Page 1 Clean Burn, Inc. 34 Zimmerman Road, Leola, PA 17540, U.S.A. Subject to change without notice. The Clean Burn logo is a trademark of Clean Burn, Inc. All other brand or product names mentioned are the...
Page 3: Declaration Of Conformity
DECLARATION OF CONFORMITY Manufacturer: Clean Burn Inc. 34 Zimmerman Rd. Leola, PA European Representative: TUV Rheinland North America 12 Commerce Rd. Newtown CT. 06470 Equipment: CTB-350 #90192 CTB-200 #90201 CTB-500 #90227 EMC Competent Body: TÜV Rheinland Product Safety GmbH Am Grauenstein D-51105 Köln...
Page 5: Table Of Contents
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 ..................
Page 6 TABLE OF CONTENTS SECTION 4: CTB INSTALLATION (continued) ............. Installing the Pressure Oil Line Components ..............4-17 Installing the Compressed Air Line ..................4-17 Wiring the Coil Tube Boiler ....................4-18 Wiring to the CTB ..................... 4-18 Wiring to the Metering Pump ..................4-19 Wiring the Load Loop Circulator ................
Page 7 CTB Technical Specifications ..................A-1 Burner Technical Specifications ................... A-2 CTB Hydronic Specifications ..................A-2 CTB Accessories and Parts Reference ................ A-3 CB-200-CTB Dimensions ..................A-5 CB-350-CTB Dimensions ..................A-6 CB-350-CTB Dual Stacked Boiler Dimensions ............A-7 CB-500-CTB Dimensions ..................A-8 CB-500-CTB Dual Stacked Boiler Dimensions ............
Page 8 TABLE OF CONTENTS APPENDIX B Wiring Diagrams ....................... B-1 Burner Wiring Diagram (CB-500-CE 5W and CB-551-CE 5W) ........ B-1 Burner Wiring Diagram (CB-551-H5 CE 5W) ............B-2 Control Box Wiring Diagram ..................B-3 Metering Pump Wiring Schematic ................B-4 CTB Ladder Schematic ..................... B-5 APPENDIX C Additional Installation and Maintenance Requirements (United Kingdom ONLY) ....
Page 9: Section 1: Introduction
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) 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), Models CB-200-CTB, CB-350-CTB, and CB-500-CTB. Consult the Table of Contents for a detailed list of topics covered.
Page 10: For Your Safety
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) 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.
Page 11 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) For Your Safety... (continued) WARNING: Never alter or modify your CTB without prior written consent of Clean Burn, Inc. Unauthorized modifications or alteration can adversely affect the proper, safe operation of your boiler.
Page 12 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) For Your Safety... (continued) Guidelines for Coil Tube Boiler Usage • This boiler is listed for commercial and/or industrial use only; it is not listed for residential use.
Page 13: Guidelines For Used Oil Tanks
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) For Your Safety... (continued) Guidelines for Used Oil Tanks For the safe storage of used oil and the safety of persons in the vicinity of the used oil supply tank,...
Page 14: Safety Labels
CTB, review all labels and heed all safety messages as printed on the labels. If any labels on your Clean Burn CTB ever become worn, lost or painted over, please call your Clean Burn dealer for free replacements.
Page 15 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) CTB Cabinet Labels (continued) 42216 42497 42421 www.cleanburn.com 42216 Burn Hazard. Fittings, piping, and boiler surface may be extremely hot. CB *** CTB 42465 Pipes contain hot water.
Page 16 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) For Your Safety... (continued) CTB Cabinet Safety Labels (continued) MULTI−OIL HEATING SYSTEM FOR COMMERCIAL OR INDUSTRIAL USE ONLY. 42308 CTB−200−CE 58.6 INPUT RATING W/NO 2 FUEL OIL (KW/HR) 1.24...
Page 17 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) CTB Cabinet Safety Labels (continued) CTB−500−CE 147.0 INPUT RATING W/NO 2 FUEL OIL (KW/HR) 13.5 0.17 13.5 0.17 13.5 0.15 13.5 0.16 13.5 0.17 13.5 0.17...
Page 18 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) For Your Safety... (continued) CTB Burner Labels Label Part # Description 42004 Burner Safety Warning Label (High Voltage/Moving Parts Hazard) 42235 Burner Safety Warning Label (Fire/Explosion Hazard - Burner Installation and Service)
Page 19: Section 2: Unpacking & Pre-Installation Considerations
Unpacking and Inspection Following is an itemized list of all components you should have received in your Clean Burn Coil Tube Boiler 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).
Page 20: Pre-Installation Considerations
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Pre-Installation Considerations The following information is critical to the proper installation of your Clean Burn Coil Tube Boiler system; read this section carefully before starting any other procedures.
Page 21 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Selecting a Location (continued) Adhere to the following minimum clearances from combustible surfaces. Specifications are also provided for servicing clearance. Be sure to check local codes which may differ from these specifications.
Page 22 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)
Page 23: Section 3: Coil Tube Boiler Assembly
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) SECTION 3: COIL TUBE BOILER ASSEMBLY Understanding Assembly Assembling your Clean Burn Coil Tube Boiler (CTB) is a multi-step process. Note that some assembly procedures apply only to certain CTB installations or configurations (i.e. single model or dual-stacked boilers);...
Page 24 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Single Boiler Assembly DETAIL OF ITEM 21 CB−350−CTB (230 V/50 Hz) SHOWN CIRCULATOR (USER SUPPLIED) I88747−C Figure 3A - Single Boiler Assembly Component Detail...
Page 25 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) CB‐350‐CTB CE PARTS LIST NUMBER PART # DESCRIPTION 90188 BASE 33529 COIL RELAY 240 VAC 30 A 33331 TERMINAL BLOCK 33340 TRANSFORMER 230V-24V 33328 RELAY DPDT 33352 RELAY DELAY...
Page 26: Ctb (Single Boiler) Assembly
WARNING: Use extreme caution when moving and lifting the CTB (with a forklift) into place on the support stand. One CTB can weigh up to 907 kg (2000 pounds). Clean Burn recom- mends placing safety blocking underneath the unit until it is properly installed and secured on the support stand.
Page 27: Dual-Stacked Boiler Assembly
One CTB can weigh up to 907 Kg (Weight of CB-500 with water). Clean Burn recommends placing safety blocking underneath the unit until it is properly installed and secured on the support stand. Failure to follow these basic safety guidelines may result in serious personal injury and/or damage to the unit.
Page 28 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Dual-Stacked Boiler Assembly "TOP" BOILER (USER SUPPLIED) ADAPTOR BRACKET "BOTTOM" BOILER (USER SUPPLIED) SUPPORT STAND I88737-C Figure 3D - Dual-Stacked Boiler Assembly Detail...
Page 29 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Dual-Stacked Boiler Assembly Assembling the Dual-Stacked Boiler (continued) Refer to Figures 3D and 3E. Assemble the adaptor bracket using the 1" x 3/8" bolts provided.
Page 30: Assembly For All Boilers
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Assembly for ALL Boilers Connecting the CTB Refer to Figures 3A, 3C, and 3D. Connecting the boiler involves three activities: • Supply Side Connections •...
Page 31: Installing The Ceramic Sleeve
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Assembly for ALL Boilers Installing the Ceramic Sleeve in the Boiler NOTE: The ceramic target is factory-installed. Refer to Figures 3F and 3G. Swing open the clean-out door on the CTB front to gain access to the combustion chamber.
Page 32 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Assembly for ALL Boilers CERAMIC SLEEVE CERAMIC I88124-B STAND Figure 3G - Ceramic Stand and Sleeve Installed in the Combustion Chamber 3-10...
Page 33: Checking The Burner Nozzle And Electrodes
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Assembly for ALL Boilers Checking the Burner Nozzle and Electrodes NOTE: The burner nozzle is factory installed. Models CB-200-CTB and CB-350-CTB use a Delavan 9-5 nozzle.
Page 34: Mounting The Burner On The Hinge Bracket
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Assembly for ALL Boilers Mounting the Burner on the Hinge Bracket NOTE: The burner may have been mounted on the CTB at the factory. If this is the case, simply check the clearance between the retention head and the boiler to make sure the burner swings freely into firing position.
Page 35: Installing The Oil Line Tubing
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Assembly for ALL Boilers Installing the Oil Line Tubing OIL LINE NOTE: DO NOT disassemble the compression OIL FITTING ON BURNER fitting from the swivel fitting. To prevent leaks, the...
Page 36: Installing The Air Line Tubing
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Assembly for ALL Boilers AIR LINE FITTING ON BURNER OIL LINE FITTING ON BURNER AIR LINE OIL LINE COMPRESSION / SWIVEL FITTING CONNECTOR BLOCK I88980...
Page 37: Section 4: Coil Tube Boiler Installation
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) SECTION 4: COIL TUBE BOILER INSTALLATION Understanding Installation Installing your Clean Burn Coil Tube Boiler (CTB) is a multi-step process which includes: (1) Oil Tank Installation Specifications...
Page 38 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Important Safety Guidelines for Safe Installation (continued) The Environmental Protection Act 1990, Part 1: Processes prescribed for air pollution control by local enforcing authorities PG1/1 (95).
Page 39: Typical Installation Diagrams
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Typical Installation Diagrams "CLASS A" STACK CAP 90 cm (3’) 3 m (10’) "CLASS A" STACK 1150 °C (2100 °F) ALL FUEL STACK INSULATED STACK WITH A...
Page 40 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Typical Installation Diagrams (continued) "CLASS A" STACK CAP 30 cm (12") "CLASS A" STACK 1150 °C (2100 °F) ALL FUEL STACK 3 m (10’) 90 cm (3’)
Page 41: Combustion Air Requirements
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Combustion Air Requirements The CTB system designer/installer must ensure that there is the proper amount of combustion air in the boiler/ mechanical room. Refer to Figure 4C.
Page 42 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)
Page 43: Oil Tank Installation Specifications
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Oil Tank Installation Specifications Ensure that your tank installation adheres to the following safety guidelines as stated here and in Section 1 of this manual.
Page 44: Installing The Tank Vent And Emergency Vent
Some codes require that you install a tank vent (to the outside) and an emergency vent for your tank as shown in Figure 4D. Tank Vent Kits are available from Clean Burn; contact your local Clean Burn dealer to order.
Page 45: Installing The Metering Pump
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Installing the Metering Pump Preparing for Installation Before starting installation of the metering pump, review Figures 4E, 4F, and 4G to become familiar with the metering pump components.
Page 46 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) PART # DESCRIPTION see chart GEARMOTOR 11322 MOUNT − METER PUMP 32037 1/8 NPT X 1/4 TUBE COMPRESSION FITTING 1/4 COPPER OR ALUM. TUBING 3/8 OR 1/2 TUBE FLARE NUT 3/8 OR 1/2 COPPER OR ALUM.
Page 47: Alternate Mounting: Horizontal Positioning
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Alternate Mounting: Horizontal Positioning ATTENTION: If the metering pump is to be mounted horizontally or on a bracket as shown in Figure 4G, the pump head must be rotated counterclockwise so that it is aligned in a horizontal position. The gauge arrow on the pump head must point up, or the pump will not prime.
Page 48: Connecting Water To The Coil Tube Boiler
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Connecting Water to the Coil Tube Boiler IMPORTANT NOTE! Detailed information on the installation and operation of the hydronics system is provided in Section 10 of this manual. The instructions provided here are abbreviated and serve only to indicate when these procedures should be performed;...
Page 49: Installing The Suction Oil Line Components
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Installing the Suction Oil Line Components ATTENTION: It is critical that you adhere to the following specifications for suction oil line installation (oil line from the tank to the pump). If these specifications are not met, the metering pump will not function correctly and the burner will shut down on reset.
Page 50 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Installing the Suction Oil Line Components (continued) (e.) Prepare the canister filter for installation (continued): • Remove the plug from one of the 1/8" gauge ports in the canister filter and install the vacuum gauge.
Page 51 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Installing the Suction Oil Line Components (continued) (2.) Install the suction oil line (continued)): m. Slide the 1/2" flare nut over the end of the 1/2" copper tubing, and flare the end of the tubing.
Page 52: Installing The Pressure Relief Oil Line Back To The Tank
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Installing the Pressure Relief Oil Line Back to the Tank ATTENTION: It is critical that you adhere to the following specifications for plumbing the pressure relief back to the tank.
Page 53: Installing The Pressure Oil Line Components
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Installing the Pressure Oil Line Components ATTENTION: It is critical that you adhere to the following specifications for pressure oil line installation (oil line from the pump to the boiler); if these specifications are not met, the metering pump will not function correctly and the burner will shut down on reset.
Page 54: Wiring The Coil Tube Boiler
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Wiring the Coil Tube Boiler WARNING: To avoid electrical shock, make sure that power to the CTB is turned OFF before connecting any wires. A licensed electrician should install all wiring to your furnace. All wiring must be in accordance with national and local codes.
Page 55: Wiring To The Metering Pump
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Wiring to the Metering Pump WARNING: DO NOT wire the oil pump directly into your building's electrical system. The oil pump must be activated (receive power from) the burner via the pump electrical circuit. DO NOT wire the pump directly to a wall outlet so that it runs continuously;...
Page 56: Installing The Stack
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Installing the Stack WARNING: Inappropriate stack materials or improper stack design/installation can adversely affect the proper, safe operation of your coil tube boiler. Stack designs are generally classified as follows: (1) "Class A"...
Page 57 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) "CLASS A" STACK CAP NON−RESTRICTIVE TYPE TO ALLOW FREE FLOW OF THE STACK GASES "CLASS A" INSULATED STACK THE LAST STACK SECTION SHALL EXTEND AT LEAST 90 cm (3’) HIGHER THAN 90 cm (3’)
Page 58: Installing The Interior Stack
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Installing the Stack (continued) DAMPER 20 cm (8") STACK PIPE 82 cm (32 1/4") BETWEEN CENTERS (CB−200−CTB) 94 cm (37 1/8") BETWEEN CENTERS (CB−350−CTB) 20 cm (8") STACK PIPE 25 cm (10")
Page 59: Installing The Barometric Damper
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Installing the Barometric Damper(s) Refer to Figure 4J. Install a single wall tee (min. 24 gauge) on the first straight vertical or horizontal stack section within 1 meter (40 inches) of the CTB breach.
Page 60: Installing The Optional Stack Safety Switch
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Installing the Optional Stack Safety Switch CAUTION: For your safety and the safe operation of your heating equipment, the stack switch must be installed by a qualified installer in accordance with the installation instructions provided here. Wiring must be accomplished in accordance with all applicable codes.
Page 61: Resetting The Stack Safety Switch
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Resetting the Stack Safety Switch WARNING: BURN HAZARD! To prevent serious personal injury, be sure to allow ample time, at least 30 minutes, for the stack, barometric damper, and switch to cool down before attempting to access and service these components.
Page 62: Installing The Stack Penetration
Install the stack cap according to the manufacturer's instructions. Installing the Draft Inducer ATTENTION: The Field brand draft inducers have been tested for use on Clean Burn Equipment. DO NOT use other models or brands of draft inducers. Understanding the Importance of the Draft Inducer The draft inducer is designed to aid in the removal of the natural draft created by the appliance to vent the combustion gases to the outside of the building.
Page 63 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Installing the Draft Inducer (continued) 90 cm (3’) 3 m (10’) 3 m (10’) MINIMUM VERTICAL STACK HEIGHT OR EQUIVALENT DRAFT SYSTEM TO MAINTAIN NOTE: INSTALL DRAFT INDUCER IN LAST −.02 W.C.
Page 64: Installing The Wall Thermostat Or Aquastat
Installing the Wall Thermostat or Aquastat IMPORTANT NOTE: A 24V wall thermostat is available separately from Clean Burn (i.e. it is not included with the CTB). If a 24V thermostat is used to activate the boiler, a qualified technician would need to remove the jumper from the external four landings on top of the black control box on the side of the boiler and use it to connect landings 5 and L1 on the internal terminal block.
Page 65 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Inspecting the Coil Tube Boiler Installation Following the completion of all installation activities described in this chapter, the CTB 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 in the installation to be corrected before CTB startup.
Page 66 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) 4-30...
Page 67: Section 5: Metering Pump Priming
SECTION 5: METERING PUMP PRIMING Understanding Metering Pump Priming Preparing your Clean Burn boiler for operation begins with priming the metering pump. The procedures in this section must be performed in sequence without interruption to properly prime the pump. IMPORTANT NOTE FOR DUAL-STACKED UNITS: The priming procedures will have to be per- formed for one burner, and then repeated for the other burner (i.e.
Page 68: Priming The Metering Pump
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Priming the Metering Pump ATTENTION: The priming process must be done precisely as described in this procedure to ensure that all air is thoroughly bled from the system. Failure to bleed all air from the system will result in repeated burner shutdowns on reset.
Page 69 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Priming the Metering Pump (continued) Activating the Pump NOTE: The coil tube boiler features a priming switch which is mounted on the left-hand side of the electrical junction box on the front of the boiler cabinet.
Page 70: Vacuum Testing The Oil Pump
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Priming the Metering Pump (continued) Run the pump until a solid stream of oil flows from the pump bleeder. This will bleed all air out of the suction line, oil filter and pump head.
Page 71 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Vacuum Testing the Oil Pump (continued) If there are no suction leaks, the system will hold vacuum. NOTE: It is acceptable for the vacuum to drop one to five inches within one minute as the seal in the pump seats.
Page 72 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)
Page 73: Section 6: Starting And Adjusting The Burner
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) SECTION 6: STARTING AND ADJUSTING THE BURNER Understanding Burner Startup and Adjustment ATTENTION: Before starting the burner, you must fill the coil tube boiler with water. Refer to Section 10 in this manual for more information on the hydronics system.
Page 74 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Preparing the Burner for SLOT COVER Startup (continued) INSTALLED Refer to Figure 6A. Loosen the REGULATOR locking nut on the air regulator. Turn the adjustment knob on the...
Page 75: Starting The Burner
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Preparing the Burner for Startup (continued) Initial Adjustments for CB-350-CTB NOTE: Only Gearmotor part # 33436 may be used with the CB-350-CTB. Maximum Input = 103 KW (350,000 BTUH) @ 9.5 LPH (2.5 GPH) per CB-551-CE 5W Burner...
Page 76 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Starting the Burner (continued) Correct Maximum Flame Adjustment (Proper Oil and Air Pressure) • Flame goes half of the way down the combustion chamber. •...
Page 77 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Starting the Burner (continued) Checking for Proper CTB System Operation: Observe the boiler temperature and water pressure. After the burner stops running when the operating aquastat set temperature is reached, check the following: •...
Page 78 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)
Page 79: Section 7: Resetting The Oil Primary Control
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) SECTION 7: RESETTING THE OIL PRIMARY CONTROL Understanding the Danfoss Oil Primary Control The oil primary control will shut the oil pump and oil solenoid off when it detects flame-out during burner operation.
Page 80 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)
Page 81: Section 8: Adjusting The Draft Over Fire
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) SECTION 8: ADJUSTING THE DRAFT OVER FIRE Understanding the Importance of Draft Draft in the Coil Tube Boiler is created as the hot combustion gases rise up the stack, creating a negative pressure inside the stack and the boiler.
Page 82: Understanding The Effect Of Exhaust Fans On Draft
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Checking for Correct Draft Over Fire (continued) Backdraft is caused by the following conditions: • Poor draft caused by improper stack design. (See Section 4.) •...
Page 83: Adjusting Draft Over Fire With A Draft Inducer Installed
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Adjusting Draft Over Fire with A Draft Inducer Installed NOTE: The draft inducer is purposely sized to create a generous draft. When adjusting the barometric damper, you will find that the flapper is open most of the time.
Page 84 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)
Page 85: Section 9: Maintenance
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) SECTION 9: MAINTENANCE Understanding Maintenance Maintaining your Clean Burn CTB is an important activity which includes several periodic maintenance activities and an annual burner tune-up...all are necessary to keep your boiler running in peak condition.
Page 86: Cleaning The Canister Filter
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Cleaning the Canister Filter ATTENTION: Never operate the oil pump with more than 10" HG of vacuum on the vacuum gauge. High vacuum on the suction side of the pump separates air from the oil (cavitation) and will cause the burner to shut down.
Page 87: Servicing The Metering Pump
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Servicing the Metering Pump Refer to Figure 9B. Remove the pump head cover (part 1). Remove the screen (part 2) and wash it. Remove and discard the used gasket (part 3).
Page 88: Cleaning The Check Valve / Screen
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Cleaning the Check Valve / Screen This procedure applies to coil tube boiler installations with inside and outside tanks. The following protective gear should be worn when cleaning the check valve/screen: •...
Page 89 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Cleaning the Ash from the Coil Tube Boiler ATTENTION: Your CTB may require frequent clean out of the ash due to contaminants in the oil or heavy use.
Page 90: Cleaning The Oil Tank
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Cleaning the Ash (continued) (2.) h. Thoroughly vacuum any remaining ash residue from the flue passages. A long wand on the hose of your shop vac is helpful in reaching all the way back.
Page 91: Section 10: The Ctb Hydronic System
IMPORTANT NOTE: When designing the system layout and application for your CTB, keep in mind that it is NOT suitable for open systems. The Clean Burn CTB has been designed to operate as a closed loop boiler system. Potable water heating (i.e. for domestic or washing purposes) can be accomplished by incorpo- rating a heat exchanger into the system.
Page 92: Ctb System Function And Configuration
(140 System Pressure The Clean Burn CTB is designed to operate in closed, pressurized hydronic systems. Certain levels of pressure are required for proper system operation--a minimum of 0.8 bar (12 PSI) should be maintained on the system where the boiler supply water temperature is 93 C (200 F) or less.
Page 93 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) 10-3...
Page 94: Ctb Setup Options
An additional circulator must be installed to flow water through the system and to the boiler. (2) In low load conditions, Clean Burn recommends the installation of a larger storage tank next to the CTB to extend the run time and to reduce the occurrence of short cycling. Position the tank close to the boiler to reduce the required connective piping as shown in sample configuration, Figure 10B.
Page 95 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) 10-5...
Page 96 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) 10-6...
Page 97: Guidelines For Ctb Setup And Operation
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Guidelines for CTB Setup and Operation Refer to the appropriate illustration in this section for your CTB system configuration, as well as Figures 4A/4B in the Installation chapter.
Page 98: Guidelines For Preventing Oxygen Contamination
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Guidelines for Preventing Oxygen Contamination ATTENTION: Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and can lead to boiler failure (and void warranty). Causes of oxygen contamination include: •...
Page 99: Section 11: Troubleshooting
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) SECTION 11: TROUBLESHOOTING The following charts and tables are provided for reference in troubleshooting any difficulties encountered in boiler operation and adjustment. • The Flow Chart outlines the proper sequence of events in boiler operation -- use this chart to help diagnose where a problem may be occurring.
Page 100 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) 11-2...
Page 101 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) PROBLEM POSSIBLE CAUSE POSSIBLE ACTION(S) Burner won’t run at all and Circuit breaker/main switch open. Close circuit breaker/switch. Green power light is NOT ON. Fuse/breaker blown.
Page 102 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) PROBLEM POSSIBLE CAUSE POSSIBLE ACTION(S) Burner ignites, but will not stay running There is a fuel delivery problem. Follow the procedures listed in the and Burner shuts off on reset within 15 next problem.
Page 103 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) PROBLEM POSSIBLE CAUSE POSSIBLE ACTION(S) Burner ignites and Burner shuts off on There is air in the fuel supply. Prime the pump. If the pump will...
Page 104 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) PROBLEM POSSIBLE CAUSE POSSIBLE ACTION(S) Pump will not prime and Pump motor is There is a leak(s) in the suction Follow the specifications in running.
Page 105 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) PROBLEM POSSIBLE CAUSE POSSIBLE ACTION(S) Pump will not prime and Pump motor is There is NO power on the Start the burner and adjust the air NOT running.
Page 106 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) 11-8...
Page 107: Ctb Technical Specifications
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) APPENDIX A Detailed Coil Tube Boiler Specifications CTB Technical Specifications Model CB-200-CTB CB-350-CTB CB-500-CTB Maximum Input 59 KW (200,000 BTUH)* 103 KW (350,000 BTUH)* 146 KW (500,000 BTUH)*...
Page 108: Burner Technical Specifications
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Burner Technical Specifications Model CB-200-CTB CB-350-CTB CB-500-CTB Burner CB-500-CE 5W CB-551-CE 5W CB-551-H5-CE 5W Ignition Transformer Danfoss Danfoss Danfoss 14,000 Volts 14,000 Volts 14,000 Volts...
Page 109: Ctb Accessories And Parts Reference
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) CTB Accessories and Parts Reference C.B. Part # 500-CTB 350-CTB 200-CTB Description 11578 90187 90199 Boiler Stacking Adapter Kit (optional) 90206 90188 90200 Boiler Stand (optional) 35116 Flange, 1"...
Page 110 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)
Page 111 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) CTB Dimensions Figure A1 - Model CB-200-CTB Dimensions (Single Boiler)
Page 112 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) CTB Dimensions Figure A2 - Model CB-350-CTB Dimensions (Single Boiler)
Page 113 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Figure A3 - Dual-Stacked Boiler Dimensions (Two CB-350-CTB Boilers)
Page 114: Cb-500-Ctb Dimensions
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Figure A4 - Model CB-500-CTB Dimensions (Single Boiler)
Page 115 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Figure A5 - Dual-Stacked Boiler Dimensions (Two CB-500-CTB Boilers)
Page 116: Burner Components
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Burner Components A-10...
Page 117 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Burner Components (continued) Item # Part # Descri ption Item # Part # Descri ption 11265 COVER - HINGED W A 31158 GASKET-SHORT.125"x.25"x3.8125" 11335 HOUSING A...
Page 118 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Burner Components (continued) I88852 Figure A7 - CB-500-CE 5W and CB-551-CE 5W Preheater Block and Electrode Assemble Component Detail A-12...
Page 119 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Burner Components (continued) Item# C.B. Part# Qty. Component Description 34169 ELECTRODE SCREW - 10-32 x 3/4 33527 PLUG IN ELECTRODE 34165 WASHER 32000 9 - 5 NOZZLE...
Page 120 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Burner Components (continued) I89010 Figure A8 - CB-551-H5 CE 5W Preheater Block and Electrode Assemble Component Detail A-14...
Page 121 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Burner Components (continued) Item # Part # Description Item # Part # Description 1 34326 10‐32 X 7/8 SLOTD PAN HD SCREW 41 32223 POPPET O‐RING (VITON) 2 33527 ELECTRODES, PLUG‐IN CB‐500‐5W 42 32222 POPPET VALVE ...
Page 122: Burner Electrode Specifications
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Burner Components (continued) INSTALLATION OF THE SPINNER RETENTION HEAD THE SPINNER RETENTION HEAD FITS INSIDE THE BURNER TUBE AND REQUIRES (3) SELF−TAPPING SCREWS. IT IS VERY IMPORTANT THAT THE SPINNER HEAD IS NOT TIPPED FROM SIDE TO SIDE OR FROM TOP TO BOTTOM.
Page 123: Removing The Nozzle For Cleaning
Check the electrodes for proper gap and clearances. Re-install the burner and adjust for optimal performance as necessary. NOTE: If the nozzle plugs within a few days after cleaning, call your Clean Burn Dealer for service. Figure A10 - Cleaning the Nozzle...
Page 124 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) CTB-200 CABINET I88982A A-18...
Page 125: Cb-200-Ctb Components
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) CB-200-CTB Components Item Ite m Part # De scription Part # Descript ion 122 82 WIRE HARNE SS HI LIMIT A 350 52 NIPPL E 1 1 /4 X 2 BL K...
Page 126 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) CTB-350 CABINET I88983A A-20...
Page 127: Cb-350-Ctb Components
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) CB-350-CTB Components Ite m Ite m Pa rt # De script ion P art # Desc ription 12 246 W IRE HARNESS HI L A...
Page 128 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) CTB-500 CABINET I89011A A-22...
Page 129: Cb-500-Ctb Components
Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) CB-500-CTB Components Item # Part # Description Item # Part # Description 12296 WIRE HARNESS HI L A 27180 LINER PROTECTOR 14315 CTB 500 UPPER PIPE ASSY.
Page 130 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) A-24...
Page 131 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) APPENDIX B Wiring Diagrams Figure B1 - CB-500-CE 5W and CB-551-CE 5W Burner Wiring Diagram...
Page 132 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Figure B2 - CB-551-H5 CE 5W Burner Wiring Diagram...
Page 133 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Figure B3 - Control Box Wiring Diagram...
Page 134 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) 230 V 50Hz POWER FROM OIL PUMP CIRCUIT (SEE BOILER CONTROL BOX WIRING DIAGRAM) INSULATE μ GEARMOTOR ROTATION IS CCWSE AS SHOWN. TO REVERSE ROTATION, REVERSE RED & BLUE LEADS...
Page 135 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) 230 VOLTS 50 Hz NOTE 1: PRIMING SEE NOTE 2 TDR TIMER CONTACT RUN - PRIME CLOSES INSTANTANEOUSLY FLOW OPERATING AQUASTAT SWITCH HI LIMIT WHEN RELAY IS ENERGIZED...
Page 136 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)
Page 137 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) APPENDIX C Additional Installation and Maintenance Requirements The following activities must also be accomplished for boiler installations in the United Kingdom: • Installing a cover over the air regulator on the burner •...
Page 138 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) Installing a Fire 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.
Page 139 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz) APPENDIX D Boiler Service Record Boiler Purchased: Date __________ From (name/phone) _______________________________ Boiler Installed: Date __________ By (name/phone)__________________________________ Boiler Inspected: Date __________ By (name/phone)__________________________________ Note: Refer to Section 9 for Maintenance Instructions...
Page 140 Coil Tube Boiler Operator's Manual: Models CB-200-CTB, CB-350-CTB and CB-500-CTB (230 V / 50 Hz)

This manual is also suitable for:

Cb-500-ctb Cb-350-ctb

CLEAN BURN CB-200-CTB Operator's Manual

Section 1: Introduction

Section 2: Unpacking & Pre-Installation Considerations

Section 3: Coil Tube Boiler Assembly

Section 4: Coil Tube Boiler Installation

SECTION 4: CTB INSTALLATION (Continued)

Section 5: Metering Pump Priming

Section 6: Starting and Adjusting the Burner

Section 7: Resetting the Oil Primary Control

Section 8: Adjusting the Draft over Fire

Section 9: Maintenance

Section 10: the Ctb Hydronic System

Section 11: Troubleshooting

Appendix A

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