INSTALLER'S MANUAL CLEAN BURN MODEL: DOUBLE-PISTON AIR COMPRESSOR #14336 Optional Accessories for Clean Burn Furnaces/Boilers I89056 PUBLICATION DATE: 1/4/10, Rev. 5 CLEAN BURN PART # 43142 IMPORTANT FOR U.S. INSTALLATIONS: All installations must be made in accordance with state and local codes which may differ from the information provided in this manual. Save these instructions for reference.
WARRANTY INFORMATION Clean Burn, Inc., MANUFACTURER, hereby warrants that MANUFACTURER's products shall be free from defect in material and workmanship under normal use according to the provisions and limitations herein set forth.
TRADEMARKS The Clean Burn logo is a trademark of Clean Burn, Inc. All other brand or product names mentioned are the registered trademarks or trademarks of their respective owners. COPYRIGHT Copyright © 2010 Clean Burn, Inc. All rights reserved. No part of this publication may be reproduced, or distributed without the prior written permission of Clean Burn, Inc. 34 Zimmerman Road, Leola, PA 17540. Subject to change without notice.
TABLE OF CONTENTS NOTE: A Special Bulletin (which appears just after the Table of Contents) has been added to your manual to highlight important information about the installation, adjustment and operation of your air compressor. Be sure to read this sheet before beginning any procedures in this manual. SECTION 1: INTRODUCTION ................................................................................... 1-1 Guide to this Manual ..........................................................................
SPECIAL BULLETIN IMPORTANT INFORMATION CONCERNING THE SERVICE RATING OF THE AIR COMPRESSOR Air compressor model #14336 has a service rating of approximately 75%. This means that the air compressor can operate continuously for approximately 45 minutes (75% of one hour), and then it must not operate for approximately 15 minutes (25% of one hour) to allow the air compressor to "cool down." This works well for most furnace/boiler installations where the unit will cycle on and off a few times during an hour.
Installer's Manual: Clean Burn Air Compressors SECTION 1: INTRODUCTION Guide to this Manual IMPORTANT! This manual provides all the instructions necessary to install the Clean Burn air compressor on your Clean Burn furnace or boiler. Refer to your equipment Operator's Manual for instructions on assembling, installing, operating, and maintaining your furnace or boiler. Consult the Table of Contents for a detailed list of topics covered in this manual.
Installer's Manual: Clean Burn Air Compressors Please read all sections in this manual carefully--including the following safety information--before beginning any installation procedures; doing so ensures your safety and the optimal performance of your Clean Burn air compressor and furnace/boiler. For Your Safety...
Installer's Manual: Clean Burn Air Compressors SECTION 2: UNPACKING Before installing the air compressor on your furnace/boiler, you should take some time to carefully unpack your shipment from Clean Burn. Unpacking and Inspecting All Components Carefully open all shipping containers and inspect all components. Immediately notify the freight company and your Clean Burn dealer in case of shipping damage or shortage(s).
Installer's Manual: Clean Burn Air Compressors 2-2
Installer's Manual: Clean Burn Air Compressors SECTION 3: INSTALLING THE AIR COMPRESSOR IMPORTANT! If you are installing your furnace/boiler and air compressor at the same time, Clean Burn recommends the following sequence of activities: 1. Assembly of Furnace/Boiler (for furnace - through the installation of mounting/stabilizer brackets). 2. Installation of Air Compressor on Furnace/Boiler 3.
Installer's Manual: Clean Burn Air Compressors 23 22 21 20 19 10 9 18 29 8 17 7 16 28 6 15 27 12 14 13 5 3 4 24 30 26 25 I89055 2 11 Figure 3A - Air Compressor Exploded View 3-2 1
Installer's Manual: Clean Burn Air Compressors ITEM QTY 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 1 1 10 11 4 12 1 13 1 14 1 15 1 16 1 17 1 18 1 19 1 20 1 21 1 22 1 23 1 24 4 25 2 26 1 27 1 28 1 29 1 30 4 PART# 32280 32234 54063 32236 32233 32146 32091 13063 32147 32157 34092 12177 32518 32210 32150 32411 70341 32412 32409 N/A 21130 34182 34181 31104 21075 25120 21179 33383 21180 34009 DESCRIPTION 1/8" ELBOW 90° HOSE BARB (3/8" H x 1/8"NPT) AIR HOSE (3/8",42" LONG) HOSE BARB(3/8"H x 1/4" NPT) BRASS STREET TEE (1
Installer's Manual: Clean Burn Air Compressors I89060 Figure 3B - Air Compressor Installed on the Saturn 140 / Saturn 240 3-4
Installer's Manual: Clean Burn Air Compressors Preparing the Furnace Cabinet (Furnace Models Saturn 140 / 240) 1. 2. Refer to Figures 3A and 3B. Install all-thread rods through the mounting holes in the base and top of the furnace cabinet. Use double nuts to securely lock the all-thread rods in position. Mounting the Air Compressor (Furnace Models Saturn 140 / 240) CAUTION: The compressor must be securely mounted as described in this section. Ensure that all nuts and bolts are firmly tightened. 1. 2.
Installer's Manual: Clean Burn Air Compressors I89056 Figure 3C - Air Compressor Installed on the CB-1750 / CB-2500 / CB-3250 3-6
Installer's Manual: Clean Burn Air Compressors Preparing the Furnace Cabinet (Furnace Models CB-1750/2500/3250) 1. 2. Refer to Figures 3A and 3C. Install all-thread rods in the mounting lugs on top of the furnace cabinet. Use double nuts to securely lock the all-thread rods in position. Mounting the Air Compressor (Furnace Models CB-1750/2500/3250) CAUTION: The compressor must be securely mounted as described in this section. Ensure that all nuts and bolts are firmly tightened. 1. 2.
Installer's Manual: Clean Burn Air Compressors I89058 Figure 3D - Air Compressor Installed on the CB-3500 / CB-5000 3-8
Installer's Manual: Clean Burn Air Compressors Preparing the Furnace Cabinet (Furnace Models CB-3500 and CB-5000) 1. 2. 3. Refer to Figures 3A/3D and your Furnace Operator's Manual for an overview of furnace assembly (refer specifically to information on the installation of the mounting/stabilizer brackets and the all-thread rods). According to the Furnace Operator's Manual, install the mounting and stabilizer brackets which hold the all-thread rods in place.
Installer's Manual: Clean Burn Air Compressors Preparing the CB-500 Series Burner for use with the Air Compressor AIR REGULATOR AIR GAUGE OIL GAUGE COMBUSTION AIR BAND I89062 Figure 3E - Component Detail of the CB-500 Series Burner WARNING: To avoid electrical shock hazards, turn off all power to the furnace, and unplug the burner before proceeding. 1. 2. 3. 4. 5. 6. 7. Figure 3E shows an exterior view of the CB-500 series burner components.
Installer's Manual: Clean Burn Air Compressors Preparing the CB-500 Series Burner for use with the Air Compressor (continued) LOCKING BAR SAVE AND USE THESE 4 SCREWS AND WASHERS TO INSTALL SQUARE CAP STEP 1 SURFACE MOUNTED AIR REGULATOR REMOVE THESE PARTS (COMPLETE REGULATOR) STEP 2 10 9 8 7 6 5 4 3 2 1 INSTALL SQUARE CAP AND "O" RING I89061 Figure 3F - Removing the Air Regulator from the Heater Block on the CB-500 Series Burner 3-11
Installer's Manual: Clean Burn Air Compressors Connecting the Air Compressor to the CB-500 Series Burner IMPORTANT: Run the 3/8" air hose directly from the air compressor to the burner. Do not use the connector block. 1. 2. 3. 4. 5. Refer to Figure 3G. Remove the female elbow 1/4" tube push fitting from the air pressure inlet port on the burner. Install the supplied 1/8" elbow on the air pressure inlet port of the burner.
Installer's Manual: Clean Burn Air Compressors Preparing the Saturn Burner for use with the Air Compressor ELECTRICAL BOX COVER AIR REGULATOR COMBUSTION AIR BAND I88584−A Figure 3H - Component Detail of the Saturn Burner WARNING: To avoid electrical shock hazards, turn off all power to the furnace, and unplug the burner before proceeding. 1. 2. 3. 4. 5. 6. 7. Figure 3H shows an exterior view of the Saturn burner components.
Installer's Manual: Clean Burn Air Compressors ITEM # PART# DESCRIPTION 1 32221 POPPET SPRING 2 32222 POPPET VALVE 3 32223 POPPET O−RING 4 32305 BRASS SEAT 5 32225 DIAPHRAM 6 32226 DIAPHRAM RING 7 33308 BONNET 8 34145 3/4" PANEL NUT 9 32202 1/4T PUSH X 1/8 NPT FEM ELBOW 7 6 R 4 O EM 3 VE 1 2 5 9 8 REMOVE I89063 Figure 3I - Removing the Air Regulator Components on the Saturn Burner Connecting the Air Compressor to the Saturn Burner IMPORTANT: Run the 3/8" air hose directly from the air compress
Installer's Manual: Clean Burn Air Compressors SECTION 4: OPERATING & MAINTAINING THE AIR COMPRESSOR Adjusting the Air Compressor During Operation It is very important to adjust the pressure relief on the air compressor to provide the burner with the precise air pressure (12 to 18 psi) required for proper burner operation. Excess air pressure is bled off through the pressure relief.
Installer's Manual: Clean Burn Air Compressors Maintaining the Air Compressor ATTENTION: Never introduce oil into the head of the air compressor. Oil will damage the teflon seals of the air compressor and will void your warranty. 1. 2. Clean the air intake filter element at least monthly according to the manufacturer's instructions included with the filter. Replace the air intake filter element annually.
140 WATTS NOZZLE HEATER WALL THERMO− STAT NOZZLE TEMP.SW.
FIGURE A2 - Saturn Burner Wiring Schematic A-2 OIL SOLENOID WALL THERMO− STAT BLACK YELLOW CAD CELL TEMP SWITCH L−150 N C BLACK BLACK BLACK GREY WIRENUT PROVING SWITCH WHITE F F PRIMARY OIL BLUE ORANGE WHITE SOLENOID AIR BLACK AIR SWITCH N.O.
Installer's Manual: Clean Burn Air Compressors DOUBLE PISTON AIR COMPRESSOR WIRING ORANGE WIRENUTS BLUE WHITE WHITE BLUE FLEX CONDUIT BROWN CONNECT ONE END OF THE GROUND WIRE TO THE GROUND SCREW ON THE COMPRESSOR AND THE OTHER END TO THE SCREW ON THE OUTSIDE OF THE JUNCTION BOX CAPACITOR TO TERMINAL BLOCK INSIDE THE BURNER HOUSING FIGURE A3 - Double-Piston Air Compressor Wiring A-3 I88533−A
Installer's Manual: Clean Burn Air Compressors A-4
