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Clean Energy CE-340 Owner's Manual

Mul-oil boiler with ce-4 burner
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Heating Systems
OWNER'S MANUAL
CE-340 Mul -Oil Boiler
With CE-4 Burner
H
CE70081
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.

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  • Page 1 Heating Systems OWNER’S MANUAL CE-340 Mul -Oil Boiler With CE-4 Burner CE70081 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.
  • Page 2 Underwriters Laboratories File # MH48829 7/3/13 Part # 70006...

  • Page 3: Table Of Contents

    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.....................

  • Page 4: Safety Considerations And Guidelines

    SAFETY CONSIDERATIONS AND GUIDELINES HAZARD DEFINITIONS: 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.
  • Page 5 SAFETY CONSIDERATIONS AND GUIDELINES 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:...

  • Page 6: Removing Items From The Combustion Chamber

    SAFETY CONSIDERATIONS AND GUIDELINES 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.

  • Page 7: Moving The Boiler Into Position

    MOVING THE BOILER INTO POSITION WARNING: Because of the weight and size, take extreme care when moving the boiler. (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.

  • Page 8: Installing The Combustion Chamber Sleeve

    BOILER ASSEMBLY 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.

  • Page 9: Installing The Burner

    BOILER ASSEMBLY APPROX. 10" SUPPORT CE70084 BLOCK (X2) Figure 4: Combustion Chamber Sleeve Location 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.

  • Page 10: Installing The Connector Block And Oil Line

    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. (4) Refer to Figure 6 (5) Line up the key in the receptacle with the slot in the cord.

  • Page 11: Boiler Installation

    BOILER INSTALLATION Refer to Figure 8 for a typical boiler installation illustration. Installation of your boiler will include the following steps: (1) Selecting a location (6) Installing the metering pump and oil lines (2) Mounting the boiler in position (7) Connecting the compressed air line (3) Connecting the electrical supply (8) Installing the wall thermostat (4) Installing the chimney components...

  • Page 12: Selecting A Location

    SIDE 6" FRONT 48" (FOR SERVICE BOTTOM 6" CE70078 CLEARANCE) Figure 9: Clearances to Combustible Materials Minimum Distances from Combustible Materials CE-340 BOILER Front (Burner) 18” (48” for service clearance) Back 18” (36” for service clearance) Side 6” 18” Chimney Connection...

  • Page 13: Mounting The Boiler In Position

    BOILER INSTALLATION Mounting the Boiler in position: WARNING: The floor or pad for boiler installation must support the weight of the boiler when it is full of water. A level concrete floor or pad is recommended. (1) Refer to Figure 8 for a typical installation. (2) Set the boiler in position.

  • Page 14: Installing The Chimney Components

    Double wall “Class A” insulated stack must be used through any building penetration and for any exterior stack. Unapproved stack material and/or installation can create a fire hazard. Contact Clean Energy Heating Systems, LLC to purchase approved stack material for your installation.
  • Page 15 BOILER INSTALLATION "CLASS A" STACK CAP NON-RESTRICTIVE TYPE 10 FT. BAROMETRIC DAMPER SET DRAFT OVER FIRE AT -0.02 IN. W.C. CE70080 Figure 10: Typical Through-the-Roof Chimney Illustration...
  • Page 16 BOILER INSTALLATION "CLASS A" STACK CAP NON-RESTRICTIVE TYPE 10 FT. INSTALL AN ADEQUATE WALL SUPPORT SYSTEM TO SAFELY BEAR THE WEIGHT OF THE "CLASS A" STACK BAROMETRIC DAMPER SET DRAFT OVER FIRE AT -0.02 IN. W.C. CE70079 Figure 11: Typical Through-the-Wall Chimney Illustration...

  • Page 17: Oil Storage Tank Setup

    BOILER INSTALLATION Oil storage tank setup: PRESSURE OIL LINE TO THE HEATING EQUIPMENT VENT SUCTION OIL LINE PRESSURE DRAIN PAN RELIEF WITH SHUT OFF RETURN OIL LINE VALVE EMERGENCY VENT SUCTION OIL LINE IS ONE CONTINUOUS PIECE OF COPPER TUBING INSTALLED THROUGH THE SLIP FITTING CHECK VALVE CLEAN OUT...
  • Page 18 BOILER INSTALLATION PRESSURE OIL LINE TO THE HEATING EQUIPMENT FILL BALL VALVE BLEEDER VALVE BALL VALVE USED FOR VACUUM GAUGE VACCUUM TEST CANISTER FILTER SUCTION OIL LINE TO TANK PRESSURE RELIEF RETURN (1/2" COPPER TUBING) OIL LINE TO THE TANK (1/4"...
  • Page 19 BOILER INSTALLATION PRESSURE OIL LINE TO THE HEATING EQUIPMENT FILL BALL VALVE BLEEDER VALVE BALL VALVE USED FOR VACUUM GAUGE VACCUUM TEST CANISTER FILTER SUCTION OIL LINE TO TANK PRESSURE RELIEF RETURN (1/2" COPPER TUBING) OIL LINE TO THE TANK (1/4"...
  • Page 20 BOILER INSTALLATION 1/2" MNPT SLIP-THROUGH 1/2" MNPT X 1/4" FITTING COMPRESSION 2" DUPLEX FITTING SUCTION OIL LINE (1/2" COPPER TUBING) PRESSURE RELIEF RETURN OIL LINE (1/4" COPPER TUBING) DETAIL A SUCTION OIL LINE IS ONE CONTINUOUS PIECE OF COPPER TUBING INSTALLED THROUGH THE SLIP FITTING 1/2"...
  • Page 21 BOILER INSTALLATION Installing the pressure oil line to the boiler: (1) Refer to Figure 17 to view the pump oil outlet options. (2) Determine the desired position of the oil outlet and rotate the 1/4” T accordingly. (3) Determine the length of copper tubing needed for the pressure line (from pump to boiler) and use the appropriate sized tubing.

  • Page 22: Connecting The Compressed Air Line

    BOILER INSTALLATION ALUMINUM CONNECTOR BLOCK OIL INLET PORT (1/4" NPT) CE70087 Figure 18: Connecting the Pressure Oil Line to the Connector Block Connecting the Compressed Air Line: (1) Refer to Figure 19. (2) mount a water trap / air regulator (adjusted to 50 psi) and shut-off valve close to the boiler.

  • Page 23: Disign And Installation Of The Hydronics System

    RELIEF VALVE safe boiler operation. Refer to Appendix A for illustrations and wire diagrams. Temperature Operating Control - Clean Energy part# 50193 Low Water Cut-Off - Clean Energy part #50194 CE70081 Figure 20: Installing the Pressure Relief...
  • Page 24 BOILER INSTALLATION VENT SEPARATOR HEATING EXPANSION ZONE TANK COLD WATER INLET WATER FLOW SYMBOLS - AIR VENT - PRESSURE REDUCING VALVE - AIR SEPARATOR - CHECK VALVE - CIRCULATOR - EXPANSION TAMK - ISOLATION VALVE CE70091 Figure 21: Typical Single Zone Connections...

  • Page 25: Inspecting The Boiler Installation

    BOILER INSTALLATION Inspecting the Boiler Installation: NOTICE: The boiler installation should be inspected by qualified personnel before it is operated to ensure all state and local codes are followed. CAUTION: Omitting or deviating from installation instructions in this manual may create hazardous operating conditions and void your warranty.

  • Page 26: Boiler Controls And Safety Components

    BOILER CONTROLS AND SAFETY COMPONENTS (1) Limit Control / Low Water Cut-Off The Limit Control shuts the 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.

  • Page 27: Starting And Adjusting The Burner

    STARTING AND ADJUSTING THE BURNER Preparing the burner for start up: (1) Plug the black cord into the top of the burner. (2) Turn on electrical power to the boiler. (3) Allow the burner heater element sufficient time to warm up the burner (time will vary according to ambient temperature).

  • Page 28: 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: Setting The Draft

    RESETTING THE OIL PRIMARY CONTROL Resetting the burner from restricted lock out: CE70032 NOTICE: If the control locks out three times before a call for heat is satisfied, it will enter restricted lockout mode in order to limit the amount of unburned oil in the combustion chamber.

  • Page 30: Maintenance

    MAINTENANCE Periodic Maintenance Schedule: (1) Clean the oil filter and pump head screen........once a year (2) Clean sludge and water from the tank........once a year (3) Clean ash from the heat exchanger..........800 hours (4) Flush the nozzle adapter heater block........2000 to 3000 hours Cleaning the oil canister filter screen: (1) Place a container under the canister filter to catch any released oil.
  • Page 31 MAINTENANCE Cleaning sludge and water from the bottom of the tank: NOTICE: Because of the nature of used oil handling practices, it is very difficult to keep all water and sludge out of the used oil supply. Drain the used oil supply tank at least once a year to ensure no unwanted substance is being delivered to the boiler.
  • Page 32 MAINTENANCE 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 CE70090 SHROUDING Figure 29: Cleaning Ash From the Heat Exchanger...
  • Page 33 MAINTENANCE NOZZLE ADAPTER HEATER BLOCK RELEASE RING ON AIR LINE FITTING QUICK DISCONNECT ELECTRICAL CONNECTOR OIL LINE SWIVEL FITTING CE70038A Nozzle adapter heater block with all components and plugs removed. CE70039 Figure 30: Flushing the Nozzle Adapter Heater Block...

  • Page 35: Boiler Dimensions

    BOILER DIMENSIONS 67" (with Burner) 34.0" 57.5" 42.5" 50" CE70077...

  • Page 36: Wire Diagrams

    WIRE DIAGRAMS CE-340 BOILER CABINET WIRE DIAGRAM: USE COPPER BOILER CONTROL CONDUCTORS ONLY ZC ZR B1 B2 CE BOILER THERMOSTAT BLACK POWER WHITE 120 VAC CIRCULATOR 1 PH BLACK AQUASTAT (Manual Reset) WHITE ORANGE DRAFT INDUCER (OPTIONAL) BURNER PUMP CONNECTOR...
  • Page 37 WIRE DIAGRAMS CE-4 BURNER WIRE DIAGRAM:...

  • Page 38: Parts Diagrams

    CE-3 / CE-4 Burner Assembly CE70043...
  • Page 39 ITEM NO. PART NUMBER DESCRIPTION QTY. 30017 Burner Blower Motor 50015 Squirrel Cage - Burner 65001 Burner Housing 20034 Motor Mount Plate 50020 Igniter 50008 Burner Manifold Block 50019 Primary Control 20033 Front Motor Cover 65002 Ignitor Hinge Plate 30034 Amber Light 30033 Green Light...
  • Page 40 Nozzle Adapter / Heater Block Assembly...
  • Page 41 ITEM NO. PART NUMBER DESCRIPTION QTY. 30001 Electrode 40005 9-5 Nozzle 50009 Nozzle Adapter / Heater Block 50024 Swivel Fitting 20008 Nozzle Adaptor Bracket - Three Legs 30002 HEAT ELEMENT 50022 SOLENOID AIR/OIL 115VAC 50063 1/8 Tube x 10-32 58040 Washer Neoprene Bonded, #10 , 1/2"...
  • Page 42 CE-4 Manifold Block Assembly CE70058...
  • Page 43 ITEM PART DESCRIPTION QTY. NUMBER 50022 SOLENOID AIR/OIL 115VAC 50021 Regulator - Surface Mount 30010 Terminal Block - Burner 50008 Burner Manifold Block 50062 Tube Fitting 1/8T x 1/8MP 50054 Air Pressure Switch 50067 Plug - Hex Socket 58030 Cap Screw Socket Head 8-32 x 5/8 Black 58035 Lock Washer #8 Z 58029...
  • Page 44 Metering Pump Assembly CE70050...
  • Page 45 ITEM NO. PART NUMBER DESCRIPTION QTY. 50030 Bushing 3/4 x 1/4 NPT 50031 Bushing 3/4 x 1/2 NPT 50037 Tee 1/2 F x 1/2 F x 1/2 M 50053 Ball Valve 1/2 NPT 50038 Plug 1/2 NPT Hex 40002 Metering Pump (A2RA-7710) 50026 ST EL 90 1/4 F x 1/4 M...
  • Page 46 CE-340 Boiler ALT. ALT. CE70101...
  • Page 47 Observation Port Lid 50010 Hinge - Observation Port 20100 Observation Port Ring 50174 Combustion Sleeve 30065 Connector Cord - 5 Wire (CE-340 Boiler) 50189 Gauge - Temp./Press. Boiler 20010 Electrical Box Lid 20086 Cover - Shrouding 50193 Aquastat - Operating (ALTERNATE)

  • Page 48: Chimney Installation Diagrams

    Through the Wall Chimney Installation: 90099 - SPARK ARRESTOR CAP 8" 90097 - WALL FIRESTOP 8" 90102 - STORM COLLAR 8" 90105 - FLASHING 2/12 - 5/12 8" 90062 90065 - INSULATED STACK 8X36 SS - INSULATED STACK 90069 - INSULATED STACK 8X18 SS 8X48 SS 90071 - INSULATED STACK 8X12 SS 10 FT.
  • Page 49 Through the Roof Chimney Installation: 90099 - SPARK ARRESTOR CAP 8" 90062 - INSULATED STACK 8X48 SS 10 FT. 90155 - DEKTITE BOOT #7 90093 - ADJUSTABLE ROOF SUPPORT 8" 90097 - WALL FIRESTOP 8" 90160 - SINGLE WALL ADAPTOR 8" 90082 - CEILING SUPPORT 8"...

  • Page 50: Service Records

    SERVICE RECORDS 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 CLEAN OIL CLEAN CLEAN ASH FROM DRAIN OIL CLEAN THE CANISTER...

  • Page 51: Alternate Controls

    TEMPERATURE OPERATING CONTROL (#50193) CE70097 ALTERNATE CE-340 Boiler Cabinet Wire Diagram: NOTE: WHEN USING THE ALTERNATE LWC AND TEMPERATURE CONTROL USE COPPER 1) CONNECT THE THERMOSTAT DIRECTLY TO THE T-T TERMINALS ON THE BURNER PRIMARY CONTROL CONDUCTORS ONLY 2) USE ADDITIONAL WATER TEMPERATURE CONTROLS TO POWER THE CIRCULATOR PUMP...

  • Page 52: Domestic Hot Water Coil Installation

    APPENDIX A Domestic Hot Water Coil Installation: 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. (1) Refer to Figure A2. (2) Remove the six nuts and bolts holding the cover in position. (3) Carefully slide the domestic hot water coil, with the rubber gasket in place, into the tube.

  • Page 53: Warranty Information

    Limited Warranty. Clean Energy Heating Systems, LLC assumes no liability for consequent damage of any kind, and by acceptance of this equipment the purchaser assumes all liability for the consequence of its use or misuse by the purchaser or others.
  • Page 54 Approved Method to Dispose of Waste Oil Sold and Serviced by: NAME: ADDRESS: TELEPHONE #: ----------------------------------------------------------------------------------------------------------------------------------------- ________________ PLACE ________________ STAMP HERE ________________ CLEAN ENERGY HEATING SYSTEMS LLC 540 MAPLE STREET HONEY BROOK PA USA 19344...

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