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

OPERATOR'S MANUAL

CLEAN BURN MODELS:

CB-200-CTB COIL TUBE BOILER with CB-525-S2 Burner & Metering Pump

CB-350-CTB COIL TUBE BOILER with CB-551-H3 Burner & Metering Pump

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

U.L. Listed Used Oil

Burning Appliance

#MH15393

Manufactured & Tested to meet

ASME Section IV

I88460−C

PUBLICATION DATE: 1/24/11, Rev. 11 CLEAN BURN PART #43146

WARNING: DO NOT assemble, install, operate, or maintain this equipment without first reading and understanding the information provided in this manual. Installation and service must be accomplished by qualified personnel. Failure to follow all safety precautions and procedures as stated in this manual may result in property damage, serious personal injury or death.

IMPORTANT FOR U.S. INSTALLATIONS: All installations must be made in accordance with state and local codes which may differ from the information provided in this manual. Save these instructions for reference.

IMPORTANT FOR CANADIAN INSTALLATIONS: The installation of this equipment is to be accomplished by qualified personnel and in accordance with the regulation of authorities having jurisdiction and CSA Standard B 139,

Installation Code for Oil Burning Equipment.

WARRANTY INFORMATION

Clean Burn, Inc., MANUFACTURER, hereby warrants that MANUFACTURER’s products shall be free from defect in material and workmanship under normal use according to the provisions and limitations herein set forth. MANUFACTURER warrants the burner and Coil Tube Boiler for a period of one (1) year from the date of purchase by the original purchaser. The steel coil tube section of the boiler only shall carry a limited warranty for a period of five (5) years from the date of purchase by the original purchaser.

LIMITATIONS:

The obligation of MANUFACTURER for breach of warranty shall be limited to products manufactured by MANUFACTURER (1) that are installed, operated and maintained according to MANUFACTURER's instructions furnished and/or available to the purchaser upon request; (2) that are installed according to all other applicable Federal, State and local codes or regulations; and (3) that the purchaser substantiates were defective in material and workmanship notwithstanding that they were properly installed and correctly maintained as set forth above and were not abused or misused.

The obligation of MANUFACTURER shall be limited to replacing or repairing the defective product, at the option of the MANUFAC-

TURER. MANUFACTURER shall not be responsible for any labor or costs of removal or reinstallation of its products and shall not be liable for transportation costs to and from its plant at Lancaster, Pennsylvania.

Use of parts for modification or repair of the product or any component part thereof not authorized or manufactured by MANUFAC-

TURER specifically for such product shall void this warranty.

This warranty shall not apply to any damage to or defect in any of MANUFACTURER's products that is directly or indirectly caused by (1) force majeure , Act of God or other accident not related to an inherent product defect; or (2) abuse, misuse or neglect of such product, including any damage caused by improper assembly, installation, adjustment, service, maintenance or faulty instruction of the purchaser.

Other than as expressly set forth hereinabove, MANUFACTURER makes no other warranty, express or implied, with respect to any of

MANUFACTURER's products, including but not limited to any warranty of merchantability or fitness for a particular purpose.

And in no event shall MANUFACTURER be responsible for any incidental or consequential damages of any nature suffered by purchaser or any other person or entity caused in whole or in part by any defect in any of MANUFACTURER's products. Any person or entity to whom this warranty extends and who claims breach of warranty against MANUFACTURER must bring suit thereon within one year from the date of occurrence of such breach of warranty or be forever barred from any and all legal or other remedies for such breach of warranty.

MANUFACTURER is not responsible for and hereby disclaims any undertaking, representation or warranty made by any dealer, distributor or other person that is inconsistent with or in any way more expansive than the provisions of this limited warranty.

This warranty grants specific legal rights and shall be read in conformity with applicable state law. In some jurisdictions, the applicable law mandates warranty provisions that provide greater legal rights than those provided for herein. In such case, this limited warranty shall be read to include such mandated provisions; and any provision herein that is prohibited or unenforceable in any such jurisdiction shall, as to such jurisdiction, be ineffective to the extent of such prohibition or unenforceability without invalidating the remaining provisions and without affecting the validity or enforceability of such provision in any other jurisdiction(s).

TRADEMARKS

The Clean Burn logo is a trademark of Clean Burn, Inc. All other brand or product names mentioned are the registered trademarks or trademarks of their respective owners.

COPYRIGHT

Copyright © 2010 Clean Burn, Inc. All rights reserved. No part of this publication may be reproduced, or distributed without the prior written permission of Clean Burn, Inc. 1835 Freedom Road, Lancaster, PA 17601. Subject to change without notice.

TABLE OF CONTENTS

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

1-1

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

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

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

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

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

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

2-1

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

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

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

Warranty Registration ......................................................................................................... 2-2

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

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

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

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

3-1

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

Single Boiler Assembly Component Detail .......................................................................... 3-2

Single Boiler Assembly ....................................................................................................... 3-4

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

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

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

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

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

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

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

Mounting the Burner .................................................................................................. 3-12

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

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

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

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

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

4-1

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

Typical Installation Diagrams ........................................................................................ 4-2

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

Oil Tank Installation Specifications ...................................................................................... 4-6

Installing the Tank Vent and Emergency Vent ............................................................... 4-7

Installing the Metering Pump ............................................................................................... 4-8

Preparing for Installation .............................................................................................. 4-8

Standard Mounting: Vertical Positioning ....................................................................... 4-8

Alternate Mounting: Horizontal Positioning ................................................................. 4-10

Connecting Water to the Coil Tube Boiler ......................................................................... 4-11

Filling the CTB with Water ........................................................................................ 4-11

Installing the Suction Oil Line Components ........................................................................ 4-12


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

Installing the Pressure Relief Oil Line Back to the Tank ..................................................... 4-15

Installing the Pressure Oil Line Components ...................................................................... 4-16

Installing the Compressed Air Line .................................................................................... 4-16

Wiring the Coil Tube Boiler .............................................................................................. 4-17

Wiring to the Oil Pump ..................................................................................................... 4-18

Wiring the Load Loop Circulator ...................................................................................... 4-18

Installing the Stack ........................................................................................................... 4-19

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

Installing the Barometric Damper ............................................................................... 4-21

Installing the Stack Safety Switch For Canadian Installations ....................................... 4-23

Resetting the Stack Safety Switch ........................................................................ 4-24

Understanding the Function of the Stack Safety Switch ......................................... 4-24

Installing the Stack Penetration ................................................................................... 4-25

Installing the Exterior Stack ........................................................................................ 4-25

Installing the Stack Cap ............................................................................................. 4-25

Installing the Draft Inducer ................................................................................................ 4-25

Installing the Wall Thermostat ........................................................................................... 4-27

Replacing the Wall Thermostat Batteries .................................................................... 4-27

Inspecting the CTB Installation ......................................................................................... 4-28

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

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

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

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

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

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

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

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

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

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

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

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

Resetting the Oil Primary Control (CB-200-CTB) .............................................................. 7-1

Resetting the Oil Primary Control (CB-350-CTB and CB-500-CTB) ................................. 7-2

Primary Control Operation/Troubleshooting Guide (CB-350-CTB and CB-500-CTB) ....... 7-4

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

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

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

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

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

Combustion Air Requirements ..................................................................................... 8-3

Adjusting Draft Over Fire With A Draft Inducer Installed .................................................... 8-3

Air for Combustion and Ventilation ..................................................................................... 8-4


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

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

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

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

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

Cleaning the Check Valve .................................................................................................. 9-3

Cleaning Ash from the CTB ................................................................................................ 9-4

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

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

Cleaning and Maintaining the Draft Inducer ......................................................................... 9-6

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

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

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

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

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

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

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

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

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

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

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

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

APPENDIX A

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

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

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

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

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

CTB Dimensions ........................................................................................................ A-4

Single Boiler Assembly Component Detail ................................................................. A-10

Burner Components ................................................................................................. A-12

CB-525-S2 (CB-200-CTB) .............................................................................. A-12

CB-551-H3 (CB-350-CTB) .............................................................................. A-14

CB-551-H5 (CB-500-CTB) .............................................................................. A-18

Removing the Nozzle for cleaning ........................................................................ A-23

CB-200-CTB Components ...................................................................................... A-24



Metering Pump Components .................................................................................... A-30


APPENDIX B

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

CTB Sequence of Operation ...................................................................................... B-4

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

Metering Pump Wiring Schematic ............................................................................... B-6

APPENDIX C

CTB Service Record ......................................................................................................... C-1

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB, and CB-500-CTB

SECTION 1: INTRODUCTION

Guide to this Manual

This manual contains all the information necessary to safely install and operate the Clean Burn Coil

Tube Boilers (CTB), Model CB-200-CTB, CB-350-CTB, and CB-500-CTB. Consult the Table of Contents for a detailed list of topics covered. You'll find this manual's step-by-step procedures easy to follow and understand. Should questions arise, please contact your Clean Burn dealer before starting any of the procedures in this manual.

As you follow the directions in this manual, you'll discover that assembling and operating the Clean

Burn CTB involves six basic activities as outlined here:

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

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

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

• OPERATION

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

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

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

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

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

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

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

WARNING!

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

Boiler.

1-1

STOP

YOUR SAFETY IS AT STAKE!

DO NOT INSTALL, OPERATE OR

MAINTAIN THIS EQUIPMENT

WITHOUT FIRST READING

AND UNDERSTANDING THE

OPERATOR'S MANUAL!


For Your Safety...

For your safety, Clean Burn documentation contains the following types of safety statements (listed here in order of increasing intensity):

• NOTE: A clarification of previous information or additional pertinent information.

• ATTENTION: A safety statement indicating that potential equipment damage may occur if instructions are not followed.

CAUTION: A safety statement that reminds of safety practices or directs attention to unsafe practices which could result in personal injury if proper precautions are not taken.

WARNING: A strong safetystatement indicating that a hazard exists which can result in injury or death if proper precautions are not taken.

DANGER!

The utmost levels of safety must be observed; an extreme hazard exists which would result in high probability of death or irreparable serious personal injury if proper precautions are not taken.

In addition to observing the specific precautions listed throughout the manual, the following general precautions apply and must be heeded to ensure proper, safe boiler operation.

DANGER! DO NOT create a fire or explosion hazard by storing or using gasoline or other flammable or explosive liquids or vapors near your boiler.

DANGER! DO NOT operate your CTB if excess oil, oil vapor or fumes have accumulated in or near your boiler. As with any oil burning appliance, improper installation, operation or maintenance may result in a fire or explosion hazard.

WARNING: DO NOT add inappropriate or hazardous materials to your used oil, such as:

• Anti-freeze

• Carburetor cleaner

• Paint thinner

• Parts washer solvents

• Gasoline

• Oil additives

• Any other inappropriate/hazardous

material

WARNING: Burning chlorinated materials (chlorinated solvents and oils) is illegal, will severely damage your heat exchanger, immediately void your warranty, and adversely affect the proper, safe operation of your CTB. Instruct your personnel to never add hazardous materials to your used oil.

1-2


For Your Safety... (continued)

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

Clean Burn, Inc. Unauthorized modifications or alteration can adversely affect the proper, safe operation of your boiler.

WARNING: The burner which is shipped with your Clean Burn CTB is to be used only with your boiler according to the instructions provided in this manual. DO NOT use the burner for any other purpose!

WARNING: The Best Operator is a Careful Operator! By using common sense, observing general safety rules, and adhering to the precautions specific to the equipment, you, the operator, can promote safe equipment operation. Failure to use common sense, observe general safety rules, and adhere to the precautions specific to the equipment may result in equipment damage, fire, explosion, personal injury and/or death.

WARNING: The installation, operation, and maintenance of this equipment must be accomplished by qualified personnel and in compliance with the specifications in the

Clean Burn Operator's Manual and with all national, state, and local codes or authorities having jurisdiction over environmental control, building inspection and fuel, fire and electrical safety and the following standards:

ASME Section IV Boiler Code for Pressure Vessels

ASME CSD-1

NFPA 30

NFPA 30A

Controls and Safety Devices for Automatically Fired Boilers

Flammable and Combustible Liquids Code

Automotive and Marine Service Station Code

NFPA 31

NFPA 70

NFPA 88A

NFPA 88B

NFPA 211

Standard for the Installation of Oil Burning Equipment

National Electrical Code

Parking Structures

Repair Garages

Chimneys, Fireplaces, Vents and Solid Fuel Burning Appliances

The International Mechanical Code

The International Building Code

The International Fire Code

The International Fuel Gas Code

Likewise, the installation, operation, and maintenance of this equipment in Canada is to be accomplished by qualified personnel and in compliance with the specifications in the

Clean Burn Operator's Manual and in accordance with the regulation of authorities having jurisdiction and the following CSA Standards:

B139 Installation Code for Oil Burning Equipment

B140.0

B140.7.2

B214

C22.1

General Requirements for Oil Burning Equipment

Oil-Fired Steam and Hot Water Boilers for Commercial and Industrial Use

Installation Code for Hydronic Heating Systems

Canadian Electrical Code, Part 1.

Failure to comply with these standards and requirements may result in equipment damage, fire, explosion, personal injury and/or death.

1-3



Guidelines for Coil Tube Boiler Usage

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

• This boiler is listed with Underwriters Laboratory (UL) to burn the following fuels:

• Used crankcase oil up to 50 SAE

• Used transmission fluid (for U.S.)

• Used hydraulic oils

• #2, #4, and #5 fuel oils

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

• Make sure you comply with all EPA regulations concerning the use of your boiler.

EPA regulations require that:

• Your used oil is generated on-site. You may also accept used oil from

"do-it-yourself" oil changers.

• Hazardous wastes, such as chlorinated solvents, are NOT to be mixed with your used oil.

• The flue gases are vented to the outdoors with an appropriate stack.

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

Contact your Clean Burn dealer for current EPA regulations.

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

1-4



Guidelines for Used Oil Tanks

For the safe storage of used oil and the safety of persons in the vicinity of the used oil supply tank, ensure that your tank installation adheres to the following safety guidelines:

• The tank installation must meet all national and local codes. Consult your local municipal authorities for more information as necessary.

• Review and adhere to the safety guidelines for used oil supply tanks as stated in the WARNING shown.

• Ensure that the tank for your boiler installation complies with all code and safety requirements as stated here. If the tank does not comply, DO NOT use it.

• If you do not have a copy of the tank safety label pictured at right, please contact your Clean Burn dealer for the label, which is to be affixed directly on your used oil supply tank.

ONLY place these listed substances in this used-oil supply tank:

- Used crankcase oil

- Used automatic transmission fluid

- Used hydraulic oil

- #2, #4, #5 fuel oil

Do NOT place flammable or corrosive substances such as gasoline, chlorinated oils, solvents, paint thinners, or any other unsafe substances in this used-oil supply tank.

Tank installation MUST comply with NFPA

30 and 31 Fire Codes, including the following requirements:

- Tank must be listed to UL 80 or UL 142.

- Tank must be vented to outside.

- Emergency vent or explosion relief must be installed on tank.

- Inside fill allowed only with funnel including

1/4 turn-to-close ball valve, which must be closed after filling.

- All other openings must be plugged.

- All oil lines must be constructed of copper, steel, or brass components. Do NOT use rubber or plastic tubing or piping, or any other inappropriate material.

1-5



Safety Labels

Following are the locations and descriptions of all labels on your CTB. The following illustrations show the location of ALL labels on your boiler. Please note that some labels denote model number, model description, etc. while others contain important safety messages.

Each Safety Label contains an important safety message starting with a key word as discussed earlier in this section (e.g. ATTENTION, CAUTION, WARNING, DANGER). For your safety and the safe operation of your CTB, review all labels and heed all safety messages as printed on the labels.

If any labels on your Clean Burn CTB ever become worn, lost or painted over, please call your Clean

Burn dealer for free replacements.

CTB Cabinet Labels

200-CTB 350-CTB 500-CTB Description

42367

42457

42027

42358

42464

42030

42421

42216

42465

42367

42457

42027

42358

42288

42030

42421

42497

42286

42367

42457

42027

42358

42496

42030

42421

42497

42493

C.B. Safety Warning Label

(multiple messages - fire/shock/burn hazards)

Made in USA / Patent Pending Combination Label

Burn Hazard / Hazardous Voltage Warning Label

UL Header Label

CTB Data Label

Electrical Shock Hazard Warning Label

CTB Hot Water Caution Label

C.B. Logo Label

CTB Model # Label

42457

42367

42263

42288

42464

42496

1-6

AIR OIL

I88568−C


CTB Cabinet Labels (continued)

42216

42497

42465

42286

42493

42421

Burn Hazard.

boiler surface may be extremely hot.

Pipes contain hot water.

Do NOT touch without wearing protective gloves.

www.cleanburn.com

42216

CB *** CTB

42286

CTB Cabinet Safety Labels

1-7



CTB Cabinet Safety Labels (continued)

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

1.4

1.4

1.4

1.4

1.4

1.4

CB 200 CTB

14

14

14

18

18

18

18

48

18

6

SIDE

POWER

1/20

1/10

400

1/6

1/10

1/3

MAXIMUM FUSE SIZE / WITH OPTIONS

120

120

120

120

120

120

120

.75

1.4

3.3

2.1

3.0

1.1

4.0

12.0

15/20

6

30

HZ

60

60

60

60

60

60

60

200000

2.5

2.7

2.5

3.4

4.0

4.0

−.06

FOR COMMERCIAL OR INDUSTRIAL USE ONLY.

LANCASTER, PENNSYLVANIA (USA)

MH15393

USED−OIL BURNING APPLIANCE

NO.

USED OIL−FIRED FURNACE

USED OIL−FIRED BOILER

For use with Integral Primary Safety Control

13084

MULTI−OIL HEATING SYSTEM


CERTIFIED TO ELECTRICAL AND FUEL BURNING REQUIREMENTS ONLY.

42358

CB 350 CTB

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

2.5

2.5

2.5

2.5

2.5

2.5

16.0

16.0

16.0

18.0

20.0

20.0

350000

6.0

7.0

7.0

7.0

9.5

9.5

−.06

18

48

18

6

SIDE

POWER

1/20

1/10

400

2/5

1/10

1/2


120

120

120

120

120

120

.75

1.4

3.3

4.7

1.1

5.8

17

20/30

6

30

HZ

60

60

60

60

60

60

42464

1-8


42288



CTB Cabinet Safety Labels (continued)

CB 500 CTB

INPUT RATING W/NO 2 FUEL OIL (BTU/HR) 500000

3.57

3.57

3.57

3.57

3.57

3.57

18

18

24

22

18

18

2.1

3.0

2.5

2.7

3.0

3.0

−.06

18

48

18

6

SIDE

POWER

1/20

1/10

500

1/2

1/3

1/2


120

120

120

120

120

120

.75

1.4

4.2

5.0

3.9

5.8

21.0

30

6

30

HZ

60

60

60

60

60

60


42496

CTB Burner Safety Labels

1-9



CTB Burner Safety Labels (continued)

CTB Burner Labels


42005

42004

42235

42321

42229

42000

42023

42005

42004

42235

42337

42229

42000

42023

42005

42004

42235

42494

42229

42000

42023

Sold/Serviced By Label

Burner Safety Warning Label

(High Voltage/Moving Parts Hazard)


(Fire/Explosion Hazard - Burner Installation and Service)

Burner Model # Label

C.B. Logo/Burner Description Label


(Fire/Explosion Hazard - Reset Button)

Burner Power Label

TOPVIEW FRONT VIEW

42321

42337

42494

42005 42235

42321

42337

42494

42000

42023

I88722−B

1-10



Metering Pump Labels


42284

42466

42284

42420

42284

42495

Metering Pump Wiring Diagram

Model Number / Warning

1-11


1-12


SECTION 2: UNPACKING & PRE-INSTALLATION

CONSIDERATIONS

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

• Removing the Shipping Crate

• Unpacking and Inspecting All Components

• Warranty Registration

• Review the Pre-Installation Considerations

Removing the Shipping Crate

1.

2.

3.

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

Remove the bolts holding the boiler on the shipping pallet.

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

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

Unpacking and Inspection

Following is an itemized list of all components you should have received in your Clean Burn Coil Tube

Boiler shipment. Open all shipping containers and inspect all components according to the list.

Immediately notify the freight company and your Clean Burn dealer in case of shipping damage or shortage(s). Keep all components together so you will have them as needed for CTB assembly and installation.

CTB Component List

• Coil Tube Boiler with factory-installed controls

(including operating aquastat, high temperature cut-off, flow switch, relief valve, and check valve)

Components packed inside boiler:

• Ceramic combustion chamber sleeve

• Combustion chamber sleeve mounting stand

• Ceramic target (pre-mounted)

• Canister filter

• Vacuum gauge

• Check valve with screen (for tank)

• Boiler gauge

• Low water cut-off

• Tube sealant

• Burner hook-up kit

• Barometric damper

• Burner

• Oil pump

• CTB base stand with hardware

• Draft Inducer

2-1


Warranty Registration

For proper warranty registration, Clean Burn requires that you fill out the provided warranty registration card and return it within 30 days to:

CLEAN BURN WARRANTY REGISTRATION

Clean Burn, Inc.

1835 Freedom Road

Lancaster, Pennsylvania 17601

Pre-Installation Considerations

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

Determining the CTB System Setup

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

(1) The type of oil storage tank you will be using (related information in Section 4)**

(2) The positioning of your oil pump (related information in Section 4)

(3) The appropriate size for your oil lines (related information in Section 4)

(4) The electrical requirements for your CTB installation (related information in Section 4)

(5) The type of hydronic installation you will be using (related information in Section 10)

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

Selecting a Location

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

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

• Proper clearances from combustibles (Figure 2A/2B). Verify according to your local safety codes.

• Safe, easy access for servicing (Figure 2A/2B).

• Adequate combustion air per ASME CSD-1, NFPA 31, and local codes (Reference Section 8).

• Proper stack installation and materials (Reference Section 4).

WARNING: For the safe installation and operation of the CTB, the boiler cannot be raised above the floor level, suspended from the ceiling, installed on a raised platform, or placed over top of any equipment, office space, parts room, etc. or installed in any other manner than directly on a concrete floor.

2-2


Selecting a Location (continued)

Adhere to the following minimum clearances from combustible surfaces. Specifications are also provided for servicing clearance. Be sure to check state and local codes which may differ from these specifications . Refer to pages A4 through A7 for boiler dimensions.

Fig. 2A/2B Description

A

B

Above

Front

C

D

Stack

Rear

E

F

G

L.H. Side

R.H. Side

Bottom

Clearance from Combustibles

18"

24"

18"

6"

6"

30"

6"

Clearance for Service

18"

48"

18"

40"

6"

30"

6"

C C

A

DRAFT

E

L.H. SIDE

G

A IR OI L

F

R.H. SIDE

B

Figure 2A - Single Boiler Minimum Installation Clearances

C

A

C

E

L.H. SIDE

F

A IR OI L

B

DRAFT

D

I88682−C

C

G

A IR OI L

Figure 2B - Dual-Stacked Boilers Minimum Installation Clearances

2-3

D

I88683−C


2-4


SECTION 3: COIL TUBE BOILER ASSEMBLY

Understanding Assembly

Assembling your Clean Burn Coil Tube Boiler (CTB) is a multi-step process. Note that some assembly procedures apply only to certain CTB installations or configurations (i.e. single model or dual-stacked boilers); the assembly procedures are outlined below as they appear in this section.

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

Single Boiler Assembly Only

• Installing the CTB on the Support Stand

Dual-Stacked Boiler Assembly Only

• Assembling the Dual-Stacked Boiler

Assembly For All Boilers

• Connecting the CTB

• Installing the Ceramic Sleeve

• Checking the Burner Nozzle and Electrodes

• Installing the Connector Block on the CTB Door

• Installing the Oil Line Tubing

• Installing the Air Line Tubing

• Locking the Burner into Firing Position

3-1

22

21

20

19

18

17

16


Single Boiler Assembly

CB−350−CTB

SHOWN

1 2

DETAIL OF ITEM 24

33

23

24

25

26

8

9

10

6

4

5

27

28

29

30

31

32

14

7

3

11

12

(USER

SUPPLIED)

13

15

34

Figure 3A - Single Boiler Assembly Component Detail

3-2

I88121−F


CB-350-CTB PARTS LIST

NUMBER QTY PART

29

26

25

21

1

1

1

1

33486

27058

12240

31176

TERMINAL BLOCK ASSEMBLY

CONTROL BOX LID

CONTROL BOX 120 AC

INSULATION – DOOR

15

14

1

1

13141

14272

ACCUMULATOR BLOCK ASSEMBLY

UPPER PIPE ASSEMBLY

12

11

1

1

35078

14293

CIRCULATOR PL36 115V 60Hz

CHECK VALVE AND PIPE ASSEMBLY

10 1 13110 CUT-OFF

7

5

1

1

35048

28149

RELIEF VALVE 3/4” MALE

HIGH TEMP CUT-OFF

1 1 11380

2

1

11

9

4

PARTS THAT DIFFER ON THE CB-200-CTB

NO QTY PART # DESCRIPTION

34 1 90200 BASE

14

13

12

22

21

20

1

1

1

1

1

1

33508 CONNECTOR CORD

31216 INSULATION 200 DOOR

11540 DOOR W.A.

14300 UPPER PIPE ASSEMBLY

35079 1-1/4” FLANGE

11095 CIRCULATOR TACO 0011 115 V

1

1

1

1

1

14298 CHECK VALVE AND PIPE ASSY

14299 LOW WATER PIPE ASSEMBLY

35116 COIL FLANGE 1” NPT

31215 INSULATION PANEL

11539 PANEL 200 REAR W.A.

PANEL 350 REAR W.A.

20

14

13

12

11

9

4

2

1

NO

34

22

21


QTY PART # DESCRIPTION

1 90206 BASE

1

1

1

1

1

1

1

1

1

1

1



11564 DOOR W.A.


35120 FLANGE 2” SET

35130 CIRCULATOR TACO 2400-50/2 115V



35121 FLANGE 1-1/2” SET



Refractory Cylinder

200-CTB

21120

Refractory Cylinder Stand 27155

350-CTB

21140

27190

500-CTB

21174

27200

3-3



5.

6.

7.

8.

9.

1.

2.

3.

Installing the CTB on the Support Stand

WARNING: Use extreme caution when moving and lifting the CTB (with a forklift) into place on the support stand. One CTB can weigh up to 2000 pounds (approximate). Clean Burn recommends placing safety blocking underneath the unit until it is properly installed and secured on the support stand. Failure to follow these basic safety guidelines may result in serious personal injury and/or damage to the unit.

4.

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

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

Move the support stand into the approximate position where the CTB is to be installed, and place blocks (approximately 10 inches high) inside the stand to provide safety support for the boiler.

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

WARNING: Secure the boiler to the forklift prior to lifting to prevent possible equipment damage or personal injury.

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

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

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

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

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

NOTE: When assembling the support stand, ensure that the channel brackets are aligned as shown; fasten the shorter brackets at the innermost set of holes.

Figure 3B - Assembling the Support Stand

I88816-A

3-4


Dual-Stacked Boiler Assembly

Assembling the Dual-Stacked Boiler

WARNING: Use extreme caution when moving and lifting one of the CTB's (with a forklift) into place on the support stand. One CTB can weigh up to 2000 pounds (approximate). Clean Burn recommends placing safety blocking underneath the unit until it is properly installed and secured on the support stand. Failure to follow these basic safety guidelines may result in serious personal injury and/or damage to the unit.

5.

6.

ATTENTION: Dual-stacked units may be installed in several combinations: two CB-200-CTB boilers, two

CB-350-CTB boilers, two CB-500-CTB boilers, or any combination of two models with the larger unit on the bottom. For optimal system functioning and to prevent system damage, each boiler must be installed/piped individually as shown in Figure 3C.

1.

2.

3.

4.

Refer to Figures 3C and 3D. Move the support stand into the approximate position where the dualstacked boiler is to be installed, and place blocks (approximately 10 inches high) inside the stand to provide safety support for the boiler.

NOTE: If the support stand has not been assembled, refer to Figure 3B.

NOTE: Only use 7 1/2" legs when stacking the boilers. Taller legs may be unstable.

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

WARNING: Secure the boiler to the forklift prior to lifting to prevent possible equipment damage or personal injury.

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

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

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

Carefully lift the assembled boiler

(with stand) off the safety blocks and move the unit into place for the rest of assembly.

NOTE: This boiler will be referred to as the "bottom" boiler for the remainder of this procedure.

I88688−C

(Procedure continued on page 3-6)

Figure 3C - Dual-Stacked Boilers (Completely Assembled)

3-5



"TOP" BOILER

(USER SUPPLIED)

ADAPTOR

BRACKET

"BOTTOM" BOILER

(USER SUPPLIED)

SUPPORT STAND

REMOVE EXTRA FLANGES FROM

BOILER TO INSTALL PLUMBING

I88671-B

Figure 3D - Dual-Stacked Boiler Assembly Detail

3-6



Assembling the Dual-Stacked Boiler (continued)

7.

8.

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

NOTE: The adaptor bracket is installed between the two boilers; it is fastened to the underside of the

"top" boiler unit.

If you have not already done so, remove the pre-assembled hardware from the top of the "bottom"

9.

boiler. You will use this hardware to fasten the adaptor bracket.

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

10.

Attach the adaptor bracket to the bottom of the boiler using the 1" x 3/8" carriage bolts provided.

DO NOT completely tighten the bolts until the two units are assembled together.

NOTE: The notches on the adaptor bracket are designed to fit around standard forklift forks.

11.

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

12.

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

13.

Install the hardware through the lower set of holes in the adaptor bracket into the top of the

"bottom" boiler while checking for proper alignment of the two units. Ensure that ALL hardware is securely tightened.

NOTE: When stacking a CB-200-CTB on top of a CB-350-CTB use an additional set of side channels turned 180 degrees to help distribute the load around the fork lift notches. This will require lifting the "top" boiler unit from the front rather than the side. Install the front channel into the adaptor bracket after the "top" unit is set on the "bottom" unit.

Figure 3E - Dual-Stacked Boiler Adaptor Bracket

3-7

I88465-A


Assembly for ALL Boilers

Connecting the CTB

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

• Supply Side Connections

• Return Side Connections

• Wiring

NOTE: If you are installing dual-stacked boilers, each boiler must be installed in the same manner according to the following guidelines for connections/wiring. Each boiler must be protected with its own low water cut-off and MUST be piped individually (i.e. piping dual-stacked units together with a single supply or return line is strictly PROHIBITED).

Supply Side Connections

• Install the pre-assembled low water cut-off onto the supply piping flange.

• Place a flange gasket between the two flanges, and tighten the bolts to secure this part.

• Install the temperature/pressure gauge into the first tee (the 1/2" tapping). Be sure to use pipe dope on the threads of the gauge. Tighten the gauge into the tee.

• Install the probe of the low water cut-off into the upper tee, using pipe dope on the threads of the probe. Tighten into the tee.

• Install the low water cut-off control onto the probe and secure.

• Connect the wiring harness from the CTB control box to the low water cut-off. Refer to the

CTB wiring diagram in Appendix B at the back of this manual.

Return Side Connections

• Mount the boiler circulator onto the flanged check valve assembly mounted on the boiler.

Place a gasket between the two flanges and tighten.

• Install the return piping assembly onto the other side of the circulator flange. Place a gasket between the two flanges and tighten.

Wiring

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

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

3-8



Installing the Ceramic Sleeve in the Boiler

NOTE: The ceramic target is factory-installed.

1.

2.

3.

Refer to Figures 3F and 3G.

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

Install the stand for the ceramic sleeve as detailed in Figure 3F. Position the stand on the coils

4.

5.

approximately 3" in from the door opening.

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

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

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

DOOR OPENING

SURFACE

CERAMIC SLEEVE

CERAMIC STAND

3"

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

3-9

I88463A



CERAMIC

SLEEVE

I88124-B

CERAMIC

STAND

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

3-10



Checking the Burner Nozzle and Electrodes

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

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

NOZZLE IS STAMPED

9−5 OR −5 ON FLAT

OF NOZZLE HEAD

NOZZLE

ELECTRODE

NOZZLE ADAPTER

SPARK GAP

OUTLINE OF RETENTION HEAD

3/16"

1/8"

NOZZLE TO BE AHEAD OF

RETENTION HEAD BY 1/8" I88144

Figure 3H - Burner Nozzle and Electrode Specifications

3-11



Mounting the Burner on the Hinge Bracket

1.

2.

3.

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

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

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

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

If the retention head "bumps" the boiler throat, adjust the hinge bracket bolts as follows:

• While supporting the burner, slightly loosen the two (2) hinge bracket bolts.

• Carefully re-position the burner so it swings freely into its firing position.

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

Installing the Connector Block on the CTB Door

1.

2.

3.

Refer to Figure 3I on the next page.

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

Remove and discard the red caps and plugs from the fittings and ports on the connector block.

DO NOT allow any dirt/debris to enter these components during CTB assembly.

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

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

3-12



Installing the Oil Line Tubing

NOTE: DO NOT disassemble the compression fitting from the swivel fitting. To prevent leaks, the

NPT threads of the compression fitting have been sealed with hydraulic sealant during assembly of the fittings at the factory.

1.

2.

3.

4.

5.

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

Loosely install the oil line tubing into the oil line fitting on the burner.

Use a wrench to slightly rotate the oil line fitting on the burner counterclockwise so the tubing lines up with the swivel assembly.

Slightly bend the tubing as shown in Figure

3I, if required, to "line up" the oil line.

Make sure that the curl in the oil line is positioned as shown in Figure 3I so that the burner can swing open correctly.

Install the oil line tubing and tighten the nuts on the compression fittings. DO NOT overtighten these fittings to avoid damaging the ferrules.

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

CONNECTOR BLOCK

FRONT VIEW OF BOILER

SWIVEL

ASSEMBLY

CONNECTOR

BLOCK

OIL LINE

OIL FITTING

ON BURNER

AIR OIL

OIL LINE FITTING

ON BURNER LINED

UP WITH OIL LINE

OIL LINE

SIDE VIEW OF BOILER

SHOWING OIL LINE INSTALLED

Figure 3I - Installation of

Connector Block and Oil Line

I88108A

3-13



AIR LINE FITTING

ON BURNER

OIL LINE FITTING

ON BURNER

AIR LINE

OIL LINE

AIR OIL

COMPRESSION /

SWIVEL FITTING

CONNECTOR BLOCK

INSTALLED ON BOILER

I88112−B

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

1.

2.

3.

Installing the Air Line Tubing

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

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

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

3.

4.

Locking the Burner into Firing Position

1.

2.

Swing the burner into firing position.

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

Plug the burner electrical cable into the receptacle on the top of the burner housing.

Tighten the locking ring to secure the electrical cable.

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

Figure 3K - Detail of Burner

Electric Receptacle

3-14


SECTION 4: COIL TUBE BOILER INSTALLATION

Understanding Installation

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

(1) Oil Tank Installation Specifications (5) Installing the Compressed Air Line

(2) Installing the Metering Pump*

(3) Connecting Water to the CTB

(4) Installing the Oil Lines

(6) Wiring the CTB and Pump

(7) Installing the Stack

(8) Inspecting the Installation

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

Clean Burn recommends that you review all procedures before beginning installation, paying careful attention to safety information statements. Figures 4A / 4B provide a general overview of a typical coil tube boiler installation and should be reviewed closely before proceeding.

WARNING: The installation, operation, and maintenance of this equipment must be accomplished by qualified personnel and in compliance with the specifications in the Clean Burn

Operator's Manual and with all national, state, and local codes or authorities having jurisdiction over environmental control, building inspection and fuel, fire and electrical safety and the following standards:

ASME Section IV

ASME CSD-1

Boiler Code for Pressure Vessels

Controls and Safety Devices for Automatically Fired Boilers

NFPA 30

NFPA 30A

NFPA 31

NFPA 70

NFPA 88A

Flammable and Combustible Liquids Code

Automotive and Marine Service Station Code

Standard for the Installation of Oil Burning Equipment

National Electrical Code

Parking Structures

NFPA 88B Repair Garages

NFPA 211 Chimneys, Fireplaces, Vents and Solid Fuel Burning Appliances

The International Mechanical Code

The International Building Code

The International Fire Code

The International Fuel Gas Code

Likewise, the installation, operation, and maintenance of this equipment in Canada is to be accomplished by qualified personnel and in compliance with the specifications in the Clean Burn Operator's Manual and in accordance with the regulation of authorities having jurisdiction and the following CSA Standards:

B139 Installation Code for Oil Burning Equipment

B140.0

B140.7.2

General Requirements for Oil Burning Equipment

Oil-Fired Steam and Hot Water Boilers for Commercial and Industrial Use

B214

C22.1

Installation Code for Hydronic Heating Systems

Canadian Electrical Code, Part 1.

Failure to comply with these standards and requirements may result in equipment damage, fire, explosion, personal injury and/or death.

WARNING: Improper installation can adversely affect the proper, safe operation of your CTB. It is critical that your boiler installer reads and follows the instructions provided in this manual.

4-1


Typical Installation Diagrams

"CLASS A" STACK CAP

WATERTIGHT ROOF FLASHING

"DEKTITE" FLASHING OR

EQUIVALENT

"CLASS A" STACK

2100 DEGREE ALL FUEL STACK

INSULATED STACK WITH A

STAINLESS STEEL LINER

10 FT

ELECTRICAL THERMO CUT−OFF (OPTIONAL)

DEDICATED ELECTRICAL CIRCUIT

110 VOLT 20 AMP

"CLASS A" KIT FOR INSTALLING

"CLASS A" STACK THROUGH CEILING

8 INCH SINGLE

WALL STACK

MIN. 24 GAUGE

OIL PUMP ELECTRICAL CIRCUIT

PRESSURE OIL LINE INSTALLED

TO CONNECTOR BLOCK ON BOILER

DRAFT

INDUCER

AIR & OIL

CONNECTIONS

AT CONNECTOR

BLOCK ON BOILER

COMPRESSED AIR LINE

(OPTIONAL)

OIL THERMO

CUT−OFF

CONTROL BOX

(ELECTRICAL

CONNECTION)

LOW WATER

CUT−OFF

TEMP/PRESSURE

GAUGE

FLOW SWITCH

RELIEF

VALVE

HIGH LIMIT

W/RESET

DRAFT

BAROMETRIC

DAMPER

FUNNEL WITH

BALL VALVE

1/4" HOLE FOR

CHECKING DRAFT

AT BREACH

EMERGENCY

VENT

FLUE

COLLAR

8" DIA.

5 FT MIN

RETURN

FLANGE SET

1−1/2 NPT

CLEAN−OUT TEE

CLEAN−OUT

CHECK VALVE

CHECK VALVE SCREEN

METERING

PUMP

250 GAL TANK

SUCTION

OIL LINE

VENT

CAP

I88679-C

Figure 4A - Typical Single Boiler Installation Diagram

(CB-350-CTB Shown)

4-2


Typical Installation Diagrams (continued)

"CLASS A"

STACK CAP

"CLASS A" STACK

2100 DEGREE ALL FUEL STACK

INSULATED STACK WITH A

STAINLESS STEEL LINER

WATERTIGHT ROOF FLASHING

"DEKTITE" FLASHING OR

EQUIVALENT

10 FT

ELECTRICAL THERMO CUT−OFF (OPTIONAL)

DEDICATED ELECTRICAL CIRCUIT

110 VOLT 20 AMP

SUPPLY

1−1/2 NPT

(OPTIONAL)

OIL THERMO

CUT−OFF

(OPTIONAL)

OIL THERMO

CUT−OFF

SUPPLY

1−1/2 NPT

RETURN

FLANGE SET

1−1/2 NPT

OIL LINE

COMPRESSED

AIR LINE

110 VOLT 20 AMP

AIR AND OIL CONNECTIONS

CONNECTOR BLOCK ON BOILERS

RETURN

FLANGE SET

1−1/2 NPT

COMPRESSED AIR LINE

CLEAN−OUT TEE



D RAF T DRAFT

PRESSURE OIL LINES INSTALLED

TO CONNECTOR BLOCKS ON BOILERS

ELECTRICAL

CONNECTIONS

BAROMETRIC DAMPER

1/4" HOLE FOR CHECKING

DRAFT AT BREACH

EMERGENCY

VENT

CLEAN−OUT TEE

8 INCH SINGLE

WALL STACK

MIN. 24 GAUGE

5 FT MIN

CLEAN−OUT

OIL PUMPS ELECTRICAL CIRCUIT

CHECK VALVE

GAUGE

A2RA−7 720

INL ET

RE LI EF

FUNNEL WITH

BALL VALVE

SUCTION OIL LINE

INL ET

CANISTER

FILTER

VENT

CAP

250 GAL TANK

CHECK VALVE SCREEN

OIL FLOW

I88726-C

Figure 4B - Typical Dual-Stacked Boiler Installation Diagram

(Two CB-350-CTB Boilers Shown)

4-3


Combustion Air Requirements

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

Refer to Figure 4C.

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

NFPA 31 requires the following for combustion air:

Units located in confined spaces (units in a boiler room/mechanical room) must have two (2) permanent openings, one near the top of the enclosure and one near the bottom of the enclosure as follows:

1. If all of the air is taken directly from the outside of the building by use of vertical ducts each of the two openings must have a total free area of not less than 1 square inch per 4,000

BTU/hr (35 square inches per gallon of oil) of the total appliance(s) input rating (NFPA 31,

Section 5.4.2.2).

2. If all of the air is taken directly from the outside of the building by use of horizontal ducts each of the two openings must have a total free area of not less than 1 square inch per 2,000

BTU/hr (70 square inches per gallon of oil) of the total appliance(s) input rating (NFPA 31,

Section 5.4.2.2).

3. If all of the air is taken directly from inside of the building - each of the two openings must have a total free area of not less than 1 square inch per 1,000 BTU/hr (140 square inches per gallon of oil) of the total appliances(s) input rating (NFPA 31 Section 5.4.1).

4-4


4-5


Oil Tank Installation Specifications

Ensure that your tank installation adheres to the following safety guidelines as stated here and in

Section 1 of this manual.

The tank safety label (shown at right) also summarizes these important specifications for tank installation and usage. If you do not have a copy of this label, please contact your Clean Burn dealer for a copy, which is to be affixed directly to your used oil supply tank.

• The tank installation must meet all national and local codes. Consult your local municipal authorities for more information as necessary.

• The tank must be listed to UL 80, UL 142, or equivalent standard.

• Use a minimum 250-gallon tank.

DO NOT use a 55-gallon drum as a substitute for an appropriate tank. The tank must be large enough to allow water, sludge, etc. to settle out of the used oil.

• Single wall tanks should have a manual shutoff type valve on the side of the tank to allow the water, sludge, etc. to be drained from the bottom of the tank.

• All unused openings in the tank must be plugged or capped off.

• For optimal system functioning, Clean Burn recommends inside tank installations as shown in Figures 4A and 4B.

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

• Carefully review the oil tank and pump installation details as shown in Figures 4A,

4B, and 4D, including the metering pump installation and specifications for the oil line installation. (Procedures for installing these components can be found in the following pages.)

ONLY place these listed substances in this used-oil supply tank:

- Used crankcase oil

- Used automatic transmission fluid

- Used hydraulic oil

- #2, #4, #5 fuel oil

Do NOT place flammable or corrosive substances such as gasoline, chlorinated oils, solvents, paint thinners, or any other unsafe substances in this used-oil supply tank.

Tank installation MUST comply with NFPA

30 and 31 Fire Codes, including the following requirements:

- Tank must be listed to UL 80 or UL 142.

- Tank must be vented to outside.

- Emergency vent or explosion relief must be installed on tank.

- Inside fill allowed only with funnel including

1/4 turn-to-close ball valve, which must be closed after filling.

- All other openings must be plugged.

- All oil lines must be constructed of copper, steel, or brass components. Do NOT use rubber or plastic tubing or piping, or any other inappropriate material.

IMPORTANT NOTE: If you are installing an inside oil tank in the same room as the boiler, you must allow a

5 foot minimum clearance between the tank and the boiler. The oil tank should be set and installed in position

BEFORE the boiler is installed.

4-6


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 PRESSURE

RELIEF OIL

LINE BACK TO

THE TANK

MUSHROOM

CAP VENT

PRESSURE

LINE

STEEL PIPE

(USER SUPPLIED)

FUNNEL WITH

BALL VALVE

EMERGENCY

VENT

PUMP

SUCTION LINE

ASSEMBLY

CHECK

VALVE

FILTER

SCREEN

CLEAN−OUT

(TANK DRAIN)

Figure 4D - Typical Metering Pump Installation with Inside Tank

Installing the Tank Vent and Emergency Vent

Some codes require that you install a tank vent (to the outside) and an emergency vent for your tank as shown in Figure 4D. Tank Vent Kits are available from Clean Burn; contact your local Clean Burn dealer to order.

Be sure to check your local codes for any additional tank installation requirements, and adhere to the following installation guidelines:

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

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

4-7


Installing the Metering Pump

Preparing for Installation

Before starting installation of the metering pump, review Figures 4E, 4F, and 4G to become familiar with the metering pump components. You will also need to accomplish the following activities:

• Verify that you have the proper metering pump for your boiler (note the specific gear motor part numbers shown in Figure 4F).

• Gather all required tools and materials as needed for installation; as indicated in the following procedures, some materials (e.g. fittings, tubing) are to be user-supplied.

• Standard mounting is vertical mounting on a wall; this pump installation is recommended.

Alternate mounting is horizontal mounting on a bracket. Be sure to carefully follow the appropriate procedures/diagrams for pump mounting.

1.

2.

• For optimal metering pump functioning, mount the pump at a distance from the oil tank that will comply with the following requirements:

The suction oil line may NOT exceed 6 feet TOTAL vertical lift AND 4 feet TOTAL horizontal lift.

Standard Mounting: Vertical Positioning

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

Use the appropriate type of bolts and washers (user-supplied) to securely mount the metering pump to the appropriate wall in your building at a distance from the tank that complies with the suction oil line requirements.

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

4-8


# PART # DESCRIPTION

1 33363 CAPACITOR − GEARMOTOR

2 see chart GEARMOTOR

3 11322 MOUNT − METER PUMP

4 32037 1/8 NPT X 1/4 TUBE COMPRESSION FITTING

5 N/A 1/4 COPPER OR ALUM. TUBING

6 N/A 3/8 OR 1/2 TUBE FLARE NUT

7 N/A 3/8 OR 1/2 COPPER OR ALUM. TUBING

8 N/A 1/8 M NPT X 3/8 OR 1/2 FLARE

9 32526 MINI BALL VALVE 1/8 MNPT X 1/8 FNPT

10 32475 METER PUMP

11 32467 1/4" X 3" NIPPLE

12 32210 1/4" STREET ELBOW

13 32336 1/4" X 3/4" BRASS BUSHING

14 32123 VACUUM GAUGE

15 32127 CANISTER FILTER− LENZ

16 32430 1/2" x 3/4" BUSHING, BRASS

17 32446 1/2" X 5" NIPPLE

18 32429 1/2" STREET TEE, BRASS

19 32137 1/2" HEX NIPPLE

20 32142 1/2" BALL VALVE

21 32062 1/4" NPT x 1/4" TUBING FITTING

22 32443 1/4" x 1/2" BUSHING

23 32141 1/2" NPT x 1/2" TUBING FLARE ADAPTER

24 32140 1/2" LONG NUT

25 32139 1/2" NPT x 1/2" TUBING SLIP ADAPTER

26 32442 2" x 1/2" x 1/2" NPT DUPLEX HEX BUSHING

27 32021 3/4" CHECK VALVE

28 32061 3/4" CHECK VALVE SCREEN

29 32445 1/2" PIPE CAP

17

18

19

20

16

29

13

10

9

6

7

8

11

14

15

5

4

3

2

12

1

23

24

21

22

25

26

24

23

16

27

28

Figure 4F - Metering Pump Component Detail

4-9

CLEAN BURN

MODEL

SATURN 140

SATURN 230

CB−1750

CB−2500

CB−3250

CB−3500

CB−5000

CB−200−CTB

CB−350−CTB

CB−500−CTB

GEARMOTOR

PART #

33291

33293

33353

33354

33572

33355

33356

33507

33295

33558


Alternate Mounting: Horizontal Positioning

1.

2.

3.

4.

5.

ATTENTION: If the metering pump is to be mounted horizontally or on a bracket as shown in

Figure 4G, the pump head must be rotated counterclockwise so that it is aligned in a horizontal position. The gauge arrow on the pump head must point up, or the pump will not prime.

Refer to Figures 4F and 4G.

Remove the two pump mounting bolts. The coupling is keyed and does not have set screws.

Rotate the pump head 180 degrees to the horizontal position as shown in Figure 4G.

Re-install and tighten the two pump mounting bolts.

Use the appropriate type of bolts and washers (user-supplied) to securely mount the metering pump to the mounting bracket, which is to be installed on the appropriate wall in your building at a distance from the tank that complies with the suction oil line requirements.

GAUGE RELIEF

A2RA−7720

INLET

ROTATION

GAUGE RELIEF

A2RA−7720

INLET

ROTATION

GAUGE RELIEF

A2RA−7720

INLET

ROTATION

GAUGE RELIEF

A2RA−7720

INLET

ROTATION

INLET

RECOMMENDED SETUP

PUMP IS MOUNTED

LEFT ON WALL

INLET

ALTERNATE MOUNTING

(NOT RECOMMENDED)

BLEED VALVE IS NOW CLOSE

TO THE WALL MAKING THE

BLEEDING DIFFICULT

I88708−B

INLET

NON−STANDARD SETUP

PUMP HEAD HAS BEEN

ROTATED 90° CCW FOR

HORIZONTAL MOUNTING

(THE 1/4" STREET ELBOW AND

1/4" X 3" NIPPLE CHANGE PLACES

IN THE PLUMBING SEQUENCE)

Figure 4G - Proper Positioning of Metering Pump Head

4-10


Connecting Water to the Coil Tube Boiler

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

1.

2.

3.

4.

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

Have the water trim installed by a certified hydronics technician according to the ASME

Section IV Boiler Code. Heat exchangers must be used for domestic water heater installations.

For air separation and elimination, Clean Burn recommends the Enhanced Spiral-Type Air

Separator which can be supplied by your local Clean Burn dealer. Installing an air separator helps ensure that air is purged from the boiler, which is necessary for optimal startup and operation of the burner.

The relief valve discharge must be piped to within four inches of the floor or to a floor drain.

Be sure to allow for clearance to remove the back panel for servicing.

Filling the Coil Tube Boiler with Water

2.

3.

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

The boiler circulator bearings are water lubricated and should not be allowed to operate dry. Filling the

CTB with water provides immediate lubrication of the bearings. Purging air from the water is also critical; doing so enables proper startup of the burner.

1.

Fill the CTB with clean tap water.

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

The pressure gauge should read 20 psig. (If a different operating pressure is needed, contact the

Clean Burn Service Department for additional instructions.)

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

4-11


Installing the Suction Oil Line Components

ATTENTION: It is critical that you adhere to the following specifications for suction oil line installation ( oil line from the tank to the pump ).

If these specifications are not met, the metering pump will not function correctly and the burner will shut down on reset. The majority of service problems with the metering pump are caused by leaks at fittings in the suction oil line; these problems are eliminated by ensuring a 100% airtight suction oil line which slants up to the pump.

• All suction oil line components must be installed as shown in Figures 4A, 4B, and 4F.

Suction line size is 1/2" diameter.

Proper installation allows the suction oil line to be filled with used oil during initial priming.

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

(1) vertical foot

(4) horizontal feet

= 0.75” hg (vacuum)

= 0.75” hg (vacuum)

NOTE: ALSO ADD 0.75" hg to the final sum to account for every oil filter, shut-off valve, and check valve on the suction side of the pump assembly.

Sample calculation: (6) vertical feet x 0.75" = 4.50" hg AND (4) horizontal feet = 0.75" hg

4.50" hg + 0.75" hg + 0.75" hg = 6.00" hg vacuum

• The metering pump must be installed with a 3/4" check valve and screen at the end of the suction oil line, or the pump will not maintain its prime.

1.

• 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 4F for a detailed look at the metering pump components and fittings.

b. Remove the plug from the 1/4" inlet port of the pump.

c. Install the 1/4" x 3" brass nipple into the 1/4" inlet port on the pump.

d. Install the 1/4" brass street elbow onto the 3" brass nipple; turn the fitting onto the nipple until it is tight and faces away from the pump mounting plate.

e. Prepare the canister filter for installation:

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

Check the direction of the arrow for the proper flow.

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

4-12


Installing the Suction Oil Line Components (continued)

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

• Remove the plug from one of the 1/8" gauge ports in the canister filter and install the vacuum gauge. Seal the threads of the gauge with Permatex #2 non-hardening gasket sealer.

• Install the 1/2" threaded pipe adapter into one side of the 1/2" ball valve.

• Install the 1/2" MPT x 1/2" flare adapter into the other side of the ball valve.

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

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

• Install the canister filter assembly onto the 1/4" brass street elbow as shown in Figure 4E.

The canister filter must be installed with the arrow pointing towards the pump (direction of oil flow).

• Install the 1/2" x 5" brass nipple into the top side of the 1/2" brass tee assembly.

• Loosely install the 1/2" brass cap onto this nipple. DO NOT tighten the cap at this time.

2.

Install the suction oil line (from the the tank to the canister filter) : a. Refer to Figures 4A, 4B, and/or 4F.

b. Prepare a piece of 1/2" O.D. copper tubing (user-supplied) which will function as the pick-up line from the tank to the canister filter. This copper tubing must have the following specifications:

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

• The tube is to slant up from the tank to the pump with no loops or high points to trap air.

c. Locate the 2" MPT x 1/2" FPT x 1/2" FPT duplex, slip-thru hex bushing (which will eventually be installed into one of the 2" openings on the tank). Note that the fitting is marked "S" for suction and "R" for return.

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

e. Install the 1/4" MPT x 1/4" compression fitting into the 1/2" x 1/4" brass bushing.

f. Install the 1/2" x 1/4" brass bushing into the "R" side of the 2" duplex slip-thru hex bushing.

g. Measure the height of the oil tank (from the bottom of the tank, NOT the floor) to the 2" opening that you are going to use for the supply oil line. Deduct 12" (305mm) from this measurement and transfer this new measurement onto the 1/2" O.D. coppper tubing.

h. Remove the locking nut and ferrel sleeve connector from the 1/2" slip fitting, and slide them over the copper tubing.

i. Slide the 1/2" O.D. copper tubing through the 1/2" slip fitting, which is installed in the "S" side of the 2" hex bushing.

j. Install the screen into one side of the 3/4" check valve (making sure the arrow is pointing away from the screen assembly).

k. Install the 3/4" x 1/2" brass bushing into the 3/4" check valve.

l. Install the 1/2" MPT x 1/2" flare adapter into the 3/4" x 1/2" brass bushing.

4-13


Installing the Suction Oil Line Components (continued)

(2.) Install the suction oil line (continued)) : m. Slide the 1/2" flare nut over the end of the 1/2" copper tubing, and flare the end of the tubing.

NOTE: Use a high-quality flaring tool (such as a Ridgid Flaring Tool) to ensure that all flares are made properly (i.e. so they will be 100% airtight).

n. Install the flared oil line and nut onto the assembled check valve/screen and tighten.

o. Pick up the assembled oil line, and carefully guide the end of the tubing with the check valve through the 2" tank opening.

p. Apply Permatex #2 non-hardening gasket sealer (or equivalent) to the threads of the 2" duplex slip-thru tank bushing, and tighten this fitting into the tank.

q. Pull the 1/2" copper tubing back up through the slip fitting until you see the mark that you put on the tubing earlier. Holding the tubing with one hand, push the ferrel sleeve connector and locking nut down the tubing, then tighten onto the 1/2" slip fitting. The oil line is now installed in the correct position off of the bottom of the tank.

r. Carefully bend the oil line up to the canister filter; use a spring bender over the oil line while bending the tubing to prevent kinks in the oil line. Allowing for the flare nut, cut off the excess tubing.

s. Install the 1/2" flare nut onto the tubing, and flare the end of the tubing.

t. Install the end of the tubing with the flare nut onto the 1/2" flare adapter (on the ball valve assembly at the canister filter).

u. Install a vent from the tank to the outside of the building according to code. The tank must be properly vented to allow air to enter the tank as oil is pumped out and to safely vent fumes to the outside. See Figures 4A, 4B, and 4D.

v. Install plugs in all other tank openings as required by code.

w. Inspect the installation. For proper suction oil line operation, make sure all components are installed and positioned as specified in this manual.

4-14


Installing the Pressure Relief Oil Line Back to the Tank

ATTENTION: It is critical that you adhere to the following specifications for plumbing the pressure relief back to the tank.

The metering pump requires the installation of a pressure relief oil line back to the tank that you are pulling oil from as shown in Figures 4A, 4B, and 4D.

• The pressure relief will open and relieve pressure if there is a restriction in the pressure oil line, clogged nozzle, etc.

Be sure to use Permatex #2 non-hardening gasket sealer to seal every threaded fitting. DO NOT use teflon tape or teflon pipe dope compounds.

1.

2.

3.

4.

Refer to Figure 4H.

Remove the plug from the relief port on top of the metering pump head.

Install the 1/8 NPT x 1/4 tube compression fitting in the relief port on top of the metering pump head.

Install 1/4" O.D. copper tubing (user-supplied) from the pressure relief port back to the oil tank.

Refer to Figure 4D as needed.

# PART # DESCRIPTION

1 32475 METERING PUMP HEAD (7720)


3 INSTALLER SUPPLIED 1/8 MNPT X 3/8 OR 1/2 FLARE

4 INSTALLER SUPPLIED 3/8 OR 1/2 COPPER OR ALUM. TUBING

5 INSTALLER SUPPLIED 3/8 OR 1/2 TUBE FLARE NUT

6 INSTALLER SUPPLIED 1/4 COPPER OR ALUM. TUBING

7 32037 1/8 MNPT X 1/4 TUBE COMP. FITTING

5

4

6

7

2

3

1

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

4-15


Installing the Pressure Oil Line Components

1.

2.

3.

ATTENTION: It is critical that you adhere to the following specifications for pressure oil line installation (oil line from the pump to the boiler); if these specifications are not met, the metering pump will not function correctly and the burner will shut down on reset.

• The parameters for pressure oil line installation are:

Length of Pressure Line

Up to 100 feet

Line Size

3/8" O.D. copper or aluminum tubing

(Please note that some installations will allow for a greater pressure line length. Contact your

Authorized Clean Burn Distributor for more information.)

• If possible, the pressure oil line should slant up to the burner with no loops or high points to trap air.

• Local codes may require the installation of an in-line "Fire-O-Matic" safety valve .

Be sure to check all appropriate codes to ensure compliance.

Refer to Figures 4A, 4B, and 4F.

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

1.

2.

NOTE: Your air compressor system must supply air pressure to the boiler with the following requirements: 25 psi and water trap or dryer.

If you do not have shop air, an optional air compressor is available. Contact your local Clean Burn dealer for more information.

3.

4.

Run a compressed air line from your shop air to the burner on the boiler. Use minimum 1/4"

O.D. copper tubing or equivalent for the compressed air line.

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

Install a pressure regulator (additional to the burner air regulator) in the air line, and set it at 50 psi.

ATTENTION: DO NOT feed full shop air pressure to the burner or damage to burner components may occur.

Install a water trap or extractor/dryer in the air line with an automatic drain so compressed air

(rather than water) is supplied to the burner.

ATTENTION: Water must not be fed to the burner, or the flame will be extinguished and the burner will shut down. Be sure to drain water from your compressor tank on a regular basis to keep water out of the air line.

4-16


Wiring the Coil Tube Boiler

WARNING: To avoid electrical shock, make sure that power to the CTB is turned OFF before connecting any wires. All wiring must be in accordance with the National Electrical Code and local codes. Properly size all wires and use Greenfield or Thin-wall Conduit for all electrical lines.

Refer to Figures 4A/4B at the beginning of this chapter for the Clean Burn recommended typical CTB installation. Specific wiring schematics are provided in Appendix B at the back of this manual.

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

(1) A dedicated electrical line to the CTB (see IMPORTANT NOTE below)

(2) A pump electrical circuit from the CTB to the oil pump (see IMPORTANT NOTE below)

(3) A separate circuit for the load loop circulator

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

Wiring to the Coil Tube Boiler

1.

2.

3.

Install a dedicated electrical circuit to the electrical junction box on the CTB. Note that a dual-stacked boiler will require two circuits, each with a single pole, single throw breaker.

CAUTION: DO NOT tie into an existing circuit or electrical overload may occur.

Wire the CTB according to the Wiring Schematic in Appendix B. Use 12-gauge copper wire for a 15 or 20 amp breaker. A 30 amp breaker requires 10-gauge copper wire.

Check for correct voltage at the CTB and refer to the following chart. Incorrect voltage may damage the CTB components.

Model Voltage

CB-200-CTB (single) 110/120

Dual-Stacked (200-CTB) 110/120

Breaker Qty. & Size*

(1) @ 15 amps

(2) @ 15 amps

Phase Hertz

Single

Single

60

60





(1) @ 20 amps

(2) @ 20 amps

(1) @ 20 amps

(2) @ 20 amps

Single

Single

Single

Single

60

60

60

60

*NOTE: Breaker size with optional equipment is 30 amps.

When installing any optional equipment

(e.g. air compressor), you must use a 30 amp breaker. Make sure a qualified electrician properly sizes and installs this electrical circuit. Note that minimum wire size with a 30 amp breaker is 10-gauge copper wire.

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

4-17


Wiring to the Oil Pump

ATTENTION: DO NOT wire the oil pump directly into your building's electrical system. The oil pump must be activated (receive power from) the burner via the pump electrical circuit.

1.

2.

Install the oil pump electrical circuit from the CTB to the oil pump location (refer to Figures

4A/4B).

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

Wiring the Load Loop Circulator

1.

2.

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

Refer to the related information and illustrations in Section 10 and the CTB Wiring Diagram in

Appendix B to locate and understand the wiring for the load loop circulator.

The cold water return in your CTB system installation should not be below 140 o F .

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

4-18


Installing the Stack

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

Stack designs are generally classified as follows:

(1) "Class A" stack through the ceiling of the building

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

Figure 4I illustrates the through-the-ceiling stack design for a single boiler; this stack design is preferable and is more commonly used. Refer to Figure 4J for the dual-stacked boiler stack design.

When designing your stack, adhere to the following specifications:

• Models CB-200-CTB and CB-350-CTB single boilers require 8" I.D. stack components.

• Model CB-500-CTB single boilers require 10" I.D. stack components.

• Models CB-200-CTB and CB-350-CTB dual-stacked units require 8" I.D. stack components run as two (2) individual stacks.

• Model CB-500-CTB dual-stacked units require 10" I.D. stack components run as two (2) individual stacks.

• Ensure that the vertical stack height is at least 10 feet.

If needed, increase the vertical length of the stack or install a draft inducer to obtain -.02" W.C. draft over fire. (Section 8 contains details on adjusting the draft.)

• Keep the horizontal stack run as short as possible ; slant it upward at a minimum of 1/4" per foot of run.

• Keep the stack design simple. Complicated stacks (with long runs and many turns) reduce draft and result in poor burner performance. Your stack may include only one 90 degree turn. All other stack turns must be at 45 degrees or less to ensure optimal draft and burner performance.

NOTE: If you plan to use an existing masonry chimney, the chimney must be lined and be located inside the building. Exterior masonry chimneys chill the stack gases and result in poor draft and poor burner performance.

ATTENTION: If you have an exhaust fan(s) in your shop, it is critical that you have adequate make up air (source of fresh air to replace the stale air exhausted by the fan).

When an exhaust fan is run without adequate make up air, the resultant vacuum in the building will draw combustion products back into the burner. This back draft causes poor burner performance and may damage vital burner components. Refer to Section 8 in this manual for additional information concerning exhaust fans and proper make up air.

Stack components should be installed in the following order:

(1) Inside stack (the stack components from the coil tube boiler breach to within 18" of the ceiling, roof, or sidewall of your building)

(2) Barometric damper(s)

(3) "Class A" stack penetration through the ceiling, roof, or sidewall

(4) "Class A" stack on the exterior of the building

(5) "Class A" stack cap

4-19


"CLASS A" STACK CAP

NON−RESTRICTIVE TYPE TO ALLOW

FREE FLOW OF TH STACK GASES

THE LAST STACK SECTION SHALL

EXTEND AT LEAST 3 FEET ABOVE

THE HIGHEST POINT. AT WHICH IT

COMES IN CONTACT WITH THE ROOF.

AND AT LEAST 3 FEET HIGHER THAN

ANY RIDGE, PARAPET WALL OR ROOF

STRUCTURE WITHIN 10 FEET OF IT

10 FEET

3 FEET

WATERTIGHT

ROOF

FLASHING

"DEKTITE" OR

EQUIVALENT

"CLASS A" UL 103HT STACK

DOUBLE WALL INSULATED

ALL FUEL,STACK WITH A

A STAINLESS STEEL LINER



DRAFT

INDUCER

BAROMETRIC

DAMPER

DRAFT

10 FT MINIMUM VERTICAL

STACK HEIGHT OR EQUIVALENT

DRAFT SYSTEM TO MAINTAIN

−.02 W.C. DRAFT OVER FIRE

8 INCH MINIMUM

SINGLE WALL STACK

MIN. 24 GAUGE

GALVANIZED

1.

2.

I88681−C

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

Installing the Interior Stack

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

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

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

4-20


Installing the Stack (continued)

DAMPER

8"

32 1/4" BETWEEN

CENTERS (CB−200−CTB)

37 1/8" BETWEEN

CENTERS (CB−350−CTB)

8"

10" BETWEEN

OPENING CENTERS

I88672-A

3.

4.

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

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

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

ATTENTION: Avoid additional 90-degree turns in the stack. Each additional 90-degree turn slows down stack gases, creates back-pressure, and results in repeated burner shutdown and unnecessary service calls. All other turns in the stack should be at a 45-degree (or smaller) angle.

Installing the Barometric Damper(s)

1.

Refer to Figure 4K. Install a single wall tee (min. 24 gauge) on the first straight vertical or horizontal stack section within three feet of the CTB breach.

NOTE: This tee is required to support the barometric damper. You must purchase this tee when you purchase your stack materials (8" single wall tee - CB# 70174; 10" single wall tee - CB# 70180).

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

4-21


Installing the Stack (continued)

2.

3.

3.

For CB-500-CTB ONLY: Install the 9"-to-10" pipe adapter in the opening of the tee as shown in

Figure 4K.

Install the barometric damper in the opening of the tee (or pipe adapter for CB-500-CTB). Use a small spirit level to make sure that it is properly level.

Install two self-tapping screws as shown in Figure 4K (i.e. one on each side of the barometric damper) to hold the damper in place. DO NOT install a screw at the bottom of the barometric damper, or the flapper of the damper will not operate correctly.

NOTE: Specifications for adjusting the barometric damper for proper draft overfire are provided in

Section 8 of this manual.

9" CLEAN BURN BAROMETRIC

DAMPER WITH ADAPTOR IN

10" SINGLE WALL TEE

ADJUST THIS WEIGHT TO

OBTAIN PROPER DRAFT

I88547

2

1

(FOR CB-500-CTB)

8" CLEAN BURN BAROMETRIC DAMPER

INSTALLED IN SINGLE WALL TEE

1

2

1

No

1

1

QTY

31198

31197

PART #

DAMPER PIPE ADAPTOR

9" BAROMETRIC DAMPER

DESCRIPTION

I88539

ADJUST THIS WEIGHT TO

OBTAIN PROPER DRAFT

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

1 1 31170

No QTY PART #

8" BAROMETRIC DAMPER

DESCRIPTION

Figure 4K - Installation of Barometric Damper

4-22


Installing the Stack Safety Switch For Canadian Installations

NOTE: CSA Standards require that all heating equipment must be installed with a stack safety switch. If your heating equipment is being installed in Canada, follow the instructions listed below.

2.

3.

4.

6.

7.

CAUTION: For your safety and the safe operation of your heating equipment, the stack switch must be installed by a qualified installer in accordance with the installation instructions provided here. Wiring must be accomplished in accordance with all applicable codes. Failure to adhere to these safety recommendations may result in serious personal injury and/or equipment damage.

1.

5.

Follow the instructions in the Operator’s Manual, Section 4 to install a proper stack, including the barometric damper which must be installed within 40 inches of the breach.

NOTE: The barometric damper must be installed so that it is level and the flapper moves freely.

Ensure that main power to the heating equipment is turned OFF.

Position the stack safety switch over the lip of the barometric damper as shown in Figure 4L.

Drill a 1/8” pilot hole for the mounting screw, and mount the stack safety switch using the mounting screw supplied with the switch.

NOTE: The mounting screw must not interfere with the free movement of the flapper on the barometric damper.

Install the wall thermostat according to the instructions provided in the Operator’s Manual, Section 4 .

Wire the wall thermostat and stack safety switch in series as shown in Figure 4M. Install the wire so that it is secured away from any hot surfaces.

When the heating equipment installation is completed, follow the instructions in the Operator’s

Manual, Sections 5 and 6 to prime the pump and start/adjust the burner.

Follow instructions in the Operator’s Manual, Section 8 to check the draft; this is crucial for the proper, safe operation of the heating equipment.

I88964

Figure 4L - Stack Safety Switch Installed on the Barometric Damper

4-23


Resetting the Stack Safety Switch

WARNING: BURN HAZARD!

To prevent serious personal injury, be sure to allow ample time, at least 30 minutes, for the stack, barometric damper, and switch to cool down before attempting to access and service these components. It is crucial to identify the cause of the stack obstruction (e.g. heavy snowfall) and correct it before resetting the stack safety switch and re-starting the burner. DO NOT operate the heating equipment with an obstructed stack ; failure to correct an obstructed stack may result in fire, explosion, and/or burn hazards causing serious personal injury or death.

NOTE: In locations where heavy snowfall occurs, it is critical that the stack remain unobstructed by snow.

For safe heating equipment operation, be sure to keep the area surrounding the stack clear of snow.

1.

2.

3.

Before resetting the stack safety switch, check the stack to make sure it is clear of any obstructions.

Remove the cover from the stack safety switch, and push the small button in the middle of the switch.

Pushing the stack safety switch reset button will re-establish the thermostat circuit, and the burner will start (assuming the wall thermostat is calling for heat).

Understanding the Function of the Stack Safety Switch

The Stack Safety Switch monitors the temperature at the barometric damper on the stack and is designed to detect the obstruction of the free flow of stack gases from the heating equipment and shut down the burner.

Obstruction of the stack results in the “spillage” of stack gases from the barometric damper, which heats up the switch. The switch then opens, disconnecting the thermostat circuit to the burner, and the burner shuts off.

Stack Safety Switch Specifications

Switching Voltage

Switch OPEN Temperature

Switch Type

24 volts

180 o F

L180, normally closed, manual reset

WALL

THERMOSTAT

CONTROL

BOX

OIL

PRIMARY

STACK

SAFETY

SWITCH

(MOUNTED ON

BAROMETRIC DAMPER)

I88976

Figure 4M - Stack Safety Switch Wiring Diagram

4-24


Installing the Stack Penetration

WARNING: When running the stack through your ceiling, roof, or sidewall, you must use

Class A/UL103 HT double-wall insulated all-fuel stack components with a stainless steel liner.

DO NOT run single-wall stack through your ceiling, roof or sidewall.

1.

2.

Refer to Figure 4I as needed.

Follow the installation instructions provided by the stack manufacturer.

Installing the Exterior Stack

1.

2.

3.

ATTENTION: All exterior stack pieces must be Class A/UL103 HT double-wall insulated all-fuel stack components with a stainless steel liner.

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

• DO NOT use Type L Vent/double-wall stack components (for approved fuel oil appliances only).

• DO NOT use single-wall stack for your exterior stack. Single-wall exterior stack chills the stack gases and results in poor draft and poor burner performance.

Refer to Figure 4I 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/UL103 HT stack cap ensures the free flow of stack gases which is essential for optimal burner performance.

1.

2.

Refer to Figure 4I as needed. Your stack cap should be classified as: Class A/UL103 HT non-restrictive, all-fuel type.

Install the stack cap according to the manufacturer's instructions.

Installing the Draft Inducer

ATTENTION: The Field brand draft inducers have been tested for use on Clean Burn Equipment. DO NOT use other models or brands of draft inducers.

Understanding the Importance of the Draft Inducer

The draft inducer is designed to aid in the removal of the natural draft created by the appliance to vent the combustion gases to the outside of the building. As the paddle wheel turns, a negative pressure is maintained within the stack so that the combustion gases can leave the boiler and travel out of the stack. (See Figure 4N.)

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

4-25


Installing the Draft Inducer (continued)

NOTE: Lubricate the motor as recommended by the Draft Inducer manufacturer.

3 FEET

10 FEET

NOTE: INSTALL DRAFT INDUCER IN LAST

SECTION OF VERTICAL STACK TO POSITION

DRAFT INDUCER AWAY FROM BOILER

BREACH SO THAT THE MOTOR DOES NOT

OVERHEAT. THIS ALSO REDUCES ASH

ACCUMULATION IN THE DRAFT INDUCER.

DO NOT MOUNT THE DRAFT INDUCER IN THE

HORIZONTAL STACK NEAR THE BOILER

BREACH

DRAFT

INDUCER

DRAFT

ADJUSTMENT

PLATE

CHECK FOR

−.02 W.C. DRAFT

OVER FIRE

DRAFT

10 FT MINIMUM VERTICAL

STACK HEIGHT OR EQUIVALENT

DRAFT SYSTEM TO MAINTAIN

−.02 W.C. DRAFT OVER FIRE

SERVICEMAN ADJUSTS

BAROMETRIC DAMPER TO

OBTAIN −.02 W.C. DRAFT

OVERFIRE

AIR OIL

I88968−B

Figure 4N - Installation of the Draft Inducer

WARNING: Turn OFF the main power to the boiler before proceeding with the installation of the draft inducer.

ATTENTION: It is very important to install the draft inducer on a vertical section of stack to isolate the inducer from excessive heat and ash buildup. Never install the draft inducer on a horizontal section of stack close to the breach where heat and ash will damage the inducer motor.

4-26


1.

2.

Installing the Draft Inducer (continued)

Refer to Figure 4N. Follow the instructions included with the draft inducer to mount the draft inducer on the section of single-wall vertical stack.

Position the draft plate all the way out so that it does not reduce the draft produced by the draft inducer. Follow directions in Section 8 (Adjusting the Draft Overfire) to set the proper draft.

Wiring the Draft Inducer for Normal Operation*

*(No exhaust fans in the building)

1.

Wire the draft inducer according to the Wiring Diagram provided in Appendix B at the back of this manual.

in the Burner Control Box and also

Installing the Wall Thermostat or Aquastat

IMPORTANT NOTE: The wall thermostat is available separately from Clean Burn (i.e. it is not included with the CTB). Refer to Appendix A in this manual for additional information on remote temperature sensing controls available from Clean Burn for your CTB system installation.

1.

2.

3.

4.

5.

6.

7.

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 at the top center of the body. ( Hold the thermostat base in one hand, and grasp the body with the other hand; push in on the latch with your thumb, and pull the cover away from the base .)

ATTENTION: DO NOT use a screwdriver to pry the cover off the base, or damage may occur.

Remove the green paper insert and the black plastic battery isolator from the battery section of the thermostat.

Refer to the Burner Wiring Diagram in Appendix B at the back of this manual. Run two wire,

18-gauge (minimum) thermostat cable from the terminals on the back of the thermostat base to the T/T terminals of the control box on the side of the boiler. DO NOT run the wiring to the primary control!

Run two wire, 18-gauge (minimum) thermostat cable from the B1/B2 terminals of the control box on the side of the boiler to the T/T terminals of the primary control on the burner.

ATTENTION: NEVER jump between T/T terminals on the burner control box or the primary control without removing one of the wires. Failure to remove one of the wires will burn out the heat anticipator on the thermostat and will cause the thermostat to fail.

Mount the thermostat base 60" to 66" from the floor using the hardware provided.

Reassemble the thermostat body onto the base. ( Align the hinges at the bottom of the cover with the slots at the bottom of the base, and swing the cover up into place .)

Replacing the Wall Thermostat Batteries

1.

2.

3.

Proper battery level is indicated by the room temperature being displayed on the LCD screen.

When the battery level becomes low, a battery icon along with the word "REPLACE" will be displayed in the lower left corner of the LCD screen. Replace the batteries to ensure proper operation, following the previous instructions on the thermostat disassembly procedure.

If the batteries are not replaced, the display will slowly become dim and not display any information.

The thermostat will eventually not function. If this happens, replace the batteries immediately.

4-27


Inspecting the Coil Tube Boiler Installation

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

NOTE: Important!

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

• Operating Aquastat

• Hi-limit Aquastat (with manual reset)

180

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

o

240 o

F (minimum)

F

Any changes to these settings should be made only by a qualified hydronics technician. See Section

10, The CTB Hydronics System, for more information.

4-28


SECTION 5: METERING PUMP PRIMING

Understanding Metering Pump Priming

Preparing your Clean Burn boiler for operation begins with priming the metering pump. The procedures in this section must be performed in sequence without interruption to properly prime the pump.

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

Required Tools and Materials

The following tools and materials are required for oil pump priming and should be gathered before starting any procedures:

• 3/8" open-end wrench

• 5/8" open-end wrench

• Rags

• Two containers (minimum one-gallon)

• Permatex #2 non-hardening gasket sealer

• Adjustable Wrench

• Pipe Wrench

5-1


6.

7.

4.

5.

1.

2.

3.

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.

Refer to Figure 5A.

Remove the 1/4" NPT plug from the side of the pump head, and set it aside.

Remove the 1/2" brass cap from the 1/2" brass nipple. Place a funnel in the opening. Slowly pour used oil into the funnel until oil comes out of the side of the pump head ; this will fill the oil line, canister filter, and pump head with oil.

ATTENTION: NEVER run the pump head dry (i.e. without oil in the pump head). Doing so will severely damage the pump.

Apply Permatex #2 non-hardening gasket sealer to the threads of the plug (removed from the pump head). Re-install the plug and tighten.

Apply Permatex #2 non-hardening gasket sealer to the threads of the 1/2" brass nipple. Re-install the 1/2" brass cap on the brass nipple and tighten.

Open the bleeder on the pump two to three (2-3) full turns, and position a container to catch oil which will flow from the bleeder during pump priming.

Close the mini ball valve at the outlet port of the pump head.

ATTENTION: Verify that the relief oil line is installed back to the tank before closing the mini ball valve. Closing the mini ball valve will cause the internal pump relief valve to open.

Figure 5A - Priming the Metering Pump

5-2


Priming the Metering Pump (continued)

8.

Activating the Pump

NOTE: The coil tube boiler features a priming switch which is mounted on the left-hand side of the electrical junction box on the hydraunics side of the boiler cabinet. The priming switch has two positions:

• PRIME (switch is in the UP position / orange indicator light is ON): this is used only for pump priming. When the switch is in the UP position, the pump circuit is activated for priming. The pump will continue to run as long as the switch is in this position. The oil primary control circuit is de-activated so the burner cannot run while the switch is in the UP position.

• BURNER (switch is in the DOWN position): this is used for normal burner operation.

When the switch is in the DOWN position, the burner controls the operation of the pump.

The pump will only run while the burner is running.

a. Refer to Figure 5B to locate the priming switch.

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

OIL PUMP

PRIMING SWITCH

PRIMING LIGHT

THERMOSTAT TERMINAL

BURNER

TERMINAL

AIR

REGULATOR

OIL

GAUGE

AIR

GAUGE

CONNECTOR BLOCK

COMPRESSED AIR LINE

OIL LINE

Figure 5B - Detail of Burner Connections/Components

5-3

I88130−B


Priming the Metering Pump (continued)

9.

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

ATTENTION: For the metering pump to operate correctly, it is very important that the system is entirely full of oil and all air is bled out. The burner will shut down if there is any air in the system.

10.

Open the mini ball valve at the outlet port of the pump head to allow the pressure oil line to be filled.

11.

Close and tighten the bleeder on the pump.

12.

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

13.

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

14.

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

15.

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

16.

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

17.

Re-connect the oil line to the connector block.

Vacuum Testing the Oil Pump

Vacuum testing the oil pump is a very accurate way to determine the following:

• The condition of the pump -- the ability of the pump to pull a vacuum and suck oil from the tank.

• The condition of the fittings, gaskets and seals from the ball valve to the pump -- these components must all be airtight to avoid suction leaks.

The following procedure provides instructions for vacuum testing the pump and canister filter on systems equipped with a ball valve.

2.

3.

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.

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 5A. Close the ball valve at the inlet to the canister filter. Observe the vacuum gauge.

NOTE: The ball valve must have a stainless steel ball and should be pressure tested by the manufacturer to ensure that it does not leak. If the ball valve leaks, the vacuum test will not be accurate.

The vacuum should increase within 30 seconds to 15 inches of vacuum. When the vacuum gauge reads 15 inches of vacuum, first close and tighten the bleeder, then turn the pump off and close the mini ball valve at the outlet port of the pump. Observe the vacuum gauge.

NOTE: If the pump will not pull at least 15 inches of vacuum, there is a very serious suction leak, or the pump is damaged.

5-4


Vacuum Testing the Oil Pump (continued)

5.

If there are no suction leaks, the system will hold vacuum.

NOTE: It is acceptable for the vacuum to drop one to five inches within one minute as the seal in the pump seats. The vacuum should then hold steady for 15 minutes.

ATTENTION: If the vacuum drops more than one to five inches within the first minute , there is one or more leaks somewhere between the pump and the ball valve. Do the following:

• Wipe your finger along the cylinder at the shaft of the pump. If there is oil here, the pump seal is damaged. Replace the pump.

• Disassemble and clean all the fittings from the pump to the ball valve. Properly seal all fittings with Permatex #2 non-hardening gasket sealer or equivalent. Check the condition of the o-ring on the canister filter and tighten the four canister filter bolts in a crisscross pattern.

• Repeat the procedure to vacuum test the system to ensure that the system is air tight.

6.

Follow the instructions to prime the metering pump after a vacuum test has been performed.

5-5


5-6


SECTION 6: STARTING AND ADJUSTING THE BURNER

Understanding Burner Startup and Adjustment

ATTENTION: Before starting the burner, you must fill the coil tube boiler with water.

Refer to

Section 10 in this manual for more information on the hydronics system. DO NOT bypass the CTB controls to operate the burner!

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

Starting and adjusting the burner involves a series of separate procedures which must be accomplished in sequence without interruption. Review all the procedures before attempting burner startup and adjustment, paying careful attention to safety information statements.

Preparing the Hydronics System for Burner Startup

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

1.

2.

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

Set the operating aquastat (on the CTB) at 180 to 200 o F .

Preparing the Burner for Startup

1.

2.

3.

If you have not already done so, disconnect one wire from the terminal block at the "thermostat" connection. (This prevents the burner from running.) A wiring diagram is provided in

Appendix B.

Turn the main power to the CTB ON (the green power light on the burner should be ON).

Wait at least 15 minutes until the preheater block is thoroughly warmed up. (Feel the back of the burner box to make sure the preheater is sufficiently warm. The proving switch on the preheater block will not allow the burner to start until the block is at least 120 o F .)

NOTE: The preheater block will remain warm as long as power is supplied to the burner. If the main power supply is ever turned OFF, you must wait at least 15 minutes until the preheater block is thoroughly warm before starting the burner.

(Continued)

6-1


Preparing the Burner for

Startup (continued)

SLOT COVER INSTALLED

4.

5.

6.

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

Turn the adjustment knob on the air regulator counterclockwise until 1/2" of the threads on the knob are exposed. DO NOT back the knob all the way out.

NOTE: The air gauge will not show any pressure until the burner starts. Before starting the burner for the first time, it is very important to turn the air regulator completely OFF as described.

Initial Adjustment of the

Combustion Air Band

Rotate the combustion air band to adjust it to the appropriate slot opening as listed in the following Initial Adjustment

Chart . Use a ruler to accurately set the slot opening at the widest section of the slot.

COMBUSTION

AIR BAND

AIR REGULATOR

LOCKING NUT

AIR GAUGE

OIL GAUGE

Figure 6A - Component Detail of the CB-551-H3 Burner

(CB-525-S2 Burner is similar)

WARNING: The combustion air band must be properly adjusted to ensure that the burner ignites and burns correctly. DO NOT attempt to start the burner with the combustion air band wide open or completely closed. The burner may not ignite correctly. Failure to heed this warning may result in a fire or explosion hazard.

IMPORTANT NOTE: This initial setting of the combustion air band will allow you to start the burner.

You will fine tune the combustion air band further as described later in these instructions.

ATTENTION: The settings shown in the chart below are only initial adjustments. Final adjustments must be done by inspecting the flame length according to the illustrations provided on the following page.

NOTE: The oil pressure is automatically adjusted by the metering pump.

Initial Adjustments for CB-200-CTB

NOTE: Only Gearmotor part #33507 may be used with the CB-200-CTB.

Maximum Input = 200,000 BTUH @ 1.4 GPH per CB 525-S2 Burner

Oil Type Oil PSI / Flame Length Air PSI Air Band

#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

14

14

18

14

18

3/8" - 1/2"

3/8" - 1/2"

3/8" - 1/2"

3/8" - 1/2"

3/8" - 1/2"

Nozzle

9-5

9-5

9-5

9-5

9-5

6-2


Preparing the Burner for Startup (continued)



Maximum Input = 350,000 BTUH @ 2.5 GPH per CB 551-H3 Burner


#2 Fuel Oil*

Used Crankcase Oil

Used ATF

Used Hydraulic Oil


12-16

12-16

12-16

12-16

12-16

1/2"

1/2"

1/2"

1/2"

1/2"

Nozzle

9-5

9-5

9-5

9-5

9-5



Maximum Input = 500,000 BTUH @ 3.57 GPH per CB 551-H5 Burner


#2 Fuel Oil*

Used Crankcase Oil

Used ATF

Used Hydraulic Oil


18

18

22

24

18

1/2"

1/2"

1/2"

1/2"

1/2"

Nozzle

9-28

9-28

9-28

9-28

9-28

* 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.

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

NOTE: The CB-350-CTB and CB-500-CTB burner oil primary controls include alarm contacts which will close should the burner fail to start. If the burner refuses to start , review the Preparing the

Burner for Startup procedure. If, after repeating this procedure, the burner still refuses to start, check the following system components for proper functioning:

• Verify that the red wire (per the burner wiring diagram) is energized to 115VAC.

• Reset the hi-limit switch.

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

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

Adjusting the Air Regulator:

As soon as the burner starts running, turn the knob on the air regulator clockwise to achieve proper operating air pressure. Refer to the Initial Adjustment Charts .

NOTE: If the safety reset on the primary control is activated and the burner stops running, see

Section 7 for further instructions on restarting you burner.

3.

Observing the Flame Length:

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

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

CAUTION

WHEN OPENING INSPECTION PORT

PORT MAY BE HOT

PROTECT HANDS

WEAR SAFETY GOGGLES

KEEP FACE AWAY

OPEN PORT SLOWLY

6-3


Starting the Burner (continued)

Correct Maximum Flame Adjustment

(Proper Oil and Air Pressure)

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

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

Incorrect Flame Adjustment

(Not Enough Combustion Air)

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

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

Incorrect Flame Adjustment

(Air Pressure too high)

• Ensure proper air pressure setting

4.

5.

Figure 6B - Flame Length Adjustment

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

Tighten the locking nuts on the air regulator.

I88372

6-4


Starting the Burner (continued)

6.

7.

8.

Checking for Proper CTB System Operation:

Observe the boiler temperature and water pressure.

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

• air has been purged from water lines

• water pressure is satisfactory (i.e. not greater than 22 psi; normal pressure is 12 psi)

• all system controls functioning properly

Reset the operating aquastat to the normal operating range (180-200 o F ) and repeat steps 6 and 7, observing the CTB operation.

9.

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

10.

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

11.

Fine Tuning the Combustion Air Band:

NOTE: The initial setting of the combustion air band may require additional adjustment.

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

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

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

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

12.

Checking for a Smokeless Burn:

Check for a smokeless burn by observing the stack while the burner is running. If you see any smoke, repeat the previous steps for setting the combustion air band and adjusting the air regulator. After adjusting the combustion air band, re-check the flame length.

NOTE: Check for a smokeless burn periodically (as you do the flame length). Immediately readjust the burner if you ever see smoke coming from the stack. Smoke indicates improper air/ fuel adjustment.

NOTE: When using instruments to adjust the burner for a smokeless burn, the following readings should be achieved:

• Draft over fire should be -.02 inch w.c. to -.04 inch w.c.

• Adjust for a smoke spot of a trace to 1

• For the CB-500-CTB adjust for a CO

2


2


2

• Cad cell reading of 200 to 500 ohms reading of 12.5 to 14% or an O

2

reading of 12 to 13.5% or an O

2

reading of 2 to 4%

reading of 4 to 7%

reading of 10.5 to 12.5% or an O

2

reading of 3 to 5%

NOTE: On the CB-200-CTB, the flame cannot be observed through the inspection door. The

CB-200-CTB must be adjusted with instruments for proper combustion. Obtain the above settings by adjusting the air band 3/8" to 1/2". The metering pump will deliver a constant oil flow and set the flame length accordingly.

6-5


6-6


SECTION 7: RESETTING THE OIL PRIMARY CONTROL

Understanding the Oil Primary Control (CB-200-CTB)

The oil primary control will go into safety lockout and shut the burner off when it detects flame-out during burner operation. The following procedure explains what should be done when this occurs.

It is very important that you follow these instructions precisely when resetting the safety on the primary control and restarting the burner.

CAD CELL WIRES

Resetting the Oil Primary Control

(CB-525-S2 Burner)

DANGER!

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

1.

2.

3.

4.

5.

I88787−D

Refer to Figure 7A.

Check the combustion chamber for fuel mist by shining a flashlight through the observation port. If you see fog (fuel mist) in the chamber, DO NOT push the reset button.

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

When you are sure all mist has been cleared from the chamber and the combustion chamber is cool, depress the red button on the primary control for a minimum of three (3) seconds, then release. Reset the control ONCE ONLY.

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

RESET BUTTON

THERMOSTAT WIRES

Figure 7A - Oil Primary Control for CB-200-CTB

ATTENTION: It is very important that the "F" and

"T" terminals of the Oil

Primary Control are wired exactly as shown in Figure 7A.

NEVER connect jumper wires to these terminals or severe damage may occur to the Oil

Primary Control.

7-1


Understanding the Oil Primary Control (CB-350-CTB and CB-500-CTB)

NOTE: This is a new control featuring the ability to activate a remote alarm in case of lock-out or latch-up.

The oil primary control will go into safety lock-out and shut the burner off when it detects flame-out during burner operation. The oil primary control will then wait approximately one minute and attempt to re-ignite the burner (recycle mode). If the burner does not re-ignite, the control will shut the burner off on safety. The following procedure explains what should be done when this occurs. It is very important that you follow these instructions precisely when resetting the safety on the primary control and restarting the burner.

Resetting the Oil Primary Control (CB-551-H3 and CB-551-H5 Burners)

1.

2.

3.

DANGER!

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

4.

Refer to Figure 7B.

Check the combustion chamber for fuel mist by shining a flashlight through the observation port.

If you see fog (fuel mist) in the chamber, DO NOT push the reset button.

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

When you are sure that all fuel mist has cleared and the boiler has cooled, push in and hold the reset button for one second, then release. This will reset the control at any time during its operation.

CAD CELL WIRES

I88107−A

AMB RED

WIRE TO

BOILER

CONTROL

BOX

RED LED

AMBER LED

RESET BUTTON

Figure 7B - Oil Primary Control For

CB-350-CTB and CB-500-CTB

7-2

ATTENTION: It is very important that the "F" and

"T" terminals of the Oil

Primary Control are wired exactly as shown in Figure 7B.

NEVER connect jumper wires to these terminals or severe damage may occur to the Oil

Primary Control.


Resetting the Oil Primary Control (continued)

5.

6.

7.

8.

Set the load temperature controller to call for heat.

NOTE: Main power should be ON and all hand-operated oil line valves open. When the call for heat is detected, the oil primary control will perform a 3-4 second self-test which is indicated by a "solid on" amber LED. After the self-test, the amber LED will turn OFF, and the burner will start.

If flame is not established within 15 seconds (TFI-Try For Ignition), lock-out will occur.

Lock-out is indicated by a "solid on" red LED and closure of the alarm contacts (see NOTE below).

To reset the control, repeat step 4.

Latch-up occurs if the control locks-out and is reset three times during a call for heat. Latch-up is indicated by "solid on" red and amber LEDs.

To reset the control from a latch-up condition:

(a) Push in and hold the reset button for approximately 40 seconds . The red and amber LED's will go out.

(b) After approximately 10 seconds, the red and amber LED's will come back ON and will then start to blink.

(c) After blinking ON/OFF for approximately 10 seconds, the red and amber LED's will go out.

Continue to hold the reset button for an additional 15 seconds, and then release the button.

(d) The burner will now start.

NOTE: Releasing the reset button at any time during this procedure (step #8) will cause

9.

the unit to remain in latch-up, and you will have to start the procedure again.

When the load temperature controller opens, the burner motor turns off within 1.2 seconds.

10.

If flame is lost during a normal run (after TFI), the burner motor turns off after 1.2 seconds. A

65-second recycle period begins, indicated by a blinking red LED. The control will restart automatically after the recycle period.

11.

Power loss during a normal run will cause the burner to safely shut down and begin a normal TFI when power is restored.

12.

If the burner will not restart at all (after having attempted oil primary control reset), contact your

Clean Burn dealer immediately.

NOTE: The oil primary control on the CB-551-H3 and CB-551-H5 Burners provides an extra set of dry contacts to accommodate an externally-mounted horn, siren, bell, or other alarm device. The contacts close when the control goes into either lock-out or latch-up mode. Because these are dry contacts, power must be supplied from an external source. The contacts are rated for 24 VAC or DC at 2 amps.

7-3


7-4


SECTION 8: ADJUSTING THE DRAFT OVER FIRE

Understanding the Importance of Draft

Draft in the Coil Tube Boiler is created as the hot combustion gases rise up the stack, creating a negative pressure inside the stack and the boiler. This negative pressure is measured as inches of water column

(W.C.) of draft. A proper draft overfire of -.02 w.c. is essential so that all combustion products travel away from the burner, down the combustion chamber, through the boiler flues and up the stack.

Checking for Correct Draft Over Fire

NOTE: The CTB's are equipped with an observation/draft reading port to check draft over fire. A qualified serviceman with proper equipment must adjust your CTB for proper draft. Contact your Clean Burn dealer for this service.

1.

2.

3.

4.

Insert the probe of the draft gauge instrument into the draft reading port in the observation port as shown in Figure 8A.

Adjust the barometric damper to achieve the required draft over fire of -0.02 w.c.

(water column).

Record the reading in the Maintenance

Record located in the Appendixes.

If correct draft over fire cannot be achieved, contact your Clean Burn dealer immediately.

ATTENTION: Only operate your CTB with a draft over fire of -0.02 w.c. Poor draft results in back pressure and poor burner performance. DO NOT operate your

CTB with a draft over fire greater than

-0.04 w.c.; an abnormally high stack temperature may result from a draft over fire that is too high.

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

Under backdraft conditions, draft overfire readings

I88257 will show positive pressure in the combustion chamber.

Backdraft means that oil spray, combustion products,

Figure 8A - Checking for Proper

Draft Over Fire 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.

8-1


Checking for Correct Draft Over Fire (continued)

Backdraft is caused by the following conditions:

• Poor draft caused by improper stack design. (See Section 4.)

• Poor draft caused by improper adjustment of the barometric damper.

• Incorrect combustion air band setting on the burner. (See Section 6.)

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

• Improper seal on clean-out door on back panel. (See Section 9.)

• Exhaust fans in your building are sucking gases down the stack.

Understanding the Effect of Exhaust Fans on Draft

Any type of exhaust fan, paint booth, or exhaust system in a building will create negative pressure in the building unless there is a source of make-up air (i.e. fresh air which enters the building and replaces the air removed by the exhaust fans.)

If there is insufficient make-up air, the exhaust fan will suck air and combustion gases down the coil tube boiler stack and create backdraft in the boiler. After the burner is shut down, the backdraft may suck the residual heat out of the combustion chamber and into the burner causing damage to the burner.

Even if the exhaust fan is on another level of the building or in another room away from the boiler, the exhaust fan will still create backdraft at the boiler.

2.

3.

4.

Checking Draft Overfire to Determine Severity of Backdraft

The following procedure is an accurate method of determining how much backdraft is created by the exhaust fans. Once this is determined, you can select the correct method for resolving the backdraft.

1.

Turn off ALL exhaust fans and close ALL doors and windows in the building (any open door or window will allow make-up air to enter the building and will negate the test).

Start the coil tube boiler 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 boiler and burner will occur (voiding the warranty). If the draft overfire remained constant at -.02 w.c., there is sufficient make-up air entering the building, and the exhaust fan is not adversely affecting the draft.

CAUTION: Under no circumstances should the equipment room ever be under a negative pressure. Look for exhaust fans, compressors, air handling units, or anything else that may take air away from the boiler. Also look for chemical fumes, solvents, refrigerants, etc. that may be in use around the boiler and cause damage to it.

8-2


Adjusting Draft Over Fire with A Draft Inducer Installed

NOTE: The draft inducer is purposely sized to create a generous draft. When adjusting the barometric damper, you will find that the flapper is open most of the time. This allows the draft inducer to suck cool air through the damper to protect the inducer motor from heat damage.

1.

2.

Use a draft gauge to check draft over fire.

Adjust the barometric damper to obtain -0.02 w.c. draft over fire. If you still have too much draft, adjust the draft plate on the draft inducer. Move the plate in 1/4" to reduce the draft. Recheck the draft reading.

8-3


8-4


SECTION 9: MAINTENANCE

Understanding Maintenance

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

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

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

Maintenance Activity

Cleaning the canister filter

Servicing the metering pump

Interval

Before vacuum gauge reads 10" HG of vacuum

At least once a year

Cleaning the check valve/screen At least once a year

Cleaning water/sludge out of oil tank At least once a year

Cleaning out ash (CB-200-CTB)* Approx. every 750 hrs. per burner hour meter

Cleaning out ash (CB-350-CTB)*

Cleaning out ash (CB-500-CTB)*

Approx. every 1000 hrs. per burner hour meter

Approx. every 1000 hrs. per burner hour meter

Cleaning / Maintaining the Draft Inducer At least once a year

Checking boiler water condition Periodically by qualified water treatment company

Annual burner tune-up At least once a year

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

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

Appendixes.

Annual Preventative Maintenance and Burner Tune-up

The Clean Burn CTB requires annual preventative maintenance. The burner also requires an annual tune-up to keep it running in peak condition. The burner tune-up should be performed by a qualified

Clean Burn service technician who has the necessary parts and expertise.

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

9-1


Cleaning the Canister Filter

ATTENTION: Never operate the oil pump with more than 10" HG of vacuum on the vacuum gauge.

High vacuum on the suction side of the pump separates air from the oil (cavitation) and will cause the burner to shut down.

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

• Rubber gloves • Safety goggles

1.

2.

3.

4.

5.

6.

7.

Close the ball valve adjacent to the filter.

Position a container under the filter.

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

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

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

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

Open the ball valve. Refer to Sections 5 and 6 for instructions on priming the pump and starting the burner.

FILTER HEAD VACUUM/PRESURE GAUGE

INSTALL IN 1/8" PORT

ELEMENT "O" RING

(IN GROOVE ON TOP

OF FILTER ELEMENT)

FILTER

ELEMENT

BOWL "O" RING

FITS IN GROOVE

IN TOP OF CANISTER

BOWL

CANISTER BOWL USE A RATCHET WRENCH WITH

A 6" EXTENSION AND 3/16" "ALLEN"

SOCKET TO REMOVE THE FOUR

"ALLEN" SCREWS

Figure 9A - Canister Filter Component Detail

9-2

DRAIN PLUG

I88281−A


Servicing the Metering Pump

1.

2.

3.

4.

5.

6.

Refer to Figure 9B.

Remove the pump head cover (part 1).

Remove the screen (part 2) and wash it.

Remove and discard the used gasket (part 3).

Install a new gasket (Clean Burn Part #32422).

Replace the screen and pump head cover.

3

2

1

PART No 32422

PART No 32423

Figure 9B - Servicing the Metering Pump

Cleaning the Check Valve / Screen

1.

2.

3.

4.

This procedure applies to coil tube boiler installations with inside and outside tanks. The following protective gear should be worn when cleaning the check valve/screen:

• Rubber gloves

• Safety goggles

5.

Refer to Figure 9C. Remove the one-piece suction oil line from the tank.

Remove the check valve and screen. 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.

9-3


TO BURNER

FUNNEL WITH

BALL VALVE

EMERGENCY

VENT

METERING PUMP

SUCTION

OIL LINE

VENT

CAP

CLEANOUT

OIL STORAGE TANK

CHECK VALVE

CHECK VALVE SCREEN 12"

I88670−F

Figure 9C - Check Valve Detail

Cleaning the Ash from the Coil Tube Boiler

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

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

1.

• Respirator for fine particles

• Safety goggles

•

•

Rubber gloves

Protective clothing

Ensure that power has been turned OFF, and all "hot" components have been allowed to cool sufficiently. Shop air should be turned OFF and disconnected. Allow at least one hour for the ceramics to cool.

9-4

2.

3.


Clean the ash from the combustion chamber (see Figure 9D): a. If the air and oil lines must be disconnected to open the clean out door:

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

2. With air and oil pressure completely bled off, disconnect the air and oil pressure lines from the bottom of the connector block.

NOTE: Cover these lines to keep dirt from entering the air / oil supply.

b. Remove the lock nuts on the clean-out door.

c. Carefully swing open the clean-out door to expose the coiled heat exchanger, flue passages, and the combustion chamber.

d. Remove the ceramic sleeve from the combustion chamber, and remove the supporting stand.

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

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

Carefully clean these elements.

g. Thoroughly vacuum any remaining ash residue from the flue passages. A long wand on the hose of your shop vac is helpful in reaching all the way back.

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

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

Clean the ash from the stack components: a. Brush accumulated ash from the stack cap.

b. Lightly tap the stack components to loosen the ash.

c. Allow ash and dust to settle in the clean-out tee or elbow, then vacuum out.

d. Disconnect the stack from the CTB breach.

e. Thoroughly vacuum out the back of the boiler, including the boiler breach (through the breach). If desired, the back panel can be removed for cleaning.

I88123-A

ATTENTION: When cleaning the combustion chamber, ensure that you do not gouge or damage the refractory material on the inside of the clean-out door and target wall.

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

Figure 9D - Accessing the Combustion Chamber for Cleaning

9-5


4.

5.

Cleaning the Ash (continued)

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

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

Close the clean-out door, install and tighten the washer and nuts. Make sure that the clean-out door and rear panel close and seal properly. Reconnect all disconnected lines (oil and air) on the bottom of the connector block.

NOTE: You may need to bleed air from the oil line before starting the burner. See Section 5 for pertinent instructions.

Cleaning the Oil Tank

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

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

End of Season Maintenance

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

Allow only trained, authorized service personnel to service your burner.

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

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

Cleaning and Maintaining the Draft Inducer

2.

3.

4.

The Draft Inducer will require periodic maintenance to ensure that the fan blades do not accumulate excessive ash which can create vibration, noise, and motor wear.

1.

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

Disconnect the wires from the draft inducer and remove it from the stack penetration.

Clean the fan blades with a scraper and wire brush.

Oil the draft inducer motor according to the manufacturer's recommendations.

9-6


SECTION 10: THE CTB HYDRONIC SYSTEM

Understanding the CTB Hydronic System

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

IMPORTANT NOTE: When designing the system layout and application for your CTB, keep in mind that it is NOT suitable for open systems. The Clean Burn CTB has been designed to operate as an

ASME Section IV Boiler (i.e. closed loop boiler system). Potable water heating (i.e. for domestic or washing purposes) can be accomplished by incorporating a heat exchanger into the system.

Special Safety Guidelines for the Design and Installation of Hydronic Systems

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

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

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

In all cases, reference should be made to the following standards:

(1) Current Edition of American National Standard ANSI/NFPA 31, "Installation of Oil Burning

Equipment" for clearances between boiler, vent connector and combustible material.

(2) Current Edition of American National Standard ANSI/NFPA 211, "Chimneys, Fireplaces, Vents, and

Solid Fuel Burning Appliances" for chimney requirements, type of venting material and clearances between vent connector pipe and combustible materials.

(3) Current Edition of American Society of Mechanical Engineers ASME CSD-1, "Controls and Safety

Devices for Automatically Fired Boilers" for assembly and operation of controls and safety devices.

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

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

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

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

10-1


CTB System Function and Configuration

Water Flow and Temperature

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

Heating systems using zone valves, zone pumps, or three-way valves may experience reduced water flow through the boiler. This condition can cause excessive water temperature rise and unstable boiler operation. The normal temperature rise across the boiler is 20 o F . Minimum operating temperature for the

CTB is 180 o F .

To avoid condensation, the return water temperature should not fall below 140 o F .

Boiler Mixing Valve 140 o F

Provided with the boiler plumbing is a 140 o F Mixing Valve set up to blend cold water return from the system to maintain a proper temperature (above 140 o F) for the “Non-condensing” design of the CTB. For optimal boiler operation with the Mixing Valve, and when burning used oils, it is recommended to run the boiler “hot” (180 o F to 200 o F). Therefore the operating aquastat setting should be no less than 180 o F. The high limit aquastat factory recommended setting is 220-240 o F.

The 140 o F Mixing Valve must be installed according to Figure 10B or 10C and must be as close as possible to the suction side of the boiler circulator . This allows the by-pass loop to function properly. When starting the boiler from cold (room temperature) the boiler water temperature will be able to come up above 140 o F within 5 to 7 minutes (variance caused by unit settings and type of fuel). As the boiler temperature rises above

160 o F the Mixing Valve will modulate and allow more system return water to be mixed into the boiler therefore supplying more hot water to the zones.

System Pressure

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

Sample System Configuration: Primary/Secondary Pumping System

A sample hydronic system setup using Clean Burn Coil Tube Boilers is shown in Figure 10A. This system, a

Primary/Secondary Pumping System, allows for many special hydronic requirements (e.g. water return temperatures below the normal 140 o F , variable flow zones, multiple zones, multi-temperature systems, and/or multiple boilers) and provides maximum flexibility while maintaining optimal system functioning. A critical advantage of this type of system is that it dramatically reduces the danger of thermal shock to the boiler.

10-2


10-3


CTB System Function and Configuration (continued)

In a Primary/Secondary Pumping System (as shown in Figure 10A), the primary loop circulator runs when any of the zones call for heat. In some system setups, the circulator may run continuously during the heating season.

The circulator pushes hot water past the zone tees; any of the secondary zone pumps can draw hot water out of the first tee (as though the tee were a boiler). Each zone then returns cooler water through the second tee where it mixes with the hot water being pushed through by the primary loop circulator. The close positioning of the two zone tees is crucial to the operation of the system; the tees must be at least 6" but not more than 12" apart. This allows for circulators of different flow rates to be used in the same system while maintaining proper flow and functioning.

CTB Setup Options

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

(1) The boiler circulator (which you may have ordered from Clean Burn for your CTB system) is sized to ensure a flow of water through the coil tube ONLY; it is NOT sized to be used as a system circulator. The boiler circulator must be installed according to Figures 10B and 10C, after the mixing valve. An additional circulator must be installed to flow water through the system and to the boiler.

(2) In low load conditions, Clean Burn recommends the installation of a larger storage tank next to the

CTB to extend the run time and to reduce the occurrence of short cycling. Position the tank close to the boiler to reduce the required connective piping as shown in sample configuration, Figure 10B.

(3) If hot water is required in the system installation for washing or other related activities, Clean

Burn offers Ergomax Heat Exchangers/Storage Tanks in various sizes . Contact your local Clean Burn representative for additional details on these CTB system components. Refer to Figure 10C for a sample system configuration using an Ergomax Heat Exchanger. This configuration is ideal for installations requiring pressure washing, car/truck washing, etc. The Ergomax unit works well with a CTB because it stores boiler water in the tank and acts as a buffer (tempering) tank while enabling reduction of short cycling.

10-4


10-5


10-6


Guidelines for CTB Setup and Operation

1.

2.

3.

4.

5.

Refer to the appropriate illustration in this section for your CTB system configuration, as well as

Figures 4A/4B in the Installation chapter.

Connect the supply and return piping to the heating system. (Additional information in

Section 4).

CAUTION: Hot water pipes shall have clearances of at least 1/2" from all combustible surfaces. For additional technical reference material, see I=B=R Installation and Piping Guide

No. 200.

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

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

Fill the entire heating system with water and vent air from the system according to the following instructions:

(a) Close the isolation valve in the boiler supply piping.

(b) Isolate all circuits by closing the zone valves or balancing valves.

(c) Attach a hose to the purge valve located just below the isolation valve in the boiler supply piping.

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

(d) Starting with one circuit, open the first zone valve ONLY.

(e) Open the purge valve.

(f) Open the fill valve (the make-up water line should be located on the system side of the isolation valve in the boiler supply piping.)

(g) Allow water to overflow from the bucket until discharge from the hose is bubble-free.

ATTENTION: Air in the hose may cause the hose to "jump" and water to spray out; ensure that the area (and equipment nearby) is protected from any possible water damage.

(h) Open the zone valve to the second zone to be purged, then close the first. Repeat this step until all zones have been purged, but always have one zone open. At completion, open all zone valves.

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

Close the fill valve.

NOTE: If the make-up water line is equipped with a pressure reducing valve, the system will automatically fill to 12 psi.

(j) Open the isolation valve in the boiler supply piping.

(k) Remove the hose from the purge valve.

(l) As soon as the boiler is filled, heat the water in the boiler to 180 o F to de-aerate the water.

10-7


Guidelines for Preventing Oxygen Contamination

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

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

• Absorption through open tanks and fittings

• Oxygen permeable material in the distribution system

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

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

• Eliminate open tanks from the system

• Eliminate and/or repair leaky fittings

• Use non-permeable materials in the distribution system

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

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

• Clean the boiler with an alkaline cleaner (e.g. soda ash or detergent) as recommended by a qualified water treatment company.

NOTE: This is necessary to remove oil or other coatings from the tube surfaces. These protective coatings are commonly applied to new tubes to prevent rusting during storage/ transit and will cause corrosion if left on the tubes during operation of the boiler.

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

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

• Refill the system with fresh water.

• Test the pH of the water in the system. The pH should be higher than 8.5 but lower than 9.5.

Add appropriate boiler water treatment compounds as recommended by your qualified water treatment company (if necessary) to bring the pH within the specified range.

• Heat the water in the boiler to 180 o F to de-aerate the water.

Guidelines for CTB Operation

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

(a) Refer to Section 6 for instructions on starting the CTB.

(b) Following burner startup, set the operating control dial at 180-200 o F .

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

10-8


SECTION 11: TROUBLESHOOTING

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

• The Flow Chart outlines the proper sequence of events in boiler operation -- use this chart to help diagnose where a problem may be occurring.

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

Action(s) to fix the problem.

11-1


11-2


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

1.

Circuit breaker/main switch open.

2.

Fuse/breaker blown.

3.

Burner cable is damaged or not plugged in properly.

1.

Oil primary control has shut down on safety reset.

2.

Wall thermostat is not operating.

3.

Heater block is not heating up.

4.

F-120 proving switch has not closed.

5.

Oil primary control terminals are not wired correctly.

6.

Oil primary control is damaged.

7.

The flow switch, operating aquastat, or high limit switch has opened.

POSSIBLE ACTION(S)

1.

Close circuit breaker/switch.

2.

Electrician should check out electrical system.

3.

Check burner cable.

1.

Follow the directions in Section 7 to reset the oil primary control.

2.

Check the wall thermostat and thermostat cable.

3.

Feel the back of the burner; it should be 140 degrees F. If the heater block is NOT HOT: (a)

Wait 15 minutes for the heater block to heat up and re-check the back of the burner, and (b) Check the block heater thermostat and block heater element. Refer to the wiring diagram and ladder schematic in Appendix B.

4.

If the block is HOT: (a) Check the red wire at the F-120 proving switch for power. If there is NO power at the red wire, refer to the wiring diagram and ladder schematic in Appendix B to troubleshoot the circuit that provides power to the proving switch. (b) If there is power at the red wire at the proving switch, check for power at the black wire.

If there is NO power at the black wire, replace the F-120 proving switch.

5.

Check the oil primary control: (a)

Check that the “F” terminals are

NOT jumped. (b) Check that the two yellow cad cell wires are connected to the “F” terminals. (c)

Check that the two thermostat wires are connected to the “T” terminals.

6.

Replace oil primary control: (a)

Check voltage – it must be 115 volts.

7.

Test the switches for power. Note that power should be indicated on both sides of the switch.

11-3


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

1.

There is a fuel delivery problem.

2.

The cad cell is dirty.

3.

Cad cell wires are loose.

4.

Cad cell / cad cell wires are damaged.

5.

The primary control is not receiving the proper ohm signal from the cad cell.

1.

There is air in the suction oil line due to leaks at the fittings

2.

There is air trapped in a high point in the pressure oil line.


1.

Follow the procedures listed in the next problem.

2.

Clean and check the condition of the cad cell and cad cell wires.

3.

Check that the yellow wires are connected properly at the “F” terminals on the oil primary control.

4.

Replace the cad cell and cad cell wires. If the cad cell is heat damaged: (a) Clean your boiler, including the combustion chamber, flues and stack. Refer to instructions in Section 9. (b)

Check for backdraft caused by exhaust fans in your building.

Follow instructions in Section 8.

5.

Disconnect the yellow wires from the “F” terminals. Start the burner and check the ohm reading from the cad cell. You have 10 seconds to perform this test before the burner shuts off on reset. Refer to Section 7 to reset the oil primary control. If the ohm reading is above 500 ohms: (a)

Check the position of the cad cell; the cad cell must “look” straight through the central hole in the retention head. (b) Check the position of the retention head according to Appendix A.

1.

Follow the procedures in Section

5 to vacuum test the pump. Reinstall and properly seal the suction line fittings to eliminate air leaks.

2.

Follow instructions in Section 4 to bleed the air out of the pressure oil line.

11-4


PROBLEM

Burner ignites and Burner shuts off on reset sometime later during the day or night.

POSSIBLE CAUSE

1.

There is air in the fuel supply.

2.

The primary control is not receiving the proper ohm signal from the cad cell.

3.

There is insufficient air pressure.

4.

The heater block is cold.

5.

The electrodes are fouled.


1.

Prime the pump. If the pump will not prime or there is air in the oil stream from the pump bleeder, follow the steps in the next problem (“Pump will not prime.”)

2.

Check for proper ohm signal.

Follow the procedures in the previous problem (top, page 11-4)

3.

Follow the instructions in Section

5 to adjust the air regulator for proper air pressure. DO NOT turn the air compressor off while the boiler is operating. If you turn the air compressor off at night, turn the wall thermostat or aquastat

OFF so the burner will not run.

4.

DO NOT shut off power to the boiler overnight, or the heater block will cool down, and the burner will not re-start the next morning. To turn the boiler “off” overnight, turn the wall thermostat or aquastat OFF. The heater block will stay hot.

5.

If oil residues have built up on the electrodes and retention head, follow the instructions in Section 8 to check for proper draft over fire.

Clean the electrodes and retention head.

11-5


PROBLEM

Pump will not prime and Pump motor is running.

POSSIBLE CAUSE

1.

There is a leak(s) in the suction line.

2.

The pump is not installed so it will fill with oil during the priming process.

3.

The pump gears are dry.

4.

The pump seal is damaged.

5.

The ball valve is closed.

6.

The canister filter is dirty.

7.

The check valve is dirty.

8.

The pump is damaged or worn out.


1.

Follow the specifications in

Section 4 to make sure the suction line is installed properly and that all fittings are 100% airtight.

2.

Make sure the pump head is filled with oil prior to starting the pump.

See Section 5.

3.

Follow the procedure in Section 5 to fill the oil line and prime the pump.

4.

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.

5.

Open the ball valve on the suction line.

6.

Refer to Section 9 to clean the canister filter.

7.

Refer to Section 9 to clean the check valve.

8.

Replace the pump.

11-6


PROBLEM

Pump will not prime and Pump motor is

NOT running.

POSSIBLE CAUSE

1.

There is NO power on the pump circuit from the burner.

2.

The pump motor has shut off on thermal overload.


1.

Start the burner and adjust the air pressure regulator to 15 PSI. (a) If the amber “pump” light on the burner comes ON, the pump circuit on the burner has activated properly. Refer to the wiring diagram and ladder schematic in Appendix B to troubleshoot the pump circuit from the burner to the pump. (b) If the amber

“pump” light on the burner does NOT come ON, there is a problem with pump circuit in the burner. With the burner running, check for power at the brown wire on the air pressure switch.

If there is NO power at the brown wire, replace the burner motor. If there is power at the brown wire, replace the air sensing switch.

2.

(a) The pump motor is too hot—the internal thermal protection switch shut the motor off. Wait for the motor to cool down; the thermal switch will automatically reset. Check voltage and amperage draw of the pump motor. Call your dealer if the problem persists. (b) The coupling is not adjusted properly, keeping the shafts of the motor and pump from turning freely. Re-position the coupling so that both shafts turn freely. (c) The shaft on the motor or oil pump will not turn freely. If you can’t turn the shafts, replace the faulty part(s).

11-7


11-8


APPENDIX A

Detailed Coil Tube Boiler Specifications

CTB Technical Specifications

Model

BTUH Input

Listed Fuels: #2 Fuel Oil

Used Crankcase Oil

Used ATF

Used Hydraulic Oil

#4, #5 Fuel Oils

Water Volume

(gallons)

Cabinet Dimensions

(LxWxH)

Overall Length

(with burner/breach)

Approximate Weight

Mounting

Electrical Requirements

(VAC @ 60 Hz)

Circuit Breaker

Approximate Amp Draw

Max. Oil Consumption

Oil Pump

Oil Pump Motor

Pump Motor Rotation

Canister Filter

Stack Size

Approx. Air Compressor

Requirements

CB-200-CTB

200,000*

1.4

5 gal.

40 x 29 x 29.5”

59”

677 lbs. (dry)

Non-Combustible

Floor

115

15 amps**

9

1.4 GPH

Suntec

A2RA-7720

Bison Gear Motor

1/20 HP

CCW shaft end

Lenz

DH 750-100

8”

2.0 CFM

@ 25 PSI

CB-350-CTB

350,000*

2.5

12 gal.

56 x 34 x 34.5”

74”

1240 lbs. (dry)

Non-Combustible

Floor

115

20 amps**

10

2.5 GPH

Suntec

A2RA-7720

Bison Gear Motor

1/20 HP

CCW shaft end

Lenz

DH 750-100

8”

2.5 CFM

@ 25 PSI

*Nominal values; actual values will vary depending on installation.

** With optional accessories, 30 amps may be required.

CB-500-CTB

500,000*

3.57

20.6 gal.

66.38 x 40 x 42”

86.13”

1600 lbs. (dry)

Non-Combustible

Floor

115

20 amps**

12

3.57 GPH

Suntec

A2RA-7720

Bison Gear Motor

1/20 HP

CCW shaft end

Lenz

DH 750-100

10”

2.5 CFM

@ 25 PSI

A-1


Burner Technical Specifications

Model

Burner

Ignition Transformer

Nozzle

Burner Motor

Burner Motor Rotation

Compressed Air

Requirements

Oil Primary Control

Heater Element in

Preheater Block

Air Pressure Switch

Heater Thermostat

CB-200-CTB

CB-525-S2

Carlin

14,000 Volts

Delavan 9-5

1/10 HP 3000 rpm

(w/ Centrifugal Switch)

CCW shaft end

2.0 CFM

@25 PSI

Carlin Oil

Primary 402

(w/ Interrupted Ignition)

400 Watts

CB-350-CTB

CB-551-H3

Carlin

14,000 Volts

Delavan 9-5

1/10 HP 3000 rpm


CCW shaft end

2.5 CFM

@25 PSI

Carlin Oil

Primary 502


400 Watts

MPL 808

140 o F

MPL 808

140 o F

CB-500-CTB

CB-551-H5

Carlin

14,000 Volts

Delavan 9-28

1/10 HP 3000 rpm


CCW shaft end

2.5 CFM

@25 PSI

Carlin Oil

Primary 502


500 Watts

MPL 808

160 o F

CB-200-CTB Hydronic Specifications

NOTE: These specifications apply for each CTB unit or coil.

• Water flow through the boiler:

15 GPM at 20 -22 ft. of head (pressure)

• Coil Dry Weight: 189 lbs.

• System operating pressure: 12 to 22 psi

• 20 o F temperature rise ( ΔΤ ) • Standard relief valve setting: 30 psi

• ASME coil length: 112 ft. long, 1" diameter steel • Relief valve capacity: 550 MBH tubing made to Sch. 40 pipe size

• Coil Volume: 5 Gallons


• Heating surface: 38.7 sq. ft.

• Factory Recommended Boiler Circulator:

TACO 0011


• Water flow through the boiler: • Coil Dry Weight: 359 lbs.

25 GPM at 18-20 ft. of head (pressure) • System operating pressure: 12 to 22 psi


• ASME coil length: 158 ft. long, 1-1/4" diameter • Relief valve capacity: 710 MBH steel tubing made to Sch. 40 pipe size

• Coil Volume: 12.3 Gallons

• Heating surface: 68 sq. ft.



B&G PL36

B&G PL55 (over 20 ft. of head)


• Water flow through the boiler:

37 GPM at 22 ft. of head (pressure)

• Coil Dry Weight: 530 lbs.

• System operating pressure: 12 to 22 psi


• ASME coil length: 195 ft. long, 1-1/2" diameter • Relief valve capacity: 970 MBH steel tubing made to Sch. 40 pipe size

• Coil Volume: 20.63 Gallons

• Heating surface: 97 sq. ft.


TACO 2400-50/2

A-2


CTB Accessories and Parts Reference

C.B. Part #

500-CTB

11578

90206

35130

35134

35120

35121

35125

28150

35110

35111

28149

35123

35124

33330

35136

35049

350-CTB

90187

90188

35078

35112

35080

35061

35079

35053

28150

35110

35111

28149

35123

35124

35117

33330

35135

35049

200-CTB

90199

90200

11095

35080

35116

35079

35053

28150

35110

35111

28149

35123

35124

33330

35048

35049

Description

Boiler Stacking Adapter Kit

Boiler Stand (base)

Circulator, TACO 0011, 115VAC

Circulator, B&G PL-36, 115VAC

Circulator, B&G PL-55, 115VAC

Circulator, TACO 2400-50/2 115VAC

B&G Circulator Flange Gasket O-Ring

TACO Circulator 500 Flange Gasket O-Ring

Flange, 1" NPT

Flange, 1-1/2 NPT

Flange, 1-1/4 NPT

TACO Flange, 500 2" NPT Set

TACO Flange, 500 1-1/2" NPT Set

Flange Gasket, 3-hole

500 Flange Gasket, 3-hole

Operating Aquastat, L4006A

Electronic Low Water Cut-Off with Probe, 750P-MT-120

Probe (only) for Low Water Cut-Off

High Temperature Cut-off, L4006H

Taco Flow Switch (without paddle)

Stainless Steel Paddle for Taco Flow Switch (sized to fit)

Stainless Steel Paddle for M&M Flow Switch (sized to fit)

Temp-Pressure Boiler Gauge

Relief Valve, 30 PSI

Well Immersion, 3/4" NPT

Ergomax Indirect Water Heater (Heat Exchangers)*

*Contact the CB Parts/Service Department for help in specifying the appropriate model.

35113

35096

35097

35098

35099

35100

E23

E24

E44

E45

E65

E109

35107

35108

Air Separator, EAS - 1-1/2 (1-1/2" piping with air vent)

Air Separator, EAS -2 (2" piping with air vent)

Remote Temperature Controls

33557 Wall Thermostat

A-3


CTB Dimensions

Figure A1 - Model CB-200-CTB Dimensions (Single Boiler)

A-4


CTB Dimensions

Figure A2 - Model CB-350-CTB Dimensions (Single Boiler)

A-5


CTB Dimensions

Figure A4 - Dual-Stacked Boiler Dimensions (Two CB-350-CTB Boilers)

A-6


CTB Dimensions

Figure A3 - Model CB-500-CTB Dimensions

A-7


CTB Dimensions

Figure A4 - Dual-Stacked Boiler Dimensions (Two CB-500-CTB Boilers)

A-8


A-9

22

21

20

19

18

17

16



CB−350−CTB

SHOWN

1 2

DETAIL OF ITEM 24

33

23

24

25

26

8

9

10

6

4

5

27

28

29

30

31

32

14

7

3

11

12

(USER

SUPPLIED)

13

15

34

Figure A5 - Single Boiler Assembly Component Detail

A-10

I88121−F


CB-350-CTB PARTS LIST

NUMBER QTY PART

29

26

25

21

1

1

1

1

33486

27058

12240

31176

TERMINAL BLOCK ASSEMBLY

CONTROL BOX LID

CONTROL BOX 120 AC

INSULATION – DOOR

15

14

1

1

13141

14272

ACCUMULATOR BLOCK ASSEMBLY

UPPER PIPE ASSEMBLY

12 1 35078 CIRCULATOR PL36 115V 60Hz

11 1 14293 CHECK VALVE AND PIPE ASSEMBLY

10 1 13110 CUT-OFF

7

5

1

1

35048

28149

RELIEF VALVE 3/4” MALE

HIGH TEMP CUT-OFF

1 1 11380

4

2

1

11

9


NO QTY PART # DESCRIPTION

34 1 90200 BASE

14

13

12

22

21

20

1

1

1

1

1

1



11540 DOOR W.A.


35079 1-1/4” FLANGE

11095 CIRCULATOR TACO 0011 115 V

1

1

1

1

1



35116 COIL FLANGE 1” NPT



PANEL 350 REAR W.A.

11

9

4

2

1

20

14

13

12

NO

34

22

21


QTY PART # DESCRIPTION

1

1

1

1

1

1

1

1

1

1

1

1

90206 BASE



11564 DOOR W.A.


35120 FLANGE 2” SET

35130 CIRCULATOR TACO 2400-50/2 115V



35121 FLANGE 1-1/2” SET



Refractory Cylinder

200-CTB

21120

Refractory Cylinder Stand 27155

350-CTB

21140

27190

500-CTB

21174

27200

A-11


Burner Components CB-200-CTB

3

5

6

SEE ILLUSTRATION

I88543 FOR PART

NUMBERS

23

22

1

2

4

21

7

1

2

4

5

6

7 8

1

0 1

1 1

2 1 3

20

8

0

1

3

4

5

2 psi

6

7

8

15

14

13

12

9

10

11

9

10

20

30

40

0

10 p si

60

50

11

12

BURNER CB − 525 − S2

19

13

14

15

I88234−C

16

17

25

24

26

27

18

Figure A6 - CB-525-S2 Burner Component Detail (CB-200-CTB)

A-12


Burner Components CB-200-CTB((continued)

Item# Clean Burn Part#

16

17

18

19

20

11

12

13

14

15

24

25

26

21

22

23

6

7

8

9

10

1

2

3

4

5

27

32253

33297

33169

33168

31113

26044

33175

26053

11335

13148

26103

11359

33400

33335

33189

33116

11243

32178

32235

32179

11265

SEE NOTE

11334

33149

33508

26052

11308

Component Description

AIR INTAKE OUTER PLATE

AIR INTAKE INNER PLATE

CARLIN PRIMARY CONTROL (W/ INTERRUPTED IGNITION)

ISOLATOR (OPTIONAL)

CARLIN IGNITER (TRANSFORMER)

CAD CELL

TRANSFORMER 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 (60 Hz)

GREEN LIGHT (POWER)

AMBER LIGHT (PUMP)

FAN SQUIRREL CAGE

MOTOR MOUNT PLATE

BLOWER MOTOR

RIGHT SIDE COVER

HOUSING (INCLUDES ITEM 23)

HEATER BLOCK ASSEMBLY

COVER-HINGED

NOZZLE ADAPTER ASSEMBLY

HINGE MOUNTING PLATE

CONNECTOR RECEPTACLE

CONNECTOR CORD (CB-200-CTB)

LATCH BRACKET

RETENTION HEAD

A-13



3

4

24

23

5

22

SEE ILLUSTRATION

I88543 FOR PARTS

NUMBER.

21

1

2

25

20

1

2

4

5 6

7

8

1

0 1

1 1

2 1

3

6

19

7

0

1

2

3

4

5

6 psi

7

8

15

14

13

9

10

12

11

8

11

9

0

10

20

30

40 psi

60

50

10

BURNER CB − 551 − H3

12

13

14

I88239−B

15

18

16

Figure A7 - CB-551-H3 Burner Component Detail (CB-350-CTB)

26

17

A-14


C. B. Part#

26103

11359

33610

33189

33116

11243

32178

32235

32179

32253

33297

33169

33168

31113

26044

33175

14085

11335

13148

11265

SEE NOTE

11334

14088

33546

26052

11376

Burner Components CB-350-CTB (continued)

Item#

12

13

14

15

16

7

8

9

10

11

4

5

6

1

2

3

22

23

24

25

26

17

18

19

20

21


Air Intake Outer Plate

Air Intake Inner Plate

Electronic Primary Control (w/ Interrupted Ignition)

Carlin Igniter (Transformer)

Cad Cell

Transformer Plate

Oil Gauge, 0-15 psi

Female Elbow, 3/16T x 1/8 NPT

Air Gauge, 0-60 psi

Female Elbow, 1/8TP x 1/8 NPT

Hour Meter, 60 Hz

Green Light (Power)

Amber Light (Pump)

Fan Squirrel Cage

Motor Mounting Plate

Blower Motor

Right Side Cover

Housing (includes item 23)

Heater Block Assembly

Cover, Hinged

Nozzle Adapter Assembly

Hinged Mounting Plate

Connector Receptacle

Connector Cord (CB-350/500 CTB)

Latch Bracket

Retention Head

A-15


Burner Components (continued)

9

15

8

7

2

6

10

1

3

4

14

13

5

11

(2)

(2)

12

52

51

50

49

48

58

57

56

55

54

53 59

27 60

46

26

(4)

17 28

25

36

37

38

39

40

41

42

43

45

44

47

46

30

(8)

31

32

(8)

33

34

35

29

1

2

3

4

5

6

7

8

9

1

0

1

1 1

2

1 3

24

16

17 19 21

(2)

23

20

18

22

I88543−A

Figure A8 - Preheater Block and Electrode Assembly Component Detail

CB-525-S2 and CB-551-H3 Burners (CB-200-CTB and CB-350-CTB)

A-16


C.B. Part# Qty.

14090

34148

34114

34147

34022

32306

32226

32364

32227

32360

26090

32190

32202

32201

33173

33041

32325

54020

33011

32359

32199

32050

32189

32043

54020

32201

33247

34036

26059

33057

34169

33183

34165

32000

13150

32007

33298

33381

33418

33313

33314

33315

33316

33317

33318

33319

33320

33321

32322

26107

32361

32223

32222

32221

32362

13142

32308

32309

33311

33312

2

2

2

2

2

1

8

8

2

2

1

1

1

1

1

1

2

1

1

1

2

1

4

1

1

1

2

2

1

1

1

1

1

1

1

1

1

1

1

2

2

1

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

Item#

35

36

37

38

39

30

31

32

33

34

2 5

26

27

28

2 9

2 0

2 1

22

23

2 4

15

16

17

18

19

10

11

12

13

14

5

6

7

8

9

3

4

1

2

55

56

57

58

59

60*

50

51

52

53

54

45

46

47

48

49

40

41

42

43

44


ELECTRODE SCREW - 10-32 x 3/4

SINGLE PIECE ELECTRODE

WASHER

9 - 5 NOZZLE

NOZZLE ADAPTOR

PLUG - 1/8 NPT

140 WATTS HEATER

INSULATED CAP CRIMP CONNECTOR

THERMOSTAT L-130

PLUG - 1/16 NPT

SWIVEL FITTING

HEX NIPPLE - 1/8 NPT x 1-1/2

MALE CONNECTOR - 3/16T x 1/8 NPT

3/16 COPPER TUBING(OIL GAUGE LINE)

MACH. SCREW PHILLIPS HD. 6-32 x 3/8 Z

TERMINAL BLOCK


TERMINAL BLOCK BRACKET

AIR PRESSURE SWITCH

HEATER BLOCK

HEX NIPPLE - 1/8 NPT x 2

FEMALE ELBOW (FOR 1/4" AIR LINE)

FEMALE ELBOW (FOR 3/8" OIL LINE)

PRE-HEATER ELEMENT - 400 WATTS

PROVING SWITCH (NORMALLY OPEN)

MALE ELBOW 1/8 x 1/8 NPT (FOR AIR GAUGE LINE)


HEATER BLOCK THERMOSTAT(NORMALLY CLOSED)

REGULATOR SURFACE MOUNT

REGULATOR LOCK PLATE

REGULATOR MOUNTING SCREW

LOCK WASHER #8 Z

REGULATOR THREADED STEM

HEX NU T - 10-32 Z

BONNET

DIAPHRAM RING

CAP AND BALL ASSEMBLY

COMPRESSION SPRING

DIAPHRAM

BRASS POPPET SEAT

POPPET ‘O” RING

POPPET VALVE

POPPET SPRING

BASE

REGULATOR KIT COMPONENTS

REGULATOR OUTER “O” RING

REGULATOR INNER “O” RING

SOLENOID INNER “O” RING

SOLENOID OUTER “O” RING

MANIFOLD MOUNT SOLENOID BODY

BODY “O” RING

PLUNGER ASSEMBLY

PLUNGER GUIDE ASSEMBLY

FLUX PLATE

WASHER SEAL

COIL

COIL HOUSING

NUT

AIR/OIL SOLENOID ASSEMBLY

REG. SQUARE CAP*

*NOTE: When the CTB is used with a metering pump, the oil regulator must be removed from the burner and replaced with the square cap.

A-17



3

4

5

22

SEE ILLUSTRATION

I88975 FOR PART

NUMBERS

21

24

23

27

1

2

25

20

6

1

2

4

5

6

7

8

1 1 1

2

1

19

26

7

0

1

2

3

4

5 psi

6

7

8

15

14

13

9

10

12

11

8

9

20

0

10 psi

30

60

50

40

10

11

12

13

14

I88969−B

15

18

16

BURNER CB − 551 − H5

Figure A9 - CB-551-H5 Burner Component Detail (CB-500-CTB)

17

A-18


C. B. Part#

11585

11584

33610

33189

33116

11243

32178

32235

32179

32253

33297

33169

33168

31113

26044

33175

14085

11335

13179

11265

SEE NOTE

11334

14088

33546

26052

11376

34417

Burner Components CB-500-CTB (continued)

Item#

12

13

14

15

16

7

8

9

10

11

4

5

6

1

2

3

22

23

24

25

17

18

19

20

21

26

27


Air Intake Outer Plate

Air Intake Inner Plate

Electronic Primary Control (w/ Interrupted Ignition)

Carlin Igniter (Transformer)

Cad Cell

Transformer Plate

Oil Gauge, 0-15 psi

Female Elbow, 3/16T x 1/8 NPT

Air Gauge, 0-60 psi

Female Elbow, 1/8TP x 1/8 NPT

Hour Meter, 60 Hz

Green Light (Power)

Amber Light (Pump)

Fan Squirrel Cage

Motor Mounting Plate

Blower Motor

Right Side Cover

Housing (includes item 23)

Heater Block Assembly

Cover, Hinged

Nozzle Adapter Assembly

Hinged Mounting Plate

Connector Receptacle

Connector Cord (CB-350/500 CTB)

Latch Bracket

Retention Head

Wing Nut 5/16

Note: When installing the blower and motor into the burner housing, the blower wheel needs to be adjusted to reduce the air gap between the side and the wheel to a maximum of 3/32" (.09375")

A-19


2

1

3

4

9

8

7 6

10

5

11

(2)

(2)

12

52

51

50

49

48

58

57

56

55

54

53 59

27 60

46

26

25

28

15

16

1

2

3

4

5

6

7

8

9

1

0

1

1 12

1

3

17

14

13

18

19

20

21

(2)

22

23

Figure A10 - Preheater Block and Electrode Assembly Component Detail

CB-551-H5 Burner (CB-500-CTB)

A-20

36

37

38

39

40

41

42

43

45

44

47

46

30

(8)

31

32

(8)

33

34

35

29

24

I88975−A


C.B. Part# Qty.

14090

34148

34114

34147

34022

32306

32226

32364

32227

32360

26126

32190

32202

32201

33334

33041

32325

54020

33561

32359

32199

32050

32189

32043

54020

32201

33247

34036

26059

33057

34169

33183

34165

32006

13150

32007

33298

33381

33418

33313

33314

33315

33316

33317

33318

33319

33320

33321

32322

26107

32361

32223

32222

32221

32362

13142

32308

32309

33311

33312

2

2

2

2

2

1

8

8

2

2

1

1

1

1

1

1

2

1

1

1

2

1

4

1

1

1

2

2

1

1

1

1

1

1

1

1

1

1

1

2

2

1

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

Item#

35

36

37

38

39

30

31

32

33

34

2 5

26

27

2 8

2 9

2 0

2 1

22

23

2 4

15

16

17

18

19

10

11

12

13

14

5

6

7

8

9

3

4

1

2

55

56

57

58

59

60*

50

51

52

53

54

45

46

47

48

49

40

41

42

43

44


ELECTRODE SCREW - 10-32 x 3/4

SINGLE PIECE ELECTRODE

WASHER

9 - 28 NOZZLE

NOZZLE ADAPTOR

PLUG - 1/8 NPT

140 WATTS HEATER

INSULATED CAP CRIMP CONNECTOR

THERMOSTAT L-130

PLUG - 1/16 NPT

SWIVEL FITTING

HEX NIPPLE - 1/8 NPT x 1-1/2

MALE CONNECTOR - 3/16T x 1/8 NPT



TERMINAL BLOCK


TERMINAL BLOCK BRACKET

AIR PRESSURE SWITCH

HEATER BLOCK

HEX NIPPLE - 1/8 NPT x 2

FEMALE ELBOW (FOR 1/4" AIR LINE)

FEMALE ELBOW (FOR 3/8" OIL LINE)

PRE-HEATER ELEMENT - 500 WATTS

PROVING SWITCH (NORMALLY OPEN)

MALE ELBOW 1/8 x 1/8 NPT (FOR AIR GAUGE LINE)


HEATER BLOCK THERMOSTAT(L160)

REGULATOR SURFACE MOUNT

REGULATOR LOCK PLATE

REGULATOR MOUNTING SCREW

LOCK WASHER #8 Z

REGULATOR THREADED STEM

HEX NU T - 10-32 Z

BONNET

DIAPHRAM RING

CAP AND BALL ASSEMBLY

COMPRESSION SPRING

DIAPHRAM

BRASS POPPET SEAT

POPPET ‘O” RING

POPPET VALVE

POPPET SPRING

BASE

REGULATOR KIT COMPONENTS

REGULATOR OUTER “O” RING

REGULATOR INNER “O” RING

SOLENOID INNER “O” RING

SOLENOID OUTER “O” RING

MANIFOLD MOUNT SOLENOID BODY

BODY “O” RING

PLUNGER ASSEMBLY

PLUNGER GUIDE ASSEMBLY

FLUX PLATE

WASHER SEAL

COIL

COIL HOUSING

NUT

AIR/OIL SOLENOID ASSEMBLY

REG. SQUARE CAP*

*NOTE: When the CTB is used with a metering pump, the oil regulator must be removed from the burner and replaced with the square cap.

A-21



NOZZLE

ELECTRODE

NOZZLE ADAPTER

SPARK GAP

OUTLINE OF RETENTION HEAD

3/16"

1/8"

NOZZLE TO BE AHEAD OF

RETENTION HEAD BY 1/8" I88144

ATTENTION: Make sure the electrodes are adjusted to the specifications in these diagrams.

Correct clearances must be maintained to avoid stray arcing. The minimum clearance to any ground source is 3/16". Stray arcing results in a weak spark, late burner ignition, and transformer failure.

NOTE: Clean Burn recommends the use of a special tool (CB Part# 70306) to set the retension head.

The burner electrodes should be replaced annually to maintain proper burner performance.

• Install the electrodes according to the setting and specifications in these diagrams.

• Use the shank of a 1/8" drill bit as a feeler gauge to set the spark gap at 1/8".

Figure A11 - Burner Electrode Specifications

A-22



Model

CB-200-CTB

CB-350-CTB

CB-500-CTB

Nozzle Size

Delavan 9-5

Delavan 9-5

Delavan 9-28

NOZZLE SIZE IS

STAMPED ON

FLAT OF

NOZZLE HEAD

HEAD DISTRIBUTOR

ORIFICE

STEM

O−RING

I88378

Removing the Nozzle for Cleaning:

2.

3.

4.

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.

Disconnect the burner power cable.

Carefully swing the burner open to its maintenance position.

Remove the nozzle from the nozzle adapter with a 5/8" socket.

5.

6.

Cleaning the Nozzle:

1.

2.

3.

4.

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 necessary.

NOTE: If the nozzle plugs within a few days after cleaning, call your Clean Burn Dealer for service.

Figure A12 - Cleaning the Nozzle

A-23


CB-200-CTB

60

43

17

A-24

I88961-B

7


33

34

35

36

37

29

30

31

32

25

26

27

28

21

22

23

24

12

13

14

15

8

9

10

11

ITEM #

1

2

3

6

7

4

5

16

17

18

19

20

50

51

52

53

46

47

48

49

54

55

56

57

58

42

43

44

45

38

39

40

41

PART # DESCRIPTION

27139 JACKET RH SIDE 200

70470 MIXING VALVE 140F & FLEX PIPE KIT 200 ‐ CTB

12240 CONTROL BOX 120 V A

14298 PIPE & CHECK VALVE 1 1/4 A

35053 GASKET FLANGE

35079 FLANGE 1 ‐ 1/4 NPT; BLACK

35052 NIPPLE 1 1/4 X 2 BLK

35118 NIPPLE 1 1/4 X 3 BLK

35115 SWING CHECK VALVE 1 1/4 NPT

35051 TEE 1 1/4 X 3/4 X 1 1/4 BLK

35065 BOILER DRAIN 3/4 NPT

27148 SHIELD RET TUBE

21057 HINGE BRACKET

70

71

90200 BOILER STAND 200 CTB 72

27136 BASE 200 CTB 73

66

67

68

69

ITEM # PART # DESCRIPTION

59 35146 BUSHING 1 1/4" ‐ 3/4" BLK

60

61

11549 BOILER STACK ADAPTOR 200CTB

33145 SCREW LUG

62

63

64

65

33168

33486

33286

33352

AMBER

SWITCH

RELAY

LIGHT

TERMINAL BLK

DPDT

DELAY

A;

ON

DIN

‐ ON

‐ RAIL SCREW

27189 SEAL PLATE STAMPED 200

27144 SEAL PLATE FRONT OUTER

74

74

27147 BRACKET HINGE 200 CTB 75

27146 FILLER FRONT TUBE 76

11537 BASE 200 CTB WA 77

33328

33327

33131

27109

33331

54013

27143

27134

31264

11154

31215

RELAY

KNOCK

BOX

SEAL

ROPE

RING

‐

‐

DPDT

ENERGY

TARGET

OUT

TERMINAL

TOP

PLATE

INSULATION

TRANSFORMER

JUNCTION

STACK

200

24

A

BLOCK

FIBERGLASS

REAR

(REFRAC)

‐

120V

SEAL/PLUG

HD

END

RETENTION

OUTER

(4 POST)

250

CTB

W/ADH

DISC,

DISC

REAR

2

ASSY

‐ BOLT (W/HDWR)

PANEL

11539 PANEL REAR 200 CTB WA

35116 FLANGE 1 NPT

27133 RING BURNER END 78

27155 STAND REFACY CYL 200 CTB 79

27132 BAFFLE RH 200

27129 RING BOTTOM STACK END

21056 HINGE BRACKET 80 27803 COIL 1" TUBE 22.5

T 200CTB

11540 DOOR 200 CTB WA

11582 HINGE BRKT 3DEG BURNER WA

14061 HOOK ‐ UP KIT ‐ 200,350,2800 11420 BURNER CB ‐ 525 ‐ S2 ASSEMBLY

34120 5/16 ‐ 18 X 2 3/4 CARR BOLT S.S.

11550 BOILER 200 CTB CABINET A

11583 BURNER MOUNT 3 DEG WA 14301 PUMP METERING CB 200 CTB A

11325 INSPECTION DOOR A 14302 BOLT HOLE FIBERGLASS TAPE A

34118 5/16 ‐ 18 X 3/4 HEX HEAD TAP SCREW 14304 ACCESSORIES 200 CTB GP

34009 3/8 ‐ 16 HEX SERR FLANGE NUT PLT 70427 DUCT CAP ROUND 8" ‐ 24 GA.

31216 INSULATION 200 FRONT DOOR 31170 DAMPER 8"

21120 REFRACTORY CYL 10 X 14 31217 INSULATION STRIP 200 TOP

27138 JACKET LH SIDE 200 31218 INSULATION STRIP 200 BOT FRT

27131 BAFFLE LH 200 31219 INSULATION STRIP 200 BOT CENTR

27150 LINER PROTECTOR 31220 INSULATION STRIP 200 BOT REAR

27149 LINER TOP CRADLE 34162 STOVE CEMENT ‐ HIGH TEMP

27123 BRACKET 350 HINGE 42027 LABEL ‐ WARNING ‐ BURN/VOLTAGE

11538 CRADLE TOP WA 42030 LABEL ‐ VOLTAGE WARNING

33508 CORD 43" CONN PLUG 42216 LABEL ‐ LOGO ‐ SMALL

27158 BRACKET BURNER CORD 42217 LABEL ‐ AIR OIL

27140 JACKET TOP 200 42231 LABEL ‐ PRIME PUMP/RUN BURNER

14335 MIXING VALVE VTC511 & T ‐ STAT 140F A.

42261 LABEL ‐ THRMOSTAT/BURNER

35138 THERMOSTAT 160F/60C FOR VTC511 42421 LABEL ‐ BOILER WARNING

35139 THERMOSTATIC BYPASS VALVE VTC511 1 ‐ 1/4" 44052 SCHEM CB 350 CTB (Wiring Dia gra m)

35147 METAL FLEX HOSE 1 1/4" ‐ 16" 42464 LABEL UL DATA CB 200 CTB

35141 CROSS 1 1/4 NPT BLK 43146 OPERATORS MANUAL CB 200/350/500 CTB

35119 1 1/4 X 1 1/4 X 1 TEE BLK 54013 ROPE ‐ FIBERGLASS HD 250 W/ADH

35124 PADDLE TACO FLOW SW 54104 HYDRAULIC / PNEUMATIC SEALANT

35066 TEE 1 1/4 X 1 1/4 X 3/4 BLK

35048 RELIEF VALVE 3/4 M

35049 WELL 3/4 NPT X 1 1/2 EXT (INS)

28149 AQUASTAT 100 ‐ 240F HIGH LIMIT

35123 FLOW SWITCH; TACO

35110 LOW WATER CUT ‐ OFF CONTROL UNIT

35057 BUSHING 3/4 X 1/2 BLK

33330 GAUGE BOILER, TEMP ‐ PRESSURE

28150 AQUASTAT 100 ‐ 200F OPERATING

A-25


CB-350-CTB

64

45

44

18

A-26

I88962-B

8



52

53

54

55

56

57

58

48

49

50

51

44

45

46

47

38

39

40

41

42

43

29

30

31

32

25

26

27

28

33

34

35

36

37

21

22

23

24

15

16

17

18

19

20

10

11

12

13

14

3

4

5

1

2

6

7

8

9


27093 JACKET R.H.

SIDE 59

12240 CONTROL BOX 120 V A 60

70471 MIXING VALVE 140F & FLEX PIPE KIT 350 ‐ CTB 61

14293 CHECK AND DRAIN 350 PIPE A 62

35053 GASKET FLANGE 63

35061 FLANGE 1 1/2 NPT, BLACK 64

35081 SWING CHECK 1 1/2 65

35069 NIPPLE 1 1/2 X 2 BLK 66

35082 TEE 1 1/2 X 3/4 X 1 1/2 BLK 67

35065 BOILER DRAIN 3/4 NPT 68

90188 BOILER STAND 350 69

21057 HINGE BRACKET 70

35079 FLANGE 1 ‐ 1/4 NPT; BLACK 71

27084 BASE CTB 72

11373 BASE CTB WA 73

27186 SEAL PLATE STAMPED 350 74

54013 ROPE ‐ FIBERGLASS HD 250 W/ADH 75

27188 SEAL PLATE FLAT FRONT 350 76

27193 BRACKET HINGE 500 77

27191 FILLER FRONT TUBE 350 CTB 78

27086 RING BURNER END 78

27190 STAND REFRACTORY 1 Pc 350 79

31176 INSULATION 350 DOOR 80


35057 BUSHING 3/4 X 1/2 BLK

33330 GAUGE BOILER, TEMP ‐ PRESSURE

35145 BUSHING 1 1/2" ‐ 3/4" BLK

28150 AQUASTAT 100 ‐ 200F OPERATING

35118 NIPPLE 1 1/4 X 3 BLK

90187 BOILER STACKING ADAPTOR 350

33131 KNOCK ‐ OUT SEAL/PLUG

33286 SWITCH DPDT ON ‐ ON

33168 AMBER LIGHT

33486 TERMINAL BLK A; DIN ‐ RAIL SCREW

33145 SCREW LUG

33352 RELAY DELAY

33328 RELAY DPDT

33327 TRANSFORMER 24 ‐ 120V

27109 BOX JUNCTION A

33331 TERMINAL BLOCK (4 POST) CTB

27187 SEAL PLATE FLAT REAR 350

27089 RING TOP STACK END

34150 3/8 ‐ 16 X 4 HHCS 18 ‐ 8

31264 ENERGY RETENTION DISC, 2 ‐ BOLT (W/HDWR)

11154 TARGET (REFRAC) DISC ASSY


11380 PANEL REAR 350 WA

34067 3/8 ‐ 16 FIN HEX NUT 18 ‐ 8 S.S.

11405 DOOR WA 82

11582 HINGE BRKT 3DEG BURNER WA 83

27037

27088

14061 HOOK ‐ UP KIT ‐ 200,350,2800

34118 5/16 ‐ 18 X 3/4 HEX HEAD TAP SCREW

RING STACK

BAFFLE LH

END

34120 5/16 ‐ 18 X 2 3/4 CARR BOLT S.S.

11369 CB 551 H3 BURNER A

11583 BURNER MOUNT 3 DEG WA 11412 DOOR 350 A.

11325 INSPECTION DOOR A 14201 ACCESSORIES 350 GP

34009 3/8 ‐ 16 HEX SERR FLANGE NUT PLT 28148 CTB 350 CABINET ASSEMBLY

21140 REFRACTORY CYL (1 Pc.

350) 70427 DUCT CAP ROUND 8" ‐ 24 GA.

27050 JACKET L.H.

SIDE 31162 INSULATION 24 X 55 1/2

27087 BAFFLE RH 31163 INSULATION STRIP 3.06

X 55.50

27090 LINER COMBUSTION CHAMBER 31164 INSULATION TOP 48 X 51

27802 COIL 1 1/4 PIPE 26.5T

31168 INSULATION STRIP 21 5/8 X 55 1/2

27115 LINER PROTECTOR 31169 INSULATION STRIP 5 5/16 X 55 1/2

27123 BRACKET 350 HINGE 31170 DAMPER 8"

11374 COVER TOP WA 31173 INSULATION STRIP 2 1/4 X 28

33546 CONN CORD 4 ‐ WIRE 51" 34162 STOVE CEMENT ‐ HIGH TEMP

27158 BRACKET BURNER CORD 42027 LABEL ‐ WARNING ‐ BURN/VOLTAGE

27095 JACKET TOP CTB 42030 LABEL ‐ VOLTAGE WARNING


35138 THERMOSTAT 160F/60C FOR VTC511

42216

42217

LABEL

LABEL

‐

‐

LOGO

AIR

‐

OIL

SMALL

35139 THERMOSTATIC BYPASS VALVE VTC511 1 ‐ 1/4" 42231 LABEL ‐ PRIME PUMP/RUN BURNER

35148 METAL FLEX HOSE 1 1/4" ‐ 24" 42286 LABEL ‐ IDENT CB ‐ 350 CTB

35149 BUSHING 1 1/2" ‐ 1 1/4" BLK 42261 LABEL ‐ THRMOSTAT/BURNER

35140 CROSS 1 1/2 NPT BLK 42292 LABEL ‐ CTB WIRING CTB ‐ 200/350/500

35068 NIPPLE 1 1/2 X 6 BLK 42366 LABEL ‐ TANK WARNING

35084 TEE 1 1/2 X 1 1/2 X 1 BLK 42367 LABEL ‐ FURNACE WARNING

35124 PADDLE TACO FLOW SW 42421 LABEL ‐ BOILER WARNING

35083 TEE 1 1/2 X 1 1/2 X 3/4 BLACK 43146 OPERATORS MANUAL CB 200/350/500 CTB

35049 WELL 3/4 NPT X 1 1/2 EXT (INS) 44052 SCHEM CB 350 CTB

28149 AQUASTAT 100 ‐ 240F HIGH LIMIT 54104 HYDRAULIC / PNEUMATIOC SEALANT

35135 RELIEF VALVEl ; 30 PSI; (for CB ‐ 350 ‐ CTB)

35123 FLOW SWITCH; TACO

35110 LOW WATER CUT ‐ OFF CONTROL UNIT

A-27

84

5

13

63


CB-500-CTB

46

45

44

40

43

42

41

39

64

74

68

69

75

70

71

72

73

76

77

78

79

80

81

83

82

18

A-28

I88997-C

3

2

8



50

51

52

53

54

55

47

48

49

56

57

58

42

43

44

45

46

35

36

37

38

39

40

41

29

30

31

32

33

34

15

16

17

18

19

10

11

12

13

14

23

24

25

26

27

28

20

21

22

5

6

7

8

9

3

4

1

2


27172 JACKET RH SIDE 500 59

70472 MIXING VALVE 140F & FLEX PIPE KIT 500 ‐ CTB 60

12240 CONTROL BOX 120 V A 61

14314 CHECK AND DRAIN 500 PIPE A 62

35125 GASKET FLANGE 2" 63

35120 FLANGE 500 2" NPT 64

35126 CHECK VALVE 2" NPT SWING; Type WCV 65

35128 NIPPLE 2 X 2 1/2" SCH 40 BLK 66

35133 TEE 2 X 3/4 X 2 NPT BLK 67

35065 BOILER DRAIN 3/4 NPT 68

90206 BOILER STAND 500 A 69


35121 FLANGE 500 1 1/2" NPT 71

27170 BASE 500 72

11572 BASE 500 CTB WA 73

27178 SEAL PLATE STAMPED 500 74

54013 ROPE ‐ FIBERGLASS HD 250 W/ADH 75

27177 SEAL PLATE FLAT FRONT 76

11581 HINGE BRKT DOOR LOWER WA 77

27179 FILLER PLATE 500 78

27166 RING BURNER END 500 78

27200 STAND REFACTORY CYL 500 CTB 79

31240 INSULATION FRONT DOOR 500 80


11564 DOOR FRONT 500 WA 82

11582 HINGE BRKT 3DEG BURNER WA 83

14103 CB ‐ 5000 HOOK ‐ UP A 84

34118 5/16 ‐ 18 X 3/4 HEX HEAD TAP SCREW

35057

33330

35144

28150

35150

33168

33486

33327

27109

34150

31264

BUSHING

GAUGE

BUSHING

AQUASTAT

NIPPLE

AMBER

BOX

3/8 ‐

16

TERMINAL

JUNCTION

X

ENERGY

1

4

3/4

2"

‐

1/4"

LIGHT

100

BLK

X

BOILER,

‐

‐

HHCS

1/2

3/4"

14"

A

18

TEMP

‐

BLK

200F

RETENTION

BLK

BLK

8

‐

PRESSURE

OPERATING

DISC, 2 ‐ BOLT (W/HDWR)

11154 TARGET (REFRAC) DISC ASSY

31239 INSULATION DOOR REAR 500

11563 DOOR REAR BREECH 500 CTB WA

34067 3/8 ‐ 16 FIN HEX NUT 18 ‐ 8 S.S.

27165 RING BOT STACK END 500

27164 BAFFLE RH 500

35149 BUSHING 1 1/4 ‐ 1 1/2 NPT

11578 BOILER STACKING ADAPT 500 CTB A

33131 KNOCK ‐ OUT SEAL/PLUG

33286 SWITCH DPDT ON ‐ ON

A; DIN ‐ RAIL SCREW

33145 SCREW LUG

33352 RELAY DELAY

33328 RELAY DPDT

TRANSFORMER 24 ‐ 120V

33331 TERMINAL BLOCK (4 POST) CTB

27176 SEAL PLATE FLAT REAR

27167 RING TOP STACK END

34120 5/16 ‐ 18 X 2 3/4 CARR BOLT S.S.

11583 BURNER MOUNT 3 DEG WA 11565 CTB 500 BOILER CABINET ASSMBLY

11325 INSPECTION DOOR A 11567 DOOR FRONT 500 A

34009 3/8 ‐ 16 HEX SERR FLANGE NUT PLT 11580 CB ‐ 551 ‐ H5 BURNER A

21174 REFRACTORY CYL 12.63

X 20 14317 ACCESSORIES 500 CTB GP

27171 JACKET LH SIDE 500 70428 DUCT CAP ROUND 10" ‐ 24 GA.

27163 BAFFLE LH 500 31197 DAMPER 9" ASSEMBLY

27181 LINER COMBR CHM TOP 500 31245 INSULATION 62.0

X 48.0

BLANKET

27804 COIL 1.50

TUBE 28.5

T 500CTB 31246 INSULATION 14.31X

62.0

BLANKET

27180 LINER PROTECTOR 500 31247 INSULATION 24.0

X 66.0

BLANKET

11596 BRACKET 500 UPPER HINGE WA 31248 INSULATION 7.50

X 66.0

BLANKET

11562 COVER TOP 500 CTB WA 34162 STOVE CEMENT ‐ HIGH TEMP

33546 CONN CORD 4 ‐ WIRE 51" 35137 NIPPLE 3/4 X 2 NPT SCH40 BRASS

27158 BRACKET BURNER CORD 42027 LABEL ‐ WARNING ‐ BURN/VOLTAGE

27173 JACKET TOP 500 42030 LABEL ‐ VOLTAGE WARNING


42217 LABEL ‐ AIR OIL

35138 THERMOSTAT 160F/60C FOR VTC511 42231 LABEL ‐ PRIME PUMP/RUN BURNER

35139 THERMOSTATIC BYPASS VALVE VTC511 1 ‐ 1/4" 42261 LABEL ‐ THRMOSTAT/BURNER

35148 METAL FLEX HOSE 1 1/4" ‐ 24"

35143 BUSHING 2" ‐ 1 1/4" BLK

35142 CROSS 2"NPT BLK

42292 LABEL ‐ CTB WIRING CTB ‐ 200/350/500

42366 LABEL ‐ TANK WARNING

42367 LABEL ‐ FURNACE WARNING

35127 NIPPLE 2 X 6 SCH 40 BLK 42457 LABEL ‐ MADE IN USA/PAT PENDING

35132 TEE 2 X 2 X 1 NPT BLK 42421 LABEL ‐ BOILER WARNING

35124 PADDLE TACO FLOW SW 42493 LABEL IDENT CB 500 CTB

35131 TEE 2 X 2 X 3/4 NPT BLK 42497 LABEL ‐ LOGO ‐ LARGE; 8" x 20"

35049 WELL 3/4 NPT X 1 1/2 EXT (INS) 43146 OPERATORS MANUAL CTB

28149 AQUASTAT 100 ‐ 240F HIGH LIMIT 44052 SCHEM CB 350 CTB (Wiri ng Dia gra m)

35136 RELIEF VALVE; 30 PSI; (for CB ‐ 500 ‐ CTB) 54104 HYDRAULIC / PNEUMATIC SEALANT

35123 FLOW SWITCH; TACO 70469 500 CTB BARE CABINET

35110 LOW WATER CUT ‐ OFF CONTROL UNIT 70477 SEAL KIT FOR TACO 2400 ‐ 50/2 CIRCULATOR

A-29


Metering Pump Components

29

17

18

19

20

16

13

10

9

7

8

SUPPLY

TO BURNER

6

RETURN

TO TANK

5

4

3

2

11

30

31

12

1

14

PACKAGED WITH

CLEAN BURN

EQUIPMENT

15

32

21

22

23

24

25

26

SINGLE PIECE OF

COPPER TUBING

(USER SUPPLIED)

24

23

16

27

PACKAGED WITH

CLEAN BURN

EQUIPMENT

28

A-30


ITEM# PART# DESCRIPTION

1 33363 CAPACITOR

2 33507 GEAR MOTOR CB 200 CTB



3 11322 MOUNT METER PUMP A

4 32037 1/8 NPT X 1/4 TUBE COMPRESSION FITTING

5 N/A 1/4 COPPER OR ALUMINUM TUBING

6 N/A 3/8 OR 1/2 TUBE FLARE NUT

7 N/A 3/8 OR 1/2 COPPER FOR ALUMINUM TUBING

8 N/A 1/8 M NPT X 3/8 OR 1/2 FLARE


10 32475 PUMP-METERED OIL

11 32467 NIPPLE 1/4 NPT X 3 ROUND BRASS

ST EL 90 1/4F-1/4M NPT

13 32336 BUSHING 3/4 X 1/4 BR.

14 32123 GAUGE (LENZ)

15 32127 CANISTER FILTER

16 32430 BUSHING 3/4" X 1/2"

17 32446 NIPPLE 1/2 X 5"-BRASS

18 32429 TEE 1/2" BRANCH

19 32137 EXTERNAL PIPE ADAPTER

20 32142 BALL VALVE 1/2 NPT

21 32062 MALE CONNECTOR 1/4 TUBE

22 32443 BUSHING 1/4 X 1/2" BRASS

23 32141 FLARED TUB.TO PIPE STRAIGHT

24 32140 LONG NUT 1/2

25 32139 TUBE TO PIPE MALE STRAIGHT

26 32442 BUSHING DUPLEX SLIP THRU

27 32021 CHECK VALVE

28 32061 CHECK VALVE SCREEN 3/4"

29 32445 PIPE CAP 1/2"-BRASS

30 32423 SCREEN PUMP (M PUMP)

31 32422 GASKET COVER (M PUMP)

32 32433 SEAL SUNTEC 7710 M P SHAFT

13176 SUCTION FITTINGS PACKAGE

A-31


A-32

Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB

APPENDIX B

Wiring Diagrams

BLACK

HT

ER

LIG

AMB

EEN

T

GR

LIGH ICAL

CH

CENTRIF

SWIT

E WHIT

D CELL CA

OW

OW

YELL

YELL

F F T T

R TE EA E H OZZL ATTS N W 140

Figure B1 -CB-525-S2 Burner Wiring Diagram (CB-200-CTB)

B-1


Wiring Diagrams (continued)

K BLAC

T

BER

LIGH

AM

EEN

T

GR

LIGH AL IC

CH

NTRIF

SWIT

CE

E WHIT

T T F F

ER EAT H LE ZZ NO ELL CAD C

OW

OW

YELL

YELL

Figure B2 - CB-551-H3 and CB551-H5 Burner Wiring Diagram (CB-350-CTB and CB-500-CTB)

B-2



RED

BLU

WHT

BLK

GRN

RED

PUR

Figure B3 - Coil Tube Boiler Wiring Diagram (Control Box)

B-3


The CTB sequence of operation is summarized as follows:

(1) A call for heat by the thermostat energizes the DPDT relay which in turn energizes the circulator delay relay and the boiler loop circulator to establish a flow of water through the coil.

(2) The low water cut-off "proves" the water level inside the boiler and allows the flow switch to close. The power then continues from the flow switch through the high limit aquastat, through the operating aquastat, and then to the burner.

(3) If the burner ignites within approximately 15 seconds and the cad cell sees flame, the burner will continue to operate until the call for heat is satisfied or the setting of the operating aquastat is reached.

(4) If the thermostat is not satisfied, but the temperature setting of the operating aquastat is reached, the burner will stop until the return water drops the water temperature in the boiler

(re-closing the operating aquastat and turning the burner back on).

(5) The boiler loop circulator will operate as long as the thermostat is calling for heat.

(6) The boiler loop circulator circuit includes a delay relay that keeps the circulator operating approximately ten minutes after the call for heat is satisfied.

B-4


NOTE 1:

TDR TIMER CONTACT

CLOSES INSTANTANEOUSLY

WHEN RELAY IS ENERGIZED

(TRIGGERED BY CR1) AND

OPENS 10 MINUTES AFTER

CR1 IS DE-ENERGIZED

H

115 VOLTS 60 Hz

OPERATING

AQUASTAT HI LIMIT

FLOW

SWITCH

SEE NOTE 2

5

LO WATER

CUT - OFF

3 1

4 P 2

PROBE

RUN - PRIME

NOTE 2:

DPDT TOGGLE SWITCH

ON BOILER CABINET

TOGGLE DOWN: BURNER

TOGGLE UP: PRIME PUMP

PRIMING

N

OIL PUMP

MOTOR

BOILER CIRC. MOTOR

DRAFT INDUCER

NOTE 3:

CB-350-CTB and CB-500-CTB

PRIMARY CONTROL IS

SHOWN. CB-200-CTB

PRIMARY CONTROL

IS SIMILAR WITH NO

ALARM.

GRN

WHT

RD

BK

SEE NOTE 1

THERMOSTAT

B

TD

R

A

T

DOUBLE POLE RELAY

CR

1

24 VAC

- CONNECTION TO

CUSTOMER POWER

- CONNECTION AT

TERMINAL BLOCK

OUTSIDE BOILER

CONTROL BOX

WHT

GRN

BK

RD

PROVING SWITCH

120°

SEE NOTE 3

BLK

CAD

CELL

F 1 F 2

LOW VOLTAGE

ALARM

CONTACT

ORG

T 1

OIL PRIMARY CONTROL

T 2

WHT

IGNITION TRANSF.

BL

SPARK GAP

AIR SOL.

BURNER MOTOR

M 3

AIR COMPRESSOR

(OPTIONAL)

OIL SOL.

AIR PRESSURE

CENTRIFUGAL SWITCH

N. C. HELD OPEN

ACTUATED BY BURNER MOTOR

L-130 NOZZLE THERMOSTAT

L-140 BLOCK THERMOSTAT

140°

140 WATTS NOZZLE HEATER

PUMP ON

A

HOUR METER

400 WATTS BLOCK HEATER

POWER ON

Figure B4 - Coil Tube Boiler Ladder Schematic

B-5



Figure B4 - Metering Pump Wiring Schematic

H44040

B-6


APPENDIX C

Boiler Service Record

Boiler Purchased: Date __________ From (name/phone) _______________________________

Boiler Installed: Date __________ By (name/phone)__________________________________

Boiler Inspected: Date __________ By (name/phone)__________________________________

Note: Refer to Section 9 for Maintenance Instructions

Draft Readings

(Date / Draft)

Burner Stack

Service Record

(Date / Initials of Technician)

Canister Metering Check Valve Chamber Stack Oil Tank A.P.M.*

Filter Pump and Screen & Flues

*A.P.M. is Annual Preventative Maintenance on the Burner (Burner Tune-up)

C-1


C-2

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