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.*
Operator's Manual: Models CB-1750, CB-2500 & CB-3250
C-2
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