CleaverBrooks CFC-500, CFC-2500, CFC-750, CFC-1000, CFC-1500 Operation, Service And Parts Manual

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Model CFC

ClearFire

Condensing Boiler

Operation, Service, and Parts

Manual Part No. 750-263 07/2010

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.

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).

iii

WARNING

DANGER

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

DO NOT ALLOW OTHERS TO OPERA TE, SERVICE, OR REP AIR THIS EQUIPMENT UNLESS THEY FULL Y 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 emphasize too strongly the need for the operator to periodically check his low water controls and to follow good maintenance and testing practices. Cross-connecting piping to low water devices must be internally inspected periodically to guard against any stoppages which could obstruct the free flow of water to the low water devices. Float bowls of these controls must be inspected frequently to check for the presence of foreign substances that would impede float ball movement.

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

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.

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Section 2 — Installation

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

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

Boiler placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Casing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Flue gas/combustion air connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Water treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Using glycol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Boiler room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Gas connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Gas train components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Gas pressure requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Gas supply pipe sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Gas header . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Boiler water piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Pressure drop curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Condensate removal and treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

Condensate tank setup options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

Condensate piping for multiple boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

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

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Horizontal Thru-Wall Stack Vent Termination . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Horizontal Thru-Wall Venting / Direct Vent Combustion Air . . . . . . . . . . . . . . . . 3-6

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

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

Vertical Venting / Inside Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Vertical Venting / Direct Vent Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Stack Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Stack design using room air for combustion . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Stack design using direct vent combustion . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Venting for multiple units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Combustion Air / Boiler Room Ventilation Requirements . . . . . . . . . . . . . . . . . 3-14

Air Supply - Unconfined Spaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Air Supply - Engineered Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Section 4 — Commissioning

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

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

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

Model CFC Boiler / Burner Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

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

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

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

Operation Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

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

Controller Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Changing Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Program Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Burner Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Fan Speed Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Initial start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Gas Train and Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Operation Check: Gas Valve, Gas Press. Switches, and CAPS . . . . . . . . . . 4-19

Low Water Cutoff Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Low and High Fire Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Modulation OFF point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Setting Combustion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

High Air Pressure Switch settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Limit Controls Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Post start-up checkout procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

Procedures for LP (Propane) Gas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Single Fuel Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Units with optional dual-fuel gas train . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

Falcon Control Functions and Customer Interface . . . . . . . . . . . . . . . . . . . . . . 4-28

Section 5 — Service and Maintenance

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

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Ignition Electrode and Flame Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Section 6 — Parts

Appendix A — CB Falcon Hydronic Control Appendix B — CB Falcon Plug-In Module Appendix C — Gas Valve Appendix D — CB Falcon Modbus Communication

Section 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-

Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Milwaukee, Wisconsin

www.cleaver-brooks.com

Section 1 — Introduction

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 very high levels of performance in a compact space. The boiler is designed to fire natural gas or propane.

Figure 1-1 CFC Boiler

Premix Burner

Pressure Vessel

Cabinet

On/Off Switch

Control Display

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, the CFC Boiler will provide many years of trouble free service. Single-pass design provides excellent thermal shock protection.

Tubes are made from UNS S32101 Duplex Stainless Steel with AluFer extended heating surface inserts for maximum heat transfer.

Dual Temperature Return

Two return pipes - high and low temperature - allow condensing performance with as little as 10% return water at condensing temperature.

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.

Insulation

Full Modulation

The burner and combustion fan modulate to provide only the

Figure 1-2 CFC Cutaway

amount of heat required, providing quiet and efficient operation under all conditions.

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

Section

1-2 Part No. 750-263

B. STANDARD EQUIPMENT

1. The Boiler

The boiler is designed for a Maximum Allowable Working Pressure (MAWP) of 125 psig (8.6 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 112 psig (7.7 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.

Integral variable speed combustion air fan provides 5:1 turndown. Combustion canister of the burner is constructed of a Fecralloy-

metal 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.

Section 1 — Introduction

Figure 1-4 Burner

Provision for direct vent combustion is furnished.

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

The gas train assembly is provided in accordance with UL certification and complies with ASME CSD-1. The gas train assembly is factory 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. C S D -1 T e s t C o c k s

High Gas Pressure Switch

Test Coc k

Manual Shutoff

Low Gas Pressure Switch

Figure 1-5 Standard Gas Train

Gas Shutoff / Selector Valve

Natural Gas Train

Propane Gas Train

Figure 1-6 Optional dual gas train

Part No. 750-263 1-3

Section 1 — Introduction

4. Control (See Figure 1-7)

The CB Falcon 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.

• Remote firing rate or setpoint control

• Setback/time-of-day setpoint

• Lead/Lag for up to 8 boilers

CB Falcon Controller

Transformer

LWCO Control Board

Terminal Strip

Fuse Block

Figure 1-7 Control panel interior

Ignition Transformer

Blower & Control Circuit Fuses

Power Supply

1-4 Part No. 750-263

5. Component/Connection Locations

Figure 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.

Figure 1-9 shows the locations of the safety valve and low water cutoff. Figure 1-10 shows the location of the return water temperature sensor. Looking at the top of the boiler, near the rear, Figure 1-11 shows the three hole sensor well for the outlet temperature sensor.

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. Refer to Chapter 3 of this manual for recommended vent sizes and lengths for the specific boiler installation.

6. Optional Equipment

Certain project-specific options may have been supplied with the boiler if these options were specified at the time of order entry. In addition, some options may have been provided (by others) that are not part of Cleaver-Brooks’ scope of supply. In either case, the Cleaver-Brooks authorized representative should be consulted for project specifics.

Section 1 — Introduction

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

A. Dual gas train for quick and easy fuel switchover. B. Reusable air filter. C. Condensate neutralization tank assembly - consists of

neutralizing media, filter, and PVC condensate holding tank with integral drain trap. This assembly is mounted beneath

the boiler and is further described in Chapter 2. D. Outside air intake for direct vent combustion. E. Outdoor temperature sensor for indoor/outdoor control. F. Header temperature sensor for multiple boiler Lead/Lag

operation. G. Auxiliary Low Water Control (shipped loose) for field piping

by others into the system piping. H. Alarm Horn for safety shutdown. I. Relays for output signal for burner on, fuel valve open. J. Stack Thermometer. K. Stack temperature limit-sensor. L. Auto air vent. M. Boiler drain valve.

Part No. 750-263 1-5

Section 1 — Introduction

Safety Relief Valve

Hot Water Outlet

Combustion Fan and Premix Gas Valve Assembly

Ignition Electrodes

Flame Rod

and

Burner Canister

Control Panel

High Temp. Return

Low Temp. Return

Flue Gas Outlet

“Finned” High Efficiency AluFer Tubes

Insulation Blanket

Figure 1-8 CFC Heat Flow and Component Orientation

1-6 Part No. 750-263

Section 1 — Introduction

Auto air vent (optional; shipped loose)

Safety Valve (shipped loose)

Low Water Cutoff Probe

Figure 1-9 Boiler Controls

Figure 1-10 Return Temperature Sensor Mounting

Part No. 750-263 1-7

Section 1 — Introduction

Figure 1-11 Outlet Temperature Sensor, Top of Pressure Vessel

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

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

See also Chapter 4 - Stack and Intake Vent Sizing and Installation.

Figure 1-12 Stack Right Side

(viewed from rear)

1-8 Part No. 750-263

Section 2

Installation

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

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

Boiler placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Casing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Flue gas/combustion air connections. . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Water treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Using glycol. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Boiler room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Gas connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Gas train components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Gas pressure requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Gas supply pipe sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Gas header . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Boiler water piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Pressure drop curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Condensate removal and treatment. . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

Condensate tank setup options . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

Condensate piping for multiple boilers . . . . . . . . . . . . . . . . . . . . . 2-31

Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

Milwaukee, Wisconsin

www.cleaver-brooks.com

Section 2 — Installation

Warning

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.

Warning

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.

Caution

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

Warning

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.

2-2 Part No. 750-263

A. ASSEMBLY

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 placement

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

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

DIM Inches

Top Clearance A 14 Side Clearance B 20 Backway C 20 Front D 36 Between Boilers E 3

Figure 2-1 Clearance Required

Part No. 750-263 2-3

Section 2 — Installation

3. Casing assembly

To assemble the CFC casing, the following tools are required:

Figure 2-2

Flat head screwdriver Phillips screwdriver Cordless screwdriver Utility knife Crescent wrench Machine head screw bit Diagonal cutters

Socket wrench 10mm socket 13mm socket 19mm socket 6” socket extension Zip-ties Sheet metal screws

Fork lift or pallet jack

1. Remove all packing material and open all boxes shipped with the boiler.

2. Remove all casing panels from box and group like pieces together for easy access.

3. Locate boiler legs and attaching nuts/bolts (Figure 2-2). Ensure all four leg height adjusters are at the same level before installing legs.

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

5. Using an appropriate jack, lift up the front of the boiler.

Note: A crane or fork lift may also be used to lift the boiler. When using a

crane, observe the rigging arrangement shown in Figure 2-3. To install the boiler legs, first lift boiler, then remove and discard the wooden base. Install legs and position the boiler. Proceed with step 10 below.

CFC

SIZE

500/750 1000 1500 1800 2500

A 70.625” 82.875” 74.875” 82” 84”

B 118.625” 130.875” 122.875” 130” 132”

C 20.5” 33.5” 32.625” 32.625 37.375”

D 3.15” 1.97” 2.76” 2.76 3.94”

E 3.15” 1.97” 2.76” 2.76 3.94”

F 20.5” 33.5” 32.625 32.625 37.375”

G 1477 lbs 1554 lbs 1940 lbs 2061 lbs 3600 lbs

Figure 2-3 CFC Standard Rigging Arrangement

2-4 Part No. 750-263

6. Attach the boiler front legs.

7. Lift up the back of the boiler using the jack and remove the wooden skid side beams.

8. Attach the rear boiler mounting legs.

9. Lifting eyes are provided for moving and positioning the boiler.

10.Before installing insulation, level the boiler using a level placed against the side of the vessel.

11.Wrap insulation blanket around pressure vessel. Ensure all pre-cut holes fit completely over boiler fittings (Figure 2-4) and blanket is snug to the vessel.

12.Peel backing from any excess length of insulation. Tuck excess portion under other end of blanket. Place backing over overlapping segments (Figure 2-5) and proceed with step 13.

Section 2 — Installation

Figure 2-5

13.Use tension springs to hold edges of blanket together. Poke end of spring through the fabric of the insulation blanket (Figure 2-6). Place one spring at the top and one at the bottom of the blanket. Place the remaining two springs equally spaced.

Figure 2-6

14.Fit one end of black plastic strap to the fastener (Figure 2-7). Wrap strap around the boiler and connect other end to fastener. Repeat with second strap. Tighten straps so blanket is snug, but do not overtighten. Do not compress insulation. Position the straps at ¼ and ¾ height.

Figure 2-4

Part No. 750-263 2-5

Section 2 — Installation

Figure 2-7

15.Using a 10mm socket, or by hand, remove 3 nuts and washers from the mounting studs extending from each side of the top plate of the boiler (Figure 2-8).

Figure 2-8

16.Attach electrical supply channels on each side (Figure 2-9).

Figure 2-9

17.Attach large side panels to each side, fitting on top of the electrical supply channel. Fasten loosely, using nuts and washers previously removed. Do not over tighten. You will need these panels to move slightly to fit the other pieces. See Figure 2-10.

2-6 Part No. 750-263

Figure 2-10

Section 2 — Installation

18.Remove control panel from box. Uncoil sensor wires and route wires out of left-hand side of panel.

19.Mount control panel on front of boiler (Figure 2-11). Make sure to route sensor wires in wiring channel on left-hand side of the boiler (see also Figure 2-41).

Figure 2-11

20.Connect control wiring (Figure 2-12):

• Connect flame rod cable (A) to stand alone electrode on right

(includes burner ground connection).

• Connect ignition cables (B) to dual igniter electrode.

• Connect remaining connectors per connection diagram (see

Figure 2-41).

Part No. 750-263 2-7

Section 2 — Installation

Figure 2-12

21.Route return water sensor (the 2-wire sensor) to the lower pipe on back of boiler, and install lower panel. Coat sensor with heat-conductive compound P/N 872-00631. Insert sensor into return pipe sensor well and secure with mounting clamp (Figure 2-13).

Figure 2-13

22.Coat outlet feed water temperature sensor (the 3-wire sensor) with heatconductive compound P/N 872-00631. Insert sensor in sensor well behind the burner (Figure 2-14).

2-8 Part No. 750-263

Figure 2-14

23.Install rear center panels (Figure 2-15).

Section 2 — Installation

Figure 2-15

24.Install C-clips on upper side panels, then install panels on boiler (Figure 2-16).

25.Install top rear panel and top center panel.

26.Attach side skirt panels to boiler legs using the supplied cap nuts (Figure 2-17).

Figure 2-16

Part No. 750-263 2-9

Section 2 — Installation

Figure 2-17

27.Attach front skirt panel to the side panels.

28.Install front panel.

Assembly is now complete.

Figure 2-18

B. FLUE GAS / COMBUSTION AIR CONNECTIONS

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

2-10 Part No. 750-263

manufacturer for proper installation and sealing instructions. See also Chapter 3 of this manual for combustion air and flue gas venting requirements.

C. WATER TREATMENT

Cleaver-Brooks ClearFire condensing boilers are suitable for heating systems without significant oxygenation capacity. Systems with continuous oxygenation capacity due to unknown or unseen leaks must be equipped with a system separation or pretreatment device.

Untreated drinking water is generally the best heating medium as filling and make-up water for a system that utilizes the Model CFC. If the water available from the main system is not suitable for use, then demineralization and/or treatment with inhibitors is necessary. Treated filling and make-up water must be checked at least once a year or more frequently if so specified in the application guidelines from the inhibitor manufacturer.

Those parts of the boiler in contact with water are manufactured with ferrous materials and corrosion-resistant stainless steel. The chloride content of the heating water must not exceed 30 mg/l and the pH level should be between 8.3 to 9.5 after six weeks of operation.

Section 2 — Installation

To maintain the boiler's efficiency and prevent overheating of the heating surfaces, the values in Tab le 2- 1 should not be exceeded. Water make-up during the lifetime of the boiler should not be greater than 3 times the system volume. A water meter should be installed on the feed line to monitor makeup water volume.

Following production of the pressure vessel, the interior surfaces are cleaned and therefore a pre-start boil out of the vessel is not needed. Should the system require boil out or cleaning after installation of the CFC, take care that no particulate matter reaches the boiler during the cleaning process. A removable filter should be used for this purpose.

Notice

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

Table 2-1 Model CFC Water Chemistry

Parameter Limit

pH 8.3 - 9.5

Chloride 30 mg/liter

Nitrates 50 mg/liter

Sulphates 50 mg/liter

Oxygen 0.1 mg/liter

Specific Conductivity 3500 umho/cm

Total Hardness <10 ppm

Part No. 750-263 2-11

Section 2 — Installation

T able 2-2 Model CFC Water Temperature Data (Non-Glycol)

Minimum supply temp. 33oF Maximum operating temp. 194oF

Maximum design temp. 210

D. USING GLYCOL

The Model CFC boiler may be operated with a solution of glycol and water. Where glycols are added, the system must first be cleaned and flushed. Correct glycol selection and regular monitoring of the in-use concentration and its stability is essential to ensure adequate, long-term freeze protection, including protection from the effects of glycol-derived corrosion resulting from glycol degradation.

Typically, ethylene glycol is used for freeze protection, but other alternatives exist, such as propylene glycol. Glycol reduces the water-side heat capacity (lower specific heat than 100% water) and can reduce the effective heat transfer to the system. Because of this, design flow rates and pump selections should be sized with this in mind.

Generally, corrosion inhibitors are added to glycol systems. However, all glycols tend to oxidize over time in the presence of oxygen, and when heated, form aldehydes, acids, and other oxidation products. Whenever inadequate levels of water treatment buffers and corrosion inhibitors are used, the resulting water glycol mixture pH may be reduced to below 7.0 (frequently reaching 5) and acid corrosion results. Thus, when pH levels drop below 7.0 due to glycol degradation the only alternative is to drain, flush, repassivate, and refill with a new inhibited glycol solution.

The following recommendations should be adhered to in applying ClearFire model CFC boilers to hydronic systems using glycol:

1) Maximum allowable antifreeze proportion (volume %): 50% antifreeze (glycol) 50% water

2) The glycol concentration determines the maximum allowable firing rate and output of the boiler(s). Please refer to the firing rate limitation and corresponding high fire speed settings vs. glycol % in the charts below.

3) Maximum allowable boiler outlet/supply temperature: 185 deg F (85 deg C).

4) Minimum water circulation through the boiler:

a) The minimum water circulation must be defined in such a

way that the temperature difference between the boiler outlet/supply and inlet/return is a maximum of 40 deg F (22 deg C), defined as DT (Delta T). A DT Limit algorithm

should be enabled in the boiler controller.

b) Independent from the hydraulics of the heating system,

constant water circulation through each boiler is required. (Requires a dedicated boiler pump if in a primary/

2-12 Part No. 750-263

Section 2 — Installation

secondary loop arrangement.) Refer to table below for minimum boiler circulation rates.

5) Minimum over-pressure at the boiler: For outlet temperatures up to the maximum of 185 deg F (85 deg C), a minimum operating pressure of 30 psig (2.1 bar) is required.

6) pH level should be maintained between 8.3 and 9.5

Glycol Application Guidelines — ClearFire Model CFC

Minimum required boiler circulation rate (gpm) at maximum firing rate.

ClearFire System ΔT (˚F) Model-Size CFC-500 88 44 29 22 CFC-750 131 66 44 33 CFC-1000 175 88 58 44 CFC-1500 263 131 88 66 CFC-1800 316 158 105 79 CFC-2500 438 219 146 110

Notes/Limitations:

1. Maximum firing rate determined by ClearFire CFC - Glycol Firing Rate Limitation chart (below). Maximum high fire blower speed should be set according to chart.

2. Glycol concentration limit of 25%-50%. Minimum required system operating pressure is 30 psig.

3. Maximum system operating temp er at ur e of 180 ˚F. Maximum ΔT of 40˚.

4. Circulation rates correlate with boiler output based on 92% nominal efficiency.

5. Standard altitude (<1000' ASL). Contact C-B for high altitude applications.

6. Pumps should be sized based on system design ΔT and minimum required flow rates.

7. At minimum firing rate, the minimum circulation rate should correspond to the boiler's turndown.

ΔT = 10˚ ΔT = 20˚ ΔT = 30˚ ΔT = 40˚

Part No. 750-263 2-13

Section 2 — Installation

CFC - Maximum Firing Rat e vs. Glycol Concentr ation

100%

98% 96% 94% 92% 90% 88% 86% 84% 82% 80% 78%

Maxi m um I nput Rat e %

76% 74% 72%

Max Firing Rate %

70%

25% 30% 35% 40% 50%

Glycol Content

Warning

The boiler must not be installed on carpeting.

CFC - High Fire Speed Setting vs % Glycol

High Fire Speed (RPM)

5400

5200

5000

4800

4600

4400

4200

4000

3800

3600

3400

25% 30% 35% 40% 50%

CFC-500/750/1000/1500 - HF RPM CFC-1800 - HF RPM CFC-2500 - HF RPM

Glycol Content

E. BOILER ROOM

The boiler room must comply with all building codes and regulations. An adequate supply of combustion air is required for safe operation. If the optional direct vent combustion air kit (Figure 2-19) is not used, ventilation must be provided to meet applicable regulations for air supply.

Casing Support Attachment

Gasket

Flexible Connection

Direct Vent Connection

Fan/Blower

Venturi

Adapter Flange

Figure 2-19 Air Inlet Extension

Notice

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

2-14 Part No. 750-263

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.

F. GAS CONNECTIONS

1. General

The ClearFire Model 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.

Gas Connection

Section 2 — Installation

Air Inlet Extension

Hot Water Out

High Temp. Return

Low Temp. Return

2. Gas Train Components

CFC boilers are equipped with a gas train that meets the requirements of ASME CSD-1, FM and XL-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 Ta bl e 2 -3 for pressure requirements.

Table 2-3 Model CFC Gas Pressure Requirements

Minimum pressure required at gas train

Boiler Model

500 7" w.c. 11" w.c.

750 7" w.c. 11" w.c. 1000 7" w.c. 11" w.c. 1500 10" w.c. 11" w.c. 1800 7" w.c. 11" w.c. 2500 9.5" w.c. 11" w.c.

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.

connection Natural Gas LP Gas

Max. pressure

28” w.c.

Alternate Flue Gas

Condensate Drain

Flue Gas Vent Connection

Figure 2-20 CFC Rear View

Gas Pressure Regulator

Shutoff Valve

Figure 2-21 Gas Regulator and

Shutoff Valve (typical)

NOTE: The pressure test port is located at the gas valve inlet flange (see Figure 2-22). The remaining test cocks are for leak test purposes and should not be used to measure gas pressure. Refer to

INSTALLATION AND MAINTENANCE

APPENDIX C - GAS VALVE

for more information.

Part No. 750-263 2-15

Section 2 — Installation

Leak Test

Pressure Test

Leak Test

Figure 2-22 Test cocks - gas

valve

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, left 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 Tab le 2 - 3 .

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 valve must be installed upstream of the regulator for use as a service valve. This is also required to provide positive 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 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 2-23 for a typical piping configuration.

2-16 Part No. 750-263

Caution

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 piping be sized to allow no more than

0.3" w.c. pressure drop from the source (gas header or utility meter) to the final unit location. Higher supply pressure systems may allow for a greater pressure drop. In ALL cases, minimum supply pressures must be met for proper operation of the boiler(s). The gas supplier (utility) should be consulted to confirm that sufficient volume and normal pressure are provided to the building at the discharge side of the gas meter or supply pipe.

Section 2 — Installation

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, see gas piping Tables 2-4 and 2-5. The data in these tables is from the NFPA 54 source book, 2006 edition.

To verify the input of each device that is connected to the gas piping, obtain the btu/hr input and divide this input by the calorific value of the gas that will be utilized. For instance, a 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 Tab l e 2 - 4 that a supply pipe size of 1-1/4" should be used as a minimum.

Part No. 750-263 2-17

Section 2 — Installation

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

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

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

Pipe Size

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

2-18 Part No. 750-263

Section 2 — Installation

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

Pipe Size

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

Actual I.D. 1.049" 1.380" 1.610" 2.067" 2.469" 3.068" 4.026" Length in feet **Maximum Capacity in Cubic Feet of Gas per Hour (cfh)

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

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

Part No. 750-263 2-19

Section 2 — Installation

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 2-23).

Tab l es 2-6 to 2-11 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 Tab le

2-4.

Table 2-6: Multiple Unit Manifold, CFC 500

CFC 500 Boilers

# of Units 1 2 3 4

Pipe Size to Boiler

Header Pipe size

1" 1" 1" 1"

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

Table 2-7: Multiple Unit Manifold, CFC 750

CFC 750 Boilers

# of Units 1 2 3 4

Pipe Size to Boiler

Header Pipe size

1" 1" 1" 1"

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

Table 2-8: Multiple Unit Manifold, CFC 1000 Table 2-9: Multiple Unit Manifold, CFC 1500

CFC 1000 Boilers

# of Units 1 2 3 4

Pipe Size to Boiler

Header Pipe size

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

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

CFC 1500 Boilers

# of Units 1 2 3 4

Pipe Size to Boiler

Header Pipe size

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

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

Table 2-10: Multiple Unit Manifold, CFC 1800 Table 2-11: Multiple Unit Manifold, CFC 2500

CFC 1800 Boilers

# of Units 1 2 3 4

Pipe Size to Boiler

Header Pipe size

2-20 Part No. 750-263

2" 2" 2" 2"

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

CFC 2500 Boilers

# of Units 1 2 3 4

Pipe Size to Boiler

Header Pipe size

2" 2" 2" 2"

2" 3" 3" 4"

Figure 2-23 Gas Piping

Section 2 — Installation

Part No. 750-263 2-21

Section 2 — Installation

G. 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. Safety valve

Pressure relief valve (Safety Valve) should be piped from the air vent piping or hot water outlet pipe (see Figure 2-24). 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.

Figure 2-24 Pressure Relief Valve Piped to Safe Point of

Discharge

Warning

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

serious personal injury or death.

3. Dual return design

The Model CFC features separate high and low temperature return water connections, allowing for condensing performance within high temperature hydronic systems. With as little as 10% return water at or below 120 deg F, the Model CFC will achieve condensing performance, with associated gains in efficiency.

If using only a single (common) return, the lower return connection should be used.

4. Pressure drop curves

The information in Figure 2-25 through Figure 2-35 and in Tables 2-12 and 2-13 can help in determining pump requirements for

Model CFC installations.

2-22 Part No. 750-263

Section 2 — Installation

Pressu re P S I

1.4

1.2

0.8

0.6

0.4

0.2

8.8

Hydraulic Resistance CFC 500

13.2

17.6

26.4

30.8

Flow - GPM

35.2

39.6

48.4

52.8

57.2

61.6

70.4

Figure 2-25 Pressure Drop Curve, CFC 500, U.S. Flow Rates

H ydrau lic R esistance CFC 500

Pressur e mbar

30 25

Metric

131

20 15 10

5 0

02345678910111213141516

Flow m 3/h

Figure 2-26 Pressure Drop Curve, CFC 500, Metric Flow Rates

Part No. 750-263 2-23

Section 2 — Installation

Pressure PSI

Hydraulic Resistance CFC 750

1.4

1.2 1

0.8

0.6

0.4

0.2 0

13.2

Flow - GPM

Figure 2-27 Pressure Drop Curve, CFC 750, U.S. Flow Rates

Hydraulic Re sistance CFC 750

Metric

Pressur e mb ar

30 25 20 15 10

5 0

0 2 3 4 5 6 7 8 910111213141516

Flow m3/h

Figure 2-28 Pressure Drop Curve, CFC 750, Metric Flow Rates

2-24 Part No. 750-263

Pressure - PSI

1.2

0.8

0.6

0.4

0.2

Section 2 — Installation

H ydraul ic Resist ance CFC 1000

0 8.8 22 44 66 88 110 132 154 176

Flow - GPM

Figure 2-29 Pressure Drop Curve, CFC 1000, U.S. Flow Rates

Pressure mbar

80 70 60 50 40 30 20 10

0 2 5 10152025303540

H ydraul ic Resist ance CFC 1000

F low m3/h

Figure 2-30 Pressure Drop Curve, CFC 1000, Metric Flow Rates

Part No. 750-263 2-25

Section 2 — Installation

Pr es sure- PSI

Hyd raulic Resistance CFC 1500

U.S. Standards

1.8

1.6

1.4

1.2 1

0.8

0.6

0.4

0.2 0

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

Flow - GPM

Figure 2-31 Pressure Drop Curve, CFC 1500, U.S. Flow Rates

Hydraulic Resistance CFC 1500

Metric

Pressure mbar

140 120 100

80 60 40 20

0 2 5 1015202530354045505560

F low m3/h

Figure 2-32 Pressure Drop Curve, CFC 1500, Metric Flow Rates

2-26 Part No. 750-263

Pressure - P SI

1.8

1.6

1.4

1.2 1

0.8

0.6

0.4

0.2 0

Section 2 — Installation

Hydraulic Resistance CFC 1800

U.S. Standards

8.8

110

132

Flow - GPM

154

176

198

220

242

264

286

308

330

352

Figure 2-33 Pressure Drop Curve, CFC 1800, U.S. Flow Rates

Hyd raulic Resistance CFC 1800

Metric

Pressure mbar

120 100

80 60 40 20

0 2 5 101520253035404550556065707580

F low m3/h

Figure 2-34 Pressure Drop Curve, CFC 1800, Metric Flow Rates

Part No. 750-263 2-27

Section 2 — Installation

Pressure - PSI

1.8

1.6

1.4

1.2

0.8

0.6

0.4

0.2

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

Hydraulic Resistance CFC 2500

U.S. Standards

Flow - GPM

Figure 2-35 Pressure Drop Curve, CFC 2500, U.S. Flow Rates

Table 2-12: Maximum flow rate through ClearFire boilers (U.S. flow rates)

System Temperature Drop

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

Boiler

Size

500954833241916121110.59 8 7

1316644332622191615131211

750

1000

1500

1800 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.

1768859443529252220181615

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

351176117887059504439353230

Flow Rate GPM

2-28 Part No. 750-263

Section 2 — Installation

Table 2-13: Maximum flow rate through ClearFire boilers (metric flow rates)

System Temperature Drop

5 1117222733384550556164

Boiler

Size 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.

Flow Rate m

/hr.

H.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. When piping condensate direct to drain, a trap (Figure 2-36) must be installed on the condensate outlet to prevent discharge of flue gases from the boiler. When using the treatment tank, a drain trap is included in the tank assembly and no external trap is required.

The water trap must be filled with water prior to commissioning and checked or refilled at each required maintenance interval.

Return Water In

Stack

Clearfire Base

6”

Notice

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.

Figure 2-36 Flue Gas Trap 6 inch

Minimum Water Column

Condensate leaving the boiler normally has a pH of 4-6. The responsible authority will inform you if a higher pH value is required for condensate piped to drain. The CFC neutralization system contains the granulate NEUTRALAT, a natural compound which acts to increase the pH of the condensate flowing through it. The neutralization system comprises the plastic neutralization tank with condensate inlet, makeup valve, drain trap, granulate chamber and condensate outlet (see Figure 2-38). The system is installed in the CFC lower collection area.

Part No. 750-263 2-29

Section 2 — Installation

Note: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.

1. Removable front

2. Min. 6” water trap

Figure 2-37 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 removal options available:

(1) Condensate direct to drain - The condensate is piped directly to a drain th rough the piping and water trap suppl ied during installation (see Figure 2-37).

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

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

• Condensate water trap (6”) required.

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

• To install the system, assemble the tank and neutralization granulate per

Figure 2-38. 4 bags of neutralization media are sufficient to fill the tank.

• Install the condensate tank cover and slide the complete assembly under the boiler

Pipe to the appropriate drain.

Drain trap

Neutralization tank

Condensate in

To drain

Float valve for makeup water

Neutralization media

Figure 2-38 Condensate Treatment Tank

The neutralization media will require periodic replacement, to be detemined by pH analysis of condensate. If condensate is too acidic (pH is below acceptable value) the neutralization media should be replaced.

The neutralizing media should be gently agitated periodically to ensure even distribution and to avoid channeling of the condensate.

2-30 Part No. 750-263

2. Condensate Piping for Multiple Boilers

More than one Model CFC boiler can be piped into a common condensate neutralization tank. See Figure 2-39 and Figure 2-40 for the suggested layout. A drain trap is built into the condensate tank. Make-up water must be supplied at the connection shown in order to prevent flue gas from entering an idle boiler. An internal float in the condensate tank activates the make-up water valve.

Section 2 — Installation

1/4" O.D. Make-up Water Supply

To Drain

Figure 2-39 Condensate Piping for Multiple Boilers

Model CFC Boiler

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

Condensate Drain Trap

Neutralization Tank

Condensate Drain Trap

Neutralization Tank

Neutralization Media

12" Minimum

To Drain

Figure 2-40 Condensate Treatment Tank for Multiple Boilers

Part No. 750-263 2-31

Section 2 — Installation

I. ELECTRICAL CONNECTIONS

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 2-41) to the control panel. AC power is to be connected to the incoming power terminals.

1. Power wiring - right side electrical supply channel.

2. Customer 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.

• Hot water return temperature sensor.

• Stack temperature sensor (optional).

• Outdoor temperature sensor (optional).

Warning

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

Warning

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

For electrical connections see Figure 2-41.

2-32 Part No. 750-263

Section 2 — Installation

Figure 2-41 Electrical Connection Diagram

Part No. 750-263 2-33

Section 2 — Installation

I. WIRING DIAGRAMS

Figure 2-42 CFC Wiring Diagram - single fuel units

Note: Wiring diagrams shown are examples only.

Installations may vary. For specific installations consult the wiring diagram provided with the boiler.

2-34 Part No. 750-263

Section 2 — Installation

Figure 2-43 CFC Wiring Diagram - dual fuel units

Part No. 750-263 2-35

Section 2 — Installation

2-36 Part No. 750-263

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

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Horizontal Thru-Wall Stack Vent Termination . . . . . . . . . . . . . . . . . 3-6

Horizontal Thru-Wall Venting / Direct Vent Combustion Air . . . . . . . . . . 3-6

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

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

Vertical Venting / Inside Combustion Air . . . . . . . . . . . . . . . . . . . . . . . 3-8

Vertical Venting / Direct Vent Combustion Air . . . . . . . . . . . . . . . . . . . 3-9

Stack Sizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Stack design using room air for combustion . . . . . . . . . . . . . . . . . . . . 3-10

Stack design using direct vent combustion. . . . . . . . . . . . . . . . . . . . . 3-11

Venting for multiple units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Combustion Air / Boiler Room Ventilation Requirements . . . . . . . . . . . 3-14

Air Supply - Unconfined Spaces . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Air Supply - Engineered Method . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Milwaukee, Wisconsin

www.cleaver-brooks.com

Section 3 — Stack and Intake Vent Sizing and Installation

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. The boiler’s appliance category is a major factor determining venting system design.

Definitions:

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.

Notice

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.

Depending on the application, the Model CFC may be considered Category II, III, or IV. The specifying engineer should dictate flue venting as appropriate to the installation.

Warning

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 II, III or IV vent system.

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

Notice

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

Section 3 — Stack and Intake Vent Sizing and Installation

Vent material should be appropriate for the Appliance Category. Application-specific information will further determine the material selected.

In some cases, PVC/CPVC material meeting ULC Type BH Class IIB specifications may be used. Use of PVC/CPVC depends on operating conditions, specific vent suppliers, and any local codes having jurisdiction. Refer to vent manufacturer’s specifications for applicability.

3. Vent Terminal Location

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

1. Combustion gases can form a white vapor plume in the winter. The plume could obstruct a window view if the termination is installed in close proximity to windows.

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

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

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

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

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

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

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

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

10. 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.

U.S. Installations- Refer to latest edition of the National Fuel Gas Code.

Vent termination requirements are as follows:

Part No. 750-263 3-3

Section 3 — Stack and Intake Vent Sizing and Installation

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

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

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

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

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

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

Canada Installations- Refer to the latest edition of CAN/CSAB149.1 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 ve r a n dah, por c h o r deck is f u l ly open o n a m inimum 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.

Warning

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

3-4 Part No. 750-263

Section 3 — Stack and Intake Vent Sizing and Installation

Venting Installation Tips

Support piping:

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

• Vertical runs - use braces.

• Under or near elbows

Caution

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.

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 through the wall to the outside. Adequate combustion and ventilation air must be supplied to the boiler room in accordance with the National Fuel Gas Code or, in Canada, the latest edition of CAN/CSA-B 149.1 and .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.

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

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

Inside Air Combustion

Intake

Flue Gas Vent

(w/Screen)

24" Minimum

Figure 3-1 Horizontal Venting

Thru-Wall Using Inside Air For

Combustion

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

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

Part No. 750-263 3-5

Section 3 — Stack and Intake Vent Sizing and Installation

• 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.

• 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.

C. HORIZONTAL THRU-WALL VENTING / DIRECT

VENT COMBUSTION AIR

Warning

Flue Gas Vent (w/Screen)

24" Minimum

18" Minimum

Air Intake (w/Screen )

24" Minimum

Figure 3-2 Horizontal Thru-wall Direct Venting System

(Direct Vent Combustion Air/Stack Venting)

3-6 Part No. 750-263

Section 3 — Stack and Intake Vent Sizing and Installation

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:

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

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

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

• 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.

• 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).

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

Warning

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

Caution

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.

Part No. 750-263 3-7

Section 3 — Stack and Intake Vent Sizing and Installation

Notice

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.

Notice

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

D. VERTICAL VENTING / INSIDE COMBUSTION AIR

10'-0" or Less

24"

Minimum

Flue Gas Vent (w/Screen)

24"

Minimum

CFC Boiler

Figure 3-3 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

3-8 Part No. 750-263

Section 3 — Stack and Intake Vent Sizing and Installation

Gas Code or, in Canada, the latest edition of CAN/CSA-B 149.1 and .2 Installation Code for Gas Burning Appliances and Equipment.

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.

Warning

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

COMBUSTION AIR

Flue Gas Vent (w/Screen)

Minimum

24"

Boiler

36" Minimum

12"

Minimum

Air Intake (w/Screen)

Figure 3-4 Vertical Stack with Direct Vent Combustion Air

These installations utilize the boiler

-mounted blower to draw combustion air from outside and vent combustion products to the outside.

To prevent condensation accumulation in the vent, it is required to install the horizontal portion of vent with a slight upward slope of

Part No. 750-263 3-9

Section 3 — Stack and Intake Vent Sizing and Installation

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.

F. S T A C K S I Z I N G

1. Stack design using room air for combustion

Table 3-1 STACK DESIGN SINGLE BOILER USING ROOM AIR

Warning

Boiler Size

CFC 500 6" Standard 80

CFC 750 6" Standard 60

CFC 1000

CFC 1500

CFC 1800

Boiler Flue

Connection

8" Standard 140

6" Option 80

10" Option 200

10" Standard 80

8" Option 60

12" Option 120

12" Standard 100

10" Option 60

Maximum length of breeching or

stack (feet)*

CFC 2500 12" Standard 110

* Each additional 90 deg. 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.

3-10 Part No. 750-263

Section 3 — Stack and Intake Vent Sizing and Installation

2. Stack design using direct vent combustion

Table 3-2 STACK SIZING USING OUTSIDE AIR FOR COMBUSTION

Boiler Flue Connection Combustion Air

Boiler

CFC 500 6" Standard

CFC750 6" Standard

8" Standard 6" 60 60

CFC1000

CFC1500

6" Option 6" 40 40

10" Option 6" 80 80

10" Standard

8" Option

Maximum length of

Duct

Connection

4" 75 75

6" 80 80

4" 40 40

6" 50 50

6" 40 40

8" 60 60

6" 30 30

8" 40 40

Flue Gas Vent in

Feet*

Maximum length of

Air Intake Duct in

Feet**

6" 60 60

12" Option

8" 80 80

6" 50 50

12" Standard

8" 80 80

CFC1800

6" 40 40

10" Option

8" 55 55

CFC 2500 12" Standard 8" 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.

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

Part No. 750-263 3-11

Section 3 — Stack and Intake Vent Sizing and Installation

G. VENTING FOR MULTIPLE UNITS

Cleaver-Brooks recommends that each Model CFC in a multiple boiler installation be vented individually. If it becomes necessary to connect multiple boilers to a common breeching, measures should be taken to ensure an unrestricted flow of flue gas from each boiler.

An active draft inducer is recommended when venting multiple boilers. In the absence of a draft inducer, ductwork sizing and connections require special attention.

Use ‘wye’ connections (not ‘tees’) to connect each boiler to the common breeching (see Examples 1 and 2 below).

Breeching should be sized upward when necessary to accommodate additional boilers (see Example 3). As a rule of thumb, the cross-sectional area of any ductwork downstream of a wye connection should be equal to or greater than the combined area of the incoming vent sections.

When multiple boilers are connected in a CB Falcon-controlled lead/ lag network, a ‘Fan rate during off cycle’ feature is available. When a boiler goes off line and completes a post purge, the fan will continue to run at a user-selectable rate. This feature provides a further measure to prevent flue gas from flowing back into the boiler.

EXAMPLE 1

GOOD

BAD





6”

6” 6”

10”

14”

6”

3-12 Part No. 750-263

EXAMPLE 2

GOOD

Section 3 — Stack and Intake Vent Sizing and Installation

10”



EXAMPLE 3

GOOD



BAD

14”

6”



6”

10”

GOOD

6” 6”

From Boilers

8”

12”

16”

6”

BAD



6”

6” 6”

6”



From Boilers

8” 8”

From Boilers

Part No. 750-263 3-13

8”

Section 3 — Stack and Intake Vent Sizing and Installation

H.COMBUSTI0N AIR/BOILER ROOM VENTILATION

REQUIREMENTS

The boiler(s) must be supplied with adequate quantities of uncontaminated air to support proper combustion and equipment ventilation. Air shall be free of chlorides, halogens, fluorocarbons, construction dust or other contaminants that are detrimental to the burner/boiler. If these contaminants are present, we recommend the use of direct vent combustion provided the outside air source is uncontaminated.

Combustion air can be supplied by means of conventional venting, where combustion air is drawn from the area immediately surrounding the boiler (boiler room must be positive pressure), or with direct vent (direct vent combustion) where air is drawn directly from the outside. All installations must comply with local Codes and with NFPA 54 (the National Fuel Gas Code - NFGC) for the U.S. and for Canada, CAN/CGA B 149.1 and B 149.2.

Note: A boiler room exhaust fan is not recommended as this type of device can

cause a negative pressure in the boiler room if using a conventional air intake.

In accordance with NFPA54, the required volume of indoor air shall be determined in accordance with the "Standard Method" or "Known Air Infiltration Rate Method. Where the air infiltration rate is known to be less than 0.40 Air Changes per Hour, the Known Air Infiltration Rate Method shall be used (see Section 8.3 in the NFPA54 Handbook for additional information).

1. Air Supply - Unconfined Spaces (For U.S. Installations Only)

A. All Air From Inside the Building - If all combustion air is

drawn from inside the building (the mechanical equipment room does not receive air from outside via louvers or vent openings and the boiler is not equipped with direct vent combustion) and the boiler is located in an unconfined space, use the following guidelines:

1. The mechanical equipment room must be provided with two permanent openings linked directly with additional room (s) of sufficient volume so that the combined volume of all spaces meet the criteria for an unconfined space. Note: An "unconfined space" is defined as a space whose volume is more than 50 cubic feet per 1,000 Btu per hour of aggregate input rating of all appliances installed in that space.

2. Each opening must have a minimum free area of one square inch per 1,000 Btu per hour of the total input rating of all gas utilizing equipment in the mechanical room.

3-14 Part No. 750-263

Section 3 — Stack and Intake Vent Sizing and Installation

3. One opening must terminate within twelve inches of the top, and one opening must terminate within twelve inches of the bottom of the room.

4. Refer to the NFGC, Section 8.3 for additional information.

B. All Air From Outdoors - If all combustion air will be received from outside the building (the

mechanical room equipment is linked with the outdoors), the following methods can be used:

1. Two Opening Method - The mechanical equipment room must be provided with two permanent openings, one terminating within twelve inches from the top, and one opening terminating within twelve inches of the bottom of the room.

2. The openings must be linked directly (Figure 3-5) or by ducts (Figure 3-6) with the outdoors.

3. Each opening must have a minimum free area of one square inch per 4,000 Btu per hour of total input rating of all equipment in the room, when the opening is directly linked to the outdoors or through vertical ducts.

4. The minimum free area required for horizontal ducts is one square inch per 2,000 Btu per hour of total input rating of all the equipment in the room.

GAS VENT

CLEARFIRE BOILER

GAS VENT

WATER

HEATER

Figure 3-5 Two Opening Outside Wall Method

12" MINIMUM

FRESH AIR OPENING

INTERIOR WALL

FRESH AIR OPENING

12" MINIMUM

Part No. 750-263 3-15

Section 3 — Stack and Intake Vent Sizing and Installation

GAS VENT

CLEARFIRE BOILER

WATER

HEATER

Figure 3-6. Two Opening Ducted Method

12" MINIMUM

OUTLET AIR DUCT

INTERIOR WALL

EXTERIOR WALL

FRESH AIR INLET DUCT

12" MINIMUM

C. One Opening Method (Figure 3-7) - One permanent opening,

commencing within 12 inches of the top of the enclosure, shall be provided.

1. The equipment shall have clearances of at least 1 inch from the sides and back and 6 inches from the front of the appliance.

2. The opening shall directly communicate with the outdoors and shall have a minimum free area of 1 square inch per 3000 BTU's per hour of the total input rating of all equipment located in the enclosure, and not less than the sum of the areas of all vent connectors in the confined space.

3. Refer to the NFGC, Section 8.3 for additional information.

3-16 Part No. 750-263

Section 3 — Stack and Intake Vent Sizing and Installation

GAS VENT

CLEARFIRE BOILER

GAS VENT

12" MINIMUM

FRESH AIR OPENING

EXTERIOR WALL

WATER

HEATER

Figure 3-7. One Opening Method

2. Air Supply - Engineered Method

When determining boiler room air requirements for an unconfined space, the size of the room, airflow, and velocity of air must be reviewed as follows:

1. Size (area) and location of air supply openings in the boiler room.

A. Two permanent air supply openings in the outer walls of the

boiler room are recommended. Locate one at each end of the boiler room, preferably below a height of 7 feet. This allows air to sweep the length of the boiler. See Figure 3-8.

B. Air supply openings can be louvered for weather protection,

but they should not be covered with fine mesh wire, as this type of covering has poor air flow qualities and is subject to clogging with dirt and dust.

C. A vent fan in the boiler room is not recommended, as it could

create a slight vacuum under certain conditions and cause variations in the quantity of combustion air. This can result in unsafe burner performance.

D. Under no condition should the total area of the air supply

openings be less than one square foot.

Part No. 750-263 3-17

Section 3 — Stack and Intake Vent Sizing and Installation

FRESH AIR OPENING

EXTERIOR WALL

GAS VENT

CLEARFIRE BOILER

GAS VENT

WATER HEATER

FRESH AIR OPENING

EXTERIOR WALL

Figure 3-8. Two Opening Engineered Method

E. Size the openings by using the formula:

Area in square feet = cfm/fpm

Where cfm = cubic feet per minute of air

Where fpm = feet per minute of air

2. Amount of Air Required (cfm). A. Combustion Air = 0.25 cfm per kBtuh.

B. Ventilation Air = 0.05 cfm per kBtuh.

C. Total air = 0.3 cfm per kBtuh (up to 1000 feet elevation.

Add 3% more per 1000 feet of added elevation).

3. Acceptable air velocity in the Boiler Room (fpm). A. From floor to 7 feet high = 250 fpm.

B. Above 7 feet above floor = 500 fpm.

Example: Determine the area of the boiler room air supply openings for (2) Clearfire 1800 boilers at 750 feet elevation. The air openings to be 5 feet above floor level.

• Air required: 1800 x 2 = 3600 kBtuh. From 2C above, 3600 x 0.3 = 1,080 cfm.

• Air Velocity: Up to 7 feet = 250 fpm from 3 above.

3-18 Part No. 750-263

Section 3 — Stack and Intake Vent Sizing and Installation

• Area required: Area = cfm/fpm = 1,080/250 = 4.32 square feet total.

• Area/Opening: 4.32/2 = 2.16 sq-ft/opening (2 required).

Notice

Consult local codes, which may supersede these requirements.

a duct connected to the burner air intake, use the following as a guide:

1. Install combustion air vent (direct vent combustion) in accordance with the boiler's Operating and Maintenance manual.

2. Provide for adequate ventilation of the boiler room or mechanical equipment room.

3. In cold climates, and to mitigate potential freeze-up of the intake pipe, it is highly recommended that a motorized sealed damper be used to prevent the circulation of cold air through the boiler during non-operating hours.

4. Refer to Figure 3-2 and Figure 3-4 for suggested piping of direct vent combustion installations. Figure 3-9 shows the optional direct vent combustion kit providing easy adaptation of the contractor supplied air duct to boiler connection. Refer to Table 3-2 for sizing the direct vent combustion air pipe.

Direct Vent CombustionIf combustion air will be drawn directly from the outside by means of

FAN/BLOWER

VENTURI

AIR SUPPLY LINE

Figure 3-9. Optional Direct Vent Combustion Kit

Part No. 750-263 3-19

Section 3 — Stack and Intake Vent Sizing and Installation

3-20 Part No. 750-263

Section 4

CFC Commissioning

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

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

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

Model CFC Boiler / Burner Controller . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

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

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

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

Operation Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

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

Controller Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Changing Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Program Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Burner Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Fan Speed Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Initial start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Gas Train and Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Operation Check: Gas Valve, Gas Press. Switches, and CAPS . . . . 4-19

Low Water Cutoff Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Low and High Fire Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Modulation OFF point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Setting Combustion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

High Air Pressure Switch settings . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Limit Controls Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Post start-up checkout procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

Procedures for LP (Propane) Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Single Fuel Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Units with optional dual-fuel gas train . . . . . . . . . . . . . . . . . . . . . 4-26

Falcon Control Functions and Customer Interface . . . . . . . . . . . . . . . . 4-28

Warning

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

Milwaukee, Wisconsin

www.cleaver-brooks.com

Section 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

Warning

When using direct vent combustion in cold climates, special care must be taken to observe combustion air temperature limits. Failure to

follow this precaution may lead to equipment damage or unsafe operation.

• Control panel must be connected to earth ground.

• Refer to Section 3 for combustion air requirements.

Boiler room ambient conditions

Relative humidity < 85% non-condensing

Ambient temperature range 0 Storage temperature range -40 Combustion air temperature 0 oC to 50 oC / 32oF to 122oF

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.

C. CONTROL SETPOINTS

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

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

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

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

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

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

Figure 4-1 Opening Control

Panel

4-2 Part No. 750-263

D. MODEL CFC BOILER / BURNER CONTROLLER

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

• Flame supervision

• Burner sequencing

• Heating/modulation control

• Hot water system pump control

• High Limit temperature control

• Thermowell-mounted NTC temperature sensors to provide measured process variable signals to the controller.

Section 4 — CFC Commissioning

Additional features include:

• User-friendly touchscreen interface

• Modbus communication capability

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

• Annunciation

• 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

• (3) configurable pump relays

• Remote modulation/remote setpoint

• Frost protection

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

Figure 4-2 CB Falcon Controller

Warning

The Model CFC is factory tested. Nevertheless, all burner safety controls should be checked upon installation, prior to initial firing.

Failure to verify burner control functioning could result in severe bodily injury or death.

Part No. 750-263 4-3

Figure 4-3 Controller status

LEDs and reset button

Section 4 — CFC Commissioning

E. CB FALCON DISPLAY/OPERATOR INTERFACE

The CB Falcon display/operator interface is mounted at the left side of the control panel for convenient access to all operating controls.

1. Home Page

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 Home page by an icon and name.

Figure 4-4 CB Falcon Display/

Operator Interface

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.

Home page

The Demand display will show one of the following:

Burner switch off Off (burner switch on but no demand) Central Heat Domestic Hot Water (if configured)

Status page

Burner state shows the currently active step in the burner operating

sequence.

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

Pumps shows the on/off status of boiler and system pumps. Modulation shows fan speed RPM settings for Demand, Limited,

and Override rates Setpoints shows the ON, Modulation, and OFF temperature setpoints.

4-4 Part No. 750-263

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.

The burner is enabled from this page by turning the <Burner switch> screen button ON (see Figure 4-5).

HOME PAGE

STATUS

SUMMARY

Section 4 — CFC Commissioning

Figure 4-5 Operation Page

SAFETY

VERIFICATION

CONFIGURATION

PASSWORD

OPERATION

CONFIGURATION

GROUP

DIAGNOSTICS

CONFIGURATION

GROUP

STATUS

DETAIL

CONFIGURATION

GROUP

Figure 4-6 Falcon Display/Interface page flow

4. Lockouts, Holds, and Alerts

To assist in monitoring boiler operation, the CB Falcon control system employs messages of three types: Lockouts, Holds, and Alerts.

• Lockouts and Holds indicate interruptions in boiler operation, whether occurring as part of the normal operating sequence or due to an abnormal condition. Lockouts require a manual reset to continue operation, while Holds do not. A Hold will automatically clear when the hold condition is removed or satisfied.

The most recent Lockouts are stored in CB Falcon memory and may be accessed through the Lockout History. Holds are not logged in memory.

Note: Before attempting to restart the boiler after a Lockout, identify and correct the Lockout condition.

• Alerts indicate conditions or events which, while not preventing boiler operation, may nevertheless be of interest in evaluating boiler performance or operating conditions. Examples include

Part No. 750-263 4-5

Section 4 — CFC Commissioning

certain operator actions, out-of-range configuration data, controller internal status reports (e.g. timers, counters, memory read/write activity), and recycle events. Alerts require no operator acknowledgment and are for informational purposes only.

The most recently occurring message (Lockout, Hold, or Alert) is displayed in the alarm banner on the Status screen (see Figure 4-

7). Press this banner to access the Alert or Lockout History, where a list of the most recently occurring Alerts/Lockouts can be viewed.

Alarm Banner

Figure 4-7 Alarm Banner

To obtain more information for a particular message, press that item in the respective history list. For Alerts, burner cycle and hours of operation at the time of occurrence will be displayed. For Lockouts, in addition to cycle and hours the screen will show on/off status of all interlocks at the time of the lockout. This information can be used to help pinpoint the cause of a particular Lockout.

See also Chapter 5, Section E - Troubleshooting.

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, Table 4-1, and make 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

4-6 Part No. 750-263

Section 4 — CFC Commissioning

• Burner Control Interlocks

• Burner Control Timings & Rates

• Burner Control Ignition

• Burner Control Flame Failure

• System Configuration

• Fan Configuration

• Lead Lag Configuration

Table 4-1 CFC default parameter settings

Parameter Group Parameter Name Access*

System ID & Access Boiler Name Service Boiler 1 0183 System ID & Access Installation data Service SERIAL NUMBER 0184

System ID & Access OEM Identification Read Only System ID & Access Installer password Service 9220 0190 System ID & Access Modbus address Service 0 1 250 ???? System ID & Access Factory data Read Only ???? Central Heat Configuration CH enable Service Enabled 0208 Central Heat Configuration CH demand source Service Stat terminal 0209

Central Heat Configuration CH modulation sensor Service Central Heat Configuration CH setpoint User 32 150 194 °F 0211 Central Heat Configuration CH TOD setpoint User 32 120 194 °F 0212 Central Heat Configuration CH on hysteresis Service 2 5 60 °F 0213 Central Heat Configuration CH off hysteresis Service 2 15 60 °F 0214 Central Heat Configuration CH outdoor reset enable Service Disabled 0215 Central Heat Configuration CH P gain Service 0 25 400 0216 Central Heat Configuration CH I gain Service 0 25 400 0217 Central Heat Configuration CH D gain Service 0 0 400 0218 Central Heat Configuration CH hysteresis step time Service 0 60 900 seconds 0219 Central Heat Configuration CH setpoint source Service Local SP 0578 Central Heat Configuration CH modulation source Service Local Modulation (PID) 0580 Central Heat Configuration CH has priority over LL Service No 0582 Central Heat Configuration CH 4mA water temperature Service 60 0583 Central Heat Configuration CH 20mA water temperature Service 180 0584

Outdoor Reset Configuration Outdoor Reset Configuration Outdoor Reset Configuration

Outdoor Reset Configuration CH ODR maximum off point Service 32 194 210 °F 0516 Outdoor Reset Configuration

Domestic HW Configuration DHW enable User Disabled 0448 Domestic HW Configuration DHW demand switch Service Domestic HW Configuration Domestic HW Configuration

Domestic HW Configuration DHW priority override time Service 0 1800 14400 seconds 0452

CH ODR max. outdoor temperature Service -40 80 140 °F 0512

CH ODR min. outdoor temperature Service -40 0 140 °F 0513

CH ODR low water temperature Service 32 80 180 °F 0514

Minimum boiler water temperature Service 32 80 180 °F 0526

DHW priority has priority over CH Service Yes 0450 DHW priority has priority over LL Service Yes 0451

Min.

Range Default Setting

CB FALCON 833-

03639

Modulation from Outlet

sensor (S3S4)

DHW switch (S6) or

sensor only 0449

Max.

Range

Parameter

Units Installation Setting

Modbus Register

(dec)

0185

0210

Part No. 750-263 4-7

Section 4 — CFC Commissioning

Table 4-1 CFC default parameter settings

Parameter Group Parameter Name Access*

Domestic HW Configuration DHW setpoint User 32 130 180 °F 0453 Domestic HW Configuration DHW TOD setpoint Service 32 120 180 °F 0454 Domestic HW Configuration DHW on hysteresi s Service 2 5 80 °F 0455 Domestic HW Configuration DHW off hysteresis Service 2 15 80 °F 0456 Domestic HW Configuration DHW P gain Service 0 25 400 0457 Domestic HW Configuration DHW I gain Service 0 25 400 0458 Domestic HW Configuration DHW D gain Service 0 0 400 0459 Domestic HW Configuration DHW hysteresis step time Service 0 60 900 seconds 0460

Domestic HW Configuration DHW modulation sensor Service Domestic HW Configuration DHW priority source Service DHW heat demand 0463

Domestic HW Storage Configuration DHW storage enable User Disabled 0504

Domestic HW Storage Configuration DHW storage time Service 0 1800 14400 seconds 0505

Domestic HW Storage Configuration DHW storage setpoint User 32 140 180 °F 0506

Domestic HW Storage Configuration DHW storage on hysteresis Service 2 5 80 °F 0507 Domestic HW Storage Configuration DHW storage off hysteresis Service 2 15 80 °F 0508 Domestic HW Storage Configuration DHW priority method Service

Burner Control Ignition Lightoff rate Service 1000 1800 3000 RPM 0197 Burner Control Ignition Ignition source Read Only External ignitor 0224 Burner Control Ignition Ignitor on during Read Only On throughout PFEP 0226 Burner Control Ignition Pilot type Read Only Direct Burner Ignition 0227 Burner Control Ignition Preignition time Service 0 0 900 seconds 0232

Burner Control Ignition Burner Control Ignition

Burner Control Ignition Flame threshold OEM 0.5 0.8 5 V or μA 0250 Burner Control Flame Failure Ignite failure response Service Lockout 0239 Burner Control Flame Failure Ignite failure retries Service 1 0240 Burner Control Flame Failure Ignite failure delay Service 30 seconds 0241 Burner Control Flame Failure MFEP flame failure response Hidden Lockout 0242 Burner Control Flame Failure Run flame failure response Read Only Lockout 0243 Burner Control Interlocks Purge rate proving OEM Fan speed 0229

Burner Control Interlocks Lightoff rate proving Service Burner Control Interlocks Interlock start check enable Hidden No ILK Check 0237 Burner Control Interlocks Interlock open response Read Only Lockout 0238

Burner Control Interlocks Burner Control Interlocks LCI enable Read Only Enabled 0248 Burner Control Interlocks PII enable Service Disabled 0249 Burner Control Interlocks ILK bounce detection enable Service Enabled 0253 Burner Control Timings & Rates Prepurge rate OEM 4000 4000 6500 RPM 0196 Burner Control Timings & Rates Postpurge rate Service 1000 2000 6500 RPM 0198 Burner Control Timings & Rates Standby rate Service 1000 1000 6500 RPM 0207 Burner Control Timings & Rates Prepurge time Service 15 15 900 seconds 0231 Burner Control Timings & Rates Run stabilization time Service 0 5 900 seconds 0235 Burner Control Timings & Rates Postpurge time Service 15 15 900 seconds 0236

Modulation (System) Configuration

Pilot Flame Est. Period (PFEP)

Main Flame Est. Period (MFEP)

Interrupted air switch (IAS) enable

Modulation Output Read Only VSD Fan PWM 0192

Read Only 4 seconds 0233

Hidden NA seconds 0234

Service

Min.

Range Default Setting

Auto: DHW sensor (S6)

or Outlet (S3S4) 0461

Drop DHW after priority

time expires 0509

Fan speed - except

during ignition

Enable during purge &

ignition

Max.

Range

Parameter

Units Installation Setting

Modbus Register

(dec)

0230

0246

4-8 Part No. 750-263

Section 4 — CFC Commissioning

Table 4-1 CFC default parameter settings

Parameter Group Parameter Name Access*

Modulation Configuration CH max. mod. rate Service 2000 5000 6000 RPM 0193 Modulation Configuration DHW max. mod. rate Service 2000 5000 6000 RPM 0194 Modulation Configuration Minimum mod. rate Service 900 1100 3000 RPM 0195 Modulation Configuration CH forced rate Service 1000 2000 6500 RPM 0199 Modulation Configuration CH forced rate time Service 0 0 14400 seconds 0200 Modulation Configuration DHW forced rate Service 1000 2000 6500 RPM 0201 Modulation Configuration DHW forced rate time Service 0 0 14400 seconds 0202 Modulation Configuration CH slow start enable Service Enabled 0477 Modulation Configuration DHW slow start enable Service Disabled 0478

Modulation Configuration Slow start ramp Service 100 500 5000 Modulation Configuration Slow start setpoint Service 0 20 180 Modulation Configuration Analog output hysteresis Hidden 0 5 400 Modulation Configuration Analog input hysteresis Service 0 2 200

Modulation Configuration Firing rate control User Auto 0204 Modulation Configuration Manual firing rate User 900 2000 6500 RPM 0205 Pump Configuration CH pump output Service No assignment 0272 Pump Configuration CH pump control Service Auto 0273 Pump Configuration CH pump overrun time Service 0 300 28800 seconds 0274

Pump Configuration Pump Configuration DHW pump output Service Pump B 0276 Pump Configuration DHW pump control Service Auto 0277 Pump Configuration DHW pump overrun time Service 0 60 28800 seconds 0278

Pump Configuration Pump Configuration DHW pump start delay Service 0 0 28800 seconds 0280 Pump Configuration Boiler pump output Service No assignment 0281 Pump Configuration Boiler pump control Service Auto 0282 Pump Configuration Boiler pump overrun time Service 0 300 28800 seconds 0283 Pump Configuration Auxiliary 1 pump output Service Pump A 0284 Pump Configuration Auxiliary 1 pump control Service Auto 0285 Pump Configuration Auxiliary 1 pump on when Service Local burner demand 0286 Pump Configuration System pump output Service No assignment 0287 Pump Configuration System pump control Service Auto 0288

Pump Configuration System pump overrun time Service 0 900 28800 seconds 0289 Pump Configuration Pump exercise interval Service 0 0 28800 seconds 0290 Pump Configuration Pump exercise time Service 0 0 28800 seconds 0291 Pump Configuration CH pump start delay Service 0 0 28800 seconds 0292 Pump Configuration Boiler pump start delay Service 0 0 28800 seconds 0293 Pump Configuration System pump start delay Service 0 0 28800 seconds 0294 Pump Configuration Auxiliary 1 pump start delay Service 0 0 28800 seconds 0295 Pump Configuration CH pump options 1 Service 0XE327 0296 Pump Configuration CH pump options 2 Service 0xC04E 0297 Pump Configuration DHW pump options 1 Service 0xE04A 0298 Pump Configuration DHW pump options 2 Service 0xC016 0299 Pump Configuration Boiler pump options 1 Service 0xE30F 0300

CH pump frost protection overrun time Service 0 3600 28800 seconds 0275

DHW pump frost protection overrun time Service 0 3600 28800 seconds 0279

Min.

Range Default Setting

Max.

Parameter

Range

Units Installation Setting

RPM/

minute 0479

deg (below

SP) 0480

steps

(5=0.1 mA) 0206

steps

(1=0.1mA) 0543

Modbus Register

(dec)

Part No. 750-263 4-9

Section 4 — CFC Commissioning

Table 4-1 CFC default parameter settings

Parameter Group Parameter Name Access*

Pump Configuration Boiler pump options 2 Service 0xC0DF 0301 Pump Configuration System pump options 1 Service 0xE36C 0302 Pump Configuration System pump options 2 Service 0x801D 0303

Pump Configuration Pump Configuration Auxiliary 1 pump options 1 Service 0x0003 0753 Pump Configuration Auxiliary 1 pump options 2 Service 0x4002 0754 Pump Configuration Auxiliary 2 pump output Service Pump C 0755 Pump Configuration Auxiliary 2 pump control Service Auto 0756 Pump Configuration Auxiliary 2 pump start delay Service 0 0 28800 seconds 0757

Pump Configuration Pump Configuration Auxiliary 2 pump options 1 Service 0x0000 0759 Pump Configuration Auxiliary 2 pump options 2 Service 0x4001 0760 Statistics Configuration Burner cycle count Read Only 0 999,999 0128 Statistics Configuration Burner run time Read Only 0 999,999 0130 Statistics Configuration CH pump cycle count Read Only 0 999,999 0132 Statistics Configuration DHW pump cycle count Read Only 0 999,999 0134 Statistics Configuration System pump cycle count Read Only 0 999,999 0136 Statistics Configuration Boiler pump cycle count Read Only 0 999,999 0138 Statistics Configuration Auxiliary 1 pump cycle count Read Only 0 999,999 0140 Statistics Configuration Auxiliary 2 pump cycle count Read Only 0 999,999 0146 System Configuration Temperature units Service Fahrenheit 0178 System Configuration Antishort cycle time Service 0 60 28800 seconds 0179 System Configuration Alarm silence time Service 0 0 3600 seconds 0180 System Configuration Power-up with lockout Read Only Do NOT clear lockout 0181 System Configuration Burner switch User Off 0203 System Configuration Blower/HSI function Read Only Blower 0225 System Configuration Flame sensor type OEM Flame rod 0228 System Configuration Forced recycle interval time Service 0 seconds 0254 System Configuration Fan speed error response Service Lockout 0255

System (Sensor) Configuration Inlet sensor type Read Only System (Sensor) Configuration

System (Sensor) Configuration Outlet sensor type Read Only 10k NTC dual safety 610 System (Sensor) Configuration S5 (outdoor) sensor type Service System (Sensor) Configuration DHW sensor type Service

System (Sensor) Configuration Stack sensor type Service Unconfigured 613 System (Sensor) Configuration Outdoor temperature source Service Unconfigured 626

System Configuration System Configuration System Configuration

Auxiliary 1 pump overrun time Service 0 300 28800 seconds 0752

Auxiliary 2 pump overrun time Service 0 0 28800 seconds 0758

S2 (remote 4-20mA or header) sensor type

Warm weather shutdown enable

Warm weather shutdown setpoint

Use STAT with EnviraCOM remote stat

OEM 4-20mA 609

Service Service 100 °F 0628

Hidden Disable 0629

Min.

Range Default Setting

10k NTC single non-

safety

10k NTC single non-

safety

10k NTC single non-

safety

Warm weather

shutdown disabled

Max.

Range

Parameter

Units Installation Setting

Modbus Register

(dec)

608

611 612

0627

Fan Configuration Absolute max. fan speed OEM 2000 6000 6500 RPM 0256 Fan Configuration Absolute min. fan speed OEM 800 800 3000 RPM 0257 Fan Configuration P WM frequency OEM 1000 3000 4000 Hz 0258 Fan Configuration Pulses per revolution Read Only 2 3 3 0259

4-10 Part No. 750-263

Section 4 — CFC Commissioning

Table 4-1 CFC default parameter settings

Parameter Group Parameter Name Access*

Fan Configuration Fan speed up ramp Service 0 0 1000 RPM/sec 0260 Fan Configuration Fan speed down ramp Service 0 0 1000 RPM/sec 0261 Fan Configuration Fan gain up Service 0 30 100 0262 Fan Configuration Fan gain down Service 0 30 100 0263 Fan Configuration Fan min. duty cycle Service 5 10 100 % 0264 High Limits Outlet high limit enable Read Only Enabled 0484 High Limits Outlet high limit setpoint Service 32 180 210 °F 0464 High Limits Outlet high limit response Read Only Lockout 0465 High Limits DHW high limit enable Service Disabled 0474 High Limits DHW high limit setpoint Service 32 No value 210 °F 0475 High Limits DHW high limit response Service Recycle & hold 0476 Stack Limit Stack limit enable Service Disabled 0466 Stack Limit Stack limit setpoint Service 32 250 266 °F 0467 Stack Limit Stack limit response Service Lockout 0468 Stack Limit Stack limit delay Service 0 300 900 seconds 0469

Delta T Limits Delta T Limits Delta T Limits Delta-T response Service

Delta T Limits Delta-T delay Service 0 5 480 minutes 0473 Delta T Limits Delta-T retry limit Service 0 3 100

Delta T Limits Delta-T rate limit enable Service Enabled 0486 Delta T Limits Delta-T inverse limit time Service 5 30 minutes 0487

Delta T Limits Delta T Limits Delta T Limits Delta T Limits Delta T Limits

T-rise Limit Outlet T-rise enable Service Disabled not used 0481 T-rise Limit T-rise degrees Service 10 °F T-rise Limit T-rise delay Service 5 minutes notused 0483 T-rise Limit Exchanger T-rise enable Service Disabled

T-rise Limit T-rise response Service T-rise Limit T-rise retry limit Service 10 not used 0493

Heat Exchanger High Limit Heat Exchanger High Limit Heat Exchanger High Limit Heat Exchanger High Limit

Heat Exchanger High Limit Heat exchanger retry limit Service Lockout not used 0596 Plate HX Preheat Plate preheat delay after tap Service 90 seconds Plate HX Preheat Plate preheat setpoint Service 200 °F not used 0689

Plate HX Preheat Plate HX Preheat Plate preheat ON hysteresis Service 5 °F not used 0691

Delta-T enable - Inlet to outlet flow

Delta-T degrees - Inlet to outlet flow

Delta-T inverse limit response

Delta-T enable - Exchanger to outlet flow

Delta-T degrees - Exchanger to outlet flow

Delta-T enable - Inlet to Exchanger flow

Delta-T degrees - Inlet to Exchanger flow

Heat exchanger high limit enable

Heat exchanger high limit setpoint

Heat exchanger high limit response

Heat exchanger high limit delay

Plate preheat on recognition time Service 10 seconds

Service Service 14 50 160 °F 0471

Service Service Disabled 0489 Service 14 50 160 °F 0490 Service Disabled 0494 Service 14 50 160 °F 0495

Service Disabled Service 32 200 266 °F Service Service 0 5 900 minutes

Min.

Range Default Setting

Enabled ΔT and inversion detect

Recycle & Delay w/

retry limit

Recycle & Delay w/

retry limit

Recycle & Delay w/

retry limit

Recycle & Delay w/

retry limit

Max.

Range

Parameter

Units Installation Setting

retries (b4

lockout)

not used

notused 0492

not used

notused

not used

Modbus Register

(dec)

0470

0472

0485

0488

0482

0491

0592 0593 0594 0595

0688

0690

Part No. 750-263 4-11

Section 4 — CFC Commissioning

Table 4-1 CFC default parameter settings

Parameter Group Parameter Name Access*

Plate HX Preheat Plate preheat OFF hysteresis Service 5 °F Plate HX Preheat Plate HX Preheat

Plate HX Preheat Tap detect ON hysteresis Service 20 °F not used 0695 Plate HX Preheat

Plate HX Preheat Tap stop Inlet-DHW degrees Service 5 °F Plate HX Preheat

Plate HX Preheat Tap detect minimum on time Service 60 seconds not used 0699 Plate HX Preheat Tap detect on threshold Service No value °F

Plate HX Preheat Plate HX Preheat

Annunciation Configuration Annunciation enable Hidden Enabled 0304 Annunciation Configuration Annunciator 1 location OEM Other 0306 Annunciation Configuration Annunciator 1 short name OEM A1 0307 Annunciation Configuration Annunciator 1 long name OEM AIR SWITCH 0309 Annunciation Configuration Annunciator 2 location Service Unused (or LCI) 0319 Annunciation Configuration Annunciator 2 short name Service A2 0320 Annunciation Configuration Annunciator 2 long name Service AUX LOW WATER 0322 Annunciation Configuration Annunciator 3 location OEM ILK 0332 Annunciation Configuration Annunciator 3 short name OEM A3 0333 Annunciation Configuration Annunciator 3 long name OEM LOW WATER 0335 Annunciation Configuration Annunciator 4 location OEM ILK 0345 Annunciation Configuration Annunciator 4 short name OEM A4 0346 Annunciation Configuration Annunciator 4 long name OEM HIGH AIR PRESSURE 0348 Annunciation Configuration Annunciator 5 location OEM ILK 0358 Annunciation Configuration Annunciator 5 short name OEM A5 0359

Annunciation Configuration Annunciator 5 long name OEM Annunciation Configuration Annunciator 6 location OEM ILK 0371 Annunciation Configuration Annunciator 6 short name OEM A6 0372 Annunciation Configuration Annunciator 6 long name OEM LOW GAS PRESSURE 0374 Annunciation Configuration Annunciator 7 location Service ILK 0384 Annunciation Configuration Annunciator 7 short name Service A7 0385 Annunciation Configuration Annunciator 7 long name Service NATURAL GAS 0387 Annunciation Configuration Annunciator 8 location Service ILK 0397 Annunciation Configuration Annunciator 8 short name Service A8 0398 Annunciation Configuration Annunciator 8 long name Service LP GAS 0400 Annunciation Configuration PII short name OEM PII 0410 Annunciation Configuration PII long name OEM Pre-Ignition ILK 0412 Annunciation Configuration LCI short name OEM LCI 0422 Annunciation Configuration LCI long name OEM Load Control Input 0424 Annunciation Configuration ILK short name OEM ILK 0434 Annunciation Configuration ILK long name OEM Interlock 0436

Plate preheat minimum on time Service 60 seconds

Tap detect degrees per second Service 2 °F

Tap detect on recognition time Service 5 seconds not used 0696

Tap stop Outlet-DHW degrees Service 10 °F

Plate preheat detect on threshold Service No value °F not used 0701 Plate preheat detect off threshold Service No value °F not used 0702

Min.

Range Default Setting

HIGH GAS

PRESSURE 0361

Max.

Range

Parameter

Units Installation Setting

not used

Modbus Register

(dec)

0692 0693 0694

0697 0698

0700

Anti-condensation Configuration CH anti-condensation enable Service Disabled 0496 Anti-condensation Configuration

CH anti-condensation setpoint Service 32 140 194 °F 0497

4-12 Part No. 750-263

Section 4 — CFC Commissioning

Table 4-1 CFC default parameter settings

Parameter Group Parameter Name Access*

Anti-condensation Configuration Anti-condensation Configuration Anti-condensation Configuration Anti-condensation Configuration Anti-condensation Configuration

Anti-condensation Configuration Anti-condensation > Delta-T Service No 0502 Anti-condensation Configuration Anti-condensation Configuration Anti-condensation Configuration Anti-condensation Configuration

Frost Protection Configuration CH frost protection enable Service Disabled 0528 Frost Protection Configuration DHW frost protection enable Service Disabled 0529

Frost Protection Configuration Frost Protection Configuration LL frost protection enable Service Disabled 0532 Frost Protection Configuration LL frost protection rate Service 0 20% 100 0533 Lead Lag Configuration Lead Lag slave enable Service Disabled 0544 Lead Lag Configuration Lead Lag master enable Service Disabled 0545 Lead Lag Configuration Lead Lag CH setpoint Service 32 150 230 °F 0546 Lead Lag Configuration Lead Lag CH TOD setpoint Service 32 120 230 °F 0547 Lead Lag Configuration Lead Lag on hysteresis Service 5 °F 0549 Lead Lag Configuration Lead Lag off hysteresis Service 15 °F 0550

Lead Lag Configuration Lead Lag Configuration Lead Lag P gain Service 0 10 400 0552 Lead Lag Configuration Lead Lag I gain Service 0 25 400 0553 Lead Lag Configuration Lead Lag D gain Service 0 0 400 0554 Lead Lag Configuration Lead Lag operation switch Service Yes/True/On 0555 Lead Lag Configuration Lead Lag CH demand switch Service STAT terminal 0556 Lead Lag Configuration Lead Lag CH setpoint source Service Local 0557

Lead Lag Configuration Lead Lag Configuration Lead Lag Configuration

Lead Lag Configuration Slave mode Service Equalize run time 0564 Lead Lag Configuration Base load rate Service 800 2000 6000 RPM 0566 Lead Lag Configuration Fan rate during off cycle Service 0 0 6000 RPM 0567 Lead Lag Configuration Slave sequence order Service 0 0568 Lead Lag Configuration Lead Lag Modbus port Service MB2 0569

Lead Lag Configuration Lead Lag Configuration Base load common Service 0 45% 100 % 0572

Lead Lag Configuration Lead selection method Service Lead Lag Configuration Lag selection method Service Lead Lag Configuration

CH anti-condensation pump force off DHW anti-condensation enable Service Disabled 0499 DHW anti-condensation setpoint Service 32 140 194 °F 0500 DHW anti-condensation pump force off Anti-condensation > Outlet limit Service No 0502

Anti-condensation > Stack limit Service No 0502

Anti-condensation > Slow start Service Yes 0502

Anti-condensation > Forced rate Service Yes 0502

Frost protect anticondensation enable Service No 0503

Outdoor frost protection setpoint Service -40 32 120 °F 0530

Lead Lag hysteresis step time Service 60 seconds 0551

Lead Lag modulation backup sensor Service

Lead Lag CH 4mA water temperature Service 80 °F 0560

Lead Lag CH 20mA water temperature Service 180 °F 0561

Lead Lag slave demand to firing delay Service 60 300 seconds 0570

Lead Lag add stage method 1 Service Firing rate threshold 0714

Service Disabled 0498

Service Disabled 0501

Min.

Range Default Setting

Use average of all

slave outlet sensors 0559

Lowest measured run

time 0574

Rotate in sequence

order 0575

Max.

Range

Parameter

Units Installation Setting

Modbus Register

(dec)

Part No. 750-263 4-13

Section 4 — CFC Commissioning

Table 4-1 CFC default parameter settings

Parameter Group Parameter Name Access*

Lead Lag Configuration Lead Lag Configuration Lead Lag Configuration Lead Lag Configuration Lead Lag Configuration Lead Lag Configuration Lead Lag Configuration Lead Lag Configuration Lead Lag Configuration

Lead Lag Configuration Lead rotation time Service 1 24 hours 0733 Lead Lag Configuration Force lead rotation time Service 1 168 hours 0734

Lead Lag Configuration Boiler off options Service Lead Lag Configuration All boilers off threshold Service 25 °F 0737

Lead Lag Configuration Lead Lag Configuration Lead Lag Configuration Lead Lag Configuration Lead Lag Configuration

Lead Lag add stage detection time 1 Service 60 300 seconds 0716 Lead Lag add stage error threshold Service 5 °F 0718 Lead Lag add stage rate offset Service -100 20% 100 % 0719 Lead Lag add stage interstage delay Service 180 900 seconds 0722 Lead Lag drop stage method 1 Service Firing rate threshold 0723 Lead Lag drop stage detection time 1 Service 60 300 seconds 0725 Lead Lag drop stage error threshold Service 10 °F 0727 Lead Lag drop stage rate offset Service -100 -3% 100 Lead Lag drop stage interstage delay Service 180 900 seconds 0731

Lead Lag CH ODR min. outdoor temperature Service -40 0 140 °F 0518

Lead Lag CH ODR low water temperature Service 80 180 °F 0519

Lead Lag CH ODR maximum off point Service 32 194 230 °F 0521 Lead Lag CH ODR min. water temperature Service 80 230 °F 0527 Lead Lag CH outdoor reset enable Service Disabled 0548

Min.

Range Default Setting

All Boilers Off option

disabled

Max.

Range

Parameter

Units Installation Setting

Modbus Register

(dec)

0728

0736

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

*Access Levels:

Read Only = parameter not configurable OEM = manufacturer only Service = password required (default password is 9220) User = no password required

4-14 Part No. 750-263

Figure 4-1 Configuration Menu

Section 4 — CFC Commissioning

1. Changing Parameter Settings

To 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. Default service level password is 9220.

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).

Figure 4-2 Parameter change dialog

Safety Parameters

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

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

2. The affected parameter group will be displayed, showing current parameter values and a prompt, “Are these parameters set to proper values?”. Press <Yes> to continue.

3. The screen will indicate RESET DEVICE NOW. Open the control panel and press the RESET button on the CB Falcon controller (press and hold for 3 seconds).

RESET must be pressed within 30 seconds to save changes.

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

Part No. 750-263 4-15

Section 4 — CFC Commissioning

1. Press <Begin>

Confirming Safety Parameter changes

3. Reset CB Falcon

2. Press <Yes>

2. Program Module

CB Falcon parameter information (non-safety parameters only) can be uploaded/downloaded using the optional Program Module. When the Program Module is installed, its features are accessible from the Falcon Setup page. Starting from the Home page, press <SETUP>, then <PROGRAM MODULE>.

G. BURNER SEQUENCE

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 limits and demand detected (terminals J6 3 and J8 3).

2. The CH pump is switched on.

3. After a system Safe Start Check, the Blower (fan) is switched on after a dynamic ILK switch test (if enabled).

Figure 4-3 Falcon Program

Module

4-16 Part No. 750-263

Section 4 — CFC Commissioning

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.

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. Tabl e 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.

Table 4-1 Fan Speed Settings

NATURAL GAS

Setting CFC-500

Max. Speed (RPM) CH 5500

Max. Speed (RPM) DHW 5500 5300 5300 5300 4600 5000

Min. Speed (RPM) 1300 1200 1100 1200 900 1100

Ignition Fan Speed (Lightoff Rate) 2200 2000 1800 1800 1500 1800

Max. Speed (RPM) CH 5200

Max. Speed (RPM) DHW 5200

Min. Speed (RPM) 1700 1600 1600 1700 1400 1400

Ignition Fan Speed (Lightoff Rate) 2400 2200 2200 2000 1800 2000

CFC-750 CFC-1000 CFC -1500 CFC-1800 CFC-2500

5300 5300 5300 4600 5000

LP GAS/DUAL FUEL

5000 5000 5000 4400 4000

Part No. 750-263 4-17

Section 4 — CFC Commissioning

I. INITIAL START-UP PROCEDURE

NOTE: For LP gas-fired units or boilers with optional dual-fuel gas train, see section K - Procedures for LP gas.

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 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 1/2 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.

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

Note: To measure supply pressure

at the CFC gas valve, use the test port on the valve inlet flange (see below). Do not use the leak test cocks to measure gas pressure.

Pressure check

Warning

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.

Figure 4-4 Premix Burner Technology - Full Modulation

4-18 Part No. 750-263

Section 4 — CFC Commissioning

Table 4-2 Model CFC Gas Pressure Requirements

Minimum pressure required at gas train

Boiler Model

500 7" w.c. 11" w.c.

750 7" w.c. 11" w.c. 1000 7" w.c. 11" w.c. 1500 10" w.c. 11" w.c. 1800 7" w.c. 11" w.c. 2500 9.5" w.c. 11" w.c.

connection Natural Gas LP Gas

Max. pressure

28” w.c.

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.

• Before proceeding, review Section 4.3 - Control Setpoints for

initial LGPS, HGPS, and CAPS settings.

Note:Close the downstream manual gas shut-off valve before

checking pressure switches and CAPS.

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

Figure 4-5 Annunciation Screen

LGPS

Part No. 750-263 4-19

Section 4 — CFC Commissioning

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 Falcon should lock out on an airflow failure. The display

will show Lockout 65 Interrupted Airflow Switch OFF.

CAPS low pressure connection

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.

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.

4-20 Part No. 750-263

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.

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 ILK section (Interlock circuit) should show A3 LOW WATER: OFF (Figure 4-6).

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.

Section 4 — CFC Commissioning

Figure 4-6 Low Water Cutoff te st

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 4-7). The high fire adjustment screw is accessed by removing the blue plastic cap from the valve cover (Figure 4-8).

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

Figure 4-7 Regulating Adjusting

Screw - Low Fire Offset

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.

Part No. 750-263 4-21

Figure 4-8 Main Gas Choke -

High Fire Adjustment

Section 4 — CFC Commissioning

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.

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

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

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 Tab l e 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.

4-22 Part No. 750-263

To set combustion:

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 4-9). If the burner does not ignite, adjust choke counterclockwise slightly until you can see a slight yellow flame at the burner during ignition. Clockwise adjustments to the low-fire offset screw may also be tried. Check that gas pressure to gas valve inlet is sufficient to fire burner (see Table 4-3 for gas pressure requirements).

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

6. Manually modulate the burner to high fire. Adjust the gas choke if necessary to obtain desired O2% (6% - 7%).

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

Section 4 — CFC Commissioning

Figure 4-9 Operation screen

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 4-3 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.

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

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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.

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.

4-24 Part No. 750-263

K. PROCEDURES FOR LP (PROPANE) GAS

• Minimum LP gas pressure required is 11" W.C. at 700' ASL.

Pressure correction required for high altitudes.

• Maximum gas pressure rating of the gas train is 1 psig.

Warning

Ensure that proper LP gas piping standards and practices are followed and that the LP gas is properly vaporized. Failure to do so

can result in serious injury or damage to the boiler.

Notice

When changing fuels, ensure the CB Falcon has been configured with the proper fan speed settings for the fuel being used. See Ta b l e 4 - 1.

1. Single fuel units

1. Close upstream manual gas shut-off valve. Disconnect power from the boiler.

Section 4 — CFC Commissioning

2. Install orifice gasket provided by replacing the existing venturigas train connection gasket with appropriate orifice (see Tab l e 4-4). Install the vortex breaker (CFC-2500 only) between venturi and blower with the main body of the vortex breaker in the vertical position. Ensure gas train-venturi connection is secure and gas tight. Ensure venturi-blower connection is tight.

Figure 4-10 LP Gas Setup - Single Fuel

CFC-1800 & CFC-2500 ONLY

CFC-2500 ONLY

3. Connect power to the boiler. Power up the controls.

4. Access boiler control Configuration menu. Press <Login>. Enter service level password: 9220. Press <OK>.

5. Select Modulation configuration. Adjust CH and DHW maximum modulation rates according to Ta b le 4- 1. Adjust minimum

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Section 4 — CFC Commissioning

modulation rate according to Tab l e 4 -1 . Return to Configuration menu.

6. Select Burner Control Ignition configuration. Adjust ignition, or

lightoff, rate according to Tabl e 4 - 1 . A warning will appear noting that you are changing a safety parameter. After changing the speed, return to Configuration menu.

7. Press <Verify> to check safety parameter change(s). Press <Begin> and check that all changes are correct. Press <Yes> if correct. If incorrect press <No> and return to appropriate parameter configuration menu to correct. After all safety parameter changes are checked, the controller requires a manual reset. Open the panel and reset the control.

8. Follow normal startup and commissioning procedures in this manual beginning with Section I - Initial Startup Procedure. Proper combustion settings for LP gas on ClearFire boilers are between 6.5 - 7.5% O2.

Table 4-4 Parts for LP Gas

Gasket

Orifice P/N Dia. (i n. )

CFC-1800 853-01309 0.625" N/A CFC-2500 853-01294 0.750" 197-00311

Vortex

Breaker

Notice

When changing a single fuel unit from LP gas to natural gas, the orifice gasket must be removed. The vortex breaker may remain in place if desired. If the vortex breaker remains installed, fan speed settings will need to be adjusted upward from the normal natural gas settings.

2. Units with optional dual-fuel gas train

Notice

When commissioning dual-fuel units, natural gas combustion setup should be performed first.

1. Shut down boiler.

2. Close the natural gas supply and open propane supply.

3. Turn fuel selector switch to ‘LP Gas’. The Falcon annunciator should show natural gas OFF and LP gas ON.

4. Turn gas selector valve to the LP gas position (see Figure 4-11).

5. Depress gas pressure switches to reset.

6. Measure gas pressure at inlet to LP gas valve - should be 11” W.C. minimum.

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Section 4 — CFC Commissioning

7. Access boiler control Configuration menu. Press <Login>. Enter service level password: 9220. Press <OK>.

8. Select Modulation configuration. Adjust CH and DHW maximum modulation rates according to Tab le 4- 1 . Adjust minimum modulation rate according to Tab l e 4 -1 . Return to Configuration menu.

9. Select Burner Control Ignition configuration. Adjust ignition, or lightoff, rate according to Tabl e 4 - 1 . A warning will appear noting that you are changing a safety parameter. After changing the speed, return to Configuration menu.

10. Press <Verify> to check safety parameter change(s). Press <Begin> and check that all changes are correct. Press <Yes> if correct. If incorrect press <No> and return to appropriate parameter configuration menu to correct. After all safety parameter changes are checked, the controller requires a manual reset. Open the panel and reset the control.

11. Follow normal startup and commissioning procedures in this manual beginning with Section I - Initial Startup Procedure. Proper combustion settings for LP gas on ClearFire boilers are between 6.5 - 7.5% O2.

LP GAS

Natural Gas Train

NAT.

To Burner

Figure 4-11 Gas selector valve

GAS

Propane Gas Train

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Section 4 — CFC Commissioning

L. FALCON CONTROL FUNCTIONS AND

CUSTOMER INTERFACE

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

•Set Point

• Time-of-Day (TOD) Set Point

•Hysteresis On and Hysteresis Off

• PID modu lation control

• Remote Enable and Remote 4-20mA Input

• Remote Modulation

• Remote Set Point

• Rate Limiting/Override

•Configurable pump/auxiliary relay contacts

•Annunciator

•Diagn ostics

•Lockout/Alarm History

•Trend Analysis

•Modbu s communications

•Lead/Lag Con trol for up to 8 boilers

Set Point, TOD Set Point, Hysteresis On, Hysteresis Off, and PID load control

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

The Time-of-Day (TOD), or setback, set point is an alternative set point that is enabled when a remote contact connected to terminals J10-2 & J10-3 is closed (Refer to Figure 2-10 CFW wiring diagram). When the circuit is open, the boiler control reverts back to the normal set point. The TOD set point can be adjusted at either the Operation page or under the Central Heat Configuration parameter group. Service level password login is required to change this parameter.

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

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The PID (Proportional-Integral-Derivative) load control operates to generate the demand source’s modulation rate. Under Central Heat configuration, the PID gain values can be adjusted to match the desired modulation response. The default gain value settings of P=25, I=25 & D=0 have proven to work well with typical applications.

Remote Enable and Remote 4-20mA Input

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

Refer to Figure 2-10 in this manual or to your specific boiler wiring diagram for remote enable and remote 4-20mA input connections. For simple remote on-off sequencing, only terminals 24 and 25 (Falcon J8-1 & J8-3) need to be connected to dry enable contacts at the remote controller. When terminal 25 (demand input) is energized, the demand is enabled. The boiler operates on its local set point and PID modulating control settings.

For remote modulation (firing rate) control, both the remote enable and remote 4-20mA input connections must be made. The default setting for the 4-20mA remote input is “Local”. This setting should be verified under the Falcon control’s Central Heat configuration group, “Central Heat>Modulation>Modulation Rate Source”. For remote modulation this parameter should be set to “S2 (J8-6) 4-20 mA with sensor on-off.

To avoid nuisance operating limit shut downs of the boiler, the Falcon’s normal operating set point should be adjusted to a value that is greater than the system header set point.

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

To configure the boiler for remote set point control, navigate to the Falcon control’s Central Heat configuration group. Change the setting of “Central Heat Configuration>Set Point>Set Point Source” to “S2 (J8-6) 4-20mA”. Next, the span of the 4-20mA needs to be established. The active set point determines the value for 20mA; “minimum water temperature” determines the value for 4mA.

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Depending on the quality of the remote input signal, the modulation rate or operating set point may fluctuate slightly because of small changes in the measured current signal or because of induced noise. Under the Modulation configuration group, the “4-20mA input Hysteresis” setting may need to be adjusted to avoid undesired fluctuations in the either the modulation rate or operating set point. The default setting is 0.2mA and can be increased to essentially filter out small fluctuations of the input signal. It may take some trial and error to establish the optimum input hysteresis setting for a particular system.

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

Rate Limiting/Override

For safety reasons or to accommodate special operating conditions, the CB Falcon incorporates a number of control functions that either limit the modulation range or set the firing rate to a specific value. These functions include Delta T limiting, Slow Start, and Forced Rate. See Appendix A for a complete listing of control functions with detailed descriptions and parametrization instructions.

Delta T limiting is designed to reduce the firing rate in case of an excessive difference between the inlet and outlet temperatures. Sensor connections to the CB Falcon are at J8-4 and -5 (inlet temperature) and J8-8,-9, and -10 (outlet temperature). Delta T limiting includes an Inversion Detection mode which when enabled becomes active in case the inlet temperature is higher than the outlet temperature (indicating reverse water flow through the boiler).

Forced Rate limiting causes the burner to stay at a fixed firing rate for a fixed time period immediately after lightoff, following the Run Stabilization period (if any). The forced rate period is optionally followed by a Slow Start function that limits the ramp-up speed of the firing rate whenever the water is colder than a user-specifiable threshold. Slow Start can help reduce set point overshoot, high limit trips, and frequent cycling.

Configurable Pump/Aux Relay Contacts

The CB Falcon Pump/Aux Relay outputs are configurable by means of six identical Pump Control Blocks. Each control block has seven parameters:

Pump Options (2 parameter blocks) - determine pump on/off conditions

Start Delay - if burner is just starting up, timer will delay pump turning on

4-30 Part No. 750-263

CleaverBrooks CFC-500, CFC-2500, CFC-750, CFC-1000, CFC-1500 Operation, Service And Parts Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Model CFC

TABLE OF CONTENTS

Introduction

Installation