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Clean Energy CE-140 Owner's Manual

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OWNER'S MANUAL
CE-140 Mul -Oil Furnace
CE-180 Mul -Oil Furnace
CE-250 Mul -Oil Furnace
With CE-3 Burner
CE-330 Mul -Oil Furnace
With CE-4 Burner
Clean Energy Heating Systems, LLC
540 Maple Street, Honey Brook, PA 19344
www.CleanEnergyHeatingSystems.com
WARNING:
For your safety - DO NOT store gasoline or other flammable
vapors and liquids in the vicinity of this or any appliance.
(888) 519-2347

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  • Page 1 OWNER’S MANUAL CE-140 Mul -Oil Furnace CE-180 Mul -Oil Furnace CE-250 Mul -Oil Furnace With CE-3 Burner CE-330 Mul -Oil Furnace With CE-4 Burner Clean Energy Heating Systems, LLC 540 Maple Street, Honey Brook, PA 19344 www.CleanEnergyHeatingSystems.com (888) 519-2347 WARNING: For your safety - DO NOT store gasoline or other flammable vapors and liquids in the vicinity of this or any appliance.
  • Page 2 8/22/12 Part # 70001...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SAFETY CONSIDERATIONS AND GUIDELINES.............. 4 FURNACE ASSEMBLY....................... 6 (1) Installing the blower................... 7 (2) Air discharge configuration................9 - Unit Heater (Free Air with no ductwork) - Central Furnace (ductwork installed) (3) Installing the combustion chamber target............12 (4) Installing the burner...................

  • 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-3 Burner is only approved for use on a furnace manufactured by Clean Energy Heating Systems. The Furnace is only approved for use with the CE-3 burner manufactured by Clean Energy Heating Systems. WARNING:...

  • Page 6: Furnace Assembly

    SAFETY CONSIDERATIONS AND GUIDELINES GUIDELINES FOR USED OIL TANKS: WARNING: To avoid serious injury or death, only store the following substances in the oil supply tank: (1) Used Crankcase Oil (2) Used Automatic Transmission Fluid (ATF) (3) Used Hydraulic Oil (4) #2 Fuel Oil (Diesel Fuel) DO NOT put flammable or corrosive substances such as gasoline, chlorinated solvents, paint thinner, or any other unsafe substance in the oil supply tank.

  • Page 7: Installing The Blower

    Figure 2: Blower Assembly Installation (CE-140, CE-180, and CE-250) Installing the Blower (CE-330): (1) Refer to Figure 2A.
  • Page 8 FURNACE ASSEMBLY (6) Install the blower pulley and motor pulley. Use a straight edge to make sure the pulleys are installed on the same plane. (7) Install the belt on the pulleys and tighten the tensioning bracket to maintain proper belt tension.

  • Page 9: Air Discharge Configuration

    FURNACE ASSEMBLY Air Discharge Configurations: Your Clean Energy Heating System may be installed in one of two ways: Unit Heater - Louvers are installed over the air outlet opening(s) to direct the hot air flow in the desired direction. Central Furnace (Static Pressure) - Duct work applications with less than 0.30”...
  • Page 10 FURNACE ASSEMBLY CE70041 Figure 4: Installing the Louvers Splitting the Air Outlet Openings Between Both Sides CE70042 Figure 5: Installing the Louvers Splitting the Air Outlet Openings Between one Side and Bottom...

  • Page 11: Central Furnace (Ductwork Installed)

    Only connect ductwork to the side air outlets on the furnace. DO NOT install ductwork on the bottom air outlet of the furnace. Refer to the tables below for air flow specifications. CE-140 Louvers Mounted on Furnace No Louvers Installed...

  • Page 12: Installing The Combustion Chamber Target

    FURNACE ASSEMBLY Installing the Combustion Chamber Target: NOTICE: Damage to the combustion chamber may occur if the furnace is used with a damaged or missing target. Inspect the target regularly for proper positioning and wear. (1) Refer to Figure 6 to view the proper position of the combustion chamber target. (2) Open the front door of the furnace by loosening the two over-center latches and swinging the door open.

  • Page 13: Installing The Burner

    FURNACE ASSEMBLY 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 7 for proper dimensions. (1) Remove the two serrated flange nuts from the front door. (2) Slide the blast tube of the burner through the throat of the front door.

  • Page 14: Installing The Connector Block And Oil Line

    FURNACE ASSEMBLY WARNING: To prevent the risk of electrical shock, shut OFF main power to the furnace before connecting or disconnecting the burner power cord. (4) Refer to Figure 8 (5) Line up the key in the receptacle with the slot in the cord.

  • Page 15: Furnace Installation

    FURNACE INSTALLATION Refer to Figure 10 for a typical furnace installation illustration. Installation of your furnace will include the following steps: (1) Selecting a location (2) Mounting the furnace in position (3) Connecting the electrical supply to the furnace (4) Installing the chimney components (5) Positioning the oil storage tank (6) Installing the metering pump system and oil lines (7) Connecting the compressed air line...

  • Page 16: Selecting A Location

    FURNACE INSTALLATION WARNING: Carefully follow all installation instructions for safe and efficient operation. Select a location: There are several considerations when selecting a location for your new furnace: (1) Do not obstruct shop personnel or equipment (2) Find a location where the warm air will be evenly distributed. (3) The installation must meet the clearance to combustible material requirements (Figure 11) (4) The location must be safely accessible for maintenance and service (5) The installation must comply with all local codes and regulations...

  • Page 17: Mounting The Furnace In Position

    FURNACE INSTALLATION Mounting the furnace in position: WARNING: Codes may require that the furnace is mounted eight (8) feet above the floor if there is potential for gasoline fumes. Refer to NFPA 88B, Standard for Repair Garages. WARNING: Use adequate structural members to safely bear the weight of the furnace when either hanging it from the ceiling or mounting it on a stand.

  • Page 18: Connecting The Electrical Supply

    ONLY a qualified electrician should run wire and make connections to the furnace. All wires must be the proper gauge and run in approved electrical conduit. All wiring must meet the requirements of the National Electrical Code. Electrical Requirements: CE-140 CE-180 120 V / 60 Hz 120 V / 60 Hz...

  • Page 19: Installing The Chimney Components

    (1) Install a dedicated electrical circuit to the junction box indicated below. - Front electrical box by the burner on the CE-140, CE-180, and CE-250 - Back electrical box by the blower on the CE-330 (2) Connect the wires according to the label found on the inside of the junction box cover or in the wire diagrams section of this manual.
  • Page 20 FURNACE INSTALLATION "CLASS A" STACK CAP NON-RESTRICTIVE TYPE 10 FT. BAROMETRIC DAMPER SET DRAFT OVER FIRE AT -0.02 IN. W.C. CE70022 Figure 14: Typical Through-the-Roof Chimney Illustration "CLASS A" STACK CAP NON-RESTRICTIVE TYPE 10 FT. SET DRAFT OVER FIRE AT -0.02 IN.

  • Page 21: Oil Storage Tank Setup

    FURNACE INSTALLATION Oil storage tank setup: PRESSURE OIL LINE TO THE FURNACE 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 22 FURNACE INSTALLATION PRESSURE OIL LINE TO THE FURNACE FILL BALL VALVE BALL VALVE USED FOR VACCUUM TEST BLEEDER VALVE VACUUM GAUGE SUCTION OIL CANISTER FILTER LINE TO TANK (1/2" COPPER TUBING) PRESSURE RELIEF RETURN OIL LINE TO THE TANK (1/4" COPPER TUBING) CE70025 Figure 17: Typical Metering Pump Installation (Standard Mounting on a Wall) (3) The metering pump system is a fixed displacement pump.
  • Page 23 FURNACE INSTALLATION PRESSURE OIL LINE TO THE FURNACE FILL BALL VALVE BALL VALVE USED FOR VACCUUM TEST BLEEDER VALVE VACUUM GAUGE SUCTION OIL CANISTER FILTER LINE TO TANK (1/2" COPPER TUBING) PRESSURE RELIEF RETURN OIL LINE TO THE TANK (1/4" COPPER TUBING) CE70014 Figure 18: Alternate Horizontal Metering Pump Mounting Installing the suction oil line:...
  • Page 24 FURNACE 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 25 FURNACE INSTALLATION Installing the pressure oil line to the furnace: (1) Refer to Figure 21 to view 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 furnace) and use the appropriate sized tubing.

  • Page 26: Connecting The Compressed Air Line

    FURNACE INSTALLATION OIL INLET PORT (1/4" NPT) CE70029 ALUMINUM CONNECTOR BLOCK Figure 22: Connecting the Pressure Oil Line to the Connector Block Connecting the Compressed Air Line: (1) Refer to Figure 23. (2) mount a water trap / air regulator (adjusted to 50 psi) and shut-off valve close to the furnace.

  • Page 27: Installing The Wall Thermostat

    FURNACE INSTALLATION Installing the wall thermostat: (1) Use the digital wall thermostat provided with the furnace. (2) Mount the wall thermostat according to the instructions provided with the thermostat. (2) Mount the thermostat on an interior wall and in a location that will be shielded from drastic temperature changes such as a door being opened.

  • Page 28: 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 furnace. (3) Allow the burner heater element sufficient time to warm up the burner (time will vary according to ambient temperature).

  • Page 29: 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 30: 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 31: 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..........1200 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 32 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 furnace.
  • Page 33 MAINTENANCE CE70037 Figure 30: Cleaning Ash From the Heat Exchanger...
  • Page 34 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 31: Flushing the Nozzle Adapter Heater Block...

  • Page 35: Furnace Dimensions

    FURNACE DIMENSIONS 76 7 8 CE-140 27 1 2 49 5 8 27 1 2 28 1 4 CE70057 CE-180 CE70001...
  • Page 36 FURNACE DIMENSIONS CE-250 CE70002 110 5 8 CE-330 28 7 8 73 5 8 28 7 8 32 3 4 CE70056...

  • Page 37: Wire Diagrams

    WIRE DIAGRAMS CE-140 AND CE-180 FURNACE CABINET WIRE DIAGRAM: CE-140 AND CE-180 BLOWER WIRE DIAGRAM: WHITE BLACK BLOWER MOTOR CAPACITOR BLACK WHITE TO FRONT JUNCTION BOX CE-180 75016...
  • Page 38 WIRE DIAGRAMS CE-250 FURNACE CABINET WIRE DIAGRAM: CE-250 BLOWER WIRE DIAGRAM: N.O. BLACK WHITE WHITE BLACK BLOWER BLUE MOTOR CAPACITOR TO FRONT JUNCTION BOX CE-250 75017...
  • Page 39 WIRE DIAGRAMS CE-330 FURNACE CABINET WIRE DIAGRAM: TO BACK CE-330 USE COPPER ELECTRICAL BOX CONDUCTORS ONLY BLACK WHITE ORANGE BURNER PUMP CONNECTOR CORD W/R HT DRAFT AUTO HIGH INDUCER SWITCH HIGH LIMIT (OPTIONAL) LIMIT 75033 CE-330 BLOWER WIRE DIAGRAM: CE-330 TO BLOWER 230 Volts MOTOR...
  • Page 40 WIRE DIAGRAMS CE-3 BURNER WIRE DIAGRAM (USED ON CE-140, CE-180, AND CE-250):...
  • Page 41 WIRE DIAGRAMS CE-4 BURNER WIRE DIAGRAM (USED ON CE-330):...

  • Page 42: Parts Diagrams

    CE-3 / CE-4 Burner Assembly CE70043...
  • Page 43 ITEM NO. PART NUMBER DESCRIPTION QTY. 30017 Burner Blower Motor 50015 Squirrel Cage - Burner 65001 Burner Housing 20034 Motor Mount Plate 50020 Igniter Burner Manifold Block 50019 Primary Control 20033 Front Motor Cover 65002 Ignitor Hinge Plate 30034 Amber Light 30033 Green Light 65006...
  • Page 44 Nozzle Adapter / Heater Block Assembly...
  • Page 45 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 46 CE - 3 Manifold Block Assembly CE70045...
  • Page 47 ITEM PART DESCRIPTION QTY. NUMBER 30010 Terminal Block - Burner 50021 Regulator- Surface Mount 50008 Burner Manifold Block 50062 Tube Fitting 1/8T x 1/8MP 50054 Air Pressure Switch 50022 Solenoid Air/Oil 115VAC 50067 Plug - Hex Socket 58030 Cap Screw Socket Head 8-32 x 5/8 Black 58035 Lock Washer #8 Z 58029...
  • Page 48 CE-4 Manifold Block Assembly CE70058...
  • Page 49 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 50 CE-140 Furnace Cabinet CE70053...
  • Page 51 ITEM NO. PART NUMBER DESCRIPTION QTY. 65020 Heat Exchanger CE 140 WA. 20144 Shrouding RH Side CE 140 20146 Shroud Top CE 140 20077 6" Shroud. Ring 20075 Front Door Hinge 20086 Top Switch Cover 20009 Electrical Box 20010 Electrical Box Lid 20080 Observation Port Lid 20100...
  • Page 52 CE-180 Furnace Cabinet CE70046...
  • Page 53 PART ITEM NO. QTY. NUMBER 65015 Heat Exchanger Weld Assembly CE180 20072 Right Side Shrouding 20073 Left Side Shrouding 50010 Hinge - Observation Port 20075 Front Door Hinge 20080 Observation Port Lid 20085 Angle Blower Mount (CE 180) 20084 Rear Shrouding 20009 Electrical Box 20010...
  • Page 54 CE-140/180 Blower CE70047...
  • Page 55 ITEM PART DESCRIPTION QTY. NUMBER 50013 Blower CE180 65013 Blower Mtr Bracket (3/4 HP Motor) 30005 Motor 3/4 HP. 30012 Capacitor 15 MFD 370V 30018 Boot Capacitor 50018 Blower Guard...
  • Page 56 CE-250 Furnace Cabinet CE70048...
  • Page 57 ITEM NO. PART NUMBER DESCRIPTION QTY. 65016 Heat Exchanger Weld Assembly CE 250 20090 CE250 Rt. Side Shroud. 20080 Observation Port Lid 20075 Front Door Hinge 50010 Hinge - Observation Port 20091 CE250 Left Side Shroud 50011 Insulation - Front Door 20095 Blower Mount 20086...
  • Page 58 CE-250 Blower CE70049...
  • Page 59 ITEM PART DESCRIPTION QTY. NUMBER 50002 Blower CE250 30004 Motor 1HP 30013 Capacitor 20 MFD 370V 30018 Boot Capacitor 50018 Blower Guard 65014 Blower Mtr Backet (1 HP)
  • Page 60 CE-330 Furnace Cabinet CE70052...
  • Page 61 Item No. Part Number Description Qty. 65019 Heat Exchanger Weld Assembly CE 330 20119 Air Sweep Right Side CE 330 20120 Air Sweep Left Side CE 330 20121 Air Sweep CE 330 20122 Shroud RH (CE 330) 20123 Shroud LH (CE 330) 20124 Shroud Top (CE 330) 20125...
  • Page 62 CE330 Blower CE70054...
  • Page 63 ITEM NO. PART NUMBER DESCRIPTION QTY. 50126 CE330 Blower Housing 20132 Blower Motor Mount CE330 20133 Tensioner Brace 30060 CE330 Blower Motor 50130 CE330 Blower Motor Bushing - 7/8" 50128 CE330 Blower Motor Pulley 50127 CE330 Blower Pulley 50129 CE330 Blower Wheel Bushing - 1" 50131 CE330 Blower Drive Belt 50123...
  • Page 64 Metering Pump Assembly CE70050...
  • Page 65 ITEM NO. PART NUMBER DESCRIPTION QTY. 50030 Bushing 3/4 x 1/4 NPT 50031 Bushing 3/4 x 1/2 NPT 50037 TEE 1/2F x 1/2F x 1/2M 50053 Ball Valve 1/2 NPT 50038 Plug 1/2 NPT Hex 40002 Metering Pump (A2RA-7710) 50026 ST EL 90°...

  • Page 66: 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 1200 HOURS CLEAN THE NOZZLE ADAPTER HEATER BLOCK 2000 TO 3000 HOURS CLEAN OIL CLEAN CLEAN ASH FROM DRAIN OIL CLEAN THE CANISTER...

  • Page 67: 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 68 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.

This manual is also suitable for:

Ce-180Ce-250Ce-330

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