Cleanburn CB-3500 series User manual

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.
CLEAN BURN MULTI-OIL FURNACE MODELS:
CB-3500 and CB-5000 with CB-500 Series BURNER
PUBLICATION DATE: 2/15/07, Rev. 10 CLEAN BURN PART #43143
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.
Copyright © 2007 Clean Burn, Inc. All rights reserved. No part of this publication may be reproduced, or distributed without
thepriorwrittenpermissionofCleanBurn,Inc. 34ZimmermanRoad,Leola,PA 17540. Subjecttochangewithoutnotice.
CLEAN BURN, INC. • 34 Zimmerman Road • Leola, PA 17540 • U.S.A.
Danfoss
ts10s
220-24050-60Hz3W
TypeBHO64
Nr.057H7036
FOR YOUR SAFETY −
DO NOT STORE GASOLINE
OR OTHER FLAMMABLE VAPORS AND LIQUIDS
IN THE VICINITY OF THIS OR ANY APPLIANCE!!
I88911
230 V / 50 Hz

TABLE OF CONTENTS
SECTION 1: INTRODUCTION ................................................................................... 1-1
GuidetothisManual ..........................................................................................................1-1
ForYourSafety... ..............................................................................................................1-2
GuidelinesforFurnaceUsage ......................................................................................1-4
GuidelinesforUsedOilTanks .....................................................................................1-5
SafetyLabels ..............................................................................................................1-6
SECTION 2: UNPACKING ......................................................................................... 2-1
Removing the Shipping Crate ..........................................................................................2-1
Unpacking and Inspecting All Components.....................................................................2-1
Furnace Component List ...........................................................................................2-1
UnpackingItemsPackedInsidetheFurnace ................................................................2-2
SECTION 3: FURNACE ASSEMBLY......................................................................... 3-1
Understanding Assembly .................................................................................................3-1
Required Tools and Materials ...................................................................................3-1
InstallingtheBlowerComponents .......................................................................................3-4
InstallingtheBlower(CB-5000ONLY) ......................................................................3-4
InstallingtheMotorontheBlower ...............................................................................3-4
WiringtheBlowerMotor.............................................................................................3-4
InstallingtheMotorPulley,BlowerPulley,andV-Belt ..................................................3-6
InstallingtheBeltGuardandtheBlowerGuard ............................................................3-7
InstallingtheHotAirDischargeComponents ......................................................................3-8
DeterminingtheAirDischargeConfiguration ................................................................3-8
UNITHEATERS: InstallingtheAirDischargeLouverAssembly .................................3-9
CENTRALFURNACES: InstallingDuctwork..........................................................3-10
InstallingtheCeramicTarget.............................................................................................3-10
InstallingtheTargetontheCombustionChamber .......................................................3-10
ClosingtheFurnaceDoor ..........................................................................................3-10
InstallingtheBurner ..........................................................................................................3-11
CheckingtheBurnerNozzleandElectrodes ...............................................................3-11
MountingtheBurnerontheHingeBracket .................................................................3-12
InstallingtheConnectorBlock,OilLineTubing,andAirLineTubing .................................3-13
InstallingtheConnectorBlockontheFurnaceDoor ...................................................3-13
InstallingtheOilLineTubing ......................................................................................3-13
InstallingtheAirLineTubing ......................................................................................3-14
LockingtheBurnerintoFiringPosition .......................................................................3-15
InstallingtheMountingandStabilizerBrackets ..................................................................3-15
InstallingtheBracketsontheFurnaceCabinet............................................................3-15

TABLE OF CONTENTS
SECTION 4: FURNACE INSTALLATION .................................................................. 4-1
UnderstandingInstallation ...................................................................................................4-1
ImportantSafetyGuidelinesforSafeInstallation ...........................................................4-1
ImportantNotestotheElectrician ................................................................................4-2
SelectingaLocation ...........................................................................................................4-4
GuidelinesforSelectingaLocation...............................................................................4-4
MountingtheFurnace.........................................................................................................4-5
CeilingMounting .........................................................................................................4-5
RaisedPlatformMounting............................................................................................4-6
FloorMounting ...........................................................................................................4-6
OilTankInstallationSpecifications ......................................................................................4-8
InstallingtheTankVentandEmergencyVent ...............................................................4-9
InstallingtheMeteringPump .............................................................................................4-10
PreparingforInstallation ............................................................................................4-10
StandardMounting:VerticalPositioning .....................................................................4-10
AlternateMounting:HorizontalPositioning .................................................................4-12
WiringtheFurnaceandPump...........................................................................................4-13
WiringtotheFurnace ................................................................................................4-13
WiringtotheMeteringPump .....................................................................................4-13
InstallingtheSuctionOilLineComponents........................................................................4-14
InstallingthePressureReliefandLow-FlowCheckValve .................................................4-17
InstallingthePressureOilLineComponents ......................................................................4-18
InstallingtheCompressedAirLine....................................................................................4-18
InstallingtheStack ...........................................................................................................4-19
InstallingtheInteriorStack.........................................................................................4-20
InstallingtheBarometricDamper ...............................................................................4-22
InstallingtheStackPenetration...................................................................................4-23
InstallingtheExteriorStack........................................................................................4-23
InstallingtheStackCap .............................................................................................4-23
InstallingtheDraftInducer .........................................................................................4-23
InstallingtheWallThermostat ...........................................................................................4-25
InspectingtheFurnaceInstallation.....................................................................................4-25
SECTION 5: METERING PUMP PRIMING ................................................................5-1
UnderstandingMeteringPumpPriming ...............................................................................5-1
RequiredToolsandMaterials ......................................................................................5-1
PreparingtheBurnerforUsewiththeMeteringPump .........................................................5-2
PrimingtheMeteringPump.................................................................................................5-4
VacuumTestingtheOilPump.............................................................................................5-6
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
CheckingtheOperationoftheBlowerMotor .....................................................................6-5

TABLE OF CONTENTS
SECTION 7: RESETTING THE FURNACE AND BURNER......................................7-1
UnderstandingFurnace/BurnerShutdowns..........................................................................7-1
TheOilPrimaryControl .....................................................................................................7-1
ResettingtheOilPrimaryControl .................................................................................7-1
UnderstandingtheFanSwitchesandHi-Limits....................................................................7-2
TheBlower/FanSwitch ......................................................................................................7-2
TheFanLimitControl ........................................................................................................7-3
TheAuxiliaryHi-TempLimitSwitch ...................................................................................7-4
SECTION 8: ADJUSTING THE DRAFT OVER FIRE ................................................8-1
CheckingforCorrectDraftOverFire .................................................................................8-1
AdjustingtheBarometricDamper .......................................................................................8-2
AdjustingDraftOverfireonFurnaceswithDraftInducers....................................................8-2
SolvingDraftOverfireProblems .........................................................................................8-3
UnderstandingtheEffectofExhaustFansonDraft .......................................................8-3
CheckingDraftOverfiretoDetermineSeverityofBackdraft.........................................8-3
InstallingaMake-upAirLouver ..................................................................................8-5
SECTION 9: MAINTENANCE ....................................................................................9-1
UnderstandingMaintenance................................................................................................9-1
PeriodicBurnerInspection .................................................................................................9-2
CleaningtheCanisterFilter .................................................................................................9-3
ServicingtheMeteringPump ..............................................................................................9-4
CleaningtheCheckValve/Screen .....................................................................................9-5
CleaningtheTank ..............................................................................................................9-6
CleaningAshfromtheFurnace ...........................................................................................9-7
AnnualBurnerTune-up ......................................................................................................9-9
EndofSeasonMaintenance ...............................................................................................9-9
SECTION 10: TROUBLESHOOTING ......................................................................10-1
FlowChart ......................................................................................................................10-2
TroubleshootingTables ....................................................................................................10-3
APPENDIX A
DetailedFurnaceSpecifications ......................................................................................... A-1
FurnaceTechnicalSpecifications................................................................................. A-1
BurnerTechnicalSpecifications................................................................................... A-2
FurnaceDimensions ................................................................................................... A-3
BurnerComponents ................................................................................................... A-6
RemovingtheNozzleforCleaning ....................................................................... A-11
Furnacecomponents ................................................................................................. A12
Blowercomponents................................................................................................... A16

TABLE OF CONTENTS
APPENDIX B
WiringDiagrams ............................................................................................................... B-1
FurnaceWiringDiagram ............................................................................................. B-1
BurnerWiringDiagram ............................................................................................... B-2
LadderSchematic ...................................................................................................... B-3
MeteringPumpWiringSchematic ............................................................................... B-4
APPENDIX C
AdditionalRequirementsfortheUnitedKingdom ............................................................... C-1
APPENDIX D
FurnaceServiceRecord .................................................................................................... D-1

Operator'sManual: ModelsCB-3500andCB-5000(230V/50Hz)
1-1
SECTION 1: INTRODUCTION
Guide to this Manual
ThismanualcontainsalltheinformationnecessarytosafelyinstallandoperatetheCleanBurn,CE-certified,
230V/50HzFurnaceModelsCB-3500andCB-5000. ConsulttheTableofContentsforadetailedlistof
topicscovered. You'llfindthismanual'sstep-by-stepprocedureseasytofollowandunderstand. Should
questionsarise,pleasecontactyourCleanBurndealerbeforestartinganyoftheproceduresinthismanual.
Asyoufollowthedirectionsinthismanual,you'lldiscoverthatassemblingandoperatingyournewfurnace
involvessixbasicactivitiesasoutlinedhere:
•UNPACKING .................................................................................................... (Section 2)
•ASSEMBLY....................................................................................................... (Section 3)
•INSTALLATION ................................................................................................ (Section 4)
• OPERATION
•Metering 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)
WARNING!
STOP
YOUR SAFETY IS AT STAKE!
DO NOT INSTALL, OPERATE OR
MAINTAIN THIS EQUIPMENT
WITHOUT FIRST READING
AND UNDERSTANDING THE
OPERATOR'SMANUAL!
Themanualalsocontainsimportantanddetailedtechnical
referencematerialswhicharelocatedatthebackofthe
manualintheAppendixes.
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 Furnace.

Operator'sManual: ModelsCB-3500andCB-5000(230V/50Hz)
1-2
For Your Safety...
Foryoursafety,CleanBurndocumentationcontainsthefollowingtypesofsafetystatements(listedhereinorder
ofincreasingintensity):
•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 strongsafetystatementindicatingthatahazardexistswhichcanresultin
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
precautionsapplyandmustbeheededtoensureproper,safefurnaceoperation.
DANGER! DO NOT create a fire or explosion hazard by storing or using gasoline or other
flammableorexplosiveliquidsorvaporsnearyourfurnace.
DANGER! DONOToperateyourfurnaceifexcessoil,oilvapororfumeshave
accumulatedinornearyourfurnace. Aswithanyoilburningappliance,improperinstallation,
operationormaintenancemayresultinafireorexplosionhazard.
WARNING: Ensurethatyourfurnaceisproperlyinstalled,adjusted,operatedandmaintained.
Improperinstallation,adjustment,operation,ormaintenancecanadverselyaffecttheproper,safe
operationofyourfurnaceandmaycauseseriouspersonalinjury/death.
WARNING: DONOTaddinappropriateorhazardousmaterialstoyourusedoil,suchas:
• Anti-freeze
• Carburetor cleaner
• Paint thinner
• Parts washer solvents
• Gasoline
• Oil additives
• Any other inappropriate/hazardous
material
WARNING: Burningchlorinatedmaterials(chlorinatedsolventsandoils)isillegal,will
severelydamageyourheatexchanger, andadverselyaffecttheproper,safeoperationofyour
furnace. Instructyourpersonneltoneveraddhazardousmaterialstoyourusedoil.

Operator'sManual: ModelsCB-3500andCB-5000(230V/50Hz)
1-3
For Your Safety... (continued)
WARNING: Neveralterormodifyyourfurnacewithoutpriorwrittenconsentof
CleanBurn,Inc. Unauthorizedmodificationsoralterationcanadverselyaffecttheproper,
safeoperationofyourfurnace.
WARNING: TheburnerwhichisshippedwithyourCleanBurnfurnaceistobeusedonly
withyourfurnaceaccordingtotheinstructionsprovidedinthismanual. DONOTusethe
burnerforanyotherpurpose!
WARNING: Electricalinstallationofthefurnaceistobeperformedonlybyqualified
personnel(i.e.licensedelectrician/engineer). Improperelectricalinstallationcanadversely
affecttheproper,safeoperationofthefurnaceandmaycauseseriouspersonalinjury/death.
WARNING: Installthefurnaceinanareaawayfromthemainshoptraffic. Itisessentialfor
personal safety that only manufacturer-trained, qualified personnel have access to operate
and maintain the furnace. Only OFTEC or Manufacturer-trained and registered
technicians should install, commission, and service the equipment.
WARNING: Topreventdamagetothefurnaceandtoensurepersonalsafety,lifting,mounting,
andhangingofthefurnacemustbeperformedinaccordancewithsafehandlingprocedures.
WARNING: DONOToperateyourfurnacewhentheambienttemperatureisabove
35o C(95oF).
WARNING: The Best Operator is a Careful Operator! By using common sense,
observinggeneralsafetyrules,andadheringtotheprecautionsspecifictotheequipment,you,
theoperator, canpromotesafeequipmentoperation. 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.
WARNING: Thisequipmentisforcommercialand/orindustrialuseonly;itisNOTfor
residentialuse.
WARNING: CallyourCleanBurndealerforservice. DONOTallowuntrained,unauthorized
personneltoserviceyourfurnace. Makesurethatyourfurnacereceivesperiodicmaintenanceto
ensureoptimalperformance.
Failure to comply with these standards and requirements may result in equipment
damage, fire, explosion, personal injury and/or death.

Operator'sManual: ModelsCB-3500andCB-5000(230V/50Hz)
1-4
Guidelines for Furnace Usage
• Thisfurnaceisdesignedtoburnthefollowingfuels:
• 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.
• Makesureyoucomplywithallenvironmentalregulationsconcerningtheuseofyourfurnace.
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.
• Ifyourfurnaceeverrequiresservice,callyourCleanBurndealer. DONOTallowuntrained,
unauthorizedpersonneltoserviceyourfurnace. Makesurethatyourfurnacereceivesannual
preventativemaintenancetoensureoptimalperformance.
For Your Safety... (continued)

Operator'sManual: ModelsCB-3500andCB-5000(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.
• Ensurethatthetankforyourfurnace
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.

Operator'sManual: ModelsCB-3500andCB-5000(230V/50Hz)
1-6
For Your Safety... (continued)
Safety Labels
FollowingarethelocationsanddescriptionsofalllabelsonyourCB-3500orCB-5000furnace. Thefollowing
illustrationsshowthelocationofALLlabelsonyourfurnace. Pleasenotethatsomelabelsdenotemodel
number,modeldescription,etc.whileotherscontainimportantsafetymessages.
EachSafetyLabelcontainsan importantsafetymessagestartingwithakeywordasdiscussedearlierinthis
section(e.g.ATTENTION,CAUTION,WARNING,DANGER). Foryoursafetyandthesafeoperationof
yourfurnace,reviewalllabelsandheedallsafetymessagesasprintedonthelabels.
IfanylabelsonyourCleanBurnfurnaceeverbecomeworn,lostorpaintedover,pleasecallyourCleanBurn
dealerforfreereplacements.
CB-3500/CB-5000 Furnace Cabinet Labels
Label Part # Description
42030 FurnaceElectricalShockHazardWarningLabel(severallocations)
42457 MadeinUSALabel
42027 FurnaceBurnHazard/HazardousVoltageWarningLabel
42367 FurnaceSafetyWarningLabel(MultipleMessages-Fire/Shock/BurnHazards)
42274 Data Label - CB-3500 CE
42275 Data Label - CB-5000 CE
42216 CleanBurnLogoLabel
42144 ModelCB-3500Label
42145 ModelCB-5000Label
42068 FurnaceBlower/FanEntanglementHazardWarningLabel(notshown-positioned
nearblower)
Danfoss 220−2 40V 50−6 0Hz 3W
t s 10s
Type BHO 64
Nr. 057H 703 6

Operator'sManual: ModelsCB-3500andCB-5000(230V/50Hz)
1-7
For Your Safety... (continued)
CB-3500/CB-5000 Furnace Cabinet Safety Labels

Operator'sManual: ModelsCB-3500andCB-5000(230V/50Hz)
1-8
For Your Safety... (continued)
CB-3500 / CB-5000 Furnace Cabinet Safety Labels (continued)
6.0
6.5
6.0
6.0
−0.06 (−1.5 mm)
89/392/EEC 72/23/EEC 89/336/EEC
BURNER REQUIRES A MINIMUM AIR SOURCE OF:
2 S.C.F.M. (57 L/MIN.) AT 25 P.S.I. (1.72 BAR).
THIS APPLIANCE IS NOT TO BE USED WITH AIR FILTERS AND
SHALL INCORPORATE NO PROVISIONS FOR MOUNTING AIR FILTERS.
INSTALL AND USE ONLY IN ACCORDANCE WITH THE
MANUFACTURER’S INSTALLATION AND OPERATING INSTRUCTIONS.
FOR COMMERCIAL OR INDUSTRIAL USE ONLY.
AUTHORITIES HAVING JURISDICTION SHOULD
BE CONSULTED PRIOR TO INSTALLATION.
THE MAINTENANCE INTERVAL FOR CLEANING ASH FROM THE FURNACE IS
APPROXIMATELY 700 HOURS. THE ASH LEFT FROM THE BURNING OF USED OIL
MAY CONTAIN METALLIC COMPOUNDS OR FOREIGN MATERIALS. THE ASH MUST BE
DISPOSED OF PROPERLY.
1.8
1/3 230
20
12
1/50
450
1/6
1/10
POWER
2
230
230
230
230
0.5
1.7
1.3
0.45
230 8.5
INPUT RATING W/NO. 2 FUEL OIL
60 (152)
2 (5)
2.5
2.5 9.5
9.5
18 (46)
18 (46)
16.0
16.0 1.1
1.1
2.5
2.5 9.5
9.5
CB 3500
16.0
16.0
1.1
1.1
350,000
BTU/HR
103
(KW)
LABEL SERIAL NO.
MULT−OIL BURNING UNIT HEATER
WHEN USED WITH THE FOLLOWING
LISTED FUELS
LEOLA, PENNSYLVANIA (USA)
42274
50
50
50
50
50
HZ
50
24 (61)
24 (61)
0.41
0.41
0.45
0.41
BTU/HR
18 (46)
18 (46)
500,000
MULT−OIL BURNING UNIT HEATER
WHEN USED WITH THE FOLLOWING
LISTED FUELS
LEOLA, PENNSYLVANIA (USA)
BURNER REQUIRES A MINIMUM AIR SOURCE OF:
2 S.C.F.M. (57 L/MIN.) AT 25 P.S.I. (1.72 BAR).
THIS APPLIANCE IS NOT TO BE USED WITH AIR FILTERS AND
SHALL INCORPORATE NO PROVISIONS FOR MOUNTING AIR FILTERS.
INSTALL AND USE ONLY IN ACCORDANCE WITH THE
MANUFACTURER’S INSTALLATION AND OPERATING INSTRUCTIONS.
FOR COMMERCIAL OR INDUSTRIAL USE ONLY.
AUTHORITIES HAVING JURISDICTION SHOULD
BE CONSULTED PRIOR TO INSTALLATION.
THE MAINTENANCE INTERVAL FOR CLEANING ASH FROM THE FURNACE IS
APPROXIMATELY 700 HOURS. THE ASH LEFT FROM THE BURNING OF USED OIL
MAY CONTAIN METALLIC COMPOUNDS OR FOREIGN MATERIALS. THE ASH MUST BE
DISPOSED OF PROPERLY.
1/4
450
1/10
1/6
230
230
230
230
POWER
2230
60 (152)
2 (5)
13.5
13.5
3.6
3.6
18.0
16.0
INPUT RATING W/NO. 2 FUEL OIL
13.5
13.53.6
3.6
16.0
18.0
CB 5000
LABEL SERIAL NO.
42275
20
15
1.3
1.7
1.3
0.45
50
50
50
50
9.0
HZ
50
24 (61)
24 (61)
3.0
3.0
−0.06 (−1.5 mm)
1.2
1.1
0.21
0.21
2.5
3.01.1
1.2
0.21
0.17
147
(KW)
89/392/EEC 72/23/EEC 89/336/EEC

Operator'sManual: ModelsCB-3500andCB-5000(230V/50Hz)
1-9
For Your Safety... (continued)
CB-3500 / CB-5000 Burner Labels
Label Part # Description
CB-3500/CB-5000 BurnerSafety Labels
I88889
42339/
42197
42340
42004
Danfoss 220− 240V 50−60Hz 3W
ts 10s
Type BHO 64
Nr. 057H703 6
42005 SoldandServicedByLabel
42004 BurnerSafetyWarningLabel
(HighVoltage/MovingPartsHazards)
42000 BurnerSafetyWarningLabel
(Fire/ExplosionHazard-ResetButton)
42235 BurnerSafetyWarningLabel
(Fire/ExplosionHazard-BurnerInstallation
andService)
42339 CB-500-CEBurnerModel/SerialNumberLabel
42340 CB-551-CEBurnerModel/SerialNumberLabel
42197 PatentPendingLabel
42229 Logo/BurnerDescriptionLabel
42023 BurnerPowerLabel

Operator'sManual: ModelsCB-3500andCB-5000(230V/50Hz)
1-10

Operator'sManual: ModelsCB-3500andCB-5000(230V/50Hz)
2-1
SECTION 2: UNPACKING
Before assembling your furnace, you must accomplish the following activities described in this section:
• Removing the Shipping Crate
• UnpackingandInspectingAllComponents
Removing the Shipping Crate
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). Keep
all components together so you will have them as needed for furnace assembly and installation.
Furnace Component List
ONE SKID containing:
• Furnacecabinet
Componentspackedontopoffurnacecabinet:
• Burner
• 2 HP Blower motor
• Blower
• Airdischarge
Componentspackedinsidefurnacecabinet:
• Ceramictarget
• Blowerassemblycomponents
• Oilpump
• Canisterfilter
• Vacuumgauge
• Checkvalve/checkvalvescreen
• Wallthermostat
• Barometricdamper
• Draftinducer(CB-5000only)
• Connectorblock
• Assortedbolts/fittings,Assemblyparts,Mountingcomponents
NOTE: Youmayhavereceivedadditionalboxesorskidsifyouorderedoptionalaccessories.
1. Carefully remove the top boards of the shipping crate. Then remove the front, back, and side
panels.
2. Carefully lift the furnace off the shipping pallet with a fork lift.
ATTENTION: DO NOT attempt to slide the furnace cabinet out of the shipping crate--you may
damagethefurnacecabinet.
NOTE: DONOTremovethesquirrelcageblowerfromthefurnacecabinet. (Theblowerisinstalledinfinal
positionforModelCB-3500;itwillrequireadditionalinstallationforModelCB-5000.)

Operator'sManual: ModelsCB-3500andCB-5000(230V/50Hz)
2-2
Unpacking Items Packed Inside the Furnace
To unpack the items packed inside the furnace cabinet (in the combustion chamber), you will need to
open the combustion chamber door.
1. Remove the four nuts and washers which hold the combustion chamber door closed. Set the nuts
and washers aside in a safe place for later re-installation after the target has been installed
(Section 3).
2. Carefullyswingthecleanoutdooropen. Removeandinspectthecomponentspackedinside.
3. Leavethedoorunfastened(open)forassembly/installationprocedurestobeaccomplishedinthe
next section.
Figure2A-AccessingtheCombustionChamber
CLEAN−OUT
DOOR
COMBUSTION
CHAMBER
FURNACE FLUE
CLEAN−OUT
BREACH
CLEAN−OUT
CAP I88913

Operator'sManual: ModelsCB-3500andCB-5000(230V/50Hz)
3-1
SECTION 3: FURNACE ASSEMBLY
Understanding Assembly
AssemblingyourCleanBurnFurnaceisasix-stepprocesswhichincludes:
(1)InstallingtheBlowerComponents
(2)InstallingtheHotAirDischargeComponents
(3)InstallingtheCeramicTarget
(4)InstallingtheBurner
(5)InstallingtheConnectorBlock,OilLineTubing,andAirLineTubing
(6)InstallingtheMountingandStabilizerBrackets
CleanBurnrecommendsthatyoureviewallassemblyproceduresbeforeproceeding,payingcarefulattentionto
safetyinformationstatements. Pleasenotethatsomeassemblyproceduresapplyonlytocertainfurnacemodels.
Figures3Aand3Bonthefollowingpagesprovideageneraloverviewofthefurnacecomponentsandtheir
properassemblyandhowtheunitshouldlookfollowingproperassembly.
Required Tools and Materials
Thefollowingtoolsarerequiredforfurnaceassemblyandshouldbegatheredbeforestartinganyprocedures:
• Variable-speedelectricdrill
• 1/4"hex-nutdriverattachmentforelectricdrill
• Setofopen-endwrenches(3/8"-5/8")
• 6"adjustablewrench
• Mediumstraight-bladescrewdriver

Operator'sManual: ModelsCB-3500andCB-5000(230V/50Hz)
3-2
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)InstallingtheHotAirDischargeComponents
(3)InstallingtheTarget
(4)InstallingtheBurner
(5)InstallingtheConnector Block, Oil Line Tubing, and Air Line Tubing
(6)Installing the Mounting and Stabilizer Brackets
NOTE: Correspondingproceduresprovidedinorderinthissection.
Figure3A-OverviewofFurnaceAssembly
Danfoss
TypeBHO 64
Nr.057H7036
ts10s
220-240V 50-60Hz 3W
NOTE: LOOP ON TARGET HOOKS
OVER MOUNTING BRACKET ON
BACK WALL OF COMBUSTION
CHAMBER
MOUNTING BRACKETS INSTALLED
ON FURNACE CABINET BASE
FURNACE BREACH
TARGET INSTALLED
ON BACK WALL OF
COMBUSTION CHAMBER
FRONT VIEW OF CABINET
PRIOR TO ASSEMBLY
SIDE VIEW OF CABINET
NOTE: BLOWER MUST BE INSTALLED
WITH BULGE ON BLOWER FACING
BACK OF FURNACE. MAKE SURE
BLOWER WHEEL ROTATION IS
CLOCKWISE AS SHOWN
3
1
JUNCTION BOX
BURNER
CABLE
FURNACE DOOR
FAN LIMIT
THROAT
BURNER
MOUNT
4
STABILIZER BRACKET
ON TOP OF FURNACE
FRONT VIEW OF CABINET
AFTER ASSEMBLY
6
STABILIZER BRACKETS
ROTATION
AIR DISCHARGE
2
I88914
CONNECTOR
BLOCK
5
4
AIR DISCHARGE
’ALL THREAD’ ROD
6
MOUNTING
BRACKET
BELOW
FURNACE
6