CLEAN BURN CB-500 series Operator'S Manual Download

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Operator's Manual: Models CB-1500 & CB-2500 (230 V / 50 Hz)

3-1

SECTION 3: FURNACE ASSEMBLY

Understanding Assembly

Assembling your Clean Burn Furnace includes the following steps:

(1) Installing the Blower Assembly
(2) Installing the Hot Air Discharge Components
(3) Installing the Energy Retention Disc
(4) Installing the Burner
(5) Installing the Connector Block, Oil Line Tubing, and Air Line Tubing

Clean Burn recommends that you review all assembly procedures before proceeding, paying careful
attention to safety information statements.

Figure 3A

on the following page provides a general overview of the furnace components and their

proper assembly.

Required Tools and Materials

The following tools are required for furnace assembly and should be gathered before starting any procedures:

•

3/8" open-end wrench

•

9/16" open-end wrench

•

Medium flat-blade screwdriver

•

Medium adjustable wrench

•

1/4" nut driver attachment for drill

•

Variable speed drill

Summary of Contents for CB-500 series

Page 1: ...erious personal injury or death CLEAN BURN INC 34 Zimmerman Road Leola PA 17540 U S A Copyright 2009 Clean Burn Inc All rights reserved No part of this publication may be reproduced or distributed without the prior written permission of Clean Burn Inc 34 Zimmerman Road Leola PA 17540 Subject to change without notice The Clean Burn logo is a trademark of Clean Burn Inc All other brand or product na...

Page 2: ......

Page 3: ... 1 1991 Safety of machinery Basic concepts general principles for design Part 1 Basic terminology methodology EN 292 2 1991 A1 Safety of machinery Basic concepts general principles for design Part 2 Technical principles and specifications EN 60204 1 2000 Safety of machinery Electrical equipment of machines General requirements EMC Standards EN 55014 1 2000 Electromagnetic Compatibility Requirement...

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Page 5: ... 5 InstallingtheHotAirDischargeComponents 3 6 InstallingtheEnergyRetentionDisc 3 9 InstallingtheEnergyRetentionDiscintheCombustionChamber 3 9 ClosingtheFurnaceDoor 3 9 InstallingtheBurner 3 9 CheckingtheBurnerNozzleandElectrodes 3 9 MountingtheBurnerontheHingeBracket 3 11 InstallingtheConnectorBlock OilLineTubing andAirLineTubing 3 12 InstallingtheConnectorBlockontheFurnaceDoor 3 12 InstallingtheO...

Page 6: ...mper 4 22 InstallingtheStackPenetration 4 23 InstallingtheExteriorStack 4 23 InstallingtheStackCap 4 23 InstallingtheOptionalDraftInducer 4 23 InstallingtheWallThermostat 4 25 InspectingtheFurnaceInstallation 4 25 SECTION 5 METERING PUMP PRIMING 5 1 Understanding Metering Pump Priming 5 1 RequiredToolsandMaterials 5 1 PrimingtheMeteringPump 5 2 VacuumTestingtheOilPump 5 4 SECTION 6 STARTING AND AD...

Page 7: ...gtheCheckValve Screen 9 7 CleaningtheTank 9 8 AnnualBurnerTune up 9 8 EndofSeasonMaintenance 9 8 SECTION 10 TROUBLESHOOTING 10 1 Troubleshooting Flow Chart 10 2 Troubleshooting Tables 10 3 APPENDIX A Detailed Furnace Specifications A 1 Furnace Technical Specifications A 1 Burner Technical Specifications A 2 Furnace Dimensions A 3 BurnerComponents A 4 RemovingtheNozzleforCleaning A 9 FurnaceCompone...

Page 8: ...TABLE OF CONTENTS APPENDIX C Additional Installation and Maintenance Requirements C 1 Installing a Cover over the Oil Air Regulators C 1 Installing a Fire Valve C 2 APPENDIX D FurnaceServiceRecord D 1 ...

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

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

Page 11: ...e must be performed in accordance with safe handling procedures WARNING DO NOT operate your furnace when the ambient temperature is above 35o C 95o F WARNING The Best Operator is a Careful Operator By using common sense observing general safety rules and adhering to the precautions specific to the equipment you the operator can promote safe equipment operation Failure to use common sense observe g...

Page 12: ...regulations require that Your used oil is generated on site You may also accept used oil from do it yourself oil changers Hazardous wastes such as chlorinated solvents are NOT to be mixed with your used oil The flue gases are vented to the outdoors with an appropriate stack Your used oil is recycled as fuel for heat recovery DO NOT operate your furnace in warm weather just to burn oil Contact your...

Page 13: ...tional and local codes Consult your local municipal authorities for more information as necessary Review and adhere to the safety guidelines for used oil supply tanks as stated in the WARNING shown Ensure that the tank for your furnace installation complies with all code and safety requirements as stated here If the tank does not comply DO NOT use it If you do not have a copy of the tank safety la...

Page 14: ...For your safety and the safe operation of your furnace review all labels and heed all safety messages as printed on the labels If any labels on your Clean Burn furnace ever become worn lost or painted over please call your Clean Burn dealer for free replacements Label Part Description 42030 FurnaceElectricalShockHazardWarningLabel severallocations 42027 Furnace Burn Hazard Hazardous Voltage Warnin...

Page 15: ...Operator s Manual Models CB 1500 CB 2500 230 V 50 Hz 1 7 For Your Safety continued CB 1500 CB 2500 Furnace Cabinet Safety Labels ...

Page 16: ...50 50 HZ 04 1 mm 18 46 1 2 1 2 4 0 4 0 1 1 4 0 0 28 0 28 0 28 3 5 1 2 73 KW 0 24 BLOWER DISCHARGE 60 152 CLEAN BURN INC THE MAINTENANCE INTERVAL FOR CLEANING ASH FROM THE FURNACE IS APPROXIMATELY 700 HOURS THE ASH LEFT FROM THE BURNING OF USED OIL MAY CONTAIN METALLIC COMPOUNDS OR FOREIGN MATERIALS THE ASH MUST BE DISPOSED OF PROPERLY BURNER REQUIRES A MINIMUM AIR SOURCE OF 2 S C F M 57 L MIN AT 2...

Page 17: ...036 42339 42340 I88889 42004 CB 1500 CB 2500 BurnerSafety Labels 42004 BurnerSafetyWarningLabel HighVoltage MovingPartsHazards 42235 BurnerSafetyWarningLabel Fire ExplosionHazard BurnerInstallationandService 42339 BurnerModel SerialNumberLabel 42229 Logo BurnerDescriptionLabel 42482 ResetWarningLabel 42309 CEMarkLabel 42023 BurnerPowerLabel 42457 MadeinUSA PatPending CombinationLabel onside ...

Page 18: ...Operator s Manual Models CB 1500 CB 2500 230 V 50 Hz 1 10 ...

Page 19: ...zed list of all components you should have received in your Clean Burn furnace shipment Open all shipping containers and inspect all components according to the list Immediately notify the freight company and your Clean Burn dealer in case of shipping damage or shortage s Keep all components together so you will have them as needed for furnace assembly and installation Furnace Component List ONE S...

Page 20: ...hers which hold the combustion chamber door closed Set the nuts and washers aside in a safe place for later re installation after the target has been installed Section 3 2 Carefully swing the combustion chamber door open Remove and inspect the components packed inside 3 Leave the door unfastened open for assembly installation procedures to be accomplished in the next section Figure 2A Accessing th...

Page 21: ...Line Tubing and Air Line Tubing Clean Burn recommends that you review all assembly procedures before proceeding paying careful attention to safety information statements Figure 3A on the following page provides a general overview of the furnace components and their proper assembly Required Tools and Materials Thefollowingtoolsarerequiredforfurnaceassemblyandshouldbegatheredbeforestartinganyprocedu...

Page 22: ...ng procedures provided in order in this section 2 3 4 5 ENERGY DISC HOOKS OVER MOUNTING NOTE LOOP ON ENERGY RETENTION BRACKET ON BACK WALL OF COMBUSTION CHAMBER 1 HOT AIR DISCHARGE FURNACE BREECH BURNER MOUNTING BRACKET BURNER CABLE FURNACE DOOR FURNACE R H BREECH THROAT LH FURNACE BREECH WITH CLEAN OUT ALL THREAD RODS COUPLINGS FOR ALL THREAD RODS CHAMBER COMBUSTION BACK WALL OF I88943 RETENTION ...

Page 23: ...ithself tappingscrews provided Drivethescrewsintothe blowerhousingthroughtheholesinthemountinganglebrackets Therearefourholesalongeach sideandacrossthetopofthebrackettofastentheblowertothefurnacecabinet 5 Installtheblowersafetyguardsasshown WARNING To avoid serious personal injury be sure to install both pieces of the blower guard around the blower prior to operating the furnace NEVER operate the ...

Page 24: ...fthefurnacecabinetas showninFigure3C Connectthepowerleadcomingfromtheblowerassemblytothe4 x6 electricalbox mountedontherearofthefurnacecabinet Connecttheblack power motorleadwiretotheconnectorblockterminalwiththeorange power wirefromthefrontelectricalbox Connectthewhite neutral motorleadwiretotheconnectorblockterminalwiththe white neutral wirefromthefrontelectricalbox Connectthetwobrownleadstothec...

Page 25: ... proper specified clearances for Central Furnace Configurations as stated in Section 4 of this manual CB 1500 Donotinstalllouvers Ductworkshouldbeinstalleddirectlyoverthedesired airdischargeopeningonthesideofthefurnacecabinet 305mmx305mm CB 2500 Determinewhichsideofthefurnacecabinetwillhavetheductworkattached Replacetheleftorrightsideinnershieldandshroudingtoaccommodatethe ductwork Donotinstalllou...

Page 26: ...portanttoproperlyinstallthehotairdischargecomponents louversandblankcoverpanels to directtheflowofairfromthefurnace AsyouwillnotefromFigures3Dand3E theairdischargepanelsareto be installed on the side s and or bottom of the furnace The air flow may be directed down front or back depending on how the louvers and cover panels are installed IMPORTANTNOTEFORCENTRALFURNACEAPPLICATIONS For ducting applic...

Page 27: ...helouvers orthefurnacewillnotoperateproperly 4 Installtheblankcoversovertheremainingairdischargeopening s onthe furnacecabinet When determining the placement of the air discharge louvers you also need to consider the required clearances from combustibles as stated in Section 4 of this manual Note that the CB 1500 is supplied with 2 louver sections which may be installed together on one side or the...

Page 28: ...views of same furnace NOTE When louver panels are split between two sides make sure the louvers are installed in the upper half of each side air discharge opening as shown here Louvers split between left side and bottom openings showing left and right side views of same furnace NOTE When louver panels are split between a side and the bottom make sure the bottom louvers are installed in the forward...

Page 29: ...alling the Energy Retention Disc at the Back of the Combustion Chamber ATTENTION DONOTfireyourfurnacewithouttheEnergyRetentionDiscinplace orcombustioncham berdamagewilloccur HandletheEnergyRetentionDisccarefullytoavoiddamagingit 1 RefertoFigure3AtoreviewtheproperpositioningoftheEnergyRetentionDisc 2 Swing open the clean out door on the furnace front to gain access to the combustion chamber 3 Useal...

Page 30: ...Nozzle and Electrode Specifications BURNER NOZZLE VIEW BB 3X NOZZLE IS STAMPED WITH SIZE ON FLAT OF NOZZLE HEAD CRITICAL DIMENSION NOZZLE MUST BE 3 mm 1 8 AHEAD OF THE DISK NOZZLE MUST NOT BE BEHIND THE DISK FRONT VIEW BB VIEW AA 3 mm 1 8 SPARK GAP I88906 5 mm 3 16 GAP BETWEEN ELECTRODES NOZZLE SIDE VIEW AA ...

Page 31: ...mounted on the hinge bracket on the furnace cabinet 3 Carefully swing the burner so the retention head enters the throat of the furnace 4 Check the clearance between the retention head and the furnace throat There must be at least 1 8 clearance so the retention head is not bumped as you swing the burner into firing position NOTE If the retention head bumps the furnace throat adjust the hinge brack...

Page 32: ... components Installing the Oil Line Tubing ATTENTION DO NOT disassemble the compression fitting from the swivel fitting To prevent leaks the NPT threads of the compression fitting have been sealed with hydraulic sealant during assembly of the fittings at the factory 1 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 bur...

Page 33: ...providesa 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 RefertoFigure3H Pushtheairlinetubingintotheswivelfittingontheconnectorblockuntil the tubing bottoms out in the fitting 3 Repeat this procedure to connect the air line tubing to the air line fitting on the side of the burner 220 240V 50 60Hz 3W ts 1...

Page 34: ...n a safe secure area 1 Swingtheburnerintofiringposition 2 Install and tighten the lock down nut on the mounting plate bolt to secure the burner in its firing position 3 Plug the burner electrical cable into the receptacle on the top of the burner housing 4 Tighten the locking ring to secure the electrical cable NOTE Be sure to properly align the plug when plugging it into thereceptacle SeeFig3I Fi...

Page 35: ...n procedures WARNING To prevent damage to the furnace and to ensure personal safety lifting mounting and hanging of the furnace must be performed in accordance with safe handling procedures Important Safety Guidelines for Safe Installation General installation of the appliance shall be in accordance with the manufacturer s literature in addition to complying with the following BS5410 Code of Pract...

Page 36: ...ay not be standard or familiar WARNING High earth leakage current earth connection is essential and must be established before connecting the main power supply WARNING Low voltage terminals are only protected by basic insulation caution is required CAUTION Use only approved wire conduit and connectors when wiring the Clean Burn furnace An emergency stop device i e panic button must be installed at...

Page 37: ... WITH THE NOTE THE LAST STACK SECTION SHALL EXTEND AT LEAST 92 cm 3 FT SPACER DO NOT CREATE FIRE HAZARDS WARNING NEVER LOCATE A STACK JOINT INSIDE WALLS OR IN A JOIST NOT PRIME AND OR THE FLOW RATE FROM VERTICAL SUCTION LIFT OR THE PUMP WILL CAUTION DO NOT EXCEED 183 cm 6 FT THE PUMP MAY DECREASE GASOLINE FUMES IN YOUR SHOP CHECK LOCAL CODES 244 cm 8 FT MIN FROM FLOOR TO FURNACE IF THERE IS A POTE...

Page 38: ...XTERIOR SINGLE WALL STACK CHILLS THE EXHAUST GASES RESULTING IN POOR BURNER PERFORMANCE AND BACK PRESSURE IN THE FURNACE WATERTIGHT ROOF FLASHING CLEAN BURN RECOMMENDS DEKTITE FLASHING FOR A WATERTIGHT SEAL ANGLE IRON SUPPORT BEAMS CEILING MOUNTING SYSTEM BRIDGED ACROSS SUFFICIENT WARNING USE MINIMUM 64 mm X 64 mm X 6 mm STRUCTURAL MEMBERS TO SAFELY SUPPORT FURNACE DOUBLE NUTS AIR DISCHARGE CHECK ...

Page 39: ...ace is mounted a minimumof244cm 8ft offthegroundifthereis thepossibilityofgasolinefumesorother combustibleorexplosivefumesinyourshoparea CLEARANCES FOR UNIT HEATER INSTALLATION WITH SIDE AIR DISCHARGE TOP offurnace 31 cm 12 FRONT burner 153 cm 60 SIDE with Air Discharge 153 cm 60 OTHERSIDE 46 cm 18 CHIMNEYCONNECTOR 46 cm 18 REAR fromblower 5 cm 2 BOTTOM 61 cm 24 CLEARANCES FOR UNIT HEATER INSTALLA...

Page 40: ...ironbridgedacrosssufficientstructuralmemberstosafelysupport thefurnace 1 Refer to Figures 4A and 4B 2 Follow the instructions as provided in the diagrams 3 Use a spirit level to make sure the cabinet is level side to side and front to back Selecting a Location continued Figure 4C Clearances from Combustibles 220 2 40 50 60 Hz 3W Nr 05 7H703 6 Ty p e BHO 64 Danf oss ts 10s 46 cm 18 OTHER SIDE WITHO...

Page 41: ...n combustiblefloorasshownin Figure4E NOTE Makesurethatblankcoverpanelsare installedoverthebottomairdischargeopeningtoallow safefloormounting 1 RefertoFigure4Eandfollowtheinstructions as provided in the diagram Figure4E CB 1500FurnaceInstalledonNon CombustibleFloor CB 2500issimilar Mounting the Furnace continued Figure 4D CB 1500 Furnace Installed on a RaisedPlatform CB 2500issimilar Danfoss Type B...

Page 42: ...osettleoutoftheusedoil Singlewalltanksmusthaveashut off valve on the side of the tank to allow thewater sludge etc tobedrainedfrom thebottomofthetank All unusedopeningsinthetankmustbe pluggedorcappedoff Foroptimalsystemfunctioning CleanBurn Recommendsinsidetankinstallationsas showninFigures4A 4B and4J The tank must be vented to the outside of the building using iron or steel pipe and fittings with...

Page 43: ...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 Figure 4F Typical Metering Pump Installation with Inside Tank Oil Tank Installation Specifications continued PUMP SUCTI...

Page 44: ...g 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 appropriateprocedures diagramsforpumpmounting Foroptimalmeteringpumpfunctioning mountthepumpatadistancefromtheoiltankthatwill complywiththefollowingrequirements ThesuctionoillinemayNOTexceed183cm 6 TOTALverticalliftAND122cm 4 TOTALhorizontall...

Page 45: ...NPT X 1 4 TUBE COMPRESSION FITTING 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 TUBING SLIP ADAPTER 26 32442 2 x 1 2 x 1 2 NPT DUP...

Page 46: ...ll and tighten the two pump mounting bolts 5 Use the appropriate type of bolts and washers user supplied to securely mount the metering pumptothemountingbracket whichistobeinstalledontheappropriatewallinyourbuildingata distancefromthetankthatcomplieswiththesuctionoillinerequirements Figure 4I Proper Positioning of Metering Pump Head GAUGE INLET RECOMMENDED SETUP PUMP IS MOUNTED LEFT ON WALL ALTERN...

Page 47: ...Ensurethattheground wireisattachedtothegreengroundscrewonthefurnacejunctionbox 3 Checkforcorrectvoltageatthefurnace andrefertothefollowingchart ATTENTION Incorrect voltage will severely damage the blower motor furnace components DO NOT operate your furnace on any non specification power system Model Voltage FuseProtection Circuit Hertz CB 1500 230 15amps Dedicated 50 CB 2500 230 15amps Dedicated 5...

Page 48: ...ckvalveandscreenattheendofthe suctionoilline orthepumpwillnotmaintainitsprime Use Permatex 2 non hardening gasket sealer on every threaded fitting DO NOT use teflontapeorteflonpipedopecompounds thetefloncanflakeoffandcausedamagetothe pumphead Thesuctionoillinemustbe100 airtightforpropersystemfunctioning Useonly high qualityflarefittingsforthecoppertubing DONOTusecompressionfittings DONOTuseanystee...

Page 49: ...oselyinstallthe1 2 brasscapontothisnipple DONOTtightenthecapatthistime Figure 4J CB 1500 Oil Line Installation Overview CB 2500 is similar OIL FLOW CHECK VALVE SCREEN SUCTION LINE IN SUCTION LINE CANISTER FILTER PRESSURE OIL LINE OIL PUMP ELECTRICAL CIRCUIT WITH BALL VALVE VENT RELIEF CLEAN OUT FUNNEL EMERGENCY VENT CAP 30 cm 12 CHECK VALVE CONNECTOR BLOCK Nr 057H7036 TypeBHO 64 Danfoss 220 240V 5...

Page 50: ...Installthe1 2 MPTx1 2 flareadapterintothe3 4 x1 2 brassbushing 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 flaresaremadeproperly i e sotheywillbe100 airtight n Installtheflaredoillineandnutontotheassembledcheckvalve screenandtighten o Pick up the assembled oil l...

Page 51: ...on hardeninggasketsealertosealeverythreadedfitting DONOTuseteflon tapeorteflonpipedopecompounds 1 RefertoFigure4K 2 Removetheplugfromthereliefportontopofthemeteringpumphead 3 Installthe1 8NPTx1 4tubecompressionfittinginthereliefportontopofthemeteringpumphead 4 Install1 4 O D coppertubing user supplied fromthepressurereliefportbacktotheoiltank RefertoFigure4Jasneeded PART DESCRIPTION 1 32475 METERI...

Page 52: ...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 Itiscriticalthatyouadheretothefollowingspecificationsforpressureoilline installation oil line from the pump to the furnace if these specifications are not met the metering pump will not function correctly a...

Page 53: ...ack or install a draft inducer to obtain 02 W C draft over fire Keep the horizontal stack run as short as possible slant it upward at a minimum of 6 5mm 1 4 per305mm 12 ofrun 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 le...

Page 54: ...m 3 ABOVE THE HIGHEST POINT AT WHICH IT COMES IN CONTACT WITH THE ROOF AND AT LEAST 60 cm 2 HIGHER THAN ANY RIDGE PARAPET WALL OR ROOF STRUCTURE WITHIN 3 m 10 OF IT FREE FLOW OF THE STACK GASES TO ALLOW INSULATED STACK WITH A STAINLESS STEEL LINER 3m 10 MIN VERTICAL STACK HEIGHT PLUS 30 cm 1 FOR CLASS A STACK COMPONENTS EVERY FITTING TO MAINTAIN PROPER DRAFT OVERFIRE SYSTEM TO SAFELY SUPPORT THE T...

Page 55: ...SS STEEL LINER CLASS A STACK PENETRATION AND CLEAN OUT TEE SINGLE WALL STACK MIN 24 GAUGE 60 cm 2 S E S L E R O M WARNING ENSURE PROPER CLEARANCES BETWEEN STACK COMPONENTS AND COMBUSTIBLES PER ALL APPLICABLE CODES DRAFT AT BREECH SETTING DRAFT ADJUST BAROMETRIC 6 mm 1 4 HOLE FOR DAMPER FOR 04 W C STACK SIZE MIN 20 cm 8 WARNING MAKE SURE TO INSTALL THE PROPER WALL SUPPORT SYSTEM TO SAFELY SUPPORT T...

Page 56: ...ing the Barometric Damper 1 RefertoFigure4L Installasinglewalltee min 24gauge afterthe90 degreeelbowinthestraight verticalstacksectionwithin90to150cm 3to5feet ofthefurnacebreach Forhorizontalstackruns Figure4M installtheteeafterthefirststraightsectionofpipe NOTE Thisteeisrequiredtosupportthebarometricdamper Youmustpurchasethisteewhen you purchase your stack materials 8 single wall tee CB 70174 2 R...

Page 57: ... Installthestackcapaccordingtothemanufacturer sinstructions Installing the Optional Draft Inducer ATTENTION The draft inducer Field brand model DI 2 is optional equipment and may be installed to ensure proper draft The Field brand draft inducer has been tested for use on Clean Burn furnaces DO NOT use other models or brands of draft inducers UnderstandingtheImportanceoftheDraftInducer Thedraftindu...

Page 58: ... VERTICAL STACK TO POSITION NOTE INSTALL DRAFT INDUCER IN LAST OVERHEAT THIS ALSO REDUCES ASH DO NOT MOUNT THE DRAFT INDUCER IN THE HORIZONTAL STACK NEAR THE FURNACE ACCUMULATION IN THE DRAFT INDUCER BREECH DRAFT INDUCER ADJUSTMENT PLATE DRAFT CLASS A STACK DOUBLE WALL INSULATED ALL FUEL STACK BAROMETRIC DAMPER TO OBTAIN 02 W C DRAFT OVERFIRE FURNACE BREECH INSTALLED ON L H CLEAN OUT CAP SINGLE WA...

Page 59: ...f the cover with the slots on the base and swing the cover into place Inspecting the Furnace Installation Following completion of all installation activities described in this chapter the furnace should be inspected by qualified personnel before firing This ensures that your installation meets all applicable national and local codes and allows for any deficiencies to be corrected before furnace st...

Page 60: ...Operator s Manual Models CB 1500 CB 2500 230 V 50 Hz 4 26 ...

Page 61: ...g pump The procedures in this section must be performed in sequence without interruption to properly prime the pump Required Tools and Materials The following tools and materials are required for oil pump priming and should be gathered before starting any procedures 3 8 open endwrench 5 8 open endwrench Rags Twocontainers minimumone gallon Permatex 2non hardeninggasketsealer AdjustableWrench PipeW...

Page 62: ...eofthepumphead thiswillfillthe oilline canisterfilter andpumpheadwithoil ATTENTION NEVERrunthepumpheaddry i e withoutoilinthepumphead doingsowill severelydamagethepump 4 ApplyPermatex 2non hardeninggasketsealertothethreadsoftheplug removedfromthe pumphead Re installtheplugandtighten 5 ApplyPermatex 2non hardeninggasketsealertothethreadsofthe1 2 brassnipple Re install the1 2 brasscaponthebrassnippl...

Page 63: ...acecabinet Theprimingswitchhastwopositions PRIME Thisisusedonlyforpumppriming WhentheswitchisinthePRIMEposition the pumpcircuitisactivatedforpriming Thepumpwillcontinuetorunaslongastheswitchisinthis position Theoilprimarycontrolcircuitisde activatedsotheburnercannotrunwhiletheswitchisin thePRIMEposition BURNER Thisisusedfornormalburneroperation WhentheswitchisintheBURNER position theburnercontrols...

Page 64: ...s from the ball valve to the pump these components must all be airtight to avoid suction leaks The following procedure provides instructions for vacuum testing the pump and canister filter on systems equipped with a ball valve ATTENTION For the pump to pull and hold vacuum it is critical that all fittings are airtight If any of these fittings are loose the pump may not pull a vacuum or may lose th...

Page 65: ...tween 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 ...

Page 66: ...Operator s Manual Models CB 1500 CB 2500 230 V 50 Hz 5 6 ...

Page 67: ... block is thoroughly warmed up Feel the back of the burner box to make sure the preheater is sufficiently warm The proving switch on the preheater block will not allow the burner to start until the block is hot NOTE The preheater block will remain warm as long as power is supplied to the burner If the main power supply is ever turned OFF you must wait at least 15 minutes until the preheater block ...

Page 68: ...st 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 The approximate oil pressure range during initial startup is 0 07 to 0 28 bar 1 to 4 psi for Model CB 1500 and 0 28 to 0 55 bar 4 to 8 psi for Model CB 2500 InitialAdjustmentsforCB 1500 Maximum Input 44 Kw 4 0 LPH 150 000 BTUH ...

Page 69: ...r 3 Observing the Flame Length Visually inspect the flame length through the observation port Refer to Figure 6B for an illustration of the desired flame length The flame should extend no more than one half of the way down the combustion chamber WARNING The observation port gets hot as the burner fires To avoid personal injury always wear heavy work gloves and safety glasses when opening the port ...

Page 70: ...length Immediately readjusttheburnerifyoueverseesmokecomingfromthestack Smokeindicatesimproperair fueladjustment NOTE Whenusinginstrumentstoadjusttheburnerforasmokelessburn thefollowing readingsshouldbeachieved Draftoverfireshouldbe 02inchw c Adjust for a smoke spot of a trace to 2 Adjust for a CO2 reading of 8 to 10 or an O2 reading of 7 to 9 Cadcellreadingbelow500ohms Checking the Operation of t...

Page 71: ...hecontrolwillshuttheburneroffonsafetylock out Thefollowingprocedureexplainswhat should be done when this occurs It is very important that you follow these instructions precisely when resetting the safety on the primary control and restarting the burner Resetting the Oil Primary Control DANGER DO NOT reset the oil primary control if oil mist is present in the combustion chamberorwhenthecombustionch...

Page 72: ...tically resetandallowtheburnertorestart ATTENTION If the L 200 hi temp limit switch is opening repeatedly the burner MUST be readjusted according to the instructions in Section 6 to correct the overheating problem or serious damage to the furnace may occur TheL 200hi templimitswitchwillopenandshutdowntheburnerifanyofthefollowingconditionsexists Thefurnaceisoverfiring ReviewthedirectionsinSection6t...

Page 73: ...OUNT FROM TERMINAL BLOCK BLACK TAN WIRE BLACK AND TAN WIRE RED TAN WIRE TO BURNER SWITCHES IN SERIES RED TAN WIRE LINKS THE 2 33390 L 200 HI LIMIT NC BLOCK FROM TERMINAL RED TAN WIRE TO TERMINAL BLOCK 33230 F 180 FAN SWITCH SWITCH AUTO RESET 33288 L 290 HI LIMIT AUXILIARY Figure7B LocatingtheFanSwitchandHi TempLimitSwitches ...

Page 74: ...Operator s Manual Models CB 1500 CB 2500 230 V 50 Hz 7 4 ...

Page 75: ...ecific 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 ...

Page 76: ...ly hold the weight in position Solving Draft Overfire Problems WARNING If you cannot achieve proper draft overfire do not operate your furnace Contact your Clean Burn dealer for assistance ATTENTION Backdraft must be resolved or your furnace will not operate correctly Under backdraft conditions draft overfire readings will show positive pressure in the combustion chamber Backdraft means that oil s...

Page 77: ...ity of Backdraft The following procedure is an accurate method of determining how much backdraft is created by the exhaust fans Once this is determined you can select the correct method for resolving the backdraft Refer to Figure 8C on the following page as needed 1 Turn off ALL exhaust fans and close ALL doors and windows in the building any open door or window will allow make up air to enter the...

Page 78: ...S BACKDRAFT 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 220 240 50 60 Hz 3W Nr 057H70 36 Typ e BHO 6 4 D anf o s s t s 10s t ...

Page 79: ...stfan Thisinformationshouldbestamped onalabelontheexhaustfan Makesuretoaddupthetotalvolumetricflowrateifmore thanoneexhaustfanexistsinthebuilding b Selectthecorrectsizeofmake upairlouvertoprovidetherequiredfreshair Ifyoucannotdeterminethevolumetricflowrateoftheexhaustfan usethefollowingprocedure Procedure2 a Countthetotalnumberofexhaustfansinthebuilding b Closeallofthedoorsandwindowsinthebuildinge...

Page 80: ...uilding 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 CALCULATED OPENING SIZE cm2 in2 REQUIRED LOUVER GRILL SIZE cm in 0 528 0 82 25 x 25 10 x ...

Page 81: ...dures for these activities are included in this chapter MaintenanceActivity Interval Periodicburnerinspection Monthly Cleaningthecanisterfilter Beforevacuumgaugereads10 HGofvacuum Servicingthemeteringpump At least once a year Cleaning out ash Approx 700 hours as indicated on the burner hour meter Cleaning the check valve screen At least once a year Cleaning water sludge out of tank At least once a...

Page 82: ...eflameisfiringtoostrongly i e flame touchesbackand orsidewallsofthe combustionchamber checktheairpressuresetting seefollowingguideline Checktheairpressurebyobservingtheairgauge properairpressuresettingsareprovidedin Section6 DONOToverfiretheburner doingsoonacontinualbasiswilldamagethefurnace Checkthecombustionairbandsettingfortheproperopeningandcleanawayanydust debrisas necessary Notethattheairban...

Page 83: ...er 3 Unscrew 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 ReferringtoFigure9B examinethefiltercomponentsasyoureassemblethem 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 S...

Page 84: ...RefertoFigure9C 2 Remove the pump 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 Figure9C ServicingtheMeteringPump 3 2 1 PART No 32423 PART No 32422 ...

Page 85: ...erglass insulation and reduces heat transfer significantly Never allow more than 6mm 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 cl...

Page 86: ... outdoortoexposetheheatexchangerfluesandthecombustion chamber CarefullyremovetheEnergyRetentonDiscwithalonghandleorpipe Lightlyvacuum theEnergyRetentionDisc e Checkthecoloroftheash itshouldbelightgrayortan ATTENTION Whiteashindicatesexcessiveairpressure Blackashorsootindicateslackof combustionair Iftheseconditionsexist callyourCleanBurndealer DONOToverfireyour furnacebyturningupthecompressedair Ov...

Page 87: ...rmatex 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 Cleaning Ash From the Furnace continued k Re install the furnace components Swing the clean out door shut install and tighten the lock down nuts so that the door seals properly Re install...

Page 88: ...the tank is low This allows sufficient time to refill the tank with used oil generated by your company over the summer months so that you have adequate fuel for the heating season Annual Burner Tune up YourCleanBurnfurnacerequiresannualperiodicmaintenance Theburnerrequiresanannualtune up similartoanautomotivetune up tokeepitrunninginpeakcondition Theburnertune upshouldbe performed by a qualified C...

Page 89: ... encountered in furnace operation and adjustment The Flow Chart outlines the proper sequence of events in furnace operation use this chart to help diagnose where a problem may be occurring More specific troubleshooting information is provided in the Troubleshooting Tables following the flow charts Each table lists a Problem Possible Cause and Possible Action s to fix the problem ...

Page 90: ...closes as it receives more than 0 7 bar 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 ...

Page 91: ...C 140 oF If the heater block is NOT HOT a Wait 15 minutes for the heater block to heat up and re check the back of the burner and b Check the block heater thermostat and block heater element Refer to the wiring diagram and ladder schematic in Appendix B 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 ...

Page 92: ...on 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 The photo current is measured with a direct current ammeter in series with the photo unit pole on terminal 12 With a flame cad cell current must be between 50 µA and 210 µA at 240V With no flame the measured photo current must be maximum 5 µ...

Page 93: ... for proper µA signal Follow the procedures in the previous problem top page 10 4 3 Follow the instructions in Section 5 to adjust the air regulator for proper air pressure DO NOT turn the air compressor off while the furnace is operating If you turn the air compressor off at night turn the wall thermostat to OFF so the burner will not run 4 DO NOT shut off power to the furnace overnight or the he...

Page 94: ...ght 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 Beca...

Page 95: ...or the motor to cooldown 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 sh...

Page 96: ...Operator s Manual Models CB 1500 CB 2500 230 V 50 Hz 10 8 ...

Page 97: ...ng hung 1 ceiling hung 2 raised platform 2 raised platform 3 non combustible platform 3 non combustible platform Electrical Requirements 230 V 50Hz 230 V 50 Hz 10 9 Amps 11 3 Amps Circuit Breaker 15 Amps 15 Amps Wall Thermostat 24 volt 24 volt Oil Pump Suntec A2RA 7710 Suntec A2RA 7710 Pump Motor 1 17 HP Bison gear motor 1 17 HP Bison gear motor Pump Motor Rotation CCW shaft end CCW shaft end Cani...

Page 98: ...foss 14 000 Volts Nozzle Delavan 9 5 Burner Motor 1 10 HP 2800 RPM with centrifugal switch Burner Motor Rotation CCW shaft end Compressed Air Requirements 0 06 CMM 1 7 Bar 2 0 CFM 20 PSI Oil Primary Control Danfoss Heater Element in Preheater Block 450 watts Air Pressure Switch MPL 808 Setting for Preheater Thermostat 60 o C 140 o F ...

Page 99: ...26 1 2 67 mm 2 5 8 673 mm 26 1 2 FRONT VIEW 476 mm 18 3 4 673 mm 26 1 2 102 mm 4 305 mm 12 305 mm 12 19 mm 3 4 673 mm 26 1 2 755 mm 29 3 4 330 mm 13 165 mm 6 1 2 755 mm 29 3 4 1300 mm 51 1 8 305 mm 12 305 mm 12 TO BOLT CENTER IS 1753 mm 69 IN MEASUREMENT FROM BOLT CENTER 1324 mm 52 1 8 1785 mm 70 470 18 1 2 CB 1500 330 mm 13 2020 mm 79 1 2 184 mm 7 1 4 216 mm 8 1 2 FURNACE DIMENSIONS CB 2500 370 m...

Page 100: ...erator s Manual Models CB 1500 CB 2500 230 V 50 Hz A 4 FigureA1 CB 500 CE5W BurnerComponentDetail Burner Components DETAIL A AIR GAUGE DETAIL B OIL GUAGE BURNER CB 500 CE 5W 30 26 3 11 12 I89016 53 32 58 ...

Page 101: ...URNER CONTROL BHO 64 27 34124 1 4 20 ESNA NUT NE ZINC 28 26103 PLATE AIR FLOW OUTER 29 11359 INNER DRAFT PLATE A 30 11551 IGNITER PLATE ASSY 31 34172 LOCK NUT KEPS 8 32 Z 32 33208 W IRE CLAMP 33 33525 PHOTO UNIT LD 34 31159 GASKET 1 8 THICK 35 26120 IGNITER PLATE 36 34061 8 32 X 1 2 SLOTTED ROUND M S Z 37 33524 IGNITER DANFOSS 38 33526 PRIMARY CABLE w PLUG 39 34403 CARRIGE BOLT 10 24 x 2 40 26121 ...

Page 102: ...1 8 8 11 12 2 1 5 4 23 24 22 2 2 16 18 20 34 41 42 43 39 40 36 38 45 35 33 44 46 47 30 17 21 37 3 48 49 50 51 52 53 54 55 56 57 58 9 8 7 10 6 I88852 4 2 28 13 29 0 9 1 8 4 5 6 7 1 2 3 1 1 12 3 1 15 17 60 19 14 26 27 25 30 59 Figure A2 Preheater Block and Electrode Assembly Component Detail ...

Page 103: ...NE 25 33289 1 PRE HEATER ELEMENT 450 WATTS 26 33378 1 PROVINGSWITCH NORMALLYOPEN 27 32325 1 MALE ELBOW 1 8 x 1 8 NPT FOR AIR GAUGE LINE 28 54020 1 3 16 COPPER TUBING OIL GAUGE LINE 29 33011 1 HEATERBLOCKTHERMOSTAT NORMALLYCLOSED 30 32359 2 REGULATOR SURFACE MOUNT 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 32 Z 35 32306 2...

Page 104: ...NG 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 5 mm 3 16 GAP BETWEEN ELECTRODES NOZZLE CRITICAL DIMENSION NOZZLE MUST BE 3 mm 1 8 AHEAD OF THE DISK NOZZLE MUST NOT BE BEHIND THE DISK 3 mm 1 8 SPARK GA...

Page 105: ... Iftheblockageisa tarry materialorahard blackmaterial callyourCleanBurndealerforservice 3 FlushallcomponentswithWD 40toremoveoilresidues 4 Reassemblethenozzlecomponents Whentighteningthestem justbarely snug itdown DONOTovertighten 5 ChecktheO ringonthenozzlestem ReplacetheO ringifitisintheleastbitcutor deformed 6 LubricatetheO ringonthenozzlestemwithacoupleofdropsofnewmotoroil thenre installthenoz...

Page 106: ...or s Manual Models CB 1500 CB 2500 230 V 50 Hz A 10 DETAIL A DETAIL C D DETAIL D CABINET CB 1500 5W CE R CE 11531 and R 11510 DETAIL B I88909 FigureA5 CB 1500FurnaceComponentDetail CB 1500 Furnace Components ...

Page 107: ...INGE BRACKET W A 36 34120 5 16 18 X 2 3 4 CARR BOLT S S 37 21076 PORT CAP 38 11325 INSPECTION DOOR A 39 11143 BURNER MOUNT W A 40 34009 3 8 16 HEX SERR FLANGE NUT PLT 41 29044 DOOR CB 2501 1502 42 29113 SIDE SHIELD RT CB 1502 2501 43 29082 SHROUD LEFT 44 33479 CONNECTOR PLUG 5 WIRE 25 45 29084 SHROUD TOP 46 12292 JUNCTION BOX A 47 21170 E LID 48 33267 CONNECTOR ID Screw In Type 49 33469 FLEX CONDU...

Page 108: ...r s Manual Models CB 1500 CB 2500 230 V 50 Hz A 12 FigureA6 CB 2500FurnaceComponentDetail DETAIL A DETAIL C DETAIL D CABINET CB 2500 CE R 5W CE 11480 and R 11511 4 DETAIL B 4 I88910 CB 2500 Furnace Components ...

Page 109: ...40 29044 DOOR CB 2501 1502 41 31183 INSULATION 42 29113 SIDE SHIELD LEFT CB 1502 2501 43 29065 SHROUD LEFT 44 29067 SHROUD TOP 45 29090 SW ITCH COVER 46 33479 CONNECTOR PLUG 5 WIRE 25 47 12292 JUNCTION BOX A Item Part Description 48 21170 E LID 49 33017 CONNECTOR OD SQUEEZE TYPE 50 33267 CONNECTOR ID SCREW IN TYPE 51 33469 FLEX CONDUIT R W 3 8 X 5 52 33142 CLAMP 3 8 FLEX CONDUIT or 1 4 53 34004 8 ...

Page 110: ...Operator s Manual Models CB 1500 CB 2500 230 V 50 Hz A 14 CB 1500 Blower Components Figure A7 CB 1500 Blower Component Detail BLOWER ASSEMBLY CB 1500 10 1 11 12 1 3 I88954 ...

Page 111: ... MOTOR EA 4 31199 BLOWER DD 1502 10 10A 5 33142 CLAMP 3 8 FLEX CONDUIT or 1 4 6 33470 FLEX CONDUIT R W 3 8 x 19 7 33000 CONNECTOR 90 DEG THRD NUT 8 33422 CAPACTR BONNET RUBBER CAP 9 33608 CAPACTR RUN 370 V 20 Mfd 10 33454 CAPACTR STRAP Hold Down Clamp 11 34159 1 4 X 3 4 SLOTTED IND HEX 12 33574 MOTOR 3 4 HP 230V 50Hz 33055 WIRE PROTECTOR anti short 43205 INSTRUCTION SHEET 14328 BLOWER CB 1500 CE A...

Page 112: ...Operator s Manual Models CB 1500 CB 2500 230 V 50 Hz A 16 Figure A8 CB 2500 Blower Component Detail CB 2500 Blower Components BLOWER ASSEMBLY CB 2500 10 11 12 13 14 15 I88956 ...

Page 113: ...50Hz 6 11482 MOTOR MOUNT WELD 7 34116 10 X 5 8 HEX WASHER HEAD TEK Z 8 34035 CB 3 8 16 X 1 25 G5 Z 9 34159 1 4 X 3 4 SLOTTED IND HEX 10 34009 3 8 16 HEX SERR FLANGE NUT PLT 11 33416 CAPACTR STRAP Hold Down Clamp 12 33422 CAPACTR BONNET RUBBER CAP 13 33608 CAPACTR RUN 370 V 20 Mfd 14 33142 CLAMP 3 8 FLEX CONDUIT or 1 4 15 33000 CONNECTOR 90 DEG THRD NUT 14326 BLOWER CB 2500 CE DD ASSEMBLY 42365 LAB...

Page 114: ...Operator s Manual Models CB 1500 CB 2500 230 V 50 Hz A 18 ...

Page 115: ...P R W HT OIL AUTO HOT BLK NEUT WHT L2 L1 HIGH L2 4 5 3 L1 L2 L1 OPTIONAL GRND BURNER SWITCH TOGGLE PRIME FACE CONNECTOR BRACKET ON FAN SWITCH TEMP Blk Wht H T Blk Wht H T BLK SWITCH FAN RED GRN RED WHT BLK WHT WHT PUR 44115 220 VOLT PRIME ON LIGHT WHITE ORNG ORNG COM NO CR1 T R A N S F O R M E R 2 4 0 V 2 4 V STACK SAFETY SWITCH JMPR R W HT DRAFT INDUCER OPTIONAL GRN GRN PUR BRN GRN BRN GRND GRN B...

Page 116: ...METER PROVING SWITCH N O GREY RED WHITE WHITE BLACK BLACK JUMPERS 1 4 5 6 7 8 9 10 13 12 11 RED RED BLACK BLACK 140 WATTS HEATER ELEMENT IN NOZZLE ADATER PULL THESE WIRES INTO BURNER BOX INSTALL INSUL L130 NC TEMP SW INSTALLED ON NOZZLE ADAPTER CAP CRIMP CONNECTOR BROWN BLACK BLACK 4 CR 140 PREHEATER THERMOSTAT GREEN WHITE W H I T E B L A C K PURPLE 6 G 3 1 2 11 12 BLACK BLUE BRN BLUE WHITE ORANGE...

Page 117: ...N TRANSF SPARK GAP HOUR METER 450 WATTS BLOCK HEATER 140 WATTS NOZZLE HEATER AIR PRESSURE M3 POWER ON PUMP ON A OIL SOL AIR SOL R R E N B U OIL PUMP MOTOR CIRC FAN MOTOR ON METAL SURFACE 33288 PROVING SWITCH 120 BK OR CAD CELL BR GRAY NEUTRAL SECONDARY TEMP SWITCH N C HOT R WHT CR M 2 E A C N DWG No 44108 M 1 F U WALL THERMOSTAT RUN PRIME PUMP ON A DANFOSS OIL PIRMARY BL BK BL 1 2 6 G 4 8 3 11 12 ...

Page 118: ...88524 Wiring Diagrams continued FigureB4 CB 1500MeteringPumpWiringSchematic FigureB5 CB 2500MeteringPumpWiringSchematic TO OBTAIN CCWSE ROTATION AT THE OUTPUT SHAFT THE 5 1 GEARBOX RATIO REQUIRES THE INPUT MOTOR TO BE REVERSED THE RED BLUE LEADS ARE INTERCHANGED NOTE GEARMOTOR ROTATION IS CCWSE AS SHOWN TO REVERSE ROTATION REVERSE RED BLUE LEADS μ INSULATE 230 V 50Hz POWER FROM OIL PUMP CIRCUIT SE...

Page 119: ...on the burner Installing a fire valve above the burner Instructions and or drawings for these activities are provided in this Appendix Figure C1 Installing a Cover over the Oil Air Regulators on the Burner Installing a Cover over the Oil Air Regulators Acover C B 31185 mustbeplacedovertheoilandairregulatortopreventunauthorized adjustmentaftertheequipmenthasbeencommissionedbyqualifiedpersonnel Figu...

Page 120: ...Valve Install a fire valve element in a position above the burner as shown in Figure C2 to provide adequate protection in accordance with BS 5410 Parts 1 and 2 Figure C2 Installation of a Fire Valve ts 10s 220 240 50 60Hz 3W Danfoss Type BHO 64 Nr 057H7036 FUSIBLE LINK I88905 ...

Page 121: ..._________________________ FurnaceInstalled Date __________ By name phone __________________________________ FurnaceInspected Date __________ By name phone __________________________________ Draft Readings Service Record Date Draft Date InitialsofTechnician 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 In...

Page 122: ...Operator s Manual Models CB 1500 CB 2500 230 V 50 Hz D 2 ...

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