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CLEAN BURN CB-500 series - User Manual

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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
the prior written permission of Clean Burn, Inc. 34 Zimmerman Road, Leola, PA 17540. Subject to change without notice.
CLEAN BURN, INC. • 34 Zimmerman Road • Leola, PA 17540 • U.S.A.
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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

Questions and Answers

  • W
    woodarielAug 29, 2025
    Why does my CLEAN BURN CB-500 Furnace burner shut off on reset periodically?
    • B
      Brian VargasAug 29, 2025
      If your CLEAN BURN Furnace burner ignites and runs, but shuts off on reset periodically, such as overnight, consider these potential causes: * Air may be entering the suction oil line due to leaks at the fittings. Perform a vacuum test on the pump as described in Section 5. Re-install and properly seal the suction line fittings to prevent air leaks. * Air may be trapped in a high point in the pressure oil line. Follow the instructions in Section 4 to bleed the air out of the pressure oil line.
  • C
    Christopher KeithAug 31, 2025
    How to fix a CLEAN BURN CB-500 when the burner won’t run and the green power light is off?
    • K
      Karen RobertsonAug 31, 2025
      If the CLEAN BURN Furnace burner won’t run and the green power light is not on, it could be due to: * An open circuit breaker or main switch. Close the circuit breaker or switch. * A blown fuse or breaker. An electrician should check the electrical system. * A damaged or improperly plugged-in burner cable. Check the burner cable.
  • A
    Autumn SandersSep 1, 2025
    What to do if the CLEAN BURN Furnace blower motor will not run?
    • J
      John Cohen MDSep 2, 2025
      If the CLEAN BURN Furnace blower motor will not run: * Check the blower motor wiring. If it's not wired correctly, refer to the wiring diagram and ladder schematic in Appendix B. Follow the directions in Section 6 to test for proper fan operation. If the fan still does not operate, shut OFF power to the furnace and call your Clean Burn dealer for service. * The blower or fan switch may be defective and need to be replaced. * The blower motor may have overheated and shut down on thermal reset. Check the voltage and amperage draw of the blower motor, and call your dealer if the problem continues.
  • L
    Luis MillerSep 3, 2025
    Why does the CLEAN BURN Furnace blower motor run all the time?
    • R
      Ryan PhillipsSep 3, 2025
      If the CLEAN BURN Furnace blower motor runs all the time, the blower motor circuit may be wired incorrectly. Refer to the wiring diagram and ladder schematic in Appendix B to troubleshoot the blower motor circuit.
  • J
    jessicacaldwellSep 5, 2025
    Why does my CLEAN BURN Burner shut off on reset within 15 seconds?
    • R
      Rachel ThompsonSep 5, 2025
      The CLEAN BURN Burner might shut off on reset within 15 seconds due to: * A fuel delivery problem. Follow the procedures listed for a fuel delivery problem. * A dirty cad cell. Clean and check the condition of the cad cell and cad cell wires. * Loose cad cell wires. Check that the blue and black wires are connected properly into the primary base (terminals 11 and 12). * Damaged cad cell / cad cell wires. Replace the cad cell and cad cell wires. * The primary control not receiving the proper µA signal from the cad cell. The photo current is measured with a direct current ammeter in series with the photo unit (+ pole on terminal 12). With a flame, cad cell current must be between 50 µA and 210 µA at 240V. With no flame, the measured photo current must be maximum 5 µA at 230V.
  • J
    javier87Sep 7, 2025
    What to do if CLEAN BURN Burner ignites and shuts off on reset periodically?
    • M
      Michael MeyerSep 7, 2025
      If your CLEAN BURN Burner ignites and runs properly, but shuts off on reset periodically, it could be due to: * Air in the suction oil line because of leaks at the fittings. You should follow the procedures to vacuum test the pump and properly seal the suction line fittings to eliminate air leaks. * Air trapped in a high point in the pressure oil line. Follow instructions to bleed the air out of the pressure oil line.
  • I
    Isabel MurphySep 12, 2025
    How to fix a CLEAN BURN Burner that won’t run at all when the green power light is not on?
    • R
      Robert GreenSep 12, 2025
      If your CLEAN BURN Burner won’t run at all and the green power light is NOT ON, it could be due to: * An open circuit breaker/main switch. Close the circuit breaker/switch. * A blown fuse/breaker. An electrician should check out the electrical system. * A damaged or improperly plugged-in burner cable. Check the burner cable.
  • R
    Randy MorrisonSep 15, 2025
    What causes a CLEAN BURN pump to not prime when the pump motor is not running?
    • R
      robert77Sep 15, 2025
      If the CLEAN BURN pump will not prime and the pump motor is NOT running, it could be due to: * No power on the pump circuit from the burner. Start the burner and adjust the air pressure regulator to 15 PSI. * The pump motor has shut off on thermal overload. The pump motor is too hot—the internal thermal protection switch shut the motor off. Wait for the motor to cool down; the thermal switch will automatically reset. Check voltage and amperage draw of the pump motor. Call your dealer if the problem persists. * The coupling is not adjusted properly, keeping the shafts of the motor and pump from turning freely. Re-position the coupling so that both shafts turn freely. * The shaft on the motor or oil pump will not turn freely. If you can’t turn the shafts, replace the faulty part(s).
  • T
    twilliamsSep 16, 2025
    What causes the blower motor to run all the time on a CLEAN BURN?
    • C
      Cody HudsonSep 17, 2025
      If the blower motor runs all the time on a CLEAN BURN, it may be due to the blower motor circuit being wired incorrectly. Refer to wiring diagram and ladder schematic to troubleshoot the blower motor circuit.
  • J
    Jacob HartmanSep 18, 2025
    What to do if the blower motor will not run on my CLEAN BURN?
    • K
      Kylie OrrSep 18, 2025
      If the blower motor will not run on your CLEAN BURN, consider the following: * The blower motor is not wired correctly. Check the blower motor wiring. Follow the directions to test for proper fan operation. If the fan does not operate, shut OFF power to the furnace and call your Clean Burn dealer for service. * The Blower / Fan switch is defective. Replace the Blower / Fan switch. * The blower motor has overheated and shut down on thermal reset. Reset the red button on the motor thermal reset. Check voltage and amperage draw of the blower motor. Call your dealer if the problem persists.

Summary

SECTION 1: INTRODUCTION

Guide to this Manual

Explains manual structure and outlines basic furnace activities.

For Your Safety...

Lists safety statements and general precautions to ensure safe furnace operation.

SECTION 2: UNPACKING

Removing the Shipping Crate

Instructions for carefully removing the furnace from its shipping crate.

Unpacking and Inspecting All Components

Itemized list and inspection of all received furnace components.

SECTION 3: FURNACE ASSEMBLY

Understanding Assembly

Overview of the six-step furnace assembly process.

Required Tools and Materials

Lists the tools and materials needed for furnace assembly.

Installing the Blower Components

Instructions for installing the blower assembly and motor.

Installing the Belt Guard and the Blower Guard

Instructions for installing protective guards for safety.

Installing the Hot Air Discharge Components

Guidance on connecting air discharge for unit heater or central furnace.

Installing the Ceramic Target

Procedure for installing the high-temperature ceramic target in the combustion chamber.

Installing the Burner

Steps for installing the burner assembly, including nozzle and electrode checks.

Installing the Connector Block, Oil Line Tubing, and Air Line Tubing

Detailed steps for connecting the oil and air lines to the burner.

Locking the Burner into Firing Position

Securing the burner in its operational position.

Installing the Mounting and Stabilizer Brackets

Instructions for installing mounting and stabilizer brackets for installation.

SECTION 4: FURNACE INSTALLATION

Understanding Installation

Overview of the multi-step furnace installation process.

Important Safety Guidelines for Safe Installation

General safety guidelines and code compliance for furnace installation.

Important Notes to the Electrician

Specific electrical installation guidance for qualified electricians.

Selecting a Location

Guidelines for choosing an appropriate and safe location for the furnace.

Mounting the Furnace

Instructions for mounting the furnace, including ceiling mounting.

Raised Platform Mounting

Steps for mounting the furnace on a raised platform.

Floor Mounting

Guidelines for floor mounting, including non-combustible floor construction.

Oil Tank Installation Specifications

Safety guidelines and requirements for used oil supply tank installation.

Installing the Metering Pump

Procedures for installing the metering pump for fuel delivery.

Wiring the Furnace and Pump

Electrical wiring instructions for the furnace and metering pump.

Installing the Suction Oil Line Components

Detailed steps for installing the oil suction line from the tank to the pump.

Installing the Pressure Relief and Low-Flow Check Valve

Installation of pressure relief and low-flow check valve for the metering pump.

Installing the Compressed Air Line

Instructions for running the compressed air line to the furnace.

SECTION 8: ADJUSTING THE DRAFT OVERFIRE

Installing the Stack

Guidelines and specifications for installing the furnace stack system.

Installing the Interior Stack

Instructions for installing the internal sections of the stack.

Installing the Barometric Damper

Steps for installing and adjusting the barometric damper to control draft.

Installing the Stack Penetration

Steps for safely penetrating walls/ceilings for the stack.

Installing the Exterior Stack

Requirements for exterior stack components.

Installing the Stack Cap

Instructions for installing the stack cap.

Installing the Draft Inducer

Installation of the draft inducer for proper exhaust venting.

Installing the Wall Thermostat

Instructions for installing the furnace wall thermostat.

SECTION 5: METERING PUMP PRIMING

Understanding Metering Pump Priming

Overview of the metering pump priming process.

Required Tools and Materials

Lists tools and materials for oil pump priming.

Preparing the Burner for Use with the Metering Pump

Steps to prepare the burner by removing the oil regulator.

Priming the Metering Pump

Detailed procedure for priming the metering pump and bleeding air.

Vacuum Testing the Oil Pump

Procedure for vacuum testing the pump and suction line for leaks.

SECTION 6: STARTING AND ADJUSTING THE BURNER

Understanding Burner Startup and Adjustment

Overview of the burner startup and adjustment procedures.

Preparing the Burner for Startup

Initial steps and checks before starting the burner.

Starting the Burner

Steps to initiate burner operation and adjust settings.

Observing the Flame Length

Visual inspection of the flame for correct length and characteristics.

Checking for a Smokeless Burn

How to check for and achieve a smokeless burn.

Checking the Operation of the Blower Motor

Verifying the correct operation of the blower motor and fan limit control.

SECTION 7: RESETTING THE FURNACE AND BURNER

Understanding Furnace;Burner Shutdowns

Explains common reasons for furnace and burner shutdowns.

Understanding the Oil Primary Control

Explains the function and operation of the oil primary control.

Resetting the Oil Primary Control

Procedure for resetting the oil primary control after a shutdown.

The Fan Switches and Hi-Limits on the CB-3500;CB-5000 Furnaces

Overview of fan switches and hi-limits for furnace protection.

The Blower;Fan Switch

Operation and function of the blower/fan switch.

The Fan Limit Control

Explanation of the fan limit control's operation and settings.

The Auxiliary Hi-Temp Limit Switch

Function of the auxiliary high-temperature limit switch for overheat protection.

SECTION 9: MAINTENANCE

Understanding Maintenance

Importance of regular furnace maintenance for peak condition.

Periodic Burner Inspection

Guidelines for regular visual inspection of burner operation.

Cleaning the Canister Filter

Procedure for cleaning the oil system's canister filter.

Servicing the Metering Pump

Steps for servicing and maintaining the metering pump.

Cleaning the Check Valve; Screen

Procedure for cleaning the check valve and screen in the oil line.

Cleaning the Tank

Instructions for draining water and sludge from the oil supply tank.

Cleaning Ash from the Furnace

Steps for accessing and cleaning ash from the combustion chamber and flues.

Annual Burner Tune-up

Recommendation for professional annual maintenance of the burner.

End of Season Maintenance

Procedures for shutting down the furnace at the end of the heating season.

SECTION 10: TROUBLESHOOTING

Flow Chart

Outlines the sequence of furnace operation for diagnosing problems.

APPENDIX A

Detailed Furnace Specifications

Contains comprehensive technical specifications for the furnaces.

Burner Technical Specifications

Details technical specifications related to the furnace burner.

Furnace Dimensions (CB-3500)

Provides dimensional drawings and measurements for the CB-3500 model.

Furnace Dimensions (CB-5000)

Provides dimensional drawings and measurements for the CB-5000 model.

Burner Components

Exploded view and list of burner components.

CB-3500 Furnace Components

Part list and descriptions for CB-3500 furnace components.

CB-5000 Furnace Components

Part list and descriptions for CB-5000 furnace components.

CB-3500 Blower Components

Part list and descriptions for CB-3500 blower components.

CB-5000 Blower Components

Part list and descriptions for CB-5000 blower components.

APPENDIX B

Wiring Diagrams

Provides electrical wiring diagrams for the furnace and its components.

Wiring Diagrams

Continuation of wiring diagrams, specifically for the burner.

Figure B3 - Ladder Schematic for Models CB-3500; CB-5000 (230 Volts; 50 Hz)

Ladder schematic illustrating the furnace's electrical control logic.

Wiring Diagrams (continued)

Wiring schematic for the metering pump.

APPENDIX C

Additional Installation Requirements

Specific installation requirements for the United Kingdom.

Installing a Fire Valve

Instructions for installing a fire valve element as per UK regulations.

APPENDIX D

Furnace Service Record

A template for recording furnace maintenance and service history.

CLEAN BURN CB-500 series Specifications

General IconGeneral
BrandCLEAN BURN
ModelCB-500 series
CategoryFurnace
LanguageEnglish

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