CleaverBrooks CBT Operation And Maintenance Manual

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Model CBT

Tubeless Vertical Boiler

Operation and Maintenance Manual

CBT-M — Full Modulation

CBT — On/Off Operation

750-382 04/2019

WARNING

DANGER

If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

— Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

WARNING

DANGER

Improper installation, adjustment, service, or maintenance can cause equipment damage, personal injury, or death. Refer to the Operation and Maintenance manual provided with the boiler. Installation and service must be performed by a qualified Cleaver-Brooks service provider.

— WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.

• If you cannot reach your gas supplier, call the fire department.

— Installation and service must be performed by a qualified Cleaver-Brooks, service agency or the gas supplier.

WARNING

DANGER

To minimize the possibility of serious personal injury, fire or damage to the equipment, never violate the following safety rules. — Always keep the area around the boiler free of combustible materials, gasoline, and other flammable liquids and vapors — Never cover the boiler, lean anything against it, stand on it, or in any way block the flow of fresh air to the boiler.

Notice

Where required by the authority having jurisdiction, the installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1.

WARNING

DANGER

The boiler and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psi (3.5 kPa).

WARNING

DANGER

Be sure the fuel supply which the boiler was designed to operate on is the same type as specified on the boiler name plate.

WARNING

DANGER

Should overheating occur or the gas supply valve fail to shut off, do not turn off or disconnect the electrical sup- ply to the boiler. Instead turn off the gas supply at a location external to the boiler.

WARNING

DANGER

Do not use this boiler if any part has been under water. Immediately call your Cleaver-Brooks service representative to inspect the boiler and to replace any part of the control system and any gas control which has been under water.

Notice

This manual must be maintained in legible condition and kept adjacent to the boiler or in a safe place for future reference. Contact your local Cleaver-Brooks representative if additional manuals are required.

WARNING

DANGER

The installation must conform to the requirements of the authority having jurisdiction or, in the absence of such requirements, to UL 795 Commercial-Industrial Gas Heating Equipment and/or the National Fuel Gas Code, ANSI Z223.1

CLEAVER-BROOKS

Model CBT

Tubeless Vertical Boiler

Operation, Service, and Parts Manual

 Cleaver-Brooks 2019

Manual Part No. 750-382

04/2019

iii

WARNING

DANGER

DO NOT OPERATE, SERVICE, OR REPAIR THIS EQUIPMENT UNLESS YOU FULLY UNDERSTAND ALL APPLICABLE SECTIONS OF THIS MANUAL.

DO NOT ALLOW OTHERS TO OPERATE, SERVICE, OR REPAIR THIS EQUIPMENT UNLESS THEY FULLY UNDERSTAND ALL APPLICABLE SECTIONS OF THIS MANUAL.

FAILURE TO FOLLOW ALL APPLICABLE WARNINGS AND INSTRUCTIONS MAY RESULT IN SEVERE PERSONAL INJURY OR DEATH.

Cleaver-Brooks equipment is designed and engineered to give long life and excellent service on the job. The electrical and mechanical devices supplied as part of the unit were chosen because of their known ability to perform; however, proper operating techniques and maintenance procedures must be followed at all times. Although these components afford a high degree of protection and safety, operation of equipment is not to be considered free from all dangers and hazards inherent in handling and firing of fuel.

Any “automatic” features included in the design do not relieve the attendant of any responsibility. Such features merely eliminate certain repetitive chores, providing more time for the proper upkeep of equipment.

It is solely the operator’s responsibility to properly operate and maintain the equipment. No amount of written instructions can replace intelligent thinking and reasoning and this manual is not intended to relieve the operating personnel of the responsibility for proper operation. On the other hand, a thorough understanding of this manual is required before attempting to operate, maintain, service, or repair this equipment.

Because of state, local, or other applicable codes, there are a variety of electric controls and safety devices which vary considerably from one boiler to another. This manual contains information designed to show how a basic burner operates.

Operating controls will normally function for long periods of time and we have found that some operators become lax in their daily or monthly testing, assuming that normal operation will continue indefinitely. Malfunctions of controls lead to uneconomical operation and damage and, in most cases, these conditions can be traced directly to carelessness and deficiencies in testing and maintenance.

It is recommended that a boiler room log or record be maintained. Recording of daily, weekly, monthly and yearly maintenance activities and recording of any unusual operation will serve as a valuable guide to any necessary investigation. Most instances of major boiler damage are the result of operation with low water. We cannot emphasize too strongly the need for the operator to periodically check his low water controls and to follow good maintenance and testing practices. Cross-connecting piping to low water devices must be internally inspected periodically to guard against any stoppages which could obstruct the free flow of water to the low water devices. Float bowls of these controls must be inspected frequently to check for the presence of foreign substances that would impede float ball movement.

The waterside condition of the pressure vessel is of extreme importance. Waterside surfaces should be inspected frequently to check for the presence of any mud, sludge, scale or corrosion.

It is essential to obtain the services of a qualified water treating company or a water consultant to recommend the proper boiler water treating practices.

The operation of this equipment by the owner and his or her operating personnel must comply with all requirements or regulations of his insurance company and/or other authority having jurisdiction. In the event of any conflict or inconsistency between such requirements and the warnings or instructions contained herein, please contact Cleaver-Brooks before proceeding.

CONTENTS

CHAPTER 1 INTRODUCTION 1-1

Pressure vessel 1-2 Burner 1-4 Gas train 1-5 Controls 1-6 Component/connection locations 1-9 Optional equipment 1-10

CHAPTER 2 INSTALLATION 2-1

Lifting and moving the boiler 2-2 Water treatment 2-2 Boiler room 2-4 Gas piping 2-5 Boiler water-side connections 2-10 Electrical connections 2-11 Wiring diagrams 2-12

CHAPTER 3 FLUE AND COMBUSTION AIR VENTING 3-1

Venting connections — general 3-2 Flue venting 3-2 Vent terminal location 3-2 Horizontal through-wall venting, inside air (Category III) 3-5 Horizontal through-wall direct venting 3-6 Horizontal through-wall flue vent termination 3-7 Vertical venting, inside combustion air (Category III) central heating 3-8 Vertical venting, direct vent combustion air (Category III) 3-9 Flue and combustion air duct design using direct vent combustion 3-9

CHAPTER 4 COMMISSIONING 4-1

Full modulation boilers 4-2 On/off boilers 4-25 Boil-out of a new unit 4-25 Post start-up checkout procedure 4-26 Falcon control functions and customer interface 4-27

CHAPTER 5 MAINTENANCE 5-1

General 5-2 Bottom blowdown 5-2 Water column blowdown 5-3 Fireside cleaning procedure/disassembly 5-5 Ignition electrode 5-7 UV scanner (full modulation only) 5-8 Waterside inspection/cleaning 5-10 Safety valve 5-11 Troubleshooting 5-11 Display diagnostics 5-27 Lay-up 5-27

CHAPTER 6 PARTS 6-1

Recommended spare parts list 6-2 Safety valves 6-3 Control panel 6-4 Burner assembly 6-6 Water Column 6-10 Feedwater piping 6-11 Gas train 6-12

Direct vent kits 6-13

CHAPTER 1 Introduction

Pressure vessel 1-2 Burner 1-4 Gas train 1-5 Controls 1-6 Component/connection locations 1-9 Optional equipment 1-10

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The Cleaver-Brooks Model CBT is a two-pass vertical tubeless steam boiler with side-mounted burner.

The CBT features thick pressure vessel plates designed to provide long life.

Full modulation and on/off options are available. On full modulation units, an ECM variable speed combustion air blower modulates the burner to precisely match steam production to demand for reduced fuel usage and cycling. The side-mount burner arrangement allows for a larger steam space to deliver exceptionally dry steam quality while allowing easy access for service and maintenance. The Falcon control keeps the boiler and burner consistently operating at peak efficiency.

On/off burners use the CB780 burner management control.

The CBT is available in 10, 15, 20, 25, and 30 HP sizes. Features include:

• Natural gas and propane fuels

• 15 psig or 150 psig design pressure

FIGURE 1-1. CBT-M boiler

• Up to 84% efficiency and high turndown with the PID modulating premix

burner.

• Low emissions: less than 20 ppm NOx (full mod, natural gas only)

• Robust pressure vessel, designed to provide long life; 5 year pressure vessel warranty

• Standard integrated control with user-friendly interface for peak operation and efficiency

Introduction

Quality construction

ASME construction ensures high quality design, safety, and reliability.

UL listed

The Model CBT and CBT-M are UL listed for both the US and Canada.

Premix technology

The Model CBT-M Boiler utilizes “Premix” technology to mix both fuel and combustion air prior to entering the firing chamber. This technology provides clean, efficient combustion with very low emission levels.

1.1 — Pressure vessel

The boilers are constructed in accordance with the ASME Boiler Construction Code, Section I for high pressure steam boilers and Section IV for low pressure steam boilers. High pressure steam boilers are stamped with the ASME “S” symbol. Low pressure steam boilers are stamped with the ASME “H” symbol. The ASME data plate can be found on the lower portion of the vessel on the front or left side (see Figure 1-2).

The CBT is a vertically oriented 2-pass tubeless pressure vessel design with a water-backed furnace. The first fireside pass utilizes radiant heat transfer and the second pass uses convection. The second pass flue passageways incorporate extended heating surfaces designed using computational fluid dynamics (CFD) modeling.

The large steam chest volume ensures exceptional dry quality steam at both high and low operating pressures.

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Pressure vessel

The pressure vessel is fully insulated with minimal use of refractory to significantly reduce radiation and convection losses. Refractory is limited to the burner dry oven and a bottom furnace target plate.

FIGURE 1-2. ASME data

(1)

FIGURE 1-2. CBT heat flow

(2)

(3)

Gases of combustion flow downward through the furnace (1), then upward through the 2nd pass (2) before exiting the flue (3).

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1.2 — Burner

1.2.1 — Full modulation (CBT-M)

Full modulation units use a premix burner with a self-regulating gas valve-venturi system, ECM variable regulating gas valve, variable speed blower, and Fecralloy metal fiber burner canister.

• Full modulation is provided using the integral variable

speed combustion air fan and Falcon control.

• The low temperature, surface combustion burner flame

provides low emissions and optimum combustion efficiency.

• Direct spark ignition with UV flame detection.

• At maximum firing rate, the sound level of the burner is

less than 70 dBA, measured in front of the boiler at a distance of 3 feet. At reduced firing rates, sound levels are even lower.

• Provision is made for optional direct vent combustion air

connection.

• Combustion Air Proving Switch standard.

• Combustion air filter is standard.

Introduction

FIGURE 1-3. Full modulation burner

1.2.2 — On-off firing (CBT)

Gas is introduced into the combustion zone from a circular manifold through multiple ports in the manifold. Burner firing is regulated by a main gas regulator operating steam pressure control. Burner includes microprocessor-based flame supervision control.

• Direct spark ignition with flame rod.

• Provision is made for optional direct vent combustion air connec-

tion.

• Combustion Air Proving Switch standard.

• Combustion air filter is standard.

FIGURE 1-4. On/off burner

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Gas train

1.3 — Gas train

The gas train assembly is provided in accordance with UL/cUL certification and is ASME CSD-1 compliant. The gas train assembly is factory assembled and wired.

VENTURI

OPTIONAL:

GAS PRESSURE REGULATOR

FULL MODULATION (CBT-M)

FIGURE 1-5. Gas train

Full modulation gas train components:

A. Single body, dual safety shutoff gas valve with integral trim regulator B. Low Gas Pressure Switch C. High Gas Pressure Switch D. (2) Manual Shutoff Valves E. Test Cocks F. Venturi G. Gas supply regulator (optional)

ON/OFF (CBT)

On/off gas train components:

H. Regulator I. Low Gas Pressure Switch J. Gas Solenoid Safety Shutoff Valve K. Gas Diaphragm Safety Shutoff Valve L. High Gas Pressure Switch M. (2) Manual Shutoff Valves

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1.4 — Controls

CONTROLS ABBREVIATIONS:

ALWCO - Auxiliary Low Water Cutoff HLC - High Limit Control HWA - High Water Alarm OLC - Operating Limit Control LWCO - Low Water Cutoff

1.4.1 — Full modulation controls

Introduction

(Optional)

FIGURE 1-6. Control panel, full modulation

(Optional)

The CB Falcon steam boiler control is an integrated burner management and modulation control with a color touch-screen display/operator interface.

The controller is capable of the following functions:

Burner sequencing with safe start check, pre-purge, direct spark ignition, and post purge.

•

• Electronic ignition.

• Flame Supervision.

• Safety shutdown with time-stamped display of lockout condition.

• PID modulating steam pressure set point control.

• Supervision of low and high gas pressure, air proving, stack back pressure, high limit, and low water.

• First-out annunciator.

• Real-time data trending.

• (3) pump/auxiliary relay outputs.

• Modbus communication capability.

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Controls

• Outdoor temperature reset.

• Remote firing rate or setpoint control

• Setback/time-of-day setpoint

• Built-in Lead-Lag control for multiple boiler systems

• Warm standby-minimum temperature control

1.4.2 — On-off controls

The Burner Control provides burner sequencing control and flame supervision.

A switch/light panel provides functionality similar to full modulation units: indicator lights for demand, fuel valve open, alarm, low water, and (optional) high water; panel switches for power on/off and ALWCO reset.

BURNER CONTROL

IGNITION

TRANSFORMER

LIGHT/BUTTON

PANEL

ALWCO

CONTROLLER

H.W.A. OPTION

LWCO CONTROLLER

PUMP CONTROL

TERMINAL STRIP

FIGURE 1-7. Control panel, on/off boilers

AIR PRESSURE

SWITCH

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1.4.3 — Water level and limit controls, all boilers

The pressure transmitter provides an analog steam pressure signal to the controller for modulated firing (full modulation units) or on/off operation.

ALWCO probe holder

Introduction

Manual valve

The high limit control (HLC) provides safety shutdown when steam pressure exceeds the maximum operating range of the boiler. It includes a manual reset switch and adjustable set point.

The operating control (OLC) is set below the maximum pressure setting of the HLC. This control is auto reset and includes adjustable set point

Standard water level controls comprise an automatic reset primary low water cutoff (LWCO) and a manual reset auxiliary low water cutoff (ALWCO). A manual reset LWCO is available where required by code.

Four individual conductance probes are mounted within the LWCO water column to indicate levels for low water, pump on, pump off, and high water alarm (optional). The solid-state level control boards reside in the boiler control enclosure.

A panel mounted ALWCO reset/test switch is provided.

The water column blowdown should be piped to a boiler blowdown system. Please refer to service and maintenance section for blowdown procedures.

Steam pressure gauge

HLC

Pressure transmitter (modulating burner only)

FIGURE 1-8. Low water and limit controls

LWCO/pump control

Gauge glass

Gauge glass blowdown valve

OLC

WC blowdown valve

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Component/connection locations

1.5 — Component/connection locations

Refer to Chapter 3 for recommended vent sizes and lengths.

AIR INLET

SURFACE BLOWOFF PIPING

PRESSURE RELIEF VALVE

GAUGE GLASS

LEVEL CONTROL

GAS TRAIN

AUX. LOW WATER CUTOFF

STACK

OUTLET

FEEDWATER PIPING

BLOWDOWN PIPING

(OPTIONAL)

FIGURE 1-9. Boiler components/connections, CBT-M

CONTROL PANEL

BURNER CABINET

ALWCO

SURFACE BLOWOFF PIPING

GAS TRAIN

LWCO

STACK OUTLET

BURNER SIGHT GLASS

FEEDWATER PIPING

AIR INLET

BOTTOM BLOWDOWN (OPTIONAL)

FIGURE 1-10. Boiler components/connections, CBT

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Introduction

1.6 — Optional equipment

Certain options are available for the Model CBT Boiler; normally these will have been specified at the time of order entry. In addition, some options may have been provided (by others) that are not part of Cleaver-Brooks scope of supply. In either case, the Cleaver-Brooks authorized representative should be consulted regarding specific project requirements.

Model CBT optional features:

• Gas pressure regulator (>1/2 psig supply)

• Gas pressure relief valve (>1 psig supply)

• Minimum Temperature/Warm Standby

• Direct vent kit combustion air adapter

• Chemical feed system

• Surface blow-off conductivity control

• Feedwater system (includes tank, pump, and control) - shipped separately

• Feedwater valves

• Blowdown valves

• Steam header valves

• High water alarm

• Time clock for setback control

• Stack temperature limit control

• Stack thermometer

• Alarm horn

• Lead-Lag steam pressure header transmitter

• Feedwater sets and condensate receivers

• Blowdown separators and tanks

• Economizers

• Complete steam skid or field-installed solutions

• Factory mounted valves

• Communications gateway

• Boiler Monitor (remote connectivity)

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CHAPTER 2 Installation

Lifting and Moving the Boiler 2-2

Water Treatment 2-2

Boiler Room 2-4

Gas Piping 2-5

Boiler Waterside Connections 2-10

Electrical Connections 2-11

Wiring Diagrams 2-12

Warning

Provisions for combustion and ventilation air must be in accordance with UL 795, CommercialIndustrial Gas Heating Equipment, cUL, or applicable provisions of the local building codes. Failure to follow this warning could result in personal injury or death

Warning

If an external electrical source is utilized, the boiler, when installed, must be electrically bonded to ground in accordance with the requirements of the authority having jurisdiction or, in the absence of such requirements, with the National Electrical Code and/or UL 795, Commercial-Industrial Gas Heating Equipment.

Caution

The boiler must be installed such that the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during appliance operation and service. Failure to follow this warning could result in equipment failure.

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Installation

2.1 — Lifting and Moving the Boiler

60° min.

FIGURE 2-1. Lifting boiler

The boiler should be lifted by the base using a suitable fork lift, or by the top using the lifting lugs provided. For fork truck lifting, ensure the forks extend through the length of the base.

Note: The boiler should not be moved by pushing, prying, or pulling on any part of the casing.

The boiler must be installed on a non-combustible floor. If the floor is not level, piers or a raised pad slightly larger in length and width than the boiler base dimensions will make boiler installation and leveling easier.

The boiler must be installed so that all components remain accessible for inspection, cleaning, or maintenance. Field-installed piping and electrical connections must be arranged so as to avoid interfering with removal of the casing panels or with the burner door.

Caution

In order to avoid damage to the unit, lifting or moving the boiler should only be done by experienced personnel suitably equipped for moving heavy equipment.

Caution

The boiler must not be installed on combustible flooring.

2.2 — Water Treatment

Properly treated boiler water will help maximize the effectiveness and lifespan of the pressure vessel. Contact your local Cleaver-Brooks representative or water management consultant for complete information on how to prevent damage resulting from inadequate water treatment.

See Table 2-1 for CBT water quality guidelines.

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Water Treatment

Important

The CBT boiler requires soft water. Failure to observe this requirement can lead to dangerous

operating conditions, and may result in damage to the boiler. If necessary, your Cleaver-Brooks representative

can provide additional information regarding your water softening requirements.

Table 2-1. CBT water quality

QUANTITY LIMITS

Oxygen <0.005 ppm CO2 0 ppm Hardness <2.0 ppm Suspended Solids <300 ppm pH 8.5 - 10.5 Sulfite >50 ppm Fe <0.1 ppm Silica <150 ppm Total Alkalinity <700 ppm Dissolved Solids <3,000 ppm

The objectives of water treatment in general are to:

1. Prevent hard scale and soft sludge deposits that inhibit heat transfer and that could lead to overheated metal and costly downtime and repairs.

2. Eliminate corrosive gases in the supply or boiler water.

To accomplish these objectives, the boiler requires proper water treatment before and after introduction of water into the unit. The selection of pretreatment processes depends upon the water source, its chemical characteristics, the amount of makeup water needed, system operation practices, etc.

Because of the variables involved, no single boiler compound can be considered a cure-all; nor is it advisable to experiment with homemade treating methods. A sound treatment program should include a weekly analysis of the water in the system.

Warning

Inadequate or improper water treatment will shorten the life of the boiler and could result in a hazardous condition.

The internal or waterside surfaces of the pressure vessel should be inspected at regular intervals for evidence of corrosion, pitting, contamination, or accumulations of foreign matter. If any of these conditions are detected, contact your local Cleaver-Brooks authorized representative for advice on corrective action. It is recommended that a properly sized water meter be installed in the raw water makeup line to accurately determine the amount of raw water admitted to the boiler.

Surface blow-off is available for steam boilers. This option allows removal of surface water impurities through a blowdown line located at the normal operating water level of the boiler. If allowed to accumulate, surface impurities may impede steam release and could cause foaming, leading to priming and carryover in the steam lines.

Corrosion and sludge deposits in old systems must be removed prior to installation of a new boiler.

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Installation

2.3 — Boiler Room

The boiler room must comply with all building codes and regulations. An adequate supply of combustion air and sufficient ventilation are required for safe operation. If the optional direct vent combustion air kit is not used, ventilation must be provided to meet applicable regulations for air supply.

TABLE 2- 2. Boiler room ambient conditions

Relative humidity < 85% non-condensing Ambient temperature range 0 Storage temperature range -40 Combustion air temperature 0

Clean combustion air is required for optimum efficiency and boiler operation (minimum combustion air 10 cfm per boiler horsepower). Dust and airborne contaminants will adversely effect burner performance. See Chapter 3, Stack and Intake Venting, for more information.

If conditions dictate, a serviceable filter must be placed at the burner inlet to eliminate airborne contamination to the burner. If a direct vent air intake is used, the intake and flue venting should be terminated so as to prevent rain, snow, dust, or debris from entering the intake piping.

Observe proper clearances above and around boiler - see Figure 2-2.

C to 50 oC / 32oF to 122oF

C to 60 oC / -40oF to 140oF

C to 50 oC / 32oF to 122oF

18”

18” 18”

IN FRONT OF

36”

ELECTRICAL CONTROL PANEL

FIGURE 2-2. Recommended Clearances

CLEARANCE ABOVE BOILER = 18”

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Gas Piping

STEAM OUTLET

WATER COLUMN

GAS INLET

COMBUSTION AIR INLET

DRAIN

GAUGE GLASS DRAIN

SAFETY RELIEF VALVE

STACK OUTLET

CONDENSATE DRAIN

SURFACE BLOWOFF

FIGURE 2-3. CBT connections

FEEDWATER

BOTTOM BLOWDOWN

GAS INLET ON/OFF UNITS

2.4 — Gas Piping

Gas pressure requirements - For proper and safe operation, each Model CBT boiler requires a stable gas pressure

input. The minimum inlet supply pressure must be as noted in Table 2-3. Pressure should be measured when the burner is firing using a manometer at the upstream test port connection on the main gas valve. For a multiple unit installation, gas pressure should be set for a single unit first, then the remaining units should be staged on to ensure that gas pressure droop is not more than 1" w.c. and never below the required pressure. Fluctuating gas pressure readings could be indicative of a faulty supply regulator or improper gas train size to the boiler.

TABLE 2- 3. Model CBT gas pressure requirements

CBT Size

(HP)

Min (“WC) Max (“WC)* Min (“WC) Max (“WC)*

Natural Gas LP Gas

10 7.0 14 11.0 14

15 7.0 14 11.0 14

20 7.0 14 11.0 14

25 7.0 14 11.0 14

30 8.0 14 11.0 14

*Maximum without upstream regulator

A manually operated shut-off valve is provided as standard on the CBT boiler. If dirt particles are present in the gas supply, it may be necessary to install an approved gas filter. Please inquire with the local gas supply company.

The boiler shall be installed such that the gas ignition system components are protected from water (dripping, spraying, etc.) during appliance operation and service.

A sediment trap must be provided upstream of the gas controls.

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Installation

If building supply gas pressure is greater than 1 psig (27.8” WC), an upstream regulator with overpressure protection and proper gas venting will be required and must be piped to a safe point of discharge. For multiple boiller installations, a dedicated gas pressure regulator is required for each boiler to ensure consistent gas pressure at the boiler.

Drip legs are required on any vertical piping at the gas supply to each boiler so that any dirt, weld slag, or debris can deposit in the drip leg rather than into the boiler gas train. The bottom of the drip leg should be removable without disassembling any gas piping. The connected piping to the boiler should be supported from pipe supports and not supported by the boiler gas train or the bottom of the drip leg.

All gas piping and components to the boiler gas train connection must comply with NFPA 54, local codes, and utility requirements as a minimum. Only gas approved fittings, valves, or pipe should be used. Standard industry practice for gas piping is normally Schedule 40 black iron pipe and fittings.

Before starting the unit(s) all piping must be cleaned to prevent the entrance of debris into the boiler gas train. Piping should be tested as noted in NFPA 54, with the boiler isolated during tests.

After initial startup, the inlet screen to the gas valve should be checked and cleaned for any debris buildup.

Gas Supply Pipe Sizing - For proper operation of a single unit or a multiple unit installation, we recommend that the gas piping be sized to allow no more than 0.3" w.c. pressure drop from the source (gas header or utility meter) to the final unit location. Higher supply pressure systems may allow for a greater pressure drop. In ALL cases, minimum supply pressures must be met for proper operation of the boiler(s). The gas supplier (utility) should be consulted to confirm that sufficient volume and normal pressure are provided to the building at the discharge side of the gas meter or supply pipe.

For installations of new boilers into an existing building, gas pressure should be measured with a manometer to ensure sufficient pressure is available. A survey of all connected “gas using devices” should be made. If appliances other than the boiler or boilers are connected to the gas supply line, then a determination must be made of how much flow volume will be demanded at one time and the pressure drop requirement when all appliances are firing.

The total length of gas piping and all fittings must be considered when sizing the gas piping. Total equivalent length should be calculated from the utility meter or source to the final unit connection. As a minimum guideline, gas piping Tables 2-4 and 2-5 should be used. The data in these tables is from the NFPA 54 source book, 2006 edition.

To verify the input of each device that is connected to the gas piping, obtain the btu/hr input and divide this input by the calorific value of the gas that will be utilized. For instance, a 40 HP unit with 1,613,253 btu/hr input divided by a gas calorific value of 1060 will result in a flow of 1,522 CFH (cubic ft/hr). The single boiler is approximately 20 feet from the gas supply header source. And with a measured gas supply pressure of 10" w.c. we find from Table 2-4 that a supply pipe size of 2" should be used as a minimum.

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Gas Piping

Table 2-4. Gas line capacity - Schedule 40 metallic pipe

Nominal

Actual I.D.

Length in feet

10 20 30 40 50 60 70 80

90 100 125 150 175 200

**Fuel: Natural Gas

**Inlet Pressure: Less than 2.0 psi

**Pressure Drop: 0.30" w.c.

**Specific Gravity: 0.60

1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4"

1.049 1.380" 1.610" 2.067" 2.469" 3.068" 4.026" **Maximum Capacity in Cubic Feet of Gas per Hour (CFH)

514 1,060 1,580 3,050 4,860 8,580 17,500 363 726 1,090 2,090 3,340 5,900 12,000 284 583 873 1,680 2,680 4,740 9,660 243 499 747 1,440 2,290 4,050 8,290 215 442 662 1,280 2,030 3,590 7,330 195 400 600 1,160 1,840 3,260 6,640 179 368 552 1,060 1,690 3,000 6,110 167 343 514 989 1,580 2,790 5,680 157 322 482 928 1,480 2,610 5,330 148 304 455 877 1,400 2,470 5,040 131 269 403 777 1,240 2,190 4,460 119 244 366 704 1,120 1,980 4,050 109 209 336 648 1,030 1,820 3,720 102 185 313 602 960 1,700 3,460

Pipe Size

Table 2-5. Gas line capacity - Schedule 40 metallic pipe

Pipe Size

Nominal 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4"

Actual I.D. 1.049" 1.380" 1.610" 2.067" 2.469" 3.068" 4.026"

Length in feet **Maximum Capacity in Cubic Feet of Gas per Hour (CFH)

100

125

150

175

200

**Fuel: Natural Gas

**Inlet Pressure: Less than 2.0 psi

**Pressure Drop: 0.50" w.c.

**Specific Gravity: 0.60

678 1,390 2,090 4,020 6,400 11,300 23,100

466 957 1,430 2,760 4,400 7,780 15,900

374 768 1,150 2,220 3,530 6,250 12,700

320 657 985 1,900 3,020 5,350 10,900

284 583 873 1,680 2,680 4,740 9,600

257 528 791 1,520 2,430 4,290 8,760

237 486 728 1,400 2,230 3,950 8,050

220 452 677 1,300 2,080 3,670 7,490

207 424 635 1,220 1,950 3,450 7,030

195 400 600 1,160 1,840 3,260 6,640

173 355 532 1,020 1,630 2,890 5,890

157 322 482 928 1,480 2,610 5,330

144 296 443 854 1,360 2,410 4,910

134 275 412 794 1,270 2,240 4,560

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2-7

Installation

Gas header - For multiple unit installations, a single common gas header is recommended with individual takeoffs for each boiler (See Figure 2-4). Boiler gas manifold piping should be sized based on volume requirements and lengths between each boiler and the fuel main header. Tables 2-6 through 2-10 indicate the proper sizing for multiple units of equal size, placed on the factory standard center with the indicated take off size. For installations with a mixed sized use, determine the flow of each unit and total the input. With the total input, find length of run from the source and determine what size header will be needed for the flow of all units firing. Pipe sizes are based on Table 2-4 with boiler gas line take-off at 20 feet from the header. If pipe runs are greater or if gas pressure is different, refer to Tables 2-4 and 2-5 for pipe sizing. Main fuel supply header should be sized for <4" w.c. pressure drop with all equipment operating at 100% capacity.

FROM METER

HEADER PIPE

MANUAL SHUTOFF

GAS STRAINER

REGULATOR SEE NOTE 1

RELIEF VALVE SEE NOTE 5

DRIP LEG

MANUAL

SHUTOFF

OPTIONAL

FIGURE 2-4. Typical gas piping - Example 1

NOTES:

1. Step-down regulator required if supply pressure >1/2 psig.

2. Refer to local fuel gas codes when applicable.

3. Header to be sized for room capacity.

4. Provision required for measuring gas supply pressure at boiler.

5. Relief valve required if gas supply pressure >1 psig.

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CBT

Gas Piping

MANUAL SHUTOFF

VALVE

REGULATOR (OPTIONAL)

STRAINER

MANUAL SHUTOFF

VALVE

GAS HEADER - SIZE FOR BOILER ROOM CAPACITY AND TO MINIMIZE PRESSURE LOSS

BY INSTALLER

FIGURE 2-5. Typical gas piping - Example 2

Pipe sizing for multiple unit manifolds

TABLE 2- 6. CBT 10 HP boilers

# of Units Pipe Size To Boiler Header Pipe Size

TABLE 2- 8. CBT 20 HP boilers

# of Units

Pipe Size To Boiler

Header Pipe Size

12 3 4

1-1/4” 1-1/4” 1-1/4” 1-1/4”

1-1/2” 1-1/2” 2” 2”

12 3 4

1-1/2” 1-1/2” 1-1/2” 1-1/2”

1-1/2” 2” 2-1/2” 2-1/2”

DRIP LEG REQUIRED FOR ANY VERTICAL RUN OF PIPING

TABLE 2- 7. CBT 15 HP boilers

# of Units Pipe Size To Boiler Header Pipe Size

TABLE 2- 9. CBT 25 HP boilers

# of Units

Pipe Size To Boiler

Header Pipe Size

12 3 4

1-1/4” 1-1/4” 1-1/4” 1-1/4”

1-1/2” 2” 2” 2-1/2”

1234

1-1/2” 1-1/2” 1-1/2” 1-1/2”

1-1/2” 2" 2-1/2” 3"

TABLE 2- 10. CBT 30 HP boilers

# of Units

Pipe Size To Boiler

Header Pipe Size

12 3 4

2” 2” 2” 2”

2” 2-1/2” 3” 3”

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2-9

Installation

2.5 — Boiler Waterside Connections

Notice

Before filling boiler, check that all waterside openings/fittings are plugged and all inspection covers are secured

A pressure relief valve (safety valve), provided with the boiler, must be installed in the mounting provided. Use pipe sealing compound and a flat sided wrench when securing the safety relief valve. Do not use a pipe wrench and do not over tighten the relief valve. The safety valve must be mounted in a vertical position so that discharge piping and code-required drains can be properly piped to prevent buildup of back pressure and accumulation of foreign material around the valve seat area. Apply only a moderate amount of pipe compound to male threads and avoid over-tightening, which can distort the seats. Use only flat-jawed wrenches on the flats provided.

Connection to the main steam header is made at the nozzle projecting upward from the boiler shell. ASME code requires a suitable stop valve to be installed between the boiler and main steam header if multiple boilers are tied to the header. This valve should be as close as possible to the boiler to facilitate venting and pressure testing. A suitably rated gate valve is recommended for this purpose.

Feedwater is introduced through the piping assembly installed on the side of the boiler vessel. A stop valve and check valve are optional equipment.

The feedwater supply should provide sufficient pressure to meet minimum flow requirements. Cleaver-Brooks offers bottom blowdown piping and valves for CBT boilers. Optional surface blowoff is also

available. A qualified boiler and piping installer should make all boiler waterside connections.

Only properly certified personnel such as the safety valve manufacturer’s certified representative can adjust or repair the boiler safety valves. Failure to follow this warning could result in serious personal injury or death.

SURFACE BLOWOFF

FEEDWATER

STEAM OUTLET

SAFETY VALVE

FIGURE 2-6. Waterside connections (boiler top view)

BOTTOM BLOWDOWN

2-10

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Electrical Connections

2.6 — Electrical Connections

A qualified electrician or service technician must make the electrical connections to the boiler; all local electrical and building codes must be adhered to.

Main power and any remote wiring should be brought to the left side of the control panel and terminated at the appropriate terminals provided.

- Connect UV Scanner to threaded connection on dry oven

- Connect spark cables to dual electrode and ignition transforme

- Plug AC power harness into blower

- Plug DC blower control harness plug into blower

- Connect incoming AC power per wiring diagram

- Connect optional heat request inputs per wiring diagram

- Connect pump controls per wiring diagram

Caution: The blower signal wiring must be isolated from the blower power wiring and the high voltage ignition cables.

750-382 CBT

FIGURE 2-7. CBT wiring and cable connections

2-11

Installation

2.7 — Wiring Diagrams

Note: Wiring diagrams shown are for example only. Installations may vary. Refer to the Cleaver-Brooks wiring diagram provided with the boiler for information specific to your installation.

Basic wiring diagram - full modulation

2-12

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CBT

Wiring Diagrams

Basic wiring diagram - on/off boiler

750-382 CBT

2-13

Installation

2-14

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CBT

CHAPTER 3 Flue and Combustion Air

Venting

Venting connections - general 3-2

Flue venting 3-2

Vent terminal location 3-2

Horizontal through-wall venting, inside air (Category III) 3-5

Horizontal through-wall direct venting 3-6

Horizontal through-wall flue vent termination 3-7

Vertical venting, inside combustion air (Category III) central heating 3-8

Vertical venting direct vent combustion air (Category III) 3-9

Flue and combustion air duct design using direct vent combustion 3-9

750-382 CBT

3-1

Flue and Combustion Air Venting

3.1 — Venting connections - general

Proper installation of flue gas exhaust venting is critical for the efficient and safe operation of the boiler. Definition of Appliance Categories Boilers are divided into four categories based on the pressure and temperature produced in the exhaust

stack and the likelihood of condensate production in the vent.

• Category I - A boiler which operates with a non-positive vent static pressure and with a vent gas temperature that avoids excessive condensate production in the vent.

• Category II - A boiler which operates with a non-positive vent static pressure and with a vent gas temperature that may cause excessive condensate production in the vent.

• Category III - A boiler which operates with a positive vent pressure and with a vent gas temperature that avoids excessive condensate production in the vent.

• Category IV - A boiler which operates with a positive vent pressure and with a vent gas temperature that may cause excessive condensate production in the vent.

The Model CBT will in most applications be considered a Category III boiler. In certain applications, such as with a condensing economizer, Category II or IV venting criteria may apply.

For additional information on boiler categorization, see latest edition standard of National Fuel Gas Code or in Canada, the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment, or applicable provisions of local building codes.

Contact the manufacturer of the vent material if there is any question about the boiler categorization and suitability of a vent material for application on a Category III vent system. Using improper venting materials can result in personal injury, death or property damage.

During winter months check the flue termination and make sure no blockage occurs from build up of ice or snow. Condensate can freeze on a flue termination. Frozen condensation at the flue termination can result in a blocked flue condition.

3.2 — Flue venting

The flue should be supported to maintain proper clearances from combustible materials. Use insulated vent pipe spacers where the venting passes through combustible roofs and walls.

Cleaver-Brooks recommends the use of flue venting systems that are certified to UL 103 or ULC C-959. Flue systems constructed of stainless steel are recommended. Please note: Type B vent is NOT appropriate for Category II, III, or IV boiler systems.

3.3 — Vent terminal location

Give special attention to the location of the vent termination to avoid possibility of property damage or personal injury.

1. Combustion gases can form a white vapor plume in the winter. The plume could obstruct a window view if

the termination is installed in close proximity to windows.

2. Prevailing winds could cause freezing of condensate and water/ice buildup on building, plants or roof.

3-2

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CBT

Vent terminal location

3. The bottom of the vent terminal and the air intake shall be located at least 24 inches above grade, including normal snow line.

4. Un-insulated single-wall metal vent pipe shall not be used outside in cold climates for venting combustion gas.

5. Through-the-wall vents for Category II and IV appliances and non-categorized condensing appliances shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of other equipment. Where local experience indicates that condensate is a problem with Category III appliances, this provision shall also apply.

6. Locate and guard vent termination to prevent accidental contact by people and pets.

7. DO NOT terminate vent in window well, alcove, stairwell or other recessed area, unless previously approved by local authority.

8. DO NOT terminate above any door, window, or gravity air intake. Condensate can freeze causing ice formations.

9. Locate or guard vent to prevent condensate from damaging exterior finishes. Use a 2' x 2' rust resistant sheet metal backing plate against brick or masonry surfaces.

10. Minimize exposed flue venting outside of building in extreme cold climates. In winter conditions condensate could freeze and block the flue pipe or termination.

11. Ensure combustion air intake(s) are a sufficient distant away from any exhaust terminations to avoid drawing in flue gases or other contaminants.

U.S. installations- Refer to latest edition of the National Fuel Gas Code. Vent termination requirements are as follows:

1. Vent must terminate at least four (4) feet below, four (4) feet horizontally, or one (1) foot above any door, window or gravity air inlet to the building.

2. The vent must not be less than seven (7) feet above grade when located adjacent to public walkways.

3. Terminate vent at least three (3) feet above any forced air inlet located within ten (10) feet.

4. Vent must terminate at least four (4) feet horizontally, and in no case above or below unless four (4) feet horizontal distance is maintained, from electric meters, gas meters, regulators, and relief equipment.

5. Terminate vent at least six (6) feet away from adjacent walls.

6. DO NOT terminate vent closer than five (5) feet below roof overhang.

Canada installations- Refer to the latest edition of CAN/CGA-B149.1 and B149.2 A vent shall not terminate:

1. Directly above a paved sidewalk or driveway which is located between two single family dwellings and serves both dwellings.

2. Less than 7 ft. (2.13m) above a paved sidewalk or paved driveway located on public property.

3. Within 6 ft. (1.8m) of a mechanical air supply inlet to any building.

4. Above a meter/regulator assembly within 3 ft. (900mm) horizontally of the vertical center-line of the regulator.

5. Within 6 ft. (1.8m) if any gas service regulator vent outlet.

6. Less than 1 ft. (300mm) above grade level.

7. Within 3 ft. (1m) of a window or door which can be opened in any building, any non-mechanical air supply inlet to any building to the combustion air inlet of any other appliance.

8. Underneath a verandah, porch or deck, unless: A. The verandah, porch or deck is fully open on a minimum of two sides beneath the floor.

B. the distance between the top of the vent termination and the underside of the verandah, porch or deck is

greater than 1 ft. (30cm)

Note: For direct vent installations where the air is piped in from outside, a protective screen on the air inlet termination elbow must be used to act as an inlet screen.

750-382 CBT

3-3

Flue and Combustion Air Venting

Examine the venting system at least once a year. Check all joints and vent pipe connections for tightness, corrosion or deterioration.

3.3.1 — Venting installation tips

Where to support piping:

• Horizontal runs- at least every five (5) feet.

• Vertical runs - use braces under or near elbows

Observe the following to avoid personal injury or property damage:

• To cut nonmetallic vent pipe, use a fine-toothed hacksaw (34 teeth per inch).

• Do not use nonmetallic vent pipe or fittings that are cracked or damaged.

• Do not use nonmetallic vent fittings if they are cut or altered.

• Do not drill holes, or use screws or rivets, in nonmetallic vent pipe or fittings.

Refer also to the vent manufacturer’s installation instructions.

3-4

FIGURE 3-1. Vent Terminations

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CBT

Horizontal through-wall venting, inside air (Category III)

3.4 — Horizontal through-wall venting, inside air (Category III)

For boilers connected to gas vents or chimneys, vent installations shall be in accordance with Part 7, Venting of Equipment, of the latest edition of National Fuel Gas Code, or in Canada, the latest edition of CAN/CGA-B 149.1 and.2 Installation Code for Gas Burning Appliances and Equipment, or applicable provisions of local building codes.

These installations utilize the boiler-mounted blower to vent the combustion products to the outside. Combustion air is taken from inside the room and the vent is installed horizontally through the wall to the outside. Adequate combustion and ventilation air must be supplied to the boiler room in accordance with the National Fuel Gas Code or, in Canada, the latest edition of CAN/CGA-B 149.1 and.2 Installation Code for Gas Burning Appliances and Equipment.

The direct vent intake should be considered in the overall length calculation of the venting system.

FIGURE 3-2. Horizontal venting through-wall

using inside air for combustion

The vent must be installed to prevent the flue gas leakage. Care must be taken during assembly to insure that all joints are sealed properly and are airtight.

The vent must be installed to prevent the potential accumulation of condensate in the vent pipes. It is recommended that:

1. The flue venting be installed with a slight downward slope of at least 1/8” per foot of horizontal run to the vent terminal.

2. The flue venting be insulated through the length of the horizontal run.

For appliances installed in extreme cold climate, it is recommended that:

1. The flue venting be installed with a slight upward slope of at least 1/8” per foot of horizontal run to the vent terminal. In this case, an approved condensate trap must be installed per applicable codes.

2. The flue venting be insulated through the length of the horizontal run.

750-382 CBT

3-5

Flue and Combustion Air Venting

FIGURE 3-3. Horizontal through-wall direct venting system, Category

III installation

3.5 — Horizontal through-wall direct venting

These installations utilize the boiler mounted blower to draw combustion air from outside and vent combustion gases to the outside.

Combustion air venting can be constructed of steel, stainless steel, PVC, CPVC, or material as deemed appropriate for the application and per local codes. The direct vent air intake should be considered in the overall length calculation of the venting system.

Care must be taken during assembly that all joints are sealed properly and are airtight for both the combustion air intake and the exhaust flue piping system.

The flue venting must be installed to prevent the potential accumulation of condensate in the stack pipes. It is recommended that:

1. Vent be installed with a slight downward slope of at least 1/8” per foot of horizontal run to the stack terminal.

2. The flue venting is to be insulated through the length of the horizontal run.

For appliances installed in extreme cold climate, it is recommended that:

3-6

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CBT

Horizontal through-wall flue vent termination

2. The flue venting is to be insulated through the length of the horizontal run.

3.6 — Horizontal through-wall flue vent termination

Multiple direct flue terminations MUST NOT be installed with a combustion air inlet directly above a flue termination. This vertical spacing would allow the flue products from the flue termination to be pulled into the combustion air intake installed above. This type of installation can cause non warrantable problems with components and poor operation of the unit due to the recirculation of flue products.

The flue terminations MUST be mounted on the exterior of the building. The flue termination should not be installed in a well or below grade. The flue termination must be installed at least one (I) foot above ground level and above normal snow levels.

Combustion air supplied from outdoors must be free of particulate and chemical contaminants. To avoid a restricted combustion air or blocked flue condition, keep all air intakes and flue terminations clear of snow, ice, leaves, debris, etc.

750-382 CBT

3-7

Flue and Combustion Air Venting

3.7 — Vertical venting, inside combustion air (Category III) central heating

Flue Vent Termination

(velocity cone type)

24”

Minimum

If 10’-0”

or less

24”

Minimum

FIGURE 3-4. Vertical stack with inside combustion air

These installations utilize the boiler mounted blower to vent the combustion products to the outside. Combustion air is taken from inside the room and the vent is installed vertically through the roof to the outside. Adequate combustion and ventilation air must be supplied to the boiler room in accordance with the National Fuel Gas Code or, in Canada, the latest edition of CAN/CGA-B 149.1 AND.2. Installation Code for Gas Burning Appliances and Equipment.

To prevent condensation accumulation in extended horizontal runs:

• It is required to install the horizontal portion of the flue venting with a slight downward slope of at least 1/8”

per foot of horizontal run.

• An approved condensate trap must be installed per applicable codes.

3-8

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CBT

Vertical venting direct vent combustion air (Category III)

3.8 — Vertical venting direct vent combustion air (Category III)

Flue Vent Termination

(velocity cone type)

24” Minimum

Air Intake

(w/Screen)

36”

Minimum

12” Minimum

FIGURE 3-5. Vertical stack with direct vent combustion air

These installations utilize the boiler mounted blower to draw combustion air from outside and vent combustion products to the outside. A positive pressure venting system is required.

To prevent condensation accumulation in extended horizontal runs, it is required to install the horizontal portion of the flue venting with a slight upward slope of at least 1/8” per foot of horizontal run; a drain with condensate trap must be installed per applicable codes.

Combustion air venting can be constructed of steel, stainless steel, PVC, CPVC, or material as deemed appropriate for the application and per local codes.

3.9 — Flue and combustion air duct design using direct vent combustion air

Boiler Size HP Stack Connection - Flue

diameter (in)**

10 6 4 160

15 6 4 140

20 6 4 120

25 6

30 8 6 120

*Each additional 90 deg. elbow equals 5 equivalent feet of ductwork. Subtract from the maximum length accordingly. Increasing the diameter of the air intake will reduce the pressure drop and thereby allow longer total vent lengths. Maximum allowable pressure

drop in combustion air intake duct is 0.25” w.c.

**The maximum allowable draft tolerance in the flue venting is +/- 0.25” w.c. as measured at the boiler's flue outlet.

Combustion Air Duct

diameter (in)

4 100

6 140

Maximum Air Intake

Length (ft)*

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3-9

Flue and Combustion Air Venting

3-10

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CBT

CHAPTER 4 Commissioning

Operating conditions 4-2

Full modulation boilers 4-2

Operating conditions 4-2 Filling boiler 4-2 Control setpoints 4-2 Water level controls 4-2 CB Falcon setup 4-4 CB Falcon display/operator interface 4-5 Lockouts, Holds, and Alerts 4-9 Controller configuration 4-10 Program module 4-17 Burner sequence 4-17 Fan speed settings 4-18 Initial startup procedure 4-18 Gas train and piping 4-18 Power-up 4-19 Operation check: gas valve, gas pressure switches, and combustion air proving switch 4-20 LWCO and ALWCO Check 4-21 Low and high fire adjustments 4-22 Modulation OFF point 4-22 Setting Combustion 4-22 Limit Controls Check 4-24

On/off boilers 4-25

Ignition adjustment 4-25 Gas Adjustments 4-25 Electrical interference test 4-25

Boil-out of a new unit 4-25

Post start-up checkout procedure 4-26

Falcon control functions and customer interface 4-27

750-382 CBT

Warning

The boiler and its gas connection must be leak tested before placing the boiler in operation.

4-1

Commissioning

4.1 — Full modulation boilers

4.1.1 — Operating conditions

• The installation site should be as free as possible from vibration, dust, and corrosive media

• The controllers should be located as far as possible from sources of electromagnetic fields, such as frequency converters or high-voltage ignition transformers

• Control panel must be connected to earth ground.

Boiler room ambient conditions

Relative humidity Ambient temperature range 0 Storage temperature range -20 Combustion air temperature 0

NOTE: When using direct vent combustion in cold climates, special care must be taken to observe combustion air temperature limits. Failure to follow this precaution may lead to equipment damage or unsafe operation.

< 85% non-condensing

C to 50 oC / 32oF to 122oF

C to 60 oC / -4oF to 140oF

C to 50 oC / 32oF to 122oF

4.1.2 — Filling boiler

Open the vent valve and fill the boiler slowly to allow entrapped air to escape. Do not close the vent valve until water is visible in the gauge glass. Check to ensure that no leaks appear at any pipe connections and correct if water leaks are noticed.

4.1.3 — Control setpoints

Preliminary settings of the burner/boiler safety controls are necessary for the initial starting of the boiler. After the burner has been properly set, minor adjustments to these controls may be necessary for the particular installation. For initial starting, set the following controls accordingly:

1. Combustion Air Proving Switch - Set the dial @ minimum.

2. Low Gas Pressure Switch - Set the dial @ minimum.

3. High Gas Pressure Switch - Set the dial @ maximum.

Depress all manual reset buttons for all controls prior to starting.

4.1.4 — Water level controls

The LWCO/pump control and ALWCO control boards are located in the boiler control panel. The LWCO control is connected to conductance probes mounted within the external water column. This column has 4 probes used for the following functions: low water cut-off, pump on, pump off, and high water alarm (optional). The ALWCO control is connected to a conductance probe(s) in a vessel-mounted probe head. The ALWCO includes a panel mounted manual reset/test switch.

4-2

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Full modulation boilers

750-382 CBT

FIGURE 4-1. CBT probe and WC levels

4-3

FIGURE 4-2. CB Falcon controller

Commissioning

4.1.5 — CB Falcon setup

The Model CBT boiler uses the CB Falcon boiler control system. Primary controller functions include:

• Flame supervision

• Burner sequencing

• PID Modulation control

• Operating Limit Control

Additional features include:

• User-friendly touchscreen interface

• Modbus communication capability

• Alarm/lockout messaging with history (last 15 messages)

• Annunciation

• Password protection of configurable parameters

• Time of Day (dual setpoint) control

• Remote reset

• (3) configurable pump relays

• Remote modulation/remote setpoint

4-4

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Full modulation boilers

FIGURE 4-3. Controller status LEDs and reset button

Please review the tables within this Commissioning section to familiarize yourself with the functions and parameters of the Controller. Also see Appendices A and B for details on control configuration and operation.

The Model CBT is factory tested. Nevertheless, all burner safety controls should be checked upon installation, prior to initial firing. Failure to verify burner control functioning could result in severe bodily injury or death.

FIGURE 4-4. CB Falcon display/operator interface

4.1.6 — CB Falcon display/operator interface

The CB Falcon display/operator interface is mounted in the boiler control panel for convenient access to all operating controls.

Note: CBT boilers will be equipped with the 833-05105 System Display. For more information see Appendix B.

750-382 CBT

4-5

Home page

Apply power to the boiler. The Home page will appear on the CB Falcon display.

FIGURE 4-5. Home Page

Commissioning

If the screen does not display properly when the unit is powered up:

• Verify that the controller is receiving power.

• Check the communication wiring between the controller and display; verify the following connections (also see Figure 4-6):

Falcon Controller (Terminal J3)

MB1 A (RED) Terminal 5 MB1 B (BLACK) Terminal 4 MB1 C (WHITE) Terminal 3

If the home screen appears, but without the Falcon icon:

1. Press <Setup>, then from the Setup screen press

Display

12 VDC

Common

RED BLK

CB Falcon

MB1 MB2

<Refresh>.

2. When the controller name shows up on the Setup screen,

press <Synchronize>. It will take a short time for the dis-

FIGURE 4-6. Falcon communications wiring

play to synchronize with the controller.

4-6

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Full modulation boilers

Note: The “Home” icon at the upper left of the display screen always returns to the Home Page.

The “Back” icon at the upper right displays the previous screen.

The camera icon will take a snapshot of the currently displayed screen. Up to 16 snapshots can

be saved and loaded to a USB device.

Display setup

Starting from the Home screen, press <Setup> then <Display Setup> for the Display Setup menu.

The Display Setup menu accesses selections for adjusting and customizing the Falcon display and for basic settings of the COM1 and COM2 Modbus ports.

After making changes, press <Save> and cycle power to the controller.

Status page

Pressing the Falcon icon on the Home page takes the user to the Status page, which summarizes boiler status and allows navigation to the configuration, operational, and diagnostic areas of the CB Falcon interface.

750-382 CBT

FIGURE 4-7. Display Setup Menu

4-7

Commissioning

FIGURE 4-8. Status page

The Demand display will show one of the following:

Burner enable off Off (burner switch on but no demand) Steam

Burner state shows the currently active step in the burner operating sequence.

The central portion of the display can be toggled between the following:

Pumps shows the status of the pump/auxiliary relay contacts Modulation shows fan speed RPM settings for Demand, Limited, and Override rates Setpoints shows the ON, Modulation, and OFF setpoints.

Note: Before clearing a lockout, first

i dentify a n d c o r r e c t t h e condition that caused the lockout.

The History banner is located near the bottom of the screen. Lockouts, Alerts, and Hold conditions will be annunciated here. Pressing the banner allows access to the Lockout and Alert history logs. In the case of a lockout alarm, the lockout can be cleared by navigating to the Lockout History and pressing <Clear Lockout>.

The steam pressure modulation setpoints can be changed from the Status page by pressing the current displayed value. A numeric keypad will pop up, allowing entry of new values.

4-8

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Full modulation boilers

FIGURE 4-9. Operation page

Operation page

From the Operation Page page the user can change setpoints, manually control the boiler’s firing rate, manually turn pumps on, and view annunciation information. If a password is required to change any of the settings on this page, the user can press the Login button to enter the password.

The burner is enabled from this page by turning the <Burner enable> screen button ON.

4.1.7 — Lockouts, Holds, and Alerts

The CB Falcon implements two kinds of faults: lockouts and alerts. The Falcon will also annunciate hold conditions which automatically clear when the condition is removed or satisfied.

Lists of fault codes and alerts can be found in Appendix A, CB Falcon Control.

LOCKOUT

• A lockout causes the boiler control to shutdown and requires manual or remote reset to clear the lockout.

• Always causes alarm contacts to close.

• Logged in lockout history in controller non-volatile memory.

ALERT

• Any fault condition that is not a lockout is an alert. Examples include boiler control abnormal conditions, faults from non-safety functions, etc.

• Alerts never require manual intervention to reset them; they are for informational use only. Normal operation continues.

• Alerts are logged in a 15-item volatile alert history sorted in chronological order. Only one instance of each alert code occurs in the history, corresponding to the most recent occurrence of that alert.

HOLD

• A hold prevents the boiler from continuing until the hold condition is satisfied.

• Holds are not alarm conditions and are not logged in memory.

750-382 CBT

4-9

Commissioning

See also Chapter 5, Section E - Troubleshooting.

4.1.8 — Controller configuration

The CB Falcon controller should be factory configured for the specific CBT boiler model. Prior to starting the boiler, verify that the factory default settings are correct for your application. Please refer to CB default settings, Table 4-1, and make any changes at this time if needed.

The CB Falcon steam control parameter settings are organized into the following parameter groups:

• System ID & access

• Steam configuration

• Modulation configuration

• Pump configuration

• Statistics configuration

• Stack limit (future)

• Annunciation

• Burner control interlocks

• Burner control timings & rates

• Burner control ignition

• Burner control flame failure

• System configuration

• Fan configuration

• Lead lag configuration (future)

TABLE 4- 1. CB Falcon factory parameter settings - Model CBT-M

Parameter Group Parameter Name Access Min.

System ID & Access Burner name Service BOILER 1 20 chars 183

System ID & Access Installation data Service SERIAL NUMBER 20 chars 184

System ID & Access OEM identification Read Only CB Falcon 833-

System ID & Access Installer password Service 9220 20 chars 190

Steam Configuration Steam enable Service Enabled 208

Steam Configuration Steam demand

switch

Steam Configuration Steam has priority

over LL

Steam Configuration Steam pressure

setpoint

Steam Configuration Steam pressure on

hysteresis

Steam Configuration Steam pressure off

hysteresis

Steam Configuration Steam TOD pressure

setpoint

Steam Configuration Steam setpoint source Service Local 578

Steam Configuration Steam modulation

rate source

Steam Configuration Steam 4mA steam

pressure

Steam Configuration Steam 20mA steam

pressure

Service B:STAT terminal 209

Service No 582

User 0 10 142.5 psig 220

Service 0 0 60 psig 221

Service 0 6 60 psig 222

Service 0 psig 542

Service Local 580

Service 0 0 psig 585

Service 0 135 150 psig 586

Range

Default Setting Max.

Range

03578

Parameter Units Installation

Setting

20 chars 185

Modbus Register

(dec)

4-10

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Full modulation boilers

TABLE 4- 1.

Parameter Group Parameter Name Access Min.

Steam Configuration Steam modulation

Steam Configuration Steam P gain Service 25 216

Steam Configuration Steam I gain Service 25 217

Steam Configuration Steam D gain Service 0 218

Steam Configuration Steam hysteresis step

Modulation Configuration

CB Falcon factory parameter settings - Model CBT-M (Continued)

Range

sensor

time

Maximum modulation rate

Minimum modulation rate

Steam forced rate Service 1000rp

Steam forced rate time

Firing rate control User A:Automatic firing 204

Manual firing rate User 800rpm 2000rpm 6500rpm RPM 205

Analog input hysteresis

Service C:Modulation from

Service 0m 0s mmm ss 219

Service 2000rp

Service 800rpm Table 4-2 3000rpm RPM 195

Service 1m 0s 240m 0s mmm ss 200

Service .2 mA 543

Default Setting Max.

Range

Inlet S1 (J8-4)

sensor

Table 4-2 6500rpm RPM 193

2000rpm 6500rpm RPM 199

Parameter Units Installation

Setting

Modbus Register

(dec)

210

Pump Configuration CH pump output Service A:No pump

Pump Configuration CH pump control Service A:Automatic pump

Pump Configuration CH pump start delay Service 0m 0s mmm ss 292

Pump Configuration CH pump overrun

time

Pump Configuration Boiler pump output Service C:Pump assigned to

Pump Configuration Boiler pump control Service A:Automatic pump

Pump Configuration Boiler pump start

delay

Pump Configuration Boiler pump overrun

time

Pump Configuration Auxiliary 1 pump

output

Pump Configuration Auxiliary 1 pump

control

Pump Configuration Auxiliary 1 pump

start delay

Pump Configuration Auxiliary 1 pump

overrun time

Pump Configuration System pump output Service D:Pump assigned to

Pump Configuration System pump control Service A:Automatic pump

Pump Configuration System pump start

delay

Pump Configuration System pump overrun

time

Pump Configuration Auxiliary 2 pump

output

Pump Configuration Auxiliary 2 pump

control

Service 1m 0s mmm ss 274

Service 0m 0s mmm ss 293

Service 1m 0s mmm ss 283

Service A:No pump

Service A:Automatic pump

Service 0m 0s mmm ss 295

Service 0m 0s mmm ss 752

Service 0m 0s mmm ss 294

Service 1m 0s mmm ss 289

Service B:Pump assigned to

Service A:Automatic pump

assignment

control

terminal B

control

assignment

control

terminal C

control

terminal A

control

272

273

281

282

284

285

287

288

755

756

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Commissioning

TABLE 4- 1.

Parameter Group Parameter Name Access Min.

Pump Configuration Auxiliary 2 pump

Statistics Configuration

CB Falcon factory parameter settings - Model CBT-M (Continued)

Range

start delay

overrun time

options 1

options 2

Burner cycle count Read Only 0 Cycles 128

Burner run time Read Only 0 Hours 130

CH pump cycle count Service 0 Cycles 132

System pump cycle count

Boiler pump cycle count

Auxiliary 1 pump cycle count

Auxiliary 2 pump cycle count

Service 0m 0s mmm ss 757

Service 3m 0s mmm ss 758

Service Inhibit for faults 759

Service Use for Local

Service 0 Cycles 136

Service 0 Cycles 138

Service 0 Cycles 140

Service 0 Cycles 146

Default Setting Max.

Range

Demands (burner)

Parameter Units Installation

Setting

Modbus Register

(dec)

760

Annunciation Configuration

Annunciator 1 location

Annunciator1 short name

Annunciator 1 long name

Annunciator 2 location

Annunciator2 short name

Annunciator 2 long name

Annunciator 3 location

Annunciator3 short name

Annunciator 3 long name

Annunciator 4 location

Annunciator4 short name

Annunciator 4 long name

Annunciator 5 location

Annunciator5 short name

Annunciator 5 long name

Annunciator 6 location

Annunciator6 short name

OEM E:Other

annunciation

OEM A1 307

OEM AIR SWITCH 309

Service C:LCI circuit 319

Service A2 320

Service LOW WATER 322

OEM D:Interlock circuit 332

OEM A3 333

OEM AUX LOW WATER 335

OEM D:Interlock circuit 345

OEM A4 346

OEM HIGH LIMIT 348

OEM D:Interlock circuit 358

OEM A5 359

OEM HIGH GAS

PRESSURE

OEM D:Interlock circuit 371

OEM A6 372

306

361

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TABLE 4- 1.

Parameter Group Parameter Name Access Min.

Annunciation Configuration

CB Falcon factory parameter settings - Model CBT-M (Continued)

Range

Annunciator 6 long name

Annunciator 7 location

Annunciator7 short name

Annunciator 7 long name

Annunciator 8 location

Annunciator8 short name

Annunciator 8 long name

PII short name OEM PII 410

PII long name OEM Pre-Ignition ILK 412

LCI short name OEM LCI 422

LCI long name OEM Limit Circuit Input 424

ILK short name OEM ILK 434

ILK long name OEM Interlock 436

OEM LOW GAS

Service E:Other

Service A7 385

Service Annunciator7 387

Service E:Other

Service A8 398

Service Annunciator8 400

Default Setting Max.

Range

PRESSURE

annunciation

Parameter Units Installation

Setting

Modbus Register

(dec)

374

384

397

Burner Control Interlocks

Burner Control Timings & Rates

Purge rate proving OEM Fan speed 229

Lightoff rate proving Service Fan speed except

Interlock open response

Interrupted air switch enable

LCI enable Read Only Enabled 248

PII enable Service Disabled 249

ILK bounce detection enable

Prepurge rate OEM 3000rp

Postpurge rate Service 1000rp

Standby rate Service 0rpm 0rpm 3000rpm RPM 207

Prepurge time Service 0m 30s 0m 30s 15m 0s mmm ss 231

Run stabilization time Service 0m 10s 15m 0s mmm ss 235

Postpurge time Service 0m 15s 0m 15s 15m 0s mmm ss 236

Forced recycle interval time

Read Only Lockout 238

Service Enable IAS during

OEM Enabled 253

OEM 0h 0m min 254

during ignition

purge & ignition

4000rpm 6500rpm RPM 196

2000rpm 6500rpm RPM 198

230

246

Burner Control Ignition

Pilot test hold Service Off 197

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Commissioning

TABLE 4- 1.

Parameter Group Parameter Name Access Min.

Burner Control Ignition

Burner Control Flame Failure

System Configuration Burner Enable User No//Off 203

System Configuration Flame sensor type Service UV power tube with

System Configuration Modulation output OEM Fan PWM 192

System Configuration Temperature units Service A:Fahrenheit 178

System Configuration Antishort cycle time Service 0m 0s mmm ss 179

System Configuration Alarm silence time Service mmm ss

System Configuration Line frequency Service Auto detect 48

System Configuration Safety configuration

CB Falcon factory parameter settings - Model CBT-M (Continued)

Range

Lightoff rate Service 1000rp

Preignition time Service 0m 0s 15m 0s mmm ss 232

PFEP Read Only 4 seconds 233

Flame threshold OEM 0.5 0.8 5 10ths (V or uA) 250

Ignite failure response Service Lockout 239

Ignite failure retries OEM 1 240

Ignite failure delay Service 0m 0s mmm ss 241

Run flame failure response

Fan speed error response

options

Read Only Lockout 243

OEM Lockout 255

OEM Ignore Flame rod

Default Setting Max.

Range

2000rpm 3000rpm RPM 197

spark interference

through 63 Hz

faults for UV config

Parameter Units Installation

Setting

Modbus Register

(dec)

228

630

631

Sensor Configuration S1 (J8-4) sensor type Service 0-150 psi 608

Sensor Configuration S2 (J8-6) sensor type Service Unconfigured 609

Fan Configuration Absolute max fan

Fan Configuration Absolute min fan

Fan Configuration PWM frequency OEM D:3000 Hz 258

Fan Configuration Pulses per revolution Read Only 2 3 3 259

Fan Configuration Fan speed up ramp Service 0 0 1000 RPM/sec 260

Fan Configuration Fan slow down ramp Service 0 0 1000 RPM/sec 261

Fan Configuration Fan gain up Service 30 262

Fan Configuration Fan gain down Service 30 263

Fan Configuration Fan min duty cycle Service 10 0-100% 264

Lead Lag Master Configuration

speed

Lead lag master enable

Lead lag hysteresis step time

Lead lag P gain Service 10 552

Lead lag I gain Service 10 553

OEM 2000 6500 6500 RPM 256

OEM 800 900 3000 RPM 257

Service No Lead Lag master 545

Service 0m 0s mmm ss 551

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Full modulation boilers

TABLE 4- 1.

Parameter Group Parameter Name Access Min.

Lead Lag Master Configuration

CB Falcon factory parameter settings - Model CBT-M (Continued)

Range

Lead lag D gain Service 0 554

Lead lag operation switch

Lead lag Steam demand switch

Lead lag Steam setpoint source

Lead lag modulation sensor

Lead Lag Modbus port

Base load common Service 75% 0 to 100% 572

Lead selection method

Lag selection method Service Sequence order 575

Lead lag add stage method 1

Lead lag add stage detection time 1

Lead lag add stage rate offset

Lead lag add stage interstage delay

Lead lag drop stage method 1

Lead lag drop stage detection time 1

Lead lag drop stage rate offset

Lead lag drop stage interstage delay

Lead rotation time Service 120h 0m min 733

Force lead rotation time

Lead lag pressure setpoint

Lead lag pressure TOD setpoint

Lead lag pressure on hysteresis

Lead lag pressure off hysteresis

Lead lag add stage pressure error threshold

Lead lag drop stage pressure error threshold

Lead lag 4 mA steam pressure

Lead lag 20 mA steam pressure

Service No//Off 555

Service STAT terminal 556

OEM Local setpoint is

Service S2 (J8-6) Steam

OEM MB2 569

Service Sequence order 574

Service Firing rate threshold

Service 2m 0s mmm ss 716

Service 0% -100% to 100% 719

Service 3m 0s mmm ss 722

Service Firing rate to drop

Service 1m 0s mmm ss 725

Service -3% -100% to 100% 728

Service 3m 0s mmm ss 731

Service 168h 0m min 734

User 0 10 135 psig 738

Service 0 psig 739

Service 0 psig 740

Service 6 psig 741

Service 3 psig 742

Service 3 psig 743

Service 0 0 psig 745

Service 0 135 150 psig 746

Default Setting Max.

Range

used

sensor

to add stage

stage

Parameter Units Installation

Setting

Modbus Register

(dec)

557

558

714

723

Lead Lag Slave Configuration

Lead lag slave enable Service Disabled 544

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Commissioning

TABLE 4- 1.

Parameter Group Parameter Name Access Min.

Lead Lag Slave Configuration

CB Falcon factory parameter settings - Model CBT-M (Continued)

Range

Slave mode Service Equalize runtime 564

Base load rate Service 3000rpm RPM 566

Fan during off cycle rate

Slave sequence order Service 0 1 to 8 568

Lead lag slave demand to firing delay

Modbus address Service 1 1 to 8 568

Service 0rpm 0rpm 4000rpm RPM 567

Service 3m 0s mmm ss 570

Default Setting Max.

Range

Parameter Units Installation

Changing parameter settings

To access the CB Falcon configuration menu, press <Configure> on the Status page.

From the Configuration menu (Figure 4-6), select the parameter group to be changed.

Setting

Modbus Register

(dec)

FIGURE 4-10. Configuration menu

Some parameters require a password entry before allowing changes. The <Login> button will appear when any password-protected parameter is displayed on the screen.

Press <Login> to display the alphanumeric keyboard. Enter password and press <OK>

Change parameter settings by selecting the parameter on the page. A dialog box appears with controls allowing the user to change the selected value. Press <Clear> to clear the current value. Enter the new value and press <OK> (press <Cancel> to leave the parameter unchanged).

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Full modulation boilers

FIGURE 4-11. Parameter change dialog

Safety parameters

When configuring safety parameters an additional verification step is required to confirm the changes.

1. When a safety parameter is changed, the Safety Parameter Verification page will appear. Press <Begin> to continue.

2. The affected parameter group will be displayed, showing current parameter values and a prompt, “Are these parameters

set to proper values?”. Press <Yes> to continue.

3. The screen will indicate RESET DEVICE NOW. Open the control panel and press the RESET button on the CB Falcon

controller (press and hold for 3 seconds).

RESET must be pressed within 30 seconds to save changes.

Note: When changing multiple safety parameters, the verification steps do not need to be completed immediately.

See Appendix for complete instructions on using the CB Falcon Display/Interface.

4.1.9 — Program module

CB Falcon parameter information (non-safety parameters only) can be uploaded/ downloaded using the optional Program Module. When the Program Module is installed, its features are accessible from the Falcon Setup page. See Appendices for instructions.

4.1.10 — Burner sequence

In addition to providing modulation control, the CB Falcon is responsible for flame supervision and burner sequencing.

The CBT boiler uses direct spark ignition (no pilot) to light the main flame. Flame

FIGURE 4-12. Program module

sensing is accomplished using an ultraviolet (UV) flame detector.

Basic burner sequencing:

1. Heat request detected (Setpoint minus On Hysteresis); LCI limits and steam demand detected (terminals J6 3 and J8 3).

2. After a system Safe Start Check, the Blower (combustion air fan) is started

3. After the ILK input is energized - 10 sec. allowed for IAS input (combustion air proving) to energize - and the purge rate

proving fan RPM is achieved, prepurge time is started.

4. When 30 sec. purge time is complete, the fan RPM is changed to the lightoff speed.

5. As soon as the fan-rpm is equal to the light-off RPM, the Trial for Ignition or Pre-Ignition Time is started (depending on

configuration). If enabled, Pre-Ignition Time will energize the ignitor and check for flame prior to TFI.

6. Trial for Ignition (4 sec).

7. The ignitor and the gas valve are energized.

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Commissioning

8. The ignitor is turned off at the end of the direct burner ignition period.

9. The fan is kept at the lightoff rate during the stabilization time.

10.Release to modulation.

11.At the end of the heat request the burner is switched off and the fan stays on until post purge is complete.

4.1.11 — Fan speed settings

The boiler firing rate is determined by the combustion air fan speed. Accordingly, fan speed settings may have to be modified for the particular application, for high altitudes, or when using direct vent combustion. The table below provides the default fan speed settings in typical applications for the various boiler sizes. To allow safe modulation through the firing range, these parameters should be initially set to the recommended speeds. Please contact your authorized Cleaver-Brooks representative for proper settings in high altitude and direct vent combustion applications.

TABLE 4- 2. Fan Speed Settings RPM

Natural Gas Propane

HP Max - High Fire Min - Low Fire Ignition HP Max - High Fire Min - Low Fire Ignition 10 5600 1300 2200 10 5200 1100 2200 15 5300 1300 2200 15 4900 1200 2200 20 5300 1300 2000 20 4600 1100 2000 25 5400 1200 2000 25 5000 1300 2000 30 6000 1100 1800 30 5700 1200 1800

4.1.12 — Initial startup procedure

Warning

Before initial startup, check for blockages in the flue venting or vent terminations. Inspect the burner and furnace for any contamination or blockages.

4.1.13 — Gas train and piping

The burner is equipped with a combination servo-regulated gas valve and venturi mixing unit. The gas valve consists of a single body with dual solenoid shut off valves, filter screen, and a built-in constant pressure gas/ air servo controller. The blower speed is controlled by the CB Falcon with airflow directly proportional to the speed of the fan. The airflow creates a drop in pressure due to the venturi effect. The modulating controller of the valve actuator senses air pressure change and brings about a change in the gas flow proportional to the air flow. The gas follows the airflow in a set ratio, so that fuel always matches the air as the burner firing rate increases or decreases.

1. Check the gas delivery system to be sure it is properly piped and wired.

2. Review available gas pressure to assure it is compatible with the main

gas regulators upstream of the Model CBT gas train. Note: The maximum rated inlet pressure to the CBT gas train is 1 psig (28" WC). An upstream regulator and overpressure protection are required if

Note: To measure supply pressure

at the CBT gas valve, use the test port on the valve inlet flange. Do not use the leak test cocks to measure gas pressure.

building supply gas pressure is greater than 1 psig.

3. To bleed air from the supply pipe, open the manual gas shut off valve upstream of the burner gas train and bleed air from the piping by loosening the union in the upstream piping or opening the inlet gas test cock.

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Full modulation boilers

4. The burner and its gas connection must be leak tested before placing the boiler into operation.

5. Gas Pressure Regulator - Using the adjusting screw on the main gas regulator, adjust the inlet pressure to the recommended levels in Table 4-3.

TABLE 4- 3. CBT Gas Pressure Requirements

CBT Size Natural Gas LP Gas

Min (“WC) Max (“WC)* Min (“WC) Max (“WC)*

10 7.0 14 11.0 14

15 7.0 14 11.0 14

20 7.0 14 11.0 14

25 7.0 14 11.0 14

30 8.0 14 11.0 14

*Maximum pressure without the use of an upstream regulator.

FIGURE 4-13. Premix burner technology - full modulation

4.1.14 — Power-up

1. Ensure blower motor is properly wired for the available power supply.

2. Verify the voltage (control voltage is 115V-1Ph.-50/60Hz) to ensure it is within specifications.

3. To power the control and blower circuits, the CC-Blower switch to the “ON” position.

4. When the control and blower circuits are powered, commissioning may begin. Turn the Demand switch to the “LOC” (Local) position. On the Operation page, the Demand status should indicate “Steam”. The boiler will now start if the LCI and ILK circuits are satisfied and the steam pressure is below the current On point.

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Commissioning

4.1.15 — Operation check: gas valve, gas pressure switches, and combustion air proving switch

Before initial firing of the burner, the gas valve, Low Gas Pressure Switch (LGPS), High Gas Pressure Switch (HGPS), and Combustion Air Proving Switch (CAPS) should be checked for proper operation.

• Before proceeding, review Section 4.3 - Control setpoints for initial LGPS, HGPS, and CAPS settings.

Note: Close the downstream manual gas shut-off valve before checking pressure switches and CAPS.

While performing the following safety checks, use the CB Falcon Annunciation screen to monitor the status of the circuits involved. Press <Annunciation> on the Operation page to access this screen.

FIGURE 4-14. Annunciation screen

LGPS

1. To check the Low Gas Pressure Switch, first close the upstream manual shutoff valve (both manual shutoff valves should now be closed).

2. Start the burner and wait 10 seconds during purge for CAPS to be made.

3. Turn the LGPS setting to maximum.

4. Open the test cock to bleed the gas line.

5. The controller should lock out. The screen will indicate Lockout 67 ILK OFF.

6. Reset the controller and change the LGPS setting back to minimum to proceed.

CAPS (Interrupted Airflow Switch)

1. Initiate burner sequence.

2. During purge cycle, set Combustion Air Proving Switch to its maximum setting.

3. The CB Falcon should lock out on an airflow failure. The display will show Lockout 65 Interrupted Airflow

Switch OFF.

Note: If the CAPS fails to open even when set to maximum, test by disconnecting the low-pressure line to the switch and initiating burner sequence. The switch should now break during the purge cycle. Reconnect low-pressure side after a successful CAPS check.

4. Following a successful CAPS check, dial the CAPS back to its minimum setting and reset the CB Falcon.

Note: The CAPS is ignored when the boiler is in “Run” state. A CAPS test must be performed during Purge or Trial for Ignition.

HGPS and GAS VALVE

1. Open the upstream manual shutoff valve and wait a few moments for gas pressure to rise.

4-20

750-382

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Full modulation boilers

2. Lower the switch setting to minimum.

3. Initiate burner sequence. During the main flame establishing period, verify gas valve LEDs energize, indicating both safety shutoff valves open.

4. The CB Falcon should lock out on an interlock failure (Lockout 67).

5. Reset CB Falcon.

6. Open the downstream manual shutoff valve to clear the lockout condition.

7. Dial the HGPS back to its maximum setting and reset.

IGNITION FAILURE CHECK

7. Close the downstream shut off valve and attempt to start the burner. The Falcon should lock out, indicating

Lockout 109 Ignition Failure.

After making the above operation checks, re-open the downstream manual shut-off valve.

4.1.16 — LWCO and ALWCO Check

• Before testing low water controls, disconnect power to the feed pump.

LWCO

1. To verify proper LWCO operation, conduct a blowdown of the water

column (refer to Chapter 5, Section 5.3 - Water Column Blowdown).

2. During WC blowdown, the burner should shut off when low water level

is reached.

3. Upon shutdown, check the LWCO control board in the CBT electrical

panel. The LED indicator should be off, indicating that the LWCO has switched off the control circuit.

ALWCO

FIGURE 4-15. LWCO test

1. To check the ALWCO, drain the boiler (refer to Chapter 5, Section 5.2 - Blowdown).

2. Observe the ALWCO control board in the CBT electrical panel. When the ALWCO level is reached, the LED indicator should go out.

3. Close the blowdown valves, refill boiler and reset the ALWCO.

• After testing the low water controls, reconnect power to the feed pump.

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Commissioning

4.1.17 — Low and high fire adjustments

All CBT boilers are factory tested firing natural gas at an altitude of 1000 ft ASL. Operating under different conditions may require re-adjustment of the gas valve.

Adjustments are made using a TORX® T40 (low fire adjustment) and 3 mm hex wrench (main gas choke). The adjustment screws should initially be set to half way through each setting’s range. The low fire adjustment screw is accessed by removing the slotted cap on the gas regulator using a blade screwdriver (see Figure 4-12). The high fire adjustment screw is accessed by removing the blue plastic cap from the valve cover (see Figure 4-13).

Turn the adjustment screw completely clockwise, counting the turns until the screw will no longer turn. Then, turn the adjustment screw counterclockwise half the number of turns counted when turning

FIGURE 4-16. Regulating adjusting

screw - low fire offset

clockwise.

NOTE:When adjusting low fire offset, clockwise adjustments increase gas flow, and counterclockwise

adjustments decrease gas flow. When adjusting the main gas choke, clockwise adjustments decrease gas flow, and counterclockwise

adjustments increase gas flow.

Refer to Appendix A for further information on gas valve setup, operation, and testing.

4.1.18 — Modulation OFF point

Prior to setting combustion, the steam pressure off hysteresis point should be adjusted upward to avoid nuisance shutdowns while the burner is under manual control. This parameter is located under Steam Configuration.

NOTE: Install the combustion analyzer probe as close as possible to the boiler vent connection. Sampling too far from the boiler vent can produce false readings due to air leakage diluting the flue gas.

FIGURE 4-17. Main gas choke -

high fire adjustment

4.1.19 — Setting Combustion

Note: A Combustion Analyzer is required to properly set-up the Model CBT burner. Do not attempt to fire and

adjust the burner without this equipment.

Note: Ensure boiler is filled with water prior to burner startup.

The burner does not have need of linkages for fuel/air adjustment, nor is a separate manual-auto switch provided for burner positioning. All firing rate adjustments are accomplished via the CB Falcon Control. Setting combustion will require manually modulating the burner via the CB Falcon from low fire to high fire to ensure a consistent air/fuel ratio.

To enable the burner, go to the Operation screen and press the <Burner switch> button at the upper left. The burner will not operate if this button is in the “OFF” state.

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Full modulation boilers

Manual Modulation - use the procedure below to change the burner firing rate manually.

1. On the CB Falcon Operation screen, press the Firing rate display.

2. A numeric keypad will appear, showing the current firing rate and operating mode.*

3. Under Firing rate control select Manual in Run.

4. Press <Clear> to clear the current RPM value.

5. Enter the desired RPM setting using the numeric keypad (refer to Table 4-2, Fan Speed Settings, for upper and lower limits).

6. Press <OK>. The display will return to the Operation screen and the burner will modulate to the chosen firing rate.

*Use Manual in Run for normal manual operation. In Manual in Run and Standby mode, the burner will not operate. Use this mode to run the blower without firing the boiler.

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To set combustion:

Commissioning

FIGURE 4-18. Operation screen

1. Check inlet gas pressure and reset low gas pressure switch.

2. At Operation screen set firing rate to low fire. Review burner sequence before proceeding.

3. Turn Demand switch to LOCAL.

4. Initiate burner firing sequence. The burner switch is accessed via the CB Falcon Operation page (Figure 4-

15). If the burner does not ignite, adjust choke counterclockwise slightly until you can see a slight yellow flame at the burner during ignition. Clockwise adjustments to the low-fire offset screw may also be tried. Check that gas pressure to gas valve inlet is sufficient to fire burner (see Table 4-3 for gas pressure requirements).

5. After burner lights, maintain in low fire position. At low fire, using main choke on gas valve and a combustion analyzer set O2 level within 3-8% O2.

6. Manually modulate the burner to high fire. Adjust the gas choke if necessary to obtain desired O2% (6.0% -

7.0%).

7. Modulate to low fire and fine tune offset screw to obtain desired O2% (6.0% - 7.0%).

Verify adjustments by modulating back and forth between low and high fire.

While setting combustion observe gas pressure at low fire and at high fire. Ensure pressure is within limits shown in Table 4-3.

4.1.20 — Limit Controls Check

The operating (OLC) and high pressure limit (HLC) controls are externally mounted to the control panel. The setting of the OLC should be slightly higher than the configured set point plus the hysteresis off value set in the CB Falcon control. The setting of the HLC should be slightly higher than the OLC. For example:

CB Falcon set point = 100.0 psig, Hysteresis Off = 5.0 psi OLC could be set to 110 psig, HLC set to 120 psig

Specific settings are determined by application and system control scheme.

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On/off boilers

The OLC and HLC can be tested while the boiler is producing steam by adjusting the switch setting downward. A lockout should result when the switch setting is at or just below the current steam pressure.

Readjust each switch (and reset HLC) after testing.

4.2 — On/off boilers

Follow steps 4.1.1 through 4.1.4 above to prepare for startup.

4.2.1 — Ignition adjustment

Normal setting is 0.5" W.C. when the burner is on. The flame must be sufficient to be proven by the flame detector and ignite the main flame.

Although it is possible to visually adjust the size of the minimum flame, the recommended method is to obtain a proper DC volt or microamp reading of the flame signal. Refer to burner control instructions for optimal flame signal readings.

4.2.2 — Gas Adjustments

Low fire combustion analysis typically is 7% to 9% O2 and less than .04% CO (400 ppm). A high fire reading typically is 3% to 4% O2 and less than .04% CO.

4.2.3 — Electrical interference test

Prior to putting the burner into service, conduct the following test to ascertain that main power will not cause the flame relay to pull in.

1. Close the manual gas valves.

2. Start the burner, the flame relay should not pull in (be energized).

3. Upon completion of successful test, proceed with startup procedures.

4. Reconnect the power supply and proceed with startup procedures.

4.3 — Boil-out of a new unit

The inside of a new boiler may contain oil, grease, or other contaminants which, if not removed, could adversely affect system performance. New units should be cleaned by boil-out before use.

Recommended boil-out procedure is as follows:

1. Determine boiler water capacity (see Table 4-4). Have sufficient cleaning material on hand to complete the job.

2. When dissolving dry chemicals, slowly introduce the chemical into warm water in a suitable container. Stir constantly until the chemical is completely dissolved.

3. An over-flow pipe should be attached to one of the top boiler openings and routed to a safe point of discharge. A relief or safety valve tapping is normally used for this purpose.

4. Water relief valves and steam safety valves must be removed before adding the boilout solution to avoid contaminating the valves. Use caution when removing and reinstalling these devices.

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Commissioning

5. All valves in the piping leading to or from the system must be closed to prevent cleaning solution from getting into the system.

6. Fill the boiler vessel with enough clean water to cover the furnace. Add the cleaning solution, then fill to the top. The water used in the initial fill should be at ambient temperature.

7. Fire the boiler intermittently so as to hold solution just at the boiling point. Boil for at least five hours. Do not produce steam pressure.

8. Allow a small amount of fresh water into the boiler. This will create a slight overflow that will carry off surface impurities.

9. Continue the boil and overflow process until the water clears. Shut the burner down.

10. Let the boiler cool to 120

F or less.

11. Drain the boiler, remove hand-hole plates and wash the waterside surfaces thoroughly using a high pressure hose.

12. Inspect the surfaces. If they are not clean, repeat boil-out procedure.

13. After closing the handholes and reinstalling safety or relief valves, fill the boiler and fire it until the water is heated to at least 180

TABLE 4- 4. Boiler water capacity

Boiler HP 10 15 20 25 30

Normal volume (gal) 150# 55 55 113 113 180

Flooded volume (gal) 150# 80 80 168 203 248

F to drive off any dissolved gases.

15# 57 57 115 115 184

15# 82 82 171 206 252

4.4 — Post start-up checkout procedure

1. Set high gas pressure switch to 50% higher than operating gas pressure at low fire. Set low gas pressure switch to 50% lower than operating gas pressure at low fire.

2. Check the draft on the outlet stack on each boiler, compare to acceptable limits (-.25 to +.25“ W.C.) and record in start up form. Operating outside of acceptable limits could result in light off and flame failure problems.

3. Switch to automatic operation and monitor flue gas to ensure consistent excess air.

4. Reassemble all panels and covers that were removed and replace any plugs that were removed to check gas pressure.

5. Verify gas pressures remain within limits shown in Table 4-3.

6. Provide instructions to owner and operators on operation, safety and maintenance of the equipment.

7. Provide instructions to owner and operators on proper water treatment guidelines and procedures.

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Falcon control functions and customer interface

4.5 — Falcon control functions and customer interface

Following is a brief overview of the Falcon control features on steam boilers. Please refer to the Falcon Control operating instructions in Appendix A for more detailed explanations.

• Set Point

• Time-of-Day (TOD) Set Point

• Hysteresis On and Hysteresis Off

• PID modulation control

• Remote Enable and Remote 4-20mA Input

• Remote Modulation

• Remote Set Point

• Configurable pump/auxiliary relay contacts

• Annunciator

• Diagnostics

• Lockout/Alarm History

• Trend Analysis

• Modbus communications

Set point, TOD set point, hysteresis on, hysteresis off, and PID load control

The set point is the value that the boiler’s PID load control attempts to maintain in order to meet the steam demand. The modulating set point can be adjusted at the Operation page or under the Steam Configuration parameter group. No password is required to change the set point. To change the set point at the Operation page, press the set point value next to “Normal”. Clear the current value and enter the new value. Press <OK> to establish the new set point.

The Time-of-Day (TOD), or setback, set point is an alternative set point that is enabled when a remote contact connected to terminals J10-2 & J10-3 is closed (Refer to Figure 2-8 CBT Wiring Diagram). When the circuit is open, the boiler control reverts back to the normal set point. The TOD set point can be adjusted at either the Operation page or under the Steam Configuration parameter group. Service level password login is required to change this parameter.

The hysteresis on and hysteresis off points can only be changed under the Steam Configuration parameter group and require a login with the Service level password. Hysteresis on is the differential below the current set point at which the boiler will restart following an off cycle. Hysteresis off is the differential above the current set point at which the boiler will cycle off – effectively the boiler’s operating limit. These two parameters apply to both the normal and TOD set points. To minimize the frequency of cycling the boiler on and off, the values of either, or both, of these settings may be increased. Default settings for Hysteresis on and off are 0 and 3 psi, respectively.

The PID (Proportional-Integral-Derivative) load control operates to generate the demand source’s modulation rate. Under Steam configuration, the PID gain values can be adjusted to match the desired modulation response. The default gain value settings of P=50, I=50 & D=0 have proven to work well with typical steam boiler applications.

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4-27

Commissioning

Remote enable and remote 4-20mA input

Remote enable and Remote 4-20mA input allow the boiler to be sequenced and/or controlled from a separate boiler room controller or building management system. The 3-position Demand switch at the front of the control panel determines whether the boiler is off, in local, or under remote control. When in the “LOC” (local) position, the boiler operates on its own set point and ignores any remote signal connections. When in the “REM” (remote) position, the boiler can be enabled and modulated by remote discrete and analog (4-20mA) inputs, respectively. When in the “OFF” position, the boiler will not operate.

Refer to Figures 2-7 & 2-8, or your specific boiler wiring diagram, for remote enable and remote 4-20mA input connections. For simple remote on-off sequencing, only terminals 24 and 25 (Falcon J8-1 & J8-3) need to be connected to dry enable contacts at the remote controller. When terminal 25 (steam demand input) is energized, the steam demand is enabled. The boiler operates on its local set point and PID modulating control settings.

For remote modulation (firing rate) control, both the remote enable and remote 4-20mA input connections must be made. The default setting for the 4-20mA remote input is “Modulation”. This setting should be verified under the Falcon control’s Steam configuration group, “Steam 4-20mA remote control”. To avoid nuisance operating limit shut downs of the boiler, the Falcon’s normal operating set point should be adjusted to a value that is greater than the system header set point.

With steam demand present and completion of a successful trial for ignition sequence, the boiler will modulate according to the 4-20mA input signal provided: 4mA = minimum modulation rate (low fire); 20mA = maximum modulation rate (high fire). The boiler will continue to modulate until the steam demand is removed, the operating limit is reached, LCI is opened (e.g. low water condition), or a Falcon lockout alarm occurs (e.g. ILK opens on a High Limit trip).

To configure the boiler for remote set point control, navigate to the Falcon control’s Steam configuration group. Change the setting of “Steam 4-20mA remote control” to “Set Point”. Next, the span of the 4-20mA needs to be established. The steam set point determines the value for 20mA; “minimum steam pressure” determines the value for 4mA.

Depending on the quality of the remote input signal, the modulation rate or operating set point may fluctuate unnecessarily because of small changes in the measured current signal. Under the Modulation configuration group, the “4-20mA input Hysteresis” setting may need to be adjusted to avoid undesired fluctuations in the either the modulation rate or operating set point. The default setting is 0.1mA and can be increased to essentially filter out small fluctuations of the input signal. It may take some trial and error to establish the optimum input hysteresis setting for a particular system.

If at any time the remote 4-20mA input signal is disconnected, the Falcon control will indicate “OPEN” under the 4-20mA input value at the operation screen. The boiler will then operate on its local set point and PID modulation control. Once the 4-20mA signal is reestablished, the boiler will resume operation under remote control.

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CHAPTER 5 Maintenance

General 5-2

Bottom blowdown 5-2

Water column blowdown 5-3

Fireside cleaning procedure/disassembly 5-5

Ignition electrode 5-7

UV scanner (full modulation only) 5-8

Waterside inspection/cleaning 5-10

Safety valve 5-11

Troubleshooting 5-11

Display diagnostics 5-27

Lay-up 5-27

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5-1

Maintenance

5.1 — General

A well-planned maintenance program will help avoid unnecessary downtime or costly repairs, and will promote safety and aid boiler inspectors. It is recommended that a boiler room log or record be maintained. Recording of daily, weekly, monthly, and yearly maintenance activities will help to obtain economical and lengthy service from the equipment.

Only trained and authorized personnel should be permitted to operate, adjust, or repair the boiler and related equipment. The boiler room should be kept free of all material and equipment not necessary to the operation of the boiler or heating system.

Be alert to unusual noises, improper gauge readings, leaks, etc. Any leaks - fuel, water, steam, exhaust gas should be repaired promptly and with attention to safety. Preventive measures, such as regularly checking the tightness of connections, should be included in regular maintenance activities.

Insurance regulations and local laws normally require periodic inspection of the pressure vessel by an authorized inspector. Inspections are usually, though not necessarily, scheduled for periods of normal boiler downtime, such as an off season. This period can be used to accomplish maintenance, replacement, or repairs that cannot easily be done at other times.

NOTE: To insure proper operation, use only Cleaver-Brooks parts for replacement.

While the inspection pertains primarily to the waterside and fireside surfaces of the pressure vessel, the inspection period provides operators with an opportunity for a detailed check of all boiler components including piping, valves, gaskets, refractory, etc. Comprehensive cleaning, spot painting, and replacement of expendable items should be planned for and taken care of during this time.

Cleaver-Brooks recommends common replacement parts be on hand during inspection and maintenance. Please refer to the Recommended Spare Parts List In the Parts section of this manual.

5.2 — Bottom blowdown

FIGURE 5-1. Bottom blowdown piping

Water treatment alone can never completely eliminate unwanted solids from boiler feedwater. In order to keep these substances to a minimum, blowdown should be performed at regular intervals.

If both a quick-opening and a slow-opening valve are present, the quick-opening valve (the valve nearest the boiler) is opened first and closed last, with blowdown controlled using the slow-opening or downstream valve.

Bottom blowdown should be done under a light load and with the water level at the normal operating level. Blowdown should be piped to a blowdown separator.

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Water column blowdown

Caution

• Never pump the quick-opening valve to blow down the boiler. Such action could cause water hammer and damage the

piping and valves. It could also cause personal injury.

• Never leave an open blowdown valve unattended.

• Remember the valve closest to the boiler must be opened first.

• Blowdown should be done at least once per shift. Depending on operations, more frequent blowdowns may be required.

Manual blowdown procedure

Blowdown is most effective when the boiler is under a light load, and when the water level is at the Normal Operating Water Level.

Be sure the blowdown piping is in proper operating condition. Waste should be piped to a point of safe discharge. To blow down the boiler:

1. Open the quick-opening valve (one closest to the boiler).

2. Open the slow-opening valve.

3. Blow down the boiler for the amount of time specified by your water treatment consultant by opening and closing the slow-opening valve. A minimum of 10 seconds with the valve fully open is recommended.

4. Some boilers may require several short blowdown cycles to maintain the proper water level.

5. Close the slow-opening valve.

6. Close the quick-opening valve.

7. Open the slow-opening valve again to drain the line between the quick and slow-opening valves.

8. Close the slow-opening valve again and double check that the shutoff is tight after the valve has cooled.

It is generally recommended that bottom blowdown be performed at least once in every eight-hour period. Actual frequency may vary depending on water conditions and boiler operating conditions. Consult the appropriate water treatment personnel regarding blowdown scheduling.

5.3 — Water column blowdown

Free flow of water through the water column and gauge glass is essential to obtaining accurate boiler water level indication and control. It is recommended that the water column and gauge glass be blown down every shift to remove accumulated solids. Regular blowdown of the water column will help maintain the integrity of the water level probes and will help to ensure trouble-free operation of the boiler. See Figure 5-2 for procedure.

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5-3

Maintenance

Open

Closed

1. Open Water Column blowdown valve (5 to 10 sec.) to discharge water from WC.

2. Close WC blowdown valve.

3. Close upper gauge glass isolation valve.

4. Open gauge glass blowdown valve to discharge water from gauge glass.

5. Close lower gauge glass isolation valve.

6. Open upper gauge glass isolation valve.

7. Open lower gauge glass isolation valve to discharge steam from gauge glass.

FIGURE 5-2. Water column and gauge glass blowdown

8. Close gauge glass blowdown valve.

Periodic replacement of the water gauge glass should be part of a regular maintenance program. A broken or discolored glass should be replaced at once.

Use a proper size rubber packing. Do not use loose packing, which could be forced below the glass and possibly plug the valve opening.

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Fireside cleaning procedure/disassembly

Close the valves when replacing the glass. Slip a packing nut, packing washer, and packing ring onto each end of the glass. Insert one end of the glass into the upper gauge valve body far enough to allow the lower end to be dropped into the lower body. Slide the packing nuts onto each valve and tighten.

It is recommended that the boiler is off and cool when the glass is replaced. However, if the glass is replaced while the boiler is in service, open the blowdown valve and slowly bring the glass up to temperature by opening the gauge valves slightly. After the glass is warmed up, close the blowdown valve and open the gauge valves completely.

5.4 — Fireside cleaning procedure/disassembly

1. Locate the manual shutoff gas valve for the gas supply to the burner and turn it to the closed or shut position.

2. Disconnect all electrical power to the control panel at the primary switch box or breaker box supplying power to the boiler.

4. Disconnect power and signal harnesses from blower.

5. Disconnect the ignition cables from the electrodes and unscrew the UV flame detector from its bracket.

6. If using room combustion air, remove air filter. Inspect and replace as necessary.

7. Disconnect the burner gas train from the gas supply piping.

8. Unscrew the nuts (4) securing the blower adapter plate to the dry oven assembly.

9. The blower motor and assembly can now be removed, providing access to the burner head and combustion chamber. The following inspections can now be performed:

• Check ignition electrodes for deposits and proper gap. Clean or replace as required.

• Check the burner canister for any damage, burn marks, or perforations. Replace if damaged. If the canister is

in good condition, clean out any dirt or dust with a vacuum cleaner or low-pressure air hose.

• Inspect the dry oven/combustion chamber area for any damage or residue. If dirt or contaminants are found, it

is recommended that the fire side be washed with a high-pressure power washer.

If any adverse conditions are observed during operation or inspection, contact your authorized Cleaver-Brooks service representative.

When inspection and servicing are completed, reassemble the burner in reverse order.

Ensure that all connections are tight and secure before reconnecting power or fuel supply. After turning the gas supply on, reset the gas pressure switches.

NOTE: A gas valve leak test is recommended during fireside inspection. See Appendix A for leak test procedure.

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5-5

Maintenance

DRY OVEN

SIGHT GLASS

BURNER CAN GASKET

BURNER

BURNER CAN GASKET

CANISTER

ADAPTER PLATE

ADAPTER PLATE GASKET

UV SCANNER

IGNITION ELECTRODE

VENTURI

FIGURE 5-3. Burner assembly - full modulation

BLOWER UNIT

ELECTRODE

SPRING PIN

ORIFICE PLATE

LOCK WASHER

FLAME ROD

FIGURE 5-4. Burner assembly - on/off

STANDOFF

BAFFLE WELDMENT

LOCK WASHER

SCREW

5-6

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Ignition electrode

5.5 — Ignition electrode

5.5.1 — Full modulation burners

Caution

The dimensions on the Ignition Electrode are not easily adjustable.

Bending the rods can cause damage to the insulating material. In addition, a bent electrode will have a tendency to return to its original shape when heated. If the electrode is out of specification, replacement is generally recommended.

The ignition electrode should be checked on an annual basis or as needed if ignition problems are encountered.

In order to verify spacing of electrode, center the burner cylinder within the dry oven. Then attach electrode to the dry oven with the screws provided. Verify the dimensions shown in Figure 5-5.

Sight glass

Flame scanner

Ignition electrode

0.64 GAP

FIGURE 5-5. Igniter, full modulation burner

5.5.2 — On/off burners

The ignition transformer requires little attention other than making sure the ignition wire is firmly attached to the transformer and the electrode. Be sure the wire insulation is in good condition and not grounded. Failure to keep the ignition electrode clean and properly set can cause faulty operation. The electrode assembly is supported by a socket in the diffuser and gas inlet tube. No adjustment is required except proper positioning of the electrode wire.

750-382 CBT

5-7

COVER

FLAME ROD

Maintenance

0.25 - 0.125

ORIFICE PLATE

FLAME ROD

BAFFLE PLATE

ORIFICE PLATE

ELECTRODE

FIGURE 5-6. Ignition electrode and flame rod, on/off burners

BAFFLE PLATE

ELECTRODE

(TIP IS FLUSH WITH

FACE OF BAFFLE PLATE)

.16

ORIFICE PLATE

BAFFLE PLATE

ELECTRODE

5.6 — UV scanner (full modulation only)

Maintenance of the UV scanner consists of periodic inspection and cleaning. To inspect, unscrew the UV flame detector from the bracket. Check to ensure that the flame viewing lens is clear and free of dust or debris. Wipe with a clean rag if necessary.

To function properly, the scanner needs a clear line of sight to the burner canister. Welding slag or other debris, an out-of-place gasket, or the boiler refractory dry oven can all potentially obstruct the scanner. To verify a line of sight, unscrew the UV scanner from the mounting bracket and ensure that it is possible to sight through the bracket to the burner can without obstruction (Figure 5-7).

Figure 5-8 shows the UV scanner wiring connections.

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CBT

UV scanner (full modulation only)

FIGURE 5-7. UV Scanner

832-2326

FIGURE 5-8. Scanner Wiring

750-382 CBT

5-9

Maintenance

5.7 — Waterside inspection/cleaning

Waterside inspection frequency may depend upon the local jurisdiction and inspector but it is recommended that a waterside inspection take place 2-3 months after initial startup.

C-B further recommends to semiannually remove all handhole covers and thoroughly clean the water side cavity and bottom of the boiler.

To inspect the boiler on the waterside, first shut off the electric power to the burner. Close all waterside stop and shutoff valves, including the steam stop valve or valves. Close the manual gas shutoff valve. After allowing the boiler to cool, open the bottom blowdown valve, crack the manual bleed valve (Figure 5-9), and drain the boiler. While the boiler is draining, note the condition of the water.

When the water has drained from the boiler, remove the handhole covers and examine the waterside surfaces. Use a good flashlight and, where necessary, a swivel mirror with an extension. Discuss any scale, sludge or other buildup on the surfaces with the water treatment company or technician.

FIGURE 5-9. Manual bleed valve

FIGURE 5-10. Inspection port (handhole) locations

On the water column piping, remove the plugs, remove all probes, and inspect. Clean as necessary, being sure to remove any debris or blockages.

Important

Clean probes are essential to proper boiler operation. Always ensure that probes remain free of debris and buildup.

If a waterside sludge buildup is noticed, flush the waterside and drain. Again, consult with the water treatment company or technician on cleaning. After inspection, install new gaskets, close the handholes, replace probes, tighten plugs, and allow water to fill the boiler while keeping the bleed valve open. Close valve before placing boiler back into operation.

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Safety valve

5.8 — Safety valve

The safety valve is an important safety device and deserves attention accordingly. Follow the recommendations of your boiler inspector regarding valve inspection and testing. The frequency of testing, either by use of the lifting lever or by raising the steam pressure, should be based on the recommendation of your boiler inspector and/or the valve manufacturer, and should be in accordance with Sections VI and VII of the ASME Boiler and Pressure Vessel Code.

FIGURE 5-11. Safety valve

Avoid excessive operation of the safety valve; a valve that is opened too frequently can develop leaks. Safety valves should be operated only often enough to assure that they are in good working order. When a pop test is required, raise the operating pressure to the set pressure of the valve, allowing it to open and reseat as it would in normal service.

Do not hand operate the valve with less than 75% of the stamped set pressure on the underside of the disc. When hand operating, be sure to hold the valve in an open position long enough to purge accumulated foreign material from the seat area and then allow the valve to snap shut.

5.9 — Troubleshooting

The Falcon lockout and alert histories (full modulation units) contain information which can help in determining the cause of problems. To view the lockout/alert history, first press the alarm banner, then press the appropriate button in the pop-up window.

View history

750-382 CBT

Alarm banner

5-11

Maintenance

The alert (or lockout) list will appear, showing date and time for each item. Pressing an individual item in the list will display additional information. Diagnostic information available for lockouts includes annunciator status, states of system inputs, and steam pressure at time of lockout.

The Falcon display touch-screen interface is a valuable tool to help identify and resolve conditions that prevent normal and safe operation of the boiler. The focus of this section is to help the boiler operator utilize the Falcon display interface to evaluate and correct conditions that can cause nuisance shutdowns and contribute to unsafe operation of the boiler.

There are 3 levels of “alarm” conditions utilized by the Falcon controller: Lockout, Hold, and Alert. Lockouts and Holds indicate interruptions in boiler operation, whether occurring as part of the normal operating sequence or due to an abnormal condition. Lockouts always require a manual reset to resume operation, while Holds will automatically resume when the hold condition is removed or satisfied. Alerts indicate conditions or events which, while not preventing normal boiler operation, may be of interest in evaluating boiler operating conditions. Alerts require no operator acknowledgment and are for informational purposes only.

A Lockout will result in boiler shut down and always requires a manual reset of the Falcon controller. In certain cases, a lockout may also require a manual reset of a safety control interlock device connected to the Falcon. These include the auxiliary low water cut-off, high limit control, and gas pressure limit controls. Typically, a safety interlock can only be reset when the condition that caused the lockout has been corrected (i.e. water level returns to normal allowing the auxiliary low water cut-off to be reset).

Lockouts, Holds, and Alerts will often provide clues to the cause of the interruption or abnormal condition that generated the message. However, sometimes these messages can be misleading and may not point directly to the actual cause of the condition. A careful reading of this chapter, the rest of the manual, and the boiler specific wiring diagram will help in resolving boiler interruptions and abnormal conditions.

The key to diagnosing recurring nuisance interruptions is to identify the underlying cause of the condition that led to the interruption. Once the underlying cause is identified a permanent solution can implemented. Too often, safety controls are reset without proper analysis of the operating condition that caused the boiler operation interruption. If not adequately addressed, the interruptions tend to be repeated with increasing frequency resulting in down time and increased maintenance. Merely resetting a safety control device does not resolve the cause of the condition that led to the lockout!

The following chart takes a methodical approach to diagnosing abnormal boiler operating conditions. This approach begins with the “Problem” as identified by the operator. The 2nd column indicates displayed messages (“Display Message”) by the Falcon display interface that will generally provide clues to the cause of the problem. The 3rd column lists “Possible Causes” and/or related “Symptoms” associated with the “Problem” and “Displayed Message”. The 4th column recommends a “Diagnostic Check” that should be investigated for a potential cause or system. The last column provides recommendation for “Corrective Measures” to resolve the problem and return to normal operation.

This chart includes the most common conditions and resolutions for successful ClearFire boiler operation. It does not include all possible lockouts and alerts. The Falcon controller appendix has a comprehensive list of lockouts, holds, and alerts. The boiler operator can use this format and method to diagnose other conditions that may not be included here.

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Troubleshooting

TABLE 5- 1. CBT troubleshooting

Problem Display Message Possible Cause/Symp-

tom

Boiler will not start -no lockout or alarm present

A. Hold 63 LCI Off A.1. Touch Screen

“Demand” status is in OFF position

A.2. Auxiliary device (e.g. OLC) is interrupting LCI circuit.

A.3. Start interlock proving switch is not closed (when using start interlock)

A.4. Jumper is not wired between start interlock (typically terminals 13 & 14) terminals in LCI circuit -- no start interlock connected

A.5. Loose wiring in Falcon LCI circuit (line 18 on wiring diagram)

B. Hold 63 Low Water B.1. Low water condi-

tion -- water level is low in sight glass

Diagnostic Check Corrective Measures

Check demand state on Falcon boiler Status screen

Check state of Operating Limit Control in LCI circuit.

Check start interlock device (e.g. air damper switch) wired in ClearFire's LCI circuit

Check for jumper between start interlock terminals in control panel -- refer to WD.

Check for 115VAC power along LCI circuit up to Falcon controller terminal J6-3

Check that Feed Water (FW) pump is running and water is flowing to boiler

Turn Demand switch to LOCAL

Check OLC setting should be slightly above Falcon setpoint + hysteresis OFF.

Correct problem with start interlock device and/or wiring connections (e.g. ensure air damper is open and damper prove switch is functioning properly)

Jumper start interlock terminals if not using a start interlock.

Secure wiring to appropriate terminal connection(s)

If FW pump is not running, see Possible Cause B.2. FW pump not running; if FW pump is running, see Possible Cause B.3. FW pump is running

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Check water level in the feed tank

Check water flow to boiler

If water level is low in feed tank, check tank make-up valve/piping and fix problem

Open boiler feedwater valve(s). Check/adjust pump pressure relief valve (if present). Remove any unnecessary restrictions.

5-13

Maintenance

Problem Display Message Possible Cause/Symp-

tom

B.2. Feed Water (FW) pump is not running, water level is low

Diagnostic Check Corrective Measures

Check blowdown valve positions.

Check for power to FW pump

Open boiler control panel and check pump relay LED ("H/L RELAY") on the Warrick LLCO/Level control board

Manually enable pump starter to "bump" pump motor.

All blowdown valves should be closed during operation, except during active blowdown procedures. Close any blowdown valves that may be open.

If no power present -connect power/replace fuses as needed

If LED is off, see Possible Cause B.4. Water Level Probe connections; if LED is on, check pump control wiring from boiler to pump contactor/starter.

If pump motor does not operate, repair or replace pump and/or motor.

B.3. Feed Water (FW) pump is running, but boiler water level is low

B.4. Water Level Probe connections

Check water flow to boiler

Listen for FW pump cavitation noise and check feed tank temperature

Check blowdown valve positions.

Check pump seals and/ or impeller

For 3 phase power only

-- check pump rotation

Check Warrick board connections in boiler control panel

Open valves, remove restrictions

If FW temperature is greater than 180F, check steam traps. Service steam traps as needed.

All blowdown valves should be closed, except during active blowdown procedures. Close any blowdown valves that may have been left open.

Service/replace FW pump as needed.

If incorrect pump rotation, swap 2 of the 3 incoming 3-phase power wire connections to pump starter/ contactor

Secure any loose connections

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CBT

Troubleshooting

Problem Display Message Possible Cause/Symp-

tom

Diagnostic Check Corrective Measures

Inspect high-temp wire-to-probe connections in boiler water column connection box (Warrick)

Tighten jam nuts on any loose probe connections.

If slight corrosion present, remove terminal connection, clean crimp-on ring terminal, re-crimp, and replace with copper flat washer between ring terminal and jam nut, tightening jam nut to secure ring terminal. Apply dielectric grease to terminal connections.

If severe corrosion present, cut-off crimpon ring terminal, strip wire end, crimp-on new high temperature, SS ring terminal, reattach with copper flat washer between ring terminal and jam nut. Apply dielectric grease to terminal connections.

750-382 CBT

B.5. Dirty water level probes

Check Warrick board "dirty probe" LED. If off, remove associated probe wire from Warrick DF board and check continuity between probe and panel ground.

If all connections secure and clean, see Possible Cause B.5. Dirty water level probes

If no continuity, remove probe. Visually inspect and clean or replace. Secure all wiring connections and coat wire terminal ring connection in probe head with dielectric grease.

Check feed water treatment/softening. Perform water softening and chemical treatment as necessary.

5-15

Maintenance

Problem Display Message Possible Cause/Symp-

tom

Boiler will not start -active lockout/alarm

C. Demand: Steam Burner state: Standby (normal)

D. Hold 100 Pressure sensor fault

E. Hold 131 Fan movement during standby

F. Lockout 67 ILK OFF AUX LOW WATER

C.1. Steam pressure is greater than Falcon ON point (SP - ON hysteresis)

D.1. Disconnected steam pressure transmitter -- Falcon Steam pressure reads "SHORT" or "OPEN".

D.2. Failed steam pressure transmitter -- Falcon Steam pressure reads "SHORT" or "OPEN".

E.1. High negative draft condition and fan turning while burner is off

F.1. Low water condition occurred, but water level in sight glass now appears normal.

Diagnostic Check Corrective Measures

Note Modulation set point, ON and OFF points on status screen

Check steam stop valve -- open or closed?

Check steam pressure transmitter wiring connections - refer to boiler wiring diagram

Reset Falcon controller. Check steam pressure reading on Falcon display.

Check draft presure at boiler flue outlet (+/-

0.25" w.c. allowed)

Check if blower is turning when not on (e.g. high negative draft can force blower to turn)

Check Auxiliary Low Water Cut-off (ALWCO) control LED located on Warrick Single Function board (smaller circuit board) located inside control panel.

Change steam Set Point, On hysteresis, and Off hysteresis parameters to desired settings.

If closed, carefully open steam stop valve to allow steam to flow to the process. Also, carefully blowdown boiler to relieve steam pressure.

If loose, open, or shorted transmitter circuit, secure wiring connections

Replace steam pressure transmitter

Resolve draft condition (e.g. adjust stack damper) to near neutral (0" w.c.)

If ALWCO control board LED is off, reset ALWCO switch. Clear Falcon lockout and restart.

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Troubleshooting

Problem Display Message Possible Cause/Symp-

tom

Diagnostic Check Corrective Measures

Check Auxiliary Low Water Cut-off (ALWCO) control LED inside control panel. Also observe primary LWCO control “LLCO” LED located on Dual Function (DF-16, larger circuit board) located inside control panel.

Check ALWCO board wiring and probe connections

If LED remains off after reset and LWCO “LLCO” LED is ON, perform water column and boiler bottom blowdown. Primary LWCO (“LLCO” LED) should go OFF during blowdown. IF “LLCO” LED REMAINS ON, DISCONNECT POWER TO FEED PUMP AND CLOSE FEED WATER VALVE IMMEDIATELY. POTENTIAL LOW WATER CONDITION PRESENT AND MUST BE RESOLVED!

Secure any loose connections. If corrosion present, remove corrosion and/or replace terminal connection.

G. Lockout 67 ILK OFF HIGH LIMIT

F.2. Low water condition -- water level is low in the sight glass -see B. Hold 63 LCI Off LOW WATER Display Message, Possible Causes, Checks, and Corrective Measures

G.1. Steam pressure exceeded High Limit Control (HLC) set point.

Observe steam pressure gauge reading and compare to HLC setting (outside the control panel) and Falcon OFF point.

Check position of steam stop valve. Observe steam pressure gauge reading.

Adjust HLC setting to setting higher than OLC setting and Falcon OFF point. Reset HLC after pressure drops below setting. Clear Falcon lockout and restart.

If stop valve closed, wait for pressure to drop enough so steam stop valve can be opened safely. Reset HLC after pressure drops below setting. Clear Falcon lockout and restart.

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5-17

Maintenance

Problem Display Message Possible Cause/Symp-

tom

H. Lockout 67 ILK OFF LOW GAS PRESSURE

I. Lockout 67 ILK OFF HIGH GAS PRESSURE

J. Lockout 65 Interrupted Airflow Switch OFF

H.1. Insufficient gas supply pressure or gas valve closed

I.1. Manual gas shutoff valve (between gas safety shut-off and venturi) closed causing gas pressure spike.

J.1. Combustion Air Proving Switch (CAPS) is not closing when blower starts during purge

Diagnostic Check Corrective Measures

Check gas supply pressure at boiler gas valve inlet during trial for ignition (refer to boiler O&M commissioning section for minimum pressure required).

Check Low Gas Pressure Switch (LGPS) setting -- should be 50% of gas supply pressure required.

Check position of manual gas shut-off valve.

Check HGPS setting -setting should be ~150% of gas supply pressure to boiler.

Check air switch (CAPS) setting; on Falcon Annunciation screen check "Interrupted Air Sw" status during purge

Check air switch (CAPS) pressure tubing connections for tightness -- one is at blower outlet, other is at blower/venturi inlet

Check air switch (CAPS) wiring connections -- white wire should be connected to COM and black wire to NO terminal.

If all previous tests pass and "Interrupted Air Sw" status during purge does not indicate ON:

Confirm gas shut-off valve is open. Increase gas supply to boiler room and/or boiler by increasing pressure out of regulator. Reset LGPS. Clear lockout on Falcon and restart.

Open manual shut-off valve between gas safety shut-off valve and venturi. Reset High Gas Pressure Switch (HGPS). Clear Falcon lockout and restart.

Adjust switch to appropriate setting. Reset HGPS. Clear Falcon lockout and restart.

Set CAPS to minimum set point. Clear lockout and restart.

If loose, tighten pressure connections. Clear lockout and restart.

If wrong or not secure, correct and secure connections. Clear lockout and restart.

Replace air switch (CAPS)

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Troubleshooting

Problem Display Message Possible Cause/Symp-

tom

J.2. Combustion Air Blower does not run or does not run to purge speed (4000 RPM)

Diagnostic Check Corrective Measures

Visually inspect blower cable/harness connections.

Observe Firing rate and Fan speed on Falcon status screen -- they should closely agree and read approximately 4000 RPM during purge.

Open control panel door. With volt meter, check for 115 VAC on both sides of blower fuse and at control panel blower terminal (T1 on newer boilers; T46 on older models).

Check that blower cable/harnesses are secure on both ends: 3-conductor power cable to blower power circuit and 4-conductor signal cable to Falcon J2 plug. If either is found loose and subsequently secured, clear lockout and restart.

If Fan speed does not match Firing rate, see next step.

If no power after blower fuse, replace blower fuse. Refer to boiler wiring diagram for correct fuse size and type for the boiler. Clear lockout and restart.

If no power before blower fuse, reset circuit breaker. Clear lockout and restart.

750-382 CBT

K. Lockout 66 Interrupted Airflow Switch ON

K.1. High negative draft condition

With 115VAC power connected to blower, temporarily disconnect 4-conductor blower signal cable from blower or Falcon J2 plug. Blower should run at full speed.

Check draft presure at boiler flue outlet (+/-

0.25" w.c. allowed)

If measured voltage is greater than 10V but less than 104V, check incoming power, neutral, and ground connections to boiler. Resolve power wiring as necessary.

If 115VAC power confirmed at blower connection and blower does not run, contact factory and/or replace blower assembly.

Resolve draft condition (e.g. adjust stack damper) to near neutral (0" w.c.)

5-19

Maintenance

Problem Display Message Possible Cause/Symp-

tom

K.2. Blower running when boiler is off

K.3. Combustion Air Proving switch (CAPS) failure

Light-off problems L. Lockout 109 Igni-

tion Failure

L.1. Gas supply - is pressure too low at boiler gas valve inlet during trial for ignition

(refer to manual's commissioning section for minimum gas supply pressure requirement and recommended gas line sizing)

Diagnostic Check Corrective Measures

Check if blower is turning when not on.

Check Firing rate and Fan speed on Falcon status screen

At Operation screen, check Modulation Firing rate setting

Check switch connections and proper function of air switch.

Check for flame signal on boiler status screen (DC Volts)

Resolve draft condition (e.g. adjust stack damper) to near neutral (0" w.c.)

If Firing rate indicates 0 or low RPM and Fan speed is at a high RPM, inspect/secure blower signal cable connections at both ends. A disconnected blower signal cable will result in the blower running at full speed.

If set to "Manual in Run & Standby", set to "Automatic" or "Manual in Run"

Correct/secure connections. Clear lockout and restart. If CAPS not functioning, replace air switch.

Increase gas supply pressure to boiler room

Increase gas supply pipe size

5-20

L.2. Manual gas valve located between gas valve and venturi closed

L.3. Gas safety shut-off valve not opening

Check position of manual shut-off valves

Check gas valve indicator LED's during trial for ignition

Adjust setting of boiler gas regulator

Clear Lockout and try again

Open Manual Gas Valve

If LED(s) not energizing, secure gas valve wiring connections. Refer to boiler wiring diagram. Ensure DIN connector is secured to gas valve.

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Troubleshooting

Problem Display Message Possible Cause/Symp-

tom

L.4. Gas supply restriction -- improperly sized high pressure regulator, gas pipe size to small, too many elbows, high lockup pressure, no gas pressure relief (>1 psig supply pressure), insufficient gas volume supply to boiler room,…

L.5. Multiple appliances sharing an insufficiently sized gas supply header

L.6. Ignitor weak or not sparking - check burner sight port for visual spark indication during trial for ignition

Diagnostic Check Corrective Measures

Monitor gas supply pressure at boiler gas valve inlet during trial for ignition and modulation -- note gas pressure at low fire and high fire rates.

Note gas supply pressure when all appliances are firing at rated capacity.

Check for flame signal on boiler status screen (DC Volts) during trial for ignition.

Check for wiring to ignition transformer; check ground of transformer

If significant fluctations in gas pressure (e.g. 5" to 10" of droop) are observed, identify gas supply restriction and correct condition(s).

If gas supply pressure drops below minimum requirement, correct gas supply header pipe sizing.

Check ignition cables for secure connection to sparking electrodes replace if connection is loose or if insulation is brittle and/or charred

Secure wiring and ground connection to ignition transformer

Check dual sparking electrodes condition, gap, and condition of insulators

750-382 CBT

Replace ignition cables

Clear Lockout and try again

Check for power between terminals 2 & 4 in control panel during trial for ignition.

L.7. Combustion Air restriction - dirty/ clogged air filter

L.8. Blocked air intake Check for flame signal inspect air intake/

L.9. Blocked flue/ exhaust

Check for flame signal inspect/clean air filter

Check for flame signal inspect flue/remove

If power present, replace ignition transformer; if no, check wiring from Falcon control to ignition transformer and secure.

Clear Lockout and try again

remove blockage

blockage

5-21

Maintenance

Problem Display Message Possible Cause/Symp-

tom

L.10. Burner canister clogged

L.11. No or poor flame signal (less than 1 VDC) -- UV flame sensing

Diagnostic Check Corrective Measures

Check for flame signal inspect burner/clean

surface. Replace burner canister if clogged or damaged.

Clear Lockout and try again

Check for flame signal; Visually check for ignition in burner sight port

Remove UV scanner for inspection.

Shut-off gas supply; remove UV scanner from burner mount, with match or lighter, place flame in front of UV scanner -- observe displayed flame signal on boiler status screen

If flame observed, inspect UV scanner; remove and clean as necessary and reinstall.

Inspect scanner mounting tube for clear line-of-sight to burner canister - remove any blockages that would inhibit scanner viewing.

If no flame signal, replace UV scanner with new one. If yes, remount UV scanner at burner. Open gas shutoff valve.

Clear Lockout and try again

M. Lockout 107 Flame lost early run

L.12. No or poor flame signal (less than 1 VDC) -- flame rod sensing

M.1. Refer to L. Lockout 109 Possible Causes and Corrective Measures

M.2. Poor combustion tuning

Check for flame signal; Visually check for ignition in burner sight port

With combustion analyzer, compare O2 levels at HF and LF with manual recommedations.

If condition persists, contact factory

If flame is observed, remove flame rod, inspect, clean and reinstall. Replace as necessary based on usage and environmental conditions.

Retune combustion settings as necessary.

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Troubleshooting

Problem Display Message Possible Cause/Symp-

tom

M.3. Flame Rod (Ionization Electrode) grounding itself

N. Lockout 122 Lightoff rate proving failed

N.1. Blower speed signal cable is too close to ignition cables

N.2. Blower speed control not functioning properly

Diagnostic Check Corrective Measures

Check flame signal and inspect flame rod position.

Observe RPM on display during trial for ignition

On display screen, compare Fan speed to Firing rate command.

Check that blower signal cable is securely connected at both ends

-- Falcon control J2 socket and blower speed control signal socket.

Increase the gap between the flame rod tip to the burner canister surface. Replace flame rod if damaged.

Route blower signal cable at least 12" away from ignition cables.

Clear Lockout and try again

If blower/fan speed does not respond to Firing rate command, perform the following Diagnostic Checks.

If Fan speed is slow to respond to Firing rate command, adjust the Fan gain up and down parameters in Fan Configuration group for better response.

Secure blower signal cable connections.

750-382 CBT

Check blower AC power fuse and connections.

With boiler demand is off, temporarily disconnect blower signal cable. With AC power connected, blower should go to max speed.

If AC power not present replace fuse.

If AC power low, check blower wiring circuit for proper connections. Check ground to boiler control panel.

If blower does not respond, recheck blower AC power circuit. If AC power is OK, replace blower.

Clear Lockout and try again

If condition persists, contact factory

5-23

Maintenance

Problem Display Message Possible Cause/Symp-

tom

O. Lockout 173 Pilot relay feedback error

P. Lockout 174 Safety relay feedback error

Flame Failure Q. Lockout 108 Flame

failure in Run

O.1. Loose wire or neutral in fuel valve circuit

P.1. High ambient temperature inside control panel.

P.2. Falcon "pump" relay output assigned task, but not used

P.3. External electrical noise (e.g. ignition sparking) near Falcon control circuit

P.4. Faulty safety interlock control (e.g. ALWCO, HLC, HGPS, LGPS);

Q.1. Refer to Lockout 109 & 107 Possible Causes and Corrective Measures -- except for Ignitor not sparking

Q.2. Poor combustion tuning

Diagnostic Check Corrective Measures

Check fuel valve wiring from control panel to gas valve connection DIN connector. With power disconnected, perform continuity check of each wire from control panel terminal to fuel valve DIN connector. Refer to boiler wiring diagram.

Measure temperature in boiler room and inside control panel.

Refer to boiler wiring diagram for Falcon "pump" relay connections. Access Falcon Pump Configuration menu.

Check that all electrical noise sources (e.g. ignition cables) are kept away from the Falcon controller and connected control circuit wiring.

Check function of each safety interlock switch in ILK circuit.

Check Lockout History for boiler state/status and cycle run time when lockout occurred.

With combustion analyzer, compare O2 levels at HF and LF with manual recommedations.

Correct/secure any loose wire connections in fuel valve circuit. Ensure DIN connector is secured to gas valve.

If room is greater than 120F, ventilate room with cooler make-up air. If control panel is greater than 140F, ventilate control panel.

Set all pump control block assignments that are not being used to “None”.

Separate and secure all control wiring from electrical noise generators such as ignition transformer and cables.

Secure wiring connections or replace faulty safety interlock control device.

If condition persists, contact factory

If feasible, identify potential adverse operating conditions at time of lockout (e.g. low fire or high fire?) and remedy.

Retune combustion settings as necessary.

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Troubleshooting

Problem Display Message Possible Cause/Symp-

tom

Q.3. Low fire (Minimum modulation speed) too low

False Flame R. Hold/Lockout 105

Flame out of sequence

R.1. Gas valve stuck open

R.2. Electrical noise from ignition cables and/or transformer

R.3. Failed UV scanner Check flame signal on

Diagnostic Check Corrective Measures

Observe if Lockout occurs at lower firing rate. Compare Minimum modulation parameter setting to Manual commissioning recommendation.

Check flame signal on display and visually check for flame through burner sight port

Check gas valve output - control panel terminal 3.

Check routing of flame signal cable/wiring so that it is at least 12" away from high voltage source.

display and visually check for flame through burner sight port

Increase Minimum modulation speed by 100-300 RPM as needed.

Clear Lockout and try again

If condition persists, contact factory

If flame observed through sight port, CLOSE manual gas shut-off valve! Check status of Safety ShutOff gas valve (SSOV) -replace gas valve if it failed to close.

If energized, check/ correct wiring.

Reroute flame signal cable/wiring away from high voltage igntion sources.

Clear Lockout and try again

If no flame, clear Lockout and observe controller status

If condition persists, replace UV scanner

Steam pressure drops too much when boiler is off

S. Demand: Steam Burner state: Standby (normal)

750-382 CBT

S.1. Steam On point is too low

Check On point setting on status screen

If UV scanner replacement does not resolve Lockout 105, contact factory.

Set Steam On hysteresis parameter to 0 (zero)

5-25

Maintenance

Problem Display Message Possible Cause/Symp-

tom

S.2. Anti-short cycle time is too long

Boiler cycles on and off too frequently

TABLE 5- 2. Common abbreviations

WD Wiring Diagram

ILK Safety InterLock circuit (always require a manual reset)

LCI Limit Control Input circuit (resets automatically)

SP Set Point (steam pressure)

PID Proportional-Integral-Derivative (control method)

SSOV Safety Shut-Off Valve

FW Feed Water

LWCO Low Water Cut-Off

ALWCO Auxiliary Low Water Cut-Off

CAPS Combustion Air Proving Switch

LGPS Low Gas Pressure Switch

HGPS High Gas Pressure Switch

HLC High Limit Control (steam pressure)

OLC Operating Limit Control (steam pressure)

LED Light Emitting Diode (common on solid state controls, such as LWCO)

AC or VAC Alternating Current (electrical power) or Voltage AC

DC or VDC Direct Current (electrical power) or Voltage DC

RPM Revolutions Per Minute (combustion air fan speed or firing rate)

DIN electrical connector type defined by German standards association

UV Ultra-Violet (flame scanner type)

T. Demand: Steam Burner state: Standby (normal)

T.1. Steam Off hysteresis setting is too low

T.2. PID gains are too aggressive, or too high

Diagnostic Check Corrective Measures

Check anti-short cycle time

Check Steam Off point on boiler status screen

Check P (proportional) and I (integral) gain settings.

Reduce ant-short cycle time parameter; set to 0 to disable this function. Anti-short cycle is located in the "Steam Configuration" parameter group.

Increase the Steam Off point hysteresis parameter setting to allow boiler to modulate longer before shutting off.

Reduce the gain values for both P and I gain. Observer control of boiler to meet steam pressure set point.

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Display diagnostics

5.10 — Display diagnostics

The CB Falcon display/interface provides diagnostic features under the Setup menu. To access display diagnostics, beginning on the Home screen, press <Setup>, then <Display Diagnostics>

If the touch screen is not working properly, it may require re-calibration. Go to Display Diagnostics as above and press <Calibrate Screen>. Follow the on-screen instructions.

Date and time

The Setup menu also allows access to system Date and Time settings. Press <Setup>, <Display Setup>, <Set Date/Time>.

5.11 — Lay-up

If the boiler will be out of use for an extended period, precautions must be taken to protect fireside and waterside surfaces from deterioration due to corrosion.

At the start of lay-up, thoroughly clean the fireside by removing any soot or other products of combustion from the fireside surfaces. After brushing all surfaces clean, sweep away or vacuum any residue. The fireside may be flushed with water; however, all surfaces should be completely dried before lay-up.

Dry lay-up

Dry lay-up is generally used when the boiler will be out of service for a lengthy time period, or where the boiler might be subject to freezing temperatures. The boiler must be thoroughly dried before dry storage, as any moisture could cause corrosion. Both fireside and waterside surfaces must be cleaned of all scale, deposits, soot, etc. A desiccant such as quick lime or silica gel should be placed in suitable containers inside the boiler vessel.

Wet lay-up

Wet storage is generally used when a boiler may be needed on short notice or in cases where dry storage is not practical. Before wet storage the vessel should be drained, thoroughly cleaned, and refilled to overflowing with treated water. If deaerated water is not available, the unit should be fired to boil the water for a short period of time.

Whichever method of lay-up is used, a periodic re-check of fireside and waterside conditions is recommended during lay-up.

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5-27

Maintenance

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CHAPTER 6 Parts

Recommended spare parts list 6-2

Safety valves 6-3

Control panel 6-4

Burner assembly 6-6

Water Column 6-12

Feedwater piping 6-13

Gas train 6-14 Direct vent kits 6-15

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6-1

6.1 — Recommended spare parts list

PART NUMBER DESCRIPTION 10-15 HP 20-25 HP 30 HP Falcon controller, steam 833-03578 Falcon Display 833-05105 Power Supply, 12VDC 832-02179 Gasket, Adapter Plate To Blower 380-01037 Gasket, Burner Canister (2) 380-01136 380-00902 380-01169 Burner Canister 380-01134 380-00900 380-01170 Ignition Cable (2) 826-00156 Pressure Gauge, 0-300 PSI 850-00122 Gasket, Electrode 380-01032 Scanner Assembly, UV 817-01743 Electrode, Ignition 380-01174 380-01172 Gasket, Venturi 800-00098 Burner Sight Glass 851-06429 Gasket, Handhole (3) 853-00934 Valve Set, Gauge Glass 825-00281 825-00132 Gauge Glass, Pyrex, Tubular 851-00199 Protector Set, Gauge Glass 912-00085 Probes, LWCO, Pump On/Off, HWA 817-03728 Probe, ALWCO 067-00873 Fuse, Blower 832-01881 Fuse, Control Circuit, 5A 832-01811 Fuse, DC Power Supply, 1A 832-02045 Fuse, 24VAC Secondary, 2A 832-02051 Ignition Transformer 832-02451 Safety Relief Valve see table next page

Parts

6-2

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Safety valves

6.2 — Safety valves

SET

PRESSURE

100

125

150

SAFETY VALVES CBT BOILERS

BOILER

10 940-04991-

15 940-04991-

20 940-04991-

25 940-04992-

30 940-04992-

10 940-07988-

15 940-07988-

20 940-07988-

25 940-02268-

30 940-02268-

10 940-03105-

15 940-03105-

20 940-03105-

25 940-03145-

30 940-03145-

10 940-03069-

15 940-03069-

20 940-02971-

25 940-02971-

30 940-02971-

10 940-02974-

15 940-02974-

20 940-02974-

25 940-02419-

30 940-02419-

10 940-02976-

15 940-02976-

20 940-02976-

25 940-02588-

30 940-02588-

SAFETY SEVLAV

PART NO. SIZE

x 1.50

x1.50

x 2.00

x 1.25

x 2.00

X 1. 00

x 1.25

x .75

x 1.00

x .75

x 1.00

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6-3

6.3 — Control panel

6.3.1 — Full modulation

ITEM

QTY

1 1 119-00440-000 CABINET, ELECTRICAL W/SUB BASE, CBT

13 1 879 -00995-000

PART NO. DESCRIPTION

DISPLAY, TOUCHSCREEN, FALCON

1 8 33-03578-000 CONTROLLER, BOILER, STEAM

CONTROLLER, LWCO & PUMP CONTROL

1 8 32-00235-000 TRANSFORMER, 115v/2 4v

IGNITION TRANSFORMER

FUSE, 5 AMP, CONTROL CIRCUIT BREAKER, CIRCUIT, 10A, 1 POLE, 120V

LABEL, DEMAND REM-OFF-LOC

Parts

INCLUDED WITH

A.L.W.C.O.

16 1 881-00138

27 1 880- 02343-000 PLUG CONNECTOR KIT, FALCON

1 881-00137 LIGHT, NEON RED

48 1 848-00531

51 1 881-00139

LIGHT, NEON GREEN

FUSE, 1 AMP

BLOWER POWER CORD

PLUG, DOMED, .500" DIA HOLE

LIGHT, NEON AMBER

427

821

ITEMS 3, 21, 22, 23, & 26 NOT SHOWN

DFL

A.L.W.C.O.

L.W.C.O./PUMP

CONTROL

12 14 15

6-4

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CleaverBrooks CBT Operation And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual