Cleanburn CB-200-CTB Manuel utilisateur

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

OPERATOR'S MANUAL

CLEAN BURN MODELS:

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

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

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

IMPORTANT FOR U.S. INSTALLATIONS: All installations must be made in accordance with state and local codes

which may differ from the information provided in this manual. Save these instructions for reference.

IMPORTANT FOR CANADIAN INSTALLATIONS: The installation of this equipment is to be accomplished by

qualified personnel and in accordance with the regulation of authorities having jurisdiction and CSA Standard B 139,

Installation Code for Oil Burning Equipment.

WARNING: DO NOT assemble, install, operate, or maintain this equipment without first

reading and understanding the information provided in this manual. Installation and

service must be accomplished by qualified personnel. Failure to follow all safety precautions

and procedures as stated in this manual may result in property damage, serious personal injury

or death.

I88460−C

U.L. Listed Used Oil

Burning Appliance

#MH15393

Manufactured & Tested to meet

ASME Section IV

WARRANTY INFORMATION

Clean Burn, Inc., MANUFACTURER, hereby warrants that MANUFACTURER’s products shall be free from defect in

material and workmanship under normal use according to the provisions and limitations herein set forth. MANUFACTURER

warrants the burner and Coil Tube Boiler for a period of one (1) year from the date of purchase by the original purchaser. The

steel coil tube section of the boiler only shall carry a limited warranty for a period of five (5) years from the date of purchase

by the original purchaser.

LIMITATIONS:

The obligation of MANUFACTURER for breach of warranty shall be limited to products manufactured by MANUFACTURER (1) that are

installed, operated and maintained according to MANUFACTURER's instructions furnished and/or available to the purchaser upon

request; (2) that are installed according to all other applicable Federal, State and local codes or regulations; and (3) that the purchaser

substantiates were defective in material and workmanship notwithstanding that they were properly installed and correctly maintained as set

forth above and were not abused or misused.

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

TURER. MANUFACTURER shall not be responsible for any labor or costs of removal or reinstallation of its products and shall not be

liable for transportation costs to and from its plant at Lancaster, Pennsylvania.

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

TURER specifically for such product shall void this warranty.

This warranty shall not apply to any damage to or defect in any of MANUFACTURER's products that is directly or indirectly caused by (1)

force majeure, Act of God or other accident not related to an inherent product defect; or (2) abuse, misuse or neglect of such product,

including any damage caused by improper assembly, installation, adjustment, service, maintenance or faulty instruction of the purchaser.

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

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

And in no event shall MANUFACTURER be responsible for any incidental or consequential damages of any nature suffered by purchaser

or any other person or entity caused in whole or in part by any defect in any of MANUFACTURER's products. Any person or entity to

whom this warranty extends and who claims breach of warranty against MANUFACTURER must bring suit thereon within one year from

the date of occurrence of such breach of warranty or be forever barred from any and all legal or other remedies for such breach of warranty.

MANUFACTURER is not responsible for and hereby disclaims any undertaking, representation or warranty made by any dealer, distribu-

tor or other person that is inconsistent with or in any way more expansive than the provisions of this limited warranty.

This warranty grants specific legal rights and shall be read in conformity with applicable state law. In some jurisdictions, the applicable

law mandates warranty provisions that provide greater legal rights than those provided for herein. In such case, this limited warranty shall

be read to include such mandated provisions; and any provision herein that is prohibited or unenforceable in any such jurisdiction shall, as

to such jurisdiction, be ineffective to the extent of such prohibition or unenforceability without invalidating the remaining provisions and

without affecting the validity or enforceability of such provision in any other jurisdiction(s).

TRADEMARKS

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

trademarks or trademarks of their respective owners.

the prior written permission of Clean Burn, Inc. 1835 Freedom Road, Lancaster, PA 17601. Subject to change without notice.

TABLE OF CONTENTS

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

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

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

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

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

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

SECTION 2: UNPACKING & PRE-INSTALLATION CONSIDERATIONS ................. 2-1

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

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

CTBComponent List .................................................................................................. 2-1

WarrantyRegistration ......................................................................................................... 2-2

Pre-InstallationConsiderations ........................................................................................... 2-2

DeterminingtheCTBSystemSetup ............................................................................. 2-2

SelectingaLocation .................................................................................................... 2-2

SECTION 3: COIL TUBE BOILER ASSEMBLY ........................................................ 3-1

UnderstandingAssembly .................................................................................................... 3-1

SingleBoilerAssemblyComponentDetail .......................................................................... 3-2

SingleBoilerAssembly ....................................................................................................... 3-4

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

Dual-StackedBoilerAssembly ........................................................................................... 3-5

AssemblingtheDual-Stacked Boiler ............................................................................ 3-5

Assemblyfor All Boilers ..................................................................................................... 3-8

ConnectingtheCTB .................................................................................................... 3-8

Installingthe Ceramic Sleeve ........................................................................................ 3-9

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

Mountingthe Burner .................................................................................................. 3-12

InstallingtheConnector Block ................................................................................... 3-12

InstallingtheOilLineTubing ...................................................................................... 3-13

InstallingtheAirLineTubing ...................................................................................... 3-14

LockingtheBurner into Firing Position ....................................................................... 3-14

SECTION 4: COIL TUBE BOILER INSTALLATION .................................................. 4-1

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

TypicalInstallationDiagrams ........................................................................................ 4-2

CombustionAir Requirements ..................................................................................... 4-4

OilTank InstallationSpecifications ...................................................................................... 4-6

InstallingtheTankVentandEmergencyVent ............................................................... 4-7

Installingthe MeteringPump ............................................................................................... 4-8

Preparingfor Installation .............................................................................................. 4-8

StandardMounting: VerticalPositioning ....................................................................... 4-8

AlternateMounting:Horizontal Positioning ................................................................. 4-10

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

FillingtheCTBwithWater ........................................................................................ 4-11

Installingthe Suction Oil LineComponents ........................................................................ 4-12

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

Installingthe Pressure Relief Oil LineBack tothe Tank ..................................................... 4-15

InstallingthePressureOilLine Components ...................................................................... 4-16

InstallingtheCompressed Air Line .................................................................................... 4-16

WiringtheCoilTube Boiler .............................................................................................. 4-17

Wiringto the Oil Pump ..................................................................................................... 4-18

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

Installingthe Stack ........................................................................................................... 4-19

InstallingtheInterior Stack ......................................................................................... 4-20

Installingthe BarometricDamper ............................................................................... 4-21

InstallingtheStackSafetySwitchForCanadian Installations ....................................... 4-23

Resettingthe Stack Safety Switch ........................................................................ 4-24

Understandingthe Function of the StackSafety Switch ......................................... 4-24

InstallingtheStack Penetration ................................................................................... 4-25

InstallingtheExterior Stack ........................................................................................ 4-25

Installingthe Stack Cap ............................................................................................. 4-25

Installingthe Draft Inducer ................................................................................................ 4-25

Installingthe WallThermostat ........................................................................................... 4-27

ReplacingtheWall Thermostat Batteries .................................................................... 4-27

Inspectingthe CTB Installation ......................................................................................... 4-28

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

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

RequiredTools and Materials ...................................................................................... 5-1

Primingthe MeteringPump ................................................................................................. 5-2

VacuumTestingtheOil Pump ............................................................................................. 5-4

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

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

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

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

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

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

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

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

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

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

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

UnderstandingtheImportanceofDraft ............................................................................... 8-1

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

Understandingthe Effect of Exhaust Fans onDraft ....................................................... 8-2

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

CombustionAir Requirements ..................................................................................... 8-3

AdjustingDraft Over Fire With ADraft InducerInstalled .................................................... 8-3

AirforCombustion and Ventilation ..................................................................................... 8-4

TABLE OF CONTENTS

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

UnderstandingMaintenance ................................................................................................ 9-1

AnnualPreventativeMaintenance & Burner Tune-up .......................................................... 9-1

CleaningtheCanister Filter ................................................................................................. 9-2

Servicingthe Metering Pump .............................................................................................. 9-3

CleaningtheCheckValve .................................................................................................. 9-3

CleaningAshfrom the CTB ................................................................................................ 9-4

CleaningtheOilTank ......................................................................................................... 9-6

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

CleaningandMaintaining the DraftInducer ......................................................................... 9-6

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

UnderstandingtheCTBHydronicSystem ......................................................................... 10-1

SpecialSafety Guidelines ........................................................................................... 10-1

CTBSystemFunction and Configuration .................................................................... 10-2

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

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

GuidelinesforPreventingOxygen Contamination ........................................................ 10-8

Guidelinesfor InitialCleaningand MaintainingWaterQuality ...................................... 10-8

GuidelinesforCTBOperation ................................................................................... 10-8

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

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

TroubleshootingTables .................................................................................................... 11-3

APPENDIX A

DetailedCTB Specifications .............................................................................................. A-1

CTBTechnical Specifications ..................................................................................... A-1

BurnerTechnicalSpecifications ................................................................................... A-2

CTBHydronic Specifications ...................................................................................... A-2

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

CTBDimensions ........................................................................................................ A-4

SingleBoiler Assembly ComponentDetail ................................................................. A-10

BurnerComponents ................................................................................................. A-12

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

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

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

Removingthe Nozzleforcleaning ........................................................................ A-23

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

CB-350-CTB Components ...................................................................................... A-26

CB-500-CTB Components ...................................................................................... A-28

MeteringPumpComponents .................................................................................... A-30

APPENDIX B

WiringDiagrams ............................................................................................................... B-1

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

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

MeteringPump WiringSchematic ............................................................................... B-6

APPENDIX C

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

TABLE OF CONTENTS

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

1-1

SECTION 1: INTRODUCTION

Guide to this Manual

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

Tube Boilers (CTB), Model CB-200-CTB, CB-350-CTB, and CB-500-CTB. Consult the Table of Contents

for a detailed list of topics covered. You'll find this manual's step-by-step procedures easy to follow and

understand. Should questions arise, please contact your Clean Burn dealer before starting any of the proce-

duresinthis manual.

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

Burn CTB involves six basic activities as outlined here:

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

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

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

• OPERATION

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

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

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

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

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

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

WARNING!

STOP

YOUR SAFETY IS AT STAKE!

DO NOT INSTALL, OPERATE OR

MAINTAIN THIS EQUIPMENT

WITHOUT FIRST READING

AND UNDERSTANDING THE

OPERATOR'S MANUAL!

Themanualalsocontainsimportantanddetailedtechnical

reference materials which are located at the back of the manual

intheAppendixes.

Please read all sections carefully--including the following

safety information--before beginning any installation/

operation procedures; doing so ensures your safety and the

optimal performance of your Clean Burn Coil Tube

Boiler.

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

1-2

For Your Safety...

For your safety, Clean Burn documentation contains the following types of safety statements (listed here

in order of increasing intensity):

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

•ATTENTION: A safety statement indicating that potential equipment damage may occur if

instructions are not followed.

CAUTION: A safety statement that reminds of safety practices or directs attention to unsafe

practices which could result in personal injury if proper precautions are not taken.

WARNING: A strong safetystatement indicating that a hazard exists which can result in

injury or death if proper precautions are not taken.

DANGER! The utmost levels of safety must be observed; an extreme hazard exists which

would result in high probability of death or irreparable serious personal injury if proper

precautions are not taken.

In addition to observing the specific precautions listed throughout the manual, the following general

precautions apply and must be heeded to ensure proper, safe boiler operation.

DANGER! DO NOT create a fire or explosion hazard by storing or using gasoline or other

flammable or explosive liquids or vapors near your boiler.

DANGER! DO NOT operate your CTB if excess oil, oil vapor or fumes have

accumulated in or near your boiler. As with any oil burning appliance, improper installation,

operation or maintenance may result in a fire or explosion hazard.

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

• Anti-freeze

• Carburetor cleaner

• Paint thinner

• Parts washer solvents

• Gasoline

• Oil additives

• Any other inappropriate/hazardous

material

WARNING: Burning chlorinated materials (chlorinated solvents and oils) is illegal, will

severely damage your heat exchanger, immediately void your warranty, and adversely affect

the proper, safe operation of your CTB. Instruct your personnel to never add hazardous

materials to your used oil.

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