CleaverBrooks CFC Operation, Service And Parts Manual

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Table Of Contents

Clearfire

Condensing Boiler

Model CFC

Gas High Efficiency Boiler

Operation, Service,

and Parts Manual

Manual Part No. 750-263 07/2008

CLEAVER-BROOKS MILWAUKEE, WISCONSIN

ANSI STANDARD Z21.13b-2004 — CSA 4.9b-2004 LOW PRESSURE BOILER

ANSI STANDARD Z21.13b-2005 — CSA 4.9b-2005

WARNING

DANGER

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.

— 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.

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.

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 supply to the boiler. Instead turn off the gas supply at a location external to the boiler.

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

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

WARNING

DANGER

A hot water boiler installed above radiation level or as required by the Authority having jurisdiction, must be provided with a low water cutoff device either as a part of the boiler or at the time of boiler installation.

Notes

The installation must conform to the requirements of the authority having jurisdiction or, in the absence of such requirements, to the National Fuel Gas Code, ANSI Z223.1 and/or CAN/CSA B149 Installation Codes.

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

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.

TO: Owners, Operators and/or Maintenance Personnel This operating manual presents information that will help to properly operate and care for the equipment. Study its contents

carefully. The unit will provide good service and continued operation if proper operating and maintenance instructions are followed. No attempt should be made to operate the unit until the principles of operation and all of the components are thoroughly understood. Failure to follow all applicable instructions and warnings may result in severe personal injury or death.

It is the responsibility of the owner to train and advise not only his or her personnel, but the contractors' personnel who are servicing, repairing or operating the equipment, in all safety aspects.

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, opera tion of equipment is not to be considered free from al l 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 free him of certain repetitive chores and give him more time to devote to 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 emph asize 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.

The services of a qualified water treating company or a water consultant to recommend the proper boiler water treating practices are essential.

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.

TABLE OF CONTENTS

Section 1 —

Introduction

Clearfire Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

The Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

The Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Burner Gas Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Component/Connection Locations . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Section 2 — Installation

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Boiler room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Mounting legs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Casing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Base mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Flue gas / combustion air connections . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Boiler Room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Gas Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Gas train components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Gas pressure requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 11

Gas supply pipe sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Gas header . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Boiler Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Water temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Pressure drop curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Condensate removal and treatment . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

Condensate Tank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

Condensate tank setup options . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

Condensate take-off and neutralization . . . . . . . . . . . . . . . . . . . . . 2-28

Condensate discharge into local drain . . . . . . . . . . . . . . . . . . . . . . 2-28

Piping treated condensate to drain . . . . . . . . . . . . . . . . . . . . . . . . 2-28

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

Condensate piping for multiple boilers . . . . . . . . . . . . . . . . . . . . . . . 2-30

Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

Section 3 — Stack and Intake Vent Sizing and Installation

Venting Connections - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Appliance Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Vent Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Vent Terminal Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Horizontal Thru-Wall Venting / Inside Combustion Air . . . . . . . . . . . . . . 3-6

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Horizontal Thru-Wall Stack Vent Termination . . . . . . . . . . . . . . . . . . 3-7

Horizontal Thru-Wall Venting / Direct Vent Combustion Air . . . . . . . . . .3-8

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Horizontal Thru-Wall Stack Vent Termination . . . . . . . . . . . . . . . . . . 3-9

Vertical Venting / Inside Combustion Air . . . . . . . . . . . . . . . . . . . . . . 3-10

Vertical Venting / Direct Vent Combustion Air . . . . . . . . . . . . . . . . . . . 3-11

Section 4 — Commissioning

Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Filling Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Control Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Model CFC Boiler / Burner Controller . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

CB Falcon Display/Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Lockouts and Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Controller Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Changing Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Burner Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Fan Speed Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Initial start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Post start-up checkout procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Section 5 — Service and Maintenance

Cleaning Procedure / Disassembly ...................................................... 5-2

Condensate Neutralization ................................................................. 5-3

Assembly ........................................................................................ 5-3

Ignition Electrode and Flame Rod ....................................................... 5-4

Troubleshootin g ............................ ............................ ........................ 5-4

Section 6 — Parts Appendix A — CB Falcon Hydronic Control Appendix B — Falcon Display/Operator Interface Appendix C — Gas Valve

Chapter 1

Introduction

CFC Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

The Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

The Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Burner Gas Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Component/Connection Locations . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Milwaukee, Wisc onsin

www.cleaver-brooks.com

Chapter 1 — Introduction

Premix Burner

Insulation

Pressure

Cabinet

On/Off

Control

Vessel

Switch

Panel

Display

A.CFC FEATURES AND BENEFITS

Compact Firetube Design (Figure 1-1 & Figure 1-2)

The CFC boiler is a single pass down fired durable Firetube boiler. The extended heating surface tubes provide for ver y high levels of performance in a compact space. The boiler is designed to fire natural gas or propane.

Figure 1-1 CFC Boiler

High Efficiency

(Figure 1-3)

With the extended heating surface tubes the boiler can produce fuel to water efficiency of up to 98% depending upon operating conditions.

Advanced Construction

Constructed to ASME standards and utilizing AluFer tube technology in a single-pass design, the CFC Boiler will provide many years of trouble free service. Single-pass design provides excellent thermal shock protection.

Ease of Maintenance

The steel enclosures are readily removable for access to all key components. A flip down step and hinged burner door provide access to all key components.

Quality Construction

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

ISO 9001 certified manufacturing process ensures the highest degree of manufacturing standards is always followed.

Full Modulation

The burner and combustion fan modulate to provide only the amount of heat required, providing quiet and efficient operation under all conditions.

Figure 1-2 CFC Cutaway

Premix Technology

The ClearFire-C 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.

Designed For Heating Applications

The pressure vessel is constructed of durable ASTM Graded Steel and Stainless Steel materials to provide many years of operating life.

The vessel is designed to prevent hot spots and has no minimum flow requirements; required for vessel stress protection.

Figure 1-3 AluFer Tube Cross

1-2 Part No. 750-263

Section

B.STANDARD EQUIPMENT

High Gas Pressure Switch

Low Gas Pressure Switch

Manual Shutoff

Test Cock

1. The Boiler

The boiler is designed for a Maximum Allowable Working Pressure (MAWP) of 60 psig (4.1 Bar) in accordance with the ASME Code for Low Pressure Section IV Hot Water Boilers and is stamped accordingly. Operating pressure shall be less than 54 psig (3.72 Bar).

The vessel is mounted on a steel base with insulation & casing provided including trim and controls. Trim and controls include safety relief valve, pressure/temperature gauge, probe type low water control, and CB Falcon hydronic boiler control with associated sensors..

2. The Burner (See Figure 1-4)

Incorporating "premix" technology , the burner utilizes a venturi, dual safety shutoff-single body gas valve, variable speed blower, and Fecralloy metal fiber burner head.

With the integral variable speed combustion air fan, 5:1 turndown is provided.

Chapter 1 — Introduction

Combustion canister of the burner is constructed of a Fecralloymetal fiber for solid body radiation of the burner flame, which provides low emissions.

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.

Provision for direct vent combustion is furnished. Combustion Air Proving Switch and High Air Pressure Switch.

3. Burner Gas Train (See Figure 1-5 & Fi gure 1-6)

The gas train assembly is provided in accordance with CSA certification and ASME CSD-1. The gas train assembly is factor y assembled and wired, consisting of the following components:

A. Low Gas Pressure Switch - manual reset B. High Gas Pressure Switch - manual reset C. Single body, dual safety shutoff gas valve with integral trim

regulator D. Integral Venturi E. Manual Shutoff Ball Valve F. CSD-1 Test Cocks

Figure 1-4

Figure 1-5 Standard Gas Train,

CSA and ASME CSD-1

Part No. 750-263 1-3

Chapter 1 — Introduction

HGPS

LGPS

GAS VALVE

TEST COCK

Figure 1-6 Standard Gas Train

Components per CSA and ASME

CSD-1

4. Control (See Figure 1-7)

The CB Fa lcon hydronic control is an integrated burner management and modulation control with a touch-screen display/operator interface.

The controller is capable of the following functions:

• Two (2) heating loops with PID load control.

• 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.

• Variable speed control of the combustion fan.

• 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.

• Outdoor temperature reset.

Figure 1-7 Control panel (hinged access panel open)

5. Component/Connection Locations

Figur e 1-8 shows the CFC component orientation and heat flow

path. Note the downfired design of the burner and the orientation of the hot water outlet and return connections. The return water connection is at the bottom of the vessel and the hot water outlet is near the top.

Figu re 1- 9 shows the locations of the safety valve and low water cutoff. Fig ure 1 -10 shows the supply and return connections and the location of the return water temperature sensor. Looking at the top of the boiler, near the rear, Fi gure 1 -11 shows the three hole sensor well for the outlet temperature sensor.

1-4 Part No. 750-263

When standing at the back of the boiler, the stack can be connected on the right side of the boiler (Figure 1-12) or on the left side (Figure 1-13). Refer to Chapter 3 of this manual for recommended vent sizes and lengths for the specific boiler installation.

6. Optional Equipment

Certain options may have been supplied with the boiler that are relative to the project requirements if these options were specified with the boiler at the time of order entry. Also, 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 for project specifics.

These are the options that are available for the CFC boi ler from Cleaver-Brooks:

A. Reusable air filter. B. Condensate neutralization treatment tank assembly -

consists of neutralizing media, filter, and PVC condensate holding tank. This assembly is mounted beneath the boiler

and is further described in Chapter 2. C. Outside air intake for direct vent combustion. D. Outdoor temperature sensor for indoor/outdoor control. E. Shipped loose Auxiliar y Low Water Control for field piping

by others into the system piping. F. Alarm Horn for safety shutdown. G. Relays for output signal for burner on, fuel valve open. H. Stack Thermometer. I. Stack temperature limit-sensor. J. Common condensate drain trap.

Chapter 1 — Introduction

Table 1-1 Model CFC W ater Temperature Data

Minimum supply temp. 33oF

Maximum operating temp. 194 Maximum design temp. 210

Part No. 750-263 1-5

Chapter 1 — Introduction

Combustion Fan and Premix Gas Valve Assembly

Burner Head

Control & Panel

“Finned” High Efficiency AluFer Tubes

ASME Code Pressure Vessel

Flue Gas Outlet

Cold Water Return

Hot Water Outlet

Safety Relief Valve

Condensate Drain

Cleaning Cover

Filling and Draining cock

Insulation Mat

Electrode Ignition and Flame Rod

Burner Canister

1-6 Part No. 750-263

Figure 1-8 CFC Heat Flow and Component Orientation

Chapter 1 — Introduction

Low Water Cutoff

Safety Valve (shipped loose)

Probe

Auto air vent (optional; shipped loose)

Return Water Sensor

Return Water In

Temperature

Water Side Inspection Port

Figure 1-9 Boiler Controls

Part No. 750-263 1-7

Figure 1-10 Return Temperature Mounting

Chapter 1 — Introduction

Hot Water Out

Return Water In

Figure 1-11 Temperature Sensor, Top of Pressure Vessel

The stack can be mounted on the right (Figure 1-12) or left (Figure 1-13) side on the back of the boiler base.

The flue gas duct sizes may be reduced at the vent connection.

Figure 1-12 Stack Right Side

(viewed from rear)

See also Chapter 4 - Stack and Intake V ent Sizing and Installation.

Figure 1-13 Stack Left Side (viewed from rear)

1-8 Part No. 750-263

Section 2

Installation

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Boiler room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Mounting legs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Casing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Base mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Flue gas/combustion air connections. . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Water treatment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Boiler Room. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Gas Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Gas train components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Gas pressure requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Gas supply pipe sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Gas header . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Boiler water piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Water temperature sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Pressure drop curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Condensate removal and treatment . . . . . . . . . . . . . . . . . . . . . . . 2-27

Condensate Tank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

Condensate tank setup options . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

Condensate take-off and neutralization . . . . . . . . . . . . . . . . . . . . . 2-28

Condensate

Piping treated condensate to drain . . . . . . . . . . . . . . . . . . . . . . 2-28

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

Condensate piping for multiple boilers . . . . . . . . . . . . . . . . . . . . . . . 2-30

Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

discharge into local drain . . . . . . . . . . . . . . . . . . . . 2-28

Milwaukee, Wisconsin

www.cleaver-brooks.com

Section 2 — Installation

Provisions for combustion and ventilation air must be in accordance with the National Fuel Gas Code, ANSI Z223.1, or the CAN/CSA B149 Installation Codes, or applicable provisions of the local building codes. Failure to follow this warning

could result in personal injury or death.

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

Caution

The installation must conform to the requirements of the authority having jurisdiction, or in the absence of such requirements, to the National Fuel Gas Code, ANSI Z223.1 and/or CAN/CSA B149 Installation Codes.

If an external electrical source is utilized, the boiler when installed must be electrically bonded to ground in accordance with the requrements of the authority having jurisdiction, or in the absence of such requirements with the National Electrical Code ANSI/NFPA 70 and/or the Canadian Electrical Code Part I CSA C22.1.

Warning

2-2 Part No. 750-263

A.ASSEMBLY

Model No. Dim CFC-500 CFC-750 CFC-1000 CFC-1500 CFC-1800 CFC-2500 Space Required (in inches) Floor to Ceiling A 96 96 96 96 96 96 Side Clearance B 24 24 24 24 24 24 Backway C 24 24 24 24 24 24 Front D 36 36 36 36 36 36 Between Boilers E 3 3 3 3 3 3

SIDE VIEW

20"

PLAN VIEW

MULTIPLE BOILERS

Minimum ceiling height

96 inches (All Boilers)

Minimum distance from combustible walls - 24 inches.

Minimum distance between boilers, 3 inches.

24”

36”

24”

Fold Down Service

Access Step

1. Packaging

The Cleaver-Brooks Model CFC boiler is shipped in three parcels. The pressure vessel assembly mounted on a skidded crate, the control panel in a box, and the outer casing with insulation in a skidded box. It is recommended that the pressure vessel be properly mounted with all piping connections attached prior to installation of the casing.

2. Boiler room

The boiler or boilers should be mounted in a space in accordance with Figure 2-1 shown below. Clearances front, rear, and sides are provided.

Note:If the boiler room is constructed with non-combustible

walls, it is possible to install the units closer to the side

walls, but the front and rear clearances must be

maintained.

Section 2 — Installation

Figure 2-1 Clearance Required

Part No. 750-263 2-3

Section 2 — Installation

Caution

3. Mounting Legs (see Figure 2-2)

1. Remove (4) boiler legs (1a) from the packaging and remove thetop two nuts and bolts (1) on the boiler mounting legs (1a)

2. Remove the wooden skid cross beam from the front of the boiler

3. Using an appropriate jack, lift up the front of the boiler at (3)

4. Attach the boiler mounting leg with the two bolts removed in stepone. Repeat for the other front leg.

5. Using an appropriate jack, lift up the back of the boiler andremove the wooden skid side beams (4).

6. Attach the rear boiler mounting legs as described in step 4.

7. Lifting eyes (5) are provided for moving and positioning theboiler.

Do not drag by boiler legs. Failure to follow this caution could result in equipment damage.

Figure 2-2 Mounting boiler legs

4. Insulation (see Figure 2-3)

1. Place the insulation blanket (1) around the pressure vessel as shown and secure with plastic straps (1a) and strap fasteners(1b).

2. Tension springs (1c) are provided to hold the edges of the blanket together.

2-4 Part No. 750-263

Notice

Do not over tighten the straps; doing so will reduce the insulation’s

effectiveness.

Section 2 — Installation

Figure 2-3 Insulation blanket

Part No. 750-263 2-5

Section 2 — Installation

Notice

9a, 9b

Figure 2-4 Attaching electrivcal supply channels and side panels

5. Casing Assembly

1. After removing the nuts and washers, attach the electrical supplychannels (2), left and right, on the mounting studs projectingfrom the top plate of the boiler (see Figure 2-4). Do not installnuts and washers.

2. Attach the side panels (3) and (5) on top of the electrical supplychannels. Fasten loosely with the provided nuts (2a) andwashers (3a).

Casing panels that are mounted with snap-in or “keyhole” type connections do not need tools

(See Figure 2-6 for next steps).

3. Remove the control panel (7) from the box and mount at thefront. The control panel is suspended by the side casing panels.

4. Route and connect electrical harnesses and cabling per Figure 3-17. Include:

• Sensor wiring/cables

•Ignition cables

•Blower cables

• Flame rod cable

5. Run main power to mounting block and fasten wires.

6. Attach the provided c-clips (9, Figure 2-5) to the sidewalls (9a& 9b) and slide on to bottom side panels.

7. Attach the front cover (10) with self-tapping screws (see Figure2-6).

8. Attach rear walls (11, 11a, 11b) to the side panels.

9. Attach top panel (12).

Figure 2-5 C-Clip retaining nuts

2-6 Part No. 750-263

Mains Supply Cable

11a

11b

Section 2 — Installation

Figure 2-6 Casing Assembly

Part No. 750-263 2-7

Section 2 — Installation

14a

Condensate Treatment Tank

6. Base mounting

The Model CFC boiler is of a condensing design. Based on local requirements the condensate can be piped to an appropriate treatment location or the optional treatment tank can be mounted under the boiler (see Figure 2-7).

For information on the condensat e treatment t ank installation, refer to section 3. Once condensate piping is completed the base casing can be installed.

1. Mount the right and left sidewalls (14 & 14a) to the boilermounting legs with the supplied cap nuts.

2. Attach the front (15) to the sidewalls (14 & 14a).

Figure 2-7 Base mounting with optional treatment tank

2-8 Part No. 750-263

B.FLUE GAS / COMBUSTION AIR CONNECTIONS

Notice

Fan/Blower

Venturi

Direct Vent Connection

Casing Support Attachment

Flexible Connection

Adapter Flange

Gasket

Warning

The high efficiency of the CFC boiler may cause water vapor to condense out of the flue gases.

The flue gases from the Model CFC boiler should be removed via a gas-tight, temperature and corrosion resistant flue gas pipeline. Only flue gas systems approved and tested by the relevant region or province are to be connected to the boiler. Refer to flue piping manufacturer for proper installation and sealing instructions. See also Chapter 4 of this manual for combustion air and flue gas venting requirements.

C.WATER TREATMENT

The Model CFC boiler is designed to operate with water chemistry ranging from a pH value of 8.3 to 9.5 with maximum permissible oxygen content of 7 ppb. For values outside this range contact your Cleaver-Brooks representative for assistance.

Section 2 — Installation

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

Model CFC Water Chemistry

Parameter Limit

Glycol 40%

pH 8.3 - 9.5

Chloride 30 mg/liter

Oxygen 0.1 mg/liter

Specific Conductivity 3500 umho/cm

Total Hardness

0 ppm as C

aCO3

D.BOILER ROOM

The boiler room must comply with all building codes and regulations. An adequate supply of combustion air is re quired for safe operation. If the optional direct vent combustion air kit (Figure 2-8) is not used, ventilation must be provided to meet applicable regulations for air supply.

Figure 2-8 Air Inlet Extension

The boiler must not be installed on carpeting.

See Section 6, Parts, for part numbers for the Direct Vent Combustion Air kits available.

Part No. 750-263 2-9

Section 2 — Installation

Air Inlet Extension Location

Flue Gas Vent Connection

Alt. Flue Gas Connection

Gas Connection

Hot Water Out

Return Water Inlet

Gas Pressure Regulator

Shutoff Valve

Clean combustion air is required for optimum efficiency and boiler operation. Dust and airborne contaminants will adversely effect burner performance. If conditions dictate, a serviceable filter must be placed in the intake piping to eliminate airborne contamination to the burner. An optional air filter is available from Cleaver-Brooks. Additionally, if a direct vent combustion air intake vent is used the intake should be directed to eliminate rain or snow from entering the intake piping. The boiler must be installed so that the gas ignition system components are protected from water (dripping, spraying, etc.) during appliance operation and service.

Figure 2-9 CFC Rear View

Figure 2-10 Gas Regulator and

Shutoff Valve(typ ical)

E. GAS CONNECTIONS

1. General

The ClearFire Series CFC gas fired condensing boilers are full modulating input units that require appropriate gas supply pressure and volume for proper operation. The gas requirements specified in this section must be satisfied to ensure efficient and stable combustion. Installation must follow these guidelines and those of any local authorities having installation jurisdiction.

2. Gas Train Components

CFC boilers are equipped with a gas train that meets the requirements of CSA and ASME CSD-1, and also the requirements of FM and GE-GAP (formerly IRI). The gas train and its components have been designed and tested to operate for the highest combustion efficiency for the CFC units.

3. Gas Pressure Requirements

For proper and safe operation, each CFC Series boiler requires a stable gas pressure input. See Table 2-1 for pressure requirements.

2-10 Part No. 750-263

Table 2-1: Gas Pressure

NOTE: The pressure test port is

located at the gas valve inlet flange (see Figure 2-11). The remaining try-cocks are for leak test purposes and should not be used to measure gas pressure. Refe r to

APPENDIX C - GAS VALVE

INSTALLATION AND MAINTENANCE

for more information.

Pressure Test

Section 2 — Installation

Boiler Input

Pressure Required at gas train connection

Low Fire High Fire

Maximum allowable pressure

500 - 1000 7" w.c. 5" w.c. 1500 10" w.c. 7" w.c.

14” w.c.

1800 7" w.c. 5" w.c. 2500 9.5" w.c. 7" w.c.

The inlet supply pressure must be as noted in Table A when firing the boiler at low fire and high fire. Actual gas 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 drop 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.

4. Gas Piping

CFC units are not standardly equipped with an upstream gas pressure regulator. Therefore, a regulator must be installed at each CFC unit. Do not use a common regulator to regulate pressure for a multiple unit installation. Note: Gas connection is at the rear of the boiler, lef t hand side as you face the rear of the boiler.

If local code permits, a flexible connection can be used between the gas line and gas valve. This will enable the burner door to be opened without disconnecting the gas line.

The regulator for each boiler must be installed with at least 2 feet of pipe between the regulator and the boiler gas train connection. The discharge range of the regulator must be able to maintain gas pressures as noted in Table A.

For buildings or boiler rooms with gas supply pressure exceeding 28" w .c. a "full lock-up" type regulator is required as well as overpressure protection (e.g. relief valve).

In addition to the regulator, a plug type or "butterball” type gas shutoff cock should be installed upstream of the regulator for use as a service valve. This is also required to provide positi ve shutoff and isolate the unit during gas piping tests.

If necessary a strainer should be installed upstream of the regulator to remove debris from the gas supply.

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 removable without disassembling any gas piping. The connected piping to the boiler should be supported from pipe

Part No. 750-263 2-11

Figure 2-11 Test cocks - gas

valve

Section 2 — Installation

Caution

supports and not supported by the boiler gas train or the bottom of the drip leg. Do not pipe across the top of the boiler as the burner swings up for service and must have proper clearance.

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 of all debris to prevent its entrance into the boiler gas train. Piping should be tested as noted in NFPA 54 and the boiler must be isolated during any tests.

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

See Figure 2-12 for a typical piping configuration.

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). The boiler must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psi (3.5 kPa).

5. Gas Supply Pipe Sizing

For proper operation of a single unit or a multiple unit installation, we recommend that the gas pipe sizing 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. 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 (cfh) 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 2-2 through 2-6 should be used. The data in these tables is from the NFPA 54 source book, 2006 edition.

2-12 Part No. 750-263

T o 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 unit with 750,000 btu/ hr input divided by a gas calorific value of 1060 will result in a cfh flow of 707. 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 Ta b le 2 -2 that a supply pipe size of 1-1/4" should be used as a minimum.

Table 2-2: 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. 1.0491.380" 1.610" 2.067" 2.469" 3.068" 4.026"

Length in feet **Maximum Capacity in Cubic Feet of Gas per Hour (cfh) 10 514 1,060 1,580 3,050 4,860 8,580 17,500

Section 2 — Installation

20 363 726 1,090 2,090 3,340 5,900 12,000 30 284 583 873 1,680 2,680 4,740 9,660 40 243 499 747 1,440 2,290 4,050 8,290 50 215 442 662 1,280 2,030 3,590 7,330 60 195 400 600 1,160 1,840 3,260 6,640 70 179 368 552 1,060 1,690 3,000 6,110 80 167 343 514 989 1,580 2,790 5,680 90 157 322 482 928 1,480 2,610 5,330 100 148 304 455 877 1,400 2,470 5,040 125 131 269 403 777 1,240 2,190 4,460 150 119 244 366 704 1,120 1,980 4,050 175 109 209 336 648 1,030 1,820 3,720 200 102 185 313 602 960 1,700 3,460 **Fuel: Natural Gas

**Inlet Pressure: Less than 2.0 psi **Pressure Drop: 0.30" w.c. **Specific Gravity: 0.60

Part No. 750-263 2-13

Section 2 — Installation

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) 10 678 1,390 2,090 4,020 6,400 11,30023,10

20 466 957 1,430 2,760 4,400 7,780 15,90 30 374 768 1,150 2,220 3,530 6,250 12,70 40 320 657 985 1,900 3,020 5,350 10,90 50 284 583 873 1,680 2,680 4,740 9,600

60 257 528 791 1,520 2,430 4,290 8,760

Table 2-3: Gas Line Capacity - Schedule 40 Metallic Pipe

Pipe Size

0 0 0 0

70 237 486 728 1,400 2,230 3,950 8,050 80 220 452 677 1,300 2,080 3,670 7,490 90 207 424 635 1,220 1,950 3,450 7,030 100 195 400 600 1,160 1,840 3,260 6,640 125 173 355 532 1,020 1,630 2,890 5,890 150 157 322 482 928 1,480 2,610 5,330 175 144 296 443 854 1,360 2,410 4,910 200 134 275 412 794 1,270 2,240 4,560 **Fuel: Natural Gas

**Inlet Pressure: Less than 2.0 psi **Pressure Drop: 0.50" w.c. **Specific Gravity: 0.60

2-14 Part No. 750-263

Section 2 — Installation

Table 2-4: Gas Line Capacity - Schedule 40 Metallic Pipe

Pipe Size

Nominal 1/2" 3/4" 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4" Actual I.D. 0.622 0.824 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) 10 1,510 3,040 5,560 11,400 17,100 32,900 52,500 92,800 189,000

20 1,070 2,150 3,930 8,070 12,100 23,300 57,100 65,600 134,000 30 869 1,760 3,210 6,590 9,880 19,000 30,300 53,600 109,000 40 753 1,520 2,780 5,710 8,550 16,500 26,300 46,400 94,700 50 673 1,360 2,490 5,110 7,650 14,700 23,500 41,500 84,700 60 615 1,240 2,270 4,660 6,980 13,500 21,400 37,900 77,300 70 569 1,150 2,100 4,320 6,470 12,500 19,900 35,100 71,600 80 532 1,080 1,970 4,040 6,050 11,700 18,600 32,800 67,000 90 502 1,010 1,850 3,810 5,700 11,000 17,500 30,900 63,100 100 462 954 1,710 3,510 5,260 10,100 16,100 28,500 58,200 125 414 836 1,530 3,140 4,700 9,060 14,400 25,500 52,100 150 372 751 1,370 2,820 4,220 8,130 13,000 22,900 46,700 175 344 695 1,270 2,601 3,910 7,530 12,000 21,200 43,300 200 318 642 1,170 2,410 3,610 6,960 11,100 19,600 40,000 500 192 401 717 1,470 2,210 4,250 6,770 12,000 24,400 1000 132 275 493 1,010 1,520 2,920 4,650 8,220 16,800 1500 106 221 396 812 1,220 2,340 3,740 6,600 13,500 **Fuel: Natural Gas

**Inlet Pressure: 2.0 psi

**Pressure Drop: 1.0 psi

**Specific Gravity: 0.60

Part No. 750-263 2-15

Section 2 — Installation

Table 2-5: Gas Line Capacity - Schedule 40 Metallic Pipe

Pipe Size

Nominal 1/2" 3/4" 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4" Actual I.D. 0.622 0.824 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) 10 2,350 4,920 9,270 19,000 28,500 54,900 87,500 155,000 316,000

20 1,620 3,380 6,370 13,100 19,600 37,700 60,100 106,000 217,000 30 1,300 2,720 5,110 10,500 15,700 30,300 48,300 85,400 174,000 40 1,110 2,320 4,380 8,990 13,500 25,900 41,300 75,100 149,000 50 985 2,060 3,880 7,970 11,900 23,000 36,600 64,800 132,000 60 892 1,870 3,520 7,220 10,300 20,300 33,200 58,700 120,000 70 821 1,720 3,230 6,640 9,950 19,200 30,500 54,000 110,000 80 764 1,600 3,010 6,180 9,260 17,800 28,400 50,200 102,000 90 717 1,500 2,820 5,800 8,680 16,700 26,700 47,100 96,100 100 677 1,420 2,670 5,470 8,200 15,800 25,200 44,500 90,300 125 600 1,250 2,360 4,850 7,270 14,000 22,300 39,500 80,500 150 544 1,140 2,140 4,400 6,590 12,700 20,200 35,700 72,900 175 500 1,050 1,970 4,040 6,060 11,700 18,600 32,900 67,100 200 465 973 1,830 3,760 5,640 10,900 17,300 30,600 62,400 500 283 593 1,120 2,290 3,430 6,610 10,300 18,600 38,000 1000 195 407 897 1,380 2,360 4,550 7,240 12,000 26,100 1500 156 327 616 1,270 1,900 3,650 5,820 10,300 21,000 **Fuel: Natural Gas

**Inlet Pressure: 3.0 psi

**Pressure Drop: 2.0 psi

**Specific Gravity: 0.60

2-16 Part No. 750-263

Section 2 — Installation

Table 2-6: Gas Line Capacity - Schedule 40 Metallic Pipe

Pipe Size

Nominal 1/2" 3/4" 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4" Actual I.D. 0.622 0.824 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) 10 3,190 6,430 11,800 24,200 36,200 69,700 111,000 196,000 401,000

20 2,250 4,550 8,320 17,100 25,600 49,300 78,600 139,000 283,000 30 1,840 3,720 6,790 14,000 20,900 40,300 64,200 113,000 231,000 40 1,590 3,220 5,880 12,100 18,100 34,900 55,600 98,200 200,000 50 1,430 2,880 5,260 10,800 16,200 31,200 49,700 87,900 179,000 60 1,300 2,630 4,800 9,860 14,800 28,500 45,400 80,200 164,000 70 1,200 2,430 4,450 9,130 13,700 26,400 42,000 74,300 151,000 80 1,150 2,330 4,260 8,540 12,800 24,700 39,300 69,500 142,000 90 1,060 2,150 3,920 8,050 12,100 23,200 37,000 65,500 134,000 100 979 1,980 3,620 7,430 11,100 21,400 34,200 60,400 123,000 125 876 1,770 3,240 6,640 9,950 19,200 30,600 54,000 110,000 150 786 1,590 2,910 5,960 8,940 17,200 27,400 48,500 98,900 175 728 1,470 2,690 5,520 8,270 15,900 25,400 44,900 91,600 200 673 1,360 2,490 5,100 7,650 14,700 23,500 41,500 84,700 500 384 802 1,510 3,100 4,650 8,950 14,300 25,200 51,500 1000 264 551 1,040 2,130 3,200 6,150 9,810 17,300 35,400 1500 212 443 834 1,710 2,570 4,940 7,880 13,900 28,400 **Fuel: Natural Gas

**Inlet Pressure: 5.0 psi

**Pressure Drop: 3.5 psi

**Specific Gravity: 0.60

Part No. 750-263 2-17

Section 2 — Installation

Table 2-7: Multiple Unit Manifold, CFC 500

Table 2-8: Multiple Unit Manifold, CFC 750

CFC 500 Boilers # of Units 1 2 3 4 Pipe Size to

Boiler

1" 1" 1" 1"

Header Pipe size

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

CFC 750 Boilers # of Units 1 2 3 4 Pipe Size to

Boiler

1" 1" 1" 1"

Header Pipe size

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

Table 2-9: Multiple Unit Manifold, CFC 1000 Table 2-10: Multiple Unit Manifold, CFC 1500

CFC 1000 Boilers # of Units 1 2 3 4 Pipe Size to

Boiler

1-1/4" 1-1/4" 1-1/4" 1-1/4"

Header Pipe size

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

CFC 1500 Boilers # of Units 1 2 3 4 Pipe Size to

Boiler

1-1/2" 1-1/2" 1-1/2" 1-1/2"

Header Pipe size

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

Table 2-11: Multiple Unit Manifold, CFC 1800 Table 2-12: Multiple Unit Manifold, CFC 2500

CFC 1800 Boilers # of Units 1 2 3 4 Pipe Size to

Boiler

2" 2" 2" 2"

Header Pipe size

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

CFC 2500 Boilers # of Units 1 2 3 4 Pipe Size to

Boiler

2" 2" 2" 2"

Header Pipe size

2" 3" 3" 4"

6. Gas Header

Design of a single common gas header with individual takeoffs for a multiple unit installation is recommended . Boiler gas manifold piping should be sized based on the volume requirements and lengths between boilers and the fuel main header (see Figure 2-12).

Tables 2-7 to 2-12 indicate the proper sizing for multiple units of equal size, placed on the factory standard center with the noted take off size. For installations with a mixed sized use, determine the flow of each unit and total the input. With the total input, determine length of run from the source and determine what size header will be needed for the flow of all units firing. Pipe sizes based on Table 2-2.

2-18 Part No. 750-263

Figure 2-12 Gas Piping

Section 2 — Installation

Part No. 750-263 2-19

Section 2 — Installation

Warning

Figure 2-13 Hot Water Return

Temperature Sensor Mounting

Figure 2-14 Outlet Temperature

Sensor Well (top of boiler)

F. BOILER WATER PIPING

1. General

All boiler hot water outlet and return piping is connected at the rear of the boiler. Piping is to be installed per local codes and regulations.The pipelines for the hot water outlet and return may be connected in the usual manner without removing the cladding elements. Unused connectors must be safely blanked off.

2. Water Temperature Sensors

Fast en the return water temperature sensor to the lower return pipe with a hose clamp and cover with insulation (see Figure 2-13). Install the outlet temperature sensor in the hot water outlet thermowell (see Figure 2-14).

3. Safety Valve

Pressure relief valve (Safety Valve) should be piped from the air vent piping or hot water outlet pipe (see Figure 2-15). 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 off oreign material around the valve seat area. Apply only a moderate amount of pipe compound to male threads and avoid overtightening, which can distort the seats. Use only flat-jawed wrenches on the flats provided.

Only properly certified personnel such as the safety valve manufacturer ’s cer tified representative should adjust or repair the boiler safety valve. Failure to follow this warning could result in

serious personal injury or death.

4. Pressure drop curves

The information in Figures 2-16 through 2-26 and in Tables 2-13

Figure 2-15 Pressure Relief Valve Piped to Safe Point of

Discharge

2-20 Part No. 750-263

and 2-14 can help in determining pump requirements for Model CFC installations.

Figure 2-16 Pressure Drop Curve, CFC 500, U.S. Flow Rates

Hydraulic Resistance CFC 500

0.2

0.4

0.6

0.8

1.2

1.4

8.8

13.2

17.6

26.4

30.8

35.2

39.6

48.4

52.8

57.2

61.6

70.4

131

Flow - GPM

Pressu re P S I

H ydrau lic R esistance CF C 500

Metric

02345678910111213141516

Flow m3/h

Pressur e mbar

Section 2 — Installation

Figure 2-17 Pressure Drop Curve, CFC 500, Metric Flow Rates

Part No. 750-263 2-21

Section 2 — Installation

Hydraulic Resistance CFC 750

0.2

0.4

0.6

0.8

1.2

1.4

13.2

Flow - GPM

Pressure PSI

Hydr au lic Resista n ce MCF750

Metric

0 2 3 4 5 6 7 8 910111213141516

Flow m3/h

Pressure mbar

Figure 2-18 Pressure Drop Curve, CFC 750, U.S. Flow Rates

Figure 2-19 Pressure Drop Curve, CFC 750, Metric Flow Rates

2-22 Part No. 750-263

Section 2 — Installation

H ydraul ic Resist an ce CF C 1000

0.2

0.4

0.6

0.8

1.2

0 8.8 22 44 66 88 110 132 154 176

Flow - GPM

Pressure - PSI

H ydraul ic Resist an ce CF C 1000

0 2 5 10152025303540

F low m3/h

Pressure mbar

Figure 2-20 Pressure Drop Curve, CFC 1000, U.S. Flow Rates

Figure 2-21 Pressure Drop Curve, CFC 1000, Metric Flow Rates

Part No. 750-263 2-23

Section 2 — Installation

Hydraulic Resistan ce CFC 1500

U.S. Standards

0.2

0.4

0.6

0.8

1.2

1.4

1.6

1.8

0 8.8 22 44 66 88 110 132 154 176 198 220 242 264

Flow - GPM

Pr essure- PSI

Hydraulic Resistance CFC 1500

Metric

100

120

140

0 2 5 1015202530354045505560

F low m3/h

Pressure mbar

Figure 2-22 Pressure Drop Curve, CFC 1500, U.S. Flow Rates

2-24 Part No. 750-263

Figure 2-23 Pressure Drop Curve, CFC 1500, Metric Flow Rates

Section 2 — Installation

Hydraulic Resistance CFC 1800

U.S. Standards

0.2

0.4

0.6

0.8

1.2

1.4

1.6

1.8

8.8

110

132

154

176

198

220

242

264

286

308

330

352

Flow - GPM

Pressure - P SI

Hyd raulic Resistance CFC 1800

Metric

100

120

0 2 5 101520253035404550556065707580

F low m3/h

Pressure mbar

Figure 2-24 Pressure Drop Curve, CFC 1800, U.S. Flow Rates

Part No. 750-263 2-25

Figure 2-25 Pressure Drop Curve, CFC 1800, Metric Flow Rates

Section 2 — Installation

Hydraulic Resistance CFC 2500

U.S. Standards

0.2

0.4

0.6

0.8

1.2

1.4

1.6

1.8

0 44 66 88 118 132 154 176 198 220 242 264 286 308 330 352 375 395 420 474

Flow - GPM

Pressure - PSI

10 20 30 40 50 60 70 80 90 100 110 120

500954833241916121110.59 8 7

750

1316644332622191615131211

1000

1768859443529252220181615

1500

260 130 87 65 52 43 37 33 29 26 24 23

1800

351176117887059504439353230

2500 470 235 157 118 95 79 67 59 52 48 43 39

Recommended flow rates relative to temperature drop so as not to exceed boiler output.

Flow Rate GPM

System Temperature Drop

Boiler

Size

Figure 2-26 Pressure Drop Curve, CFC 2500, U.S. Flow Rates

Table 2-13: Maximum flow rate through ClearFire boilers (U.S. flow rates)

2-26 Part No. 750-263

Table 2-14: Maximum flow rate through ClearFire boilers (metric flow rates)

Notice

5 1117222733384550556164

500 21.6 10.9 7.5 5.4 4.3 3.6 2.7 2.5 2.3 2 1.8 1.6

750 29.75 15 10 7.5 6 5 4.3 3.6 3.4 2.9 2.7 2.5

1000 40 20 14 10 8 7 6 5 4.5 4 3.6 3.4

15005929.5201512108.47.56.665.45.2

180080402720161311.310 9 87.36.8

2500 106.7 53.4 36.7 26.8 21.6 17.9 15.2 13.4 11.8 10.9 9.8 8.8

Recommended flow rates relative to temperature drop so as not to exceed boiler output.

System Temperature Drop

Flow Rate m

/hr.

Boiler

Size

6”

Return Water In

Stack

Clearfire Base

G.CONDENSATE REMOVAL AND TREATMENT

The condensate generated during normal boiler operation must be removed in accordance with local codes and regulations. The condensate can be piped to a local treatment system or run into the optional condensate treatment assembly. Regardless of the method used, a trap (Fig ure 2- 27) must be installed on the condensate outlet to prevent discharge of the flue gases from the boiler.

Section 2 — Installation

H.CONDENSATE TANK INSTALLATION

A boiler condensate collection tank or gravity drain is required. The condensation piping must incorporate a water trap approved by the local authorities. The water trap must be filled with water prior to commissioning and checked or refilled at each required maintenance interval. The water trap is required to prevent discharge of flue gases into the boiler room.

The condensate occurring during operation in both the boiler and the flue gas pipeline has to be neutralized and piped to a safe drain. The conditions for the discharge of condensates into public drain systems are determined by the local authorities and municipalities.

The responsible authority will inform you of any requirements for raising the pH value from 4.3 to the frequently prescribed higher value. The CFC neutralization system contains the granulate NEUTRALAT which comprises natural components and brings about an increase in pH of the condensate flowing through it. The neutralization system comprises the plastic neutralization tank with condensate inlet, a base screen plate, filter mat, granulate chamber and condensate outlet (see Figure 2-28). The system is installed in the CFC lower collection area.

Figure 2-27 Flue Gas Trap 6 inch

Minimum Water Column

Figure 2-28 Condensate Tank,

Base Screen and Filter Mat

Part No. 750-263 2-27

Section 2 — Installation

1. Removable front

2. Min. 6” water trap

1. Removable Front Panel

2. 6” Water Trap

3. Neutralization Material

4. Plastic Drain Pipe

5. Neutralized Condensate reservoir

Figure 2-29 Condensate Piped

Direct to Drain

1. Condensate Tank Setup Options

The boiler is supplied with boiler legs (standard) which are sized to permit the installation of the condensate collection tank. There are two (2) condensate tank styles available:

(1) The condensate is piped directly to a drain through the piping and water trap supplied during installation (see Figure 2-29).

(2) The condensate is held in a condensate tank under the boiler. The condensate is neutralized as it passed through the granular bed. The neutralized condensate is then piped to the drain (see

Figure 2-30).

Condensate Take-off and Neutralization

To ensure compliance with regulations, it is important to contact the responsible authorities prior to the planning and execution of the boiler installation. Condensate flow of 5 to 12 GPH can be expected depending on boiler size and return water temperature.

Figure 2-30 Condensate Tank with neutralization material.

Figure 2-31 Condensate

Discharge Piping

3. Condensate discharge into local drain

For discharge into a local drain a water trap must be installed per Figure 2-31.

1. Piping is to be a minimum of 3/4” NPT.

2. Maximum discharge pipe height from floor to be 9”.

3. Condensate water trap (6”) required.

4. Piping treated condensate to drain

Figure 2-32 shows the gravity flow condensate treatment assembly.

• Item (1) is the bottom side casing of the boiler.

• Item (2) is the water trap 6” minimum.

• Item (3) is the condensate tank assembly

• Item (4) is the condensate drain line.

• Item (5) is the condensate reservoir tank.

2-28 Part No. 750-263

• Item (6) is the piping from trap to the treatment tank.

Figure 2-32 Condensate Treatment Assembly

Treated Condensate Reservoir

Filter Mat

Condensate Base and Screen

Granulate Bag (6.5Lbs.)

5. Installation

1. To install the system, assemble the tank, base screen, filter and neutralization granulate per the diagram Figure 2-33.

2. The granulate treatment media is supplied in 6.5 pound bags (see Table 2-15). Pour the granulate into the bottom of the tank, covering the filter mat.

3. Install piping as shown. Install the condensate tank cover and slide the complete assembly under the boiler

Pipe to the appropriate drain.

Section 2 — Installation

Figure 2-33 Condensate

Table 2-15: Neutralization Granulate

Model No. of Bags (single boiler Multiple boilers

CFC 500, 750, 1000 3 Add 1 bag per boiler

CFC 1500, 1800 4 Add 2 bags per boiler

CFC 2500 5 Add 2 bags per boiler

Part No. 750-263 2-29

Treatment Tank

Section 2 — Installation

To Drain

Slope Towards Neutralization Tank

1/4" ODC Make-up Water Supply

Condensate Drain Trap

Neutralization Tank

To Drain

Condensate Drain Trap

Slope Towards Neutralization Tank

1" NPT. Minimum Header Size (Use PVC Pipe or other Nonferrous Material)

Model CFC Boiler

Neutralization Tank

12" Minimum

I. CONDENSATE PIPING FOR MULTIPLE BOILERS

More than one Model CFC boiler can be piped into a common condensate neutralization tank. See Figure 2-34 and Figure 2-35 for the suggested layout. A condensate trap with a minimum 6 inch water column must be provided to prevent the flue gas from entering the boiler room. Make-up water must be supplied at the connection shown in order to prevent flue gas from entering an idle boiler. An optional condensate drain trap is available from CB.

Figure 2-34 Condensate Piping for Multiple Boilers

Figure 2-35 Condensate Treatment Tank for Multiple Boilers

2-30 Part No. 750-263

J. ELECTRICAL CONNECTIONS

Warning

A qualified electrician or service technician must make the electrical connections to the boiler.

For typical CFC electrical component mounting see the electrical diagram mounted on the inside of the removable front panel.

For specific information on your boiler electrical system refer to the Cleaver-Brooks wiring diagram provided with the boiler.

Power is to be run from the rear of the boiler through either the left or right electrical supply channels (see Figure 2-36) to the control panel. AC power is to be connected to the incoming power terminals.

1. Power wiring - right side electrical supply channel.

2. Cu stomer connections should be brought in on the right side refer to wiring diagram.

3. Temperature sensor wiring - left side electrical supply channel.

Note: The following temperature sensor cables should be run

through the left side wiring channel.

• Hot water outlet temperature sensor.

Section 2 — Installation

• Hot water return temperature sensor.

• Stack temperature sensor (optional).

• Outdoor temperature sensor (optional).

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

Ensure ignition cables are properly connected and not in direct contact with any sharp metal edges.

For electrical connections see Figure 2-36.

Part No. 750-263 2-31

Section 2 — Installation

Figure 2-36 Electrical Connection Diagram

2-32 Part No. 750-263

K.WIRING DIAGRAMS

Section 2 — Installation

Figure 2-37 Wiring Diagram (base configuration)

Part No. 750-263 2-33

Section 2 — Installation

Figure 2-38 Wiring Diagram (with available options)

2-34 Part No. 750-263

Chapter 3

Stack and Intake Vent Sizing and Installation

Venting Connections - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Appliance Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Vent Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Vent Terminal Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Horizontal Thru-Wall Venting / Inside Combustion Air . . . . . . . . . . . . . 3-6

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Horizontal Thru-Wall Stack Vent Termination . . . . . . . . . . . . . . . . . 3-7

Horizontal Thru-Wall Venting / Direct Vent Combustion Air . . . . . . . . . . 3-8

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Horizontal Thru-Wall Stack Vent Termination . . . . . . . . . . . . . . . . . 3-9

Vertical Venting / Inside Combustion Air . . . . . . . . . . . . . . . . . . . . . . 3-10

Vertical Venting / Direct Vent Combustion Air . . . . . . . . . . . . . . . . . . 3-11

Milwaukee, Wisconsin

www.cleaver-brooks.com

Chapter 3 — Stack and Intake Vent Sizing and Installation

Notice

Warning

A.VENTING CONNECTIONS - GENERAL

1. Appliance Categories

Proper installation of flue gas exhaust venting is critical for the efficient and safe operation of the CFC 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.

For additional information on boiler categorization, see appropriate ANSI Z21 Standard and the latest edition Standard of National Fuel Gas Code or in Canada, the latest edition of CSA Standard B149 Installation Code for Gas Burning Appliances and Equipment, or applicable provisions of local building codes.

• 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 CFC boiler is rated as a Categor y IV boil er according to ANSI Z21.13. Depending on the application, the specifying engineer may dictate alternative category flue venting as deemed appropriate.

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 or IV vent system. Using improper venting materials can result in personal injury, death or property damage.

During winter months check the vent cap and make sure no blockage occurs from build up of snow. Condensate can freeze on the vent cap. Frozen condensate on the vent cap can result in a blocked flue condition.

2. Vent Stack

The vent should be supported to maintain proper clearances from combustible materials.

Use insulated vent pipe spacers where the vent passes through combustible roofs and walls.

3-2 Part No. 750-263

Chapter 3 — Stack and Intake Vent Sizing and Installation

18" Minimum

24" Minimum

Air Intake (w/Screen)

Flue Gas Vent (w/Screen)

3. Vent Terminal Location

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

Figure 3-1 Horizontal flue thru-wall stack and intake

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. 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 Categor y 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.

Part No. 750-263 3-3

Chapter 3 — Stack and Intake Vent Sizing and Installation

18" Minimum

24" Minimum

Flue Gas Vent (w/Screen)

Air Intake (w/Screen)

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. DO NOT extend exposed stack pipe outside of building. In winter conditions condensate could freeze and block stack pipe.

11. Multiple direct stack installations require a four (4) foot clearance between the stack caps, center to center.

Figure 3-2 Horizontal flue thru-wall stack and intake

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.

3-4 Part No. 750-263

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.

Chapter 3 — Stack and Intake Vent Sizing and Installation

Warning

Caution

Canada Installations- Refer to the latest edition of CAN/CSA-

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:

• The verandah, porch or deck is fully open on a minimum of two sides beneath the floor.

• 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.

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

Venting Installation Tips

Support piping:

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

• Vertical runs - use braces:

• Under or near elbows

Follow items listed below to avoid personal injury or property damage.

• Cut nonmetallic vent pipe with 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.

Part No. 750-263 3-5

Chapter 3 — Stack and Intake Vent Sizing and Installation

Warning

24" Minimum

Flue Gas Vent

Inside Air Combustion

Intake

(w/Screen)

B.HORIZONTAL THRU-WALL VENTING / INSIDE

COMBUSTION AIR

1. Installation

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/CSA-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 th rough 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/CSA-B 149.1 and

Figure 3-3 Horizontal Venting

Thru-Wall Using Inside Air For

Combustion

.2 Installation Code for Gas Burning Appliances and Equipment. The direct vent cap is not considered in the overall length of the

venting system. The vent must be installed to prevent flue gas leakage. Care must

be taken during assembly to insure that all joints are sealed properly and are airtight.

(CATEGORY III & IV)

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

1. The vent be installed with a slight downward slope of not more than 1/4" per foot of horizontal run to the vent terminal.

2. The vent be insulated through the length of the horizontal run.

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

1. The vent be installed with a slight upward slope of not more than 1/4" per foot of horizontal run to the vent terminal. In this case, an approved condensate trap must be installed per applicable codes.

2. The vent be insulated through the length of the horizontal run.

2. Horizontal Thru-Wall Stack Vent Termination

The stack vent cap MUST be mounted on the exterior of the building. The stack vent cap cannot be installed in a well or below grade. The stack vent cap must be installed at least one (l) foot above ground level and above normal snow levels.

No substitutions of flue pipe or vent cap material are allowed. Such substitutions would jeopardize the safety and health of inhabitants.

The stainless steel direct vent cap must be furnished in accordance with AGA/ CSA requirements.

3-6 Part No. 750-263

Chapter 3 — Stack and Intake Vent Sizing and Installation

18" Minimum

24" Minimum

Air Intake (w/Screen )

Flue Gas Vent (w/Screen)

C.HORIZONTAL THRU-WALL VENTING / DIRECT

VENT COMBUSTION AIR

(CATEGORY III & IV)

Figure 3-4 Horizontal Thru-wall Direct Venting System Category III Installation

(Direct Vent Combustion Air/Stack Venting)

1. Installation

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

The sealed combustion air vent cap is not considered in the overall length 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 stack piping system.

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

1. The vent be installed with a slight downward slope of not more than 1/4" per foot of horizontal run to the stack terminal.

2. The stack vent is to be insulated through the length of the horizontal run.

Part No. 750-263 3-7

Chapter 3 — Stack and Intake Vent Sizing and Installation

Notice

Warning

Notice

Caution

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

1. The stack vent be installed with a slight upward slope of not more than 1/4" per foot of horizontal run to the vent terminal. In this case, an approved condensate trap must be installed per applicable codes.

2. The stack vent is to be insulated through the length of the horizontal run.

2. Horizontal Thru-Wall Stack Vent Termination

The stack vent cap MUST be mounted on the exterior of the building. The stack vent cap cannot be installed in a well or below grade. The stack vent cap must be installed at least one (I) foot above ground level and above normal snow levels.

Multiple stack vent caps should be installed in the same horizontal plane with a three (3) foot clearance from the side of one stack cap to the side of the adjacent stack vent cap(s).

Multiple direct stack vent caps MUST NOT be installed with one combustion air inlet directly above a stack vent cap. This vertical spacing would allow the flue products from the stack vent cap 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.

If the boiler is vented directly out through the sidewall with no elbows and less than 6 feet of vent pipe, a restricted direct vent cap should be utilized.

Combustion air supplied from outside must be free of particulate and chemical contaminants. T o avoid a blocked flue condition, keep all the vent caps clear of snow, ice, leaves, debris, etc.

No substitutions of flue pipe or vent cap material are allowed. Such substitutions would jeopardize the safety and health of inhabitants.

The Stainless Steel direct vent cap must be furnished in accordance with AGA/CSA requirements.

3-8 Part No. 750-263

Chapter 3 — Stack and Intake Vent Sizing and Installation

CFC Boiler

Flue Gas Vent (w/Screen)

24"

Minimum

10'-0" or Less

24"

Minimum

D.V ERTICAL VENTING / INSIDE COMBUSTION AIR

(CATEGORY III & IV) CENTRAL HEATING

Figure 3-5 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/CSA-B 149.1 and .2 Installation Code for Gas Burning Appliances and Equipment.

UL 17-38 Certified Venting Material (e.g. AL29-4C) MUST be used. The vent must be installed to prevent flue gas leakage. Care must

Part No. 750-263 3-9

Chapter 3 — Stack and Intake Vent Sizing and Installation

Warning

Boiler

Flue Gas Vent (w/Screen)

Air Intake (w/Screen)

36" Minimum

24"

Minimum

12"

Minimum

be taken during assembly to insure that all joints are sealed properly and are airtight.

For certain installations PVC or CPVC may be used. Contact your authorized Cleaver-Brooks representative for details.

To prevent the condensation accumulation in the vent, it is required to install the horizontal portion of vent with a slight upward slope of not more than 1/4" per foot of horizontal run and an approved condensate trap must be installed per applicable codes.

No substitutions of flue pipe or vent cap material are allowed. Such substitutions would jeopardize the safety and health of inhabitants.

The Stainless Steel non-restricted direct vent cap must be furnished in accordance with AGA/CSA requirements.

E. VERTICAL VENTING / DIRECT VENT

(CATEGORY III & IV)

COMBUSTION AIR

Figure 3-6 Vertical Stack with Direct Vent Combustion Air

3-10 Part No. 750-263

Chapter 3 — Stack and Intake Vent Sizing and Installation

Warning

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

UL 17-38 Certified Venting Material (e.g. AL29-4C) MUST be used. The vent must be installed to prevent flue gas leakage. Care must be taken during assembly to insure that all joints are sealed properly and are airtight.

For certain installations PVC or CPVC may be used. Contact the authorized Cleaver-Brooks representative for details.

To prevent condensation accumulation in the vent, it is required to install the horizontal portion of vent with a slight upward slope of not more than 1/4" per foot of horizontal run and an approved condensate trap must be installed per applicable codes.

No substitutions of flue pipe or vent cap material are allowed. Such substitutions would jeopardize the safety and health of inhabitants.

The stainless steel non-restricted direct vent cap must be furnished in accordance with AGA/CSA requirements.

Part No. 750-263 3-11

Chapter 3 — Stack and Intake Vent Sizing and Installation

6" Standard 6" 80

4" Option 4" 40

CFC 750 6" Standard 6" 80

8" Standard 8" 140

6" Option 6" 80

10" Option 10" 220

10" Standard 10" 140

8" Option 8" 90

12" Option 12" 250

12" Standard 12" 60

10" Option 10" 40

CFC 2500 12" Standard 12" 110

* Each additional 90 elbow equals 5 equivalent feet of ductwork. Subtract from the maximum or minimum length accordingly.

Maximum allowable pressure drop in flue vent ducting is 0.25" w.c.

Boiler Stack

Connection

Stack/Vent

Size

Maximum length of breeching or

stack [feet]*

Boiler Size

CFC 500

CFC 1000

CFC 1500

CFC 1800

F. STAC K SIZ ING

1. Stack design using room air for combustion

3-12 Part No. 750-263

Chapter 3 — Stack and Intake Vent Sizing and Installation

6" Standard 4" 6" 75 75

4" Option 4" 4" 40 40

CFC750 6" Standard 4" 6" 40 40

8" Standard 6" 8" 60 60

6" Option 6" 6" 40 40

10" Option 6" 10" 70 70

10" Standard 6" 10" 40 40

8" Option 6" 8" 30 30

12" Option 6" 12" 45 45

12" Standard 6" 12" 30 30

10" Option 6" 10" 25 25

CFC 2500 12" Standard 8" 12" 100 100

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

CFC1500

CFC1800

Maximum allowable pressure drop in combustion air intake duct is - 0.25" w.c.

Boiler

CFC 500

CFC1000

Flue Gas Vent in

Feet*

Maximum length of

Air Intake Duct in

Feet**

Boiler Stack

Connection

Boiler Air

Intake Duct &

Connection

Boiler

Vent/Stack

Size

2. Stack design using direct vent combustion

Maximum length of

Part No. 750-263 3-13

Chapter 4

CFC Commissioning

Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Filling Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Control Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Model CFC Boiler / Burner Controller . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

CB Falcon Display/Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Home Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Status Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Operation Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Lockouts and Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Controller Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Changing Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Burner Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Fan Speed Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Initial start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Gas Train and Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Operation Check: Gas Valve, Gas Press. Switches, and CAPS . . . . . . 4-14

LOW WATER CUTOFF Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Low and High Fire Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Modulation OFF point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Setting Combustion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

High Air Pressure Switch settings . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Limit Controls Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Post start-up checkout procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Warning

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

Milwaukee, Wisc onsin

www.cleaver-brooks.com

Chapter 4 — CFC Commissioning

A.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 highvoltage ignition transformers

• Control panel must be connected to earth ground.

Boiler room ambient conditions

Relative humidity < 85% non-condensing

Ambient temperature range 0 Storage temperature range -40

C to 50 oC / 32oF to 122oF

C to 60 oC / -40oF to 140oF

B.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 emerges. Check to ensure that no leaks appear at any pipe connections and correct if water leaks are noticed.

Figure 4-1 Opening Control

Panel

C.CONTROL SETPOINTS

Preliminary settings of the burner/boiler safety controls are necessary for the initial star ting of the boiler. Af ter 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.

4. High Air Pressure Switch - Set the dial @ maximum.

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

D.MODEL CFC BOILER / BURNER CONTROLLER

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

• Flame supervision

• Heating/modulation control

• Hot water system pump control

• High Limit temperature control

Additional features include:

• User-friendly touchscreen interface

Figure 4-2 CB Falcon Controller

4-2 Part No. 750-263

• Modbus communication capability

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

• Expanded Annunciation option

Warning

• Outdoor reset

• Central Heating and Domestic Hot Water loop control

• Password protection of configurable parameters

• Time of Day (dual setpoint) control

• High Stack Temperature limit

• Remote reset

• Lead/Lag sequencing (future)

• (3) configurable pump relays

• Remote modulation/remote setpoint (future)

• Frost protection Please review the tables within this Commissioning section to

familiarize yourself with the functions and parameters of the Controller.

Chapter 4 — CFC Commissioning

The Model CFC is factory tested. Never theless, 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.

E. CB FALCON DISPLAY/OPERATOR INTERFACE

The CB Falcon disp lay/operator interface is mounted at the left side of the control panel for convenient access to all operating controls. A thermowell-mounted NTC temperature sensor provides the measured process variable signal to the controller.

1. Home Page

Turn on the control panel BOILER switch to apply power to the boiler. The Home page will appear on the CB Falcon display.

Each CB Falcon in the hydronic system is represented on the Ho me page by an icon and name.

2. Status Page

Pressing the Falcon icon 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.

Figure 4-3 Controller status

LEDs and reset button

Figure 4-4 CB Falcon Display/

Operator Interface

Part No. 750-263 4-3

Chapter 4 — CFC Commissioning

Home page

Status page

HOME

PAGE

CONFIGURATION

SAFETY

VERIFICATION

CONFIGURATION

GROUP

CONFIGURATION

GROUP

CONFIGURATION

GROUP

STATUS

SUMMARY

PASSWORD

DIAGNOSTICS

STATUS

DETAIL

OPERATION

3. Operation Page

The operation page displays the CB Falcon running operation, including setpoint and firing rate values. From this page the user can change setpoints, manually control the boiler’s firing rate, manually turn pumps on, view annunciation information, and switch between heating loops (Central Heat and Domestic Hot Water). 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.

Figure 4-5 Operation Page

Falcon Display/Interface page flow

4-4 Part No. 750-263

4. Lockouts and Alerts

The CB Falcon implements two kinds of faults: lockouts and alerts. Lists of fault codes and alerts can be found in Appendix A, CB

Falcon Hydronic 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.

ALERT

• Every other kind of problem that isn't a lockout is an alert. Examples include boiler control abnormal conditions, LL master problems, faults from non-safety functions, etc.

• Alerts never require manual intervention to reset them; that is, if the alert clears up, then normal operation will continue.

Chapter 4 — CFC Commissioning

• 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.

F. CONTROLLER CONFIGURATION

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

CB Falcon configuration is grouped into the following functional groups:

• System Identification & Access

• CH - Central Heat ConfigurCation

• Outdoor Reset Configuration

• DHW - Domestic Hot Water Configuration

• Modulation Configuration

• Pump Configuration

• Statistics Configuration

•High Limits

• Stack Limit

• Other Limits

• Anti-condensation Configuration

• Frost Protection Configuration

• Annunciation Configuration

• Burner Control Interlocks

• Burner Control Timings & Rates

• Burner Control Ignition

• Burner Control Flame Failure

• System Configuration

• Fan Configuration

• Lead Lag Configuration

Part No. 750-263 4-5

Chapter 4 — CFC Commissioning

Table 4-1 CB Falcon factory parameter settings - Model CFC

Min.

Parameter Group Parameter Name Access

System ID & Access Boiler Name Service Boiler 1 System ID & Access Installation data Service CFC System ID & Access Installer password Service 9220 System ID & Access OEM Identification Read Only MB00xxxx System ID & Access Modbus address Service 0 2 250 System ID & Access Factory data Read Only CFC

Statistics Configuration Burner cycle count Read Only 0 999,999 Statistics Configuration Burner run time Read Only 0 999,999 Statistics Configuration CH pump cycle count Read Only 0 999,999 Statistics Configuration DHW pump cycle count Read Only 0 999,999 Statistics Configuration System pump cycle count Read Only 0 999,999 Statistics Configuration Boiler pump cycle count Read Only 0 999,999 Statistics Configuration Auxiliary pump cycle count Read Only 0 999,999

System Configuration Temperature units Service Fahrenheit System Configuration Antishort cycle time Service 0 60 28800 seconds System Configuration Alarm silence time Service 0 0 3600 seconds System Configuration Modulation Output Read Only VSD Fan PWM

Range Default Setting Max. Range

Parameter

Units

Installation

Setting

Modulation Configuration CH max. mod. rate Service 2000 See Table 4-2 6000 RPM Modulation Configuration DHW max. mod. rate Service 2000 See Table 4-2 6000 RPM Modulation Configuration Minimum mod. rate Service 900 See Table 4-2 3000 RPM Modulation Configuration CH forced rate Service 1000 2000 6500 RPM Modulation Configuration CH forced rate time Service 0 0 14400 seconds Modulation Configuration DHW forced rate Service 1000 2000 6500 RPM Modulation Configuration DHW forced rate time Service 0 0 14400 seconds Modulation Configuration Analog output hysteresis Service 0 5 20 Modulation Configuration CH slow start enable Service Disabled Modulation Configuration DHW slow start enable Service Disabled Modulation Configuration Slow start ramp Service 100 200 1000 RPM Modulation Configuration Slow start setpoint Service 0 20 180 Modulation Configuration Burner switch User Off Modulation Configuration Firing rate control User Auto Modulation Configuration Manual firing rate User 900 2000 6500 RPM

Fan Configuration Absolute max. fan speed Read Only 6000 RPM Fan Configuration Absolute min. fan speed Read Only 900 RPM Fan Configuration PWM frequency Read Only 3000 Hz Fan Configuration Pulses per revolution Read Only 3 Fan Configuration Fan speed up ramp Service 0 0 1000 RPM/sec Fan Configuration Fan speed down ramp Service 0 0 1000 RPM/sec Fan Configuration Fan gain up Service 0 30 100 Fan Configuration Fan gain down Service 0 30 100 Fan Configuration Fan min. duty cycle Service 5 10 100 %

4-6 Part No. 750-263

Chapter 4 — CFC Commissioning

Min.

Parameter Group Parameter Name Access

Burner Control Ignition Preignition time Service 0 0 900 seconds Burner Control Ignition Lightoff rate Service 1000 See Table 4-2 3000 RPM Burner Control Ignition Flame threshold Read Only 0.5 0.8 5 V or A

Burner Control Flame Failure Ignite failure response Service Lockout Burner Control Flame Failure Ignite failure retries Service 0 Burner Control Flame Failure Ignite failure delay Read Only 0 seconds Burner Control Flame Failure Run flame failure response Read Only Lockout

Burner Control Interlocks Purge rate proving Read Only Fan speed Burner Control Interlocks Lightoff rate proving Read Only Fan speed Burner Control Interlocks Interlock open response Read Only Lockout

Burner Control Interlocks Burner Control Interlocks IAS start check enable Read Only Disabled Burner Control Interlocks LCI enable Read Only Enabled Burner Control Interlocks PII enable Service Disabled

Burner Control Timings & Rates

Interrupted air switch (IAS) enable

Prepurge rate Read Only 3000 4000 6500 RPM

Postpurge rate Service 1000 2000 6500 RPM

Prepurge time Service 15 15 900 seconds

Run stabilization time Service 0 5 900 seconds

Postpurge time Service 15 15 900 seconds

Read Only

Range Default Setting Max. Range

Enable during

purge & ignition

Parameter

Units

Installation

Setting

High Limits Outlet high limit setpoint Service 32 180 210 °F High Limits Outlet high limit response Read Only Lockout High Limits DHW high limit enable Service Disabled High Limits DHW high limit setpoint Service 32 150 210 °F High Limits DHW high limit response Service Recycle & hold

Stack Limit Stack limit enable Service Disabled Stack Limit Stack limit setpoint Service 32 250 266 °F Stack Limit Stack limit response Service Lockout Stack Limit Stack limit delay Service 0 300 900 seconds

Other Limits Delta-T enable Service Disabled Other Limits Delta-T degrees Service 14 80 160 °F Other Limits Delta-T response Service Other Limits Delta-T delay Service 0 300 3600 seconds

Annunciation Configuration Annunciation enable Service Enabled Annunciation Configuration Annunciator 1 location Service Other Annunciation Configuration Annunciator 1 short name Service A1 Annunciation Configuration Annunciator 1 long name Service AIR SWITCH Annunciation Configuration Annunciator 2 location Service LCI

Part No. 750-263 4-7

Chapter 4 — CFC Commissioning

Min.

Parameter Group Parameter Name Access

Annunciation Configuration Annunciator 2 short name Service A2 Annunciation Configuration Annunciator 2 long name Service LOW WATER Annunciation Configuration Annunciator 3 location Service Unused Annunciation Configuration Annunciator 3 short name Service A3

Annunciation Configuration Annunciator 3 long name Service Annunciation Configuration Annunciator 4 location Service ILK Annunciation Configuration Annunciator 4 short name Service A4

Annunciation Configuration Annunciator 4 long name Service Annunciation Configuration Annunciator 5 location Service ILK Annunciation Configuration Annunciator 5 short name Service A5

Annunciation Configuration Annunciator 5 long name Service Annunciation Configuration Annunciator 6 location Service ILK Annunciation Configuration Annunciator 6 short name Service A6

Annunciation Configuration Annunciator 6 long name Service Annunciation Configuration Annunciator 7 location Service Unused Annunciation Configuration Annunciator 7 short name Service A7 Annunciation Configuration Annunciator 7 long name Service Annunciator7 Annunciation Configuration Annunciator 8 location Service Unused Annunciation Configuration Annunciator 8 short name Service A8 Annunciation Configuration Annunciator 8 long name Service Annunciator8 Annunciation Configuration PII short name Service PII Annunciation Configuration PII long name Service Pre-Ignition ILK Annunciation Configuration LCI short name Service LCI

Annunciation Configuration LCI long name Service Annunciation Configuration ILK short name Service ILK Annunciation Configuration ILK long name Service Interlock

Range Default Setting Max. Range

AUXILIARY LOW

WATER

HIGH AIR

PRESSURE

HIGH GAS

PRESSURE

LOW GAS

PRESSURE

Load Control

Input

Parameter

Units

Installation

Setting

Central Heat Configuration CH enable User Enabled

Central Heat Configuration CH demand source Service Central Heat Configuration CH sensor Service Outlet sensor Central Heat Configuration CH setpoint User 32 150 194 °F Central Heat Configuration CH TOD setpoint Service 32 120 194 °F Central Heat Configuration CH on hysteresis Service 2 5 60 °F Central Heat Configuration CH off hysteresis Service 2 15 60 °F Central Heat Configuration CH outdoor reset enable Service Disabled Central Heat Configuration CH P gain Service 0 50 400 Central Heat Configuration CH I gain Service 0 50 400 Central Heat Configuration CH D gain Service 0 0 400 Central Heat Configuration CH hysteresis step time Service 0 60 900 seconds

CH ODR max. outdoor

Outdoor Reset Configuration

temperature Service -40 80 140 °F CH ODR min. outdoor

temperature Service -40 0 140 °F CH ODR min. water

temperature Service 32 50 180 °F

Sensor & Stat

terminal

4-8 Part No. 750-263

Chapter 4 — CFC Commissioning

Min.

Parameter Group Parameter Name Access

Domestic HW Configuration DHW enable User Disabled

Domestic HW Configuration DHW demand source Service

Domestic HW Configuration

Domestic HW Configuration Domestic HW Configuration DHW priority time Service 0 1800 14400 seconds Domestic HW Configuration DHW setpoint User 32 140 180 °F Domestic HW Configuration DHW TOD setpoint Service 32 120 180 °F Domestic HW Configuration DHW on hysteresis Service 2 5 80 °F Domestic HW Configuration DHW off hysteresis Service 2 15 80 °F Domestic HW Configuration DHW P gain Service 0 50 400 Domestic HW Configuration DHW I gain Service 0 50 400 Domestic HW Configuration DHW D gain Service 0 0 400 Domestic HW Configuration DHW hysteresis step time Service 0 60 900 seconds Pump Configuration CH pump output Service Pump C Pump Configuration CH pump control Service Auto Pump Configuration CH pump overrun time Service 0 60 28800 seconds

Pump Configuration Pump Configuration DHW pump output Service No assignment Pump Configuration DHW pump control Service Auto Pump Configuration DHW pump overrun time Service 0 60 28800 seconds

Pump Configuration Pump Configuration Boiler pump output Service No assignment Pump Configuration Boiler pump control Service Auto Pump Configuration Boiler pump overrun time Service 0 60 28800 seconds Pump Configuration Auxiliary pump output Service Pump A Pump Configuration Auxiliary pump control Service Auto Pump Configuration Auxiliary pump on when Service CH pump on Pump Configuration System pump output Service Pump B Pump Configuration System pump control Service Auto Pump Configuration System pump overrun time Service 0 60 28800 seconds Pump Configuration Pump exercise interval Service 0 0 28800 seconds Pump Configuration Pump exercise time Service 0 0 28800 seconds

DHW priority has priority over CH Service Yes

DHW priority has priority over LL Service No

CH pump frost protection overrun time Service 0 3600 28800 seconds

DHW pump frost protection overrun time Service 0 3600 28800 seconds

Range Default Setting Max. Range

Outlet sensor &

DHW switch

Parameter

Units

Installation

Setting

Frost Protection Configuration CH frost protection enable Service Disabled Frost Protection Configuration DHW frost protection enable Service Disabled

Frost Protection Configuration

Anti-condensation Configuration CH anti-condensation enable Service Disabled

Anti-condensation Configuration

Outdoor frost protection setpoint Service -40 32 120 °F

CH anti-condensation setpoint Service 32 140 194 °F

CH anti-condensation pump force off Service Disabled

DHW anti-condensation enable Service Disabled

Part No. 750-263 4-9

Chapter 4 — CFC Commissioning

Min.

Parameter Group Parameter Name Access

Anti-condensation Configuration

Anti-condensation Configuration Anti-condensation > Delta-T Service No

Anti-condensation Configuration

Lead Lag Configuration Lead Lag slave enable Service Disabled Lead Lag Configuration Fan rate during off cycle Service 900 1500 6500 RPM

** Shaded parameters are Safety Parameters and require Verification and manual reset of the control prior to operation. Please refer to Section A, "Changing parameter settings".

DHW anti-condensation setpoint Service 32 140 194 °F

DHW anti-condensation pump force off Service Disabled

Anti-condensation > Outlet limit Service No

Anti-condensation > Stack limit Service No

Anti-condensation > Slow start Service Yes

Anti-condensation > Forced rate S ervice Yes

Range Default Setting Max. Range

Parameter

Units

Installation

Setting

*Access Levels:

Read Only = parameter not user-configurable Service = password required (9220) User = no password required

4-10 Part No. 750-263

1. Changing Parameter Settings

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

Some parameters require a password entry before allowing changes. The <Login> button will appear when any passwordprotected 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).

Chapter 4 — CFC Commissioning

Figure 4-6 Configuration Menu

Figure 4-7 Parameter change dialog

Safety Parameters

For safety configuration 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.

Part No. 750-263 4-11

Chapter 4 — CFC Commissioning

1. Press <Begin>

2. Press <Yes>

3. Reset CB Falcon

Confirming Safety Parameter changes

G.BURNER SEQUENCE

4-12 Part No. 750-263

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

The CFC boiler uses direct spark ignition (no gas pilot) to light the main flame. Flame sensing is accomplished with a flame rod, or ionization electrode.

Basic burner sequencing (Central Heat):

1. Heat request detected (Setpoint minus On Hysteresis); LCI demand detected (terminal J6 3).

2. The CH pump is switched on.

3. After a system Safe Start Check, the Bl ower (f an ) i s sw it c h ed on a fter a dynamic ILK switch test (if enabled).

4. After the ILK input is energized, 10 sec. allowed for IAS input (combustion air proving) to energize, and purge rate proving fan RPM is achieved - prepurge time is started.

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

6. As soon as the fan-rpm is equal to the light-off RPM , the Trial for Ignition (4 sec.) or Pre-Ignition Time is started (depending on configuration).

7. Pre-Ignition Time will energize the ignitor and check for flame.

Warning

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

8. Trial for Ignition.

9. The ignition and the gas valve are switched on.

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

11.The fan is kept at the lightoff rate during the stabilization timer, if any.

12.Before the release to modulation, the fan is switched to minimum RPM for the CH Forced Rate and Slow Start Enable, if the water is colder than the threshold.

13.Release to modulation.

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

15.A new CH-request is blocked for the forced off time set by the Anti Short Cycle (if enabled).

16.The pump stays on during the pump overrun time (if enabled).

17.At the end of the pump overrun time the pump will be switched off.

H.FAN SPEED SETTINGS

Because the input is determined by the fan speed, fan speed settings may have to be modified for the particular application, for high altitudes, or when using direct vent combustion. Ta b le 4 - 2 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.

Chapter 4 — CFC Commissioning

Setting CFC-500 CFC-750 CFC-1000 CFC-1500 CFC-1800 CFC -2500 Max. Speed (RPM) CH 5500 Max. Speed (RPM) DHW 5500 5300 5300 5300 4600 5000 Min. Speed (RPM) 1300 1200 1100 1100 900 1100 Ignition Fan Speed (Lightoff Rate) 2200 2000 1800 1800 1500 1800

I. INITIAL START-UP PROCEDURE

1. Gas Train and Piping

The ClearFire burner is equipped with a combination servoregulated 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 accordingly brings

Part No. 750-263 4-13

Table 4-2 Fan Speed Settings

5300 5300 5300 4600 5000

Chapter 4 — CFC Commissioning

about a change in the gas flow proportional to the air pressure. 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 CFC gas train. Note: The maximum rated inlet pressure to the CFC gas train is 1/2 psig (14.0" WC). An upstream regulator and overpressure protection are required if 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.

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 Model CFC Gas

Pressure Requirements

Pressure Required at

Boiler Input

5001000

1500 10" w.c. 7" w.c. 1800 7" w.c. 5" w.c. 2500 9.5" w.c. 8" w.c.

gas train connection Low Fire High

Fire

7" w .c. 5" w.c.

Max. pressure

14” w .c.

Figure 4-8 Premix Burner Technology - Full Modulation

2. Power-Up

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

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

3. 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.

4-14 Part No. 750-263

• Before proceeding, review Section 4.3 - Control Setpoints for

CAPS low pressure connection

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 .

Chapter 4 — CFC Commissioning

Figure 4-9 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

1. Initiate burner sequence.

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

maximum setting.

3. The CB F alcon s hould lock out on a n airflow failure. The disp lay

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.

Part No. 750-263 4-15

Chapter 4 — CFC Commissioning

HGPS and GAS VALVE

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

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. A test of the flame rod circuit can also be performed at this time.

Disconnect the flame rod cable and attempt to start the burner. The CB Falcon should lock out, indicating Lockout 109 Ignition Failure.

Figure 4-10 Low Water Cutoff

test

8. Replace flame rod electrode and grounding tab.

After verifying proper operation of LGPS, HGPS, CAPS, and Gas Valve, re-open the downstream manual shut-off valve.

4. LOW WATER CUTOFF Check

1. Hold down the LOW WATER RESET-TEST switch for 3 seconds.

2. Check Annunciation screen. The LCI section (Limit Control Input

circuit) should show A2 Water level: OFF (Figure 4-8).

3. Press RESET-TEST switch once to reset.

5. Low and High Fire Adjustments

All CFC boilers are factory tested firing natural gas at an altitude of 1000 ft ASL. Operating under different conditions may require readjustment 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 4-11). The high fire adjustment screw is accessed by removing the blue plastic cap from the valve cover (see Figure 4-12).

T urn the adjustment screw completely clockwise, counting the turns

Figure 4-11 Regulating

Adjusting Screw - Low Fire

Offset

4-16 Part No. 750-263

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

Chapter 4 — CFC Commissioning

6. Modulation OFF point

Prior to setting combustion, the Modulation OFF point should be adjusted upward to avoid nuisance shutdowns while the burner is under manual control.

7. Setting Combustion

Note: A Combustion Analyzer is required to properly set-up the

Model CFC 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 two or more times to ensure a consistent air/fuel ratio.

Figure 4-12 Main Gas Choke -

High Fire Adjustment

Part No. 750-263 4-17

Chapter 4 — CFC Commissioning

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

2. A numeric keypad will appear, showing the current firing rate.

3. Press <Clear> to clear the current value.

4. Enter the desired RPM setting using the numeric keypad (refer to Table 4-2, Fan Speed Settings).

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

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

To set com busti on:

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 LOCAL/REMOTE switch to LOCAL.

4. Initiate burner firing sequence. The burner switch is accessed

via the CB Falcon Operation page (Figure 4-11). 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

Figure 4-13 Operation screen

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.

4-18 Part No. 750-263

6. Manually modulate the burner to high fire. Adjust the gas choke if necessary to obtain desired O2% (5% - 6%).

7. Modulate to low fire and fine tune offset screw to obtain desired O2% (5% - 6%).

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.

8. High Air Pressure Switch settings

The High Air Pressure witch (HAPS) is used to safely shut down the boiler in case of a blocked flue or blocked condensate condition.

The HAPS switch setting for each model CFC can be found below:

Table 4-4 HAPS Settings

Model Setting CFC-500 3.5” W.C. CFC-750 3.5” W.C. CFC-1000 3.5” W.C. CFC-1500 4.5” W.C. CFC-1800 4.5” W.C. CFC-2500 5.25” W.C.

Chapter 4 — CFC Commissioning

The HAPS has a manual reset, similar to the High/Low gas pressure switches.

Note: In the event of a HAPS lockout, investigate possible causes

before attempting to restart boiler.

9. Limit Controls Check

The Modulation Off (operating limit) and High Limit functions can be tested while the boiler is operating by adjusting the respective setting downward and allowing the boiler outlet temperature to rise. The Modulation Off point is the sum of the Modulating setpoint and the Hysteresis Off value. The Modulation On point is the setpoint minus the Hysteresis On value.

When the boiler’s outlet temperature exceeds either of these settings, the boiler will shut down. When the operating limit is exceeded, the boiler will automatically recycle upon the outlet temperature dropping below the on point. When the High Limit is exceeded, a lockout should result requiring a manual reset of the control after the temperature has dropped below the high limit setting.

Before testing the High Limit, temporarily set the Modulation OFF point higher than the High Limit setting.

Restore Modulation OFF and High Limit to operational settings after testing.

Specific settings are determined by application. Maximum High Limit for Model CFC is 210 deg F.

Part No. 750-263 4-19

Chapter 4 — CFC Commissioning

The High Limit setting is considered a safety parameter. Any changes made will require a password login and reset of the CB Falcon.

J. POST START-UP CHECKOUT PROCEDURE

1. Ensure proper air venting to expansion tank.

2. 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.

3. 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.

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

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

6. Verify HAPS switch operation by simulating a blocked flue condition.

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

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

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

4-20 Part No. 750-263

Chapter 5

Service and Maintenance

Cleaning Procedure / Disassembly ........................................... 5-2

Condensate Neutralization ...................................................... 5-3

Assembly ............................................................................. 5-3

Ignition Electrode and Flame Rod ............................................ 5-4

Troubleshooting ... .................................................................. 5-4

Caution

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.Failure to do so may result in equipment failure.

Caution

Verify proper operation after servicing. Failure to do so may result in equipment

Milwaukee, Wisconsin

www.cleaver-brooks.com

Chapter 5 — Service and Maintenance

A. Gas Assist lift cylinders (2) B. Burner head hold down nuts

(BOTH SIDES)

Caution

Figure 5-1 Service Step

Figure 5-2 Burner Head (in

place)

On an annual basis the boiler vessel and burner combustion system must be checked and cleaned. This work is to be carried out by an authorized Cleaver-Brooks Service Technician.

A.CLEANING PROCEDURE / DISASSEMBLY

1. Close off the gas supply to the boiler and disconnect electrical power at the primary switch box.

2. Remove the front casing panel and fold the integral step down (see Figure 5-1).

3. Remove the top casing of the boiler.

4. Disconnect the gas piping to the burner head.

5. Disconnect the electrical connections to the blower assembly.

6. Remove air combustion piping if supplied.

7. Unscrew the four- (4) hold down nuts securing the burner door to the pressure vessel.

8. The burner door, burn er head, blower motor and assembly will lift on the provided gas struts (see Figure 5-3).

9. The blower motor and gas valve assembly assembly can be removed from the boiler.

10. The burner head can be separated from the head assembly by removing 4 bolts and washers.

Check the burner head for any damage, burn marks or perforations. If damage is determined replace the damaged parts. If the canister is in good condition clean out any dirt and contaminates with a vacuum cleaner inside and out alternating with compressed air to dislodge any debris of combustion.

1. With the burner head and blower removed the combustion chamber can be accessed for all service requirements.

2. Check ignition and ionization electrodes for deposits and proper gap. Clean or replace as needed.

3. Inspect the pressure vessel and combustion chamber area for any damage or contamination (see Figu re 5-4). If dirt or contaminates are found it is recommended that the tubes be washed with a high-pressure power washer.

Figure 5-3 Burner Door

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.

5-2 Part No. 750-263

B.CONDENSATE NEUTRALIZATION

Important

Important note concerning the neutralization system:

The neutralization granulate NEUTRALAT is supplied in 6.5 lb. bags. The bags have 2 wrappers. The actual granulate is contained in a mesh type inner wrapper which in turn is enclosed in a sealed outer wrapper; do not remove the mesh wrapper.

After removing the outer wrapper, the fine dust formed during transport should be shaken out as it can impair the effectiveness. The granulate is placed in the granulate chamber around the vertical round inlet tube on the filter mat (not in the container behind it, which is for the neutralized condensate).

Once a year - or after consumption (dissolving) of the granulate - the neutralization system should be thoroughly cleaned, i.e. rinsed with water. For this the neutralization tank can be easily removed and replaced after taking off the removable front and disconnecting the condensate connector.

The tank is located between 2 rails with a stop at the rear. As it is harmless, the residual neutralization granulate can be disposed of with the domestic waste. For the CFC 750-1000, the granulate tank requires three (3) 6.5 lb. bags of NEUTRALAT. The CFC 15001800 requires four (4) 6.5 lb. bags of NEUTRALAT.

Chapter 5 — Service and Maintenance

Figure 5-4 Combustion

Chamber and Tube Sheet

Applications where multiple boilers are used will require more frequent maintenance and replacement of the neutralization media

The granulate tank is to be filled with NEUTRALAT neutralisation granulate as described above before the first commissioning

C.ASSEMBLY

1. Assembly is the reverse of the above instructions.

2. A new rope gasket should be installed on the burner door. See recommended spare parts list.

Part No. 750-263 5-3

Chapter 5 — Service and Maintenance

Figure 5-5 Electrode Setup

D.IGNITION ELECTRODE AND FLAME ROD

The ignition and ionization electrodes should be checked on an annual basis. If damaged it should be replaced as shown in Figure 5-5 with the electrode turned towards the burner mantle after it is inserted into the burner head.

1/8” gap between ionization electrode and the surface of the burner canister.

1/8” gap between ignitor electrode and ground electrode.

E. TROUBLESHOOTING

Lockout Conditions

1. Observe lockout code and description - refer to CB Falcon appendix if

necessary.

2. After determining lockout condition, investigate possible causes.

3. When cause is diagnosed, remedy condition.

4. Reset control. Boiler should be able to start normally.

5. If lockout recurs, further investigation is required. Repeat steps 1

through 4 as needed. If necessary, contact your CB service representative for technical support.

EXAMPLE: Lockout 79 Outlet Temperature High Limit

1. Before resetting control to clear lockout, check for sufficient water flow

through boiler. Possible sources of insufficient flow include closed water valves, insufficient pump speed, air trapped in boiler (inadequate air venting), or modulation set point and off point close to outlet high limit setting.

The CB Falc on system display/interface provides extensive boiler diagnostic data at the time of lockout that can help in determining the source of a problem. This information is accessed through the Lockout History.

2. Remedy condition that caused lockout to occur.

3. Reset control by pressing <Clear Lockout> from the Lockout History

screen.

Light-off Problems

The distance between the flame rod and the burner (mantle) should be 1/8” (see Figu re 5-6 ). The dimensions on both the booster ignitors and the flame rod are not easily adjustable - bending the rods can cause damage to the insulation material. Also a bent electrode will return to its original shape when heated. If an electrode or flame rod is out of specification, replacement is generally required. Clean or replace as necessary.

5-4 Part No. 750-263

Chapter 5 — Service and Maintenance

1/8”

Flame Rod

Booster Ignitor

Bottom of

Burner Canister

1/8”

1/2”

Figure 5-7 Ignitor Electrodes

Electrode spacing for the booster ignitor should be 1/8”. The distance of the nearest booster ignitor electrode to the mantle

is approximately 1/2” (See Figure 5-7).

Figure 5-6 Flame Rod and

Ignitors

Part No. 750-263 5-5

Chapter 6

Parts

Recommended Spare Parts List Model CFC ................................. 6-1

Boiler mechanical assembly ...................................................... 6-2

Boiler mechanical assembly parts list ......................................... 6-3

Connection Sizes ...................................................................... 6-3

Gas train ................................................................................. 6-4

Gas train parts list .................................................................... 6-4

MSOV Kit ...... ........ ......... ........ ......... ........ ......... ......... ........ ...... 6-4

Electrical Assemblies ................................................................ 6-5

Electrical Assemblies Parts List .................................................. 6-6

Control Panel ........................................................................... 6-6

Blower Fuse ............................................................................. 6-6

CFC Optional Parts List ............................................................. 6-7

Vent Connections ..................................................................... 6-7

Table 6-1. Recommended Spare Parts List Model CFC

Boiler Size

Item 500 750 1000 1500 1800 2500

Ionization Electrodes 380-1062 380-1062 380-1060 380-1060 380-1060 380-1060 Dual Electrode, Sparking 380-1061 380-1061 380-1061 380-1061 380-1061 380-1061 Dual Electrode Gasket 380-1032 380-1032 380-1032 380-1032 380-1032 38 0-10 32 Burner Canister 380-1045 380-1045 380-1029 380-1030 380-1030 380-1074 Water Side Gaskets 853-350 Manual 750-263 750-263 750-263 750-263 750-263 750-263 Falcon Controller, Hydronic 833-3639 833-3639 833-3639 833-3639 833-3639 833-3639 Power Supply, 12VDC 832-2410 832-2410 832-2410 832-2410 832-2410 832-2410 Fuses (5A), Control Circuit 832-1811 832-1811 832-1811 832-1811 832-1811 832-1811 Gasket,Burner Canister (2) 380-1053 380-1053 380-1033 380-1034 380-1034 380-1034 Gasket, Adapter to Blower 380-1037 380-1037 380-1037 380-1076 380-1038 380-1038 Cable, Blower Signal 832-2434 832-2434 832-2434 832-2434 832-2434 832-2434 Ionization Cable (Flame Rod) 826-157 826-157 826-157 826-157 826-157 826-157 Ignition Cable (2) 826-156 826-156 826-156 826-156 826-156 826-156 Blower Power Cord 832-2101 832-2101 832-2101 832-2101 832-2101 832-2101 Blower Fuse 15A 832-1812 832-1812 832-1812 832-2241 832-2241 832-2241 Burner Sight Glass 851-26 851-26 851-26 851-26 851-26 851-26 Retainer, Sight Glass 65-879 65-879 65-879 65-879 65-879 65-879 Gasket, Sight Glass (2) 853-213 853-213 853-213 853-213 853-213 853-213

Milwaukee, Wisconsin

www.cleaver-brooks.com

Chapter 6 — Parts

Figure 6-1. Boiler mechanical assembly

6-2 Part No. 750-263

Table 6-2. Boiler mechanical assembly parts list

2500500 750 1000 1500 1800

BOILER SIZE

500 750

1000

1500 1800 2500

BOILER SIZE

Chapter 6 — Parts

Table 6-3. Connection Sizes

Part No. 750-263 6-3

Chapter 6 — Parts

BOILER SIZE

Figure 6-2. Gas train

Table 6-4. Gas train parts list

Table 6-5. MSOV Kit

BOILER SIZE 500 750 1000 1500 1800 2500

1’’ NPT KIT# 380-01046 1.25’’ NPT KIT# 380-1047 BUTTERBALL VALVE 941-01944 941-01944 941-01944 941-01945 941-01945 941-01945 NIPPLE, CLOSED 857-00673 857-00673 857-00673 857-00709 857-00709 857-00709 ADAPTER, GAS VALVE 800-00092 800-00092 800-00092 800-00093 800-00093 800-00093 O-RING W/HARDWARE GASKET W/HARDWARE 800-98 800-98 800-98 800-99 800-99 800-99

6-4 Part No. 750-263

Figure 6-2. Electrical Assemblies

INCOMING POWER AND CUSTOMER CONNECTION TERMINALS

Chapter 6 — Parts

Part No. 750-263 6-5

Chapter 6 — Parts

Table 6-6. Electrical Assemblies Parts List

ITEM QTY PART NO. DESCRIPTION

1 1 See Table 6-6 CONTROL PANEL 2 1 833 03577 DISPLAY, SYSTEM 3 1 833-03725 DISPLAY, LOCAL 5 1 832 02410 POWER SUPPLY (INCLUDED W/SYSTEM DISPLAY) 6 1 833 03639 FALCON CONTROLLER 7 1 832 00235 TRANSFORMER 8 1 832 02451 IGNITION TRANSFORMER

9 1 833 03547 CONTROLLER, LWCO 10 2 848 01166 FUSE BLOCK, SINGLE POLE 11 1 See Table 6-7 FUSE, 15 AMP, LPCC TIME DELAY, BLOWER FUSE 12 1 832 01811 FUSE, 5 AMP, CONTROL CIRCUIT 13 2 836 01147 SWITCH, SELECTOR, 2 POSITION 14 2 836 01136 CONTACT BLOCK 15 1 879 00995 NAME PLATE, BOILER OFF-ON 16 1 879 00995 NAME PLATE LOCAL/REMOTE 17 832 02326 TERMINAL BLOCK 18 8 832 02328 TERMINAL, GROUNDING 19 3 832 02248 TERMINAL END RETAINING ANCHOR 20 832 02327 TERMINAL LABEL CLIP 21 3 832 02249 JUMPER, 2 POLE 22 1 848 01321 FUSE BLOCK 23 1 832 01211 FUSE, 1 AMP 24 2 832 01951 DIN RAIL 25 2 826B00156 IGNITION CABLE 26 1 826B00157 FLAME ROD CABLE 27 1 832B02434 BLOWER SIGNAL CABLE 28 1 826B00160 CABLE HARNESS 29 832B02452 BLOWER POWER CORD

Table 6-7. Control Panel

Boiler Size

500 750 1000 1500 1800 2500

ITEM 1 - CONTROL PANEL 283-03537 283-03537 283-03536 283-03535 283-03542 283-03492

Table 6-8. Blower Fuse

Boiler Size

500 750 1000 1500 1800 2500

ITEM 11 - BLOWER FUSE 832-01812 832-01812 832-01812 832 -022 41 832-02241 832 -022 41

6-6 Part No. 750-263

Table 6-9. CFC Optional Parts List

DESCRIPTION PART NO.

DIRECT VENT KIT, CFC 500, 750 & 1000 880-01312 DIRECT VENT KIT, CFC 1500 & 1800 880-01313 DIRECT VENT KIT, CFC 2500 880-2451 AIR INLET FILTER, CFC 500, 750 & 1000 843-266 AIR INLET FILTER, CFC 1500, 1800, & 2500 843-267 AIR FILTER CLEANING KIT 880CONDENSATE TREATMENT SYSTEM, CFC 500, 750 & 1000 617-00187 CONDENSATE TREATMENT SYSTEM, CFC 1500 & 1800 617-00187 FLUE GAS CONDENSATE NEUTRALIZING MEDIA 947-00007 OPTIONAL SAFETY VALVE SET @ 30 PSI 940-478 OUTDOOR TEMP. SENSOR, INCL. EXTERNAL MOUNTING HARDWARE 817-4467 ALARM HORN 817-3571 STACK TEMPERATURE SENSOR 817-4403 HEADER TEMPERATURE SENSOR 817-4468 DHW OUTLET TEMPERATURE SENSOR 817-4403 INLET TEMPERATURE SENSOR 817-4404 PLUG-IN MODULE (PIM) 833-3640 AUX. LOW WATER CUTOFF 817-3390 ALARM HORN 817-3571 BOILER AIR VENT VALVE 940-7358

Chapter 6 — Parts

Table 6-10. Vent Connections

Model CFC

Connection Size 500 750 1000 1500 1800 2500

4” 6” 039-1704 039-1704 039-1646 NA NA NA

8” NA NA 039-1647 10” NA NA 12”NANANA

039-1684 NA NA NA NA NA

039-1645 NA NA

039-1705 039-1644 039-1644 NA

039-1688 039-1688 039-1688

STANDARD OPTIONAL

Part No. 750-263 6-7

APPENDIX A - CB FALCON HYDRONIC CONTROL

Hydronic Control

PRODUCT DATA

FEATURES

Safety and Boiler Protection

• Frost Protection, Slow Start, Anti-condensate, Boiler Delta-T, Stack Limit, Boiler Limit, DHW Limit, Outlet TRise Limit

Integrated Control Functions:

• Primary Flame Safeguard Control

• Internal or external spark generator

• Analog Input using 10kohm NTC Sensor

• Outlet Limit And Temperature

• DHW (Domestic Hot Water) Limit and Temperature

• Stack Temperature Limit and Temperature

• Inlet Temperature

• Outdoor Temperature

• Other Analog Inputs

• PWM Feedback

• Flame Signal from either a Flame Rod or Ultraviolet Detector

• PID Load Control

• CH (Central Heat)

APPLICATION

The CB Falcon is a hydronic boiler control system that provides heat control, flame supervision, circulation pump

control, fan control, boiler control, and electric ignition function. It will also provide boiler status and error reporting.

Multiple boilers can be joined together to heat a system instead of a single, larger burner or boiler. Using boilers in parallel is more efficient, costs less, reduces emissions, improves load control, and is more flexible than the traditional large boiler.

• DHW (Domestic Hot Water)

• Digital Inputs

• Pre Ignition Interlock

• LCI (Load [or Limit]Control Input)

• Airflow Interlock

• Annunciation (8 Programmable) (6 Programmable plus High Fire and Low Fire Switch Interlocks)

• Remote Reset

• TOD (Time of Day)

CB Falcon System Consists of:

CB Falcon Control Device

833-3577 Touchscreen Display—required for setup and ModBus communication but not required for the system to operate once the CB Falcon is programmed. Flame Rod or UV flame detector Temperature Sen sor, NTC Type 10KΩ at 77°F (25°C) or 12KΩ at 77°F (25°C) Limit Sensor, NTC Type 10KΩ at 77°F (25°C) Local Keyboard Display Module Fans (VFD)

CB FALCON HYDRONIC CONTROL

• Digital Outputs

• Pump Control (3 outputs, 5 different programmable features)

• Combustion Blower

• External Ignition

• Pilot Valve

•Main Valve

•Alarm

• Analog Outputs

• Modulation

•4-20mA

•0-10 Vdc

• PWM for Variable Frequency Drives

• Algorithm Prioritization

• Burner Demand

• CH, DHW and Frost Protection

• Firing Rate Limiting

• Anti-Condensate, Stack Limit, Boiler Delta-T, Boiler Slow Start, Outlet Limit, On and Off Hysteresis

• Two Temperature Loops of Control

•CH

• DHW

• High Limit Control (Meets UL 353)

• Fifteen Item Fault Code History including equipment status at time of lockout

• Fifteen Item Alert Code Status including equipment status at time of internal alerts

• 24Vac Device Power

• 24 or 120Vac Digital I/O models available.

• Flame Signal test jacks (Vdc)

• Three Status LEDs

•Power

•Flame

•Alarm

• Analog NTC Sensor Inputs (10kohm or 12kohm)

NOTE: 12kohm sensors cannot be used for Limit

Application functions.

• Flame Sensing

• Ultraviolet

•Flame Rod

• Single Element (Internal spark generator and flame sense using the same element)

• Dual Element (separate elements for ignition spark and flame sense)

750-265 2

CleaverBrooks CFC Operation, Service And Parts Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Model CFC

Installation

Service and Maintenance

Parts