CLEAN BURN MODEL: SATURN™ A2 MULTI-OIL FURNACE · flammable or explosive liquids or vapors near your furnace. DANGER! DO NOT operate your furnace if excess oil, oil vapor or fumes

OPERATOR'S MANUALCLEAN BURN MODEL: SATURN™ A2 MULTI-OIL FURNACE

with SATURN™ A2 BURNER

IMPORTANT FOR U.S. INSTALLATIONS: All installations must be made in accordance with state and local codeswhich may differ from the information provided in this manual. Save these instructions for reference.

IMPORTANT FOR CANADIAN INSTALLATIONS: These instructions have been reviewed and accepted byUnderwriters' Laboratories of Canada as being appropriate for the installation of the ULC labelled productsidentified herein. The use of these instructions for the installation of products NOT bearing the ULC label andNOT identified herein may result in an unacceptable or hazardous installation.

IMPORTANT FOR CANADIAN INSTALLATIONS: The installation of this equipment is to be accomplished byqualified personnel and in accordance with the regulation of authorities having jurisdiction and CSA Standard B 139,Installation Code for Oil Burning Equipment.

PUBLICATION DATE: 2/1/06, Rev. 2 CLEAN BURN PART # 43166

U.L. Listed Used OilBurning Appliance#MH15393 (N)

U.L.-C Listed#CMP217

WARNING: DO NOT assemble, install, operate, or maintain this equipment without firstreading and understanding the information provided in this manual. Installation and

service must be accomplished by qualified personnel. Failure to follow all safety precautionsand procedures as stated in this manual may result in property damage, serious personal injuryor death.

Clean Burn, Inc., MANUFACTURER, hereby warrants that MANUFACTURER's products shall be free from defect inmaterial and workmanship under normal use according to the provisions and limitations herein set forth. MANUFACTURERwarrants the heat exchanger/combustion chamber, excluding the stainless steel flame target, for one (1) year from the date ofpurchase by the purchaser and pro rata thereafter according to the following schedule: (a) If the defect occurs during thesecond year, customer pays 60% of parts, replacement or repair. (b) If the defect occurs during the third year, customerpays 70% of parts, replacement or repair. (c) If the defect occurs during the fourth year, customer pays 80% of parts,replacement or repair. (d) If the defect occurs during the fifth year, customer pays 90% of parts, replacement or repair.MANUFACTURER warrants all other Clean Burn products for a period of one (1) year from the date of purchase by thepurchaser.

LIMITATIONS:The obligation of MANUFACTURER for breach of warranty shall be limited to products manufactured by MANUFACTURER (1) that areinstalled, operated and maintained according to MANUFACTURER's instructions furnished and/or available to the purchaser uponrequest; (2) that are installed according to all other applicable Federal, State and local codes or regulations; and (3) that the purchasersubstantiates were defective in material and workmanship notwithstanding that they were properly installed and correctly maintained as setforth above and were not abused or misused.

The obligation of MANUFACTURER shall be limited to replacing or repairing the defective product, at the option of theMANUFACTURER. MANUFACTURER shall not be responsible for any labor or costs of removal or reinstallation of its products andshall not be liable for transportation costs to and from its plant at Leola, Pennsylvania.

Use of parts for modification or repair of the product or any component part thereof not authorized or manufactured byMANUFACTURER specifically for such product shall void this warranty.

This warranty shall not apply to any damage to or defect in any of MANUFACTURER's products that is directly or indirectly caused by (1)force majeure, Act of God or other accident not related to an inherent product defect; or (2) abuse, misuse or neglect of such product,including any damage caused by improper assembly, installation, adjustment, service, maintenance or faulty instruction of the purchaser.

Other than as expressly set forth hereinabove, MANUFACTURER makes no other warranty, express or implied, with respect to any ofMANUFACTURER's products, including but not limited to any warranty of merchantability or fitness for a particular purpose.

And in no event shall MANUFACTURER be responsible for any incidental or consequential damages of any nature suffered by purchaseror any other person or entity caused in whole or in part by any defect in any of MANUFACTURER's products. Any person or entity towhom this warranty extends and who claims breach of warranty against MANUFACTURER must bring suit thereon within one year fromthe date of occurrence of such breach of warranty or be forever barred from any and all legal or other remedies for such breach of warranty.

MANUFACTURER is not responsible for and hereby disclaims any undertaking, representation or warranty made by any dealer,distributor or other person that is inconsistent with or in any way more expansive than the provisions of this limited warranty.

This warranty grants specific legal rights and shall be read in conformity with applicable state law. In some jurisdictions, the applicablelaw mandates warranty provisions that provide greater legal rights than those provided for herein. In such case, this limited warranty shallbe read to include such mandated provisions; and any provision herein that is prohibited or unenforceable in any such jurisdiction shall, asto such jurisdiction, be ineffective to the extent of such prohibition or unenforceability without invalidating the remaining provisions andwithout affecting the validity or enforceability of such provision in any other jurisdiction(s).

WARRANTY INFORMATION

TABLE OF CONTENTSSECTION 1: INTRODUCTION.................................................................................... 1-1

Guide to this Manual ........................................................................................................ 1-1For Your Safety... ............................................................................................................. 1-2

Guidelines for Furnace Usage ................................................................................... 1-4Guidelines for Used Oil Tanks .................................................................................. 1-5Safety Labels ............................................................................................................. 1-6

SECTION 2: UNPACKING ......................................................................................... 2-1Removing the Shipping Pallet .......................................................................................... 2-1Unpacking and Inspecting All Components ..................................................................... 2-1

Furnace Component List ........................................................................................... 2-1Warranty Registration ...................................................................................................... 2-2

SECTION 3: FURNACE ASSEMBLY ......................................................................... 3-1Understanding Assembly ................................................................................................. 3-1

Required Tools and Materials ................................................................................... 3-1Installing the Observation Port ......................................................................................... 3-2Installing the Fan Assembly ............................................................................................. 3-3Installing the Burner ......................................................................................................... 3-4

Checking the Burner Nozzle and Electrodes ............................................................. 3-4Mounting the Burner ................................................................................................. 3-5

SECTION 4: FURNACE INSTALLATION................................................................... 4-1Understanding Installation ............................................................................................... 4-1Selecting a Location ......................................................................................................... 4-4

Guidelines for Selecting a Location .......................................................................... 4-4Mounting the Furnace ...................................................................................................... 4-5

Ceiling Mounting ...................................................................................................... 4-5Raised Platform Mounting ........................................................................................ 4-5Floor Mounting.......................................................................................................... 4-6

Oil Tank Installation Specifications ................................................................................. 4-7Installing the Tank Vent and Emergency Vent .......................................................... 4-8

Installing the Metering Pump ........................................................................................... 4-9Preparing for Installation ........................................................................................... 4-9Standard Mounting: Vertical Positioning ............................................................... 4-10Alternate Mounting: Horizontal Positioning .......................................................... 4-12

Wiring the Furnace and Pump........................................................................................ 4-13Wiring to the Furnace .............................................................................................. 4-13Wiring to the Metering Pump .................................................................................. 4-13

Installing the Suction Oil Line Components .................................................................. 4-14Installing the Pressure Relief and Low-Flow Check Valve ........................................... 4-16Installing the Pressure Oil Line Components ................................................................. 4-16Installing the Compressed Air Line ............................................................................... 4-17

TABLE OF CONTENTSSECTION 4: FURNACE INSTALLATION (continued)

Installing the Stack ......................................................................................................... 4-17Installing the Interior Stack ..................................................................................... 4-20Installing the Barometric Damper ........................................................................... 4-20Installing the Stack Penetration ............................................................................... 4-21Installing the Exterior Stack .................................................................................... 4-21Installing the Stack Cap ........................................................................................... 4-21Installing the Optional Draft Inducer ....................................................................... 4-21

Installing the Wall Thermostat ....................................................................................... 4-23Inspecting the Furnace Installation................................................................................. 4-23

SECTION 5: METERING PUMP PRIMING ................................................................ 5-1Understanding Metering Pump Priming .......................................................................... 5-1

Required Tools and Materials ................................................................................... 5-1Priming the Metering Pump ............................................................................................. 5-1Vacuum Testing the Oil Pump ......................................................................................... 5-4

SECTION 6: STARTING AND ADJUSTING THE BURNER ...................................... 6-1Understanding Burner Startup and Adjustment ............................................................... 6-1Preparing the Burner for Startup ...................................................................................... 6-1Starting the Burner ........................................................................................................... 6-3Checking the Operation of the Fan/Blower Motor ........................................................... 6-4

SECTION 7: RESETTING THE OIL PRIMARY CONTROL ....................................... 7-1Understanding the Oil Primary Control ........................................................................... 7-1Using the Reset Button..................................................................................................... 7-1

SECTION 8: ADJUSTING THE DRAFT OVER FIRE ................................................. 8-1Understanding the Importance of Draft ............................................................................ 8-1Checking for Correct Draft Over Fire .............................................................................. 8-1Adjusting the Barometric Damper ................................................................................... 8-2Solving Draft Overfire Problems ..................................................................................... 8-2

Understanding the Effect of Exhaust Fans on Draft .................................................. 8-3Checking Draft Overfire to Determine Severity of Backdraft ................................... 8-3Installing a Make-up Air Louver ............................................................................... 8-5

TABLE OF CONTENTSSECTION 9: MAINTENANCE ..................................................................................... 9-1

Understanding Maintenance ............................................................................................. 9-1Annual Burner Tune-up ................................................................................................... 9-1Cleaning the Canister Filter ............................................................................................. 9-2Servicing the Metering Pump........................................................................................... 9-3Cleaning Ash from the Furnace ....................................................................................... 9-4Cleaning the Check Valve ................................................................................................ 9-6Cleaning the Tank ............................................................................................................ 9-7End of Season Maintenance ............................................................................................. 9-7

APPENDIX ADetailed Furnace Specifications ...................................................................................... A-1

Furnace Technical Specifications ............................................................................. A-1Burner Technical Specifications............................................................................... A-2Furnace Dimensions ................................................................................................. A-3Burner Components .................................................................................................. A-4Fan Limit Control ................................................................................................... A-12

APPENDIX BWiring Diagrams ............................................................................................................. B-1

APPENDIX CFurnace Service Record .................................................................................................. C-1

Operator's Manual: Saturn™ A2

1-1

SECTION 1: INTRODUCTIONGuide to this Manual

This manual contains all the information necessary to safely install and operate the Clean BurnSaturn™ A2 Furnace. Consult the Table of Contents for a detailed list of topics covered. You'll findthis manual's step-by-step procedures easy to follow and understand. Should questions arise, pleasecontact your Clean Burn dealer before starting any of the procedures in this manual.

As you follow the directions in this manual, you'll discover that assembling and operating your newfurnace involves five basic activities as outlined here:

• 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!

STOPYOUR SAFETY IS AT STAKE!

DO NOT INSTALL, OPERATE ORMAINTAIN THIS EQUIPMENTWITHOUT FIRST READING

AND UNDERSTANDING THEOPERATOR'S MANUAL!

The manual also contains important and detailedtechnical reference materials which are located at theback of the manual in the Appendixes.

Please read all sections carefully--including theimportant safety information found in this section--before beginning any installation/operationprocedures; doing so ensures your safety and theoptimal performance of your Clean Burn furnace.


1-2

For Your Safety...For your safety, Clean Burn documentation contains the following types of safety statements (listed herein order of increasing intensity). Note the safety key words printed in bold for each:

• NOTE: A clarification of previous information or additional pertinent information.

• ATTENTION: A safety statement indicating that potential equipment damage may occur ifinstructions are not followed.

CAUTION: A safety statement that reminds of safety practices or directs attention to unsafepractices which could result in personal injury if proper precautions are not taken.

WARNING: A strong safety statement indicating that a hazard exists which can result ininjury or death if proper precautions are not taken.

DANGER! The utmost levels of safety must be observed; an extreme hazard exists whichwould result in high probability of death or irreparable serious personal injury if properprecautions are not taken.

In addition to observing the specific precautions listed throughout the manual, the following generalprecautions apply and must be heeded to ensure proper, safe furnace operation.

DANGER! DO NOT create a fire or explosion hazard by storing or using gasoline or otherflammable or explosive liquids or vapors near your furnace.

DANGER! DO NOT operate your furnace if excess oil, oil vapor or fumes haveaccumulated in or near your furnace. As with any oil burning furnace, 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, willseverely damage your heat exchanger, immediately void your warranty, and adversely affectthe proper, safe operation of your furnace. Instruct your personnel to never add hazardousmaterials to your used oil.


1-3

For Your Safety... (continued)

WARNING: Never alter or modify your furnace without prior written consent ofClean Burn, Inc. Unauthorized modifications or alteration can adversely affect the proper,safe operation of your furnace.

WARNING: The burner which is shipped with your Clean Burn furnace is to be used onlywith your furnace according to the instructions provided in this manual. DO NOT use theburner for any other purpose!

WARNING: The Best Operator is a Careful Operator! By using common sense,observing general safety rules, and adhering to the precautions specific to the equipment, you,the operator, can promote safe equipment operation. Failure to use common sense, observegeneral safety rules, and adhere to the precautions specific to the equipment may result inequipment damage, fire, explosion, personal injury and/or death.

WARNING: The installation, operation, and maintenance of this equipment in the U.S.must be accomplished by qualified personnel and in compliance with the specifications in theClean Burn Operator's Manual and with all national, state, and local codes or authoritieshaving jurisdiction over environmental control, building inspection and fuel, fire andelectrical safety and the following standards of the National Fire Protection Association.

NFPA 30 Flammable and Combustible Liquids CodeNFPA 30A Automotive and Marine Service Station CodeNFPA 31 Standard for the Installation of Oil Burning EquipmentNFPA 211 Chimneys, Fireplaces, Vents and Solid Fuel Burning AppliancesNFPA88A Parking StructuresNFPA 88B Repair GaragesNFPA 70 National Electrical Code

The NFPA standards may be obtained from:National Fire Protection Association (NFPA)1 Batterymarch Park, P.O. Box 9101Quincy, Massachusetts 02269-9101

Likewise, the installation, operation, and maintenance of this equipment in Canada is to beaccomplished by qualified personnel and in compliance with the specifications in theClean Burn Operator's Manual and in accordance with the regulation of authorities havingjurisdiction and CSA Standard B 139, Installation Code for Oil Burning Equipment.

Failure to comply with these standards and requirements may result in equipmentdamage, fire, explosion, personal injury and/or death.


1-4

Guidelines for Furnace Usage

• This furnace is listed for commercial and/or industrial use only; it is not listed for residentialuse.

• This furnace is listed with Underwriters Laboratory and Underwriters' Laboratories ofCanada to burn the following fuels:

• #2 and #4 fuel oils• Used crankcase oil up to 50 SAE• Used transmission fluid• Used hydraulic oil

• Make sure you comply with all EPA regulations concerning the use of your furnace. EPAregulations require that:

• 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 yourused 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 furnace

in warm weather just to burn oil.Contact your Clean Burn dealer for current EPA regulations.

• If your furnace ever requires service, call your Clean Burn dealer. DO NOT allowuntrained, unauthorized personnel to service your furnace. Make sure that your furnacereceives annual preventative maintenance to ensure optimal performance.



1-5


Guidelines for Used Oil Tanks

For the safe storage of used oil and the safety ofpersons in the vicinity of the used oil supply tank,ensure that your tank installation adheres to thefollowing safety guidelines:

• The tank installation must meet allnational and local codes. Consult yourlocal municipal authorities for moreinformation as necessary.

• Review and adhere to the safetyguidelines for used oil supply tanksas stated in the WARNING shown.

• Ensure that the tank for your furnaceinstallation complies with all code andsafety requirements as stated here. If thetank does not comply, DO NOT use it.

• If you do not have a copy of the tanksafety label pictured at right, pleasecontact your Clean Burn dealer for thelabel, which is to be affixed directly onyour used oil supply tank.


1-6

For Your Safety... (continued)Safety Labels

Following are the locations and descriptions of all labels on your Clean Burn Saturn™ A2 furnace. Thefollowing illustrations show the location of ALL labels on your furnace. Please note that some labelsdenote 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 inthis section (e.g. ATTENTION, CAUTION, WARNING, DANGER). For your safety and the safeoperation of your furnace, review all labels and heed all safety messages as printed on the labels.

If any labels on your Clean Burn furnace ever become worn, lost or painted over, please call your CleanBurn dealer for free replacements.

Saturn™ A2 Furnace Cabinet Labels

Label Part # Description42380 Saturn™ A2 Name Label42367 Furnace Safety Warning Label (Multiple Messages - Fire/Shock/Burn Hazards)42374 UL Data Label42358 UL Header Label42373 Saturn™ Series Name Label42383 Saturn™ Series Logo Label42027 Furnace Burn Hazard/Hazardous Voltage Warning Label42030 Furnace Electrical Shock Hazard Warning Label42045 Made in USA Label42197 Patent Pending Label42137 Date Code Label42068 Furnace Blower/Fan Entanglement Hazard Warning Label

42374

0

10

20 30 40

60

50

42358

42373


1-7


Saturn™ A2 Furnace Cabinet Safety Labels


1-8


Saturn™ A2 Furnace Cabinet Safety Labels

1.0

FOR COMMERCIAL OR INDUSTRIAL USE ONLY.

250

1/3

1/3

MAXIMUM FUSE SIZE

TOTAL CIRCUIT AMPACITY

42374

120

120

120

16.3

20

3.9

3.5

2.0

60

60

60

1/3

POWER

1/20

1/10

60

12

BLOWER

ATF 1.0

1.0

1.0

1.0

DISCHARGE

120

120

120

24

2

18

5.2

60

60

60

HZ

60

18

12.0

12.0

10.0

10.0

N/A

1.0

1.0

1.0

.03−.04

N/A

N/A

N/A

N/A

N/A

SATURN−A−UH−2

1.0

UL ATOM AIR

10.0

PRESSURE

1.0

ULC

N/A

OIL

140000

N/AN/AN/A

LEOLA, PENNSYLVANNIA (USA)

NO.

MH15393

13084

FOR COMMERCIAL OR INDUSTRIAL USE ONLY.

MULTI−OIL HEATING SYSTEM

42358

USED OIL−FIRED FURNACEUSED−OIL BURNING APPLIANCE

CERTIFIED TO ELECTRICAL AND FUEL BURNING REQUIREMENTS ONLY.

USED OIL−FIRED BOILER


1-9


Saturn™ A2 Burner Labels

Label Part # Description42004 Burner Safety Warning Label

(High Voltage/Moving Parts Hazards)42242 Burner Power Label42457 Patent Pending / Made in USA Label42375 Saturn Burner Description Label42235 Burner Safety Warning Label

(Fire/Explosion Hazard -Burner Installation and Service)

42005 Sold and Serviced By Label42000 Burner Safety Warning Label

(Fire/Explosion Hazard - Reset Button)42381 Saturn™ Series Logo Label42371 Burner Air Intake Plate Description Label

Saturn™ A2 Burner Safety Labels3020

10

0 60

50

40

50

60

10

0

4020 30

.495


1-10


2-1

SECTION 2: UNPACKINGBefore assembling your furnace, you must accomplish the following activities described in this section:

• Removing the Shipping Pallet• Unpacking and Inspecting All Components• Warranty Registration

Removing the Shipping PalletATTENTION: Your furnace cabinet is attached to the shipping pallet with two screws to keep thecabinet from shifting during shipment. You must remove the shipping pallet prior to assembly andinstallation of the furnace. DO NOT use the pallet as a platform for furnace installation!

1. Locate the shipping screws which attach the cabinet to the pallet by looking through the roundfan opening on the side of the furnace cabinet.

2. Remove and discard the two screws. Carefully lift the furnace off the shipping pallet with a forklift, and discard the pallet.

Unpacking and Inspecting All Components

Following is an itemized list of all components you should have received in your Clean Burn furnaceshipment. Open all shipping containers and inspect all components according to the list. Immediatelynotify the freight company and your Clean Burn dealer in case of shipping damage or shortage(s). Keepall components together so you will have them as needed for furnace assembly and installation.

Furnace Component List

ONE SKID containing:• Furnace cabinet

ONE BOX containing:• Burner

ONE SKID containing:• Fan assembly• Metering pump• Canister filter• Vacuum gauge• Check valve• Wall thermostat• Barometric damper• Assorted bolts/fittings for assembly/installation of furnace components• Operator's Manual

NOTE: You may have received additional boxes or skids if you ordered optional accessories.


2-2

Warranty Registration

For proper warranty registration, Clean Burn requires that you fill out the provided warranty registrationcard and return it within 30 days to:

CLEAN BURN WARRANTY REGISTRATIONClean Burn, Inc.

34 Zimmerman RoadLeola, Pennsylvania 17540


3-1

0

10

20 30 40

60

50

SECTION 3: FURNACE ASSEMBLYUnderstanding AssemblyAssembling your Clean Burn Saturn™ A2 Furnace includes the following steps:

(1) Installing the Observation Port(2) Installing the Fan Assembly(3) Installing the Burner

Clean Burn recommends that you review all assembly procedures before proceeding, paying carefulattention to safety information statements. Figures 3A and 3B provide a general overview of thefurnace components and their proper assembly and how the unit should look following proper assembly.

Required Tools and Materials

The following tools and materials are required for furnace assembly and should be gathered beforestarting any procedures:

Figure 3A - Overview of Furnace Assembly

• 9/16" open-endwrench

• Medium flat-blade screwdriver

• Medium adjustablewrench

• 1/4" nut driver


3-2

ASSEMBLY OFOBSERVATION PORT

ASSEMBLED OBSERVATION PORT

OBSERVATION PORT

HALF−MOONPIECE

FACE PLATE

Figure 3B - Three-dimensional View - Furnace Completely Assembled

Installing the Observation PortCAUTION: To prevent serious personal injury, the observation port must be correctly installedaccording to the following procedure. A properly installed observation port permits safe obser-

vation of the flame during furnace operation. Be sure to follow all safety procedures as outlined in thismanual when observing the flame through the port.

1. Refer to Figure 3B.2. Use a 1/4" nut driver to remove the two (2) self-tapping screws from the half-moon piece.3. Position the half-moon piece and the faceplate on the observation port, and install the two

self-tapping screws.4. Open the port and make sure the faceplate moves and closes freely. If the faceplate hangs up,

loosen the hex-head screws slightly until the faceplate closes correctly.


3-3

Installing the Fan Assembly

CAUTION: Ducting the Saturn™ A2 Furnaceis not permitted; it is intended for use as a Unit

Heater ONLY.

1. Refer to Figure 3C.2. Attach the fan assembly to the furnace

cabinet using the six hex-head bolts.3. Make sure that fan blade is centered in the

round opening on the cabinet. Spin the fanblade to check that it spins freely.

4. Remove the cover of the electrical junctionbox.

5. Attach the fan motor electrical cable to theelectrical junction box.

6. Connect the fan motor wires according to thewiring schematic provided in Appendix B atthe back of the manual.

Figure 3C - Fan Installed onFurnace Cabinet


3-4

BURNER NOZZLE

NOZZLE IS STAMPED EITHER 9−5OR −5 ON FLAT OF NOZZLE HEAD

SIDE VIEW − AA

3/16" GAP BETWEENELECTRODES & NOZZLE

CRITICAL DIMENSIONS:ELECTRODES MUST BE

FLUSH WITH NOZZLE TIP.RETENTION HEAD DISK MUST

BE FLUSH WITH NOZZLE TIP

1/8"SPARK

GAP

SIDE VIEW − BB

VIEW − AA

VIEW − BB

3X

I88340

Installing the Burner

Checking the Burner Nozzle and Electrodes

NOTE: The burner nozzle, a Delavan 9-5, is factory installed. The nozzle size is indicated on thenozzle as shown in Figure 3D. Refer also to Appendix A at the back of the manual for additionalspecifications/instructions on the burner nozzle.

ATTENTION: Check the electrode settings as specified in Figure 3D. The electrode settings must becorrect for your burner to operate properly.

Figure 3D - Burner Nozzle and Electrode Specifications


3-5

Installing the Burner (continued)

Mounting the Burner

ATTENTION: Burner tube components (e.g. electrodes and retention head) are factory set. Handle theburner with extreme care so that burner components are not damaged.

ATTENTION: DO NOT use teflon tape on any fittings. Teflon tape residues will plug vital burnercomponents.

1. Remove the nut from the bolt on the mounting flange of the furnace cabinet, and set it aside forlater use.

2. Lift the burner into position so the burner hinge plate is mounted on the hinge bracket on thefurnace cabinet as shown in Figure 3E.

3. Carefully swing the burner so the retention head enters the throat of the furnace.4. Check the clearance between the retention head and the furnace throat.

NOTE: There must be at least 1/8" clearance, so the retention head is not "bumped" as youswing the burner into firing position.

5. DO NOT allow any dirt/debris to enter the burner during furnace assembly/installation.6. Install and tighten the lock-down nut on the mounting plate bolt to secure the burner in its firing

position.

Figure 3E - Mounting the Burner


3-6

NOTE: Your furnace is now assembled and ready for installation. Install the furnaceas soon as possible so the burner and/or fan are not "bumped" or damaged. If you muststore the furnace for a period of time before installation, make sure it is located in a safe,secure area.


4-1

SECTION 4: FURNACE INSTALLATIONUnderstanding InstallationInstalling your Clean Burn furnace is a multi-step process which includes:

(1) Selecting a Location(2) Mounting the Furnace(3) Oil Tank Specifications (review)(4) Installing the Metering Pump(5) Wiring the Furnace and Pump(6) Installing the Oil Lines(7) Installing the Compressed Air Line(8) Installing the Stack(9) Installing the Wall Thermostat(10) Inspecting the Installation

Clean Burn recommends that you review all procedures before beginning installation, paying carefulattention to safety information statements. Figures 4A and 4B provide a general overview of typicalfurnace installations and should be reviewed closely before proceeding.

WARNING: The installation, operation, and maintenance of this equipment in the U.S.must be accomplished by qualified personnel and in compliance with the specifications in the

Clean Burn Operator's Manual and with all national, state, and local codes or authorities havingjurisdiction over environmental control, building inspection and fuel, fire and electrical safety and thefollowing standards of the National Fire Protection Association.

NFPA 30 Flammable and Combustible Liquids CodeNFPA 30A Automotive and Marine Service Station CodeNFPA 31 Standard for the Installation of Oil Burning EquipmentNFPA 211 Chimneys, Fireplaces, Vents and Solid Fuel Burning AppliancesNFPA88A Parking StructuresNFPA 88B Repair GaragesNFPA 70 National Electrical Code

The NFPA standards may be obtained from:National Fire Protection Association (NFPA)1 Batterymarch Park, P.O. Box 9101Quincy, Massachusetts 02269-9101

Likewise, the installation, operation, and maintenance of this equipment in Canada is to be accomplishedby qualified personnel and in compliance with the specifications in the Clean Burn Operator's Manualand in accordance with the regulation of authorities having jurisdiction and CSA Standard B 139,Installation Code for Oil Burning Equipment.

Failure to comply with these standards and requirements may result in equipment damage, fire,explosion, personal injury and/or death.

WARNING: Improper installation can adversely affect the proper, safe operation of yourfurnace. It is critical that your furnace installer reads and follows the instructions provided in

this manual.


4-2

FOR RELATEDSEE SECTION 8

1/4" HOLE FORSETTING DRAFT.

PROCEDURES.

THERMOSTAT24 VOLT WALL

TH

ER

MO

ST

AT

CA

BLE

ELECTRIC SERVICE

DE

DIC

AT

ED

ELE

CT

RIC

CIR

CU

IT

OIL

PU

MP

ELE

CT

RIC

AL

CIR

CU

IT

"2 W

IRE

" M

IN 1

8 G

A.

OIL STORAGE TANK

CLEAN OUT

R H RO TATI ON

I NL ET G AUGE

INLET

PRESSURE OIL LINE

VENT PIPEWITH VENT CAP

EMERGENCY VENT VALVE

CANISTER FILTER IN SUCTION LINE

INSTALL 2" x 2" x 4"ELECTRICAL BOXON OIL PUMP MOTOR

SUCTION OIL LINE

FLARE FITTINGCAUTION: SUCTION OIL LINEMUST BE 100% AIRTIGTH. AIRLEAKS CAUSE THE BURNER TOPERIODICALLY SHUT DOWN ONSAFETY LOCK−OUT

REMOVABLE STANDPIPE

CHECK VALVE − INSTALL WITH ARROW UP

SEE TANK/PUMPINSTALLATION DIAGRAMTO PROPERLY INSTALLTHE SUCTION OIL LINEAND PUMP

COMPRESSED AIR LINEINSTALLED DIRECTLYIN FITTING AT THE BOTTOMOF BURNER

ELECTRICALJUNCTIONBOX

DOUBLE NUTS

DOUBLE NUTS

NON−RESTRICTIVE"CLASS A" STACK CAP

OUTSIDE STACK ANDSTACK PENETRATIONS THROUGHCEILING, ROOF, OR SIDEWALL MUSTBE "CLASS A" FOR FIRE SAFETY ANDTO MAINTAIN PROPER DRAFT

EXTERIOR SINGLE WALL STACKDOES NOT MEET CODE. EXTERIORSINGLE WALL STACK CHILLS THEEXHAUST GASES RESULTING INPOOR BURNER PERFORMANCE ANDBACK PRESSURE IN THE FURNACE

WATERTIGHT ROOF FLASHING:CLEAN BURN RECOMMENDS "DEKTITE"FLASHING FOR A WATERTIGHT SEAL

"CLASS A" INSULALTED STACKWITH A STAINLESS STEEL LINER

MAKE SURE TO INSTALL ALL STACK COMPONENTS WITHPROPER CLEARANCE FROMCOMBUSTIBLES

MAKE SURE TO INSTALL THE PROPER ROOF SUPPORTSYSTEM TO SAFELY SUPPORT THESTACK

CEILING MOUNTING SYSTEM

USE MINIMUM 2−1/2" x 2−1/2"ANGLE IRON BEAMS, BRIDGED ACROSSSUFFICIENT STRUCTURAL MEMBERS TOSAFELY SUPPORT FURNACE

(4) "ALL THREAD" SUPPORT RODS5/8" (1.6 CM) DIAMETER FOR ALL MODELS

MAKE SURE TO USE DOUBLENUTS TO SECURELY FASTEN SUPPORT RODS

LOUVER SIDE

SE SL

EROMBAROMETRICDAMPER

SINGLE WALLSTACK

ELBOW ORCEAN−OUT TEE

DOUBLE TAP BUSHING

"SLIP THRU"TUBING FITTINGS

OIL FLOW

"CLASS A" KIT FORINSTALLING"CLASS A" STACKTHROUGH CEILING

Figure 4A - Typical Furnace Installation


4-3

AIR INTAKE

DAMPER FOR −.04 W.C.ADJUST BAROMETRIC

1/4" HOLE FORSETTING DRAFT.

DRAFT AT BREECH

THERMOSTAT24 VOLT WALL

TH

ER

MO

ST

AT

CA

BLE

ELECTRIC SERVICE

DE

DIC

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ELE

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RIC

CIR

CU

IT

OIL

PU

MP

ELE

CT

RIC

AL

CIR

CU

IT

"2 W

IRE

" M

IN 1

8 G

A.

COMPRESSED AIR LINE

OIL STORAGE TANK

CLEAN OUTCLEAN OUT

NOTE: LOCAL CODES MAYREQUIRE ELECTRICALSHUT−OFFS AT OR NEARTHE FURNACE AND PUMP

STANDPIPE SPECIFICATIONS;USE MIN. 1/2" I.D. STEEL PIPE ORMIN. 5/8" COPPER TUBING FOR INSIDE TANK

FOR OUTSIDE TANK USE MIN. 3/4"

MIN. 12" FROM CHECK VALVE TO TANK BOTTOM

OIL LINE

DIAMETER OF COPPER TUBING MUST BE MAINTAINED FOR FULL LINE LENGTH

MIN. CLEARANCES TO COMBUSTIBLESAND MIN. SERVICES DISTANCES:

TOP 18"FRONT (BURNER SIDE) 24"REAR (STACK SIDE) 36"BOTTOM 24"LOUVER END 60"FAN END 24"CHIMNEY CONNECTOR 18"

HORIZONTAL SUCTION LINE NOT TO

CAUTION: KEEP THE SUCTION LINE

NOTE: THE LAST STACK SECTION SHALL EXTEND AT LEAST 2 FT ABOVE THE HIGHESTPOINT AT WHICH IT COMES IN CONTACT WITH THE ROOF, AND AT LEAST 2 FT HIGHER

THAN ANY RIDGE, PARAPET WALL OR ROOF STRUCTURE WITHIN 10 FT OF IT

10 FEET

2 FEET

10 FT VERTICAL STACK HEIGHT OREQIVALENT DRAFT SYSTEM TOMAINTAIN −.02" WC DRAFT OVER FIRE

MINIMUM 8 INCHESSTACK COMPONENTSREQUIRED. DO NOT

REDUCE STACK SIZEFURNACE

MIN

. 5 F

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T

MA

KE

SU

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YO

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AC

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MO

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8 F

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MIN

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ND

IF T

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ITY

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OR

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IN Y

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R S

HO

P. R

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TO

NF

PA

−88B

MAX. 6 FEETVERTICAL SUCTION LIFT

OR NOT TO EXCEED10" HG OF VACUUM

100%AIRTIGHTSUCTIONOIL LINE

LOC

AL

FIR

E C

OD

EEXCEED 10" HG OF VACUUM

AS SHORT AS POSSIBLE

12 INCHES

Figure 4B - Typical Furnace Installation - Detailed


4-4

I88601

24 "FAN SIDE

TOP18 "

18 "CHIMNEY

CONNECTOR

36 "REAR

60 "LOUVER SIDE 24 "

FRONT

96 " BOTTOM − IF THERE IS POTENTIAL FOR GASOLINE FUMES

24 " BOTTOM − IF THERE IS NO POTENTIAL FOR GASOLINE FUMES

Selecting a LocationGuidelines for Selecting a Location

The location you select for your furnace must allow the following:• Unobstructed, even heat distribution.• Safe, easy access for servicing.• Unobstructed passage for shop vehicles and equipment.• Proper clearances from combustibles. Verify according to your local safety codes.• Adequate combustion air per local codes.• Proper stack installation.

WARNING: Adhere to the following minimum clearances from combustible surfaces andto provide adequate clearance for servicing; failure to maintain proper clearances may result in

fire, explosion, personal injury or death.

TOP....................................... 18"FRONT (burner side) ............ 24"REAR (stack side) ................ 36"LOUVER END ..................... 60"BLOWER/FAN END ........... 24"BOTTOM ............................. 24"CHIMNEY CONNECTOR .. 18"

WARNING: Your localcodes may require that

your furnace is mounted aminimum of eight (8) feet off theground if there is the possibilityof gasoline fumes or othercombustible or explosive fumesin your shop area. Refer toNFPA-88B.

Figure 4C - Clearances from Combustibles


4-5

Raised Platform Mounting

WARNING: To prevent serious personalinjury, make sure the platform is designed

to safely bear the weight of the furnace and allowsafe servicing of furnace components. Theplatform must be constructed of non-combustiblematerials (e.g. steel) and must be securelyanchored to an adjacent wall.

1. Refer to Figure 4D and follow theinstructions as provided in the diagram.

Figure 4D - Furnace Installed onRaised Platform

Mounting the Furnace

After selecting a safe and appropriate location for your furnace, construct the mounting system asrequired by the location and the following specifications.

Ceiling Mounting

WARNING: To prevent serious personal injury, ensure that your furnace mounting system cansafely bear the suspended weight of the furnace and allow safe servicing of furnace components.

Use minimum 2-1/2" x 2-1/2" x 1/4" angle iron beams bridged across sufficient structural members tosafely support the furnace.

1. Refer to Figures 4A and 4B.2. Follow the instructions as provided in the diagrams.3. Use a spirit level to make sure the cabinet is level side to side and front to back.

IF T

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IS N

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4-6

Mounting the Furnace (continued)Floor Mounting

CAUTION: If you are installing yourfurnace in an area with a combustible floor, you mustconstruct a non-combustible floor as shown in Figure 4E. Refer to NFPA-31 or CSA-B-139.

1. Refer to Figure 4E and follow the instructions as provided in the diagram.

Figure 4E - Furnace Installed on Non-Combustible Floor

(2.5 CM) LIP FOROIL CONTAINMENT

TALL CINDER BLOCK

MIN. 24 GA STEEL

FIREGUARD SHEETROCK

COMBUSTIBLE MATERIALMIN. 2" (5 CM) TALL MASONRY BLOCKS TOALLOW CLEARENCE FO INSTALLATION OFFITTINGS ON THE CONNECTOR BLOCK

PAN WITH MIN. 1 INCHMIN. 24 GA STEEL

8 INCHES (20 CM)

OR EQUIVALENT

MIN. 18" (46 CM)MIN. 18" (46 CM)


4-7

Oil Tank Installation Specifications

Ensure that your tank installation adheres to thefollowing safety guidelines as stated here and inSection 1 of this manual.

The tank safety label (shown at right) alsosummarizes these important specifications for tankinstallation and usage. If you do not have a copy ofthis label, please contact your Clean Burn dealer fora copy, which is to be affixed directly to your usedoil supply tank.

• The tank installation must meet allnational and local codes. Consult yourlocal municipal authorities for moreinformation as necessary.

• The tank must be listed to UL 80 orUL 142.

• Use a minimum 250-gallon tank.DO NOT use a 55-gallon drum as asubstitute for an appropriate tank. Thetank must be large enough to allow water,sludge, etc. to settle out of the used oil.

• The tank must have a manual shut-offtype valve on the side of the tank to allowthe water, sludge, etc. to be drained fromthe bottom of the tank.

• All unused openings in the tank must beplugged or capped off.

• The tank must be vented to the outside ofthe building using iron or steel pipe andfittings with an approved vent cap.

• Carefully review the oil tank and pumpinstallation details as shown in Figures 4A,4B, and 4F, including the metering pumpinstallation and specifications for the oilline installation. (Procedures for installingthese components can be found in thefollowing pages.)


4-8

Oil Tank Installation Specifications (continued)

Figure 4F - Typical Metering Pump Installation with Inside Tank

Installing the Tank Vent and Emergency Vent

National codes require that you install a tank vent (to the outside) and an emergency vent for your tankas shown in Figure 4F. Tank Vent Kits are available from Clean Burn; contact your local Clean Burndealer to order. Be sure to check your local codes for any additional tank installation requirements, andadhere to the following installation guidelines:

• Install a length of minimum 2" steel pipe (user-supplied) terminating outside with a propervent cap as shown in Figure 4F. Consult local codes for information and requirementsconcerning the proper venting of oil storage tanks.

• Install an emergency vent as shown in Figure 4F. Contact your tank manufacturer forinformation concerning the proper emergency vent for your tank.

PUMP

SUCTION LINE ASSEMBLY

EMERGENCYVENT

MUSHROOMCAP VENT

SCREENFILTER

VALVECHECK

(USER SUPPLIED)STEEL PIPE

FUNNEL WITH BALL VALVE

CLEAN−OUT(TANK DRAIN)

TANK VENT KITS AVAILABLE FROM CLEAN BURN: CB Part # 70380 − 4" Tank Vent Kit (2) elbows (2) 6" nipples (1) mushroom cap vent (1) emergency vent


4-9

Figure 4G - Metering Pump Components

Installing the Metering Pump

Preparing for Installation

Before starting installation of the metering pump, review Figure 4G to become familiar with themetering pump components. You will also need to accomplish the following activities:

• Verify that you have the proper metering pump for your furnace model.• Gather all required tools and materials as needed for installation; as indicated in the

following procedures, some materials (e.g. fittings, tubing) are to be user-supplied.• Standard mounting is vertical mounting on a wall; this pump installation is recommended.

Alternate mounting is horizontal mounting on a bracket. Be sure to carefully follow theappropriate procedures/diagrams for pump mounting.

2

10

# PART # DESCRIPTION1 33363 CAPACITOR − GEARMOTOR

8 21119 LID − METER PUMP HOUSING

3 11322 MOUNT − METER PUMP

9 32327 METER PUMP10 32467 1/4" X 3" NIPPLE

7 32335 ADAPTOR PIPE 1/4F X 1/8M6 32424 LOW FLOW CHECK VALVE

4 32425 1/4 NPT BRASS TEE 5 32293 RELIEF VALVE

11 32210 1/4" STREET ELBOW12 32336 1/4 X 3/4 BRASS BUSHING

14 32127 CANISTER FILTER− LENZ

17 32463 NIPPLE, 3/8" x 5", BRASS

15 32342 NIPPLE, 1/4" CLOSE, BRASS

18 32461 PIPE CAP, 3/8", BRASS

9

43

12

5

11

14

16

8

6

13

13 32123 VACUUM GAUGE

2 33291 GEARMOTOR

17

18

4

15

16 32462 PIPE REDUCER, 1/4" x 3/8", BRASS

7

1

19

19 32089 1/2" CHECK VALVE


4-10

Installing the Metering Pump (continued)

Standard Mounting: Vertical Positioning

1. Refer to Figures 4G, 4H, 4I, 4J. Note that the metering pump is shipped with the pump headalready positioned for vertical wall mounting.

2. Use the appropriate type of bolts and washers (user-supplied) to securely mount the meteringpump to the appropriate wall in your building.

Figure 4H - Standard (Recommended) Vertical Mounting of the Metering Pump


4-11


Standard Mounting: Vertical Positioning

Figure 4I - Metering Pump Component Detail for Standard Vertical Mounting

10 33291 GEARMOTOR

# PART # DESCRIPTION

5 32327 METER PUMP4 32335 ADAPTOR PIPE 1/4F X 1/8M3 32424 LOW FLOW CHECK VALVE2 32425 1/4 NPT BRASS TEE

1 32293 RELIEF VALVE

6 33304 COUPLING METER PUMP 7 11322 MOUNT METER PUMP 8 21119 LID−METER PUMP HOUSING

9 33363 CAPACITOR GEARMOTOR


4-12


Figure 4J - Proper Positioning of Metering Pump Head

Alternate Mounting: Horizontal Positioning

ATTENTION: If the metering pump is to be mounted horizontally or on a bracket as shown inFigure 4J, the pump head must be rotated counterclockwise so that it is aligned in a horizontal position.The gauge arrow on the pump head must point up, or the pump will not prime.

1. Refer to Figures 4G and 4J.2. Remove the two pump mounting bolts. The coupling is keyed and does not have set screws.3. Rotate the pump head 180 degrees to the horizontal position as shown in Figure 4J.4. Re-install and tighten the two pump mounting bolts.5. Use the appropriate type of bolts and washers (user-supplied) to securely mount the metering

pump to your mounting bracket.

GAUGE

INLET

INLETINLETGAUGE

INLET

RECOMMENDED SETUPPUMP IS MOUNTEDLEFT ON WALL

ALTERNATE MOUNTING

TO THE WALL MAKING THEBLEED VALVE IS NOW CLOSE

I88708

ROTATION

ROTATION

INLET

GAUGE

INLET

INLET

(NOT RECOMMENDED)

BLEEDING DIFFICULT

ROTATION ROTATION

NON−STANDARD SETUPPUMP HEAD HAS BEENROTATED 90° CCW FORHORIZONTAL MOUNTING(THE 1/4" STREET ELBOW AND1/4" X 3" NIPPLE CHANGE PLACESIN THE PLUMBING SEQUENCE)

INLETINLET


4-13

Wiring the Furnace and Pump

WARNING: To avoid electrical shock, make sure that power to the furnace is turned OFFbefore connecting any wires. A licensed electrician should install all wiring to your furnace. All

wiring must be in accordance with the National Uniform Electrical Code and local codes. Properly sizeall wires and use electrical conduit for all electrical lines.

Wiring your furnace involves the installation of two lines:(1) A dedicated electrical line to the furnace(2) A pump electrical circuit from the furnace to the metering pump

Necessary wiring specifications are provided in this section and in the Wiring Schematics located inAppendix B at the back of the manual.

Wiring to the Furnace

1. Install a dedicated electrical circuit to the electrical junction box on the furnace.WARNING: DO NOT tie into an existing circuit, or electrical overload may occur.

2. Wire the furnace according to the Wiring Schematic, Figure B1, in Appendix B.3. Check for correct voltage at the furnace, and refer to the following chart.

ATTENTION: Incorrect voltage will severely damage the blower motor/furnace components.DO NOT operate your furnace on any non-specification power system.

Model Voltage Breaker Size* Circuit HertzSaturn™ A2 110/120 20 amps Dedicated 60

*NOTE: Breaker size with optional equipment is 30 amps. When installing anyoptional equipment (e.g. air compressor or draft inducer), you must use a 30 amp breaker. Makesure a qualified electrician properly sizes and installs this electrical circuit.

4. DO NOT turn on main power until instructed to do so.

Wiring to the Metering Pump

WARNING: DO NOT wire the pump directly into your building's electrical system. The pumpmust be activated (receive power) from the burner via the pump electrical circuit. DO NOT wire

the pump directly to a wall outlet so that it runs continuously; this will seriously damage your meteringpump and/or furnace and may result in a fire or explosion hazard.

1. Install the pump electrical circuit from the furnace to the metering pump location.2. Wire the pump circuit according to the appropriate Wiring Schematic, Figure B4 (Appendix B).


4-14

ATTENTION: It is critical that you adhere to the following specifications for suction oil lineinstallation (oil line from the tank to the pump). If these specifications are not met, the metering pumpwill not function correctly and the burner will shut down on reset.

• All suction oil line components must be installed as shown in the appropriate diagramsprovided in this manual (see Figures 4A, 4B). Proper installation allows the suctionoil line to be filled with used oil during initial priming.

• The metering pump must be installed with a 1/2" check valve (without screen) at the end ofthe suction oil line, or the pump will not prime (and maintain prime).

• Use Permatex #2 non-hardening gasket sealer on every threaded fitting. DO NOT use teflontape or teflon pipe dope compounds--these substances cause the fittings to leak. The suctionoil line must be 100% airtight for proper system functioning.

• Use only high-quality flare fittings on the copper tubing to ensure that the suction oil line is100% airtight. DO NOT use compression fittings. DO NOT use any steel pipe unions.DO NOT use sweat copper pipe. These types of fittings cause leaks in the suction oil lineand will require re-installation to achieve proper specifications.

• The suction oil line must slant up to the pump; any high spots will trap air and will not allowthe pump to prime.

1. Assemble the suction oil line fittings:a. Refer to Figure 4G for a detailed look at the metering pump components and fittings.b. Remove the plug from the 1/4" inlet port of the pump.c. Install the 1/4" x 3" brass nipple into the 1/4" inlet port on the pump.d. Prepare the canister filter by installing the 3/4" x 1/4" brass hex bushing in the outlet port of

the canister filter. Install the 3/4" x 1/4" brass hex bushing in the inlet port of the canisterfilter.

e. Install the canister filter assembly on the 1/4" brass nipple. Make sure the canister filter isinstalled with the arrow (direction of oil flow) towards the pump.

f. Remove the plug from one of the 1/8" gauge ports in the canister filter. DO NOT install thevacuum gauge yet. (Keeping this port open allows easy filling of the suction line duringpump priming.)

g. Install the 1/4" brass tee in the hex bushing in the inlet port of the canister filter. Make surethe tee is positioned so the fill port is pointing straight up.

h. Loosely install the 3/8" cap into the fill port. You will seal and tighten this cap later aspart of the pump priming procedure.

i. Install a 1/4" close nipple and 1/4" ball valve (user-supplied) in the bottom port of thebrass tee.

j. Install a 1/2" MPT x 1/2" flare fitting (user-supplied) in the bottom port of the ball valve.DO NOT use a compression fitting!

Installing the Suction Oil Line Components


4-15

Installing the Suction Oil Line Components (continued)

2. Install the suction oil line:a. Refer to Figures 4A, 4B, and/or 4G.b. Prepare a piece of 1/2" O.D. copper tubing (user-supplied) which will function as the pick-up

tube from the tank to the canister filter. This copper tubing must have the followingspecifications:

• The tube must be one continuous piece of 1/2" O.D. copper tubing with no kinksor fittings.

• The tube is to slant up from the tank to the pump with no loops or high points totrap air.

• The check valve (1/2", without screen) must be installed on the end of the tubing.The inlet of the check valve must be a minimum 12" off the bottom of the tank toprevent sludge, water, etc. from entering the system.

• Assemble the tubing according to Figures 4A/4B. Use a high-quality flaring tool(such as a Rigid Flaring tool) to make sure the flares at both ends of the tube aremade properly and the flare fittings are 100% airtight.

c. Purchase a 2" male x 1/2" female hex bushing (which will eventually be installed into theopening on the tank).

d. Install a 1/2" MPT x 1/2" slip fitting (user-supplied) into the hex bushing in the tank. (Thisfitting is designed to allow the 1/2" tubing to slide through it.)

e. Slide the 1/2" copper tubing through the slip fitting.f. Prepare the check valve by installing a 1/2" MPT x 1/2" flare fitting (user-supplied) in the

outlet port of the check valve (the arrow on the check valve must point to this fitting).DO NOT use compression fittings.

g. Install the check valve on the end of the copper tubing.h. Carefully guide the end of the tubing with the check valve through the opening in the tank,

ensuring that the check valve is at least 12" off the bottom of the tank.i. Install the hex bushing into the opening in the tank.j. Install the end of the tubing to the flare fitting on the ball valve at the canister filter.k. Tighten the slip fitting on the copper tubing to hold the tubing in place.l. Install a vent from the tank to the outside according to code. The tank must be properly

vented to allow air to enter the tank as oil is pumped from the tank and to safely vent fumesto the outside.

m. Install plugs in all other tank openings as required by code.n. Inspect the installation. Make sure all components are installed and positioned as specified in

this manual.NOTE: The majority of service problems with the metering pump are caused by leaks at fittings in thesuction oil line. These problems are eliminated by ensuring a 100% airtight suction oil line which slantsup to the pump and has absolutely no high points in the line to trap air.


4-16

ATTENTION: It is critical that you adhere to the following specifications for pressure relief andlow-flow check valve installation; if these specifications are not met, the metering pump will notfunction correctly and the burner will shut down on reset.

The metering pump requires the installation of a pressure relief and low-flow check valve as shown inFigure 4G. The pressure relief will open and relieve pressure on the line if there is a restriction in thepressure oil line, clogged nozzle, etc. The low-flow check valve is a vital component which maintainspressure in the oil pressure line. Be sure to use Permatex #2 non-hardening gasket sealer to seal everythreaded fitting. DO NOT use teflon tape or teflon pipe dope compounds.

1. Refer to Figure 4G.2. Install the low-flow check valve in the 1/8" outlet port of the pump using the assembled fittings

as shown.3. Install 1/4" O.D. copper tubing (user-supplied) from the pressure relief back to the oil tank.

NOTE: Remove one of the 2" plugs from a tank opening and carefully drill a 1/4" hole in themiddle of the plug. Re-install the plug in the tank opening and guide the 1/4" tubing through thehole so that an inch of tubing is through the hole.

Installing the Pressure Relief and Low-Flow Check Valve

ATTENTION: It is critical that you adhere to the following specifications for pressure oil lineinstallation (oil line from the pump to the furnace); if these specifications are not met, themetering pump will not function correctly and the burner will shut down on reset.

• The parameters for pressure oil line installation are:Length of Pressure Line Line SizeUp to 100 feet 3/8" O.D. copper tubing

• The pressure oil line must slant up to the burner with no loops or high points to trap air.

• Local codes may require the installation of an in-line "Fire-O-Matic" safety valve.Be sure to check all appropriate codes to ensure compliance.

1. Refer to Figures 4A, 4B, and 4G.2. Make sure you have purchased all the necessary fittings to complete the installation correctly.3. Install the fittings and components as shown in the related illustrations. Be sure to use permatex #2

non-hardening gasket sealer to seal every threaded fitting. DO NOT use teflon tape or teflon pipe dopecompounds.

Installing the Pressure Oil Line Components


4-17

Installing the Stack

WARNING: Inappropriate stack materials or improper stack design/installation can adverselyaffect the proper, safe operation of your furnace. Contact your Clean Burn dealer to purchase the

proper stack components for your furnace.Stack designs are generally classified as follows:

(1) "Class A" stack through the ceiling of the building(2) "Class A" stack through the sidewall and up the side of the building

Figures 4K and 4L illustrate these stack designs. Choose the stack design which is appropriate for yourfurnace installation and review all specifications provided in the illustration. When designing yourstack, adhere to the following specifications:

• Use minimum 8" I.D. stack components.• Ensure that the vertical stack height is at least 10 feet. If needed, increase the vertical length

of the stack or install a draft inducer to obtain -.02" W.C. (maximum) draft over fire. (Section 8contains details on adjusting the draft.)

• Keep the horizontal stack run as short as possible; slant it upward at a minimum of 1/4" perfoot of run.

• Keep the stack design simple. Complicated stacks (with long runs and many turns) reducedraft and result in poor burner performance. Your stack may include only one 90 degree turn.All other stack turns must be at 45 degrees or less to ensure optimal draft and burnerperformance.

NOTE: If you plan to use an existing masonry chimney, the chimney must be inside the building.Exterior masonry chimneys chill the stack gases and result in poor draft and poor burner performance.ATTENTION: If you have an exhaust fan(s) in your shop, it is critical that you have adequatemake up air (source of fresh air to replace the stale air exhausted by the fan). When an exhaust fan isrun without adequate make up air, the resultant vacuum in the building will draw combustion productsback into the burner. This back draft causes poor burner performance and may damage vital burnercomponents. Refer to Section 8 in this manual for additional information.

Installing the Compressed Air Line

NOTE: Your air compressor system must supply air pressure to the furnace with the followingrequirements: 50 psi and water trap or dryer. If you do not have shop air, an optional air compressoris available. Contact your local Clean Burn dealer for more information.1. Run a compressed air line from your shop air to the burner on the furnace. Use minimum 1/4"

O.D. copper tubing or equivalent for the compressed air line.2. Install an easily accessible shut-off valve in the air line so the burner can be serviced without

shutting off the shop air in your service area.3. If necessary, install a pressure regulator (additional to the burner air regulator) in the air line, and

set it at 50 psi.ATTENTION: DO NOT feed full shop air pressure to the burner or damage to burnercomponents may occur.

4. Install a water trap or extractor/dryer in the air line with an automatic drain so compressed air(rather than water) is supplied to the burner.ATTENTION: Water must not be fed to the burner, or the flame will be extinguished and theburner will shut down. Be sure to drain water from your compressor tank on a regular basis tokeep water out of the air line.


4-18

NOTE: MAXIMUM −0.02 W.C.

TO

MA

NIN

TA

IN P

RO

PE

R D

RA

FT

OV

ER

FIR

E

GASES FROM BEING SUCKED

IT IS FACING AWAY FROMMUST BE INSTALLED SOBAROMETRIC DAMPER

INSTALLING "CLASS A" STACK"CLASS A" KIT FOR

THROUGH CEILING

ATTENTION:

SEE SECTION 8FURNACE OPERATION.

DRAFT OVERFIRE IS ESSENTIAL FOR PROPER

MIN. 8" STACK SIZE:

SIN

GLE

WA

LL S

TA

CK

MIN

. 24

GA

UG

E

ROOF FLASHINGWATERTIGHT

NOTE: THE LAST STACK SECTION SHALL EXTEND AT LEAST

( 61 CM) HIGHER THAN ANY RIDGE, PARAPET, WALL OR ROOFSTRUCTURE WITHIN 10 FEET ( 3 M ) OF IT.

COMES IN CONTACT WITH THE ROOF AND AT LEAST 2 FEET3 FEET (92 CM) ABOVE THE HIGHEST POINT AT WHICH IT

FREE FLOW OF THE STACK GASES"CLASS A" STACK CAP − NON−RESTRICTIVE TYPE TO ALLOW

"CLA

SS

A"

ST

AC

K C

OM

PO

NE

NT

S

10 F

T. M

IN. V

ER

TIC

AL

ST

AC

K H

EIG

HT

INS

ULA

TE

D S

TA

CK

WIT

H A

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AIN

LES

S S

TE

EL

LIN

ER

10’

2’

Stack components should be installed in the following order:(1) Inside stack (the stack components from the furnace breach to within 18" of the ceiling, roof,

or sidewall of your building)(2) Barometric damper(3) "Class A" stack penetration through the ceiling, roof, or sidewall(4) "Class A" stack on the exterior of the building(5) "Class A" stack cap

Installing the Stack (continued)

Figure 4K - Installation of "Class A" Stack Through Roof/Ceiling


4-19

FURNACE

NOTE: MAXIMUM −0.02 W.C.

( 61 CM) HIGHER THAN ANY RIDGE, PARAPET, WALL OR ROOFCOMES IN CONTACT WITH THE ROOF AND AT LEAST 2 FEET3 FEET (92CM) ABOVE THE HIGHEST POINT AT WHICH ITNOTE: THE LAST STACK SECTION SHALL EXTEND AT LEAST

10 F

T. M

IN. V

ER

TIC

AL

ST

AC

K H

EIG

HT

10’

"CLASS A" STACK CAP − NON−RESTRICTIVE TYPE TO ALLOW FREE FLOW OF THE STACK GASES

FURNACE OPERATION.IS ESSENTIAL FOR PROPER

BAROMETRIC DAMPER

DRAFT OVERFIRE

SEE SECTION 8

STRUCTURE WITHIN 10 FEET ( 3 M ) OF IT.

"CLA

SS

A"

ST

AC

K C

OM

PO

NE

NT

SIN

SU

LAT

ED

ST

AC

K W

ITH

A S

TA

INLE

SS

ST

EE

L LI

NE

R

"CLASS A" STACKPENETRATION AND CLEAN−OUT TEE

SINGLE WALL STACKMIN. 24 GAUGE

2 F

EE

T (

61 C

M)

SE SL

EROM

Figure 4L - Installation of "Class A" Stack Through Sidewall


4-20

Installing the Interior Stack

WARNING: Single wall stack components may be used only for those portions of the stackwhich are located inside your building and away from any fire/burn hazards.

1. Install the single wall stack with proper clearances from combustibles. Also ensure that the stackis located a safe distance from all shop personnel.

2. Install an elbow or clean-out tee at the junction of the horizontal and vertical stack componentsto allow for easy cleaning of the stack.ATTENTION: Avoid additional 90-degree turns in the stack. Each additional 90-degree turnslows down stack gases, creates back-pressure, and results in repeated burner shutdown andunnecessary service calls. All other turns in the stack should be at a 45-degree (or smaller) angle.NOTE: IMPORTANT for Canadian Installations - Local codes may require the installation ofa clean-out tee.

Installing the Barometric Damper

1. Refer to Figure 4M. Install a single wall tee (min. 24 gauge) on the first straight vertical orhorizontal stack section within one to three feet of the furnace breach.NOTE: This tee is required to support the barometric damper. You must purchase this tee whenyou purchase your stack materials (8" single wall tee - CB#70174).

2. Install the barometric damper in the opening of the tee. Use a small spirit level to make sure thatit is properly level.

3. Install two self-tapping screws as shown in Figure 4M (i.e. one on each side of the barometricdamper) to hold the damper in place. DO NOT install a screw at the bottom of the barometricdamper, or the flapper of the damper will not operate correctly.

NOTE: Specifications for adjusting the barometric damper for proper draft overfire are provided inSection 8 of this manual.

I885398" CLEAN BURN BAROMETRIC DAMPERINSTALLED IN SINGLE WALL TEE ADJUST THIS WEIGHT TO

OBTAIN PROPER DRAFT

1

No QTY PART # DESCRIPTION

8" BAROMETRIC DAMPER3117011

Figure 4M - Installation of Barometric Damper


4-21

Installing the Exterior Stack

ATTENTION: All exterior stack pieces must be insulated "Class A" ("all fuel") stack components witha stainless steel liner. DO NOT use "Class B" natural gas stack components. DO NOT use single-wallstack for your exterior stack. Single-wall exterior stack chills the stack gases and results in poor draftand poor burner performance.

1. Refer to Figure 4K/4L as needed.2. Follow the installation instructions provided by the stack manufacturer.3. Install water-tight roof flashing around the penetration of the exterior stack.

NOTE: Clean Burn recommends the use of "Dektite" roof flashing (or equivalent) whichensures a water-tight seal when installed properly. Contact your local Clean Burn dealer fordetails.

Installing the Stack Cap

NOTE: Proper installation of a "Class A" stack cap ensures the free flow of stack gases which isessential for optimal burner performance.

1. Refer to Figure 4K/4L as needed. Your stack cap should be classified as: "Class A"non-restrictive, "fuel-oil type".

2. Install the stack cap according to the manufacturer's instructions.

Installing the Optional Draft Inducer

ATTENTION: The draft inducer, Field brand model DI-2, is optional equipment with the Saturn™A2 furnace and may be installed to ensure proper draft. The Field brand draft inducer has been testedfor use on Clean Burn furnaces. DO NOT use other models or brands of draft inducers.

Understanding the Importance of the Draft InducerThe draft inducer is designed to mechanically establish draft. As the paddle wheel turns, the combustiongases are sucked up through the furnace and out of the stack. (See Figure 4N.) Proper sizing,installation, and adjustment of the draft inducer are critical for optimal draft inducer operation.Follow these instructions carefully.

Installing the Draft InducerWARNING: Turn OFF the main power to the furnace before proceeding with the installation ofthe draft inducer.

Installing the Stack Penetration

WARNING: When running the stack through your ceiling, roof, or sidewall, you must use aproper insulated "Class A" stack penetration with a stainless steel liner. DO NOT run single-wall

stack through your ceilng, roof or sidewall. Single-wall penetrations do not meet safety codes and maycreate a fire hazard. Provide proper clearances to combustibles per all applicable codes.

1. Refer to Figure 4K/4L as needed.2. Follow the installation instructions provided by the stack manufacturer.


4-22

ATTENTION: It is very important to install the draft inducer on a vertical section of stack to isolatethe inducer from excessive heat and ash buildup. Never install the draft inducer on a horizontal sectionof stack close to the furnace breach where heat and ash will damage the inducer motor.

1. Refer to Figure 4N. Follow the instructions included with the draft inducer to mount the draftinducer on the section of single-wall vertical stack.

2. Position the draft plate all the way out so that it does not reduce the draft produced by the draftinducer. You will adjust the draft plate later as part of Adjusting the Draft Overfire(Section 8).

Figure 4N - Installation of the Optional Draft Inducer

I88623

10’ 2

’

FURNACE OPERATION.OVERFIRE SERVICEMAN ADJUSTS−0.02 W.C. DRAFT CHECK FOR

11 F

EE

T(

3.33

ME

TE

RS

)

BREECH SO THE MOTOR DOES NOTDRAFT INDUCER AWAY FROM FURNACESECTION OF VERTICAL STACK TO POSITIONNOTE: INSTALL DRAFT INDUCER IN LAST

OVERHEAT. THIS ALSO REDUCES ASH

DO NOT MOUNT THE DRAFT INDUCER IN THE HORIZONTAL STACK NEAR THE FURNACE

ACCUMULATION IN THE DRAFT INDUCER.

BREECH.

DRAFT INDUCER

ADJUSTMENT PLATE

DRAFT

"CLASS A" STACK

BAROMETRIC DAMPER TOOBTAIN −.02 W. C. DRAFTOVERFIRE

VE

RT

ICA

L S

TA

CK

SIN

GLE

WA

LL, 2

4 G

AU

GE

INT

ER

IOR

ST

AC

K

5 F

EE

T −

8 F

EE

T(1

.5 M

ET

ER

S −

2.5

ME

TE

RS

)

OPTIONAL


4-23

Installing the Wall Thermostat

ATTENTION: Before installing the round Honeywell thermostat, remove the red shipping tab.DO NOT turn the dial on the thermostat until the red shipping tab has been removed, or serious damageto the thermostat will occur!

1. Select a location for the thermostat on an interior wall away from the furnace and cold drafts.2. Run "two wire" (minimum 18 gauge) thermostat cable between the burner and the thermostat.3. Remove the yellow jumper wire from the "T" terminals of the oil primary control. Save this

jumper wire for use during pump priming.4. Connect the thermostat wires to the two "T" terminals on the oil primary control.5. Follow the manufacturer's instructions to wire the thermostat.

Inspecting the Furnace Installation

Following completion of all installation activities described in this chapter, the furnace should beinspected by qualified personnel before firing. This ensures that your installation meets all applicablenational and local codes and allows for any deficiencies to be corrected before furnace startup. Improperinstallation may void your warranty.

Installing the Optional Draft Inducer (continued)

Wiring the Draft Inducer for Normal Operation**(No exhaust fans in the building)

1. Wire the draft inducer according to the Furnace Wiring Diagram provided in Appendix B at theback of this manual.


4-24


5-1

SECTION 5: METERING PUMP PRIMINGUnderstanding Metering Pump PrimingPreparing your Clean Burn furnace for operation begins with priming the metering pump. Theprocedures in this section must be performed in sequence without interruption to properly prime thepump.

Required Tools and MaterialsThe following tools and materials are required for oil pump priming and should be gathered beforestarting any procedures:

• 3/8" open-end wrench• Rags• Two containers (minimum one-gallon)• Medium straight-blade screwdriver

ATTENTION: The priming process must be done precisely as described in this procedure to ensurethat all air is thoroughly bled from the system. Failure to bleed all air from the system will result inrepeated burner shutdowns on reset.1. Refer to Figure 5A.2. Remove the canister from the canister filter. Fill the canister 2/3 full with used oil (DO NOT use

new motor oil--it will not burn). Replace the canister. Be sure to tighten the four bolts evenly.3. Make sure the vacuum gauge has not been installed yet. During filling of the suction line, air

bleeds from the open vacuum gauge port.

Priming the Metering Pump

Figure 5A - Priming the Metering Pump


5-2

4. Remove the 3/8" cap from the 3/8" nipple. Place a funnel in the opening. Slowly pour used oilinto the funnel until the suction line, including the canister filter, is full.NOTE: Oil should flow from the vacuum gauge port which indicates that the suction line,canister filter, and pump head are completely full of oil.

5. Now install the vacuum gauge in the gauge port of the canister filter. Seal the threads of thegauge with Permatex gasket sealer.

6. Also install and tighten the 3/8" cap at the filling nipple. Seal the plug threads with Permatexgasket sealer to make sure the suction line is 100% airtight.

7. Open the bleeder on the pump two to three (2-3) full turns, and position a container to catch oilwhich will flow from the bleeder during pump priming.

8. Disconnect the pressure oil line from the burner and position a container to catch oil which willflow from the pressure oil line during pump priming.

9. Activating the PumpWARNING: Activating the pump for pump priming involves running the burner byjumping the "F" terminals of the oil primary control. This procedure (i.e. jumping the "F"terminals) should be used only for this specific purpose--never for normal operation. Thisprocedure is accomplished easily by two people: one at the burner and one at the wall thermostat.ATTENTION: When performing this procedure, never jump from an "F" terminal to a "T"terminal, or severe damage to the primary control will occur.a. Refer to Figure 5B, Step 1. Locate the yellow jumper wire which you removed and saved

during installation of the wall thermostat.b. Connect the jumper wire to one "F" terminal on the primary control.c. Refer to Figure 5B, Step 2.d. Turn the switch on the wall thermostat to HEAT, and adjust the thermostat above room

temperature. The burner should start running.

Priming the Metering Pump (continued)

Figure 5B - Jumping the Oil Primary Control

ATTENTION: Never touch a jumper wire from an "F" terminal to a "T" terminal on the oilprimary control. This will severely damage your primary control. Make sure that the plastic

barrier strip is in place between the "F" and "T" terminals as shown in Figure 5B.

STEP ONE STEP TWO STEP THREE

CAD CELL WIRES CAD CELL WIRES CAD CELL WIRES

JUMPER WIRE JUMPER WIRETHERMOSTAT WIRE

F2F1

T2T1

F2F1

T2T1

F2F1

T2T1

THERMOSTAT WIRE


5-3

Priming the Metering Pump (continued)

e. Immediately turn the knob on the air regulator clockwise until the air gauge registers10 to 12 psi. You will adjust the air pressure further during burner startup and operation.NOTE: No air pressure will register on the air gauge until the burner starts running.

f. The pump should start running.g. Within ten seconds, jump the "F" terminals by connecting the jumper wire to the other "F"

terminal.NOTE: If the safety reset on the primary control activates and the burner stops running whileperforming this procedure, follow the instructions in Section 7 to reset the oil primary controland restart the burner.

10. Run the pump until a solid stream of oil flows from the pump bleeder. This will bleed all air outof the suction line, oil filter and pump head.ATTENTION: For the metering pump to operate correctly, it is very important that the systemis entirely full of oil and all air is bled out. The burner will shut down if there is any air in thesystem.

11. Close and tighten the bleeder on the pump.12. Continue to operate the pump until a solid stream of used oil flows from the end of the pressure

oil line. This will flush air and debris from the pressure oil line.ATTENTION: For the metering pump to operate correctly, it is very important that the systemis entirely full of oil and all air is bled out. The burner will shut down if there is any air in thesystem.

13. Turn the power OFF so the pump and burner stop running.14. Re-connect the pressure oil line fitting at the burner (or install a plug in the tee if your pressure

oil line has a tee installed at the high point.)15. Remove the jumper wire from the "F" terminals, and make sure the cad cell wires are now

connected to the "F" terminals as illustrated in Figure 5B, Step 3. Save the jumper wire forfuture pump priming.


5-4

Vacuum Testing the Oil Pump

Vacuum testing the oil pump is a very accurate way to determine the following:• The condition of the pump -- the ability of the pump to pull a vacuum and suck oil from the tank.• The condition of the fittings, gaskets and seals from the ball valve to the pump -- these

components must all be airtight to avoid suction leaks.The following procedure provides instructions for vacuum testing the pump and canister filter onsystems equipped with a ball valve.

ATTENTION: For the pump to pull and hold vacuum, it is critical that all fittings are airtight. If any ofthese fittings are loose, the pump may not pull a vacuum or may lose the vacuum rapidly. It is alsocritical that all fittings in the suction line, including fittings on the canister filter, are 100% airtight.

1. Follow the instructions to prime the pump (previous procedure).NOTE: The pump will not pull a vacuum if the pump is dry. There must be oil in the gears ofthe pump before the pump can pull a vacuum.

2. With the pump running, open the bleeder two to three full turns, and make sure that oil is flowingfrom the bleeder. DO NOT close the bleeder yet.

3. Refer to Figure 5A. Close the ball valve and observe the vacuum gauge.NOTE: The ball valve must have a stainless steel ball and should be pressure tested by themanufacturer to ensure that it does not leak. If the ball valve leaks, the vacuum test will not beaccurate.

4. The vacuum should increase within 15 seconds to 20 to 25 inches of vacuum. When the vacuumgauge reads 20 to 25 inches of vacuum, first close and tighten the bleeder, then turn the pumpoff.NOTE: If the pump will not pull at least 20 inches of vacuum, there is a very serious suctionleak, or the pump is damaged.

5. If there are no suction leaks, the system will hold vacuum.NOTE: It is acceptable for the vacuum to drop one to five inches within one minute as the sealin the pump seats. The vacuum should then hold steady for 15 minutes.

ATTENTION: If the vacuum drops more than one to five inches within the first minute, there isone or more leaks somewhere between the pump and the ball valve. Do the following:

• Wipe your finger along the cylinder at the shaft of the pump. If there is oil here, the pumpseal is damaged. Replace the pump.

• Disassemble and clean all the fittings from the pump to the ball valve. Properly seal allfittings with Permatex #2 non-hardening gasket sealer or equivalent. Check the condition ofthe o-ring on the canister filter and tighten the four canister filter bolts in a crisscross pattern.

• Repeat the procedure to vacuum test the system to ensure that the system is air tight.


6-1

I88584COMBUSTIONAIR BAND

AIR GAUGE

LOCKING NUT

AIR REGULATOR

SECTION 6: STARTING AND ADJUSTING THE BURNER

Understanding Burner Startup and AdjustmentStarting and adjusting the burner involves a series of separate procedures which must be accomplishedin sequence without interruption. Review all the procedures before attempting burner startup andadjustment, paying careful attention to safety information statements.

Preparing the Burner for Startup

1. Turn the switch on the wall thermostat OFF.NOTE: If your thermostat does not have an OFF setting, disconnect one thermostat wire sothe burner will not run.

2. Turn the main power to the furnace ON.3. Wait at least 15 minutes until the preheater block is thoroughly warmed up. (Feel the back of the

burner box to make sure the preheater is sufficiently warm. The proving switch on the preheater

Figure 6A - Component Detail of the Saturn™ A2 Burner

block will not allow theburner to start until the blockis hot.)NOTE: The preheater blockwill remain warm as long aspower is supplied to theburner. If the main powersupply is ever turned OFF,you must wait at least 15minutes until the preheaterblock is thoroughly warmbefore starting the burner.

4. Refer to Figure 6A to locatethe air regulator. Loosen thelocking nuts on the airregulator.

5. Turn the adjustment knobson the air regulatorcounterclockwise until 1/2"of the threads on the knobare exposed. DO NOT backthe knob all the way out.

NOTE: The air gauge will not show any pressure until the burner starts. Before starting the burner for the firsttime, it is very important to turn the air regulator completely OFF as described.


6-2

Preparing the Burner for Startup (continued)

6. Initial Adjustment of the Combustion Air Band:WARNING: The combustion air band must be properly adjusted to ensure that the burnerignites and burns correctly. DO NOT attempt to start the burner with the combustion air band

wide open or completely closed. The burner may not ignite correctly. Failure to heed this warning mayresult in a fire or explosion hazard.

• Refer to Figure 6A to locate the combustion air band.• Rotate the combustion air band to adjust it to the appropriate initial slot opening as listed

in the following Initial Adjustment Charts. Use a ruler to accurately set the slotopening at the widest section of the slot.

IMPORTANT NOTE: This initial setting of the combustion air band will allow you to start the burner.You will fine tune the combustion air band further as described later in these instructions.

ATTENTION: The settings shown in the charts below are only initial adjustments. Finaladjustments must be done by inspecting the flame length according to the illustrationprovided on the following page.

NOTE: The oil pressure is automatically adjusted by the metering pump.

Initial Adjustments for the Saturn™ A2 FurnaceMaximum Input = 140,000 BTUH @ 1.0 GPH with Saturn™ A2 BurnerOil Type Oil PSI / Flame Length Air PSI Air Band Nozzle#2 Fuel Oil check flame length 10-12 3/16" 9-5#4 Fuel Oil check flame length 10-12 3/16" 9-5Used Crankcase Oil check flame length 10-12 3/16" 9-5Used ATF check flame length 10-12 3/16" 9-5Used Hydraulic Oil check flame length 10-12 3/16" 9-5

Starting the Burner

1. Turn the switch on the wall thermostat to HEAT and adjust the thermostat setting above roomtemperature to start the burner.

2. Adjusting the Air Regulator:As soon as the burner starts running, turn the knob on the air regulator clockwise to achieveproper operating air pressure. Refer to the Initial Adjustment Charts.NOTE: If the safety reset on the primary control is activated and the burner stops running, seeSection 7 for further instructions on restarting your burner.

3. Observing the Flame Length:Visually inspect the flame length through the observation port. Refer to Figure 6B for anillustration of the desired flame length. The flame should extend no more than one-half of theway down the combustion chamber.

WARNING: The observation port gets hot as the burner fires. To avoid personal injury, alwayswear heavy work gloves and safety glasses when opening the port and viewing the flame.


6-3

Figure 6B - Flame Length Adjustment

4. Check the flame length after the burner has fired for 15 minutes.5. Tighten the locking nuts on the air regulator.6. Fine Tuning the Combustion Air Band:

NOTE: The initial setting of the combustion air band may require additional adjustment.• Refer to Figure 6A to identify the combustion air band location on the burner.• Observe the flame. The flame should be yellow-white with sharp tips and no "sparkles."• If the flame is orange in color or the flame length is too long, the oil you are burning

requires MORE combustion air. OPEN the air band 1/8" to 1/4", and re-check the flamefor the proper characteristics.

• Re-check the flame after ten minutes. You should see a yellow-white flame with sharptips and no "sparkles", and the flame should extend half of the way down the combustionchamber.

(procedure continued on next page)

Correct Maximum Flame Adjustment(Proper Oil and Air Pressure with correct supply ofCombustion Air):

• Flame goes half of the way down thecombustion chamber.

• Flame does not touch back or walls ofcombustion chamber.

Incorrect Flame Adjustment(Not Enough Combustion Air):

• Flame must not touch back or walls ofcombustion chamber.

• Increase combustion air by opening theair band on the side of the burner.

Incorrect Flame Adjustment(Air Pressure Too High):

• Ensure proper air pressure setting.

I88372

Starting the Burner (continued)

NOTE: Increasing combustion air will shorten the flame;decreasing the combustion air will lengthen the flame.


6-4

Starting the Burner (continued)

7. Checking for a Smokeless Burn:Check for a smokeless burn by observing the stack while the burner is running. If you see anysmoke, repeat the previous steps for setting the combustion air band and adjusting the airregulator. After adjusting the combustion air band, re-check the flame length.NOTE: Check for a smokeless burn periodically (as you do the flame length). Immediatelyreadjust the burner if you ever see smoke coming from the stack. Smoke indicates impropercombustion air adjustment.NOTE: When using instruments to adjust the burner for a smokeless burn, the followingreadings should be achieved:

• Draft over fire should be -.02 inch w.c.• Adjust for a smoke spot of a trace to 2• Adjust for a CO2 reading of 8 to 10% or an O2 reading of 7 to 9%• Cad cell reading below 500 ohms

Checking the Operation of the Fan Motor

NOTE: It is important to verify that the fan motor operates correctly to ensure that the fan switch isproperly cycling the fan motor as described below. Also refer to Appendix A at the back of the manualfor additional pertinent information.

1. Start the burner and adjust it as described previously in this section.2. The fan motor will not start until the burner has been running for 5 to 15 minutes to heat up the

combustion chamber and heat exchanger. At this point, the fan switch will activate the fanmotor.

3. Once the fan motor has activated, turn the burner off by turning the wall thermostat to OFF.4. With the burner off, the fan motor should continue to run for 5 to 10 minutes until the

combustion chamber is cooled down. The fan switch will then shut off the motor.

WARNING: If the fan motor does not operate as described, immediately shut down yourfurnace to avoid potential equipment damage and/or fire hazard. Contact your Clean Burn dealer

immediately.


7-1

SECTION 7: RESETTING THE OIL PRIMARY CONTROL

Understanding the Oil Primary Control

NOTE: The Saturn™ A2 primary controller (CB Part #33400) is a recycle type control, which featuresinterrupted ignition operation.

The oil primary control will go into safety lockout and shut the burner off when it detects flame-outduring burner operation. The oil primary control will then wait approximately one to two minutes andattempt to re-ignite the burner (recycle mode). If the burner does not re-ignite, the control will shut theburner off on safety. The following procedure explains what should be done when this occurs. It is veryimportant that you follow these instructions precisely when resetting the safety on the primary controland restarting the burner.

Using the Reset Button

DANGER! DO NOT push the reset button more than once! DO NOT push the reset button ifoil mist is present in the combustion chamber or when the combustion chamber is hot! DO NOT

operate your furnace if excess oil, oil vapor or fumes have accumulated in or near your furnace. As withany oil burning furnace, improper operation may result in a fire or explosion hazard.1. Refer to Figure 7A.2. Check the combustion chamber for fuel mist by shining a flashlight through the observation port.

If you see fog (fuel mist) in the chamber, DO NOT push the reset button.3. If the combustion chamber is hot, allow the furnace to cool for at least 30 minutes. DO NOT

push the reset button.4. When you are sure all mist has been cleared from the chamber and the combustion chamber is

cool, depress the red button on the primary control for a minimum of three (3) seconds, thenrelease. Reset the control ONCE ONLY.

5. If the burner will not restart, call your Clean Burn dealer immediately.

Figure 7A - Oil Primary Control

ATTENTION: Never touch a jumper wirefrom an "F" terminal to a "T" terminal onthe oil primary control. This will severelydamage your primary control. Make surethe plastic barrier strip is in place betweenthe "F" and "T" terminals as shown inFigure 7A.

CAD CELL WIRES

THERMOSTAT WIRE

RESET BUTTON

F2

F1

T2

T1


7-2


8-1

I88257

SECTION 8: ADJUSTING THE DRAFT OVER FIRE

Checking for Correct Draft Over Fire

WARNING: Correct draft over fire isessential for the proper and safe operation

of your furnace.

Your furnace is equipped with an observation/draft reading port to check draft over fire. Aqualified serviceman with proper equipment mustcheck/adjust your furnace for proper draft.Contact your Clean Burn dealer for this service.

1. Insert the probe of the draft gaugeinstrument into the draft reading port inthe observation port as shown inFigure 8A.NOTE: Follow the directions with thedraft gauge to use your specific type ofgauge.

2. Note the draft overfire reading on the draftgauge.ATTENTION: Draft over fire readingshould be -.02 w.c. maximum. Poor draft(i.e. -.01 to +.04) results in backpressure in the furnace and poor burnerperformance. Too much draft sucks theheat from the furnace and results inabnormally high stack temperature. Figure 8A - Checking for Proper

Draft Over Fire

Understanding the Importance of Draft

Draft in the furnace is created as the hot combustion gases rise up the stack, creating a negative pressureinside the stack and the furnace. This negative pressure is measured as inches of water column (W.C.)of draft. A proper draft overfire of -.02 w.c. is essential so that all combustion products travel awayfrom the burner, down the combustion chamber, through the furnace flues and up the stack.


8-2

I88258

ADJUST THIS WEIGHTTO OBTAIN PROPERDRAFT OVERFIRE

BAROMETRIC DAMPER

Figure 8B - Adjustment of Barometric Damper

Solving Draft Overfire Problems

WARNING: If you cannot achieve proper draft overfire, do not operate your furnace!Contact your Clean Burn dealer for assistance.

ATTENTION: Backdraft must be resolved or your furnace will not operate correctly!Under backdraft conditions, draft overfire readings will show positive pressure in the combustionchamber. Backdraft means that oil spray, combustion products, and heat are blown back against theburner. Backdraft results in oil-fouled retention heads and electrodes. Severe backdraft will force heatback against the burner and result in heat damage to the cad cell and transformer.

Backdraft is caused by the following conditions:• Poor draft caused by improper stack design. (See Section 4.)• Poor draft caused by improper adjustment of the barometric damper.• Incorrect combustion air band setting on the burner. (See Section 6.)• Furnace flues are plugged with ash. (See Section 9.)• Clean-out gasket on clean-out doors is out of position. (See Section 9.)• Exhaust fans in your building are sucking gases down the stack.

Adjusting the Barometric Damper

NOTE: If the draft overfire is not -.02 w.c. (max.), it is necessary to adjust the barometric damper.

1. Before starting the burner, turn the weighton the flapper COUNTERCLOCKWISEuntil the flapper remains closed. This willprovide maximum draft for the furnace.

2. Follow the directions in Section 6 to startand adjust the burner.

3. With the burner running, check the draftoverfire with a draft gauge.

4. As shown in Figure 8B, adjust the weighton the flapper to obtain a consistent-.02 w.c. (max.) draft overfire. Turn theweight COUNTERCLOCKWISE toincrease draft (i.e. draft increases as theflapper closes). Turn the weightCLOCKWISE to decrease draft (i.e. draftdecreases as the flapper opens).

5. Tighten the locking nut to securely holdthe weight in position.


8-3

Understanding the Effect of Exhaust Fans on Draft

Any type of exhaust fan, paint booth, or exhaust system in a building will create negative pressure in thebuilding unless there is a source of make-up air (i.e. fresh air which enters the building and replaces theair removed by the exhaust fans.) Refer to Figure 8C on the following page.

If there is insufficient make-up air, the exhaust fan will suck air and combustion gases down the furnacestack and create backdraft in the furnace. Even if the exhaust fan is on another level of the building or inanother room away from the furnace, the exhaust fan will still create backdraft at the furnace.

Checking Draft Overfire to Determine Severity of Backdraft

The following procedure is an accurate method of determining how much backdraft is created by theexhaust fans. Once this is determined, you can select the correct method for resolving the backdraft.Refer to Figure 8C on the following page as needed.

1. Turn off ALL exhaust fans and close ALL doors and windows in the building (any open door orwindow will allow make-up air to enter the building and will negate the test).

2. Start the furnace and adjust the barometric damper so that the draft overfire is -.02 w.c. (maximum).3. Check the draft overfire again. Now have someone start the exhaust fans.4. Note how much the draft overfire has changed.

ATTENTION: If the draft overfire changed towards positive, it is mandatory that make-up airis provided to the building or severe damage to the furnace and burner will occur (voiding thewarranty). If the draft overfire remained constant at -.02 w.c., there is sufficient make-up airentering the building, and the exhaust fan is not adversely affecting the draft.


8-4

RISING HOT COMBUSTION GASESPRODUCE DRAFT IN THE STACK

DRAFT OVERFIRE OF −.02 W.C. MEANSCOMBUSTION GASES ARE FLOWINGAWAY FROM THE BURNER, THROUGHTHE FURNACE FLUES AND UP THESTACK.

EXHAUST FAN CREATES BACK DRAFT IN STACK AND SUCKSCOMBUSTION GASES DOWN THE STACK AND BACK INTO THEFURNACE.

OIL SPRAY AND HEAT IS FORCED BACK AGAINST THEBURNER AND RESULTS IN OIL−FOULED ELECTRODES ANDRETENTION HEAD. SEVERE BACK DRAFT WILL HEAT DAMAGETHE CAD CELL AND TRANSFORMER.

SERVICEMAN ADJUSTSBAROMETRIC DAMPER TOOBTAIN −.02 W.C. DRAFTOVERFIRE

PROPER DRAFT BACK DRAFT

RIS

ING

HO

T C

OM

BU

ST

ION

GA

SE

S P

RO

DU

CE

DR

AF

T

EX

HA

US

T F

AN

CR

EA

TE

S B

AC

K D

RA

FT

IN S

TA

CK

COMBUSTION GASES

BACK DRAFT

PROPER DRAFT COMBUSTION AIR TOBURNER

BA

CK

DR

AF

T C

RE

AT

ED

BY

EX

HA

US

T F

AN

I88616

Figure 8C - Proper Draft vs. Backdraft


8-5

Installing a Make-up Air Louver

Exhaust Fans and Make-up Air Louvers

When exhaust fans are operated in tight buildings, there is little or no source of fresh air to replace theair removed from the building by the exhaust fan. This results in negative pressure (vacuum) in thebuilding which creates severe backdraft problems at the furnace.

Properly sized make-up air louvers are designed to allow adequate fresh air to enter the building duringoperation of the exhaust fans. The louvers automatically open under the vacuum created by the exhaustfans. The louvers open just enough to provide the correct CFM of fresh air. The louvers automaticallyclose when the exhaust fans are turned off.

Sizing the Make-up Air Louver

Procedure 1: (a) Determine the CFM rating of the exhaust fan. This information should be stamped ona label on the exhaust fan. Make sure to add up the total CFM if more than oneexhaust fan exists in the building.

(b) Select the correct size of make-up air louver to provide the required CFM of fresh air.

If you cannot determine the CFM rating of the exhaust fan, use the following procedure.

Procedure 2: (a) With all exhaust fans running, open one of the large bay doors so that it is just 2 feetopen. Position a helper at this door.

(b) Start the furnace and check for proper -.02 w.c. draft overfire (maximum).(c) As you watch the draft gauge, instruct your helper to slowly close the large bay door.

When the draft overfire is affected, stop closing the door.(d) Open the large bay door just enough to allow the draft overfire to return to a proper

-.02 w.c. (maximum). The size of this opening represents the approximate size of themake-up air louver required.

(e) Measure the size of the opening and calculate the square inches. Select a make-up airlouver that is at least 10% larger than this opening.

Example of Calculations for Sizing Make-up Air Louver1. Opening Size 12' (144") x 1' (12") = 12 square feet (1728 (square inches)2. Add 10% 1728 square inches x 1.1 = 2000 square inches3. Louver Size Select 48" x 48" louver = 2304 square inches

(Installation instructions are provided on the next page)


8-6

Installing the Make-up Air Louver

NOTE: It is very important to follow these instructions carefully to ensure proper performance of thelouver.

1. The louver must not be close to the furnace. The fresh air should travel at least 40 to 50 feetbefore reaching the furnace so the air warms up. The furnace will not heat well if it is receivingcold return air.

2. The louver must be high in the sidewall of the building so the cold fresh air does not blow acrossthe floor level and chill the service personnel.

3. The louver should be installed in the opposite wall from the location of the exhaust fan. Thiswill quickly vent diesel exhaust from the top of the building and reduce the amount of run timefor the exhaust fan.


9-1

SECTION 9: MAINTENANCEUnderstanding MaintenanceMaintaining your Clean Burn furnace is an important activity which includes several periodicmaintenance activities and an annual burner tune-up...all are necessary to keep your furnace running inpeak condition. Failure to maintain and/or improper servicing by unqualified personnel may adverselyaffect the proper, safe operation of your furnace, may reduce the service life of your furnace, and mayvoid your warranty.

The following chart summarizes all the maintenance activities which should be performed on the furnaceat the intervals indicated. Instructions/procedures for these activities are included in this chapter.

Maintenance Activity IntervalCleaning the canister filter Before vacuum gauge reads 10" HG of vacuumServicing the metering pump At least once a yearCleaning out ash Approx. 700 hours as indicated on the burner hour meter*Cleaning the check valve At least once a yearCleaning water/sludge out of tank At least once a yearAnnual burner tune-up At least once a year

*It is very important to clean ash from the furnace on schedule. Normal use of the furnace requiresclean-out at least twice during the heating season. Heavy, around-the-clock usage requires morefrequent clean-out. For instance, one month of continual running of the furnace is 720 hours (24 hours x30 days = 720 hours).

NOTE: IMPORTANT! Record all maintenance activities in the Maintenance Record provided in theAppendixes.

Annual Burner Tune-up

Your Clean Burn furnace requires annual periodic maintenance. The burner requires an annual tune-up--similar to an automotive tune-up--to keep it running in peak condition. The burner tune-up should beperformed by a qualified Clean Burn service technician who has the necessary parts and expertise..

Contact your local Clean Burn dealer to schedule the annual periodic maintenance which is usually(preferably) performed during warm weather to prepare the furnace for the next heating season. Variouslevels of service are provided to fit your particular need.


9-2

Cleaning the Canister Filter

ATTENTION: Never operate your furnace with more than 10" HG of vacuum on the suction side ofthe pump. High vacuum separates air from the oil and results in erratic burner operation.

The following protective gear should be worn when cleaning the filter:• Rubber gloves• Safety goggles

1. Close the ball valve adjacent to the filter.2. Position a container under the filter.3. Unscrew the four bolts to drain the oil from the canister.4. Remove the canister bowl.5. Clean the screen and the bowl in a parts washer.6. Referring to Figure 9A, examine the filter components as you reassemble them.7. Check the condition of the O-rings. Replace any that are cracked or worn.8. Ensure that the canister filter is 100% airtight by firmly tightening the four bolts.9. Open the ball valve. Refer to Sections 5 and 6 for instructions on priming the pump and starting

the burner.

Figure 9A - Servicing the Canister Filter

I88259−A

USE A RATCHET WRENCH WITH A 6" EXTENSIONAND 3/16" "ALLEN" SOCKET TO REMOVE THEFOUR "ALLEN" SCREWS

TO BURNER

BACK TOTANK


9-3

Servicing the Metering Pump

1. Refer to Figure 9B.2. Remove the pump head cover (part 1).3. Remove the screen (part 2) and wash it.4. Remove and discard the used gasket (part 3).5. Install a new gasket (Clean Burn Part #32422).6. Replace the screen and pump head cover.

Figure 9B - Servicing the Metering Pump

3

2

1

PART No 32423

PART No 32422


9-4

Cleaning Ash from the Furnace

NOTE: The maintenance interval for cleaning ash from the furnace is approximately 700 hours ofoperation as indicated on the hour meter on the burner. Be sure to clean the ash from your furnace atleast twice during the heating season. Your furnace may require more frequent clean out of the ash dueto contaminants in the oil or heavy use. As ash accumulates, furnace heat output declines, and the stacktemperature rises. 1/8" of ash has the insulating capacity of one inch of fiberglass insulation and reducesheat transfer significantly. Never allow more than 1/4" of ash to accumulate in the combustion chamber,heat exchanger flues, or stack.

CAUTION: Be aware that used oils may contain heavy metallic compounds or foreignmaterials. When burned, these compounds are deposited within the furnace, necessitating

careful cleaning. Make sure you use a sturdy ladder or scaffolding for safe access to ceiling-hungfurnaces.

NOTE: When cleaning the furnace, static electricity may build up in the shop vac hose. If this occurs,use #12 copper wire wrapped around the hose with the other end connected to the furnace (or otherground source) to eliminate the static.

The following protective gear should be worn when cleaning the ash:• Respirator for fine particles •Rubber gloves• Safety goggles •Protective clothing

1. Ensure that power has been turned OFF, and all "hot" components have been allowed to coolsufficiently. Allow at least one hour for the target to cool.

2. Clean out the burner throat:a. Disconnect the burner power cable.b. Remove the lock-down nut and swing the burner open.c. Clean out the burner throat using a small scraper to remove the residues.ATTENTION: Keep the burner open (swung out) so that you do not knock or bend burnercomponents when cleaning out the combustion chamber.

3. Clean the ash from the stack components:a. Brush accumulated ash from the stack cap.b. Lightly tap the stack components to loosen the ash.c. Allow ash and dust to settle in the clean-out tee or elbow.d. Vacuum ash from the clean-out tee, or disconnect the stack and vacuum ash from the elbow.

4. Remove the clean-out door(s) to clean ash from inside the combustion chamber (see Figure 9C):a. Disconnect the stack from the furnace breach.b. Remove the clean-out panel from the back of the furnace.c. Remove the clean-out door(s) to expose the heat exchanger flues and the combustion

chamber.d. Check the color of the ash--it should be light gray or tan.

ATTENTION: White ash indicates excessive air pressure. Black ash or soot indicates toomuch oil pressure. If these conditions exist, call your Clean Burn dealer. DO NOT overfireyour furnace by turning up the compressed air and/or oil pressure. Overfiring will damagethe combustion chamber and heat exchanger and will void your warranty.


9-5

e. Use your shop vac to vacuum ash from the flues.NOTE: Avoid "packing" the ash in the back of the tubes by first vacuuming the flues beforepushing the flue brush down the flues.

f. Use a flue brush to thoroughly clean the flues.g. Thoroughly vacuum any remaining ash residue from the flues.h. Check the flues for rust.

ATTENTION: The presence of rust in the flues indicates that chlorinated materials arebeing burned. Burning chlorinated materials will severely damage your heat exchanger andvoid your warranty. Contact your Clean Burn dealer for instructions to test your oil forchlorine contamination before firing your furnace.

i. Inspect the fiberglass rope gasket.NOTE: Make sure the fiberglass rope gasket is in good condition and the clean-outdoor(s) seal(s) tightly. If the door(s) does not seal tightly, replace damaged components.

j. Re-install the furnace components: clean-out door(s), clean-out panel, and stack.NOTE: You may need to bleed air from the oil line before starting the burner. See Section 5for the pertinent instructions.

k. Swing the burner into firing position. Install the lock-down nut and plug in the burner powercable.

Figure 9C - Accessing the Combustion Chamber for Cleaning

Cleaning the Ash (continued)


9-6

Figure 9D - Cleaning the Check Valve

Cleaning the Check Valve

This procedure applies to furnace installations with inside and outside tanks. The following protectivegear should be worn when cleaning the check valve/screen:

• Rubber gloves• Safety goggles

1. Refer to Figure 9D. Remove the standpipe from the tank.2. Remove the check valve and filter. Clean these components in a parts washer.3. Check the operation of the check valve. The valve must seat so it is airtight to hold pump prime.4. Re-assemble and re-install the components. Apply Permatex #2 non-hardening gasket sealer or

equivalent to the threaded fittings. Firmly tighten all connections so the suction line is 100%airtight.

5. Follow pump priming instructions in Section 5 to re-establish prime.

R H ROT AT ION

INLET GAUGE

INLET

CANISTER FILTER IN SUCTION LINE


9-7

Cleaning the Tank

DO NOT allow water, sludge, or other debris to accumulate in your oil supply tank to the point that non-combustible or harmful materials are drawn into the pump or burner.

Drain water and sludge from the bottom of your tank at least once a year, and more frequently with wateraccumulation.

NOTE: If your used oil tank has not been cleaned on a regular basis, a considerable amount of sludge,etc. may have accumulated on the bottom of the tank. Under these circumstances, it is advisable for youto hire your used oil hauler to pump the tank. Make sure the tank is pumped to the bottom to remove allsludge, etc. from the tank (your used oil hauler may charge an additional fee for this type of service).The best time to pump the used oil tank is at the end of the heating season when the tank is low. Thisallows sufficient time to refill the tank with used oil (generated by your company over the summermonths) so that you have adequate fuel for the heating season.

End of Season Maintenance

ATTENTION: Turn main power to your furnace OFF at the end of the heating season. EPA regula-tions allow your used oil to be burned only for "heat recovery." DO NOT operate your furnace duringwarm weather just to burn oil, or severe damage to the combustion chamber/heat exchanger may occur.

Contact your local Clean Burn dealer to schedule your annual burner tune-up. Allow only trained,authorized service personnel to service your burner.


9-8


A-1

APPENDIX ADetailed Furnace Specifications

SPECIFICATIONS Saturn™ A2

BTUH Input 140,000 @ 1.0 GPH Listed Fuels #2, #4 Fuel Oils

Used Crankcase Oil Used ATF Used Hydraulic Oil

Cabinet Dimensions (L x W x H, inches)

33.75 / 29.75 / 29.00

Furnace Dimensions with Fan & Burner (L x W x H, inches)

47.75 / 40.75 / 29.00

Approximate Weight (lbs.) 320 Mounting Ceiling Hung

Bench Tank Kit Non-combustible Platform

Electrical Requirements 110/120 Volts, 60 Hz Circuit Breaker for Unit Heater 20 Amps Circuit Breaker for Furnaces with Optional Accessories

Refer to specifications included with optional accessories

Wall Thermostat 24 Volt Heat Anticipator Setting: 0.2 Amps

Oil Pump Suntec A2RA-7710 (CB# 32327) Pump Motor Bison gear motor (CB# 33291) Pump Motor Rotation CCW shaft end Canister Filter Lenz DH 750-100 Stack Size 8” Fan Motor HP 1/3 Fan Blade / Pitch Three Blade / 21° Fan Limit Control Honeywell L4064B

8” Probe Fan Limit Settings Hi-Limit – 200

Fan ON – 120 Fan OFF – 100


A-2

Burner Technical Specifications

Burner Saturn™ A2

Ignition Transformer Carlin Transformer14,000 volts

Nozzle Delavan 9-5

Burner Motor 1/10 HP 3200 RPMwith centrifugal switch

Burner Motor Rotation CCW shaft end

Compressed Air Requirements 2.0 CFM @ 20 PSI

Oil Primary Control Carlin Oil Primary

Heater Element in Preheater Block 250 watts

Air Pressure Switch MPL 808

Preheater Temperature Switch L-150


A-3

I88119

TOP VIEW (SHOWING MOUNTING LUGS)

FRONT VIEW (BURNER SIDE)

BACK VIEW (FURNACE BREECH SIDE)SIDE VIEW (FAN SIDE)

20.875

33.750

29.000Ø21.250

33.750

29.750

29.000

40.000WITH FAN INSTALLED

SIDE VIEW (LOUVER SIDE)

16.250

WITH BURNER INSTALLED

23.125

47.000

Furnace Dimensions


A-4

Figure A1 - Burner Component Detail

Burner Components

TO

HO

LE

B

TO

SLO

T

A

TO

HO

LE

A

A

B

1

2

3

4

5

10

6

7

8911

1213

1415

1617

18

19

TO

HO

LE

A

20

21

21

JUM

PE

R

22 23

24

24


A-5

Burner Components (continued)

ITEM# PART# DESCRIPTION

1 34362 1/4-20 WING NUT - BRASS2 11488 COMB. AIR INTAKE OUTER PLATE ASS’Y3 11489 COMB. AIR INTAKE INNER PLATE ASS’Y4 33465 BLOWER5 33258 QUICK CONNECTOR - FEMALE6 33259 QUICK CONNECTOR - MALE7 11326 BLOWER MOUNTING PLATE8 13169 HEATER BLOCK ASS’Y9 32000 NOZZLE - 9-510 26088 TRANSFORMER PLATE11 33189 “CARLIN” IGNITION TRANSFORMER12 33116 CAD CELL13 11308 RETENTION HEAD ASS’Y14 11294 BURNER MOUNTING PLATE15 33400 “CARLIN” PRIMARY CONTROL16 26071 ELECTRICAL BOX COVER17 33169 POWER INDICATING LIGHT - GREEN18 13134 AIR PRESSURE COMPONENTS ASS’Y19 26070 ELECTRICAL BOX20 26066 BURNER HOUSING21 34166 6" STEEL CABLE22 33536 TERMINAL BLOCK23 32201 MACH. SCREW-PHILLIPS HD. 6-32 x 3/8" Z24 34178 SCREW, WA FZ 8-32 x 3/8"


A-6


Figure A2 - Preheater Block Assembly Component Detail

13

22

34

56

78

9

1112

15

1

14

16

17

18 19

20

21

23

30

24

2

10

25

26

272829

31

21

21

32

33

TO TERMINAL # 5ON PLUG

TO TERMINAL # 4 ON PLUG

TO TERMINAL # 6ON PLUG


A-7


1 13169 HEATER BLOCK ASS’Y2 34054 SCREW, 1/4 - 20 x 1/2 HEX HD3 33321 NUT4 33319 COIL5 33318 SEAL WASHER6 33317 FLUX PLATE7 33316 PLUNGER GUIDE ASS’Y8 33315 PLUNGER ASS’Y9 33314 “O” RING - BODY10 33313 BODY- MANIFOLD MOUNT11 33312 “O” RING - OUTER - MANIFOLD MOUNT12 33311 “O” RING - INNER - MANIFOLD MOUNT13 26115 HEATER BLOCK - SATURN SERIES14 34165 BONDED WASHER15 34169 SCREW 10-32 x 3/416 33183 SINGLE PIECE ELECTRODE17 34135 LOCKWASHER18 26116 NOZZLE SUPPORT BRACKET - SATURN19 32000 NOZZLE - 9-520 34146 SCREW - 10-32 x 3/821 32119 PLUG - 1/6 NPT22 33041 PROVING SWITCH - 120 D. N. O.23 33140 TERMINAL - RIGHT ANGLE - FEMALE - INSULATED24 33455 TEMPERATURE SWITCH - 150 D.N.C.25 32457 ELBOW-5/32 PUSH TO 10-32 MALE - SWIVEL - COMPOSITE26 32341 NIPPLE - 3" x 1/8 - BRASS27 26075 PLATE - LOCKING28 34070 SET SCREW - 1/4 x 1/429 33256 HEATER - 250 W - 5/16 DIA.30 33381 CONNECTOR - CRIMP INSULATED CAP31 33259 QUICK DISCONECT32 32322 SOLENOID - OIL33 54149 5/32 AIR LINE 12" LONG



A-8

BURNER NOZZLE

NOZZLE IS STAMPED EITHER 9−5OR −5 ON FLAT OF NOZZLE HEAD

SIDE VIEW − AA

3/16" GAP BETWEENELECTRODES & NOZZLE

CRITICAL DIMENSIONS:ELECTRODES MUST BE

FLUSH WITH NOZZLE TIP.RETENTION HEAD DISK MUST

BE FLUSH WITH NOZZLE TIP

1/8"SPARK

GAP

SIDE VIEW − BB

VIEW − AA

VIEW − BB

3X

I88340


Figure A3 - Burner Electrode Component Detail


A-9

HEAD DISTRIBUTOR STEM

ORIFICE O−RING

NOZZLE SIZE ISSTAMPED ON

FLAT OF NOZZLE HEAD

I88678


Removing the Nozzle for Cleaning:

1. Remove the lock-down nut on the mounting flange bolt.2. Disconnect power from the burner.3. Carefully swing the burner open to its maintenance position.4. Remove the nozzle from the nozzle adapter with a 5/8" socket.

Cleaning the Nozzle:

1. Unscrew the stem from the nozzle head.2. Spray WD-40 or equivalent through the orifice to thoroughly remove any blockage.

ATTENTION: DO NOT damage or deform the nozzle orifice; DO NOT use a torch tipcleaner or other inappropriate device to clean the orifice. If the blockage is a "tarry"material or a hard, black material, call your Clean Burn dealer for service.

3. Flush all components with WD-40 to remove oil residues.4. Reassemble the nozzle components. When tightening the stem, just barely "snug" it down.

DO NOT overtighten.5. Check the O-ring on the nozzle stem. Replace the O-ring if it is in the least bit cut or

deformed.6. Lubricate the O-ring on the nozzle stem with a couple of drops of new motor oil, then re-

install the nozzle.7. Check the electrodes for proper gap and clearances.8. Re-install the burner and adjust for optimal performance as described in Section 6.

NOTE: If the nozzle plugs within a few days after cleaning, call your Clean Burn Dealer forservice.

Figure A4 - Cleaning the Nozzle

Model Nozzle SizeSaturn™ A2 Delavan 9-5


A-10


Figure A5 - Air Pressure Assembly Component Detail

I881

81

17

1

12

10

2827

2625

2423

31

2

29

20

19

18

16

30

21

22

34

1413

98

7

43

56

11

15

AIR

PR

ES

SU

RE

AS

SE

MB

LY


A-11

1 13134 AIR SUPPLY ASS’Y2 32285 AIR REGULATOR3 33310 THREADED KNOB4 34022 NUT, 10-325 34145 NUT, PANEL, 3/46 33308 BONNET7 32228 SPRING DISC8 32227 COMPRESSION SPRING9 32226 DIAPHRAGM RING10 32225 DIAPHRAGM11 32305 BRASS POPPET SEAT12 32223 POPPET “O” RING13 32222 POPPET VALVE14 32221 POPPET SPRING15 33308 REGULATOR BODY16 32459 FITTING STRAIGHT MALE - 5/32 PUSH x 1/8 NPT17 32007 HEX PLUG - 1/8 NPT18 32486 MALE BRASS TEE - 1/8 NPT19 33057 AIR PRESSURE SWITCH20 32179 PRESSURE GAUGE - 0-60 - SQ.21 32150 NIPPLE, 1/8 NPT, CLOSE, HEX, BRASS22 32334 2" BRASS NIPPLE - 1/8 NPT23 33321 NUT24 33319 COIL25 33318 WASHER SEAL26 33317 FLUX PLATE27 33316 PLUNGER GUIDE ASS'Y28 33315 PLUNGER29 33314 "O" RING - BODY30 33322 BODY - MANIFOLD MOUNT31 32323 SOLENOID, AIR, MANIFOLD MOUNT




A-12

50

100150

200

250

CAUTIONDO NOT ROTATE

HOLD DIAL WHEN SETTINGPOINTERS

FAN OFF(LEFT POINTER)

FAN ON(MIDDLE POINTER)

LIMIT(RIGHT POINTER)

I88840

CAUTIONDO NOT ROTATE

HOLD DIAL WHEN SETTINGPOINTERS

25050

150100 200

FANLOAD

LINE

LINE

LIMITLOAD

OR

AN

GE

WIR

E (

CO

NN

EC

T T

O F

AN

)

RE

D W

IRE

(C

ON

NE

CT

TO

LIM

IT)

TO RELEASEWIRE, PUSHSCREWDRIVERIN AND PULLWIRE OUT

BLACK WIRE

BRASSJUMPER

Fan Limit Control

Understanding the Operation of the Fan Limit ControlThe fan limit control senses air temperature within the furnace cabinet. This control contains twoswitches: the limit switch and the fan switch.

Fan Switch: The fan switch is normally open and provides power to the fan. When the fan limitcontrol senses "Fan On" temperature, the fan switch closes and starts the fan. When the wall thermostatis satisfied and the burner shuts off, the fan continues to run until the fan limit control senses the "FanOff" temperature. At this temperature, the fan switch opens and shuts off the fan.NOTE: The fan limit control has a white fan switch button. Make sure the white button is pulled OUTfor automatic (normal) operation. When the button is pushed in (manual setting), the fan will runcontinuously.

Limit Switch: The limit switch is normallyclosed and provides power to the oil primarycontrol on the burner. If the fan limit controlsenses 200 degrees F, the limit switch opensand shuts off power to the oil primary controland the burner stops running. The fan continuesto run. Once the fan limit control senses 170degrees F, the limit switch automatically resetsand restarts the burner.NOTE: It is very important to avoid cyclingthe burner on hi limit as described above. Ifthe hi limit activates, immediately check andre-adjust burner settings.ATTENTION: DO NOT change the fan limitsettings from the specified settings, or severedamage to the furnace cabinet may occur.

To Set Pointers on the Fan Limit Dial1. Turn OFF main power to the furnace.2. Remove the fan limit control cover.3. While holding the dial securely in place

with your thumb, move the pointer tothe desired setting.

ATTENTION: DO NOT rotate the dial whensetting the pointers. This severely damages thecontrol.

Fan Limit Control Settings: Saturn™ A2Fan Off: 100Fan On: 120Limit: 200

Figure A6 - Fan Limit Control Components


B-1

L1

L2

3

4

L2

WHITE

WHITE

BLACK

WHITE

OIL PUMP

BLACK

BLACK

L1

L2

CIRC. FANMOTOR

BLACK

GREENGROUNDSCREWRED

ORANGE

BLACKRED

GREEN

GREEN

WHITE

REDBLACK

I88546

FAN LIMIT SWITCH(COVER REMOVED)

PURPLE

WHITE

WHITE

L1

120 VOLTS, 60 Hz, SINGLE PHASE

FAN (OPTIONAL)DRAFT INDUCER

BLACK

WHITE

ORANGE

APPENDIX B

Figure B1 - Saturn™ A2 Furnace Wiring Diagram

Wiring Diagrams


B-2

RE

D

COMPRESSORAIR

(OPTIONAL)BLA

CK

AIRSWITCH

N.O. GRN

RED

LIGHTGREEN

BLACK

BURNER

MOTOR

PRIMARY

OIL

YE

LLO

W

YE

LLO

W

CA

D C

ELL

THERMO−

BLU

E

STAT

WALL

WHITE

TRANS−FORMER

AIR

SOLENOID

WH

ITE

FF

L−150 N CBLOCK HEATER 250 WATTS

SOLENOID SWITCHPROVING

OIL

TEMP SWITCH

1 32 4 1165 7 98 10 12 13

BLA

CK

OR

AN

GE

WH

ITE

WH

ITE

RE

D

CAP

WHITE

ORANGE

OR

AN

GE

ORANGE

BLACK

BLACK PU

RP

LE

RE

D

BLA

CK

WH

ITE

WH

ITE

JUMPER

RE

D

WHITE

BLA

CK

GREY WIRENUT

BLA

CK

BLA

CK

NO

TE:

The

Satu

rn

A2

prim

ary

cont

rolle

r is a

recy

cle

type

con

trol w

ith fo

ur w

ires a

nd fe

atur

esin

terr

upte

d ig

nitio

n op

erat

ion

TM

BLA

CK

BLA

CK

WH

ITE

GR

EE

N

Figure B2 - Saturn™ A2 Burner Wiring Diagram

Wiring Diagrams (continued)


B-3

CENTRIFUGAL SWITCH

SERVICESWITCH

6/26/02

DATE

DWG. No.

DATE:

BY

44083R.M.

CUSTOMER POWER - CONNECTION TO

PURPLE

RED

DISCONNECTOPTIONAL

WHT OILPRIMARYCONTROL

AIR COMPRESSOR (OPTIONAL)

250 WATTS BLOCK HEATER

SPARK GAP

IGNITION TRANSF.

BLOCK TEMP. SWITCH

BURNER MOTOR

3M

AIR PRESSURE

OR

POWER ON

OIL SOL.

AIR SOL.

MODEL SATURN A-2

PROVING SWITCH120°

CADCELL

BK F F

HOT NEUTRAL

WALLTHERMOSTAT

T T

OIL PUMP MOTOR

M 2

DWG. No.............44083

M 1

CIRC. FAN MOTOR

PUR

PLE

FAN

HI LIMIT

BLACK

L - 150

- CONNECTION TO

- LANDING NUMBER

6 1

4 5

3 2

PLUG (MALE-FEM.)CONNECTOR

ON PLUG

BL

Figure B3 - Ladder Schematic for Saturn™ A2 (120 Volts / 60 Hz)


B-4

Figure B4 - Metering Pump Wiring Schematic

Wiring Diagrams (continued)


C-1

APPENDIX CFurnace Service Record

Furnace Purchased: Date __________ From (name/phone)________________________________

Furnace Installed: Date ___________ By (name/phone)__________________________________

Furnace Inspected: Date __________ By (name/phone)__________________________________

Draft Readings Service Record(date / reading) (date / initials of serviceman)

Burner Stack Canister Chamber Stack Oil Tank A.P.M.*Filter & Flues

*A.P.M. = Annual Preventative Maintenance of Burner (Burner Tune-up)


C-2

Documents

CLEAN BURN MODEL: SATURN™ A2 MULTI-OIL FURNACE · flammable or explosive liquids or vapors near your furnace. DANGER! DO NOT operate your furnace if excess oil, oil vapor or fumes