Page 1 OPERATOR'S MANUAL CLEAN BURN MULTI-OIL FURNACE MODELS: CB-3500 with CB-525-S2 BURNER CB-5000 with CB-550-S2 BURNER USED-OIL BURNING APPLIANCE #MH15393 (N) LISTED USED OIL-FIRED I88798-C FURNACE PUBLICATION DATE: 05/12/14, Rev. 14 CLEAN BURN PART #43144 WARNING: DO NOT assemble, install, operate, or maintain this equipment without first reading and understanding the information provided in this manual.
Page 3: Warranty Information
If the defect occurs within the first ten (10 years or 15,000 hours, whichever comes first), Clean Burn will replace or repair the heat exchanger/combustion chamber.
Page 4 TRADEMARKS The Clean Burn logo is a trademark of Clean Burn, LLC. All other brand or product names mentioned are the registered trademarks or trademarks of their respective owners. COPYRIGHT Copyright ©...
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 Furnace Usage ....................1-4 Guidelines for Used Oil Tanks ....................1-5 Safety Labels .......................... 1-6 SECTION 2: UNPACKING ........................2-1 Removing the Shipping Crate .......................
Page 6 TABLE OF CONTENTS SECTION 4: FURNACE INSTALLATION ..................4-1 Understanding Installation......................4-1 Selecting a Location ........................4-3 Guidelines for Selecting a Location ..................4-3 Mounting the Furnace........................4-4 Ceiling Mounting ........................4-4 Raised Platform Mounting ..................... 4-5 Floor Mounting ........................4-5 Oil Tank Installation Specifications ....................
Page 7 TABLE OF CONTENTS SECTION 6: STARTING AND ADJUSTING THE BURNER ........... 6-1 Understanding Burner Startup and Adjustment 6-1 Preparing the Burner for Startup ....................6-1 Starting the Burner ........................6-3 Checking the Operation of the Blower Motor ................6-5 SECTION 7: RESETTING THE FURNACE AND BURNER ............ 7-1 Understanding Furnace/Burner Shutdowns ...................
Page 8 Burner Technical Specifications ....................A-2 Furnace Dimensions ........................A-3 Burner Components ........................A-6 Removing the Nozzle for cleaning ..................A-13 CB-3500 Furnace Components ....................A-14 CB-3500 Blower Components ....................A-16 CB-5000 Furnace Components ....................A-18 CB-5000 Blower Components ....................A-20 Metering Pump Components ......................
Page 9: Section 1: Introduction
This manual contains all the information necessary to safely install and operate the Clean Burn Furnace Models CB-3500 and CB-5000. 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 procedures in this manual.
Page 10: For Your Safety
Operator's Manual: Models CB-3500 & CB-5000 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 Clean Burn, LLC. Unauthorized modifications or alteration can adversely affect the proper, safe operation of your furnace. WARNING: The burner which is shipped with your Clean Burn furnace is to be used only with your furnace according to the instructions provided in this manual. DO NOT use the...
Page 12: Guidelines For Furnace Usage
Contact your Clean Burn dealer for current EPA regulations. • If your furnace ever requires service, call your Clean Burn dealer. DO NOT allow untrained, unauthorized personnel to service your furnace. Make sure that your furnace receives annual preventative maintenance to ensure optimal performance.
Page 13: Guidelines For Used Oil Tanks
Operator's Manual: Models CB-3500 & CB-5000 For Your Safety... (continued) Guidelines for Used Oil Tanks WARNING For the safe storage of used oil and the safety of persons in the vicinity of the used oil supply tank, ensure that your tank installation adheres to the following safety guidelines: •...
Page 14: Safety Labels
(e.g. ATTENTION, CAUTION, WARNING, DANGER). For your safety and the safe operation of your furnace, review all labels and heed all safety messages as printed on the labels. If any labels on your Clean Burn furnace ever become worn, lost or painted over, please call your Clean Burn dealer for free replacements.
Page 15 Operator's Manual: Models CB-3500 & CB-5000 For Your Safety... (continued) Furnace Cabinet Safety Labels WARNING WARNING Fire, explosion and burn hazards: Hazardous voltage. Maintain clearances from To prevent serious injury, shut OFF main combustibles as listed on unit. power to unit before removing cover.
Page 16 Operator's Manual: Models CB-3500 & CB-5000 For Your Safety... (continued) CB-3500/CB-5000 Furnace Cabinet Safety Labels MODEL NO. CB-3500 MODEL NO. CB-5000 INPUT RATING W/NO 2 FUEL OIL (BTU/HR) 350000 INPUT RATING W/NO 2 FUEL OIL (BTU/HR) 500000 ATOM AIR ATOM AIR...
Page 17 Operator's Manual: Models CB-3500 & CB-5000 For Your Safety... (continued) 42005 CB-3500/CB-5000 Burner Labels Label Part # Description 42004 42005 Sold and Serviced By Label 42321 42229 42004 Burner Safety Warning Label 42322 (High Voltage/Moving Parts Hazards) 42000 Burner Safety Warning Label...
Page 18 Operator's Manual: Models CB-3500 & CB-5000 1-10...
Page 19: Section 2: Unpacking
Model CB3500; it will require additional installation for Model CB5000.) Unpacking and Inspecting All Components Following is an itemized list of all components you should have received in your Clean Burn furnace 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: Unpacking Items Packed Inside The Furnace
I88293-A Figure 2A - Accessing the Combustion Chamber Warranty Registration For proper warranty registration, Clean Burn requires that you fill out the provided warranty registration card and return it within 30 days to: CLEAN BURN WARRANTY REGISTRATION Clean Burn, LLC.
Page 21: Section 3: Furnace Assembly
(5) Installing the Connector Block, Oil Line Tubing, and Air Line Tubing (6) Installing the Mounting and Stabilizer Brackets Clean Burn recommends that you review all assembly procedures before proceeding, paying careful attention to safety information statements. Please note that some assembly procedures apply only to certain furnace models.
Page 22 ON FURNACE CABINET BASE I88801-C Figure 3A - Overview of Furnace Assembly Complete assembly of the CB-3500/CB-5000 furnace according to the following list of activities as illustrated above: (1) Installing the Blower Assembly (2) Installing the Hot Air Discharge Components...
Page 23 Operator's Manual: Models CB-3500 & CB-5000 STABILIZER BRACKETS MOUNTING BRACKETS I88288-B Figure 3B - Three-dimensional View - Furnace Completely Assembled with Louver Assembly for Unit Heater Application NOTE: This figure shows the mounting/stabilizer brackets in place for a ceiling mounting installation. If your furnace will be floor...
Page 24: Installing The Blower Components
Operator's Manual: Models CB-3500 & CB-5000 Installing the Blower Components NOTE: The blower is installed in final position on the CB-3500 cabinet. The blower for the CB-5000 requires additional installation as described in the following procedure. Installing the Blower (Model CB-5000 ONLY) NOTE: For proper air flow through the furnace, the blower must be positioned so the bulge on the blower faces toward the rear of the furnace as illustrated in Figures 3A, 3B, and 3D.
Page 25 Operator's Manual: Models CB-3500 & CB-5000 BLOWER ASSEMBLY PARTS LIST 2 HP MOTOR MOTOR PULLEY MOTOR MOUNTING PLATE BOLT MOTOR TENSIONING BRACKET BLOWER PULLEY SELF-TAPPING BOLT 10 V-BELT 11 MOTOR MOUNTING BRACKET 12 SQUARE HEAD BOLT 13 MOTOR BUSHING (7/8" HUB) 14 BLOWER BUSHING (1"...
Page 26: Installing The Motor Pulley, Blower Pulley, And V-Belt
Operator's Manual: Models CB-3500 & CB-5000 Installing the Blower Components (continued) Installing the Motor Pulley, Blower Pulley, and V-Belt MODEL CB-3500 MODEL CB-5000 BLOWER PULLEY (31225) BLOWER PULLEY (31225) BLOWER BUSHING - 1" HUB (31226) BLOWER BUSHING - 1" HUB...
Page 27: Installing The Belt Guard And The Blower Guard
Operator's Manual: Models CB-3500 & CB-5000 Installing the Motor Pulley, Blower Pulley, and V-Belt (continued) Align drilled holes in bushing flange with tapped holes in the pulley. Use the capscrews and washers provided with the bushing package to fasten the pulley on to the bushing. DO NOT COMPLETELY TIGHTEN THE SCREWS AT THIS POINT! Make sure you can still slide the bushing and pulley for future alignment with the motor pulley.
Page 28: Installing The Hot Air Discharge Components
Operator's Manual: Models CB-3500 & CB-5000 Installing the Hot Air Discharge Components Determining the Air Discharge Configuration The CB-3500 and CB-5000 furnaces may be configured for use as EITHER a Unit Heater or a Central Furnace as described below. (1) Unit Heater Furnace with blower for FREE AIR applications.
Page 29: Unit Heaters: Installing The Air Discharge Louver Assembly
Operator's Manual: Models CB-3500 & CB-5000 UNIT HEATER APPLICATIONS: Installing the Air Discharge Louver Assembly The body of the air discharge louver assembly is shipped assembled and is packed on top of the furnace cabinet. The louvers, nuts and bolts, which must be assembled separately, are packed inside the combustion chamber.
Page 30: Central Furnaces: Installing Ductwork
Sizing the Ductwork: • For Model CB-3500, the outlet on the air discharge is 20" x 20". The main duct (CB-3500) must initially maintain an outlet size of 20" x 20". •...
Page 31: Installing The Burner
Checking the Burner Nozzle and Electrodes NOTE: The burner nozzle is factory installed. Model CB-3500 uses a Delavan 9-5 nozzle. Model CB-5000 uses a Delavan 9-11 nozzle. The nozzle size is indicated on the nozzle head as shown in Figure 3H.
Page 32: Mounting The Burner On The Hinge Bracket
Operator's Manual: Models CB-3500 & CB-5000 Installing the Burner (continued) Mounting the Burner on the Hinge Bracket ATTENTION: Burner tube components (e.g. electrodes and retention head) are factory set. Handle the burner with extreme care so that burner components are not damaged.
Page 33: Installing The Connector Block, Oil Line Tubing, And Air Line Tubing
Operator's Manual: Models CB-3500 & CB-5000 Installing the Connector Block, Oil Line Tubing, and Air Line Tubing ATTENTION: DO NOT use teflon tape on any fittings. Teflon tape will plug vital burner components and void your warranty. Installing the Connector Block on the Furnace Door OIL LINE Refer to Figure 3I.
Page 34: Installing The Air Line Tubing
Operator's Manual: Models CB-3500 & CB-5000 Installing the Connector Block, Oil Line Tubing, and Air Line Tubing (continued) Installing the Oil Line Tubing (continued) Make sure that the curl in the oil line is positioned as shown in Figure 3I so that the burner can swing open correctly.
Page 35: Locking The Burner Into Firing Position
Operator's Manual: Models CB-3500 & CB-5000 Locking the Burner into Firing Position Swing the burner into firing position. Install and tighten the lock-down nut on the mounting plate bolt to secure the burner in its firing position. Plug the burner electrical cable into the receptacle on the CONNECTOR PLUG top of the burner housing.
Page 36 Operator's Manual: Models CB-3500 & CB-5000 3-16...
Page 37: Section 4: Furnace Installation
Likewise, the installation, operation, and maintenance of this equipment in Canada is to be accomplished by qualified personnel and in compliance with the specifications in the Clean Burn Operator's Manual and in accordance with the regulation of authorities having jurisdiction and the following CSA Standards: B139 - Installation Code for Oil Burning Equipment;...
Page 38 FOR MORE DRAFT TURN WEIGHT 1/4" HOLE FOR SETTING DRAFT AT BREACH COMPRESSED AIR LINE INSTALLED TO ALUMINUM CONNECTOR BLOCK BALL VALVE SUCTION VENT OIL LINE EMERGENCY VENT VALVE ELECTRICAL SERVICE STORAGE TANK I88359-F Figure 4A - Typical CB-3500/5000 Furnace Installation...
Page 39: Selecting A Location
Operator's Manual: Models CB-3500 & CB-5000 Selecting a Location Guidelines for Selecting a Location The location you select for your furnace must allow the following: • Unobstructed, even heat distribution. • Safe, easy access for servicing. • Unobstructed passage for shop vehicles and equipment.
Page 40: Mounting The Furnace
Operator's Manual: Models CB-3500 & CB-5000 Mounting the Furnace After selecting a safe and appropriate location for your furnace, construct the mounting system as required by the location and the following specifications. Ceiling Mounting WARNING: To prevent serious personal injury, ensure that your furnace mounting system can safely bear the suspended weight of the furnace and allow safe servicing of furnace components.
Page 41: Raised Platform Mounting
Add 12" (minimum) to all sides of the cabinet to achieve the total measurement for the • non-combustible floor. EXAMPLE: The CB-3500 measures 58" long x 35" wide. 58" + 12" + 12" = 82" long 35" + 12" + 12" = 59" wide Refer to Figure 4E.
Page 42 Operator's Manual: Models CB-3500 & CB-5000 Constructing A Non-Combustible Floor (continued) Place a 24-gauge sheet metal pan with a 1" containment lip on top of the masonry blocks. This will provide containment of any oil that may be spilled while working on the furnace.
Page 43: Oil Tank Installation Specifications
If you do not have a copy of this label, please contact your Clean Burn dealer for Fire and explosion hazards a copy, which is to be affixed directly to your used To prevent serious injury or death: oil supply tank.
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 4F. Tank Vent Kits are available from Clean Burn; contact your local Clean Burn dealer to order. Be sure...
Page 45: Installing The Metering Pump
Operator's Manual: Models CB-3500 & CB-5000 Installing the Metering Pump Preparing for Installation Before starting installation of the metering pump, review Figures 4G, 4H, and 4I to become familiar with the metering pump components. You will also need to accomplish the following activities: •...
Page 46 Operator's Manual: Models CB-3500 & CB-5000 # PART # DESCRIPTION SUPPLY RETURN TO BURNER 33363 CAPACITOR - GEARMOTOR TO TANK 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
Operator's Manual: Models CB-3500 & CB-5000 Installing the Metering Pump (continued) Alternate Mounting: Horizontal Positioning ATTENTION: If the metering pump is to be mounted horizontally or on a bracket as shown in Figure 4I, 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: Wiring The Furnace And Pump
Operator's Manual: Models CB-3500 & CB-5000 Wiring the Furnace and Pump WARNING: To avoid electrical shock, make sure that power to the furnace is turned OFF before connecting any wires. A licensed electrician should install all wiring to your furnace. All wiring must be in accordance with the National Uniform Electrical Code and local codes.
Page 49: Installing The Suction Oil Line Components
Operator's Manual: Models CB-3500 & CB-5000 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 Operator's Manual: Models CB-3500 & CB-5000 Installing the Suction Oil Line Components (continued) (1.) (e.) Prepare the canister filter for installation (continued): • Install this assembly into one side of the 1/2" brass tee. • Install the assembled 1/2" tee into the 3/4" x 1/2" brass bushing, which is installed in the inlet port of the canister filter.
Page 51 Operator's Manual: Models CB-3500 & CB-5000 Install the suction oil line (from the the tank to the canister filter): a. Refer to Figures 4H and 4J. Prepare a piece of 1/2" O.D. copper tubing (user-supplied) which will function as the pick-up line from the tank to the canister filter. This copper tubing must have the following specifications: •...
Page 52: Installing The Pressure Relief Oil Line Back To The Tank
Operator's Manual: Models CB-3500 & CB-5000 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. The metering pump requires the installation of a pressure relief oil line back to the tank that you are pulling oil from as shown in Figures 4F, and 4J.
Page 53: Installing The Pressure Oil Line Components
Contact your local Clean Burn dealer for more information. Run a compressed air line from your shop air to the connector block on the furnace -- for Model CB-3500 use minimum 1/4" O.D. copper tubing or equivalent; for Model CB-5000, use 3/8" O.D. copper tubing or equivalent.
Page 54: Installing The Stack
Installing the Stack WARNING: Inappropriate stack materials or improper stack design/installation can adversely affect the proper, safe operation of your furnace. Contact your Clean Burn dealer to purchase the proper stack components for your furnace. Stack designs are generally classified as follows: (1) "Class A"...
Page 55: Installing The Interior Stack
Operator's Manual: Models CB-3500 & CB-5000 Installing the Interior Stack WARNING: Single wall stack components may be used only for those portions of the stack which are located inside your building and away from any fire/burn hazards. Install the single wall stack with proper clearances from combustibles. Also ensure that the stack is located a safe distance from all shop personnel.
Page 56 Operator's Manual: Models CB-3500 & CB-5000 Installing the Stack (continued) "CLASS A" STACK CAP NON-RESTRICTIVE TYPE TO ALLOW FREE FLOW OF THE STACK GASES NOTE: THE LAST STACK SECTION SHALL EXTEND AT LEAST 3 FEET (90 CM) HIGHER THAN ANY RIDGE, PARAPET, WALL, OR ROOF STRUCTURE WITHIN 10 FEET (3 M) OF IT.
Page 57: Installing The Barometric Damper
For horizontal stack runs (as shown in Figure 4M), install the tee after the first straight section of pipe. NOTE: The tee is required to support the barometric damper. You must purchase this tee when you purchase your stack materials (8" single wall tee - CB#70174 for CB-3500; 10" single wall tee - CB#70180 for CB-5000).
Page 58: Installing The Stack Safety Switch For Canadian Installations
Operator's Manual: Models CB-3500 & CB-5000 Installing the Stack Safety Switch For Canadian Installations NOTE: CSA Standards require that all heating equipment must be installed with a stack safety switch. If your heating equipment is being installed in Canada, follow the instructions listed below.
Page 59: Resetting The Stack Safety Switch
Operator's Manual: Models CB-3500 & CB-5000 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 60: Installing The Stack Penetration
The Field brand model DI-2 is available as optional equipment for the CB-3500 furnace. The Field brand draft inducers have been tested for use on Clean Burn furnaces. DO NOT use other models or brands of draft inducers.
Page 61 Operator's Manual: Models CB-3500 & CB-5000 Installing the Draft Inducer (continued) Note: Lubricate the motor as recommended by the Draft Inducer manufacturer. "CLASS A" STACK DRAFT NOTE: INSTALL DRAFT INDUCER IN LAST INDUCER SECTION OF VERTICAL STACK TO POSITION DRAFT INDUCER AWAY FROM FURNACE BREACH SO THAT THE MOTOR DOES NOT OVERHEAT.
Page 62: Installing The Wall Thermostat
Operator's Manual: Models CB-3500 & CB-5000 Installing the Draft Inducer (continued) Refer to Figure 4R. Follow the instructions included with the draft inducer to mount the draft inducer on the section of single-wall vertical stack. Position the draft plate all the way out so that it does not reduce the draft produced by the draft inducer.
Page 63: Section 5: Metering Pump Priming
SECTION 5: METERING PUMP PRIMING Understanding Metering Pump Priming Preparing your Clean Burn furnace 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. Required Tools and Materials...
Page 64: Priming The Metering Pump
Operator's Manual: Models CB-3500 & CB-5000 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 65 Priming the Metering Pump (continued) Activating the Pump NOTE: The CB-3500 and CB-5000 furnaces feature a priming switch which is mounted on the left-hand side of the electrical junction box on the front of the furnace cabinet. The priming switch has two positions: •...
Page 66: Vacuum Testing The Oil Pump
Operator's Manual: Models CB-3500 & CB-5000 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 67 Operator's Manual: Models CB-3500 & CB-5000 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 68 Operator's Manual: Models CB-3500 & CB-5000...
Page 69: Section 6: Starting And Adjusting The Burner
Operator's Manual: Models CB-3500 & CB-5000 SECTION 6: STARTING AND ADJUSTING THE BURNER Understanding Burner Startup and Adjustment Starting and adjusting the burner involves a series of separate procedures which must be accomplished in sequence without interruption. Review all the procedures before attempting burner startup and adjustment, paying careful attention to safety information statements.
Page 70 Operator's Manual: Models CB-3500 & CB-5000 Preparing the Burner for Startup (continued) Initial Adjustment of the Combustion Air Band for CB-3500 Furnaces: WARNING: The combustion air band must be properly adjusted to ensure that the burner ignites and burns correctly. DO NOT attempt to start the burner with the combustion air band wide open or completely closed.
Page 71: Starting The Burner
Operator's Manual: Models CB-3500 & CB-5000 Preparing the Burner for Startup (continued) ATTENTION: The settings shown in the charts below are only initial adjustments. Final adjustments must be done by inspecting the flame length according to the illustrations provided on the following page. NOTE: The oil pressure is automatically adjusted by the metering pump. Initial Adjustments for CB-3500 Maximum Input = 350,000 BTUH @ 2.5 GPH with CB525-S2 Burner...
Page 72: Starting The Burner
Check the flame length after the burner has fired for 15 minutes. Tighten the locking nuts on the air regulator. Fine Tuning the Combustion Air Band for CB-3500 Furnaces: NOTE: The initial setting of the combustion air band may require additional adjustment.
Page 73: Checking The Operation Of The Blower Motor
Operator's Manual: Models CB-3500 & CB-5000 Starting the Burner (continued) Fine Tuning the Air Intake for CB-5000 Furnaces: • Refer to Figure 6B to identify the air intake location on the burner. • Observe the flame. • If you see "sparkles" in the flame, or the flame is orange in color, the oil you are burning requires MORE combustion air.
Page 74 Operator's Manual: Models CB-3500 & CB-5000...
Page 75: Section 7: Resetting The Furnace And Burner
If the burner will not restart, review the information provided in this section on the functioning of the Fan Switches and the Hi-Temp Limit Switches. • If the burner still will not restart, contact your Clean Burn Distributor for immediate service. The Oil Primary Control AMBER LED...
Page 76: The Blower/Fan Switch
Understanding the Fan Switches and Hi-Limits on the CB-3500/CB-5000 Furnaces The CB-3500 and CB-5000 furnaces feature redundant fan switches and redundant limit switches. The two fan switches enable efficient working of the fan/blower for both unit heater and central furnace applications. The two limit switches serve to protect the furnace from damage due to overheating.
Page 77: The Fan Limit Control
Operator's Manual: Models CB-3500 & CB-5000 The Fan Limit Control Understanding the Operation of the Fan Limit Control The fan limit control, which is a probe style control, senses air temperature within the furnace cabinet. This control contains two switches: the fan switch and the limit switch. This control is especially important for the functioning of the fan with ducted applications.
Page 78: The Auxiliary Hi-Temp Limit Switch
The Auxiliary Hi-Temp Limit Switch The CB-3500 and CB-5000 furnaces are equipped with an auxiliary L-290 high temperature limit switch which is mounted on a bracket at the front of the combustion chamber as shown in Figure 7B. This switch senses the build-up of heat within the combustion chamber beyond the fan limit control setting and is designed to protect the furnace from damage due to overheating.
Page 79: Section 8: Adjusting The Draft Overfire
A qualified serviceman with proper equipment must check/adjust your furnace for proper draft. Contact your Clean Burn dealer for this service. Insert the probe of the draft gauge instrument into the draft reading port in the observation port as shown in Figure 8A.
Page 80: Adjusting The Barometric Damper
Operator's Manual: Models CB-3500 & CB-5000 Adjusting the Barometric Damper NOTE: If the draft overfire is not in the -.02 to -.04 w.c. range, it is necessary to adjust the barometric damper. Before starting the burner, turn the weight on the flapper COUNTERCLOCKWISE until the flapper remains closed.
Page 81: Solving Draft Overfire Problems
Operator's Manual: Models CB-3500 & CB-5000 Solving Draft Overfire Problems WARNING! If you cannot achieve proper draft overfire, do not operate your furnace! Contact your Clean Burn dealer for assistance. ATTENTION: Backdraft must be resolved or your furnace will not operate correctly! Under backdraft conditions, draft overfire readings will show positive pressure in the combustion chamber.
Page 82 Operator's Manual: Models CB-3500 & CB-5000 Special Note to EXHUST FAN CREATES BACKDRAFT IN STACK AND SUCKS COMBUSTION GASES DOWN THE Service Personnel STACK AND BACK INTO THE FURNACE BACKDRAFT TO ARRIVE AT PROPER DRAFT MEASUREMENTS BE SURE THAT ALL FANS WITHIN THE BUILDING...
Page 83: Installing A Make-Up Air Louver
Operator's Manual: Models CB-3500 & CB-5000 Installing a Make-up Air Louver Exhaust Fans and Make-up Air Louvers When exhaust fans are operated in tight buildings, there is little or no source of fresh air to replace the air removed from the building by the exhaust fan. This results in negative pressure (vacuum) in the building which creates severe backdraft problems at the furnace.
Page 84 Operator's Manual: Models CB-3500 & CB-5000 Installing a Make-up Air Louver (continued) Calculated Opening Size Required Louver/Grill Size (square feet) (inches) From 0.000 to 0.569 10 X 10 From 0.570 to 0.900 12 X 12 From 0.901 to 1.556 16 X 16 From 1.557 to 2.070...
Page 85: Section 9: Maintenance
SECTION 9: MAINTENANCE Understanding Maintenance Servicing your Clean Burn furnace in a timely manner is very important to keep your furnace running in peak condition. Just as an automobile requires periodic maintenance such as oil changes, engine tune-ups, etc. your Clean Burn furnace also requires regularly scheduled service.
Page 86: Periodic Burner Inspection
Operator's Manual: Models CB-3500 & CB-5000 Periodic Burner Inspection Following initial start up of the burner, you should inspect the operation of the burner periodically--ideally on a monthly basis. Doing so ensures that the system is functioning efficiently and safely.
Page 87: Cleaning The Canister Filter
Operator's Manual: Models CB-3500 & CB-5000 Cleaning the Canister Filter ATTENTION: Never operate your furnace with more than 10" HG of vacuum on the suction side of the pump. High vacuum separates air from the oil and results in erratic burner operation.
Page 88: Servicing The Metering Pump
Remove the pump head cover (part 1). Remove the screen (part 2) and wash it. Remove and discard the used gasket (part 3). Install a new gasket (Clean Burn Part #32422). Replace the screen and pump head cover. L I E...
Page 89: Cleaning The Check Valve
Operator's Manual: Models CB-3500 & CB-5000 Cleaning the Check Valve This procedure applies to furnace installations with inside and outside tanks. The following protective gear should be worn when cleaning the check valve/screen: • Rubber gloves • Safety goggles Refer to Figure 9D. Remove the one-piece suction oil line from the tank.
Page 90: Cleaning The Tank
Operator's Manual: Models CB-3500 & CB-5000 Cleaning the Tank DO NOT allow water, sludge, or other debris to accumulate in your oil supply tank to the point that non-combus- tible or harmful materials are drawn into the pump or burner.
Page 91: Cleaning Ash From The Furnace
Operator's Manual: Models CB-3500 & CB-5000 Cleaning Ash from the Furnace NOTE: The maintenance interval for cleaning ash from the furnace is approximately 700 hours of operation as indicated on the hour meter on the burner (refer to the servicing intervals at the beginning of this chapter). Be sure to clean the ash from your furnace at least twice during the heating season. Your furnace may require...
Page 92 ATTENTION: The presence of rust in the flues indicates that chlorinated materials are being burned. Burning chlorinated materials will severely damage your heat exchanger and void your warranty. Contact your Clean Burn dealer for instructions to test your oil for chlorine contamination before firing your furnace.
Page 93: Cleaning And Maintaining The Draft Inducer
Clean Burn service technician who has the necessary parts and expertise. Contact your local Clean Burn dealer to schedule the annual periodic maintenance which is usually (preferably) performed during warm weather to prepare the furnace for the next heating season. Various levels of service are provided to fit your particular need.
Page 94 Operator's Manual: Models CB-3500 & CB-5000 9-10...
Page 95: Section 10: Troubleshooting
Operator's Manual: Models CB-3500 & CB-5000 SECTION 10: TROUBLESHOOTING The following charts and tables are provided for reference in troubleshooting any difficulties encountered in furnace operation and adjustment. • The Flow Chart outlines the proper sequence of events in furnace operation -- use this chart to help diagnose where a problem may be occurring.
Page 96 Operator's Manual: Models CB-3500 & CB-5000 10-2...
Page 97 Operator's Manual: Models CB-3500 & CB-5000 PROBLEM POSSIBLE CAUSE(S) 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. Electrician should check out electrical system. Burner cable is damaged or not Check burner cable.
Page 98 Operator's Manual: Models CB-3500 & CB-5000 PROBLEM POSSIBLE CAUSE(S) POSSIBLE ACTION(S) Burner ignites, but will not stay There is a fuel delivery problem. Follow the procedures listed in the running and Burner shuts off on reset next problem. within 15 seconds.
Page 99 Operator's Manual: Models CB-3500 & CB-5000 PROBLEM POSSIBLE CAUSE(S) POSSIBLE ACTION(S) Burner ignites and Burner shuts off There is air in the fuel supply. Prime the pump. If the pump on reset sometime later during the will not prime or there is air in day or night.
Page 100 Operator's Manual: Models CB-3500 & CB-5000 PROBLEM POSSIBLE CAUSE(S) POSSIBLE ACTION(S) Pump will not prime and Pump There is a leak(s) in the suction Follow the specifications in Section motor is running. line. 4 to make sure the suction line is installed properly and that all fittings are 100% airtight.
Page 101 Operator's Manual: Models CB-3500 & CB-5000 PROBLEM POSSIBLE CAUSE(S) POSSIBLE ACTION(S) Pump will not prime and Pump motor is There is NO power on the pump Start the burner and adjust the air NOT running. circuit from the burner. pressure regulator to 15 PSI. (a) If the amber “pump”...
Page 102 Operator's Manual: Models CB-3500 & CB-5000 10-8...
Page 103: Furnace Technical Specifications
Operator's Manual: Models CB-3500 & CB-5000 APPENDIX A Detailed Furnace Specifications Furnace Technical Specifications FURNACE MODEL CB-3500 CB-5000 BTUH Input 350,000* 500,000* @ 2.3 GPH @ 3.0 GPH Listed Fuels: #2, #4, #5 Fuel Oils #2, #4, #5 Fuel Oils...
Page 104: Burner Technical Specifications
Operator's Manual: Models CB-3500 & CB-5000 Burner Technical Specifications NOTE: These burner specifications apply to both furnace models, CB-3500 and CB-5000, except where differences are noted within the table. Burner CB-525-S2 (CB-3500) CB-525-S2 (CB-5000) Ignition Transformer Carlin Transformer 14,000 Volts...
Page 105: Furnace Dimensions
Operator's Manual: Models CB-3500 & CB-5000 Furnace Dimensions (CB-3500) 53 3/4" (137 cm) 9 3/8" 4 1/2" 15" 20" (11 cm) (38 cm) (24 cm) (51 cm) TOP VIEW (LESS BLOWER AND LOUVERS) SECURE ANGLE TO FURNACE 27" (WITH GUARDS) WITH (4) SCREWS (2 PLCS.)
Page 106 Operator's Manual: Models CB-3500 & CB-5000 Furnace Dimensions (CB-5000) 58" 147 cm 18 1/2" 2 1/2" 11" 24" (6 cm) (47 cm) (28 cm) (61 cm) TOP VIEW (LESS BLOWER AND LOUVERS) 31 3/4" (WITH GUARDS) SECURE ANGLE TO FURNACE (81 cm) WITH (4) SCREWS (2 PLCS.)
Page 107 Operator's Manual: Models CB-3500 & CB-5000...
Page 108: Burner Components
Operator's Manual: Models CB-3500 & CB-5000 Burner Components (CB-3500 with CB-525-S2) SEE ILLUSTRATION I88543 FOR PART NUMBERS CB - 525 - S2 BURNER I88234-C Figure A1 - CB-525-S2 Burner Component Detail (for CB-3500 Furnaces)
Page 109 Operator's Manual: Models CB-3500 & CB-5000 Burner Components (CB-525-S2) (continued) Item# C.B. Part# Qty. Component Description 26103 AIR INTAKE OUTER PLATE 11359 AIR INTAKE INNER PLATE 33400 CARLIN PRIMARY CONTROL (INTERRUPTED IGNITION) 33335 ISOLATOR (OPTIONAL) 33189 CARLIN IGNITER (TRANSFORMER) 33116...
Page 110 Operator's Manual: Models CB-3500 & CB-5000 Burner Components (CB-5000 with CB-550-S2) SEE ILLUSTRATION I88543 FOR PART NUMBERS BURNER CB - 550 - S2 I88186-D Figure A2 - CB-550-S2 Burner Component Detail (for CB-5000 Furnaces)
Page 111 Operator's Manual: Models CB-3500 & CB-5000 Burner Components (CB-550-S2) (continued) Item# C.B. Part# Qty. Component Description 11410 DRAFT PLATE, OUTER ASSEMBLY 26104 DRAFT PLATE, INNER ASSEMBLY 33400 PRIMARY CONTROL (INTERRUPTED IGNITION) 33189 IGNITER (TRANSFORMER) 33116 CAD CELL 11243 TRANSFORMER PLATE...
Page 112 Operator's Manual: Models CB-3500 & CB-5000 Burner Components (continued) I88543-A Figure A3 - Preheater Block Assembly Component Detail A-10...
Page 113 Operator's Manual: Models CB-3500 & CB-5000 Burner Components (continued) Item# C.B. Part# Qty. Component Description 34169 ELECTRODE SCREW - 10-32 x 3/4 33183 SINGLE PIECE ELECTRODE 34165 WASHER 32000 9 - 5 NOZZLE 32002 9-11 NOZZLE 13150 NOZZLE ADAPTOR 32007...
Page 114 Operator's Manual: Models CB-3500 & CB-5000 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 115: Removing The Nozzle For Cleaning
Check the electrodes for proper gap and clearances. Re-install the burner and adjust for optimal performance as described in Section 6. NOTE: If the nozzle plugs within a few days after cleaning, call your Clean Burn Dealer for service. Figure A5 - Cleaning the Nozzle...
Page 116 Operator's Manual: Models CB-3500 & CB-5000 CABINET CB-3500 ( # 11315 ) DETAIL A DETAIL B DETAIL C I88957-A A-14...
Page 117 Operator's Manual: Models CB-3500 & CB-5000 ITEM# PART# Description ITEM# PART# Description 31091 DUCT CAP ROUND 8" • 24098 HANGER CHANNEL 21010 STACK PIPE FLASH RING • 24099 HANGER ANGLE 24077 SIDE - RIGHT • 11137 DOOR A. CB-3500 34028 5/16-18 X 3/4 SERR HEX FLANG •...
Page 118 Operator's Manual: Models CB-3500 & CB-5000 BLOWER ASSEMBLY CB-3500 I88958 A-16...
Page 119 Operator's Manual: Models CB-3500 & CB-5000 ITEM# PART# Description ITEM# PART# Description 33533 BLOWER MOTOR 2HP • 14045 ACC BAG CB-3500, CB-5000 A. 31084 BLOWER 24087 MOTOR MOUNT 34072 5/16-18 STOVER TOP LOCK NUT 25046 ANGLE FRONT 34328 5/16-18 X 3/4 HEX HEAD FLANGE...
Page 120 Operator's Manual: Models CB-3500 & CB-5000 CABINET CB-5000 ( # 11302 ) DETAIL A DETAIL B DETAIL C I88959-A A-18...
Page 121 Operator's Manual: Models CB-3500 & CB-5000 ITEM# PART# Description ITEM# PART# Description 31092 DUCT CAP ROUND 10" - 28 GA. • 14084 FIBERGLASS ROPE A 25032 STACK PIPE FLASH RING DH • 25096 HANGER CHANNEL 25085 SIDE - RIGHT •...
Page 122 Operator's Manual: Models CB-3500 & CB-5000 BLOWER ASSEMBLY CB-5000 I88960 A-20...
Page 123 Operator's Manual: Models CB-3500 & CB-5000 ITEM# PART# Description ITEM# PART# Description 33533 BLOWER MOTOR 2HP • 14045 ACC BAG CB-3500, CB-5000 A. 31056 BLOWER 24087 MOTOR MOUNT 34072 5/16-18 STOVER TOP LOCK NUT 25046 ANGLE FRONT 34328 5/16-18 X 3/4 HEX HEAD FLANGE...
Page 124: Metering Pump Components
Operator's Manual: Models CB-3500 & CB-5000 Metering Pump Components SUPPLY TO BURNER RETURN TO TANK G AU R .H O TA TI O PACKAGED WITH CLEAN BURN EQUIPMENT SINGLE PIECE OF COPPER TUBING (USER SUPPLIED) PACKAGED WITH CLEAN BURN EQUIPMENT...
Page 125 Operator's Manual: Models CB-3500 & CB-5000 ITEM# PART# Description ITEM# PART# Description 33363 CAPACITOR • 13176 SUCTION FITTINGS PACKAGE 33355 GEAR MOTOR CB3500 • 32431 PLUG 1/2" HEX 33356 GEAR MOTOR CB5000 11322 MOUNT METER PUMP A 32037 1/8 NPT X 1/4 TUBE COMPRESSION FITTING...
Page 126 Operator's Manual: Models CB-3500 & CB-5000 A-24...
Page 127: Wiring Diagrams
Operator's Manual: Models CB-3500 & CB-5000 APPENDIX B Wiring Diagrams Figure B1 - CB-3500/CB-5000 Furnace Wiring Diagram (with Draft Inducer - standard for CB-5000; optional with CB-3500)
Page 128 Operator's Manual: Models CB-3500 & CB-5000 Wiring Diagrams Figure B2 - CB-3500/CB-5000 with CB-500 Series Burner...
Page 129 Operator's Manual: Models CB-3500 & CB-5000 DRAWING : I44048 OPTIONAL SERVICE MODELS CB-3500/CB-5000 DISCONNECT SWITCH 220 VOLTS BLOWER MOTOR 200° - CONNECTION TO CUSTOMER POWER FAN LIMIT CONTROL 110 VOLTS COIL SEE OPERATOR'S MANUAL HI LIMIT L 290 DOUBLE POLE RELAY...
Page 130: Metering Pump Wiring Schematic
Operator's Manual: Models CB-3500 & CB-5000 Wiring Diagrams (continued) ENCLOSED J-BOX GROUND BLUE L 2 (WHT) L 1 (BLK) * 115 V 60 HZ POWER FROM OIL PUMP CIRCUIT (SEE FURNACE SCHEMATIC) I44040 Figure B4 - Metering Pump Wiring Schematic...
Page 131 Operator's Manual: Models CB-3500 & CB-5000 Understanding the Oil Primary Control Model 40200 / 42230 Cad Cell Oil Primary Control Data Sheet Model 40200/ 42230 CAD Cell Oil C77009 Primary Control Data Sheet • Oil pump bleed assist • Thermostat/aquastat compatible up to 1 min.
Page 132 Operator's Manual: Models CB-3500 & CB-5000 Understanding the Oil Primary Control (continued) Model 40200 / 42230 Cad Cell Oil Primary Control Data Sheet C77010 Start-up & operation continued... Pump Prime To enter pump prime: 1. Start a CFH cycle. During Pre-Ignition or Pre-Purge, press Reset until motor turns off (10 seconds), then in Pump Prime, release Reset button.
Page 133: Furnace Service Record
Operator's Manual: Models CB-3500 & CB-5000 APPENDIX C Furnace Service Record Furnace Purchased: Date __________ From (name/phone)________________________________ Furnace Installed: Date __________ By (name/phone)__________________________________ Furnace Inspected: Date __________ By (name/phone)__________________________________ Note: Refer to Section 9 for Maintenance Instructions Draft Readings Service Record...
Page 134 Operator's Manual: Models CB-3500 & CB-5000...

This manual is also suitable for:

Cb-5000

CLEAN BURN CB-3500 Operator's Manual

Section 1: Introduction

Guide to this Manual

Section 2: Unpacking

Section 3: Furnace Assembly

Section 4: Furnace Installation

Section 5: Metering Pump Priming

Section 6: Starting and Adjusting the Burner

Section 7: Resetting the Furnace and Burner

Section 8: Adjusting the Draft Overfire

Section 9: Maintenance

Section 10: Troubleshooting

Appendix A

Appendix B

APPENDIX B Wiring Diagrams

Appendix C

Quick Links

Need help?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for CLEAN BURN CB-3500

Summary of Contents for CLEAN BURN CB-3500

This manual is also suitable for:

Table of Contents