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TABLE OF CONTENTS

SAFETY CONSIDERATIONS AND GUIDELINES.............................................................. 4

REMOVING ITEMS FROM THE COMBUSTION CHAMBER............................................ 6

MOVING THE BOILER INTO POSITION .......................................................................... 7

BOILER ASSEMBLY........................................................................................................... 7
 

  (1)  Installing the combustion chamber sleeve......................................................... 8

 

(2)  Installing the burner........................................................................................... 9

 

(3)  Installing the connector block and oil line.......................................................... 10

BOILER INSTALLATION..................................................................................................... 11
 

(1)  Selecting a location........................................................................................... 12

 

(2)  Mounting the boiler in position........................................................................... 13

 

(3)  Connecting the electrical supply........................................................................ 13

 

(4)  Installing the chimney components................................................................... 14

 

(5)  Oil storage tank set up ...................................................................................... 17

 

(6)  Installing the metering pump and oil lines......................................................... 17

 

(7)  Connecting the compressed air line.................................................................. 22

 

(8)  Installing the wall thermostat............................................................................. 22

 

(9)  Disign and Installation of the Hydronics System............................................... 23

 

(10)  Inspecting the Boiler Installation...................................................................... 25

BOILER CONTROLS AND SAFETY COMPONENTS........................................................ 26

PREPARING THE METERING PUMP FOR START UP..................................................... 26

STARTING AND ADJUSTING THE BURNER.................................................................... 27
 

(1)  Preparing the burner for start up....................................................................... 27

 

(2)  Priming the oil pump.......................................................................................... 27

 

(3)  Adjusting the Burner.......................................................................................... 27

RESETTING THE OIL PRIMARY CONTROL..................................................................... 28

SETTING THE DRAFT........................................................................................................ 29

MAINTENANCE.................................................................................................................. 30

SEQUENCE OF OPERATION............................................................................................34

BOILER DIMENSIONS....................................................................................................... 35

WIRE DIAGRAMS.............................................................................................................. 36

PARTS DIAGRAMS............................................................................................................ 38

CHIMNEY INSTALLATION DIAGRAMS............................................................................. 48

SERVICE RECORDS......................................................................................................... 50

APPENDIX A ...................................................................................................................... 51
 (1) 

Alternate 

Controls............................................................................................... 

51

 

(2) Domestic Hot Water Coil Installation.................................................................. 52

WARRANTY INFORMATION............................................................................................. 53

Summary of Contents for CE-340

Page 1: ...Energy Heating Systems LLC 540 Maple Street Honey Brook PA 19344 www CleanEnergyHeatingSystems com 888 519 2347 WARNING For your safety DO NOT store gasoline or other flammable vapors and liquids in the vicinity of this or any appliance CE70081 H Heating Systems ...

Page 2: ...7 3 13 Part 70006 Underwriters Laboratories File MH48829 ...

Page 3: ...il lines 17 7 Connecting the compressed air line 22 8 Installing the wall thermostat 22 9 Disign and Installation of the Hydronics System 23 10 Inspecting the Boiler Installation 25 BOILER CONTROLS AND SAFETY COMPONENTS 26 PREPARING THE METERING PUMP FOR START UP 26 STARTING AND ADJUSTING THE BURNER 27 1 Preparing the burner for start up 27 2 Priming the oil pump 27 3 Adjusting the Burner 27 RESET...

Page 4: ... Indicates a hazardous situation which can result in death or serious personal injury if not avoided DANGER Indicates a hazardous situation which will result in death or serious personal injury if not avoided DANGER DO NOT store or use gasoline or other flammable explosive liquids vapors in or around the boiler DANGER DO NOT operate the boiler if excess oil oil vapors or fumes have accumulated in ...

Page 5: ...egulations and authorities having jurisdiction and the following CSA Standards B139 Installatin Code for Oil Burning Equipment B140 0 General Requirements for Oil Burning Equipment B140 7 2 Oil Fired Steam and Hot Water Boilers for Commercial and Industrial Use B214 Installation Code for Hydronic Heating Systems C22 1 Canadian Electrical Code Part 1 GUIDELINES FOR BOILER USE This boiler is for ind...

Page 6: ... FROM THE COMBUSTIN CHAMBER WARNING Waste oil may contain gasoline Take precaution when handling and storing waste oil ADDITIONAL GUIDELINES FOR CANADIAN INSTALLATIONS NOTICE This appliance has been evaluated to electrical and fuel burning requirements only 1 The installation including stack height requirements and distance from property lines shall be in accordance with the authorities having jur...

Page 7: ...y lifting 3 The boiler can be lifted from either side with a forklift or pallet truck 4 The boiler can also be lifted from either the front or back The legs are spaced 27 apart which allows the use of a standard pallet truck WARNING Because of the weight and size take extreme care when moving the boiler x2 ANGLE WELDED TO BOILER FRAME CE70095 ANGLE WELDED TO BOILER FRAME 24 0 27 0 BETWEEN LEGS BOT...

Page 8: ... of the combustion chamber sleeve 2 Open the front door of the boiler by loosening the four bolts and swinging the door open 3 Place the 3 x3 x20 support blocks on the bottom of the combustion chamber as shown 4 Place the combustion chamber sleeve on top of the support blocks and flush with the front door 5 Close the front door and secure the four bolts BOILER ASSEMBLY Figure 3 Proper Position of ...

Page 9: ...two serrated flange nuts from the front door 2 Slide the blast tube of the burner through the throat of the front door 3 Fasten the burner to the front door by tightening the two serrated flange nuts Figure 5 Nozzle and Electrode Settings BOILER ASSEMBLY 3 16 GAP BETWEEN ELECTRODES AND NOZZLE CE70018 1 8 GAP BETWEEN ELECTRODES ELECTRODE 1 8 PAST NOZZLE Figure 4 Combustion Chamber Sleeve Location A...

Page 10: ...l line will need to be disconnected before the door is opened Figure 7 Installing the Connector Block and Oil Line Figure 6 Installing the Burner Cord 4 Refer to Figure 6 5 Line up the key in the receptacle with the slot in the cord 6 Tighten the electrical cord when in position NOTICE Make sure the plug and receptacle are properly aligned The ground prong in the receptacle is longer than the othe...

Page 11: ...he compressed air line 3 Connecting the electrical supply 8 Installing the wall thermostat 4 Installing the chimney components 9 Design and Installation of hydronics system 5 Positioning the oil storage tank 10 Inspecting the boiler installation BOILER INSTALLATION 8 FT MAXIMUM LIFT DEDICATED ELECTRIC SERVICE OIL PUMP ELECTRICAL CIRCUIT COMPRESSED SUCTION OIL LINE 10 FT 3 FT 8 MIN RELIEF RETURN CE...

Page 12: ...egulations 6 Keep the stack chimney system simple A complicated stack with multiple elbows and long horizontal runs will reduce the natural draft of the unit which can damage critical burner components Figure 9 Clearances to Combustible Materials Minimum Distances from Combustible Materials WARNING Carefully follow all installation instructions for safe and efficient operation BOILER INSTALLATION ...

Page 13: ...nnecting the electrical supply to the Boiler Electrical Requirements 120 V 60 Hz Single Phase 20 Amp dedicated circuit WARNING Shut off main power to the boiler before making any electrical connections ONLY a qualified electrician should run wire and make connections to the boiler All wires must be the proper gauge and run in approved electrical conduit All wiring must meet the requirements of the...

Page 14: ...east 1 4 per foot Keep the stack installation simple Multiple turns and horizontal runs will reduce the natural draft of the boiler which may damage critical burner components 3 Single wall stack may be used inside the building Observe proper clearances from combustibles Do not put single wall stack in areas that may create a burn hazard to personnel 4 Install a barometric damper as shown in Figur...

Page 15: ...Roof Chimney Illustration 10 FT 3 FT MIN CLASS A STACK COMPONENTS MINIMUM 10 FT VERTICAL STACK HEIGHT TO MAINTAIN PROPER DRAFT SINGLE WALL STACK COMPONENTS BAROMETRIC DAMPER CLASS A STACK CAP NON RESTRICTIVE TYPE SET DRAFT OVER FIRE AT 0 02 IN W C CE70080 ...

Page 16: ...FT CE70079 3 FT MIN CLASS A STACK CAP NON RESTRICTIVE TYPE MINIMUM 10 FT VERTICAL STACK HEIGHT TO MAINTAIN PROPER DRAFT CLASS A STACK COMPONENTS INSTALL AN ADEQUATE WALL SUPPORT SYSTEM TO SAFELY BEAR THE WEIGHT OF THE CLASS A STACK SET DRAFT OVER FIRE AT 0 02 IN W C BAROMETRIC DAMPER ...

Page 17: ...ed tank warning label near the fill location Installing the metering pump system and oil lines Metering Pump Installation Guidelines 1 Use non hardening thread sealer for all threaded pipe fittings DO NOT use teflon tape 2 The pump must be installed with the shaft in the horizontal position and the oil outlet pointing up NOTICE The gauge arrow on the front of the pump head must be pointing up CAUT...

Page 18: ...ihood of sludge and or water being delivered to the boiler 6 The metering pump system is not weatherproof Mount the pump indoors only Mounting the metering pump assembly NOTICE The metering pump system comes assembled for standard mounting on a wall STANDARD MOUNTING 1 Refer to Figure 13 for a typical metering pump installation standard mounting on a wall 2 Use appropriate hardware to mount the me...

Page 19: ...ction line tubing and install it on the foot valve 7 Insert the suction tubing into the tank and tighten the 2 duplex fitting 8 Carefully bend the 1 2 copper suction line tubing up to the filter and cut it to length 9 Flare the 1 2 copper suction line tubing and install it on the filter Installing the pressure relief oil line back to the tank 1 Refer to Figure 15 and 16 2 Install the 1 2 MNPTx1 4 ...

Page 20: ...NUOUS PIECE OF COPPER TUBING INSTALLED THROUGH THE SLIP FITTING A DETAIL A 1 2 MNPT SLIP THROUGH FITTING 1 2 FLARE FITTING SUCTION OIL LINE 1 2 COPPER TUBING PRESSURE RELIEF RETURN OIL LINE 1 4 COPPER TUBING 2 DUPLEX FITTING 1 2 MNPT X 1 4 COMPRESSION CE70027 PRESSURE RELIEF VALVE PRESSURE RELIEF RETURN OIL LINE TO THE TANK 1 4 COPPER TUBING LOW FLOW CHECK VALVE ...

Page 21: ...variables such as oil temperature and viscosity Clean Energy Heating Systems does not recommend exceeding 150 feet of total pressure oil line 4 Refer to Figure 18 5 Connect the pressure oil line to the aluminum connector block on the side of the boiler NOTICE By connecting the oil line to the connector block the swivel fitting is utilized which allows the front clean out door to be opened without ...

Page 22: ...ed with the thermostat 2 Mount the thermostat on an interior wall and in a location that will be shielded from drastic temperature changes such as a door being opened 3 Mount the thermostat at eye level to allow for easy viewing and adjustment 4 Run the thermostat cable from the wall thermostat to the T T terminals on the boiler control Install a jumper wire between the T T terminals on the primar...

Page 23: ...p water is being added Make up water will introduce oxygen which will lead to corrosion 6 Incorporate an air seperator and air vent to properly purge all air from the system to allow proper water circulation 7 Refer to Figure 21 for typical single zone connections 8 The Pressure Reducing Valve Boiler Fill Valve should be set at 12 psi 9 Refer to Figure 20 A water pressure safety relief valve must ...

Page 24: ...1 Typical Single Zone Connections CE70091 AIR VENT AIR SEPARATOR EXPANSION TANK COLD WATER INLET P1 HEATING AIR SEPARATOR AIR VENT ISOLATION VALVE EXPANSION TAMK PRESSURE REDUCING VALVE CHECK VALVE CIRCULATOR WATER FLOW SYMBOLS ZONE ...

Page 25: ...gh make up air for proper ventilation and combustion air refer to figure 22 CAUTION If the boiler is unattended during extremely cold weather and there is a component failure or power outage frozen plumbing and water damage may occur in a short time Equip the system so that it senses low temperature and initiates an effective action Contact your local heating contractor for assistance Figure 22 Lo...

Page 26: ...burner off if the water temperature in the boiler reaches the water temperature set point The Limit Control will automatically reset when the water temperature drops to the required temperature The Low Water Cut Off shuts the burner off if the the water level in the boiler goes below the Low Water Cut Off sensor 2 High Limit Aquastat Manual Reset The High Limit Aquastat shuts the burner off if the...

Page 27: ...reset button The yellow light will turn off and the burner will start again 3 Within 15 seconds click push and release the reset button This will transition the primary control to Pump Prime mode which will bypass the flame sensor and keep the pump on for 4 minutes 4 Open the pump bleeder valve and purge all air bubbles from the pump refer to figure 23 5 After 4 minutes the yellow light on the pri...

Page 28: ...efore continuing Vapor filled combustion chamber Allow the unit to cool for 30 minutes and all vapors to dissipate before resetting the oil primary control 3 When the combustion chamber has cooled and there is no vapor or excess oil in the combustion chamber push the reset button for 3 seconds and release 4 If the burner does not restart contact the Clean Energy Heating Systems service department ...

Page 29: ...rers instructions for adjusting the barometric damper to obtain 0 02 w c draft over fire 4 If a proper draft is not obtained follow the instructions below to check for a vacuum in your building Checking for vacuum in your building 1 Have someone slowly open an overhead door while you are taking a draft reading 2 Watch the draft gauge and tell them to stop when you get a 0 02 w c draft over fire 3 ...

Page 30: ...the 4 socket head screws in a crisscross pattern NOTICE Do not over tighten or the aluminum filter casting may crack Cleaning the oil pump head screen 1 Place a container under the oil pump head to catch any released oil 2 Use a 5 32 allen wrench to loosen the pump head cover 3 Remove the cover pump head screen and gasket Carefully scrape the gasket off if any pieces remain stuck to the pump head ...

Page 31: ...t clean out door 5 Remove the combustion sleeve and support blocks 6 Remove the back shrouding Remove the six 6 nuts fastening the back clean out door 7 Brush out the combustion chamber and use an industrial vacuum to clean out the remaining ash 8 Use a 3 flue brush to completely remove ash from the flue tubes 9 Remove the chimney if necessary Make sure there is no obstruction in the chimney 10 Fa...

Page 32: ...re 29 Cleaning Ash From the Heat Exchanger CE70090 REMOVE FOUR 4 BOLTS AND SWING OPEN FRONT CLEAN OUT DOOR REMOVE COMBUSTION SLEEVE AND SUPPORT BLOCKS LOOSEN SIX 6 NUTS AND REMOVE BACK CLEAN OUT DOOR REMOVE BACK SHROUDING ...

Page 33: ... Heater Block MAINTENANCE 33 Nozzle adapter heater block with all components and plugs removed CE70039 A A NOZZLE ADAPTER HEATER BLOCK RELEASE RING ON AIR LINE FITTING QUICK DISCONNECT ELECTRICAL CONNECTOR OIL LINE SWIVEL FITTING CE70038A ...

Page 34: ... Air Solenoid opens Burner Motor supplying combustion air starts Air pressure switch closes as it receives more than 10 psi of air pressure Air Pressure Switch sends power to the Pump Circuit Relay Centrifugal Switch closes and sends power to Air Pressure Switch Pump Circuit Relay closes by receiving power from the valve circuit purple wire on the Oil Primary Control Flame established in combustio...

Page 35: ...BOILER DIMENSIONS 35 57 5 42 5 67 with Burner 34 0 CE70077 50 ...

Page 36: ...AFT INDUCER OPTIONAL OIL PUMP WHITE RED BLACK ORANGE CONNECTOR CORD RED 75045 BURNER WHITE BLK CE BOILER USE COPPER CONDUCTORS ONLY BOILER CONTROL AQUASTAT Manual Reset TR TW POWER 120 VAC 1 PH L1 L2 GRD GRD BLACK WHITE C2 C1 ZC ZR B1 B2 L1 L2 THERMOSTAT RED RED CIRCULATOR ...

Page 37: ...EATER THERMOSTAT 200 WATT HEATER SOLENOID AIR IGNITER BURNER MOTOR POWER LIGHT PUMP LIGHT AIR SWITCH N O HOUR METER RED RED RED ORANGE VIOLET BLACK WHITE CAD CELL BLUE BLACK AIR COMPRESSOR OPTIONAL BLACK WHITE BROWN WHITE T PRIMARY CONTROL WALL THERMOSTAT N O 75043 RED VIOLET WHT WHT WHT BROWN CENTRIFUGAL SWITCH 200 WATT HEATER MODEL CE 4 CE 330 HOT AIR FURNACE JUMPER WIRE CE 340 HOT WATER BOILER ...

Page 38: ...12 28 25 19 39 CE70043 21 22 18 8 35 34 40 41 2 5 7 3 10 17 37 11 16 20 31 15 4 1 23 24 27 42 43 30 26 14 9 36 32 38 33 29 6 13 21 38 CE 3 CE 4 Burner Assembly ...

Page 39: ...033 Cap Screw Socket Head 10 24 x 3 8 SS 7 22 20037 Air Intake Outer Plate 1 23 58023 Flange Serrated Nut 10 24 Z 3 24 50065 1 8 MP X 2 HEX NIPPLE 2 25 30038 Terminal Block Quick Disconnect Female 1 26 30026 Terminal Block Quick Disconnect Male 1 27 50056 1 4 TUBE 1 8 FNPT 90 1 28 30027 Post Contact Igniter 2 29 50059 3 8 CP x 1 8 FP 90o 1 30 50051 3 8 Compression Nut 1 31 50052 3 8 Compression Fe...

Page 40: ...40 1 4 12 6 15 9 10 14 3 2 11 5 13 8 7 Nozzle Adapter Heater Block Assembly ...

Page 41: ...ree Legs 1 6 30002 HEAT ELEMENT 1 7 50022 SOLENOID AIR OIL 115VAC 1 8 50063 1 8 Tube x 10 32 1 9 58040 Washer Neoprene Bonded 10 1 2 OD 1 10 58045 Pan Head Phillips Mach Screw 10 32 x 7 8 Z 1 11 58016 Machine Screw 10 32 x 1 2 Z Ext Tooth LW 2 12 30003 Thermostat 120F Proving Switch 1 13 30011 Thermostat 150F Heater 1 14 50067 Plug Hex Socket 10 15 50064 1 8 x 1 1 2 Nipple 1 ...

Page 42: ...42 2 5 7 6 4 5 3 12 11 9 8 10 1 CE70058 CE 4 Manifold Block Assembly ...

Page 43: ...erminal Block Burner 1 4 50008 Burner Manifold Block 1 5 50062 Tube Fitting 1 8T x 1 8MP 2 6 50054 Air Pressure Switch 1 7 50067 Plug Hex Socket 12 8 58030 Cap Screw Socket Head 8 32 x 5 8 Black 4 9 58035 Lock Washer 8 Z 4 10 58029 Machine Screw 8 32 x 3 8 Z 2 11 30002 HEAT ELEMENT 1 12 30011 Thermostat 150F Heater 1 ...

Page 44: ...44 26 14 9 23 2 8 7 6 12 20 13 21 19 18 17 16 15 1 5 3 4 10 22 25 11 24 CE70050 Metering Pump Assembly ...

Page 45: ... 2 12 40001 Metering Pump Coupling 1 13 20007 Metering Pump Cover 1 14 50006 GAUGE for FILTER 1 15 50039 1 8 MP x 1 4 FP Plated 1 16 50046 Low Flow Check Valve 1 17 50040 1 4 NPT Tee Brass 1 18 50047 Relief Valve 1 19 50041 1 4 Comp x 1 4 NPT 1 20 50081 Gearmotor CE 140 1 20 50080 Gearmotor CE 180 1 20 50069 Gearmotor CE 250 1 20 50124 Gearmotor CE 330 1 20 50200 Gearmotor CE 340 1 21 60001 Meteri...

Page 46: ...46 CE 340 Boiler 25 27 26 28 24 21 22 23 20 14 13 12 11 10 9 8 7 6 5 4 1 2 3 15 16 17 18 CE70101 19 ALT ALT ...

Page 47: ...ow Water Cut Off ALTERNATE 1 13 20185 Top Boiler Shrouding 1 14 20186 Back Boiler Shrouding 1 15 50192 HL Aquastat Manual Reset 1 16 30023 Terminal Block 1 17 20009 Electrical Box 1 18 50191 AquaSmart Boiler Control 1 19 20187 Shrouding Brace Boiler 1 20 20183 Right Side Boiler Shrouding 1 21 50007 Connector Block Oil 1 22 50042 Swivel 3 8 Comp 1 4 NPT 1 23 20182 Hookup Tube CE 340 Boiler 1 24 501...

Page 48: ... INSULATED STACK 8X18 SS 90071 INSULATED STACK 8X12 SS 10 FT CE70093 3 FT MIN 90099 90155 90090 90075 90086 90161 SINGLE WALL 8 X24 90163 SW TEE 8 90162 SINGLE WALL ELBOW 8 90160 SINGLE WALL ADAPTOR 8 90067 INSULATED STACK 8X24 SS 90062 WALL BAND 8 INSULATED TEE WALL SUPPORT 8 WITH CAP 8 DEKTITE BOOT 7 INSULATED STACK 8X48 SS SPARK ARRESTOR CAP 8 ...

Page 49: ...E BOOT 7 90160 SINGLE WALL ADAPTOR 8 90163 SW TEE 8 90161 SINGLE WALL 8 X24 90093 ADJUSTABLE ROOF SUPPORT 8 90097 WALL FIRESTOP 8 CE70092 90082 CEILING SUPPORT 8 USED WITH INSULATED CEILING 90102 STORM COLLAR 8 90105 FLASHING 2 12 5 12 8 90065 INSULATED STACK 8X36 SS 90069 INSULATED STACK 8X18 SS 90071 INSULATED STACK 8X12 SS ...

Page 50: ...ER PUMP HEAD THE HEAT STORAGE NOZZLE ADAPTER HOURS FILTER SCREEN EXCHANGER TANK HEATER BLOCK CLEAN THE OIL CANISTER FILTER ONCE PER YEAR CLEAN THE PUMP HEAD SCREEN ONCE PER YEAR CLEAN ASH FROM THE HEAT EXCHANGER 800 HOURS CLEAN THE NOZZLE ADAPTER HEATER BLOCK 2000 TO 3000 HOURS ...

Page 51: ...MP WHITE RED BLACK ORANGE CONNECTOR CORD RED 75048 BURNER CE BOILER USE COPPER CONDUCTORS ONLY AQUASTAT Manual Reset POWER 120 VAC 1 PH L1 L2 GRD GRD BLACK WHITE Alt Temperature AQUASTAT CUT OFF Alt LWC Operating Control LOW WATER BLK RED WHT NOTE WHEN USING THE ALTERNATE LWC AND TEMPERATURE CONTROL 1 CONNECT THE THERMOSTAT DIRECTLY TO THE T T TERMINALS ON THE BURNER PRIMARY CONTROL 2 USE ADDITION...

Page 52: ...ter coil with the rubber gasket in place into the tube 4 Tighten the hot water coil in postion with the six nuts and bolts Figure A2 Domestic Hot Water Coil Location CE70098 REMOVE COVER AND INSERT DOMESTIC HOT WATER COIL DANGER Mixing valves must be used to supply domestic hot water at a safe temperature Mixing valves are not intended to be the only scalding safe guard ...

Page 53: ...d within thirty 30 days of purchase to activate Warranty Coverage B The equipment must be fired at rated capacity only with fuels listed on data label C The equipment must be installed operated and maintained in accordance with Federal State and Local regulations as well as with all MANUFACTURER S installation and operating instructions D The equipment must not be installed in any corrosive atmosp...

Page 54: ...____ ________________ ________________ PLACE STAMP HERE CLEAN ENERGY HEATING SYSTEMS LLC 540 MAPLE STREET HONEY BROOK PA USA 19344 Approved Method to Dispose of Waste Oil Sold and Serviced by NAME ADDRESS TELEPHONE ...

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