Cleanburn CB-200-CTB User manual

PUBLICATION DATE: 5/3/10, Rev. 7 CLEAN BURN PART #43186
OPERATOR'S MANUAL
WARNING: DO NOT assemble, install, operate, or maintain this equipment without first
reading and understanding the information provided in this manual. Installation and
service must be accomplished by qualified personnel. Failure to follow all safety precautions
and procedures as stated in this manual may result in property damage, serious personal injury
or death.
Copyright © 2010 Clean Burn, Inc. All rights reserved. No part of this publication may be reproduced, or distributed
withoutthepriorwrittenpermissionofCleanBurn,Inc. 34ZimmermanRoad,Leola,PA 17540,U.S.A. Subjecttochange
without notice. The Clean Burn logo is a trademark of Clean Burn, Inc. All other brand or product names mentioned are the
registered trademarks or trademarks of their respective owners.
I88729−B
230 V / 50 Hz
CLEAN BURN COIL TUBE BOILER MODELS:
CB-200-CTB COIL TUBE BOILER with CB-500-5W Burner & Metering Pump
CB-350-CTB COIL TUBE BOILER with CB-551-5W Burner & Metering Pump
CB-500-CTB COIL TUBE BOILER with CB-551-H5-5W Burner & Metering Pump

DECLARATIONOFCONFORMITY
Manufacturer: CleanBurnInc.
34ZimmermanRd.
Leola,PA
USA
EuropeanRepresentative: TUVRheinlandNorthAmerica
12CommerceRd.
NewtownCT.06470
USA
Equipment: CTB-350 #90192
CTB-200 #90201
CTB-500 #90227
EMCCompetentBody: TÜVRheinlandProductSafetyGmbH
AmGrauenstein
D-51105Köln
IherebydeclarethattheabovenamedmachinerycomplieswithEssentialHealthandSafetyRequirementsof
theIndustrialMachineryDirective(IMD-98/37/EEC)asamended,withtheLowVoltageDirective(LVD–
73/23/EEC)asamended,andwiththeElectromagneticCompatibilityDirective(EMC–89/336/EEC)as
amended.
SafetyStandard:
EN 230: 1990 MonoblocOilBurners–Safety,Control,andRegulationDevicesandSafetyTimes.
EN292-1:1991 Safetyofmachinery-Basicconcepts,generalprinciplesfordesign-Part1:Basic
terminology,methodology.
EN292-2:1991+A1 Safetyofmachinery-Basicconcepts,generalprinciplesfordesign-Part2:Technical
principlesandspecifications
EN60204-1:2000 Safetyofmachinery.Electricalequipmentofmachines.Generalrequirements.
EMCStandards:
EN 55014-1: 2000 ElectromagneticCompatibility–RequirementsforHouseholdAppliances,Electric
Tools,andSimilarApparatus.Part1:Emission.
EN 55014-2: 2000 ElectromagneticCompatibility–RequirementsforHouseholdAppliances,Electric
Tools,andSimilarApparatus.Part2:Immunity.
EN 50165: 1997 ElectricalEquipmentofNon-ElectricAppliancesforHouseholdandSimilarPurposes.
SafetyRequirements.
Note: AboveequipmentissubjecttoanEMCTechnicalConstructionFileandCompetentBodyCertificate
NumberAV 720325540001.
________________________
3 May, 2010 Ryan D. Gamber
EngineeringManager

TABLE OF CONTENTS
SECTION 1: INTRODUCTION.................................................................................... 1-1
Guide to this Manual........................................................................................................1-1
For Your Safety... .............................................................................................................1-2
Guidelines for CTB Usage ........................................................................................1-4
Guidelines for Used Oil Tanks.................................................................................. 1-5
Safety Labels .............................................................................................................1-6
SECTION 2: UNPACKING & PRE-INSTALLATION CONSIDERATIONS................. 2-1
Removing the Shipping Crate ..........................................................................................2-1
Unpacking and Inspection................................................................................................ 2-1
CTB ComponentList .................................................................................................2-1
Pre-InstallationConsiderations ...........................................................................................2-2
DeterminingtheCTBSystemSetup .............................................................................2-2
SelectingaLocation ....................................................................................................2-2
SECTION 3: COIL TUBE BOILER ASSEMBLY ........................................................ 3-1
UnderstandingAssembly ....................................................................................................3-1
CTB(SingleBoiler)Assembly ............................................................................................3-2
InstallingtheCTBontheSupportStand.......................................................................3-4
Dual-StackedBoilerAssembly ...........................................................................................3-5
AssemblingtheDual-StackedBoiler ............................................................................3-5
AssemblyforAllBoilers .....................................................................................................3-8
ConnectingtheCTB ....................................................................................................3-8
InstallingtheCeramicSleeve........................................................................................3-9
CheckingtheBurnerNozzleandElectrodes ...............................................................3-11
MountingtheBurnerontheHingeBracket .................................................................3-12
InstallingtheConnectorBlock ...................................................................................3-12
InstallingtheOilLineTubing ......................................................................................3-13
InstallingtheAirLineTubing ......................................................................................3-14
LockingtheBurnerintoFiringPosition .......................................................................3-14
SECTION 4: COIL TUBE BOILER INSTALLATION .................................................. 4-1
UnderstandingInstallation ...................................................................................................4-1
ImportantSafetyGuidelines .........................................................................................4-1
TypicalInstallationDiagrams........................................................................................4-3
CombustionAirRequirements .....................................................................................4-5
OilTankInstallationSpecifications......................................................................................4-7
InstallingtheTankVentandEmergencyVent ...............................................................4-8
InstallingtheMeteringPump ...............................................................................................4-9
PreparingforInstallation ..............................................................................................4-9
StandardMounting:VerticalPositioning .......................................................................4-9
AlternateMounting:HorizontalPositioning .................................................................4-11
ConnectingWatertotheCoilTubeBoiler.........................................................................4-12
FillingtheCTBwithWater ........................................................................................4-12
InstallingtheSuctionOilLineComponents........................................................................4-13
InstallingthePressureReliefOilLineBacktotheTank .....................................................4-16

SECTION 4: CTB INSTALLATION (continued) .............................................................
InstallingthePressureOilLineComponents ......................................................................4-17
InstallingtheCompressedAirLine....................................................................................4-17
WiringtheCoilTubeBoiler ..............................................................................................4-18
WiringtotheCTB .....................................................................................................4-18
WiringtotheMeteringPump .....................................................................................4-19
WiringtheLoadLoopCirculator ...............................................................................4-19
InstallingtheStack ...........................................................................................................4-20
InstallingtheInteriorStack.........................................................................................4-22
InstallingtheBarometricDamper ...............................................................................4-23
InstallingtheOptionalStackSafetySwitch .................................................................4-24
ResettingtheStackSafetySwitch ........................................................................4-25
UnderstandingthefunctionoftheStackSafetySwitch ..........................................4-25
InstallingtheStackPenetration...................................................................................4-26
InstallingtheExteriorStack........................................................................................4-26
InstallingtheStackCap .............................................................................................4-26
InstallingtheDraftInducer .........................................................................................4-26
InstallingtheWallThermostatorAquastat ........................................................................4-28
ReplacingtheWallThermostatBatteries ....................................................................4-28
InspectingtheCTBInstallation .........................................................................................4-29
SECTION 5: METERING PUMP PRIMING ................................................................5-1
Understanding Metering Pump Priming .......................................................................... 5-1
RequiredToolsandMaterials ......................................................................................5-1
PrimingtheMeteringPump.................................................................................................5-2
VacuumTestingtheOilPump.............................................................................................5-4
SECTION 6: STARTING AND ADJUSTING THE BURNER ......................................6-1
Understanding Burner Startup and Adjustment ............................................................... 6-1
Preparing the Hydronics System for Burner Startup ........................................................6-1
Preparing the Burner for Startup ......................................................................................6-1
Starting the Burner ........................................................................................................... 6-3
SECTION 7: RESETTING THE OIL PRIMARY CONTROL .......................................7-1
UnderstandingtheDanfossOilPrimaryControl ..................................................................7-1
ResettingtheDanfossOilPrimaryControl ..........................................................................7-1
SECTION 8: ADJUSTING THE DRAFT OVER FIRE ................................................8-1
UnderstandingtheImportanceofDraft ...............................................................................8-1
CheckingforCorrectDraftOverFire .................................................................................8-1
UnderstandingtheEffectofExhaustFansonDraft .......................................................8-2
CheckingDraftOverFiretoDetermineSeverityofBackdraft ......................................8-2
AdjustingDraftOverFirewithaDraftInducerInstalled ...............................................8-3
TABLE OF CONTENTS

TABLE OF CONTENTS
SECTION 9: MAINTENANCE ....................................................................................9-1
UnderstandingMaintenance................................................................................................9-1
AnnualPreventativeMaintenance&BurnerTune-up ..........................................................9-1
CleaningtheCanisterFilter .................................................................................................9-2
ServicingtheMeteringPump ..............................................................................................9-3
CleaningtheCheckValve/Screen .....................................................................................9-4
CleaningAshfromtheCTB................................................................................................9-5
CleaningtheOilTank .........................................................................................................9-6
EndofSeasonMaintenance ...............................................................................................9-6
SECTION 10: THE CTB HYDRONIC SYSTEM .......................................................10-1
UnderstandingtheCTBHydronicSystem .........................................................................10-1
SpecialSafetyGuidelines ...........................................................................................10-1
CTBSystemFunctionandConfiguration....................................................................10-2
CTBSetupOptions...................................................................................................10-4
GuidelinesforCTBSetupandOperation ..........................................................................10-7
GuidelinesforPreventingOxygenContamination ........................................................10-8
GuidelinesforInitialCleaningandMaintainingWaterQuality ......................................10-8
GuidelinesforCTBOperation ...................................................................................10-8
SECTION 11: TROUBLESHOOTING ......................................................................11-1
CTBSequenceofOperation ............................................................................................11-1
FlowChart ......................................................................................................................11-2
TroubleshootingTables ....................................................................................................11-3
APPENDIX A
DetailedCTBSpecifications .............................................................................................. A-1
CTBTechnicalSpecifications ..................................................................................... A-1
BurnerTechnicalSpecifications................................................................................... A-2
CTBHydronicSpecifications...................................................................................... A-2
CTBAccessoriesandPartsReference........................................................................ A-3
CB-200-CTBDimensions .......................................................................................... A-5
CB-350-CTBDimensions .......................................................................................... A-6
CB-350-CTBDualStackedBoilerDimensions .......................................................... A-7
CB-500-CTBDimensions .......................................................................................... A-8
CB-500-CTBDualStackedBoilerDimensions .......................................................... A-9
BurnerComponents ........................................................................................................ A-10
CB-500-CE5WSeriesBurnerComponents ............................................................ A-10
CB-500-CE5WandCB-551-CE5WPreheaterBlockAssemblyDetail ................. A-12
CB-551-H5CE5WPreheaterBlockAssemblyDetail ............................................. A-14
BurnerElectrodeSpecifications ................................................................................ A-16
RemovingtheNozzleforCleaning............................................................................. A-17
CB-200-CTBComponents............................................................................................. A-18
CB-350-CTBComponents............................................................................................. A-20
CB-500-CTBComponents............................................................................................. A-22

APPENDIX B
WiringDiagrams ............................................................................................................... B-1
BurnerWiringDiagram(CB-500-CE5WandCB-551-CE5W) ................................ B-1
BurnerWiringDiagram(CB-551-H5CE5W)............................................................ B-2
ControlBoxWiringDiagram ...................................................................................... B-3
MeteringPumpWiringSchematic ............................................................................... B-4
CTBLadderSchematic..................................................................................................... B-5
APPENDIX C
AdditionalInstallationandMaintenanceRequirements(UnitedKingdomONLY) ............... C-1
APPENDIX D
CTBServiceRecord......................................................................................................... D-1
TABLE OF CONTENTS

CoilTubeBoilerOperator'sManual: ModelsCB-200-CTB,CB-350-CTBandCB-500-CTB(230V/50Hz)
1-1
SECTION 1: INTRODUCTION
Guide to this Manual
This manual contains all the information necessary to safely install and operate the Clean Burn Coil
TubeBoilers(CTB),ModelsCB-200-CTB,CB-350-CTB,andCB-500-CTB. ConsulttheTableof
Contentsforadetailedlistoftopicscovered. You'llfindthismanual'sstep-by-stepprocedureseasytofollow
andunderstand. Shouldquestionsarise,pleasecontactyourCleanBurndealerbeforestartinganyofthe
proceduresinthismanual.
As you follow the directions in this manual, you'll discover that assembling and operating the Clean
Burn CTB involves six basic activities as outlined here:
•UNPACKING & PRE-INSTALLATION CONSIDERATIONS ............................ (Section 2)
•ASSEMBLY....................................................................................................... (Section 3)
•INSTALLATION ................................................................................................ (Section 4)
• OPERATION
•Oil Pump Priming ................................................................................ (Section 5)
•Starting and Adjusting the Burner..................................................... (Section 6)
• Resetting the Oil Primary Control...................................................... (Section 7)
• Adjusting the Draft .............................................................................. (Section 8)
• MAINTENANCE ................................................................................................ (Section 9)
• THE CTB HYDRONICS SYSTEM.....................................................................(Section 10)
WARNING!
STOP
YOUR SAFETY IS AT STAKE!
DO NOT INSTALL, OPERATE OR
MAINTAIN THIS EQUIPMENT
WITHOUT FIRST READING
AND UNDERSTANDING THE
OPERATOR'SMANUAL!
Themanualalsocontainsimportantanddetailedtechnical
referencematerialswhicharelocatedatthebackofthemanual
intheAppendixes.
Please read all sections carefully--including the following
safety information--before beginning any installation/
operation procedures; doing so ensures your safety and the
optimal performance of your Clean Burn Coil Tube
Boiler.

CoilTubeBoilerOperator'sManual: ModelsCB-200-CTB,CB-350-CTBandCB-500-CTB(230V/50Hz)
1-2
For Your Safety...
For your safety, Clean Burn documentation contains the following types of safety statements (listed here
in order of increasing intensity):
•NOTE: A clarification of previous information or additional pertinent information.
•ATTENTION: A safety statement indicating that potential equipment damage may occur if
instructions are not followed.
CAUTION: A safety statement that reminds of safety practices or directs attention to unsafe
practices which could result in personal injury if proper precautions are not taken.
WARNING: A strong safetystatement indicating that a hazard exists which can result in
injury or death if proper precautions are not taken.
DANGER! The utmost levels of safety must be observed; an extreme hazard exists which
would result in high probability of death or irreparable serious personal injury if proper
precautions are not taken.
In addition to observing the specific precautions listed throughout the manual, the following general
precautions apply and must be heeded to ensure proper, safe boiler operation.
DANGER! DO NOT create a fire or explosion hazard by storing or using gasoline or other
flammable or explosive liquids or vapors near your boiler.
DANGER! DO NOT operate your CTB if excess oil, oil vapor or fumes have
accumulated in or near your boiler. As with any oil burning appliance, improper installation,
operation or maintenance may result in a fire or explosion hazard.
WARNING: DO NOT add inappropriate or hazardous materials to your used oil, such as:
• Anti-freeze
• Carburetor cleaner
• Paint thinner
• Parts washer solvents
• Gasoline
• Oil additives
• Any other inappropriate/hazardous
material
WARNING: Burning chlorinated materials (chlorinated solvents and oils) is illegal, will
severely damage your heat exchanger, immediately void your warranty, and adversely affect
the proper, safe operation of your CTB. Instruct your personnel to never add hazardous
materials to your used oil.

CoilTubeBoilerOperator'sManual: ModelsCB-200-CTB,CB-350-CTBandCB-500-CTB(230V/50Hz)
1-3
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.
WARNING: The burner which is shipped with your Clean Burn CTB is to be used only
with your boiler according to the instructions provided in this manual. DO NOT use the
burnerforanyotherpurpose!
WARNING:ForthesafeinstallationandoperationoftheCTB,theboilercannotberaised
abovethefloorlevel,suspendedfromtheceiling,installedonaraisedplatform,orplacedovertop
ofanyequipment,officespace,partsroom,etc.orinstalledinanyothermannerthandirectlyona
concretefloor.
WARNING: Electricalinstallationoftheboileristobeperformedonlybyqualified
personnel(i.e.licensedelectrician/engineer). Improperelectricalinstallationcanadversely
affecttheproper,safeoperationoftheboilerandmaycauseseriouspersonalinjury/death.
WARNING: Installtheboilerinanareaawayfromthemainshoptraffic. Itisessentialfor
personal safety that only manufacturer-trained, qualified personnel have access to operate
and maintain the boiler.
WARNING: DONOToperateyourboilerwhentheambienttemperatureisabove
35o C(95oF).
WARNING: The Best Operator is a Careful Operator! By using common sense,
observinggeneralsafetyrules,andadheringtotheprecautionsspecifictotheequipment,you,
theoperator,can promotesafeequipmentoperation. Failuretousecommonsense,observe
general safety rules, and adhere to the precautions specific to the equipment may result in
equipment damage, fire, explosion, personal injury and/or death.
WARNING: Theinstallation,operation,andmaintenanceofthisequipmentmustbe
accomplishedbyqualifiedpersonnelandincompliancewiththespecificationsinthe
CleanBurnOperator'sManualandwithallnational,state,andlocalcodesorauthorities
havingjurisdictionoverenvironmentalcontrol,buildinginspectionandfuel,fireand
electricalsafety.
Failure to comply with these standards and requirements may result in equipment
damage, fire, explosion, personal injury and/or death.

CoilTubeBoilerOperator'sManual: ModelsCB-200-CTB,CB-350-CTBandCB-500-CTB(230V/50Hz)
1-4
Guidelines for Coil Tube Boiler Usage
• This boiler is listed for commercial and/or industrial use only; it is not listed for residential
use.
• Thisboilerisdesignedtoburnthefollowingfuels:
• Used crankcase oil up to 50 SAE
• Usedtransmissionfluid
• Usedhydraulicoils
• #2, #4, and #5 fuel oils
NOTE: Used oils may contain other substances, including gasoline, that may hinder
performance.
• Makesureyoucomplywithallenvironmentalregulationsconcerningtheuseofyourboiler.
Theseregulationsrequirethat:
• Your used oil is generated on-site. You may also accept used oil from
"do-it-yourself" oil changers.
• Hazardous wastes, such as chlorinated solvents, are NOT to be mixed with your
used oil.
• The flue gases are vented to the outdoors with an appropriate stack.
• Your used oil is recycled as fuel for "heat recovery". DO NOT operate your boiler
in warm weather just to burn oil.
ContactyourCleanBurndealerforcurrentenvironmentalregulations.
• If your CTB ever requires service, call your Clean Burn dealer. DO NOT allow untrained,
unauthorized personnel to service your CTB. Make sure that your boiler receives annual
preventative maintenance to ensure optimal performance.
For Your Safety... (continued)

CoilTubeBoilerOperator'sManual: ModelsCB-200-CTB,CB-350-CTBandCB-500-CTB(230V/50Hz)
1-5
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,
ensure that your tank installation adheres to the
following safety guidelines:
•The tank installation must meet all
national and local codes. Consult your
local municipal authorities for more
information as necessary.
•Review and adhere to the safety
guidelines for used oil supply tanks
as stated in the WARNING shown.
• Ensure that the tank for your boiler
installation complies with all code and
safety requirements as stated here. If the
tank does not comply, DO NOT use it.
• If you do not have a copy of the tank
safety label pictured at right, please
contact your Clean Burn dealer for the
label, which is to be affixed directly on
your used oil supply tank.

CoilTubeBoilerOperator'sManual: ModelsCB-200-CTB,CB-350-CTBandCB-500-CTB(230V/50Hz)
1-6
For Your Safety... (continued)
Safety Labels
Following are the locations and descriptions of all labels on your CTB. The following illustrations show
the location of ALL labels on your boiler. Please note that some labels denote model number, model
description, etc. while others contain important safety messages.
Each Safety Label contains an important safety message starting with a key word as discussed earlier in
this section (e.g. ATTENTION, CAUTION, WARNING, DANGER). For your safety and the safe
operation of your 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
Burndealerforfreereplacements.
Label Part # Description
CTB Cabinet Labels
42367
DATE
42457
OIL
AIR
I88785−B
CODE
42503
42306
42308
42481
42367 C.B.SafetyWarningLabel(multiplemessages-fire/shock/burnhazards)
42457 MadeinUSA/PatentPendingLabel
42027 BurnHazard/HazardousVoltageWarningLabel
42308 Header Label
42481 CB-200-CTBCEDataLabel
42306 CB-350-CTBCEDataLabel
42503 CB-500-CTBCEDataLabel
42030 ElectricalShockHazardWarningLabel
42421 CTBHotWaterCautionLabel
42216 C.B.Logo Label- 22cm x 11 cm (8.75"x 4.25")
42297 C.B.Logo Label- 51cm x 20 cm (20"x 8")
42465 CB-200-CTBModel#Label
42286 CB-350-CTBModel#Label
42502 CB-500-CTBModel#Label

CoilTubeBoilerOperator'sManual: ModelsCB-200-CTB,CB-350-CTBandCB-500-CTB(230V/50Hz)
1-7
CTB Cabinet Safety Labels
CTB Cabinet Labels (continued)
42421
Burn Hazard.
Fittings, piping, and
boiler surface may be
extremely hot.
Pipes contain hot water.
Do NOT touch without
wearing protective
gloves.
42497
CB *** CTB
www.cleanburn.com
42286
42216
42286
42465
42216
42502

CoilTubeBoilerOperator'sManual: ModelsCB-200-CTB,CB-350-CTBandCB-500-CTB(230V/50Hz)
1-8
For Your Safety... (continued)
CTB Cabinet Safety Labels (continued)
FOR COMMERCIAL OR INDUSTRIAL USE ONLY.
MULTI−OIL HEATING SYSTEM
NO.
42308
7616122
INPUT RATING W/NO 2 FUEL OIL (KW/HR)
46
CTB−200−CE
3.8 14
58.6
46
−.06 (1.5MM)
16
MAXIMUM FUSE SIZE / WITH OPTIONS
230
230
230
POWER
1/10
1/20
400
SIDE
HZ
.56
.40
1.65
50
50
50
230
1/3
15/20
1.8
6
50
42481
1/6 230 1.10 50
3.8
3.8
3.8
3.8
3.8
14 2.7
14
18
18
18 4.0
4.0
3.4
2.5
2.5
220 1.5 50
1.24
1.24
1.24
.96
.96
.96
.23
.28
.28
.17
.19
.17
FOR COMMERCIAL OR INDUSTRIAL USE ONLY.
1/10 230 .56 50

CoilTubeBoilerOperator'sManual: ModelsCB-200-CTB,CB-350-CTBandCB-500-CTB(230V/50Hz)
1-9
CTB Cabinet Safety Labels (continued)
7616
122
INPUT RATING W/NO 2 FUEL OIL (KW/HR)
46
CTB−500−CE
46
−.06 (1.5mm)
16
MAXIMUM FUSE SIZE / WITH OPTIONS
230
230
230
POWER
1/10
1/20
500
SIDE
HZ
50
50
50
230
1/2 50
42503
1/2 230 50
230
FOR COMMERCIAL OR INDUSTRIAL USE ONLY.
13.5
13.5
13.5
13.5
13.5
13.5
147.0
16
20
16
16
16
22
1.1
1.4
1.1
1.1
1.1
1.5
2.5
2.3
2.5
2.5
2.5
2.1
0.17
0.16
0.17
0.17
0.17
0.15
1/4
2.7
3.0
0.70
1.9
0.40
1.3 50
10.0
20.0

CoilTubeBoilerOperator'sManual: ModelsCB-200-CTB,CB-350-CTBandCB-500-CTB(230V/50Hz)
1-10
For Your Safety... (continued)
CTB Burner Labels
Label
Part # Description
CTB BurnerSafety Labels
42004 BurnerSafetyWarningLabel(HighVoltage/MovingPartsHazard)
42235 BurnerSafetyWarningLabel(Fire/ExplosionHazard-BurnerInstallationandService)
42470 CB-500-CE-5WBurnerModel/SerialNumber
42483 CB-551-CEBurnerModel/SerialNumber
42508 CB-551-H5-CEBurnerModel/SerialNumber
42229 C.B.Logo/BurnerDescriptionLabel
42482 BurnerSafetyWarningLabel(Fire/ExplosionHazard-ResetButton)
42309 CEMarkLabel
42023 BurnerPowerLabel
I88854−B
42470
42483
42508

CoilTubeBoilerOperator'sManual: ModelsCB-200-CTB,CB-350-CTBandCB-500-CTB(230V/50Hz)
2-1
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). Keep all components together so you will have them as needed for CTB assembly and
installation.
Model CB-200-CTB, CB-350-CTB and CB-500-CTB Component List
• Coil Tube Boiler with factory-installed controls
(including operating aquastat, high temperature cut-off, flow switch, relief valve, and check valve)
Components packed inside boiler:
• Ceramiccombustionchambersleeve
• Combustionchambersleevemountingstand
• Ceramic target (pre-mounted)
• Canister filter
• Vacuum gauge
• Check valve with screen (for tank)
• Boilergauge
• Tubesealant
• Burner hook-up kit
• Barometricdamper
• Burner
• Oilpump(meteringpump)
• CTBbasestandwithhardware
• DraftInducer
Before assembling your coil tube boiler (CTB) , you must accomplish the following activities described
in this section:
• Removing the Shipping Crate
• Unpacking and Inspecting All Components
• Warranty Registration
• Review the Pre-Installation Considerations
Removing the Shipping Crate
1. Carefully remove the top boards of the shipping crate. Then remove the front, back, and side
panels.
2. Remove the bolts holding the boiler on the shipping pallet.
3. Carefully lift the CTB off the shipping pallet with a fork lift.
ATTENTION: DO NOT attempt to slide the CTB out of the shipping crate--you may damage the
cabinet.

CoilTubeBoilerOperator'sManual: ModelsCB-200-CTB,CB-350-CTBandCB-500-CTB(230V/50Hz)
2-2
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.
Determining the CTB System Setup
Before installing the CTB, you must determine the following which relate to your installation:
(1) Thetypeofoilstoragetankyouwillbeusing(relatedinformationinSection4)**
(2) The positioning of your oil pump (related information in Section 4)
(3) The appropriate size for your oil lines (related information in Section 4)
(4) The electrical requirements for your CTB installation (related information in Section 4)
(5) The type of hydronic installation you will be using (related information in Section 10)
**IMPORTANT NOTE: If you are installing an inside oil tank in the same room as the boiler, you
mustallowa1.5m(5ft)minimumclearancebetweenthetankandtheboiler. Theoiltankshouldbesetand
installed in position BEFORE the boiler is installed.
Selecting a Location
The location you select for your CTB must allow the following:
• Installation in a dedicated boiler/mechanical room with a minimum fire rating of two (2)
hours.
• Installationonasubstantial,level,non-combustibleconcretefloor(minimum10cm/4"thick).
• Proper clearances from combustibles. Verify according to your local safety codes.
• Safe, easy access for servicing.
• Adequatecombustionairpernationalandlocalcodes.
• Proper stack installation and materials.
WARNING: For the safe installation and operation of the CTB, the boiler cannot be raised
above the floor level, suspended from the ceiling, installed on a raised platform, or placed over
top of any equipment, office space, parts room, etc. or installed in any other manner than directly on a
concrete floor.