CLEAN BURN CB-3500 series Operator'S Manual Download

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Operator's Manual: Models CB-3500 & CB-5000

A-15

ITEM#

PART# Description

31091

DUCT CAP ROUND 8"

21010

STACK PIPE FLASH RING

24077

SIDE - RIGHT

34028

5/16-18 X 3/4 SERR HEX FLANG

21057

HINGE BRACKET

24069

DIVIDER

21102

FLUE TUBE CB3500/CB5000

24068

BASE

34126

3/8-16 X 2 HHCS GR-5

10.

24116

FIRE DRUM

11.

34121

5/16-18 TOP LOCK NUT S.S.

12.

21039

.438 X 1.5 X .135 FLAT WASHER

13.

70418

COMB CHAMBER BAND KIT - 3500

24182

REINFORCEMENT BAND - 3500

34397

3/8 X 1 HHCS - SS

34398

3/8 SERRATED FLANGE NUT - SS

34399

3/8 SPLIT LOCK WASHER - SS

14.

11213

DOOR APRON

15.

34118

5/16-18 X 3/4 HEX WASHER HEAD

16.

34119

3/8-16 X 3 HHCS GR-2 ZINC

17.

21056

HINGE BRACKET

18.

34095

3/8-16 S TOVER L/N GR-B CAD/WAX

19.

24075

OUTSIDE DOOR

20.

34009

3/8-16 HEX SERR FLANGE NUT PLT

21.

14102

CB-3500 HOOK-UP A

22.

34051

5/16-18 X 1 1/2 HHCS GR-2 ZINC

23.

21101

CONNECTOR BLOCK

24.

32311

ACCUMULATOR

25.

32039

ADAPT 1/4 OD X 1/8 P

26.

13017

AIR LINE ASSEMBLY

27.

13128

OIL LINE A

28.

32304

NUT - LONG

29.

32303

SLEEVE

30.

32245

SWIVEL 1/4NPTM,1/4NPTF

31.

11033

HINGE BRACKET W A

32.

11143

BURNER MOUNT W A

33.

34120

5/16-18 X 2 3/4 CARR BOLT S.S.

34.

11325

INSPECTION DOOR A

35.

21076

PORT CAP

36.

24103

DOOR INSULATION

37.

21114

LID

38.

3315

CONNECTOR PLUG

39.

12214

JUNCTION BOX ASSY.

40.

33145

SCREW LUG

41.

33182

CONTACTOR 240V

42.

33207

CONT 120V 60HZ 1POLE

43.

21113

BOX - JUNCTION

44.

33273

CONNECTOR 90 DEG. SNAP-TITE

45.

33286

SWITCH DPDT ON-ON

46.

33186

AMBER LIGHT 120V

47.

33299

PLASTIC WIRE PROT

48.

24080

SIDE - LEFT

49.

33245

FAN LIMIT SWITCH

50.

24119

COVER

51.

14173

MOTOR HARNESS, CB3501

52.

24079

TOP

53.

24108

ORIFICE

54.

24114

3500 DISCHARGE - ANGLE BOTTOM

55.

24092

LOUVER

56.

14160

DIFFUSER OUTLET 3500 A

57.

33230

FAN SWITCH - SURFACE MOUNT 180

58.

25115

PLATE

59.

33288

AUXIL HI LIMIT-AUTO RESET 290

60.

24082

BLOWER ANGLE

61.

24083

BLOWER CLOSING ANGLE

62.

24078

BACK

63.

31232

ENERGY RETENTION DISC

64.

24100

RING

65.

22076

STACK PIPE COLLAR

ITEM#

PART# Description

•

24098

HANGER CHANNEL

•

24099

HANGER ANGLE

•

11137

DOOR A. CB-3500

•

14170

PUMP MTR CB-3500 A

•

14174

COMPRESSOR AIR LARGE (1/2HP)

•

24062

FRONT FLUE PLATE

•

24065

FRONT FLUE CAP - BOTTOM

•

24066

BACK FLUE CAP

•

31111

SPRING HANDLE

•

31170

DAMPER 8"

•

33283

THERMOSTAT - WALL

•

34162

STOVE CEMENT - HIGH TEMP

•

42027

LABEL - WARNING - BURN/VOLTAGE

•

42030

LABEL - VO LTAGE WARNING

•

42045

LABEL - MADE IN USA - 2X3

•

42068

LABEL - TANGLE / CUTTING

•

42144

LABEL - CB-3500

•

42146

LABEL 220 V

•

42174

LABEL FURN CB 3500

•

42197

LABEL - PAT PEND

•

42216

LABEL-LOGO-ENG'D LIKE NO OTHER

•

42217

LABEL - AIR OIL

•

42227

LABEL-FURN CAB E SCH

•

42231

LABEL - PRIME PUMP/RUN BURNER

•

42302

LABEL PULLEY INSTRCTNS (31072)

•

42366

LABEL - TANK WARNING

•

42367

LABEL - FURNACE WARNING

•

43144

OPERATORS MANUAL CB 3500, 5000

•

44037

FURN CAB ELEC SCHEM

•

11315

FURNACE CABINET CB-3501 A

Summary of Contents for CB-3500 series

Page 1: ...on 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 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 b...

Page 2: ......

Page 3: ...r removal or reinstallation of its products and shall not be liable for transportation costs to and from its plant at Janesville Wisconsin Use of parts for modification or repair of the product or any component part thereof not authorized or manufactured by MANUFACTURER specifically for such product shall void this warranty This warranty shall not apply to any damage to or defect in any of MANUFAC...

Page 4: ...tive to the extent of such prohibition or unenforceability without invalidating the remaining provisions and without affecting the validity or enforceability of such provision in any other jurisdiction s TRADEMARKS The Clean Burn logo is a trademark of Clean Burn LLC All other brand or product names mentioned are the registered trademarks or trademarks of their respective owners COPYRIGHT Copyrigh...

Page 5: ... 6 Installing the Belt Guard and the Blower Guard 3 7 Installing the Hot Air Discharge Components 3 8 Determining the Air Discharge Configuration 3 8 UNIT HEATERS Installing the Air Discharge Louver Assembly 3 9 CENTRAL FURNACES Installing Ductwork 3 10 Installing the Energy Retention Disc 3 10 Installing the Energy Retention Disc in the Combustion Chamber 3 10 Closing the Furnace Door 3 10 Instal...

Page 6: ...ng the Pressure Relief Oil Line Back to the Tank 4 16 Installing the Pressure Oil Line Components 4 17 Installing the Compressed Air Line 4 17 Installing the Stack 4 18 Installing the Interior Stack 4 19 Installing the Barometric Damper 4 21 Installing the Stack Safety Switch For Canadian Installations 4 22 Resetting the Stack Safety Switch 4 23 Understanding the Function of the Stack Safety Switc...

Page 7: ...R FIRE 8 1 Checking for Correct Draft Over Fire 8 1 Adjusting the Barometric Damper 8 2 Adjusting Draft Overfire on Furnaces with Draft Inducers 8 2 Solving Draft Overfire Problems 8 3 Understanding the Effect of Exhaust Fans on Draft 8 3 Checking Draft Overfire to Determine Severity of Backdraft 8 3 Installing a Make up Air Louver 8 5 SECTION 9 MAINTENANCE 9 1 Understanding Maintenance 9 1 Period...

Page 8: ...Furnace Components A 14 CB 3500 Blower Components A 16 CB 5000 Furnace Components A 18 CB 5000 Blower Components A 20 Metering Pump Components A 22 APPENDIX B Wiring Diagrams B 1 Furnace Wiring Diagram B 1 Burner Wiring Diagram B 2 Ladder Schematic B 3 Metering Pump Wiring Schematic B 4 Cad Cell Oil Primary Details B 5 APPENDIX C Furnace Service Record C 1 TABLE OF CONTENTS ...

Page 9: ...basic activities as outlined here UNPACKING Section 2 ASSEMBLY Section 3 INSTALLATION Section 4 OPERATION Metering Pump Priming Section 5 Starting and Adjusting the Burner Section 6 Resetting the Furnace and Burner Section 7 Adjusting the Draft Section 8 MAINTENANCE Section 9 The manual also contains important and detailed technical reference materials which are located at the back of the manual i...

Page 10: ... precautions are not taken In addition to observing the specific precautions listed throughout the manual the following general precautions apply and must be heeded to ensure proper safe furnace operation DANGER DO NOT create a fire or explosion hazard by storing or using gasoline or other flammable or explosive liquids or vapors near your furnace DANGER DO NOT operate your furnace if excess oil o...

Page 11: ...liance with the specifications in the Clean Burn Operator s Manual and with all national state and local codes or authorities having jurisdiction over environmental control building inspection and fuel fire and electrical safety and the following standards NFPA 30 Flammable and Combustible Liquids Code NFPA 30A Automotive and Marine Service Station Code NFPA 31 Standard for the Installation of Oil...

Page 12: ...at may hinder performance Make sure you comply with all EPA regulations concerning the use of your furnace EPA regulations require that Your used oil is generated on site You may also accept used oil from do it yourself oil changers Hazardous wastes such as chlorinated solvents are NOT to be mixed with your used oil The flue gases are vented to the outdoors with an appropriate stack Your used oil ...

Page 13: ...low all instructions for tank installation in Operator s Manual ONLY place these listed substances in this used oil supply tank Used crankcase oil Used automatic transmission fluid Used hydraulic oil 2 fuel oil Do NOT place flammable or corrosive substances such as gasoline chlorinated oils solvents paint thinners or any other unsafe substances in this used oil supply tank Do NOT weld or allow ope...

Page 14: ... any labels on your Clean Burn furnace ever become worn lost or painted over please call your Clean Burn dealer for free replacements CB 3500 CB 5000 Furnace Cabinet Labels Label Part Description 42030 Furnace Electrical Shock Hazard Warning Label several locations 42457 Made in USA Patent Pending Combination Label 42027 Furnace Burn Hazard Hazardous Voltage Warning Label 42367 Furnace Safety Warn...

Page 15: ... hand protection when opening inspection port Keep face away and open port slowly 42367 Rev 2 42030 Rev 2 Hazardous voltage To prevent serious injury shut OFF main power to unit before removing cover Line voltage is present on most subbase terminals when power is ON If the furnace is not wired correctly fire shock or damage could result ONLY a qualified electrician should wire this furnace ONLY us...

Page 16: ...FILTERS INSTALL AND USE ONLY IN ACCORDANCE WITH THE MFR S INSTALLATION AND OPERATING INSTRUCTIONS FOR COMMERCIAL OR INDUSTRIAL USE ONLY AUTHORITIES HAVING JURISDICTION SHOULD BE CONSULTED PRIOR TO INSTALLATION VOLTS AMPS HZ OIL PUMP MOTOR HP BURNER MOTOR HP 1 6 1 10 400 120 120 120 60 60 60 POWER 3 2 1 4 3 3 BURNER HEATERWATTS 60 2 BLOWER MOTOR HP AIR COMPRESS OPT HP 3 5 3 9 60 60 120 120 1 3 1 3 ...

Page 17: ...l Serial Number Label 42197 Made in USA Patent Pending Combination Label not shown positioned on side of burner 42229 Logo Burner Description Label 42023 Burner Power Label Hazardous high voltage and moving parts hazard To avoid electric shock and injury from moving parts turn power OFF before opening cover WARNING 42004 Rev 2 Fire and explosion hazard Do NOT press reset button until you read and ...

Page 18: ...Operator s Manual Models CB 3500 CB 5000 1 10 ...

Page 19: ...scharge Blower Draft inducer CB 5000 only Oil pump Metering Pump OR J Pump includes suction oil line fittings package Components packed inside furnace cabinet Energy Retention Disc Blower assembly components 2 HP Blower motor Canister filter Vacuum gauge Check valve check valve screen Wall thermostat Barometric damper Connector block Burner oil line and air line components Operator s Manual litera...

Page 20: ...n chamber you will need to open the combustion chamber door 1 Remove the four nuts and washers which hold the combustion chamber door closed Set the nuts and washers aside in a safe place for later re installation after the Energy Retention Disc has been installed Section 3 2 Carefully swing the combustion chamber door open Remove and inspect the components packed inside 3 Leave the door unfastene...

Page 21: ...ocedures before proceeding paying careful attention to safety information statements Please note that some assembly procedures apply only to certain furnace models Figures 3A and 3B on the following pages provide a general overview of the furnace components and their proper assembly and how the unit should look following proper assembly Required Tools and Materials The following tools and material...

Page 22: ... I88801 C AIR DISCHARGE ROTATION ENERGY RETENTION DISC INSTALLED ON BACK WALL OF COMBUSTION CHAMBER FURNACE BREACH MOUNTING BRACKETS INSTALLED ON FURNACE CABINET BASE STABILIZER BRACKETS NOTE BLOWER MUST BE INSTALLED WITH BULGE ON BLOWER FACING BACK OF FURNACE MAKE SURE BLOWER WHEEL ROTATION IS CLOCKWISE AS SHOWN SIDE VIEW OF CABINET FRONT VIEW OF CABINET PRIOR TO ASSEMBLY FRONT VIEW OF CABINET AF...

Page 23: ...letely Assembled with Louver Assembly for Unit Heater Application NOTE This figure shows the mounting stabilizer brackets in place for a ceiling mounting installation If your furnace will be floor or platform mounted the brackets are not needed STABILIZER BRACKETS MOUNTING BRACKETS I88288 B ...

Page 24: ...flush with the side of the blower 5 Use a self tapping bolt to install the motor tensioning bracket on the blower according to the dimensions provided in Figure 3C 6 Lift up on the end of the motor mounting plate until the hole in the side of the plate is aligned with the slot in the motor tensioning bracket Push a bolt through the slot and install a nut loosely just to hold the plate in position ...

Page 25: ... MOTOR MOUNTING BRACKET 12 SQUARE HEAD BOLT 13 MOTOR BUSHING 7 8 HUB 14 BLOWER BUSHING 1 HUB 15 LOCKWASHER 16 CAPSCREWS I88876 A CB 3500 BLOWER CB 5000 BLOWER DETAIL OF BRACKET INSTALLATION NOTE The brackets must be installed at the correct position on the side of the blower as shown here Note the measurements provided which should aid your positioning of the brackets 8 5 22 cm 18 5 46 5 cm 11 5 2...

Page 26: ...ed and does not fit into place file the key to the proper size or replace it with a new key 4 Slide the bushing with key inserted onto the shaft so the tapered end will engage into the pulley NOTE If bushing does not slide freely on shaft wedge a screwdriver blade into the saw cut at the flange OD to open the bore of the bushing CAUTION Excessive wedging will split the bushing MODEL CB 3500 1 BLOW...

Page 27: ...y with the blower pulley a Place the blower bushing inch from the end of the shaft and tighten the capscrews securely 9 Ft Lbs if using a torque wrench b Place a level or straight edge flat onto the two most outer edges of the blower pulley c Place the motor pulley and bushing about inch away from the straight edge d Start tightening the screws on the motor bushing As the screws are tightened the ...

Page 28: ...o the following chart for the proper air discharge ducting specifications installation to be accomplished by HVAC professionals ONLY Be sure to adhere to the specified clearances as stated in Section 4 of this manual Installing the Hot Air Discharge Components ATTENTION A qualified electrician must check the blower motor amperage during operation of the furnace to ensure that motor amperage does n...

Page 29: ...he heated air 1 Position the body of the air discharge as desired over the hot air outlet on the furnace i e facing forward right or left ATTENTION KEEP THE ORIFICE PLATE IN PLACE as shown in Figure 3G when installing the louver assembly The orifice plate is necessary for proper air flow from the furnace 2 Use the 12 self tapping screws to securely attach the body of the louver assembly to the fur...

Page 30: ...vided in this manual Establish correct duct size according to the following specifications and use radial bends or turning vanes to allow for proper air flow Sizing the Ductwork For Model CB 3500 the outlet on the air discharge is 20 x 20 The main duct CB 3500 must initially maintain an outlet size of 20 x 20 For Model CB 5000 the outlet on the air discharge is 24 x 24 The main duct CB 5000 must i...

Page 31: ... the back of the manual for additional specifications instructions on the burner nozzle NOTE Check the electrode settings as specified in Figure 3H The electrode settings must be correct for your burner to operate properly Figure 3H Burner Nozzle and Electrode Specifications BURNER NOZZLE VIEW BB 3X NOZZLE IS STAMPED WITH SIZE ON FLAT OF NOZZLE HEAD CRITICAL DIMENSION NOZZLE MUST BE 1 8 AHEAD OF T...

Page 32: ...the hinge bracket on the furnace cabinet 3 Carefully swing the burner so the retention head enters the throat of the furnace 4 Check the clearance between the retention head and the furnace throat There must be at least 1 8 clearance so the retention head is not bumped as you swing the burner into firing position NOTE If the retention head bumps the furnace throat adjust the hinge bracket bolts as...

Page 33: ...NTION DO NOT disassemble the compression fitting from the swivel fitting To prevent leaks the NPT threads of the compression fitting have been sealed with hydraulic sealant during assembly of the fittings at the factory 1 Remove and discard the red caps from the oil line tubing 2 Loosely install the oil line tubing into the oil line fitting on the burner 3 Use a wrench to slightly rotate the oil l...

Page 34: ...ne according to Figure 3J which provides a larger front view of the connector block assembly Installing the Air Line Tubing 1 Remove and discard the red caps from the air line tubing 2 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 3 Repeat this procedure to connect the air line tubing to the air line fitting o...

Page 35: ... below The mounting brackets must be attached to the furnace base to allow ceiling installation of the furnace using all thread rods See Figures 3A 3B The weight of the furnace must be supported by the mounting brackets The stabilizer brackets are installed on the top of the furnace to properly align the all thread rods The stabilizer brackets will not support the furnace 1 Refer to Figures 3A and...

Page 36: ...Operator s Manual Models CB 3500 CB 5000 3 16 ...

Page 37: ... NFPA 30 Flammable and Combustible Liquids Code NFPA 30A Automotive and Marine Service Station Code NFPA 31 Standard for the Installation of Oil Burning Equipment NFPA 211 Chimneys Fireplaces Vents and Solid Fuel Burning Appliances NFPA88A Parking Structures NFPA 88B Repair Garages NFPA 70 National Electrical Code The International Mechanical Code The International Building Code The International ...

Page 38: ...earances from combustible surfaces as stated in Section 4 These clearances also provide adequate space for servicing Failure to maintain proper clearances may result in fire explosion personal injury or death 10 FT MIN VERTICAL STACK HEIGHT 10 3 AIR OIL CAUTION DO NOT EXCEED 6 FEET VERTICAL SUCTION LIFT OR THE PUMP WILL NOT PRIME AND OR THE FLOW RATE FROM THE PUMP MAY DECREASE 8 FT MIN FROM FLOOR ...

Page 39: ...e adequate clearance for servicing also refer to Figure 4B for visual reference failure to main tain proper clearances may result in fire explosion personal injury or death WARNING National codes require that your furnace is mounted a minimum of eight 8 feet off the ground when installing the furnace in a repair facility Refer to NFPA 88B Standard for Repair Garages Chapter 3 Hazards Sec 3 2 3 1 C...

Page 40: ... INSTALLING CLASS A STACK THROUGH CEILING I88805 C WARNING ENSURE PROPER CLEARANCES BETWEEN STACK COMPONENTS AND COMBUSTIBLES PER ALL APPLICABLE CODES WARNING BE SURE TO INSTALL THE PROPER ROOF SUPPORT SYSTEM TO SAFELY SUPPORT THE STACK WATERTIGHT ROOF FLASHING CLEAN BURN RECOMMENDS DEKTITE FLASHING FOR A WATERTIGHT SEAL CLASS A STACK COMPONENTS INSULATED STACK WITH A STAINLESS STEEL LINER BAROMET...

Page 41: ...onstructing A Non Combustible Floor 1 Determine the size of floor you will need to construct Measure the width and length of the cabinet of the furnace Add 12 minimum to all sides of the cabinet to achieve the total measurement for the non combustible floor EXAMPLE The CB 3500 measures 58 long x 35 wide 58 12 12 82 long 35 12 12 59 wide 2 Refer to Figure 4E Install two 2 pieces of 5 8 sheet rock o...

Page 42: ...e that the installation adheres to all clearances from combustibles as stated at the beginning of Section 4 in this manual 8 After positioning the furnace cabinet on the sheet metal pan install 2 tall minimum cinder blocks 4 under each corner of the furnace to elevate the cabinet off the sheet metal pan to allow clearance for installation of fittings on the connector block LIP FOR OIL CONTAINMENT ...

Page 43: ... oil tank and pump installation details as shown in Figures 4A 4F and 4J Pertinent information is also supplied with the metering pump and oil line installation procedures following in Section 4 Ensure that the oil supply tank is properly maintained refer to Section 9 in this manual for related procedures ATTENTION For outside tank installations and or tanks larger than 500 gallons contact your lo...

Page 44: ...tion guidelines Install a length of minimum 2 steel pipe user supplied terminating outside with a proper vent cap as shown in Figure 4F Consult local codes for information and requirements concerning the proper venting of oil storage tanks Install an emergency vent as shown in Figure 4F Contact your tank manufacturer for information concerning the proper emergency vent for your tank PUMP SUCTION L...

Page 45: ... wall this pump installation is recommended Alternate mounting is horizontal mounting on a bracket Be sure to carefully follow the appropriate procedures diagrams for pump mounting For optimal metering pump functioning mount the pump at a distance from the oil tank that will comply with the following requirements The suction oil line may NOT exceed 6 feet TOTAL vertical lift AND 4 feet TOTAL horiz...

Page 46: ...EAN BURN MODEL 33293 33355 CB 3500 33354 33356 CB 2500 CB 5000 33507 CB 200 CTB 28 28 32061 3 4 CHECK VALVE SCREEN 16 23 23 17 16 20 19 18 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 TUBIN...

Page 47: ... two pump mounting bolts 5 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 INLET ATTENTION RECOMMENDED SETUP PUMP IS MOUNTED LEFT ON WALL ALTERNATE MOUNTING TO THE WALL MAKING...

Page 48: ...e furnace to the metering pump Necessary wiring specifications are provided in this section and in the Wiring Schematics located in Appendix B at the back of the manual Wiring to the Furnace 1 Install a dedicated electrical circuit to the electrical junction box on the furnace Refer to NFPA 70 for wire size and distances 2 Wire the furnace according to the Wiring Schematic Figure B1 in Appendix B ...

Page 49: ...n oil line or the pump will not maintain its prime Use Permatex 2 non hardening gasket sealer on every threaded fitting DO NOT use teflon tape or teflon pipe dope compounds the teflon can flake off and cause damage to the pump head The suction oil line must be 100 airtight for proper system functioning Use only high quality flare fittings for the copper tubing DO NOT use compression fittings DO NO...

Page 50: ... 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 Figure 4J Oil Line Installation Overview OF COPPER TUBING TO CREATE SLUDGE TRAP 12 IN OFF TANK BOTTOM CHECK VALVE IS MINIMUM INSIDE TANK CONTINUOUS PIECE TO HOLD TUBING INSTALL SLIP FITTING IN PLACE I88807 E COMPRESSED AIR LINE NOT...

Page 51: ...l Install the 1 2 MPT x 1 2 flare adapter into the 3 4 x 1 2 brass bushing m Slide the 1 2 flare nut over the end of the 1 2 copper tubing and flare the end of the tubing NOTE Use a high quality flaring tool such as a Ridgid Flaring Tool to ensure that all flares are made properly i e so they will be 100 airtight n Install the flared oil line and nut onto the assembled check valve screen and tight...

Page 52: ...hreaded fitting DO NOT use teflon tape or teflon pipe dope compounds 1 Refer to Figure 4K 2 Remove the plug from the relief port on top of the metering pump head 3 Install the 1 8 NPT x 1 4 tube compression fitting in the relief port on top of the metering pump head 4 Install 1 4 O D copper tubing user supplied from the pressure relief port back to the oil tank Refer to Figure 4J as needed I89004 ...

Page 53: ...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 ATTENTION It is critical that you adhere to the following specifications for pressure oil line installation oil line from the pump to the furnace if these specifications are not met the metering pum...

Page 54: ...ded 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 m...

Page 55: ...e Figure 4L Installation of Class A Stack Through Roof Ceiling SINGLE WALL STACK CLASS A KIT FOR INSTALLING CLASS A STACK THROUGH CEILING I88805 C WARNING ENSURE PROPER CLEARANCES BETWEEN STACK COMPONENTS AND COMBUSTIBLES PER ALL APPLICABLE CODES WARNING BE SURE TO INSTALL THE PROPER ROOF SUPPORT SYSTEM TO SAFELY SUPPORT THE STACK WATERTIGHT ROOF FLASHING CLEAN BURN RECOMMENDS DEKTITE FLASHING FOR...

Page 56: ...R PROPER FURNACE OPERATION SEE SECTION 8 SINGLE WALL STACK MIN 24 GAUGE BAROMETRIC DAMPER CLASS A STACK PENETRATION AND CLEAN OUT TEE 10 FT 3 M 3 FT 90 cm NOTE THE LAST STACK SECTION SHALL EXTEND AT LEAST 3 FEET 90 CM HIGHER THAN ANY RIDGE PARAPET WALL OR ROOF STRUCTURE WITHIN 10 FEET 3 M OF IT 10 FT 3 M MINIMUM VERTICAL STACK HEIGHT CLASS A STACK COMPONENTS INSULATED STACK WITH A STAINLESS STEEL ...

Page 57: ...o support the barometric damper You must purchase this tee when you purchase your stack materials 8 single wall tee CB 70174 for CB 3500 10 single wall tee CB 70180 for CB 5000 2 For CB 5000 ONLY Install the 9 to 10 pipe adapter in the opening of the tee as shown in Figure 4N 3 Install the barometric damper in the opening of the tee or pipe adapter for CB 5000 furnaces Use a small spirit level to ...

Page 58: ...talled so that it is level and the flapper moves freely 2 Ensure that main power to the heating equipment is turned OFF 3 Position the stack safety switch over the lip of the barometric damper as shown in Figure 4P 4 Drill a 1 8 pilot hole for the mounting screw and mount the stack safety switch using the mounting screw supplied with the switch NOTE The mounting screw must not interfere with the f...

Page 59: ...ch check the stack to make sure it is clear of any obstructions 2 Remove the cover from the stack safety switch and push the small button in the middle of the switch 3 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 Figure 4Q Stack Safety Switch Wiring Diagram Understanding the Function...

Page 60: ...iances only DO NOT use black stack pipe for solid fuel burning appliances only DO NOT use single wall stack for your exterior stack Single wall exterior stack chills the stack gases and results in poor draft and poor burner performance 1 Refer to Figure 4L 4M as needed 2 Follow the installation instructions provided by the stack manufacturer 3 Install water tight roof flashing around the penetrati...

Page 61: ...er motor Installing the Draft Inducer continued Note Lubricate the motor as recommended by the Draft Inducer manufacturer CLASS A STACK DRAFT INDUCER DRAFT ADJUSTMENT PLATE NOTE INSTALL DRAFT INDUCER IN LAST SECTION OF VERTICAL STACK TO POSITION DRAFT INDUCER AWAY FROM FURNACE BREACH SO THAT THE MOTOR DOES NOT OVERHEAT THIS ALSO REDUCES ASH ACCUMULATION IN THE DRAFT INDUCER DO NOT MOUNT THE DRAFT ...

Page 62: ...se ATTENTION DO NOT use a screwdriver to pry the cover off the base or damage may occur 3 Remove the green paper insert and the black plastic battery isolator from the battery section of the thermostat 4 Refer to the Burner Wiring Diagram in Appendix B at the back of this manual Run two wire 18 gauge minimum thermostat cable from the terminals on the back of the thermostat base to the T T terminal...

Page 63: ... procedures in this section must be performed in sequence without interruption to properly prime the pump Required Tools and Materials The following tools and materials are required for oil pump priming and should be gathered before starting any procedures 3 8 open end wrench 5 8 open end wrench Rags Two containers minimum one gallon Permatex 2 non hardening gasket sealer Adjustable Wrench Pipe Wr...

Page 64: ...verely damage the pump 4 Apply Permatex 2 non hardening gasket sealer to the threads of the plug removed from the pump head Re install the plug and tighten 5 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 6 Open the bleeder valve on the pump two to three 2 3 full turns and position a container to catc...

Page 65: ...l 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 F...

Page 66: ...ittings gaskets and seals from the ball valve to the pump these components must all be airtight to avoid suction leaks The following procedure provides instructions for vacuum testing the pump and canister filter on systems equipped with a ball valve ATTENTION For the pump to pull and hold vacuum it is critical that all fittings are airtight If any of these fittings are loose the pump may not pull...

Page 67: ...een 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 th...

Page 68: ...Operator s Manual Models CB 3500 CB 5000 5 6 ...

Page 69: ...il the preheater block is thoroughly warm before starting the burner Figure 6A Component Detail of the CB 525 S2 Burner for CB 3500 Furnaces 4 Refer to Figure 6A or 6B depending on your burner model to locate the air regulator Loosen the locking nut on the air regulator 5 Turn the adjustment knob on the air regulator counterclockwise until 1 2 of the threads on the knob are exposed DO NOT back the...

Page 70: ... accurately set the slot opening at the widest section of the slot 7 Initial Adjustment of the Air Intake for CB 5000 Furnaces WARNING The air intake must be properly adjusted to ensure that the burner ignites and burns correctly DO NOT attempt to start the burner with the air intake wide open or completely closed Failure to heed this warning may result in fire or explosion hazard Refer to Figure ...

Page 71: ...on Preparing the Burner for Startup continued ATTENTION The settings shown in the charts below are only initial adjustments Final adjustments must be done by inspecting the flame length according to the illustrations provided on the following page NOTE The oil pressure is automatically adjusted by the metering pump Starting the Burner 1 Adjust the thermostat setting above room temperature to start...

Page 72: ...d 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 ...

Page 73: ...hen using instruments to adjust the burner for a smokeless burn the following readings should be achieved Draft over fire should be 02 inch w c Adjust for a smoke spot of a trace to 2 Adjust for a CO2 reading of 8 to 12 or an O2 reading of 4 to 8 Cad cell reading of 200 to 500 ohms Starting the Burner continued Checking the Operation of the Blower Motor NOTE It is important to verify that the blow...

Page 74: ...Operator s Manual Models CB 3500 CB 5000 6 6 ...

Page 75: ...osion hazard 1 Refer to Figure 7A 2 Check the combustion chamber for fuel mist by shining a flashlight through the observation port If you see fog fuel mist in the chamber DO NOT push the reset button 3 If the combustion chamber is hot allow the furnace to cool for at least 30 minutes DO NOT push the reset button 4 When you are sure all mist has been cleared from the chamber and the combustion cha...

Page 76: ... an F 180 blower fan switch normally open which is surface mounted at the front of the combustion chamber as shown in Figure 7B The blower fan switch senses the temperature of the combustion chamber as the burner is firing When the combustion chamber reaches the proper temperature the switch closes and sends power to the blower motor relay to turn ON the blower When the wall thermostat is satisfie...

Page 77: ...mit switch opens and shuts off power to the oil primary control and the burner stops running The fan or blower continues to run Once the fan limit control senses 170 degrees F the limit switch automatically resets and restarts the burner ATTENTION It is very important to avoid cycling the burner on hi limit as described above If the hi limit activates immediately check and readjust burner settings...

Page 78: ... If the fan blower has stopped running for any reason during furnace operation the heat in the furnace may cause the L 290 hi temp limit switch to open Ensure that the fan blower is functioning properly The fan limit control is not functioning properly If the fan limit control has malfunctioned the L 290 could cycle on off repeatedly If this occurs contact your Clean Burn Distributor immediately f...

Page 79: ... type of gauge 2 Note the draft overfire reading on the draft gauge ATTENTION The draft reading should be in the 02 to 04 w c range Poor draft i e 01 to 08 results in back pressure in the furnace and poor burner performance Too much draft overfire i e greater than 04 sucks the heat from the furnace and results in abnormally high stack temperature Figure 8A Checking for Proper Draft Overfire Unders...

Page 80: ...aft increases as the flapper closes Turn the weight CLOCKWISE to decrease draft i e draft decreases as the flapper opens 5 Tighten the locking nut to securely hold the weight in position Adjusting Draft Over Fire on Furnaces with Draft Inducers CB 5000 Standard CB 3500 Optional NOTE The draft inducer is purposely sized to create a generous draft When adjusting the barometric damper you will find t...

Page 81: ...building and replaces the air removed by the exhaust fans Refer to Figure 8C on the following page If there is insufficient make up air the exhaust fan will suck air and combustion gases down the furnace stack and create backdraft in the furnace Even if the exhaust fan is on another level of the building or in another room away from the furnace the exhaust fan will still create backdraft at the fu...

Page 82: ...RAFT IN STACK AND SUCKS COMBUSTION GASES DOWN THE STACK AND BACK INTO THE FURNACE OIL SPRAY AND HEAT IS FORCED BACK AGAINST THE BURNER AND RESULTS IN OIL FOULED ELECTRODES AND RETENTION HEAD SEVERE BACKDRAFT WILL HEAT AND DAMAGE THE CAD CELL AND THE TRANSFORMER PROPER DRAFT RISING HOT COMBUSTION GASES PRODUCE PROPER DRAFT TO ARRIVE AT PROPER DRAFT MEASUREMENTS BE SURE THAT ALL FANS WITHIN THE BUIL...

Page 83: ... on the exhaust fan Make sure to add up the total CFM if more than one exhaust fan exists in the building b Select the correct size of make up air louver to provide the required CFM of fresh air If you cannot determine the CFM rating of the exhaust fan use the following procedure Procedure 2 a Count the total number of exhaust fans in the building b Close all of the doors and windows in the buildi...

Page 84: ...receiving cold return air 2 The louver must be high in the sidewall of the building so the cold fresh air does not blow across the floor level and chill the service personnel 3 The louver should be installed in the opposite wall from the location of the exhaust fan This will quickly vent diesel exhaust from the top of the building and reduce the amount of run time for the exhaust fan Installing a ...

Page 85: ...or these activities are included in this chapter Maintenance Activity Interval Periodic Burner Inspection Monthly Cleaning the canister filter Before vacuum gauge reads 10 HG of vacuum Servicing the metering pump At least once a year Cleaning the check valve screen At least once a year Cleaning water sludge out of tank At least once a year Cleaning out ash Approx 700 hours per the burner hour mete...

Page 86: ...pressure setting see following guideline Check the air pressure by observing the air gauge proper air pressure settings are provided in Section 6 DO NOT overfire the burner doing so on a continual basis will damage the furnace Check the combustion air band setting for the proper opening and clean away any dust debris as necessary Note that the air band should NEVER be set fully open or closed Chec...

Page 87: ...the four bolts to drain the oil from the canister 4 Remove the canister bowl 5 Clean the screen and the bowl in a parts washer 6 Referring to Figure 9B examine the filter components as you reassemble them 7 Check the condition of the O rings Replace any that are cracked or worn 8 Ensure that the canister filter is 100 airtight by firmly tightening the four bolts 9 Open the ball valve Refer to Sect...

Page 88: ...ump head cover part 1 3 Remove the screen part 2 and wash it 4 Remove and discard the used gasket part 3 5 Install a new gasket Clean Burn Part 32422 6 Replace the screen and pump head cover Figure 9C Servicing the Metering Pump INLET GAUGE ROTATION A2RA 7720 I88332 A 3 2 1 PART No 32423 PART No 32422 RELIEF ...

Page 89: ...e components in a parts washer 3 Check the operation of the check valve The valve must seat so it is airtight to hold pump prime 4 Re assemble and re install the components Apply Permatex 2 non hardening gasket sealer or equivalent to the threaded fittings Firmly tighten all connections so the suction line is 100 airtight 5 Follow pump priming instructions in Section 5 to re establish prime Figure...

Page 90: ...gular basis a considerable amount of sludge etc may have accumulated on the bottom of the tank Under these circumstances it is advisable for you to hire your used oil hauler to pump the tank Make sure the tank is pumped to the bottom to remove all sludge etc from the tank your used oil hauler may charge an additional fee for this type of service The best time to pump the used oil tank is at the en...

Page 91: ... heat transfer significantly Never allow more than 1 4 of ash to accumulate in the combustion chamber heat exchanger flues or stack CAUTION Be aware that used oils may contain heavy metallic compounds or foreign materials When burned these compounds are deposited within the furnace necessitating careful cleaning The following protective gear should be worn when cleaning the ash Respirator for fine...

Page 92: ...refully swing open the clean out door to expose the heat exchanger flues and the combustion chamber e Check the color of the ash it should be light gray or tan ATTENTION White ash indicates excessive air pressure Black ash or soot indicates lack of combustion air If these conditions exist call your Clean Burn dealer DO NOT overfire your furnace by turning up the compressed air Overfiring will dama...

Page 93: ...n main power to your furnace OFF at the end of the heating season This will prevent the oil from being cooked in the pre heater block when it is not in use Failure to do so may result in carbon build up in the burner preheater block which will block oil flow ATTENTION Turn main power to your furnace OFF at the end of the heating season EPA regulations allow your used oil to be burned only for heat...

Page 94: ...Operator s Manual Models CB 3500 CB 5000 9 10 ...

Page 95: ...ntered in furnace operation and adjustment The Flow Chart outlines the proper sequence of events in furnace operation use this chart to help diagnose where a problem may be occurring More specific troubleshooting information is provided in the Troubleshooting Tables following the flow charts Each table lists a Problem Possible Cause and Possible Action s to fix the problem ...

Page 96: ...han 10 psi of air pressure Pump circuit starts oil pump Yellow indicator light ON Pump circuit opens oil solenoid Air sensing switch receives power from centrifugal switch INITIAL START UP Combustion air band adjusted for proper combustion air Centrifugal switch closes and sends power to air sensing switch Burner motor starts and reaches full rpm Burner ignites Oil primary control receives 500 ohm...

Page 97: ...0 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 diagr...

Page 98: ...y 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 l...

Page 99: ...ignal Follow the procedures in the previous problem top page 10 4 3 Follow the instructions in Section 5 to adjust the air regulator for proper air pressure DO NOT turn the air compressor off while the furnace is operating If you turn the air compressor off at night turn the wall thermostat to OFF so the burner will not run 4 DO NOT shut off power to the furnace overnight or the heater block will ...

Page 100: ... 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 t...

Page 101: ... 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 Blower motor runs all the time 1 Blower motor circuit is wired incorrectly 2 Blower relay is stuck in the closed position 1 Refer to wiring diagram and ladder schematic in Appendix B to troubleshoot the blower circ...

Page 102: ...Operator s Manual Models CB 3500 CB 5000 10 8 ...

Page 103: ... Ceiling hung 2 non combustible platform Electrical Requirements VAC 60 Hz Min 220 volts 60 Hz Max 240 volts 60 Hz Min 220 volts 60 Hz Max 240 volts 60 Hz Circuit Breaker 35 amps 35 amps Wall Thermostat 24 volt Battery Operated 24 volt Battery Operated Oil Pump Suntec A2RA 7720 Suntec A2RA 7720 Oil Pump Motor 1 20 HP 1 20 HP Pump Motor Rotation CCW shaft end CCW shaft end Canister Filter Lenz DH 7...

Page 104: ...2 CB 5000 Ignition Transformer Carlin Transformer 14 000 Volts Nozzle Delavan 9 5 CB 3500 Delavan 9 11 CB 5000 Burner Motor 1 10 HP 3200 RPM w Centrifugal Switch Burner Motor Rotation CCW shaft end Compressed Air Requirements 2 0 CFM 25 PSI CB 3500 2 5 CFM 25 PSI CB 5000 Oil Primary Control Oil Primary Control W Interrupted Ignition Heater Element in Preheater Block 400 Watts Air Pressure Switch M...

Page 105: ... BOLTS 2 PLCS SECURE ANGLE TO FURNACE WITH 4 SCREWS 2 PLCS TOP VIEW LESS BLOWER AND LOUVERS 137 cm 36 1 4 20 8 1 8 18 1 4 27 WITH GUARDS 35 1 2 34 1 2 25 22 3 4 6 3 4 58 74 WITH BURNER 51 cm 4 1 2 24 cm 9 1 4 24 cm 7 1 4 53 3 4 15 9 3 8 20 11 cm 46 cm 21 cm 51 cm 92 cm 18 cm 69 cm 88 cm 90 cm 64 cm 58 cm 17 cm 147 cm 188 cm I88296 A 95 cm 37 1 2 ...

Page 106: ...ECURE CHANNEL TO FURNACE WITH 2 BOLTS 2 PLCS 27 cm SIDE VIEW 20 cm 97 cm 38 1 4 I88297 B 100 cm 39 1 2 81 cm 31 3 4 WITH GUARDS 21 cm 8 1 4 55 cm 21 3 4 TOP VIEW LESS BLOWER AND LOUVERS 69 cm 27 SECURE ANGLE TO FURNACE WITH 4 SCREWS 2 PLCS 7 1 8 18 cm 24 61 cm 58 147 cm 102 cm 40 2 1 2 6 cm 24 61 cm 11 28 cm 47 cm 18 1 2 84 cm 33 41 3 4 106 cm ...

Page 107: ...Operator s Manual Models CB 3500 CB 5000 A 5 ...

Page 108: ...ner Component Detail for CB 3500 Furnaces 3 4 5 17 20 22 14 9 12 10 11 15 23 26 I88234 C CB 525 S2 BURNER 8 1 2 6 7 16 25 150 130 120 110 140 160 170 13 2 1 1 1 2 1 7 6 8 1 9 0 1 2 3 4 5 6 7 8 9 10 11 0 12 13 14 15 psi OIL 60 AIR 30 20 50 psi 40 0 10 5 4 13 18 19 21 24 SEE ILLUSTRATION I88543 FOR PART NUMBERS ...

Page 109: ...9 32235 1 FEMALE ELBOW 3 16 T x 1 8 NPT 10 32179 1 AIR GAUGE 0 60 PSI 11 32253 1 FEMALE ELBOW 1 8 TP x 1 8 NPT 12 33297 1 HOUR METER 60 Hz 13 33169 1 GREEN LIGHT POWER 14 33168 1 AMBER LIGHT PUMP 15 31113 1 FAN SQUIRREL CAGE 16 26044 1 MOTOR MOUNT PLATE 17 33175 1 BLOWER MOTOR 18 26053 1 RIGHT SIDE COVER 19 11335 1 HOUSING INCLUDES ITEM 23 20 13148 1 HEATER BLOCK ASSEMBLY 21 11265 1 COVER HINGED 2...

Page 110: ...er Component Detail for CB 5000 Furnaces 19 18 13 4 5 10 0 40 psi 50 20 30 AIR 60 OIL psi 15 14 13 12 0 11 10 9 8 7 6 5 4 3 2 1 0 9 1 8 6 7 1 2 1 1 12 3 1 170 160 140 110 120 130 150 25 16 7 6 8 BURNER CB 550 S2 I88186 D 26 23 15 11 10 12 9 14 22 20 21 17 5 4 3 27 1 2 24 SEE ILLUSTRATION I88543 FOR PART NUMBERS ...

Page 111: ... x 1 8 NPT 9 32179 1 AIR GAUGE 0 60 PSI 10 32253 1 FEMALE ELBOW 1 8 TP x 1 8 NPT 11 33297 1 HOUR METER 60 Hz 12 33169 1 GREEN LIGHT POWER 13 33168 1 AMBER LIGHT PUMP 14 31113 1 FAN SQUIRREL CAGE 15 26044 1 MOTOR MOUNT PLATE 16 33175 1 BLOWER MOTOR 17 26053 1 RIGHT SIDE COVER 18 11335 1 HOUSING INCLUDES ITEM 22 19 13148 1 HEATER BLOCK ASSEMBLY 20 11265 1 COVER HINGED 21 SEE NOTE ON DRAWING NOZZLE A...

Page 112: ...il Burner Components continued 14 26 24 30 29 59 32 31 8 8 11 12 2 1 5 4 22 23 21 2 2 16 18 19 34 41 42 43 39 40 36 38 45 35 33 44 17 20 37 3 48 49 50 51 52 53 54 55 56 57 58 9 8 7 10 6 I88543 A 4 2 27 13 28 0 9 1 8 4 5 6 7 1 2 3 1 1 12 3 1 15 17 17 0 16 0 14 0 11 0 12 0 13 0 15 0 60 25 47 46 46 ...

Page 113: ... ELEMENT 400 WATTS 25 33041 1 PROVING SWITCH NORMALLY OPEN 26 32325 1 MALE FITTING 1 8 x 1 8 NPT FOR AIR GAUGE LINE 27 54020 1 3 16 COPPER TUBING OIL GAUGE LINE 28 33011 1 HEATER BLOCK THERMOSTAT NORMALLY CLOSED 29 32359 2 REGULATOR SURFACE MOUNT 30 14090 1 REGULATOR LOCK PLATE 31 34148 8 REGULATOR MOUNTING SCREW 32 34114 8 LOCK WASHER 8 Z 33 34147 2 REGULATOR THREADED STEM 34 34022 2 HEX NU T 10 ...

Page 114: ...NER TUBE AND REQUIRES 3 SELF TAPPING SCREWS IT IS VERY IMPORTANT THAT THE SPINNER HEAD IS NOT TIPPED FROM SIDE TO SIDE OR FROM TOP TO BOTTOM USE PROVIDED SCREWDRIVER AS WEDGE TO HOLD THE SPINNER RETENTION HEAD IN POSITION THEN TIGHTEN THE THREE SCREWS TO LOCK THE HEAD IN POSITION 3 16 GAP BETWEEN ELECTRODES NOZZLE CRITICAL DIMENSION NOZZLE MUST BE 1 8 AHEAD OF THE DISK NOZZLE MUST NOT BE BEHIND TH...

Page 115: ... or deform the nozzle orifice DO NOT use a torch tip cleaner or other inappropriate device to clean the orifice If the blockage is a tarry material or a hard black material call your Clean Burn dealer for service 3 Flush all components with WD 40 to remove oil residues 4 Reassemble the nozzle components When tightening the stem just barely snug it down DO NOT overtighten 5 Check the O ring on the ...

Page 116: ...ETAIL A DETAIL B DETAIL C 2 3 4 5 6 7 8 9 20 21 31 32 33 34 35 38 37 39 48 49 50 52 50 51 53 60 61 62 63 64 57 59 58 22 23 24 25 26 27 28 29 28 29 30 36 CABINET CB 3500 11315 40 41 42 44 45 46 43 54 56 65 1 10 11 12 13 14 15 16 17 18 19 15 55 47 I88957 A ...

Page 117: ...3145 SCREW LUG 41 33182 CONTACTOR 240V 42 33207 CONT 120V 60HZ 1POLE 43 21113 BOX JUNCTION 44 33273 CONNECTOR 90 DEG SNAP TITE 45 33286 SWITCH DPDT ON ON 46 33186 AMBER LIGHT 120V 47 33299 PLASTIC WIRE PROT 48 24080 SIDE LEFT 49 33245 FAN LIMIT SWITCH 50 24119 COVER 51 14173 MOTOR HARNESS CB3501 52 24079 TOP 53 24108 ORIFICE 54 24114 3500 DISCHARGE ANGLE BOTTOM 55 24092 LOUVER 56 14160 DIFFUSER OU...

Page 118: ...Operator s Manual Models CB 3500 CB 5000 A 16 2 3 4 5 6 7 8 9 8 4 21 20 11 12 13 14 15 16 17 18 19 11 1 10 I88958 BLOWER ASSEMBLY CB 3500 ...

Page 119: ...1 HHCS GR 5 ZINC 9 31225 BLOWER PULLEY 3500 5000 10 31229 BLOWER BELT 3500 A BELT 11 34116 10 X 5 8 HEX WASHER HEAD TEK Z 12 11125 BELT GUARD ASSY 13 31226 SHEAVE BUSHING 1 14 21013 1 KEY 1 4 X 1 1 4 15 31192 REPLACEMENT BEARING PACKAGE 16 31194 1 SHAFT W KEYWAY 15 17 31238 SHEAVE BUSHING 7 8 18 31223 MOTOR PULLEY 3500 BLOWER 19 31187 MOTOR MOUNT BRACKET 20 21012 9 KEY SQ 3 16 X 1 21 31228 BLOWER ...

Page 120: ... DETAIL A DETAIL C DETAIL B 2 3 4 5 6 7 8 9 20 31 30 32 33 35 36 38 39 40 49 50 51 52 53 54 55 56 62 64 63 21 22 23 24 25 26 27 28 27 28 29 57 58 60 61 34 CABINET CB 5000 11302 37 42 43 44 46 45 47 48 41 65 1 19 18 17 16 15 14 13 12 11 10 15 I88959 A 59 ...

Page 121: ...W LUG 43 33182 CONTACTOR 240V 44 33207 CONT 120V 60HZ 1POLE 45 21113 BOX JUNCTION 46 33273 CONNECTOR 90 DEG SNAP TITE 47 33286 SWITCH DPDT ON ON 48 33186 AMBER LIGHT 120V 49 12215 MOTOR HARNESS CB5001 50 33245 FAN LIMIT SWITCH 51 25114 COVER 52 25087 TOP 53 25070 ORIFICE PLATE 54 21107 5000 DISCHARGE ANGLE BOTTOM 55 24034 LOUVER 56 14161 DIFFUSER OUTLET 5000 A 57 25067 BLOWER FLANGE 58 25068 BLOWE...

Page 122: ...Operator s Manual Models CB 3500 CB 5000 A 20 BLOWER ASSEMBLY CB 5000 2 3 4 5 6 7 8 9 20 22 21 1 10 11 12 13 14 15 16 17 18 19 11 I88960 ...

Page 123: ...9 31225 BLOWER PULLEY 3500 5000 10 31230 BLOWER BELT 5000 A BELT 11 34116 10 X 5 8 HEX WASHER HEAD TEK Z 12 11238 BELT GUARD ASSY 13 21013 1 KEY 1 4 X 1 1 4 14 31226 SHEAVE BUSHING 1 15 31192 REPLACEMENT BEARING PACKAGE 16 31195 1 SHAFT W KEYWAY 18 17 31238 SHEAVE BUSHING 7 8 18 31227 MOTOR PULLEY 5000 BLOWER 19 31188 MOTOR MOUNT BRACKET 20 34290 5 16 18 X 3 4 SQUARE HEAD 21 21012 9 KEY SQ 3 16 X ...

Page 124: ... IN LET RO TA TIO N N I O U T 13 27 15 1 28 16 23 24 26 25 24 23 17 16 22 21 20 19 18 PACKAGED WITH CLEAN BURN EQUIPMENT PACKAGED WITH CLEAN BURN EQUIPMENT 29 A2RA 7710 GA UG E INL ET R H RO TAT ION INL ET 30 31 SINGLE PIECE OF COPPER TUBING USER SUPPLIED 7 4 8 SUPPLY TO BURNER 6 5 RETURN TO TANK RELIE F ...

Page 125: ...D BRASS 12 32210 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 PIP...

Page 126: ...Operator s Manual Models CB 3500 CB 5000 A 24 ...

Page 127: ...RN GRN DOUBLE SINGLE ORG WHT PUR WHT WHT ORG BLK WHT SWITCH FAN TAN W BLACK STRIPE N C N O PUR PUR BLK BLK BLK ORG 110 VOLT LIGHT HIGH LIMIT BLUE INSULATED I44037 TAN W RED STRIPE TOGGLE SWITCH 6 5 4 1 2 3 5 4 6 DOUBLE POLE DOUBLE THROW TOGGLE SWITCH DETAIL OF CONNECTOR 1 2 3 VOLTS IN CONNECT 2 HP BLOWER MOTOR ACCORDING TO THE LABEL SUPPLIED WITH THE MOTOR FOR CW ROTATION FACING THE SHAFT AND 230 ...

Page 128: ...VE THE BLADE IN THE RELEASE SLOT TO REMOVE OR INSTALL A WIRE TO RELEASE THE JAWS CAREFULLY PULL THE BLADE OF THE SCREWDRIVER I88249 C IS CLIPPED TO THE INSIDE OF THE BURNER HOUSING ON THE RIGHT FROM THE RELEASE SLOT 8 BLACK BLACK CAD CELL YELLOW YELLOW NOZZLE TEMP SW THERMO WALL STAT BURNER SWITCH CENTRIFICAL BLACK MOTOR ORANGE BLUE FORMER PRIMARY OIL T F T F BLUE TRANS BLACK LIGHT GREEN WHITE WHI...

Page 129: ...EN ACTUATED BY BURNER MOTOR BURNER MOTOR MANUAL 220 VOLTS TOGGLE UP PRIME TOGGLE DOWN BURNER D P D T OPTIONAL SERVICE DISCONNECT SWITCH 2 R SINGLE POLE RELAY 110 V COIL 1 R 110 VOLTS 110 VOLTS COIL BLOWER MOTOR DOUBLE POLE RELAY DRAFT INDUCER MOTOR OIL PUMP MOTOR 2 M 1 M E C A N R U CUSTOMER POWER CONNECTION TO F N L2 L1 MODELS CB 3500 CB 5000 ON FURNACE CABINET TOGGLE SWITCH SEE OPERATOR S FAN LI...

Page 130: ... CB 3500 CB 5000 B 4 Wiring Diagrams continued Figure B4 Metering Pump Wiring Schematic R E D BLK GRN BLUE L 2 WHT L 1 BLK CAP BLK BLK SEE FURNACE SCHEMATIC I44040 115 V 60 HZ POWER FROM OIL PUMP CIRCUIT ENCLOSED J BOX GROUND ...

Page 131: ... control should recycle restart after 65 seconds 3 If control does not operate as described check the wiring Start up operation Do not start the burner if the combustion chamber contains oil or oil vapor The amber LED every 3 to 4 seconds green LED will be on or blinking Power ON Open all manual oil line valves Close the line switch Self test 1 The control performs a boot up test to verify interna...

Page 132: ...button for 2 seconds CAD cell seeing light Green LED on and amber LED blinking 1 second on 4 seconds off Remove one yellow lead from FF terminals If the amber LED If the amber LED goes OFF the control is OK and light is leaking into the burner housing OR CAD cell is defective OR there is a problem with the CAD cell wiring or holder If appliance was recently shut down CAD cell may see residual hot ...

Page 133: ...______________________ Furnace Installed Date __________ By name phone __________________________________ Furnace Inspected Date __________ By name phone __________________________________ Draft Readings Service Record Date Draft Date Initials of Technician Burner Stack Canister Metering Check Valve Chamber Stack Oil Tank A P M Filter Pump and Screen Flues Note Refer to Section 9 for Maintenance I...

Page 134: ...Operator s Manual Models CB 3500 CB 5000 C 2 ...

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