Clean Energy CE-340 Manuel utilisateur
OWNER’S MANUAL
CE-340 Mul-Oil Boiler
With CE-4 Burner
Clean 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
7/3/13 Part # 70006
Underwriters Laboratories File # MH48829
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
WARNING: Incorrect installation, adjustment, or misuse of this heating equipment
could result in death, severe personal injury, or substantial property damage.
To the Equipment Owner:
• Read and understand all instructions
provided in this manual
• Installation and service must be
completed by qualified personnel who
are familiar with oil-fired appliances.
• Save this manual for future reference.
To the Professional, Qualified Installer or
Service Agency:
• Read and carefully follow all instructions
provided in this manual before installing, starting,
or servicing this heating equipment.
• All installations must be made in accordance
with state and local codes having jurisdiction.
SAFETY CONSIDERATIONS AND GUIDELINES
NOTICE: Intended to clarify or bring special attention to previous information.
CAUTION: Indicates a hazardous situation, which can result in minor or moderate
personal injury if not avoided.
WARNING: 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 or around the boiler.
DANGER: Improper installation, operation, or maintenance of the boiler may create a
fire or explosion hazard.
WARNING: DO NOT mix unapproved substances to the used oil supply, such as:
• Anti-Freeze
• Carburetor Cleaner
• Paint Thinner
• Parts Washer and/or Solvents
• Gasoline
• Oil Additives
• Chlorinated solvents
• Any other inappropriate / hazardous material
Instruct your personnel NEVER to add unapproved substances to your used oil.
Burning any unapproved substance will immediately void the boiler warranty and may
cause damage and unsafe operating conditions.
WARNING: Unauthorized boiler modifications may cause damage and unsafe
operating conditions.
HAZARD DEFINITIONS:
SAFETY CONSIDERATIONS:
4
WARNING: The CE-4 Burner is only approved for use on heating equipment
manufactured by Clean Energy Heating Systems. The boiler is only approved for use
with the CE-4 burner manufactured by Clean Energy Heating Systems.
WARNING: The installation, operation, and maintenance of this equipment in the
United States must be done by qualified personnel according to instructions in the
Clean Energy Heating Systems Owner’s Manual and in accordance with all national,
state, and local codes or authorities having jurisdiction and the following standards:
ASME Section IV Boiler Code for Pressure Vessels
ASME CSD-1 Controls and Safety Devices for Automatically Fired Boilers
NFPA 30 Flammable and Combustible Liquids Code
NFPA 30A Automotive and Marine Service Station Code
NFPA 31 Installation of Oil Burning Equipment
NFPA 70 National Electrical Code
NFPA 88A Parking Structures
NFPA 88B Repair Garages
NFPA 211 Chimney’s, Fireplaces, Vents and Solid Fuel Burning Appliances
Likewise, the installation, operation, and maintenance of this equipment in Canada must
be done by qualified personnel according to instructions in the Clean Energy Heating
Systems Owner’s Manual and in accordance with all regulations 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 industrial and/or commercial use only. This boiler is not intended
for residential use.
• Clean Energy Heating Systems boilers are listed with Underwriters Laboratories (UL)
in the U.S. and Canada to burn the following fuels:
• #2 fuel oil
• Used crankcase oil up to 50 SAE
• Used hydraulic oil
• Used automatic transmission fluid (U.S.)
• The EPA regulations for burning used oil are as follows:
• Your supply of used oil is generated on-site. You may also collect oil from
“do-it-yourself” oil changers.
• Do not mix hazardous wastes, such as chlorinated solvents, with your used oil.
• The exhaust gases of the heating equipment must be vented to the outside
with an appropriate stack system.
• The boiler is used to recycle used oil for “heat recovery”. The boiler is not
to be used in warm weather just to dispose of used oil.
• Only trained authorized personnel should service and maintain the boiler. Be sure
the boiler receives annual maintenance to ensure safe and efficient operation.
5
SAFETY CONSIDERATIONS AND GUIDELINES
GUIDELINES FOR USED OIL TANKS:
(1) The tank installation must comply with NFPA 30 and NFPA 31 fire codes.
(2) The tank should be installed on a slight slope with a drain on the low end to allow sludge
and water to be removed from the bottom of the tank.
(3) All oil lines must be constructed of copper, steel, or brass components. DO NOT use
rubber, plastic, or any other inappropriate material for oil lines.
(4) Be sure to follow all instructions for tank installation in the Owner’s Manual.
6
WARNING: To avoid serious injury or death, only store the following substances in
the oil supply tank:
(1) Used Crankcase Oil
(2) Used Automatic Transmission Fluid (ATF)
(3) Used Hydraulic Oil
(4) #2 Fuel Oil (Diesel Fuel)
DO NOT put flammable or corrosive substances such as gasoline, chlorinated solvents,
paint thinner, or any other unsafe substance in the oil supply tank.
WARNING: To avoid serious injury or death, do not weld or allow open flames within
35 feet of the used oil supply tank.
SAFETY CONSIDERATIONS AND GUIDELINES
(1) Remove the four nuts from the front door.
(2) Carefully swing the front door open.
(3) Remove the items packed inside the combustion chamber.
(4) Leave the door open to install the combusion chamber sleeve as instructed later in this
manual.
REMOVING ITEMS 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 jurisdiction concerning environmental quality,
as well as fuel, fire, and electrical safety and Table 7 in CSA B140.0-03.
(2) The structure in which the boiler is housed shall be no less than 4.6 m (15 ft) high at the
point where the boiler is situated and have a minimum length and width of 6 m (20 ft) and
a minimum floor area of 37 m2(400 ft2).
(3) Every month, the fire side of the heat exchanger and flue piping must be cleaned.
(4) Every month, the oil-feed reservoir must be cleaned.
(5) Every year, the exhaust stack must be cleaned.
(6) Whenever any cleaning, including that of the flue piping and exhaust stack, is done, proper
protective clothing including gloves and a face mask or respirator must be worn.
(7) Keep the fuel valve nearest to the supply tank shut off when the burner is shut off for
extended periods.
CAUTION: Used oils contain heavy metallic compounds and foreign materials. When
burned, these compounds are emitted from or deposited within this heating appliance
and therefore care should be taken when using, cleaning and maintaining this equipment.
Figure 2: Typical Boiler Assembly
Follow the steps below for boiler
assembly (refer to Figure 2):
(1) Install the combustion
chamber sleeve
(2) Install the burner
(3) Install the connector block
and oil line
BOILER ASSEMBLY
7
Figure 1: Boiler Shown Without Shrouding To Reveal Lifting Points
(1) Refer to Figure 1.
(2) There are two angles 24” apart to allow for easy 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)
BOTTOM
VIEW
NOTICE: To reduce the chance of damage, move the boiler into position before installing the
burner.
MOVING THE BOILER INTO POSITION
CE70082
2
3
1
8
Installing the Combustion Chamber Sleeve:
NOTICE: Improper combustion may occur if the boiler is used with a damaged or missing
combustion sleeve. Inspect the combustion sleeve regularly for proper positioning and wear.
(1) Refer to Figures 3 and 4 to view the proper position 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 the Combustion Chamber Sleeve
COMBUSTION SLEEVE
FLUSH AGAINST DOOR
CE70083
9
Installing the Burner:
NOTICE: The nozzle, electrode, and retention head may need adjustment after shipping and
installation. The nozzle should remain centered in the retention head. Refer to Figure 5 for
proper dimensions.
(1) Remove the 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
APPROX.
10"
SUPPORT
BLOCK (X2)
CE70084
10
Installing the Connector Block and Oil Line:
(1) Refer to Figure 7 to position the connector block.
(2) Fasten the connector block to the side of the boiler
with the bolts provided.
(3) Install the supplied 3/8” copper tubing from the swivel
fitting in the connector block to the burner.
NOTICE: The connector block with the swivel fitting
must be used to allow the front door to swing open
properly. If the connector block is not used the oil 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 other prongs and must be lined up
properly.
BOILER ASSEMBLY
WARNING: To prevent the risk of electrical
shock, shut OFF main power to the boiler before
connecting or disconnecting the burner power
cord.
CE70013
CE70085
Oil Line
Connector Block
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