CleaverBrooks CFC-500, CFC-2500, CFC-750, CFC-1000, CFC-1500 Operation, Service And Parts Manual
...
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.
ii
!
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.
iv
TABLE OF CONTENTS
Section 1 —
Introduction
Clearfire Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
The Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
The Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Burner Gas Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Component/Connection Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
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
v
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
vi
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
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.
S
E
Section 2 — Installation
C
B
D
DIM Inches
Top Clearance A 14
Side Clearance B 20
Backway C 20
Front D 36
Between Boilers E 3
B
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
B
A
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
o
Maximum design temp. 210
F
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
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