3500 5000 CE manual-opt

3500 5000 CE manual-opt
OPERATOR'S MANUAL
CLEAN BURN MULTI-OIL FURNACE MODELS:
CB-3500 and CB-5000 with CB-500 Series BURNER
230 V / 50 Hz
2 20-
24
0
50 -6
3W s
0Hz ts 10
fo ss
64
6
BHO 03
Type05 7H7
Nr.
Dan
FOR YOUR SAFETY −
DO NOT STORE GASOLINE
OR OTHER FLAMMABLE VAPORS AND LIQUIDS
I88911
IN THE VICINITY OF THIS OR ANY APPLIANCE!!
PUBLICATION DATE: 2/15/07, Rev. 10
CLEAN BURN PART #43143
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.
CLEAN BURN, INC. • 34 Zimmerman Road • Leola, PA 17540 • U.S.A.
The Clean Burn logo is a trademark of Clean Burn, Inc. All other brand or product names mentioned are the registered
trademarks or trademarks of their respective owners.
Copyright © 2007 Clean Burn, Inc. All rights reserved. No part of this publication may be reproduced, or distributed without
the prior written permission of Clean Burn, Inc. 34 Zimmerman Road, Leola, PA 17540. 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
SECTION 3: FURNACE ASSEMBLY ......................................................................... 3-1
Understanding Assembly ................................................................................................. 3-1
Required Tools and Materials ................................................................................... 3-1
Installing the Blower Components ....................................................................................... 3-4
Installing the Blower (CB-5000 ONLY) ...................................................................... 3-4
Installing the Motor on the Blower ............................................................................... 3-4
Wiring the Blower Motor ............................................................................................. 3-4
Installing the Motor Pulley, Blower Pulley, and V-Belt .................................................. 3-6
Installing the Belt Guard and the Blower Guard ............................................................ 3-7
Installing the Hot Air Discharge Components ...................................................................... 3-8
Determining the Air Discharge Configuration ................................................................ 3-8
UNIT HEATERS: Installing the Air Discharge Louver Assembly ................................. 3-9
CENTRAL FURNACES: Installing Ductwork .......................................................... 3-10
Installing the Ceramic Target ............................................................................................. 3-10
Installing the Target on the Combustion Chamber ....................................................... 3-10
Closing the Furnace Door .......................................................................................... 3-10
Installing the Burner .......................................................................................................... 3-11
Checking the Burner Nozzle and Electrodes ............................................................... 3-11
Mounting the Burner on the Hinge Bracket ................................................................. 3-12
Installing the Connector Block, Oil Line Tubing, and Air Line Tubing ................................. 3-13
Installing the Connector Block on the Furnace Door ................................................... 3-13
Installing the Oil Line Tubing ...................................................................................... 3-13
Installing the Air Line Tubing ...................................................................................... 3-14
Locking the Burner into Firing Position ....................................................................... 3-15
Installing the Mounting and Stabilizer Brackets .................................................................. 3-15
Installing the Brackets on the Furnace Cabinet ............................................................ 3-15
TABLE OF CONTENTS
SECTION 4: FURNACE INSTALLATION .................................................................. 4-1
Understanding Installation ................................................................................................... 4-1
Important Safety Guidelines for Safe Installation ........................................................... 4-1
Important Notes to the Electrician ................................................................................ 4-2
Selecting a Location ........................................................................................................... 4-4
Guidelines for Selecting a Location ............................................................................... 4-4
Mounting the Furnace ......................................................................................................... 4-5
Ceiling Mounting ......................................................................................................... 4-5
Raised Platform Mounting ............................................................................................ 4-6
Floor Mounting ........................................................................................................... 4-6
Oil Tank Installation Specifications ...................................................................................... 4-8
Installing the Tank Vent and Emergency Vent ............................................................... 4-9
Installing the Metering Pump ............................................................................................. 4-10
Preparing for Installation ............................................................................................ 4-10
Standard Mounting: Vertical Positioning ..................................................................... 4-10
Alternate Mounting: Horizontal Positioning ................................................................. 4-12
Wiring the Furnace and Pump ........................................................................................... 4-13
Wiring to the Furnace ................................................................................................ 4-13
Wiring to the Metering Pump ..................................................................................... 4-13
Installing the Suction Oil Line Components ........................................................................ 4-14
Installing the Pressure Relief and Low-Flow Check Valve ................................................. 4-17
Installing the Pressure Oil Line Components ...................................................................... 4-18
Installing the Compressed Air Line .................................................................................... 4-18
Installing the Stack ........................................................................................................... 4-19
Installing the Interior Stack ......................................................................................... 4-20
Installing the Barometric Damper ............................................................................... 4-22
Installing the Stack Penetration ................................................................................... 4-23
Installing the Exterior Stack ........................................................................................ 4-23
Installing the Stack Cap ............................................................................................. 4-23
Installing the Draft Inducer ......................................................................................... 4-23
Installing the Wall Thermostat ........................................................................................... 4-25
Inspecting the Furnace Installation ..................................................................................... 4-25
SECTION 5: METERING PUMP PRIMING ................................................................ 5-1
Understanding Metering Pump Priming ............................................................................... 5-1
Required Tools and Materials ...................................................................................... 5-1
Preparing the Burner for Use with the Metering Pump ......................................................... 5-2
Priming the Metering Pump ................................................................................................. 5-4
Vacuum Testing the Oil Pump ............................................................................................. 5-6
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 ..................................................................... 6-5
TABLE OF CONTENTS
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
Understanding the Fan Switches and Hi-Limits .................................................................... 7-2
The Blower/Fan Switch ...................................................................................................... 7-2
The Fan Limit Control ........................................................................................................ 7-3
The Auxiliary Hi-Temp Limit Switch ................................................................................... 7-4
SECTION 8: ADJUSTING THE DRAFT OVER FIRE ................................................ 8-1
Checking for Correct Draft Over Fire ................................................................................. 8-1
Adjusting the Barometric Damper ....................................................................................... 8-2
Adjusting Draft Overfire on Furnaces with Draft Inducers .................................................... 8-2
Solving Draft Overfire Problems ......................................................................................... 8-3
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 / Screen ..................................................................................... 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
SECTION 10: TROUBLESHOOTING ...................................................................... 10-1
Flow Chart ...................................................................................................................... 10-2
Troubleshooting Tables .................................................................................................... 10-3
APPENDIX A
Detailed Furnace Specifications ......................................................................................... A-1
Furnace Technical Specifications ................................................................................. A-1
Burner Technical Specifications ................................................................................... A-2
Furnace Dimensions ................................................................................................... A-3
Burner Components ................................................................................................... A-6
Removing the Nozzle for Cleaning ....................................................................... A-11
Furnace components ................................................................................................. A12
Blower components ................................................................................................... A16
TABLE OF CONTENTS
APPENDIX B
Wiring Diagrams ............................................................................................................... B-1
Furnace Wiring Diagram ............................................................................................. B-1
Burner Wiring Diagram ............................................................................................... B-2
Ladder Schematic ...................................................................................................... B-3
Metering Pump Wiring Schematic ............................................................................... B-4
APPENDIX C
Additional Requirements for the United Kingdom ............................................................... C-1
APPENDIX D
Furnace Service Record .................................................................................................... D-1
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
SECTION 1: INTRODUCTION
Guide to this Manual
This manual contains all the information necessary to safely install and operate the Clean Burn, CE-certified,
230 V / 50 Hz Furnace Models CB-3500 and CB-5000. 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 six basic activities as outlined here:
•
•
•
•
•
UNPACKING ....................................................................................................
ASSEMBLY .......................................................................................................
INSTALLATION ................................................................................................
OPERATION
• Metering Pump Priming ......................................................................
• Starting and Adjusting the Burner .....................................................
• Resetting the Oil Primary Control ......................................................
• Adjusting the Draft ..............................................................................
MAINTENANCE ................................................................................................
The manual also contains important and detailed technical
reference materials which are located at the back of the
manual in the Appendixes.
(Section 2)
(Section 3)
(Section 4)
(Section 5)
(Section 6)
(Section 7)
(Section 8)
(Section 9)
WARNING!
Please read all sections carefully--including the following
safety information--before beginning any installation/
operation procedures; doing so ensures your safety and the
optimal performance of your Clean Burn 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-3500 and CB-5000 (230 V / 50 Hz)
For Your Safety...
For your safety, Clean Burn documentation contains the following types of safety statements (listed here in order
of increasing intensity):
•
NOTE: A clarification of previous information or additional pertinent information.
•
ATTENTION: A safety statement indicating that potential equipment damage may occur if
instructions are not followed.
CAUTION: A safety statement that reminds of safety practices or directs attention to unsafe
practices which could result in personal injury if proper precautions are not taken.
WARNING: A strong safety statement indicating that a hazard exists which can result in
injury or death if proper precautions are not taken.
DANGER! The utmost levels of safety must be observed; an extreme hazard exists which
would result in high probability of death or irreparable serious personal injury if proper
precautions are not taken.
In addition to observing the specific precautions listed throughout the manual, the following general
precautions apply and must be heeded to ensure proper, safe furnace operation.
DANGER! DO NOT create a fire or explosion hazard by storing or using gasoline or other
flammable or explosive liquids or vapors near your furnace.
DANGER! DO NOT operate your furnace if excess oil, oil vapor or fumes have
accumulated in or near your furnace. As with any oil burning appliance, improper installation,
operation or maintenance may result in a fire or explosion hazard.
WARNING: Ensure that your furnace is properly installed, adjusted, operated and maintained.
Improper installation, adjustment, operation, or maintenance can adversely affect the proper, safe
operation of your furnace and may cause serious personal injury/death.
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, and adversely affect the proper, safe operation of your
furnace. Instruct your personnel to never add hazardous materials to your used oil.
1-2
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
For Your Safety... (continued)
WARNING: Never alter or modify your furnace without prior written consent of
Clean Burn, Inc. 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: Electrical installation of the furnace is to be performed only by qualified
personnel (i.e. licensed electrician/engineer). Improper electrical installation can adversely
affect the proper, safe operation of the furnace and may cause serious personal injury/death.
WARNING: Install the furnace in an area away from the main shop traffic. It is essential for
personal safety that only manufacturer-trained, qualified personnel have access to operate
and maintain the furnace. Only OFTEC or Manufacturer-trained and registered
technicians should install, commission, and service the equipment.
WARNING: To prevent damage to the furnace and to ensure personal safety, lifting, mounting,
and hanging of the furnace must be performed in accordance with safe handling procedures.
WARNING: DO NOT operate your furnace when the ambient temperature is above
35o C (95o F).
WARNING: The Best Operator is a Careful Operator! By using common sense,
observing general safety rules, and adhering to the precautions specific to the equipment, you,
the operator, can promote safe equipment operation. Failure to use common sense, observe
general safety rules, and adhere to the precautions specific to the equipment may result in
equipment damage, fire, explosion, personal injury and/or death.
WARNING: The installation, operation, and maintenance of this equipment must be
accomplished by qualified personnel and in compliance with the specifications in the
Clean Burn Operator's Manual and with all national, state, and local codes or authorities
having jurisdiction over environmental control, building inspection and fuel, fire and
electrical safety.
WARNING: This equipment is for commercial and/or industrial use only; it is NOT for
residential use.
WARNING: Call your Clean Burn dealer for service. DO NOT allow untrained, unauthorized
personnel to service your furnace. Make sure that your furnace receives periodic maintenance to
ensure optimal performance.
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-3500 and CB-5000 (230 V / 50 Hz)
For Your Safety... (continued)
Guidelines for Furnace Usage
•
This furnace is designed to burn the following fuels:
• Used crankcase oil up to 50 SAE
• Used transmission fluid
• Used hydraulic oils
• #2, #4, and #5 fuel oils
NOTE: Used oils may contain other substances, including gasoline, that may hinder
performance.
•
Make sure you comply with all environmental regulations concerning the use of your furnace.
These regulations require that:
• Your used oil is generated on-site. You may also accept used oil from
"do-it-yourself" oil changers.
• Hazardous wastes, such as chlorinated solvents, are NOT to be mixed with your
used oil.
• The flue gases are vented to the outdoors with an appropriate stack.
• Your used oil is recycled as fuel for "heat recovery". DO NOT operate your boiler
in warm weather just to burn oil.
Contact your Clean Burn dealer for current environmental regulations.
•
If your furnace ever requires service, call your Clean Burn dealer. DO NOT allow untrained,
unauthorized personnel to service your furnace. Make sure that your furnace receives annual
preventative maintenance to ensure optimal performance.
1-4
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
For Your Safety... (continued)
Guidelines for Used Oil Tanks
For the safe storage of used oil and the safety of
persons in the vicinity of the used oil supply tank,
ensure that your tank installation adheres to the
following safety guidelines:
•
•
•
•
The tank installation must meet all
national and local codes. Consult your
local municipal authorities for more
information as necessary.
Review and adhere to the safety
guidelines for used oil supply tanks
as stated in the WARNING shown.
Ensure that the tank for your furnace
installation complies with all code and
safety requirements as stated here. If the
tank does not comply, DO NOT use it.
If you do not have a copy of the tank
safety label pictured at right, please
contact your Clean Burn dealer for the
label, which is to be affixed directly on
your used oil supply tank.
1-5
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
For Your Safety... (continued)
Safety Labels
Following are the locations and descriptions of all labels on your CB-3500 or CB-5000 furnace. The following
illustrations show the location of ALL labels on your furnace. Please note that some labels denote model
number, model description, etc. while others contain important safety messages.
Each Safety Label contains an important safety message starting with a key word as discussed earlier in this
section (e.g. ATTENTION, CAUTION, WARNING, DANGER). For your safety and the safe operation of
your furnace, review all labels and heed all safety messages as printed on the labels.
If any labels on your Clean Burn furnace ever become worn, lost or painted over, please call your Clean Burn
dealer for free replacements.
Danfoss
220−240V 50−60Hz 3W
ts 10s
Type BHO 64
Nr. 057H7036
CB-3500/CB-5000 Furnace Cabinet Labels
Label Part #
42030
42457
42027
42367
42274
42275
42216
42144
42145
42068
Description
Furnace Electrical Shock Hazard Warning Label (several locations)
Made in USA Label
Furnace Burn Hazard/Hazardous Voltage Warning Label
Furnace Safety Warning Label (Multiple Messages - Fire/Shock/Burn Hazards)
Data Label - CB-3500 CE
Data Label - CB-5000 CE
Clean Burn Logo Label
Model CB-3500 Label
Model CB-5000 Label
Furnace Blower/Fan Entanglement Hazard Warning Label (not shown - positioned
near blower)
1-6
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
For Your Safety... (continued)
CB-3500/CB-5000 Furnace Cabinet Safety Labels
1-7
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
For Your Safety... (continued)
CB-3500 / CB-5000 Furnace Cabinet Safety Labels (continued)
LEOLA, PENNSYLVANIA (USA)
LEOLA, PENNSYLVANIA (USA)
LABEL SERIAL NO.
LABEL SERIAL NO.
MULT−OIL BURNING UNIT HEATER
WHEN USED WITH THE FOLLOWING
LISTED FUELS
CB 3500
INPUT RATING W/NO. 2 FUEL OIL
MULT−OIL BURNING UNIT HEATER
WHEN USED WITH THE FOLLOWING
LISTED FUELS
89/392/EEC 72/23/EEC 89/336/EEC
BTU/HR
(KW)
350,000
103
CB 5000
INPUT RATING W/NO. 2 FUEL OIL
2.5
9.5
16.0
1.1
6.0
0.41
3.6
13.5
89/392/EEC 72/23/EEC 89/336/EEC
BTU/HR
(KW)
500,000
147
18.0
1.2
0.17
2.5
2.5
9.5
16.0
1.1
6.5
0.45
3.6
13.5
16.0
1.1
3.0
0.21
2.5
9.5
16.0
1.1
6.0
0.41
3.6
13.5
16.0
1.1
3.0
0.21
2.5
9.5
16.0
1.1
6.0
0.41
3.6
13.5
18.0
1.2
3.0
0.21
−0.06 (−1.5 mm)
−0.06 (−1.5 mm)
2 (5)
18 (46)
24 (61)
2 (5)
18 (46)
24 (61)
60 (152)
18 (46)
24 (61)
60 (152)
18 (46)
24 (61)
POWER
POWER
HZ
HZ
2
230
8.5
50
2
230
9.0
50
1/6
230
1.3
50
1/6
230
1.3
50
1/10
230
0.45
50
1/10
230
0.45
50
450
230
1.7
50
450
230
1.7
50
1/50
230
0.5
50
1/4
230
1.3
50
1/3
230
1.8
50
12
15
20
20
THE MAINTENANCE INTERVAL FOR CLEANING ASH FROM THE FURNACE IS
APPROXIMATELY 700 HOURS. THE ASH LEFT FROM THE BURNING OF USED OIL
MAY CONTAIN METALLIC COMPOUNDS OR FOREIGN MATERIALS. THE ASH MUST BE
DISPOSED OF PROPERLY.
THE MAINTENANCE INTERVAL FOR CLEANING ASH FROM THE FURNACE IS
APPROXIMATELY 700 HOURS. THE ASH LEFT FROM THE BURNING OF USED OIL
MAY CONTAIN METALLIC COMPOUNDS OR FOREIGN MATERIALS. THE ASH MUST BE
DISPOSED OF PROPERLY.
BURNER REQUIRES A MINIMUM AIR SOURCE OF:
2 S.C.F.M. (57 L/MIN.) AT 25 P.S.I. (1.72 BAR).
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
MANUFACTURER’S INSTALLATION AND OPERATING INSTRUCTIONS.
FOR COMMERCIAL OR INDUSTRIAL USE ONLY.
BURNER REQUIRES A MINIMUM AIR SOURCE OF:
2 S.C.F.M. (57 L/MIN.) AT 25 P.S.I. (1.72 BAR).
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
MANUFACTURER’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.
42274
1-8
42275
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
For Your Safety... (continued)
CB-3500 / CB-5000 Burner Labels
Label Part #
Description
42005
42004
Sold and Serviced By Label
Burner Safety Warning Label
(High Voltage/Moving Parts Hazards)
Burner Safety Warning Label
(Fire/Explosion Hazard - Reset Button)
Burner Safety Warning Label
(Fire/Explosion Hazard - Burner Installation
and Service)
CB-500-CE Burner Model/Serial Number Label
CB-551-CE Burner Model/Serial Number Label
Patent Pending Label
Logo/Burner Description Label
Burner Power Label
42000
42235
42339
42340
42197
42229
42023
CB-3500/CB-5000 BurnerSafety Labels
1-9
42004
Danfoss
Type BHO 64
Nr. 057H7036
220−240V 50−60Hz 3W
ts 10s
42197
42339/
42340
I88889
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
1-10
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
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
Removing the Shipping Crate
1.
2.
Carefully remove the top boards of the shipping crate. Then remove the front, back, and side
panels.
Carefully lift the furnace off the shipping pallet with a fork lift.
ATTENTION: DO NOT attempt to slide the furnace cabinet out of the shipping crate--you may
damage the furnace cabinet.
NOTE: DO NOT remove the squirrel cage blower from the furnace cabinet. (The blower is installed in final
position for Model CB-3500; it will require additional installation for Model CB-5000.)
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
Components packed on top of furnace cabinet:
• Burner
• 2 HP Blower motor
• Blower
• Air discharge
Components packed inside furnace cabinet:
• Ceramic target
• Blower assembly components
• Oil pump
• Canister filter
• Vacuum gauge
• Check valve / check valve screen
• Wall thermostat
• Barometric damper
• Draft inducer (CB-5000 only)
• Connector block
• Assorted bolts/fittings, Assembly parts, Mounting components
NOTE: You may have received additional boxes or skids if you ordered optional accessories.
2-1
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
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 clean out 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
CLEAN−OUT
BREACH
COMBUSTION
CHAMBER
CLEAN−OUT
CAP
FURNACE FLUE
Figure 2A - Accessing the Combustion Chamber
2-2
I88913
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
SECTION 3: FURNACE ASSEMBLY
Understanding Assembly
Assembling your Clean Burn Furnace is a six-step process which includes:
(1) Installing the Blower Components
(2) Installing the Hot Air Discharge Components
(3) Installing the Ceramic Target
(4) Installing the Burner
(5) Installing the Connector Block, Oil Line Tubing, and Air Line Tubing
(6) Installing the Mounting and Stabilizer Brackets
Clean Burn recommends that you review all assembly procedures before proceeding, paying careful attention to
safety information statements. Please note that some assembly procedures apply only to certain furnace models.
Figures 3A and 3B on the following pages provide a general overview of the furnace components and their
proper assembly and how the unit should look following proper assembly.
Required Tools and Materials
The following tools are required for furnace assembly and should be gathered before starting any procedures:
•
•
•
•
•
Variable-speed electric drill
1/4" hex-nut driver attachment for electric drill
Set of open-end wrenches (3/8" - 5/8")
6" adjustable wrench
Medium straight-blade screwdriver
3-1
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
’ALL THREAD’ ROD
6
STABILIZER BRACKET
ON TOP OF FURNACE
AIR DISCHARGE
JUNCTION BOX
FAN LIMIT
BURNER
CABLE
4
4
BURNER
MOUNT
Danfoss
T ype B HO 64
N r. 057H7036
2 20-2 40V 50-60Hz 3W
ts 10s
THROAT
CONNECTOR
BLOCK
FURNACE DOOR
FRONT VIEW OF CABINET
PRIOR TO ASSEMBLY
5
MOUNTING
BRACKET
BELOW
FURNACE
6
FRONT VIEW OF CABINET
AFTER ASSEMBLY
1
2
ROTATION
NOTE: BLOWER MUST BE INSTALLED
WITH BULGE ON BLOWER FACING
BACK OF FURNACE. MAKE SURE
BLOWER WHEEL ROTATION IS
CLOCKWISE AS SHOWN
AIR DISCHARGE
STABILIZER BRACKETS
NOTE: LOOP ON TARGET HOOKS
OVER MOUNTING BRACKET ON
BACK WALL OF COMBUSTION
CHAMBER
3
TARGET INSTALLED
ON BACK WALL OF
COMBUSTION CHAMBER
FURNACE BREACH
SIDE VIEW OF CABINET
6
MOUNTING BRACKETS INSTALLED
ON FURNACE CABINET BASE
I88914
Figure 3A - Overview of Furnace Assembly
Complete assembly of the CB-3500/CB-5000 furnace according to the following list of activities as
illustrated above:
(1) Installing the Blower Assembly
(2) Installing the Hot Air Discharge Components
(3) Installing the Target
(4) Installing the Burner
(5) Installing the Connector Block, Oil Line Tubing, and Air Line Tubing
(6) Installing the Mounting and Stabilizer Brackets
NOTE: Corresponding procedures provided in order in this section.
3-2
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
STABILIZER
BRACKETS
220
0
-24
3W
z 10s
60H ts
50-
ss
nfo
64
Da
O
e BHH7036
Typ 057
Nr.
MOUNTING
BRACKETS
I88915
Figure 3B - Three-dimensional View - Furnace Completely Assembled
with Louver Assembled for Unit Heater Application
NOTE: This figure shows the mounting/stabilizer brackets in place for a ceiling mounted installation. If your
furnace will be floor or platform mounted, the brackets are not needed.
WARNING: Keep hands and fingers clear of the motor pulley or serious personal
injury may occur.
3-3
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
Installing the Blower Components
NOTE: The blower is installed in final position on the CB-3500 cabinet. The blower for the CB-5000
requires additional installation as described in the following procedure.
Installing the Blower (Model CB-5000 ONLY)
NOTE: For proper air flow through the furnace, the blower must be positioned so the bulge on the blower
faces toward the rear of the furnace as illustrated in Figures 3A, 3B, and 3D.
1.
Remove the hex-head screws, which hold the blower in the shipping position.
2.
Carefully slide the blower rearward on the cabinet into position against the blower inlet lip.
3.
Use self-tapping screws to install the angle support at the back of the blower to complete the
blower inlet lip.
4.
Install at least three (3) self-tapping screws to each side of the blower inlet to safely support the
blower.
Installing the Motor on the Blower
1.
2.
3.
4.
5.
6.
7.
8.
9.
Refer to Figures 3C and 3D.
Use self-tapping bolts to install the motor mounting bracket on the blower according to the
dimensions provided in Figure 3C.
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 3C.
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 lower holes in the motor mounting plate
and motor. Tighten the nuts to hold the motor firmly in position.
Wiring the Blower Motor
WARNING: To avoid electrical shock, make sure the main power to the furnace is turned OFF
before wiring the blower motor.
1.
Refer to the Furnace Wiring Diagram provided in Appendix B at the back of this manual.
2.
Install the electrical cable between the electrical junction box on the front of the furnace and the
electrical access on the blower motor.
3.
Connect the wires in the junction box according to the Furnace Wiring Diagram (Appendix B).
NOTE: The blower motor is rated for 220/240 volts, single phase. Make sure the proper electrical
circuit to the furnace has been provided by a qualified electrician as shown in the Furnace Wiring
Diagram.
3-4
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
CB−3500 BLOWER
21"
53 cm
11.5"
29 cm
18.5"
46.5 cm
8.5"
22 cm
BLOWER ASSEMBLY PARTS LIST
1 NUT
2 NUT
3 2 HP MOTOR
4 MOTOR PULLEY
5 MOTOR MOUNTING PLATE
6 BOLT
7 MOTOR TENSIONING BRACKET
8 BLOWER PULLEY
9 SELF−TAPPING BOLT
10 V−BELT
11 MOTOR MOUNTING BRACKET
12 SQUARE HEAD BOLT
CB−5000 BLOWER
DETAIL OF BRACKET INSTALLATION
NOTE: The brackets must be installed at the correct position on the side of the blower as shown here.
Note the measurements provided which should aid your positioning of the brackets.
I88289
Figure 3C - Expanded View of Blower Assembly
3-5
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
Installing the Blower Components (continued)
Installing the Motor Pulley, Blower Pulley, and V-Belt
1.
2.
3.
4.
5.
6.
7.
Refer to Figures 3C and 3D.
Slide the pulleys into position on the motor and blower shafts. ATTENTION: Make sure that
the face of the motor is flush with the side of the blower. Then position the motor pulley 3 cm
(1-1/8") out from the face of the motor. Failure to properly position the motor and the motor
pulley may cause damage to the motor or blower bearings. Now tighten the locking screw in the
motor pulley hub.
Position the key in the slot on the motor shaft. ATTENTION: Use a straight edge to make sure
the blower pulley is aligned with the motor pulley, or vibration and bearing damage may occur.
Install the double set of locking screws on the blower pulley. (Install the smaller locking screw
and tighten it firmly; then install the second locking screw and tighten it firmly.) It is important
to install both locking screws to prevent the locking screws from working loose.
Install the V-belt on the motor pulley and the blower pulley.
To tension the V-belt, lift up on the end of the motor mounting plate. Firmly tighten the nut and
bolt on the tensioning bracket.
Check that there is a 2 cm (3/4") deflection in the tensioned V-belt. DO NOT overtension the V-belt.
Repeat step #6 if necessary to achieve the proper tension on the V-belt.
NOTE: If you ever need to remove the blower wheel, you must remove both locking screws.
I88290
Figure 3D - Blower Assembly Installed on Furnace Cabinet
3-6
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
Installing the Belt Guard and the
Blower Guard
BLOWER GUARD
WARNING: To prevent serious
personal injury, DO NOT operate the
furnace without the belt and blower guards in
place.
1.
2.
BELT GUARD
Refer to Figure 3E.
Install the belt guard and blower guard as
shown.
I88802−A
Figure 3E - Installing the Belt and Blower Guards
3-7
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
Installing the Hot Air Discharge Components
Determining the Air Discharge Configuration
The CB-3500 and CB-5000 furnaces may be configured for use as EITHER a Unit Heater or a Central
Furnace as described below.
(1) Unit Heater
Furnace with blower for FREE AIR applications.
HOT AIR DISCHARGE: Louver assembly (components supplied)
NOTE: If the peak of your shop roof/ceiling is 4.3 m (14') or higher, install
industrial-size ceiling fans to aid in efficient, even heat distribution. A minimum
of one 1.4 m (56") Blade Industrial Ceiling Fan or equivalent is recommended
for each 186 m2 (2000 ft2)of shop space.
Be sure to adhere to the specified clearances as stated in Section 4 of this
manual.
(2) Central Furnace
Furnace with blower for DUCTING applications from 0.06 kPa
(0.25" WC) to 0.10 kPa (0.40" WC) static pressure.*
HOT AIR DISCHARGE: Ductwork (Refer to the following chart for the
proper air discharge/ducting specifications; installation to be accomplished by
HVAC professionals ONLY.)
Be sure to adhere to the specified clearances as stated in Section 4 of this
manual.
Air Flow - Cubic Meters per Minute (CMM) or Cubic Feet per Minute (CFM)
and Static Pressure (SP) Specifications
PARAMETER
UNIT HEATER
CENTRAL FURNACE
Louver Assembly
(orifice plate installed)
Ductwork
(orifice plate removed)
Opening Size
(for ductwork)
Static Pressure
kPa in Outlet
(Inches WC in Outlet)
Free Air*
0.06 kPa*
(0.25)
0.10 kPa*
(0.40)
N/A
CB-3500 CMM
(CB-3500 CFM)
119
(4200)
113
(4000)
110
(3900)
51cm x 51cm
(20" x 20")
CB-5000 CMM
(CB-5000 CFM)
156
(5500)
147
(5200)
144
(5100)
61cm x 61cm
(24" x 24")
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.
3-8
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
UNIT HEATER APPLICATIONS: Installing the Air Discharge Louver Assembly
The body of the air discharge louver assembly is shipped assembled and is packed on top of the furnace
cabinet. The louvers, nuts and bolts, which must be assembled separately, are packed inside the combustion
chamber.
It is very important to install the air discharge to direct the flow of the hot air from the furnace as desired for
your application. As you will note from Figure 3F, the air discharge may be installed facing forward (as shown)
or rotated 90o to the left or right. Additionally, the louvers may be installed horizontally or vertically to direct the
flow of the heated air.
1.
2.
3.
Position the body of the air discharge as desired over the hot air outlet on the furnace (i.e. facing
forward, right, or left).
ATTENTION: KEEP THE ORIFICE PLATE IN PLACE (as shown in Figure 3F) when installing
the louver assembly. The orifice plate is necessary for proper air flow from the furnace.
Use the 12 self-tapping screws to securely attach the body of the louver assembly to the furnace
cabinet.
Install the louvers in the desired position (i.e. horizontally or vertically) using the bolts and locking nuts
provided.
ATTENTION: DO NOT restrict the flow of hot air from the furnace by closing the louvers, or
damage to the furnace and/or blower motor may occur.
AIR DISCHARGE WITH
LOUVERS MOUNTED
HORIZONTALLY
AIR DISCHARGE WITH
LOUVERS MOUNTED
VERTICALLY
STABILIZER
BRACKET
ORIFICE
PLATE
3W
H z 10s
50-60 ts
22
D anf
os
0-240
s
O 64
BH 7036
057H
T ype
N r.
I88916
MOUNTING
BRACKET
Figure 3F - Installation of the Hot Air Discharge Louver Assembly
3-9
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
CENTRAL FURNACE APPLICATIONS: Installing Ductwork
If you plan to install ductwork on your furnace, it is mandatory that qualified HVAC personnel design
and install the ductwork system to the Air Flow and SP specifications provided in this manual.
Establish correct duct size according to the following specifications and use radial bends or turning vanes to
allow for proper air flow.
Sizing the Ductwork:
• For Model CB-3500, the outlet on the air discharge is 51 cm x 51 cm (20" x 20"). The main
duct on a CB-3500 must initially maintain an outlet size of 51 cm x 51 cm (20" x 20").
• For Model CB-5000, the outlet on the air discharge is 61 cm x 61 cm (24" x 24"). The main
duct on a CB-5000 must initially maintain an outlet size of 61 cm x 61 cm (24" x 24").
Additionally, to ensure proper air flow from the furnace and to prevent damage to related furnace components,
adhere to the following guidelines for installing ductwork with your CB-3500 or CB-5000 central furnace
application.
Installation Guidelines for Ductwork:
• It is essential that qualified HVAC personnel properly design the ductwork for your
furnace and determine the static pressure for your ducting application;
ATTENTION: Failure to adhere to the static pressure and Air Flow specifications provided in this
manual may result in damage to the blower motor.
• The ductwork should be installed directly over the opening in the top of the furnace cabinet (i.e.
where the louver assembly would be installed for free air applications.)
• THE ORIFICE PLATE MUST BE REMOVED for all ductwork applications.
• Existing ductwork at your installation site may NOT be appropriate or meet the specifications for
your furnace installation.
Installing the Ceramic Target
Installing the Ceramic Target on the Combustion Chamber
ATTENTION: DO NOT fire your furnace without the flame target in place, or combustion chamber
damage will occur. The target is high-temperature ceramic--handle it carefully to avoid damage.
1.
2.
3.
Refer to Figure 3A at the beginning of this section to review the proper positioning of the target.
Swing open the clean-out door on the furnace front to gain access to the combustion chamber.
Use a long rod to support the ceramic target as you guide it into position on the back of the
combustion chamber. The eye bolt on the back of the target fits over the hook on the target
mounting bracket which is located on the back of the combustion chamber.
Closing the Furnace Door
1.
2.
After the ceramic target 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.
3-10
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
Installing the Burner
Checking the Burner Nozzle and Electrodes
NOTE: The burner nozzle is factory installed. Model CB-3500 uses a Delavan 9-5 nozzle. Model
CB-5000 uses a Delavan 9-11 nozzle. The nozzle size is indicated on the nozzle head as shown in
Figure 3G. Refer also to Appendix A at the back of the manual for additional specifications/instructions on the
burner nozzle.
NOTE: Check the electrode settings as specified in Figure 3G. The electrode settings must be correct for
your burner to operate properly.
NOZZLE IS STAMPED
9−5 OR 9−11 ON FLAT
OF NOZZLE HEAD
NOZZLE
ELECTRODE
NOZZLE ADAPTER
3mm (1/8") SPARK GAP
OUTLINE OF RETENTION HEAD
5 mm
(3/16")
3 mm
(1/8")
NOZZLE TO BE AHEAD OF
RETENTION HEAD BY 3 mm (1/8")
Figure 3G - Burner Nozzle and Electrode Specifications
3-11
I88757
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
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.
2.
3.
4.
Remove the nut from the mounting flange of the furnace cabinet, and set it aside for later use.
Lift the burner into position so that it is mounted on the hinge bracket on the furnace cabinet.
Carefully swing the burner so the retention head enters the throat of the furnace.
Check the clearance between the retention head and the furnace throat. There must be at least
3 mm (1/8") clearance, so the retention head is not "bumped" as you swing the burner into
firing position.
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.
3-12
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
Installing the Connector Block, Oil Line Tubing, and Air Line Tubing
ATTENTION: DO NOT use teflon tape on any fittings. Teflon tape will plug vital burner components.
Installing the Connector Block on the Furnace Door
OIL LINE
1.
2.
3.
Refer to Figure 3H.
Use the two (2) bolts to install the aluminum connector
block onto the furnace door.
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.
OIL FITTING
ON BURNER
Danfoss
Type BHO 64
Nr. 057H7036
220-240V 50-60Hz 3W
ts 10s
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.
1.
SWIVEL
ASSEMBLY
CONNECTOR
BLOCK
Remove and discard the red caps from the oil line
SIDE VIEW OF FURNACE
tubing.
SHOWING OIL LINE INSTALLED
I88886
2.
Loosely install the oil line tubing into the oil line fitting
Figure 3H - Installation of
on the burner.
Connector Block and Oil Line
3.
Use a wrench to slightly rotate the oil line fitting on the
burner counterclockwise so the tubing lines up with the
swivel assembly. Slightly bend the tubing as
shown in Figure 3H, if required, to "line up" the oil line.
4.
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.
(procedure continued on next page)
3-13
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
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 3H 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 3I, 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 3I. Push the air line tubing into the 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.
AIR LINE FITTING
ON BURNER
OIL LINE FITTING
ON BURNER
Danfoss
Type BHO 64
Nr. 057H7036
220-240 V 50- 60Hz 3W
ts 10s
AIR LINE
OIL LINE
COMPRESSION/
SWIVEL FITTING
CONNECTOR BLOCK
INSTALLED ON
FURNACE CABINET
I88917
Figure 3I - Installation of Connector Block, Oil Line, and Air Line (Front View)
3-14
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
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.
PLUG ON CAM
LOCK CABLE
NOTE: Be sure to properly align the plug when
plugging it into the receptacle. See Fig 3J.
SLOT IN PLUG
MUST ALIGN WITH
SLOT IN
RECEPTACLE
RECEPTACLE ON
TOP OF BURNER
I88354A
Figure 3J - Detail of Burner
Electric Receptacle
Installing the Mounting and Stabilizer Brackets
Installing the Brackets on the Furnace Cabinet (For Ceiling Mounting Only)
NOTE: If you are ceiling mounting your furnace, it is critical that the mounting and stabilizer brackets
be installed as described below.
The mounting brackets must be attached to the furnace base to allow ceiling installation of the furnace
using "all-thread" rods. See Figures 3A/3B.
The weight of the furnace must be supported by the mounting brackets. The stabilizer brackets are
installed on the top of the furnace to properly align the "all-thread" rods. The stabilizer brackets will not
support the furnace.
1.
2.
3.
Refer to Figures 3A and 3B.
Install both mounting brackets 2.5 cm (1") channel on the base of the furnace using the four (4) bolts
supplied.
Install the two (2) stabilizer brackets on the top of the furnace using self-tapping screws.
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.
3-15
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
3-16
Operator's Manual: Models CB-3500 & CB-5000 (230 V / 50 Hz)
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. Figures 4A provides a general overview of a typical furnace
installation and should be reviewed closely before proceeding.
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. Access to the furnace must be restricted; only trained, qualified personnel should be permitted
to perform installation and operation procedures.
WARNING: To prevent damage to the furnace and to ensure personal safety, lifting, mounting,
and hanging of the furnace must be performed in accordance with safe handling procedures.
Important Safety Guidelines for Safe Installation
General installation of the appliance shall be in accordance with the manufacturer's literature, in addition
to complying with the following:
BS5410
Code of Practice for Oil Firing
1997: Installation up to 45 KW output capacity for space heating and hot water supply
purposes.
1998: Installation of 44 KW and above capacity for space heating, hot water and steam
supply purposes.
1978: Installation for furnaces, kilns, ovens and other industrial purposes.
The Building Regulations:
England and Wales: Approved Document J: Heat Producing Appliances (1991).
Scotland: Technical standards for compliance with the Building Standard (Scotland) Regulations
1990, Part F: Heat Producing Installations and Storage of Liquid and Gaseous Fuels.
Northern Ireland: The Building Regulations (Northern Ireland) 1990. Technical Booklet L Heat Producing Appliances, July 1991.
Republic of Ireland: The Building Regulations of Ireland 1997, Part J: Heat Producing
Appliances.
Isle of Man, Jersey and Guernsey: The Building Bylaws - BS 7671: 1992 IEE Wiring
Regulations 16th Edition.
4-1
Operator's Manual: Models CB-3500 & CB-5000 (230 V / 50 Hz)
Important Safety Guidelines for Safe Installation (continued)
The Environmental Protection Act 1990, Part 1: Processes prescribed for air pollution control by
local enforcing authorities PG1/1 (95).
Secretary of State's Guidance: Waste Oil Burners, less than 0.4 MW net rated thermal input.
November 1995 (Appendix A of OFTEC OFSA 103).
OFTEC Guidelines: Document OFG100 for externally serviced oil fired appliances.
Important Notes to the Electrician
WARNING: Electrical installation of the furnace is to be performed only by qualified personnel
(i.e. licensed electrician/engineer). Improper electrical installation can adversely affect the
proper, safe operation of the furnace and may cause serious personal injury/death.
WARNING: Before completing any furnace wiring, refer to the wiring diagrams in Appendix B
at the back of the manual. Carefully review the wiring assignments and colors, noting that the
Clean Burn wire colors may not be "standard" or familiar.
WARNING: High earth leakage current / earth connection is essential and must be established
before connecting the main power supply.
WARNING: Low voltage terminals are only protected by basic insulation--caution is required.
CAUTION: Use only approved wire conduit and connectors when wiring the Clean Burn
furnace. An emergency stop device (i.e. "panic button") must be installed at ground level in the
mains cable to the furnace to ensure the safety of furnace operators and service personnel. The external
disconnect device must employ a contact separation of 3mm in all poles; the external breaker must be an
approved type.
CAUTION: The main cable must be introduced into the control box using conduit connectors
which provide adequate strain relief. The main cable installation must be accomplished using suitably
rated and approved wiring (BASEC or HAR) or appropriate current-carrying capacity. The wires should have
a minimum rating of 90 degrees C.
NOTE: According to Clause 4A of 61000-3-11 (International Electrical Standard), the user must
determine, in consultation with the supply authority, that the furnace is connected only to a supply with
an impedance of 3.773 x 10-3 + 2.358 x 10-3 or less.
4-2
HIGHEST POINT AT WHICH IT
COMES IN CONTACT WITH
THE ROOF, AND AT LEAST
61 cm (2') HIGHER THAN
ANY RIDGE, PARAPET OR
ROOF STRUCTURE WITHIN
3 m (10') OF IT.
Danfoss
6mm (1/4") HOLE FOR
SETTING DRAFT.
ADJUST BAROMETRIC
DAMPER FOR −.04" W.C.
DRAFT AT BREECH
220-240V 50- 60H z 3W
ts 10s
Ty pe BH O64
N r. 057H 7036
CAUTION: DO NOT EXCEED 1.8 m (6’)
VERTICAL SUCTION LIFT OR THE PUMP WILL
NOT PRIME AND/OR THE FLOW RATE FROM
THE PUMP MAY DECREASE
ELECTRIC SERVICE
PRESSURE OIL LINE
MAXIMUM 1.8 m (6’)
24 VOLT WALL
THERMOSTAT
COMPRESSED AIR LINE
2.4 m (8’) MIN. FROM FLOOR TO FURNACE IFTHERE IS A POTENTIAL
FOR GASOLINE FUMES IN YOUR SHOP. CHECK LOCAL CODES.
"2 WIRE" MIN 18 GA.
THERMOSTAT CABLE
DEDICATED ELECTRIC CIRCUIT
OIL PUMP ELECTRICAL CIRCUIT
3m
(10 FT)
3 m (10’) MINIMUM VERTICAL STACK HEIGHT PLUS 30 cm (1’) FOR
EVERY FITTING TO MAINTAIN PROPER DRAFT OVERFIRE
61 cm
(2 FT)
Operator's Manual: Models CB-3500 & CB-5000 (230 V / 50 Hz)
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
NOTE: THE LAST STACK
proper clearances may result in fire,
SECTION SHALL EXTEND AT
LEAST 92 cm (3') ABOVE THE
explosion, personal injury, or death.
CLEANOUT
WITH DRAIN
BALL VALVE
SUCTION
OIL LINE
VENT
CAP
EMERGENCY
VENT VALVE
CONTINUOUS PIECE
OF COPPER TUBING
INSIDE TANK
CHECK VALVE IS MINIMUM
30 cm (12") OFF TANK BOTTOM
TO CREATE A SLUDGE TRAP
INSTALL SLIP FITTING
TO HOLD TUBING
IN PLACE
30 cm
(12")
Figure 4A - Typical CB-3500 / CB-5000 Furnace Installation
4-3
I88918
Operator's Manual: Models CB-3500 & CB-5000 (230 V / 50 Hz)
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 CB-3500/CB-5000
INSTALLATIONS
• TOP (above blower) ..........................
• FRONT (burner) ...............................
• SIDES ...........................................
• CHIMNEY CONNECTOR .................
• REAR ...........................................
• BOTTOM .........................................
• WARM AIR DUCTS within 3ft.** .......
**Where applicable
5 cm (2")
152 cm (60")
61 cm (24")
46 cm (18")
46 cm (18")
61 cm (24")
15 cm (6")
WARNING: Local codes may require
that your furnace is mounted a minimum of
2.4 m (8') off the ground if there is the possibility
of gasoline fumes or other combustible or
explosive fumes in your shop area.
TOP
5 cm (2")
46 cm (18")
REAR
61 cm (24")
SIDES
40
3W
10s
60Hz ts
50-
220-2
oss
64
BHO 036
Type057H7
N r.
Danf
46 cm (18")
CHIMNEY
CONNECTOR
152 cm (60")
FRONT
61 cm (24")
BOTTOM
Figure 4B - Clearances from Combustibles
4-4
I88919
Operator's Manual: Models CB-3500 & CB-5000 (230 V / 50 Hz)
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
minimum 64 mm x 64 mm x 6 mm (2-1/2" x 2-1/2" x 1/4") angle iron beams 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 level to make sure the cabinet is level side to side and front to back.
"CLASS A" STACK CAP
NON−RESTRICTIVE TYPE TO ALLOW
FREE FLOW OF THE STACK GASES
"CLASS A" STACK: INSULATED
STACK WITH A STAINLESS
STEEL LINER
WARNING: OUTSIDE STACK AND
STACK PENETRATIONS THROUGH
CEILING, ROOF, AND SIDE WALLS MUST
BE "CLASS A" FOR FIRE SAFETY AND
TO MAINTAIN A PROPER DRAFT
WARNING: MAKE SURE TO INSTALL
THE PROPER ROOF SUPPORT SYSTEM
TO SAFELY SUPPORT THE STACK
WARNING: USE MINIMUM 64 mm x 64 mm
(2−1/2" X 2−1/2") ANGLE IRON BEAMS,
BRIDGED ACROSS SUFFICIENT
STRUCTURAL MEMBERS, TO SAFELY
SUPPORT THE FURNACE
EXTERIOR SINGLE WALL STACK DOES
NOT MEET CODE AND CHILLS THE
EXHAUST GASES RESULTING IN POOR
BURNER PERFORMANCE AND BACK
PRESSURE IN THE FURNACE
WATERTIGHT ROOF FLASHING:
CLEAN BURN RECOMMENDS "DEKTITE"
FLASHING FOR A WATERTIGHT SEAL
DOUBLE NUTS
(4) "ALL THREAD" SUPPORT RODS
CB−3500: USES 16 mm (5/8") RODS
CB−5000: USES 19 mm (3/4") RODS
INSTALL SUPPORT RODS THROUGH
CHANNELS ON FURNACE CABINET
"CLASS A" KIT FOR
INSTALLING
"CLASS A" STACK
THROUGH CEILING
SINGLE
WALL STACK
WARNING: MAKE SURE TO USE
DOUBLE NUTS TO SECURELY FASTEN
SUPPORT RODS
Dan fo ss
T yp e BHO 64
Nr. 0 57 H703 6
2 2 0-2 4 0V 5 0-60 Hz 3 W
ts 10 s
MOUNTING BRACKET
I88920
Figure 4C - Ceiling Mounting Installation Overview
4-5
Operator's Manual: Models CB-3500 & CB-5000 (230 V / 50 Hz)
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.
1.
Da nf oss
Ty p e BHO 6 4
N .r 0 57 H7 03 6
2 2 0-2 4 0V 5 0-6 0Hz 3 W
ts 1 0 s
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), you must
construct a non-combustible floor as shown in
Figure 4E.
I88921
Figure 4D - Furnace Installed on
Raised Platform
Constructing A Non-Combustible Floor
1.
Determine the size of floor you will need to construct:
• Measure the width and length of the cabinet of the furnace.
• Add 30 cm (12") minimum to all sides of the cabinet to achieve the total measurement for the
non-combustible floor.
EXAMPLE: The CB-3500 measures 147 cm (58") long x 89 cm (35") wide.
147 cm + 30 cm + 30 cm = 207 cm (82") long
89 cm + 30 cm + 30 cm = 149 cm (59") wide
2.
Refer to Figure 4E. Install two (2) pieces of 16 mm (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.
Place a sheet of 24-gauge (minimum) galvanized sheet metal on top of the sheet rock; the sheet metal
must cover the sheet rock completely.
Place 10 cm (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.
3.
4.
4-6
Operator's Manual: Models CB-3500 & CB-5000 (230 V / 50 Hz)
Constructing A Non-Combustible Floor (continued)
5.
6.
7.
8.
Place a 24-gauge sheet metal pan with a 2.5 cm (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 30 cm (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 5 cm (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.
Danfoss
Type BH O 64
N r. 0 57H 7036
MIN. 24 GA STEEL
PAN WITH MIN. 2.5 cm
(1") LIP FOR
OIL CONTAINMENT
22 0-24 0V 5 0-6 0Hz 3W
ts 1 0s
30 cm
(MIN. 12")
30 cm
(MIN. 12")
20 cm (8") MIN.
TALL CINDER BLOCK
1 PIECE
MIN. 24 GA STEEL
2 PIECES FIREEGUARD
SHEETROCK OR EQUIVALENT
COMBUSTIBLE MATERIAL
MIN. 5 cm (2") TALL MASONRY BLOCKS TO
ALLOW CLEARANCE FOR INSTALLATION OF
FITTINGS ON THE CONNECTOR BLOCK
Figure 4E - Furnace Installed on Non-Combustible Floor
4-7
I88922
Operator's Manual: Models CB-3500 & CB-5000 (230 V / 50 Hz)
Oil Tank Installation Specifications
Ensure that your tank installation adheres to the
following safety guidelines as stated here and in
Section 1 of this manual.
The tank safety label (shown at right) also
summarizes these important specifications for tank
installation and usage. If you do not have a copy of
this label, please contact your Clean Burn dealer for
a copy, which is to be affixed directly to your used
oil supply tank.
•
•
•
•
•
•
•
•
The tank installation must meet all
national and local codes. Consult your
local municipal authorities for more
information as necessary.
Use a minimum 1000 Liter tank. DO NOT
use drums as a substitute for an appropriate
tank. The tank must be large enough to allow
water, sludge, etc. to settle out of the used oil.
The tank must have a manual shut-off
type valve on the side of the tank to allow
the water, sludge, etc. to be drained from
the bottom of the tank.
All unused openings in the tank must be
plugged or capped off.
For optimal system functioning, Clean Burn
Recommends inside tank installations as
shown in Figures 4A, 4F, and 4J.
The tank must be vented to the outside of
the building using iron or steel pipe and
fittings with an approved vent cap.
Carefully review the oil tank and pump
installation details as shown in Figures 4A,
4F, and 4J including the metering pump
installation and specifications for the oil
line installation. (Procedures for installing
these components can be found in the
following pages.)
Ensure that the oil supply tank is properly
maintained; refer to Section 9 in this manual
for related procedures.
ATTENTION: For outside tank installations and/or tanks larger than 1890 Liters (500 gallons),
contact the Clean Burn Service Department for installation recommendations and specifications.
4-8
Operator's Manual: Models CB-3500 & CB-5000 (230 V / 50 Hz)
Oil Tank Installation Specifications (continued)
TANK VENT KITS AVAILABLE FROM CLEAN BURN:
CB Part # 70380 − 4" Tank Vent Kit
(2) elbows
(2) 6" nipples
(1) mushroom cap vent
(1) emergency vent
PUMP
MUSHROOM
CAP VENT
STEEL PIPE
(USER SUPPLIED)
SUCTION LINE
ASSEMBLY
FUNNEL WITH
BALL VALVE
EMERGENCY
VENT
CHECK
VALVE
FILTER
SCREEN
CLEAN−OUT
(TANK DRAIN)
Figure 4F - Typical Metering Pump Installation with Inside Tank
Installing the Tank Vent and Emergency Vent
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 5 cm (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.
4-9
Operator's Manual: Models CB-3500 & CB-5000 (230 V / 50 Hz)
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, ensure that the pump is mounted at a distance not
more than 122 cm (4 feet) from the oil tank.
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 not more than 122 cm (4') from the tank.
Figure 4G - Standard (Recommended) Vertical Mounting of the Metering Pump
4-10
Operator's Manual: Models CB-3500 & CB-5000 (230 V / 50 Hz)
#
PART #
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
see chart
11322
32062
32293
32425
32424
32335
21119
32327
32467
32210
32336
32123
32127
32430
32246
32429
32137
32142
32062
32443
32141
32140
32139
32442
32021
32061
32445
DESCRIPTION
GEARMOTOR
MOUNT − METER PUMP
MALE CONNECTOR 1/4 T TO 1/4 NPT
RELIEF VALVE
1/4 NPT BRASS TEE
LOW FLOW CHECK VALVE
ADAPTOR PIPE 1/4F X 1/8M
LID − METER PUMP HOUSING
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
4
5
2
7
8
10
11
29
17
3
6
9
13
16
12
14
18
15
19
20
23
24
21
22
25
26
24
23
16
27
28
CLEAN BURN
MODEL
GEARMOTOR
PART #
CB−1502
CB−2501
CB−3500
CB−5000
CB−200−CTB
CB−350−CTB
33425
33426
33427
33428
33530
33436
I88728−D
Figure 4H - Metering Pump Component Detail
4-11
Operator's Manual: Models CB-3500 & CB-5000 (230 V / 50 Hz)
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.
Re-install and tighten the two pump mounting bolts.
Use the appropriate type of bolts and washers (user-supplied) to securely mount the metering
pump to the mounting bracket, which is to be installed on the appropriate wall in your building at a
distance not more than 122 cm (4 feet) from the oil tank.
ROTATION
GAUGE
INLET
GAUGE
INLET
GAUGE
INLET
INLET
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
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
4-12
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
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 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 electrical junction box on the furnace and adhere to the
following specifications for wire type:
WARNING: DO NOT tie
Model
Wire Specification/Type
into an existing circuit, or
Model 3500
10 gauge, 4-wire / copper wire ONLY
electrical overload may occur.
Model 5000
10-gauge, 4-wire / copper wire ONLY
2.
Wire the furnace according to the Wiring Schematic, Figure B1, in Appendix B. Ensure that the
ground wire is attached to the GREEN ground screw on the furnace junction box.
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*
Circuit
Hertz
CB-3500
230
30 amps*
Dedicated
50
CB-5000
230
30 amps*
Dedicated
50
*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. 10-gauge
copper wire is required for a 30 amp breaker.
3.
4.
DO NOT turn on main power until instructed to do so.
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.
4-13
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
Installing the Suction Oil Line Components
ATTENTION: It is critical that you adhere to the following specifications for suction oil line
installation (oil line from the tank to the pump). If these specifications are not met, the metering pump
will not function correctly and the burner will shut down on reset. The majority of service problems with the
metering pump are caused by leaks at fittings in the suction oil line; these problems are eliminated by ensuring
a 100% airtight suction oil line which slants up to the pump.
1.
•
All suction oil line components must be installed as shown in Figures 4H and 4J. Suction line size
is 13 mm (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 183 cm (6') TOTAL vertical lift AND 122 cm (4')
TOTAL horizontal lift (which equals 6.0” hg maximum operating vacuum). To determine if
your suction oil line will meet this specification for maximum operating vacuum, base the calculation
for your installation on the following equivalents:
30 cm vertical (1')
= 0.75” hg (vacuum)
122 cm horizontal (4') = 0.75” hg (vacuum)
NOTE: ALSO ADD 0.75" hg to the final sum to account for every oil filter, shut-off valve, and
check valve on the suction side of the pump assembly.
Sample calculation: 183 cm (6') vertical x (0.75" hg/30 cm) = 4.50" hg AND
122 cm (4') horizontal = 0.75" hg
4.50" hg + 0.75" hg + 0.75" hg = 6.00" hg vacuum
•
The metering pump must be installed with a check valve and screen at the end of the
suction oil line, or the pump will not maintain its prime.
•
Use Permatex #2 non-hardening gasket sealer on every threaded fitting. DO NOT use
teflon tape or teflon pipe dope compounds; the teflon can flake off and cause damage to the
pump head.
•
The suction oil line must be 100% airtight for proper system functioning. Use only
high-quality flare fittings for the copper tubing. DO NOT use compression fittings.
DO NOT use any steel pipe unions. DO NOT use sweat copper pipe. These types of fittings
cause air leaks in the suction oil line and will require re-installation.
•
The suction oil line must slant up to the pump; any high spots will trap air and will not
allow the pump to prime.
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.
4-14
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
Installing the Suction Oil Line Components (continued)
(e.) Prepare the canister filter for installation (continued):
• Install the 3/4" x 1/2" brass bushing into the inlet port of the canister filter.
• 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.
220-240V 5 0- 60H z 3W
t s 10s
OIL FLOW
Type BH O 64
Nr. 0 57H 7036
OIL PUMP ELECTRICAL CIRCUIT
Danfoss
COMPRESSED AIR LINE
PRESSURE OIL LINE
CAUTION: DO NOT EXCEED 6 FT (1828 mm)
VERTICAL SUCTION LIFT OR THE PUMP WILL
NOT PRIME AND/OR THE FLOW RATE FROM
THE PUMP MAY DECREASE
BALL VALVE
MAXIMUM 6 FT (1828 mm)
(1.)
FUNNEL
WITH BALL VALVE
RADIAL BEND MADE
WITH TUBING BENDER
SUCTION LINE
CANISTER FILTER
IN SUCTION LINE
VENT
CAP
EMERGENCY
VENT RELIEF
CONTINUOUS PIECE
OF COPPER TUBING
INSIDE TANK:
13 mm (1/2") O.D.
INSTALL SLIP FITTING
TO HOLD TUBING
IN PLACE
CHECK VALVE SCREEN
CLEAN−OUT
CHECK VALVE IS MINIMUM
305 mm (12 IN.) OFF TANK
BOTTOM TO CREATE SLUDGE TRAP
Figure 4J - Oil Line Installation Overview
4-15
I88923
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
2.
Install the suction oil line (from the the tank to the canister filter):
a. Refer to Figures 4H and 4J. Prepare a piece of 1/2" O.D. copper tubing (user-supplied) which will
function as the pick-up line from the tank to the canister filter. This copper tubing must have the
following specifications:
• The tube must be one continuous piece of 1/2" O.D. copper tubing with no kinks
or fittings.
• The tube is to slant up from the tank to the pump with no loops or high points to
trap air.
c. Locate the 2" MPT x 1/2" FPT x 1/2" FPT duplex, slip-thru hex bushing (which will eventually be
installed into one of the 2" openings on the tank). Note that the fitting is marked "S" for suction
and "R" for return.
d. Install the 1/2" MPT x 1/2" slip fitting into the "S" side of the 2" duplex slip-thru hex bushing.
e. Install the 1/4" MPT x 1/4" compression fitting into the 1/2" x 1/4" brass bushing.
f. Install the 1/2" x 1/4" brass bushing into the "R" side of the 2" duplex slip-thru hex bushing.
g. Measure the height of the oil tank (from the bottom of the tank, NOT the floor) to the 2"
opening that you are going to use for the supply oil line. Deduct 12" (305mm) from this
measurement and transfer this new measurement onto the 1/2" O.D. 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 Figures 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.
4-16
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
Installing the Pressure Relief and Low-Flow Check Valve
ATTENTION: It is critical that you adhere to the following specifications for pressure relief and
low-flow check valve installation; if these specifications are not met, the metering pump will not
function correctly and the burner will shut down on reset.
The metering pump requires the installation of a pressure relief and low-flow check valve as shown in
Figures 4H, 4J, and 4K.
• The pressure relief will open and relieve pressure on the line if there is a restriction in the
pressure oil line, clogged nozzle, etc.
• The low-flow check valve is a vital component which maintains pressure in the oil pressure
line.
Be sure to use Permatex #2 non-hardening gasket sealer to seal every threaded fitting. DO NOT use
teflon tape or teflon pipe dope compounds.
1.
2.
3.
4.
Refer to Figure 4K.
Remove the plug from the gauge port on top of the metering pump head.
Install the pressure relief valve assembly in a vertical position in the gauge port. Note that the
directional arrows on the relief valve must be positioned so that the arrows point away from the
pump head (i.e. in the direction of the oil flow).
Install 1/4" O.D. copper tubing (user-supplied) from the pressure relief back to the oil tank.
Refer to Figure 4J as needed.
PRESSURE RELIEF
VALVE COMPONENTS
Included with metering pump
32062
MALE CONNECTOR
1/4 T TO 1/4 NPT
TO BURNER
32293
RELIEF VALVE
32425
1/4 NPT BRASS TEE
32424
LOW FLOW CHECK VALVE
32335
ADAPTOR PIPE, 1/4 F X 1/8 M
TO TANK
FROM PUMP
Figure 4K - Pressure Relief Valve Assembly Detail
4-17
I88692−A
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
Installing the Pressure Oil Line Components
ATTENTION: It is critical that you adhere to the following specifications for pressure oil line
installation (oil line from the pump to the furnace); if these specifications are not met, the metering pump
will not function correctly and the burner will shut down on reset.
1.
2.
3.
•
The parameters for pressure oil line installation are:
Length of Pressure Line
Line Size
Up to 30 m (100')
10 mm (3/8") O.D. copper tubing
•
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.
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
requirements: 1.7 bar (25 psi) and water trap or dryer. If you do not have shop air, an optional air compressor is available. Contact your local Clean Burn dealer for more information.
1.
Run a compressed air line from your shop air to the connector block on the furnace -- for Model
CB-3500 use minimum 6 mm (1/4") O.D. copper tubing or equivalent; for Model CB-5000, use
10 mm (3/8") O.D. copper tubing or equivalent.
2.
Install an easily accessible shut-off valve in the air line so the burner can be serviced without
shutting off the shop air in your service area.
3.
If necessary, install a pressure regulator (additional to the burner air regulator) in the air line, and
set it at 3.5 bar (50 psi).
ATTENTION: DO NOT feed full shop air pressure to the burner or damage to burner
components may occur.
4.
Install a water trap or extractor/dryer in the air line with an automatic drain so compressed air
(rather than water) is supplied to the burner.
ATTENTION: Water must not be fed to the burner, or the flame will be extinguished and the
burner will shut down. Be sure to drain water from your compressor tank on a regular basis to
keep water out of the air line.
4-18
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
Installing the Stack
WARNING: Inappropriate stack materials or improper stack design/installation can adversely
affect the proper, safe operation of your 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. 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:
• Model CB-3500 requires minimum 20 cm (8") I.D. stack components.
Model CB-5000 requires minimum 25 cm (10") I.D. stack components.
• Ensure that the vertical stack height is at least 3 m (10') PLUS 45 cm (1.5') for every fitting
(e.g. 45 degree, 90 degree, or T) in the stack run. If needed, increase the vertical length
of the stack or install a draft inducer to obtain -.02" W.C. draft over fire. (Section 8 contains details
on adjusting the draft.)
• Keep the horizontal stack run as short as possible; slant it upward at a minimum of 6 mm (1/4")
per 30 cm (1') 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 (from furnace breach to within 45 cm (18") of ceiling, roof, or sidewall of 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
(6) Draft Inducer (standard component for Model CB-5000; optional accessory for Model CB-3500)
4-19
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
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.
WARNING: ENSURE PROPER
CLEARANCES BETWEEN STACK
COMPONENTS AND COMBUSTIBLES
PER ALL APPLICABLE CODES.
WARNING: BE SURE TO INSTALL THE
PROPER ROOF SUPPORT SYSTEM TO
SAFELY SUPPORT THE STACK
3 m (10’)
WATERTIGHT ROOF FLASHING:
CLEAN BURN RECOMMENDS
"DEKTITE" FLASHING FOR A
WATERTIGHT SEAL
"CLASS A" KIT FOR
INSTALLING "CLASS A"
STACK THROUGH
CEILING
1/4" HOLE FOR
SETTING DRAFT.
ADJUST BAROMETRIC
DAMPER FOR −.04 W.C.
DRAFT AT BREECH
ATTENTION:
BAROMETRIC DAMPER
MUST BE INSTALLED SO
IT IS FACING AWAY FROM
EXHAUST GASES FROM
−0.02 W.C. DRAFT
OVERFIRE IS
ESSENTIAL FOR
PROPER FURNACE
OPERATION.
SEE SECTION 8
Danfoss
T ype B HO 64
N r. 057H7036
220-240 V 50-60Hz 3W
t s 10s
I88924
Figure 4L - Installation of "Class A" Stack Through Roof/Ceiling
4-20
3 m (10’) MINIMUM VERTICAL STACK HEIGHT PLUS 30 cm (1’)
FOR EVERY FITTING TO MAINTAIN PROPER DRAFT OVERFIRE
NOTE: THE LAST STACK SECTION SHALL EXTEND AT LEAST
90 cm (3’) ABOVE THE HIGHEST POINT AT WHICH IT COMES IN
CONTACT WITH THE ROOF AND AT LEAST 60 cm (2’) HIGHER
THAN ANY RIDGE, PARAPET, WALL OR ROOF STRUCTURE
WITHIN 3m (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
SINGLE WALL STACK
MIN. 24 GAUGE
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: Local codes may require the installation of a clean-out tee.
60 cm (2’)
1.
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
Installing the Stack (continued)
3 m (10’)
"CLASS A" STACK COMPONENTS
INSULATED STACK WITH A STAINLESS STEEL LINER
3 m (10’) MINIMUM VERTICAL STACK HEIGHT
NOTE: THE LAST STACK SECTION SHALL EXTEND AT
LEAST 90 cm (3’) ABOVE THE HIGHEST POINT AT
WHICH IT COMES IN CONTACT WITH THE ROOF AND AT
LEAST 60 cm (2’) HIGHER THAN ANY RIDGE,
PARAPET, WALL, OR ROOF STRUCTURE WITHIN
3 m (10’) OF IT.
60 cm (2’)
"CLASS A" STACK CAP
NON−RESTRICTIVE TYPE TO ALLOW
FREE FLOW OF THE STACK GASES
"CLASS A" STACK
PENETRATION AND
CLEAN−OUT TEE
−.02 W.C. DRAFT OVERFIRE IS
ESSENTIAL FOR PROPER FURNACE
OPERATION. SEE SECTION 8.
BAROMETRIC
DAMPER
Da nf oss
Ty pe BHO 64
Nr. 0 57 H70 36
22 0 -24 0 V 50 -6 0Hz 3W
ts 1 0s
SINGLE WALL
STACK
MIN. 24 GAUGE
Figure 4M - Installation of "Class A" Stack Through Sidewall
4-21
I88925
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
Installing the Barometric Damper
1.
Refer to the stack installation drawing, Figure 4L. Install a single wall tee (min. 24 gauge) after the
90o elbow in the straight vertical stack section within 90 cm to 152 cm (3' to 5') 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 for CB-3500; 10" single wall tee CB#70180 for CB-5000).
2.
For CB-5000 ONLY: Install the 9"-to-10" pipe adapter in the opening of the tee as shown in
Figure 4N.
3.
Install the barometric damper in the opening of the tee (or pipe adapter for CB-5000 furnaces). Use a
small spirit level to make sure that it is properly level.
4.
Install two self-tapping screws (i.e. one on each side of the barometric damper) to hold the damper in
place as shown in Figures 4N and 4O . DO NOT install a screw at the bottom of the barometric
damper, or the flapper of the damper will not operate correctly.
NOTE: Specifications for adjusting the barometric damper for proper draft overfire are provided in
Section 8 of this manual.
9" CLEAN BURN BAROMETRIC
DAMPER WITH ADAPTOR IN
10" SINGLE WALL TEE
I88547
ADJUST THIS WEIGHT TO
OBTAIN PROPER DRAFT
2
1
(FOR CB-5000)
2
1
31198
DAMPER PIPE ADAPTOR
1
1
31197
9" BAROMETRIC DAMPER
No QTY PART #
DESCRIPTION
Figure 4N - Installation of 9" Barometric Damper for Model CB-5000 Furnaces
I88539
8" CLEAN BURN BAROMETRIC DAMPER
INSTALLED IN SINGLE WALL TEE
ADJUST THIS WEIGHT TO
OBTAIN PROPER DRAFT
1
1
(FOR CB-3500)
1
31170
No QTY PART #
8" BAROMETRIC DAMPER
DESCRIPTION
Figure 4O - Installation of 8" Barometric Damper for Model CB-3500 Furnaces
4-22
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
Installing the Stack Penetration
WARNING: When running the stack through your ceiling, roof, or sidewall, you must use
Class A double-wall insulated all-fuel stack components with a stainless steel liner. DO NOT run
single-wall stack through your ceiling, roof or sidewall. NEVER locate a stack joint inside walls or in a joist
spacer. Ensure proper clearances from combustibles per all applicable codes.
1.
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 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 Draft Inducer
ATTENTION: The draft inducer, Field brand model DI-3, is standard equipment for CB-5000 furnaces and
must be installed to ensure proper draft. The Field brand model DI-2 is available as optional equipment for the
CB-3500 furnace. The Field brand draft inducers have 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 4P.)
Proper sizing, installation, and adjustment of the draft inducer are critical for optimal draft inducer
operation.
4-23
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
NOTE: INSTALL DRAFT INDUCER IN LAST
SECTION OF VERTICAL STACK TO POSITION
DRAFT INDUCER AWAY FROM FURNACE
BREACH SO THAT THE MOTOR DOES NOT
OVERHEAT. THIS ALSO REDUCES ASH
ACCUMULATION IN THE DRAFT INDUCER.
5 FEET − 8 FEET
(1.5 METERS − 2.5 METERS)
DO NOT MOUNT THE DRAFT INDUCER IN THE
HORIZONTAL STACK NEAR THE FURNACE
BREACH
10 FT. (3M) MINIMUM VERTICAL STACK HEIGHT
10 FT. (3 M)
"CLASS A" STACK
2 FT.
(60 cm)
Installing the Draft Inducer (continued)
DRAFT
INDUCER
DRAFT
ADJUSTMENT
PLATE
CHECK FOR
−.02 W.C. DRAFT
OVERFIRE
SERVICEMAN ADJUSTS
BAROMETRIC DAMPER TO
OBTAIN −.02 W.C. DRAFT
OVERFIRE
Danf oss
T yp e B HO64
2 20 -24 0V 50 -60 Hz 3W
t s 1 0s
Nr. 05 7H703 6
CLEAN−OUT CAP
INSTALLED ON L.H.
FURNACE BREACH
I88926
Figure 4P - Installation of the Draft Inducer
4-24
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
Installing the Draft Inducer (continued)
Installing the 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.
1.
2.
Refer to Figure 4P. 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. You will adjust the draft plate later as part of Adjusting the Draft Overfire
(Section 8).
Wiring the Draft Inducer for Normal Operation*
*(No exhaust fans in the building)
1.
Wire the draft inducer according to the Furnace Wiring Diagram provided in Appendix B at the
back of this manual.
Installing the Wall Thermostat
1.
2.
3.
4.
5.
6.
Select a location for the thermostat on an interior wall away from any hot or cold drafts.
Remove the top cover from the thermostat by pushing gently on the latch on the right side of the case.
(Hold the thermostat base in one hand, and grasp the cover 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.
Remove the black plastic tab located in the battery compartment.
Refer to the Furnace Wiring Diagram in Appendix B at the back of this manual. Run two wire, 18gauge (minimum) thermostat cable from the terminals on the back of the thermostat base to the terminal
block located on top of the electrical junction box (on top of the furnace cabinet).
ATTENTION: NEVER jump between terminals of the thermostat wire 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.
Mount the thermostat base 152 cm to 168 cm (60" to 66") from the floor using the hardware provided.
Re-assemble the thermostat cover onto the base. (Align the hinges on the side of the cover with the
slots on the base, and swing the cover into place.)
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 safety
codes and allows for any deficiencies to be corrected before furnace startup. Improper installation may
damage the equipment.
4-25
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
4-26
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
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.
ATTENTION: Please note that in order to use the metering pump with the CB-500 Series burner (and to
accomplish pump priming), the oil regulator assembly must first be removed from the preheater block
assembly. The following procedure provides the necessary instructions.
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
Rags
Two containers - minimum 3.8 liters (1 gallon)
Medium straight-blade screwdriver
5-1
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
Preparing the Burner for Use with the Metering Pump
WARNING: To avoid electrical shock hazards, turn off all power to the furnace, and unplug the
burner before proceeding.
1.
2.
3.
4.
5.
6.
7.
Figure 5A shows an exterior view of the burner components. In this procedure, you will be
removing the oil regulator from the preheater block assembly to prepare the burner for use with
the metering pump.
Remove the self-tapping screw and swing open the double-hinged lid to expose the heater block
assembly.
Use a 1/8" Allen wrench to loosen the two locking bolts on the locking bar.
Remove the locking bar.
Refer to Figure 5B. Use a 5/32" Allen wrench to remove the four (4) bolts and washers holding
the surface-mounted oil regulator in place, then carefully remove the oil regulator.
NOTE: Keep the oil regulator assembly in a safe place in case a standard J-type oil transfer
pump is installed at a later date. (You would then need to re-install the oil regulator assembly.)
Clean the top of the heater block to remove used oil, etc. DO NOT allow any debris to fall into
the oil passageways which have been exposed by the removal of the oil regulator.
Install the square cap with the o-ring using the four (4) bolts and washers. Tighten the four bolts
firmly in a crisscross pattern to ensure that there are no leaks.
DOUBLE−HINGED LID
AIR REGULATOR
REMOVE
OIL REGULATOR
-240
2 20
Da
3W
z 10 s
-6 0H ts
50
ss
nfo
64
HO 36
e B H70
Typ 0 57
Nr.
AIR GAUGE
OIL GAUGE
COMBUSTION
AIR BAND
I88899
Figure 5A - Detail of Burner Components
5-2
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
SAVE AND USE THESE 4
SCREWS AND WASHERS
TO INSTALL SQUARE CAP
STEP 1
REMOVE
THESE PARTS
SURFACE MOUNTED
OIL REGULATOR
(COMPLETE
REGULATOR)
STEP 2
10
9
8
7
6
5
4
3
2
1
INSTALL
SQUARE CAP
AND "O" RING
I88193
Figure 5B - Detail of Heater Block with Surface-Mounted Oil Regulator
5-3
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
Priming the Metering Pump
ATTENTION: The priming process must be done precisely as described in this procedure to ensure
that all air is thoroughly bled from the system. Failure to bleed all air from the system will result in
repeated burner shutdowns on reset.
1.
2.
3.
4.
5.
6.
Refer to Figure 5C.
Remove the 5/8" plug from the side of the pump head, and set it aside.
Remove the 1/2" brass cap from the 1/2" brass nipple. Place a funnel in the opening. Slowly
pour used oil into the funnel until oil comes out of the side of the pump head; this will fill the
oil line, canister filter, and pump head with oil.
ATTENTION: NEVER run the pump head dry (i.e. without oil in the pump head); doing so will
severely damage the pump.
Apply Permatex #2 non-hardening gasket sealer to the threads of the plug (removed from the
pump head). Re-install the plug and tighten.
Apply Permatex #2 non-hardening gasket sealer to the threads of the 1/2" brass nipple. Re-install
the 1/2" brass cap on the brass nipple and tighten.
Open the bleeder on the pump two to three (2-3) full turns, and position a container to catch oil
which will flow from the bleeder during pump priming.
Figure 5C - Priming the Metering Pump
5-4
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
Priming the Metering Pump (continued)
7.
Activating the Pump
NOTE: The CB-3500 and CB-5000 furnaces feature a priming switch which is mounted on the
left-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 / orange indicator light is ON): this is used only
for pump priming. When the switch is in the UP position, the pump circuit is activated for
priming. The pump will continue to run as long as the switch is in this position. The oil
primary control circuit is de-activated so the burner cannot run while the switch is in the UP
position.
• BURNER (switch is in the DOWN position): this is used for normal burner operation.
When the switch is in the DOWN position, the burner controls the operation of the pump.
The pump will only run while the burner is running.
a. Refer to Figure 5D to locate the priming switch.
b. Turn the priming switch to the UP position. The pump should immediately start running.
c. Run the oil pump until proper oil flow has been established and the oil lines have been
completely flushed out. (The following steps provide specific instructions.)
PRIMING LIGHT
LOCKING NUT
OIL PUMP
PRIMING SWITCH
Da
nfos
s
Ty
Nr pe BH
. 05
7H O 64
70
36
22
0-2
40
50
-60
Hz
ts 3W
10
s
AIR REGULATOR
OIL GAUGE
AIR GAUGE
CONNECTOR BLOCK
COMPRESSED AIR LINE
OIL LINE
Figure 5D - Detail of Burner Connections/Components
5-5
I88927
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
Priming the Metering Pump (continued)
8.
9.
10.
11.
12.
13.
14.
15.
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.
Close and tighten the bleeder on the pump.
Turn the priming switch to the DOWN position so that the pump stops running.
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.
Turn the priming switch to the 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
flushed out.
Turn the priming switch to the DOWN position so that the pump stops running.
Re-connect the oil line to the connector block.
Vacuum Testing the Oil Pump
Vacuum testing the oil pump is a very accurate way to determine the following:
• The condition of the pump -- the ability of the pump to pull a vacuum and suck oil from the tank.
• The condition of the fittings, gaskets and seals from the ball valve to the pump -- these
components must all be airtight to avoid suction leaks.
The following procedure provides instructions for vacuum testing the pump and canister filter on
systems equipped with a ball valve.
ATTENTION: For the pump to pull and hold vacuum, it is critical that all fittings are airtight. If any of
these fittings are loose, the pump may not pull a vacuum or may lose the vacuum rapidly. It is also
critical that all fittings in the suction line, including fittings on the canister filter, are 100% airtight.
1.
2.
3.
4.
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.
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.
Refer to Figure 5C. Close the ball valve and 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.
The vacuum should increase within 15 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.
NOTE: If the pump will not pull at least 15 inches of vacuum, there is a very serious suction
leak, or the pump is damaged.
5-6
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
Vacuum Testing the Oil Pump (continued)
5.
If there are no suction leaks, the system will hold vacuum.
NOTE: It is acceptable for the vacuum to drop one to five inches within one minute as the seal
in the pump seats. The vacuum should then hold steady for 15 minutes.
ATTENTION: If the vacuum drops more than one to five inches within the first minute, there is
one or more leaks somewhere between the pump and the ball valve. Do the following:
• Wipe your finger along the cylinder at the shaft of the pump. If there is oil here, the pump
seal is damaged. Replace the pump.
• Disassemble and clean all the fittings from the pump to the ball valve. Properly seal all
fittings with Permatex #2 non-hardening gasket sealer or equivalent. Check the condition of
the o-ring on the canister filter and tighten the four canister filter bolts in a crisscross pattern.
• Repeat the procedure to vacuum test the system to ensure that the system is air tight.
5-7
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
5-8
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
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.
ATTENTION: Please verify that the oil regulator has been removed from the burner as shown in
Figure 6A. If the oil regulator has not been removed, please refer to Section 5 for the necessary
instructions -- Preparing the Burner for Use with the Metering Pump. The metering pump will
automatically supply the correct fuel flow to the burner.
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 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, you must wait at least 15 minutes until the preheater
block is thoroughly warm before starting the burner.
Refer to Figure 6A to locate the
air regulator. Loosen the
AIR REGULATOR
locking nut on the air regulator.
Turn the adjustment knob
on the air regulator
counterclockwise until 1/2"
LOCKING NUT
of the threads on the knob
are exposed. DO NOT back
COVER PLATE
the knob all the way out.
NOTE: The air gauge will not
show any pressure until the
burner starts. Before starting
the burner for the first time, it
is very important to turn the
air regulator completely OFF as
AIR GAUGE
described.
OIL GAUGE
(continued on next page)
3W s
10
22
0- 24
0
50
z
-60H ts
ss
nfo
64
Da
HO 36
B 70
pe
Ty 057H
Nr.
COMBUSTION
AIR BAND
I88901
Figure 6A - Component Detail of the CB-500 CE Burner
for the CB-3500 Furnace
6-1
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
Preparing the Burner for Startup (continued)
6.
Initial Adjustment of the Combustion Air Band for CB-3500 Furnaces:
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. Failure to heed this warning may result in fire or explosion hazard.
• Refer to Figure 6A to locate the combustion air band. Note that the burner has an adjustable
combustion air band.
• Rotate the combustion air band to adjust it to the appropriate slot opening as listed in the
Initial Adjustment Charts on the next page. Use a ruler to accurately set the slot opening at the
widest section of the slot.
7.
Initial Adjustment of the Air Intake for CB-5000 Furnaces:
WARNING: The air intake must be properly adjusted to ensure that the burner ignites and
burns correctly. DO NOT attempt to start the burner with the air intake wide open or completely
closed. Failure to heed this warning may result in fire or explosion hazard.
• Refer to Figure 6B to locate the air intake. Note that the burner has an adjustable
air intake with a locking tab.
• Rotate the locking tab DOWN and OPEN the air intake by rotating the disk (CCW) to the
appropriate slot opening as listed in the following Initial Adjustment Charts on the next page.
• Rotate the locking tab UP to lock the air intake in place.
AIR REGULATOR
LOCKING NUT
COVER PLATE
40
0- 2
22
n
Da
fos
3W s
Hz
60 ts 10
5 0-
s
64
HO 36
e B 70
Typ 057H
Nr.
LOCK TAB
AIR GAUGE
OIL GAUGE
AIR INTAKE OPENING
I88928
Figure 6B - Component Detail of the CB-550-CE Burner for CB-5000 Furnaces
6-2
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
Preparing the Burner for Startup (continued)
ATTENTION: The settings shown in the charts below are only initial adjustments. Final adjustments
must be done by inspecting the flame length according to the illustrations provided on the following
page.
NOTE: The oil pressure is automatically adjusted by the metering pump.
Initial Adjustments for CB-3500
NOTE: Only Gearmotor part # 33427 may be used with the CB-3500 (230 V / 50 Hz)
Maximum Input = 103 KW (350,000 BTUH) @ 9.5 LPH (2.5 GPH) per CB-500 Series Burner
Oil Type
Oil Pressure/Flame Length Air Bar (PSI)
Air Band Nozzle
#2 Fuel Oil*
Used Crankcase Oil
Used ATF
Used Hydraulic Oil
#4 and #5 Fuel Oils
check flame length
check flame length
check flame length
check flame length
check flame length
0.8-1.1
0.8-1.1
0.8-1.1
0.8-1.1
0.8-1.1
(12-16)
(12-16)
(12-16)
(12-16)
(12-16)
20 mm (3/4")
20 mm (3/4")
20 mm (3/4")
20 mm (3/4")
20 mm (3/4")
9-5
9-5
9-5
9-5
9-5
Initial Adjustments for CB-5000
NOTE: Only Gearmotor part # 33428 may be used with the CB-5000 (230 V / 50 Hz)
Maximum Input = 147 KW (500,000 BTUH) @ 13.5 LPH (3.6 GPH) per CB-500 Series Burner
Oil Type
Oil Pressure/Flame Length Air Bar (PSI)
Air Band Nozzle
#2 Fuel Oil*
Used Crankcase Oil
Used ATF
Used Hydraulic Oil
#4 and #5 Fuel Oils
check flame length
check flame length
check flame length
check flame length
check flame length
0.8-1.1
0.8-1.1
0.8-1.1
0.8-1.1
0.8-1.1
(12-16)
(12-16)
(12-16)
(12-16)
(12-16)
6 mm (1/4")
6 mm (1/4")
6 mm (1/4")
6 mm (1/4")
6 mm (1/4")
9-11
9-11
9-11
9-11
9-11
*If you are burning light viscosity oils such as #2 fuel oil, it may be necessary to install a smaller nozzle. Call
your Clean Burn dealer for more information.
Starting the Burner
1.
2.
Adjust the thermostat setting above room temperature to start the burner.
NOTE: If the burner refuses to start, review the Preparing the Burner for Startup procedure. If,
after repeating this procedure, the burner still refuses to start, check the following system components
for proper functioning:
• Verify that the red wire as shown in the Burner Wiring Diagram (Appendix B) is energized
to230VAC.
• Verify that the prime switch (on the control box) is set to RUN (i.e. DOWN position).
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.
(Starting the Burner procedure continues on the next page)
6-3
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
Starting the Burner (continued)
3.
Observing the Flame Length:
Visually inspect the flame length through the observation
port. Refer to Figure 6C for an illustration of the desired
flame length. The flame should extend no more than
one-half of the way down the combustion chamber.
CAUTION
WHEN OPENING INSPECTION PORT
WARNING: The observation port gets hot as the burner
fires. To avoid personal injury, always wear heavy work
gloves and safety glasses when opening the port and
viewing the flame.
PORT MAY BE HOT
PROTECT HANDS
WEAR SAFETY GOGGLES
KEEP FACE AWAY
OPEN PORT SLOWLY
Correct Maximum Flame Adjustment
(Proper Oil and Air Pressure with correct supply of Combustion Air)
• 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
Figure 6C - Flame Length Adjustment
4.
5.
Check the flame length after the burner has fired for 15 minutes.
Tighten the locking nuts on the air regulator.
6-4
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
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 3 mm to 6mm (1/8" to 1/4"), and
re-check the flame for the proper characteristics.
• Re-check the flame after five minutes. You should see a yellow-white flame with sharp
tips and no "sparkles", and the flame should extend half of the way down the combustion
chamber.
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 or air intake 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 12% or an O2 reading of 4 to 8%
• Cad cell reading of 200 to 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 information on the fan limit control.
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 limit control 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 limit control will then shut off the blower motor.
CAUTION: If the blower motor does not operate as described, immediately shut down your
furnace and contact your Clean Burn dealer.
6-5
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
6-6
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
SECTION 7: RESETTING THE FURNACE AND BURNER
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.
Understanding the Oil Primary Control
The oil primary control will shut the oil pump and oil solenoid off when it detects flame-out during burner
operation. The oil primary control will then wait approximately 15 seconds (while the burner motor, air
solenoid, and transformer are energized) and attempt to re-ignite the burner (recycle mode). If the burner does
not re-ignite, the control will shut the burner off on safety lock-out. The following procedure explains what
should be done when this occurs. It is very important that you follow these instructions precisely when
resetting the safety on the primary control and restarting the burner.
Resetting the Oil Primary Control
DANGER! DO NOT reset the oil primary control if oil mist is present in the combustion
chamber or when the combustion chamber is hot! DO NOT operate your furnace if excess oil,
oil vapor or fumes have accumulated in or near the unit. As with any oil burning appliance, improper operation
may result in a fire or explosion hazard.
1.
2.
3.
4.
5.
Refer to Figure 7A.
Allow 5 to 10 minutes for all fuel mist to exhaust from the combustion chamber.
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 that all fuel mist has cleared and the furnace has cooled, push in and hold the
reset button for three seconds, then release. This will reset the control at any time during its operation.
If the burner will not restart, call your Clean Burn dealer immediately.
I88853
Figure 7A - Danfoss Oil Primary Control
7-1
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
Understanding the Fan Switches and Hi-Limits on the
CB-3500/CB-5000 Furnaces
The CB-3500 and CB-5000 furnaces feature redundant fan switches and redundant limit switches. The two
fan switches enable efficient working of the fan/blower for both unit heater and central furnace applications. The
two limit switches serve to protect the furnace from damage due to overheating. Review the following specifics
on each of the switches/controls to understand their operation; refer to the Furnace Wiring Diagrams in
Appendix B at the back of this manual to review the installation of these switches.
The Blower/Fan Switch
The CB-3500/CB-5000 furnaces feature an F-180 blower/fan switch (normally open) which is surfacemounted at the front of the combustion chamber as shown in 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 switch closes and sends power to the blower motor relay to turn ON the blower.
When the wall thermostat is satisfied and the burner shuts off, the blower/fan continues to run until the switch
senses that the combustion chamber has cooled down. The switch then opens and shuts off the blower/fan.
AIR DISCHARGE
33288 L−290 HI−TEMP SWITCH
33230 FAN SWITCH
ORIFICE
PLATE
ACCESS
PLATE
CB−3500/5000 FURNACE WITH CLEAN−OUT DOOR
OPEN TO SHOW HEAT EXCHANGER
DETAIL OF HI−TEMP SWITCH AND FAN SWITCH
INSTALLED ON FRONT HEADER OF FURNACE
I88929
Figure 7B - Locating the F-180 Fan Switch amd the L-290 Hi-Temp Limit Switch
7-2
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
The Fan Limit Control
Understanding the Operation of the Fan Limit Control
The fan limit control, which is a probe style control, senses air temperature within the furnace cabinet. This
control contains two switches: the fan switch and the limit switch. This control is especially important for the
functioning of the fan with ducted applications.
Fan Switch: The fan switch is normally open and provides power to the fan (or blower). When the fan limit
control senses "Fan On" temperature, the fan switch closes and starts the fan (or blower). When the wall
thermostat is satisfied and the burner shuts off, the fan continues to run until the fan limit control senses the "Fan
Off" temperature. At this temperature, the fan switch opens and shuts off the fan (or blower).
NOTE: The fan limit control has a white fan switch button. Make sure the white button is pulled OUT for
automatic (normal) operation. When the button is pushed in (manual setting), the fan will run continuously.
Limit Switch: The limit switch is normally closed
and provides power to the oil primary control on
the burner. If the fan limit control senses 93 oC
(200 oF), the limit switch opens and shuts off
power to the oil primary control and the burner
stops running. The fan (or blower) continues to
run. Once the fan limit control senses 77 oC
(170 oF), the limit switch automatically resets and
restarts the burner.
ATTENTION: It is very important to avoid
cycling the burner on hi limit as described above.
If the hi limit activates, immediately check and
readjust burner settings.
ATTENTION: DO NOT change the fan limit
settings from the specified settings, or severe
damage to the furnace cabinet may occur.
CAUTION
DO NOT ROTATE
HOLD DIAL WHEN SETTING
POINTERS
FAN OFF
(LEFT POINTER)
LIMIT
(RIGHT POINTER)
TO RELEASE
WIRE, PUSH
SCREWDRIVER
IN AND PULL
WIRE OUT
ORANGE WIRE (CONNECT TO FAN)
LOAD
LOAD
FAN
LIMIT
LINE
LINE
RED WIRE (CONNECT TO LIMIT)
CAUTION
DO NOT ROTATE
HOLD DIAL WHEN SETTING
POINTERS
Setting the Pointers on the Fan Limit
Control Dial
1.
Turn OFF main power to the furnace.
2.
Remove the fan limit control cover.
3.
While holding the dial securely in place
with your thumb, move the pointer to
the desired setting.
ATTENTION: DO NOT rotate the dial when
setting the pointers; doing so will severely
damage the control.
BRASS
JUMPER
Fan Limit Control Settings: CB-3500/CB-5000
Fan Off:
Fan On:
Limit:
FAN ON
(MIDDLE POINTER)
38 oC (100 oF)
49 oC (120 oF)
99 oC (210 oF)
BLACK WIRE
(230 VOLTS)
I88381
Figure 7C - Fan Limit Control Components
7-3
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
The Auxiliary Hi-Temp Limit Switch
The CB-3500 and CB-5000 furnaces are equipped with an auxiliary L-290 high temperature limit switch which
is mounted on a bracket at the front of the combustion chamber as shown in Figure 7B. This switch senses the
build-up of heat within the combustion chamber beyond the fan limit control setting and is designed to protect
the furnace from damage due to overheating.
Understanding the Function of the Auxiliary L-290 Auto-Reset Hi-Temp Limit Switch
If the temperature of the combustion chamber has exceeded the range of the fan limit control, the auxiliary
L-290 auto-reset hi-temp limit switch opens and shuts off power to the primary control on the burner, and the
burner shuts down. After the combustion chamber has sufficiently cooled, the L-290 switch will automatically
reset, and allow the burner to re-start.
The L-290 hi-temp limit switch will open and shut down the burner if any of the following conditions exists:
• If the fan/blower has stopped running for any reason during furnace operation, the heat
in the furnace may cause the L-290 hi-temp limit switch to open. Ensure that the fan/blower is
functioning properly.
• The fan limit control is not functioning properly. If the fan limit control has malfunctioned,
the L-290 could cycle on/off repeatedly. If this occurs, contact your Clean Burn Distributor
immediately for service.
• The furnace is overfiring. Review the directions in Section 6 in the Operator’s Manual 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 of the Operator’s
Manual.
ATTENTION: It is very important to determine the reason for the opening of the L-290 switch 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.
7-4
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
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.
2.
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.
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.
I88257
Figure 8A - Checking for Proper
Draft Overfire
8-1
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
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.
TO OBTAIN PROPER
Follow the directions in Section 6 to start
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
the weight in position.
Figure 8B - Adjustment of Barometric Damper
Adjusting Draft Overfire on Furnaces with Draft Inducers
(CB-5000 Standard; CB-3500 Optional)
NOTE: The draft inducer is purposely sized to create a generous draft. When adjusting the barometric
damper, you will find that the flapper is open most of the time. This allows the draft inducer to suck cool air
through the damper to protect the inducer motor from heat damage.
1.
2.
Use a draft gauge to check draft overfire.
Adjust the barometric damper to obtain -0.02 w.c. draft overfire. If you still have too much draft,
adjust the draft plate on the draft inducer. Move the plate in 6 mm (1/4") to reduce the draft. Recheck
the draft reading.
8-2
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
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.
• 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.
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.
2.
3.
4.
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).
Start the furnace and adjust the barometric damper so that the draft overfire is -.02 w.c.
Check the draft overfire again. Now have someone start the exhaust fans.
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. 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-3500 and CB-5000 (230 V / 50 Hz)
BACKDRAFT
EXHUST FAN CREATES BACKDRAFT IN STACK
AND SUCKS COMBUSTION GASES DOWN THE
STACK AND BACK INTO THE FURNACE
50-
3W
60Hzts 10s
240
2 20-
o ss
f
64
36
e BHO 70
T yp. 0 57H
Nr
D an
To arrive at proper
draft measurements
be sure that all fans
within the building
are running while
adjusting the draft
to final levels!
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
RISING HOT
COMBUSTION
GASES PRODUCE
PROPER DRAFT
W
310s
50- 60Hzts
240
220-
D an
fo ss
64
e BHO 036
7
T yp. 057H
Nr
I88930
Figure 8C - Proper Draft vs. Backdraft
8-4
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
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 amount 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)
(b)
(c)
(d)
(e)
(f)
Count the total number of exhaust fans in the building.
Close all of the doors and windows in the building except for one overhead garage door.
Start the furnace and allow it to run for 15 minutes to bring it up to temperature.
Set the draft-over-fire for -.02" to -.04" W.C.
Turn ON all of the exhaust fans in the building.
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.
Example of Calculations for Sizing Make-up Air Louver
Measured door opening: 366 cm (144") wide x 30 cm (12") high
• Convert to cm2 (ft2) - in this case it equals 10,980 cm2 (1728 in2)
• Multiply by 1.1 correction factor (10,980 cm2 x 1.1 = 12,078 cm2)
(1728 in2 x 1.1 = 1901 in2)
• Multiply by free area factor (12,078 cm2 x 1.25 = 15,098 cm2
(1901 in2 x 1.25 = 2367 in2)
• Refer to sizing chart on the following page - required grill size would be:
(1) 137cm x 137cm (54in. x 54 in.) grill
8-5
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
Installing a Make-up Air Louver (continued)
REQUIRED LOUVER / GRILL SIZE
cm
in
25 x 25
10 x 10
30 x 30
12 x 12
41 x 41
16 x 16
46 x 46
18 x 18
51 x 51
20 x 20
61 x 61
24 x 24
76 x 76
30 x 30
91 x 91
36 x 36
107 x 107
42 x 42
122 x 122
48 x 48
137 x 137
54 x 54
152 x 152
60 x 60
CALCULATED OPENING SIZE
in2
cm2
0 – 528
0 – 82
529 – 836
83 – 130
837 – 1,445
131 – 224
1,446 – 1,923
225 – 299
1,924 – 2,390
300 – 370
2,391 – 3,166
371 – 490
3,167 – 4,769
491 – 739
4,770 – 7,150
740 – 1109
7,151 – 9,182
1,110 – 1,424
9,183 – 12,355
1,425 – 1,915
12,356 – 15,499
1,916 – 2,400
15,500 – 19,650
2,401 – 3,045
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 12 to 15 meters
(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-3500 and CB-5000 (230 V / 50 Hz)
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
tune-ups, 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, and may reduce the service life of
your furnace.
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 the
Appendixes.
9-1
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
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
CAUTION
port; the flame should extend no more than one-half of
WHEN OPENING INSPECTION PORT
the way down the combustion chamber.
-If the flame is diminishing or displays wide
PORT MAY BE HOT
variations, clean the canister filter and check
PROTECT HANDS
valve/screen (procedures provided in this
WEAR SAFETY GOGGLES
section).
KEEP FACE AWAY
OPEN PORT SLOWLY
-If the flame is firing too strongly (i.e. flame
touches back and/or side walls of the
combustion chamber), 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.
AIR REGULATOR
LOCKING NUT
COVER PLATE
0 -2
22
Da
nfo
40
3W
Hz 0s
60 ts 1
50-
ss
64
O
BH 7036
pe H
Ty 05 7
Nr.
AIR GAUGE
OIL GAUGE
COMBUSTION
AIR BAND
I88901
Figure 9A - Component Detail of the CB-525-S2 Burner (CB-550-S2 is similar)
9-2
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
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.
Open the ball valve. Refer to Sections 5 and 6 for instructions on priming the pump and starting
the burner.
BACK TO
TANK
TO BURNER
USE A RATCHET WRENCH WITH A 6" EXTENSION
AND 3/16" "ALLEN" SOCKET TO REMOVE THE
FOUR "ALLEN" SCREWS
I88716−B
Figure 9B - Canister Filter Component Detail
9-3
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
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
PART No 32422
PART No 32423
Figure 9C - Servicing the Metering Pump
9-4
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
Cleaning the 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.
2.
3.
4.
5.
Refer to Figure 9D. Remove the one-piece suction oil line from the tank.
Remove the check valve and filter. Clean these components in a parts washer.
Check the operation of the check valve. The valve must seat so it is airtight to hold pump prime.
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.
Follow pump priming instructions in Section 5 to re-establish prime.
METERING PUMP
TO BURNER
FUNNEL WITH
BALL VALVE
VENT
CAP
SUCTION
OIL LINE
EMERGENCY
VENT
945 LITER TANK
(250 GALLONS)
CLEANOUT
CHECK VALVE
CHECK VALVE SCREEN
I88717−B
Figure 9D - Check Valve Detail
9-5
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
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-3500 and CB-5000 (230 V / 50 Hz)
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. 3 mm (1/8") of ash has
the insulating capacity of 2.5 cm (1') of fiberglass insulation and reduces heat transfer significantly. Never allow
more than 6 mm (1/4") of ash to accumulate in the combustion chamber, heat exchanger flues, or
stack.
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
BREACH
COMBUSTION
CHAMBER
CLEAN−OUT
CAP
FURNACE FLUE
Figure 9E - Accessing the Combustion Chamber for Cleaning
9-7
I88913
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
Cleaning the Ash (continued)
1.
2.
3.
Ensure that power has been turned OFF, and all "hot" components have been allowed to cool
sufficiently. Carefully remove the target with a long handle or pipe. Lightly vacuum the target.
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.
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.
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.
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. 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-3500 and CB-5000 (230 V / 50 Hz)
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. This will
prevent the oil from being "cooked" in the pre-heater block when it is not in use. Failure to do so may result in
carbon build up in the burner preheater block which will block oil flow.
ATTENTION: 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.
9-9
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
9-10
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
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
Air sensing switch
receives power from
centrifugal switch.
Air sensing switch closes
as it receives more than
0.7 bar (10 psi) of air
pressure.
Blower switch senses OFF temperature of
71 °C (160 °F) and Blower switch opens.
Warm air delivered
to heated area.
Hour meter starts.
Yellow indicator
light ON.
Pump circuit starts
oil pump.
Blower stops running.
Blower switch sends power
to motor, and blower starts.
FURNACE COOL DOWN SEQUENCE
Blower switch senses ON
temperature of 82 °C (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.
INITIAL START-UP
Air regulator adjusted to
proper air pressure.
BURNER IGNITION SEQUENCE
Pump circuit opens
oil solenoid.
F120 proving switch remains closed and oil
primary control has power.
NORMAL BURNER OPERATION
Preheater thermostat cycles 450 watt block
heater element and maintains 60 °C (140 °F)
block temperature.
When block temperature reaches 49 °C
(120 °F) , the F120 proving switch closes
and sends power to the oil primary control.
INITIAL START-UP
BURNER PRE-IGNITION SEQUENCE
Preheater thermostat activates 450 watt block
heater element and heats the block to 60 °C (140 °F).
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 Interupted
(15 sec.) 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.
Primary control relay
opens and the burner
shuts off.
FLOW CHART
230 V / 50 Hz
I88849
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-3500 and CB-5000 (230 V / 50 Hz)
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
PROBLEM
Burner won’t run at all and
Green power light is NOT ON.
Burner won’t run at all and
Green power light is ON.
POSSIBLE CAUSE
POSSIBLE ACTION(S)
1.
2.
Circuit breaker/main switch open.
Fuse/breaker blown.
1.
2.
3.
3.
1.
2.
Burner cable is damaged or not
plugged in properly.
Oil primary control has shut down
on safety reset.
Wall thermostat is not operating.
3.
Heater block is not heating up.
3.
4.
F-120 proving switch has not
closed.
4.
5.
Check the condition of the Oil
primary control.
5.
6.
Oil primary control is damaged.
6.
7.
The L290 or L-290 limit switches
have opened.
7.
1.
10-3
2.
Close circuit breaker/switch.
Electrician should check out
electrical system.
Check burner cable.
Follow the directions in Section 7
to reset the oil primary control.
Check the wall thermostat and
thermostat cable.
Feel the back of the burner; it
should be 60 oC (140 oF). 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.
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.
(a) Check the physical condition
of the top primary control cover
and the lower base to make sure
there was no heat damage.
(b) Disconnect the top cover of
the primary control and check the
base wiring. Follow the burner
wiring label.
Replace oil primary control: (a)
Check voltage – it must be
230 volts.
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-3500 and CB-5000 (230 V / 50 Hz)
PROBLEM
Burner ignites, but will not stay running
and Burner shuts off on reset within 15
seconds.
Burner ignites and runs properly, but the
burner shuts off on reset periodically
(e.g. the burner goes off on reset during
the night and requires resetting in the
morning).
POSSIBLE CAUSE
POSSIBLE ACTION(S)
1.
There is a fuel delivery problem.
1.
2.
The cad cell is dirty.
2.
3.
Cad cell wires are loose.
3.
4.
Cad cell / cad cell wires are
damaged.
4.
5.
The primary control is not
receiving the proper µA signal
from the cad cell.
5.
1.
There is air in the suction oil line
due to leaks at the fittings
1.
2.
There is air trapped in a high point
in the pressure oil line.
2.
10-4
Follow the procedures listed in the
next problem.
Clean and check the condition of
the cad cell and cad cell wires.
Check that the blue and black
wires are connected properly into
the primary base (terminals 11
and 12)
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.
The photo current is measured
with a direct current ammeter in
series with the photo unit (+ pole
on terminal 12). With a flame,
cad cell current must be between
50 µA and 210 µA at 240V.
With no flame, the measured
photo current must be maximum
5 µA at 230V.
Follow the procedures in Section
5 to vacuum test the pump. Reinstall and properly seal the
suction line fittings to eliminate air
leaks.
Follow instructions in Section 4 to
bleed the air out of the pressure
oil line.
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
PROBLEM
Burner ignites and Burner shuts off on
reset sometime later during the day or
night.
POSSIBLE CAUSE
POSSIBLE ACTION(S)
1.
There is air in the fuel supply.
1.
2.
2.
3.
The primary control is not
receiving the proper µA signal
from the cad cell.
There is insufficient air pressure.
4.
The heater block is cold.
4.
5.
The electrodes are fouled.
5.
10-5
3.
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.”)
Check for proper µA signal.
Follow the procedures in the
previous problem (top, page 10-4)
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.
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.
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.
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
PROBLEM
Pump will not prime and Pump motor is
running.
POSSIBLE CAUSE
POSSIBLE ACTION(S)
1.
There is a leak(s) in the suction
line.
1.
2.
2.
3.
The pump is not installed so it will
fill with oil during the priming
process.
The pump gears are dry.
4.
The pump seal is damaged.
4.
5.
The ball valve is closed.
5.
6.
The canister filter is dirty.
6.
7.
The check valve is dirty.
7.
8.
The pump is damaged or worn
out.
8.
10-6
3.
Follow the specifications in
Section 4 to make sure the
suction line is installed properly
and that all fittings are 100%
airtight.
Make sure the pump head is filled
with oil prior to starting the pump.
See Section 5.
Follow the procedure in Section 5
to fill the oil line and prime the
pump.
With the pump not running, wipe
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.
Open the ball valve on the suction
line.
Refer to Section 9 to clean the
canister filter.
Refer to Section 9 to clean the
check valve.
Replace the pump.
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
PROBLEM
POSSIBLE CAUSE
POSSIBLE ACTION(S)
1.
There is NO power on the
pump circuit from the burner.
1.
2.
The pump motor has shut off
on thermal overload.
2.
Blower motor runs all the time.
1.
Blower motor circuit is wired
incorrectly.
1.
Blower motor will not run.
1.
The blower motor is not wired
correctly.
1.
2.
The Blower / Fan switch is
defective.
The blower motor has
overheated and shut down on
thermal reset.
2.
3.
Pump will not prime and Pump motor is
NOT running.
3.
10-7
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 motor circuit.
Check the blower motor wiring. Refer
to the wiring diagram and ladder
schematic in Appendix B. Follow the
directions in Section 6 to test for
proper fan operation. If the fan does
not operate, shut OFF power to the
furnace and call your Clean Burn
dealer for service.
Replace the Blower / Fan switch.
Reset the red button on the motor
thermal reset. Check voltage and
amperage draw of the blower motor.
Call your dealer if the problem
persists.
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
10-8
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
APPENDIX A
Detailed Furnace Specifications
Furnace Technical Specifications
Furnace Model
CB-3500
CB-5000
Maximum Input
103 KW (350,000 BTUH)
At 9.5 LPH (2.5 GPH)
147 KW (500,000 BTUH)
At 13.5 LPH (3.6 GPH)
#2, #4, #5 fuel oils
Used crankcase oil
Used ATF
Used hydraulic oil
#2, #4, #5 fuel oils
Used crankcase oil
Used ATF
Used hydraulic oil
Cabinet Dimensions
LXWXH
147cm X 88cm X 90cm
(58” X 34 ½” X 35 ½”)
LXWXH
155cm X 97cm X 100cm
(61” X 38 ¼” X 39 ½”)
Furnace Dimensions with
Blower and Burner
LXWXH
188cm X 88cm X 154cm
(74” X 34 ½” X 60 ½”)
LXWXH
198cm X 97cm X 184cm
(78” X 38 ¼” X 72 ½”)
380 Kg (836 lbs.)
470 Kg (1036 lbs.)
Listed Fuels
Approximate Weight
Mounting
Electrical Requirements
- ceiling hung
- non-combustible platform
- ceiling hung
- non-combustible platform
230 Volts / 50 Hz
230 Volts / 50 Hz
Maximum Fuse Size
20 Amps
25 Amps
Wall Thermostat
24 Volts
24 Volts
Suntec A2RA-7710
Suntec A2RA-7710
1/20 HP
1/20 HP
CCW shaft end
CCW shaft end
Lenz DH-750-100
Lenz DH-750-100
20 cm (8”)
25 cm (10”)
2 HP
2 HP
Blower Motor Relay
30 Amp double pole
30 Amp double pole
Pump and D-I Relay
20 Amp single pole
20 Amp single pole
Blower / Fan Switch
F180
F180
Fan Limit Control
Honeywell L4064B
Honeywell L4064B
Fan Limit Settings
Hi Limit – 99 oC (210oF)
Fan On – 49 oC (120 oF)
Fan Off – 38 oC (100 oF)
Hi Limit – 99 oC (210oF)
Fan On – 49 oC (120 oF)
Fan Off – 38 oC (100 oF)
L290 (auto reset)
L290 (auto reset)
Oil Pump
Pump Motor
Pump Motor Rotation
Canister Filter
Stack Size
Blower Motor HP
Hi-Temp Limit Switch
A-1
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
Burner Technical Specifications
NOTE: These burner specifications apply to both furnace models, CB-3500 and CB-5000, except
where differences are noted within the table.
Burner
CB-500-CE-5W Series
Ignition Transformer
Danfoss (14,000 Volts)
Nozzle
Delavan 9-5 (CB-3500)
Delavan 9-11 (CB-5000)
Burner Motor
1/10 HP 2800 RPM
With Centrifugal Switch
Burner Motor Rotation
CCW Shaft End
Compressed Air Requirements
CB-3500 - 0.06 CMM @ 1.7 Bar
(2.0 SCFM @ 25 psi)
CB-5000 - 0.07 CMM @ 1.7 Bar
(2.5 SCFM @ 25 psi)
Oil Primary Control
Danfoss
Heater Element in Preheater Block
450 Watts
Air Pressure Switch
MPL 808
60oC (140oF)
Setting for Preheater Thermostat
A-2
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
Furnace Dimensions (CB-3500)
53 3/4"
(137 cm)
20"
(51 cm)
7 1/4"
(18 cm)
8 1/8"
(21 cm)
TOP VIEW
(LESS BLOWER AND LOUVERS)
SECURE ANGLE TO FURNACE
WITH (4) SCREWS (2 PLCS.)
27" (WITH GUARDS)
(69 cm)
22 3/4"
(58 cm)
25"
(64 cm)
36 1/4"
(92 cm)
4 1/2"
(11 cm)
20 "
(51 cm)
9 3/8"
(24 cm)
18 1/4"
(46 cm)
15"
(38 cm)
Danfoss
Ty pe BHO 64
Nr . 057H7036
35 1/2"
(90 cm)
AIR DISCHARGE
220-240V 50-60H z 3W
ts 10s
6 3/4"
(17 cm)
SIDE VIEW
7 3/8"
(19 cm)
FRONT VIEW
SECURE CHANNEL TO FURNACE
WITH (2) BOLTS (2 PLCS.)
34 1/2"
(88 cm)
58"
(147 cm)
I88931
74" (WITH BURNER)
(188 cm)
A-3
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
Furnace Dimensions (CB-5000)
58"
(147 cm)
2 1/2"
(6 cm)
24"
(61 cm)
21 3/4"
(55 cm)
7 1/8"
(18 cm)
8 1/4"
(21 cm)
TOP VIEW
(LESS BLOWER AND LOUVERS)
SECURE ANGLE TO FURNACE
WITH (4) SCREWS (2 PLCS.)
31 3/4" (WITH GUARDS)
(81 cm)
27"
(69 cm)
33"
(84 cm)
40"
(102 cm)
11"
(28 cm)
24"
(61 cm)
18 1/2"
(47 cm)
Danfoss
Ty pe BH O 64
Nr . 057H7036
220-240V 50-6 0Hz 3W
ts 10s
39 1/2"
(100 cm)
AIR DISCHARGE
8"
(20 cm)
SIDE VIEW
9"
(23 cm)
FRONT VIEW
SECURE CHANNEL TO FURNACE
WITH (2) BOLTS (2 PLCS.)
38 1/4"
(97 cm)
61 1/8"
(155 cm)
I88932
78" (WITH BURNER)
(198 cm)
A-4
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
A-5
33
A-6
34
12
35
13
Figure A1 - Burner Component Detail
17
14
2
0
1
2
3
5
6
psi
7
8
10
11
9
12
13
14
15
15
4
3
0
10
4
psi
20
60
30
40
16
50
18
10
19
8
7
20
I88933
26
9
27
2
5
6
7
8
10
11
12
13
24
25
4
21
1
SEE ILLUSTRATION
I88852 FOR PART
NUMBERS.
28
9
USE ON THE
CB−5000
BURNER ONLY
11
1
5
6
22
29
30
31
23
32
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
Burner Components
CB-3500 with CB-500-CE
CB-5000 with CB-550-CE
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
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
C.B. Part#
33521
33523
33522
26122
33526
26121
33524
26120
33528
33525
26095
11359
32178
32235
32179
32253
33161
33166
33338
31113
26044
33337
26053
11335
13156
11265
SEE NOTE
11334
11285
33534
26052
11308
11427
26106
11410
26104
Component Description
BURNER CONTROL, BHO 64
FRONT PLATE FOR BHO 64
BASE FOR BHO 64
PLATE, DANFOSS PRIMARY
PRIMARY CABLE WITH PLUG
COVER, DANFOSS IGNITER
DANFOSS IGNITER, TYPE EBI 230V
PLATE, DANFOSS IGNITER
SPARK-PLUG CABLE
PHOTO UNIT LD
AIR INTAKE OUTER PLATE
AIR INTAKE INNER PLATE
OIL GAUGE 0-15 PSI
FEMALE ELBOW (3/16 T x 1/8 NPT)
AIR GAUGE 0-60 PSI
FEMALE ELBOW (1/8 TP x 1/8 NPT)
HOUR METER (50 Hz)
GREEN LIGHT (POWER) 230V
AMBER LIGHT (PUMP) 230 V
FAN SQUIRREL CAGE
MOTOR MOUNT PLATE
BLOWER MOTOR (230 V)
RIGHT SIDE COVER
HOUSING (INCLUDES ITEM 26)
HEATER BLOCK ASSEMBLY
COVER-HINGED
NOZZLE ADAPTER ASSEMBLY
HINGE MOUNTING PLATE
CONNECTOR RECEPTACLE
CONNECTOR PLUG
LATCH BRACKET
RETENTION HEAD - CB-3500
RETENTION HEAD - CB-5000
LOCKING LEVER
OUTER DRAFT PLATE
INNER DRAFT PLATE ASSEMBLY
A-7
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
Burner Components (continued)
58
(8)
57
31
56
32
(8)
55
60
54
1
3
53
4
2
33
34
59
35
52
36
51
9
50
5
11
37
39
40
47
27
(2)
12
6
(4) 17
30
38
48
(2)
10
30
49
8
7
28
45
41
26
29
42
46
43
44
15
14
1
2
3
4
5
6
7
13
25
8
9
10
11
12
13
16
22 (2)
17
20
18
21
19
23
24
Figure A3 - Preheater Block Assembly Component Detail
A-8
I88852
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
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#
Qty.
34169
33527
34165
32000
32002
13150
32007
33375
33381
33418
32199
32050
32189
32043
54020
32201
33247
34036
26059
33278
33057
26090
32190
32202
32201
33289
33378
32325
54020
33011
32359
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
33384
33320
33321
33371
26107
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
2
1
4
1
1
1
1
2
1
1
1
1
1
1
1
2
8
8
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
1
Component Description
ELECTRODE SCREW - 10-32 x 3/4
PLUG IN ELECTRODE
WASHER
9 - 5 NOZZLE - CB-3500
9-11 NOZZLE - CB-5000
NOZZLE ADAPTOR
PLUG - 1/8 NPT
140 WATTS HEATER
INSULATED CAP CRIMP CONNECTOR
THERMOSTAT L-130
PLUG - 1/16 NPT
SWIVEL FITTING
HEX NIPPLE - 1/8 NPT x 1-1/2
MALE CONNECTOR - 3/16T x 1/8 NPT
3/16 COPPER TUBING(OIL GAUGE LINE)
MACH. SCREW PHILLIPS HD. 6-32 x 3/8 Z
TERMINAL BLOCK
MACH. SCREW PHILLIPS HD. 6-32 x 1/4 Z
TERMINAL BLOCK BRACKET
THERMAL CUT-OFF
AIR PRESSURE SWITCH
HEATER BLOCK
HEX NIPPLE - 1/8 NPT x 2
FEMALE ELBOW (FOR 1/4" AIR LINE)
FEMALE ELBOW (FOR 3/8" OIL LINE)
PRE-HEATER ELEMENT (450 WATTS)
PROVING SWITCH (NORMALLY OPEN)
MALE ELBOW 1/8 x 1/8 NPT (FOR AIR GAUGE LINE)
3/16 COPPER TUBING(OIL GAUGE LINE)
HEATER BLOCK THERMOSTAT(NORMALLY CLOSED)
REGULATOR SURFACE MOUNT
REGULATOR MOUNTING SCREW
LOCK WASHER #8 Z
REGULATOR THREADED STEM
HEX NU T - 10-32 Z
BONNET
DIAPHRAM RING
CAP AND BALL ASSEMBLY
COMPRESSION SPRING
DIAPHRAM
BRASS POPPET SEAT
POPPET ‘O” RING
POPPET VALVE
POPPET SPRING
BASE
REGULATOR KIT COMPONENTS
REGULATOR OUTER “O” RING
REGULATOR INNER “O” RING
SOLENOID INNER “O” RING
SOLENOID OUTER “O” RING
MANIFOLD MOUNT SOLENOID BODY
BODY “O” RING
PLUNGER ASSEMBLY
PLUNGER GUIDE ASSEMBLY
FLUX PLATE
WASHER SEAL
COIL (230 V)
COIL HOUSING
NUT
AIR/OIL SOLENOID ASSEMBLY (230 V)
REG. SQUARE CAP
A-9
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
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
VI E
W
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.
5 mm (3/16") GAP
BETWEEN
ELECTRODES &
NOZZLE
CRITICAL DIMENSION:
NOZZLE MUST BE
3 mm (1/8") AHEAD OF
THE DISK. NOZZLE MUST
NOT BE BEHIND THE DISK.
3 mm (1/8")
SPARK GAP
SIDE VIEW A−A
FRONT VIEW B−B
Figure A4 - Burner Electrode Specifications with Spinner Retention Head
A-10
I88850
Operator's Manual: Models CB-3500 and CB-5000 (230 V /50 Hz)
Burner Components (continued)
DISTRIBUTOR
HEAD
NOZZLE SIZE IS
STAMPED ON
FLAT OF
NOZZLE HEAD
ORIFICE
STEM
O−RING
I88678
Model
CB-3500
CB-5000
Nozzle Size
Delavan 9-5
Delavan 9-11
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.
2.
3.
4.
5.
6.
7.
8.
Unscrew the stem from the nozzle head.
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.
Flush all components with WD-40 to remove oil residues.
Reassemble the nozzle components. When tightening the stem, just barely "snug" it down.
DO NOT overtighten.
Check the O-ring on the nozzle stem. Replace the O-ring if it is in the least bit cut or
deformed.
Lubricate the O-ring on the nozzle stem with a couple of drops of new motor oil, then reinstall the nozzle.
Check the electrodes for proper gap and clearances.
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 A5 - Cleaning the Nozzle
A-11
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
CABINET
CB-3500 CE & R
(CE # 11432 and R # 11508)
DETAIL A
DETAIL B
DETAIL C
I88934
A-12
Operator's Manual: Models CB-3500 and CB-5000 (230 V /50 Hz)
CB-3500 Furnace Components
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
Part #
31091
21010
24077
34028
21057
24069
21102
24068
34126
24116
34121
21039
70418
24182
34397
34398
34399
11213
34118
34119
21056
34095
24075
34009
14102
34051
21101
32311
32039
13017
13128
32304
32303
32245
11033
11143
34120
11325
21076
24103
21114
33150
12294
33145
33210
33486
33273
21173
33299
Description
DUCT CAP ROUND 8"
STACK PIPE FLASH RING
SIDE - RIGHT
5/16-18 X 3/4 SERR HEX FLANG
HINGE BRACKET
DIVIDER
FLUE TUBE CB3500/CB5000
BASE
3/8-16 X 2 HHCS GR-5
FIRE DRUM
5/16-18 TOP LOCK NUT S.S.
.438 X 1.5 X .135 FLAT WASHER
COMB CHAMBER BAND KIT - 3500
REINFORCEMENT BAND - 3500
3/8 X 1 HHCS - SS
3/8 SERRATED FLANGE NUT - SS
3/8 SPLIT LOCK WASHER - SS
DOOR APRON
5/16-18 X 3/4 HEX WASHER HEAD
3/8-16 X 3 HHCS GR-2 ZINC
HINGE BRACKET
3/8-16 STOVER L/N GR-B CAD/WAX
OUTSIDE DOOR
3/8-16 HEX SERR FLANGE NUT PLT
CB-3500 HOOK-UP A
5/16-18 X 1 1/2 HHCS GR-2 ZINC
CONNECTOR BLOCK
ACCUMULATOR
ADAPT 1/4 OD X 1/8 P
AIR LINE ASSEMBLY
OIL LINE A
NUT - LONG
SLEEVE
SWIVEL 1/4NPTM,1/4NPTF
HINGE BRACKET W A
BURNER MOUNT W A
5/16-18 X 2 3/4 CARR BOLT S.S.
INSPECTION DOOR A
PORT CAP
DOOR INSULATION
LID
CONNECTOR PLUG
JUNCTION BOX INTERNATL 5 WIRE A.
SCREW LUG
CONT 230V 50HZ 2POLE
TERMINAL BLOCK ASSY.
CONNECTOR 90 DEG. SNAP-TITE
BOX - JUNCTION
PLASTIC WIRE PROT
Item
#
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
A-13
Part #
33544
33331
24080
33245
24119
14173
24079
24108
24114
24092
14160
33230
25115
33288
24082
24083
24078
11154
24100
33340
33286
33338
Description
RELAY-COIL 24VAC 30A
TERMINAL BLOCK 4 POST
SIDE - LEFT
FAN LIMIT SWITCH
COVER
MOTOR HARNESS, CB3501
TOP
ORIFICE
3500 DISCHARGE - ANGLE BOTTOM
LOUVER
DIFFUSER OUTLET 3500 A
FAN SWITCH - SURFACE MOUNT 180
PLATE
AUXIL HI LIMIT-AUTO RESET 290
BLOWER ANGLE
BLOWER CLOSING ANGLE
BACK
TARGET (REFRAC) DISC ASSY
RING
TRANSFORMER 24-240V
SWITCH DPDT ON-ON
AMBER LIGHT 220V
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
CABINET
CB-5000 CE & R
(CE #11433 and R # 11509)
DETAIL A
DETAIL B
DETAIL C
I88935
A-14
Operator's Manual: Models CB-3500 and CB-5000 (230 V /50 Hz)
CB-5000 Furnace Components
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
Part #
31092
25032
25085
34028
21057
25110
21102
25078
34126
25107
70419
25130
34397
34398
34399
34121
21039
11213
34118
34119
34095
21056
11033
14103
34051
21101
32311
32039
13017
13129
32304
32303
32245
34120
11143
11325
21076
34009
25083
25119
25088
33150
21114
12229
33486
33145
33210
33340
33273
Description
DUCT CAP ROUND 10" - 28 GA.
STACK PIPE FLASH RING DH
SIDE - RIGHT
5/16-18 X 3/4 SERR HEX FLANG
HINGE BRACKET
DIVIDER
FLUE TUBE CB3500/CB5000
BASE
3/8-16 X 2 HHCS GR-5
FIRE DRUM
COMB CHAMBER BAND KIT - 5000
REINFORCEMENT BAND - 5000
3/8 X 1 HHCS - SS
3/8 SERRATED FLANGE NUT - SS
3/8 SPLIT LOCK WASHER - SS
5/16-18 TOP LOCK NUT S.S.
.438 X 1.5 X .135 FLAT WASHER
DOOR APRON
5/16-18 X 3/4 HEX WASHER HEAD
3/8-16 X 3 HHCS GR-2 ZINC
3/8-16 STOVER L/N GR-B CAD/WAX
HINGE BRACKET
HINGE BRACKET W A
CB-5000 HOOK-UP A
5/16-18 X 1 1/2 HHCS GR-2 ZINC
CONNECTOR BLOCK
ACCUMULATOR
ADAPT 1/4 OD X 1/8 P
AIR LINE ASSEMBLY
OIL LINE A
NUT - LONG
SLEEVE
SWIVEL 1/4NPTM,1/4NPTF
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
OUTSIDE DOOR
DOOR INSULATION
SIDE - LEFT
CONNECTOR PLUG
LID
JUNCTION BOX INTERNATL A
TERMINAL BLK ASSY.
SCREW LUG
CONT 230V 50HZ 2POLE
TRANSFORMER 24-240V
CONNECTOR 90 DEG. SNAP-TITE
Item
#
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
A-15
Part #
33299
21173
33286
12215
33245
25114
25087
25070
21107
24034
14161
25067
25068
11154
25086
25100
33230
25115
33288
33338
33544
33331
Description
PLASTIC WIRE PROT
BOX - JUNCTION INTL 5 WIRE
DPDT ON-ON
MOTOR HARNESS (CB5001)
FAN LIMIT SWITCH
COVER
TOP
ORIFICE PLATE
5000 DISCHARGE - ANGLE BOTTOM
LOUVER
DIFFUSER OUTLET 5000 A
BLOWER FLANGE
BLOWER CLOSING ANGLE
TARGET (REFRAC) DISC ASSY
BACK
RING
FAN SWITCH - SURFACE MOUNT 180
PLATE
AUXIL HI LIMIT-AUTO RESET 290
AMBER LIGHT 220V
RELAY-COIL 24V 30A
TERMINAL BLOCK 4 POST
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
BLOWER ASSEMBLY
CB-3500 CE & R
(CE # 11436 and R # 11514)
I88936
A-16
Operator's Manual: Models CB-3500 and CB-5000 (230 V /50 Hz)
CB-3500 Blower Components
Item #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Part #
31228
34165
31084
25046
34159
31194
31192
31072
31180
210131
21112
11125
34116
34328
34290
210129
31178
33373
34072
24087
31187
11436
11514
Description
BLOWER WIRE GUARD 3500/5000
#12 X 9/16 BONDED NEOPRENE
BLOWER
ANGLE FRONT
1/4 X 3/4 SLOTTED IND HEX
1" SHAFT W/KEYWAY (15")
REPLACEMENT BEARING PACKAGE
BLOWER PULLEY; 10.75" OD
BELT V B58 (CB-3500I-2 HP MTR)
KEY 1/4 X 1 1/4
TAB
BELT GUARD ASSY
10 X 5/8 HEX WASHER HEAD TEK Z
5/16-18 X 3/4 HEX HEAD FLANGE
5/16-18 X 3/4 SQUARE HEAD
KEY SQ. 3/16 X 1
BK-60 PULLEY 5/8" BORE
BLOWER MOTOR 2HP (230V/50HZ)
5/16-18 STOVER TOP LOCK NUT
MOTOR MOUNT
MOTOR MOUNT BRACKET
ACCESS GRP CB-3500 CE
ACCESSORY GROUP CB-3500-R-MP
A-17
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
BLOWER ASSEMBLY
CB-5000 CE & R
(CE # 11437 and R # 11515)
I88937
A-18
Operator's Manual: Models CB-3500 and CB-5000 (230 V /50 Hz)
CB-5000 Blower Components
Item #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Part #
31228
34165
31056
25046
31195
31192
31072
210304
21112
11238
34116
31088
34159
31188
34290
210129
31179
33373
34072
24087
34328
11437
11515
Description
BLOWER WIRE GUARD 3500/5000
#12 X 9/16 BONDED NEOPRENE
BLOWER
ANGLE FRONT
1" SHAFT W/KEYWAY (18")
REPLACEMENT BEARING PACKAGE
BLOWER PULLEY; 10.75" OD
1/4 SQ X 3" KEY
TAB
BELT GUARD WA
10 X 5/8 HEX WASHER HEAD TEK Z
V BELT B-64
1/4 X 3/4 SLOTTED IND HEX
MOTOR MOUNT BRACKET
5/16-18 X 3/4 SQUARE HEAD
KEY SQ. 3/16 X 1
BK-57 PULLEY 5/8" BORE
BLOWER MOTOR 2HP (230V/50HZ)
5/16-18 STOVER TOP LOCK NUT
MOTOR MOUNT
5/16-18 X 3/4 HEX HEAD FLANGE
ACCESS GRP CB-5000 CE
ACCESSORY GROUP CB-5000-R-MP
A-19
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
A-20
FAN
POWER
220 VOLT
LIGHT
BURNER
PUR
B-1
RED
GREEN
FOR CB−3500, CB−5000 WITH DRAFT INDUCER.
5
L2
L2
L2
3
L1
L1
WH / BL STRIPE
BLOWER
SWITCH
N.O.
H44118
DOUBLE
POLE
RELAY
CR 1
OR
BK
BL
YEL
SEC :
PRI :
24 V
240 V
TRANSFORMER
WALL
THERMOSTAT
DRAFT
INDUCER
220 VOLTS
OIL
PUMP
220 VAC
50 Hz
OPTION FOR CB−3500
GROUND
NEUTRAL
HOT LEG
JUMPER
OPTIONAL
STACK
SAFETY
SWITCH
NOTE TO ELECTRICIAN:
CB−3500 / CB−5000 REQUIRE A
2 WIRE 220 VOLTS−50 Hz LINE
AND A GOOD GROUND WIRE.
WH / RED STRIPE
HI−TEMP
SWITCH
N.C.
Wiring Diagrams
BLACK
220 VOLTS
BLOWER
MOTOR
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
APPENDIX B
Figure B1 - CB-3500/CB-5000 Furnace Wiring Diagram
(with Draft Inducer - standard for CB-5000; optional with CB-3500)
WHITE
Figure B2 - CB-3500/CB-5000 with CB-500 Series Burner
L130 NC
TEMP. SW.
INSTALLED
ON NOZZLE
ADAPTER
RED
H44107
BLACK
BLUE
FORMER
TRANS−
BLACK
BLACK
6
G
4
8
1
WHITE
CR
ORANGE
GREY
3
2
BLACK
140
BLACK
WHITE
JUMPERS
BLACK
BLACK
PULL THESE WIRES INTO
BURNER BOX & INSTALL INSUL
CAP CRIMP CONNECTOR
RED
BLACK
THERMAL CUT−OFF 199°
DANFOSS OIL
PRIMARY
12
11
BRN
140 WATTS HEATER ELEMENT
IN NOZZLE ADATER
CAD CELL
AIR
SOLENOID
BLUE
WHITE
YELLOW
MOTOR
BURNER
1 2 3 4
W
H
I
T
E
GREEN
BROWN
CAPACITOR
7 8
RED
9 10 11 12 13
BLACK
PURPLE
5 6
GREEN
LIGHT
OIL
SOLENOID
BLUE
JUMPER
B-2
CENTRIFICAL
SWITCH
CONNECTOR (FACE)
AMBER
LIGHT
PREHEATER THERMOSTAT
WHITE
BROWN
BLACK
BLUE
WHITE
AIR
AIR
SWITCH
N.O.
METER
HOUR
(OPTIONAL)
COMPRESSOR
BLOCK HEATER 400 WATTS
WHITE
PROVING
SWITCH
N.O.
B
L
A
C
K
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
Wiring Diagrams
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
INTERNATIONAL CB 3500 & CB 5000
OPTIONAL SERVICE
DISCONNECT SWITCH
5 PRONG, DANFOSS PIMARY
WITH CENTRIFUGAL SWTCH
HOT
H44119
DWG. No.............
NEUTRAL
TRANSF.
230 V BLOWER MOTOR
24 VOLTS
STACK SAFETY SWITCH
M1
CR
1
BLOWER SWITCH
(METAL SURFACE: 33230)
230 VOLTS COIL
MC
R1
FAN
CR
HI LIMIT
A
HI LIMIT TEMP SWITCH N/C
(ON METAL SURFACE: 33390)
PUMP ON
RUN
DRAFT INDUCER
(OPTIONAL)
- PRIME
F
U
R
N
A
C
E
GRN
PUR
RD
WHT
BK
WHT
BK
PUR
RD
OIL PUMP MOTOR
M2
CAD
CELL
PROVING SWITCH
120°
BK
- CONNECTION TO
CUSTOMER POWER
OR
3
DANFOSS OIL
PIRMARY
JUMPER
8
GRN
BL
11
BK
12
1
G
6
BR
WHT
2
4
GRAY
BL
CR
2
SPARK GAP
IGNITION TRANSF.
AIR COMP (OPTIONAL)
AIR SOL.
BURNER MOTOR
M3
CR
AIR PRESSURE
OIL SOL.
PUMP ON
A
CENTRIFUGAL SWITCH
N. C. HELD OPEN
ACTUATED BY BURNER MOTOR
DWG. No.
DATE:
HOUR METER
H44119
A.D.
12/06/06
DATE
BLOCK THERMOSTAT
450 WATTS BLOCK HEATER
NOZZLE ADAPTOR THERMOSTAT
140 WATTS NOZZLE HEATER
BY
POWER ON
B-3
B
U
R
N
E
R
Figure B3 - Ladder Schematic for Models CB-3500 / CB-5000 (230 Volts / 50 Hz)
WALL THERMOSTAT
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
Wiring Diagrams (continued)
WIRING DIAGRAM FOR CB−3500 AND CB−5000
230 V 50Hz POWER FROM OIL PUMP CIRCUIT
(SEE FURNACE SCHEMATIC)
INSULATE
µ
GEARMOTOR ROTATION IS CCWSE AS SHOWN. TO
REVERSE ROTATION, REVERSE RED & BLUE LEADS
I88524
Figure B4 - Metering Pump Wiring Schematic
B-4
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
APPENDIX C
Additional Installation Requirements
The following activities must also be accomplished for furnace installations in the United Kingdom:
•
•
Installing a cover over the oil/air regulators on the burner
Installing a fire valve above the burner
Instructions and/or drawings for these activities are provided in this Appendix.
Installing a Cover over the Oil/Air Regulators
22
0-2
40
50
3W
Hz 10s
-60 ts
ss
n fo
64
Da
HO 3 6
0
B
pe H7
Ty 0 5 7
Nr.
Figure C1 - Installing a Cover over the Oil/Air Regulators on the Burner
C-1
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
Installing a Fire Valve
Install a fire valve element in a position above the burner as shown in Figure C2 to provide adequate
protection in accordance with BS 5410 Parts 1 and 2.
FUSIBLE LINK
3W s
10
220
Dan
-240
50
z
-60H ts
s
fos
64
HO 36
e B 70
Typ 057H
Nr.
I88905
Figure C2 - Installation of a Fire Valve
C-2
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
APPENDIX D
Furnace Service Record
Furnace Purchased:
Date __________
From (name/phone)________________________________
Furnace Installed:
Date ___________
By (name/phone)__________________________________
Furnace Inspected:
Date __________
By (name/phone)__________________________________
Draft Readings
(date / reading)
Service Record
(date / initials of serviceman)
Burner
Canister
Filter
Stack
Chamber
& Flues
Stack
*A.P.M. = Annual Preventative Maintenance of Burner (Burner Tune-up)
D-1
Oil Tank
A.P.M.*
Operator's Manual: Models CB-3500 and CB-5000 (230 V / 50 Hz)
D-2
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement