CleaverBrooks CFC-E, CFC-E 500, CFC-E 750, CFC-E 1500, CFC-E 1000 Series Manual

CFC-E

ClearFire Condensing Boiler

Boiler Book
02/2018

BOILER BOOK CFC-E

FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

STACK/BREECHING SIZE CRITERIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

CB FALCON CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

EXAMPLE SYSTEM SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Fireside Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Premix Burner Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

ClearFire CE Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Model CFC-E Dimensional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Efficiencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-16

Waterside Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-20

High Fire Speed Settings vs. % Glycol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Maximum Firing Rate vs. % Glycol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Condensate Piped Direct to Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Neutralization Capsule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Combo Trap/Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Treatment Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Condensate Piping for Multiple Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Tank Detail, Multiple Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Gas Piping Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Gas Header Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Model CFC-E Minimum Room Clearance Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

CFC-E Seismic Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Two Opening Outside Wall Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Two Opening Ducted Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

One Opening Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Two Opening Engineered Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Boiler Air Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Horizontal through-wall venting using inside air for combustion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Horizontal flue through-wall with direct vent combustion intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Inside Air - Vertical Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Vertical Stack with Direct Vent Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

CFC-E Rear Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

CB Falcon Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Primary/Secondary Piping Schematic, Single Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Primary/Secondary Piping Schematic, Two Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Primary/Secondary Piping Schematic, Three Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Primary Variable Flow Piping Schematic, Single Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Primary Variable Flow Piping Schematic, Two Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

Primary Variable Flow Piping Schematic, Three Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Primary Variable Flow Piping Schematic, Single Boiler with Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Primary Variable Flow Piping Schematic, Single Boiler with Heat Exchanger and Dual Return . . . . . . . . . . . . . . . . . . . . . . 59

Table of Contents

List of Figures

List of Tables

U.S. Standard Dimensions Model CFC-E Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Dimensions (Metric) Model CFC-E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Model CFC-E Boiler Ratings (Sea Level to 2000 Feet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Altitude Correction for Input Capacity at Various Altitude Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

CFC-E Efficiencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Noise level (dBA) measured 3 feet in front of boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

14

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BOILER BOOK CFC-E

Model CFC-E Minimum Over Pressure Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Safety Relief Valve Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Model CFC-E Water Chemistry Requirements in accordance with ABMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Glycol Minimum Flow Recommendations for ClearFire Model CFC-E Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Condensate piping for multiple boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Model CFC-E Minimum and Maximum Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Model CFC-E Minimum Required Gas Pressure Altitude Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Stack Sizing Using Outside Air for Combustion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Operating Conditions - Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Operating Conditions - Display/Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

CB Falcon burner sequence (Central Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

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BOILER BOOK CFC-E FEATURES AND BENEFITS

FEATURES AND BENEFITS

Compact Firetube Design

The Model CFC-E boiler is a high mass, vertical down fired robust firetube boiler. The internal
extended-heating surface tubes provide very high levels of performance in a compact space. The
large water volume makes the CFC-E ideal for variable flow primary pumping systems.

Large Water Volume

The large water volume makes the CFC-E ideal for variable flow primary pumping systems.

Advanced Technology

Tubes, tube sheets, and combustion chamber are constructed from UNS S32101 duplex stainless
steel. Tubes feature AluFer tube inserts for optimal heat transfer.

Advanced Fireside Construction

The extended heating surface design provides the ideal solution for the demands of a condensing
boiler and helps to recover virtually all the latent heat of the flue gas. Each tube consists of an outer
stainless steel tube (waterside) and the AluFer extended heating surface profile on the flue gas side.

High Efficiency

With the extended heating surface tubes the CFC-E boiler will provide fuel to water efficiency of up to
99% at low fire and 95% at high fire with 80 degrees F return water temperature.

Ease of Maintenance

The powder coated steel casing is designed for easy removal and re-assembly. As shown in Figure 1,
the burner is hinged and is provided with hydraulic pistons for simple opening for service of the spark
electrode, inspection of the burner cylinder, tubes and combustion chamber.

Figure 1. Fireside Access

Quality Construction

ASME Code construction ensures high quality design, safety, third party inspection, and reliability,
and accordingly bears the ASME Section IV “H” stamp.

Premix Technology

The burner utilizes “Premix” technology to mix both gas fuel and combustion air prior to entering the
burner canister, with air leading the fuel during burner firing transitions. Combined with the surface
combustion burner and self-regulating gas valve-venturi fuel-air ratio control, this technology provides
very low emission levels, exceptionally safe operation, and nearly 100% combustion efficiency.

Full Modulation

The variable speed combustion air blower with ECM technology provides modulated firing for precise

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BOILER BOOK CFC-E FEATURES AND BENEFITS

linear load tracking, reduced on-off cycling, and reduced electrical consumption.

Figure 2. Premix Burner Technology

Designed For Heating Applications

The pressure vessel is designed for 125 psig MAWP (Maximum Allowable Working Pressure) and is
constructed of durable ASTM Grade Steel and Stainless Steel materials. The true counter flow heat
exchanger design equates to optimal heat transfer. The design also prevents hot spots, does not
require a minimum flow for thermal shock protection, and does not require a minimum return water
temperature. In fact, the design carries a 20-year thermal shock warranty.

Because of its design characteristics, the Model CFC-E is well suited for applications utilizing indoor/
outdoor reset controls, radiant floor heating, snow melt systems, ground source heat pump systems
and systems that utilize variable speed circulating pumps. It may also be employed in standard hot
water systems that require higher heated water at colder outdoor temperatures but then require lower
temperatures during warmer heating days, realizing fuel efficiency savings over traditional hot water
boilers.

While the design does not lend itself to the direct supply of potable water, a separate storage tank
with an internal heat exchanger can be employed, as the onboard controls permit domestic water
programming. Therefore, the Model CFC-E can service both hydronic heating and domestic water
source heating.

Dual Return

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

SCAQMD Certified

The CFC-E is certified by the South Coast Air Quality Management District.

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BOILER BOOK CFC-E PRODUCT OFFERING

PRODUCT OFFERING

Dimensions, ratings, and product information may change to meet current market requirements and
product improvements. Therefore, use this information as a guide.

Standard Equipment

Equipment described below is for the standard boiler offering:

1. The Boiler
A. Each boiler size is designed for a Maximum Allowable Working Pressure (MAWP) of 125 psig

(8.6 Bar), constructed in accordance with the ASME Code Section IV and bear the “H” stamp.

B. The insulated pressure vessel is mounted on a base and a powder coated steel casing is

provided.

C. A drain valve connection is provided at the front bottom for field piping of a boiler drain valve,

which can be furnished as an option.

2. Boiler Trim and Controls

• The following items are furnished:

• Probe Type Low Water Cutoff control, manual reset.

• High Water Temperature Cutoff, manual reset.

• NTC (negative temp. coefficient) sensor for hot water supply temperature.

• NTC sensor for hot water return temperature.

• ASME Safety Relief Valve set @ 125 psig. (8.6 Bar) (Optional SRV set points available.)

• Combination Temperature/Pressure Gauge.

3. Burner Control
A. The Falcon

controller is an integrated burner management and modulation control with a color

touch-screen display/operator interface. Its functions include the following:

• 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

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BOILER BOOK CFC-E PRODUCT OFFERING

Figure 3. ClearFire CE Control Panel

4. Forced Draft Burner
A. The burner is a “Pre-mix” design consisting of a unitized venturi, single body dual safety gas

valve, blower, and burner head. Consistent fuel-air ratio is maintained with a self-regulating

gas valve-venturi system which automatically compensates for changes in air density.
B. Full modulation is accomplished with a variable speed fan for 5:1 turndown ratio.
C. For near flameless combustion, the burner utilizes a Fecralloy-metal fiber head.

D. Noise level at maximum firing is less than 70 dBA regardless of boiler size.

E. Operating on Natural Gas, NOx emissions will be less than 20 PPM regardless of boiler size.

F. As an option, the burner is capable of direct vent combustion.

G. Ignition of the main flame is via direct spark, utilizing high voltage electrodes and a UV

scanner for flame supervision.

H. To ensure adequate combustion air is present prior to ignition, and to ensure the fan is

operating, a combustion air proving switch is furnished.

I. A High Air Pressure Switch is provided to ensure burner lockout if excessive back pressure

due to a blocked stack occurs.

J. For ease of maintenance and inspection, the burner is furnished with hydraulic rods and easy

opening lockdown nuts, which permit the burner to swing up. This provides full access to the

burner and electrodes, as well, to the tube sheet and tubes.

K. Supports direct vent combustion air.

5. Burner Gas Train

The standard gas train is equipped in accordance with UL certification and complies with ASME
CSD-1. Each burner gas train includes:

• Low Gas Pressure Interlock, manual reset.

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BOILER BOOK CFC-E DIMENSIONS AND RATINGS

• High Gas Pressure Interlock, manual reset.

• ASME CSD-1 Test Cocks.

• Downstream manual ball type shutoff valve.

• Single body dual safety shutoff gas valve.

Optional Equipment

For option details, contact the local authorized Cleaver-Brooks representative. In summary, here are
some of the options that can be provided with the boiler:

A. Reusable air filter.
B. Condensate neutralization tank assembly - consists of neutralizing media, filter, and PVC condensate holding

tank with integral drain trap.
C. Outside air intake for direct vent combustion.
D. Outdoor temperature sensor for indoor/outdoor control.
E. Header temperature sensor for multiple boiler Lead/Lag operation.
F. Auxiliary Low Water Control (shipped loose) for field piping by others into the system piping.
G. Alarm Horn for safety shutdown.
H. Relays for output signal for burner on, fuel valve open.
I. Stack Thermometer.
J. Stack temperature limit-sensor.
K. Auto air vent.
L. Boiler drain valve.
M. Adjustable feet.
N. Seismic anchoring brackets.
O. Protocol translator for communications

DIMENSIONS AND RATINGS

For layout purposes, the overall dimensions for the Model CFC-E are shown in Table 1 (US
Dimensions) and Table 2 (Metric Dimensions) including the various pipe connection sizes for supply
and return water, drain, and vent. The performance ratings for the boiler are shown in Table 3.

Altitude

See Table 4 for input capacity ratings at various altitude levels.

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BOILER BOOK CFC-E DIMENSIONS AND RATINGS

OPTIONAL ADJUSTABLE FEET ALLOW FOR

1.56” TO 3.88” ADDITIONAL HEIGHT

Figure 4. Model CFC-E Dimensional Views

9

BOILER BOOK CFC-E DIMENSIONS AND RATINGS

Table 1. U.S. Standard Dimensions Model CFC-E Boiler

ITEM DIMENSIONS (inches) 500 750 1000 1500 2000

A Overall Height 78.0 78.0 78.0 79.9 79.9
B Overall Width 34.9 34.9 34.9 35.8 35.8
C Overall Depth 49.4 49.4 49.4 56 56
D Width Less Casing 32.1 32.1 32.1 33.0 33.0
E Gas Connection to Floor 70.3 70.3 70.3 73.9 73.9
F Side of Casing to Gas Connection 3.7 3.7 3.7 7.1 7.1
G Side of Casing to Air Inlet 10.8 10.8 10.8 10.8 10.8
H Top of Casing to Air Inlet 7.7 7.7 7.7 7.1 7.1
J Floor to Condensate Drain 6.3 6.3 6.3 6.3 6.3
K Floor to Bottom of Casing 11.0 11.0 11.0 11.0 11.0

L Side of Base to Flue Outlet (Centered) 7.4 7.4 7.4 8.5 8.5
M Side of Base to Flue Outlet (Offset) 6.4 6.4 6.4 7.5 7.5
N Rear of Base to Flue Outlet 6.5 6.5 6.5 7.5 7.5

P Casing Depth 36.3 36.3 36.3 42.4 42.4

Q Casing Height 67.0 67.0 67.0 68.9 68.9

R Floor to Lower Return Connection 16.8 16.8 16.8 16.8 16.8

S Floor to Upper Return Connection 31.8 31.8 31.8 31.8 31.8

T Floor to Supply Connection 59.5 59.5 59.5 59.5 59.5
U Floor to Air vent Connection 66.3 66.3 66.3 66.3 66.3

V Air Vent Line Projection From Rear of Casing 3.2 3.2 3.2 3.3 3.3

CONNECTIONS

W Water Low Temp. Return, Class150 RF Flange 2-1/2" 2-1/2" 2-1/2" 4" 4"

X Water High Temp. Return, Class150 RF Flange 2-1/2" 2-1/2" 2-1/2" 4" 4"

Y Water Outlet, Class150 RF Flange 2-1/2" 2-1/2" 2-1/2" 4" 4"

Z Air Vent, NPT 1-1/2" 1-1/2" 1-1/2" 1-1/2" 1-1/2"

AA Vessel Drain, NPT 1-1/2" 1-1/2" 1-1/2" 1-1/2" 1-1/2"
BB Flue Gas Outlet

CC Combustion Air - Nominal 6" 6" 6" 8" 8"
DD Gas, NPT 1" 1" 1" 1-1/2" 1-1/2"
EE Condensate Drain, NPT 1" 1" 1" 1" 1"
FF Electrical Opening, Left or Right 1.6" 1.6" 1.6" 1.6" 1.6"
GG Safety Relief Valve Vessel Connection, NPT 1-1/4" 1-1/4" 1-1/4" 1-1/4" 1-1/4"

HH Safety Relief Valve

KK Water Outlet Coupling, NPT 1-1/4" 1-1/4" 1-1/4" 1-1/4" 1-1/4"

(Standard) - Nominal 6" 6" 8" 8" 8"
(Option) - Nominal 8" 8" 6" 10" 10"

30 psig Inlet x Outlet, NPT 1" x 1-1/4" 1" x 1-1/4" 1" x 1-1/4" 1" x 1-1/4" 1-1/4" x 1-1/2"
50 psig Inlet x Outlet, NPT 3/4" x 1" 3/4" x 1" 3/4" x 1" 3/4" x 1" 1" x 1-1/4"
60 psig Inlet x Outlet, NPT 3/4" x 1" 3/4" x 1" 3/4" x 1" 3/4" x 1" 1" x 1-1/4"
75 psig Inlet x Outlet, NPT 3/4" x 1" 3/4" x 1" 3/4" x 1" 3/4" x 1" 3/4" x 1"
80 psig Inlet x Outlet, NPT 3/4" x 1" 3/4" x 1" 3/4" x 1" 3/4" x 1" 3/4" x 1"
100 psig Inlet x Outlet, NPT 3/4" x 1" 3/4" x 1" 3/4" x 1" 3/4" x 1" 3/4" x 1"
125 psig Inlet x Outlet, NPT 3/4" x 1" 3/4" x 1" 3/4" x 1" 3/4" x 1" 3/4" x 1"

JJ Flue Coupling, NPT 3/4" 3/4" 3/4" 3/4" 3/4"

FORK POCKETS (inches)

LL Pocket Height 3.9 3.9 3.9 3.9 3.9

MM Pocket Width 11.8 11.8 11.8 11.8 11.8

NN Overall Pocket Width 27.6 27.6 27.6 27.6 27.6

WEIGHTS

Dry Weight (lb) 1298 1298 1396 1861 2041
Shipping Weight (lb) 1413 1413 1511 1986 2166
Operating Weight (lb) 2065 2065 2113 2778 2858
Water Volume (gallon) 92 92 86 110 98

CLEARANCES

Top 14"
Side 3"
Rear 20"
Front 36"

Notes:

• Boiler rear must be accessible for servicing.

• Side clearance to wall or between boilers.

• Side clearance typical each side.

10

BOILER BOOK CFC-E DIMENSIONS AND RATINGS

Table 2. Dimensions (Metric) Model CFC-E

ITEM DIMENSIONS (mm) 500 750 1000 1500 2000

A Overall Height 1982 1982 1982 2028 2028
B Overall Width 886 886 886 908 908
C Overall Depth 1255 1255 1255 1422 1422
D Width Less Casing 816 816 816 838 838
E Gas Connection to Floor 1786 1786 1786 1877 1877
F Side of Casing to Gas Connection 95 95 95 180 180
G Side of Casing to Air Inlet 275 275 275 273 273
H Top of Casing to Air Inlet 196 196 196 180 180

J Floor to Condensate Drain 160 160 160 160 160
K Floor to Bottom of Casing 279 279 279 279 279
L Side of Base to Flue Outlet 189 189 189 217 217

M Side of Base to Flue Outlet (Offset) 164 164 164 192 192
N Rear of Base to Flue Outlet 165 165 165 190 190

P Casing Depth 921 921 921 1077 1077
Q Casing Height 1703 1703 1703 1749 1749
R Floor to Lower Return Connection 428 428 428 428 428
S Floor to Upper Return Connection 808 808 808 808 808
T Floor to Supply Connection 1511 1511 1511 1511 1511

U Floor to Air vent Connection 1683 1683 1683 1683 1683

V Air Vent Line Projection From Rear of Casing 81 81 81 84 84

FORK POCKETS (mm)

LL Pocket Height 100 100 100 100 100

MM Pocket Width 300 300 300 300 300

NN Overall Pocket Width 700 700 700 700 700

WEIGHTS

Dry Weight (kg) 589 589 633 844 926
Shipping Weight (kg) 641 641 686 901 983
Operating Weight (kg) 939 939 969 1260 1280
Water Volume (liter) 350 350 324 416 370

CLEARANCES (mm)

Top 356
Side 76
Rear 508
Front 914

Notes:

• Boiler rear must be accessible for servicing.

• Side clearance to wall or between boilers.

• Side clearance typical each side.

11

BOILER BOOK CFC-E DIMENSIONS AND RATINGS

Table 3. Model CFC-E Boiler Ratings (Sea Level to 2000 Feet)

Boiler Size

Description Units 500 750 1000 1500 2000

Input Max.

Natural Gas
Propane
Natural Gas
Propane

Output at 120/80 F [49/27 C] 100% Firing

Output at 180/140 F [82/60 C] 100% Firing

MAWP

MAWT

Maximum Operating Setpoint

Water Content

Btu/Hr 500,000 750,000 1,000,000 1,500,000 2,000,000

KCal/Hr 126,000 189,000 252,000 378,000 504,000

Ft3/Hr
Ft3/Hr
M3/Hr
M3/Hr

Btu/Hr 470,000 705,000 940,000 1,410,000 1,880,000

KCal/Hr 118,440 177,660 236,880 355,320 473,760

BHP 14 21 28 42 56

KW 138 207 275 413 551

Btu/Hr 440,000 660,000 880,000 1,320,000 1,760,000

KCal/Hr 110,880 166,320 221,760 332,640 443,520

BHP 13 20 26 39 53

KW 129 193 258 387 516

psi 125 125 125 125 125

Bar 8.6 8.6 8.6 8.6 8.6

°F 210 210 210 210 210
°C 99 99 99 99 99

°F 194 194 194 194 194
°C 90 90 90 90 90

Gallons 92 92 86 110 98

Liters 350 350 324 416 370

500 750 1000 1500 2000
200 300 400 600 800

14 21 28 42 57

5.7 8.5 11 17 23

Weight w/o Water

Standby Heat Loss

ECM Blower Motor Size
Operating Voltage, Blower
Control Circuit
Max Current Draw, Blower
Max Current Draw Cont. Circuit
Max Over Current Protection

Condensate Quantity Firing Nat. Gas & operating @ 120/80 F.

Flue Gas Mass Flow @ 100% Firing

Pounds 1,298 1,298 1,396 1,861 2,041

Kg 589 589 633 844 926

Btu/Hr 1000 1500 2000 3000 4000

Watts 293 440 586 879 1172

Watts 335 335 335 1,700 1,700
Volts/Ph/Hz 115/1/60 115/1/60 115/1/60 115/1/60 115/1/60
Volts/Ph/Hz 115/1/60 115/1/60 115/1/60 115/1/60 115/1/60

Amperes 4 4 4 13.5 13.5
Amperes 1.5 1.5 1.5 2 2
Amperes 20 20 20 20 20

Gal/Hr 3.5 5 7 10 13.5

lb/hr 557 835 1,113 1,670 2,226
kg/hr 252 379 505 758 1010

12

BOILER BOOK CFC-E PERFORMANCE DATA

Table 4. Altitude Correction for Input Capacity at Various Altitude Levels

Natural Gas MBTU/h at various altitudes

700' ASL 2000' 4000' 6000' 8000' 10000'

CFC-E 2000

CFC-E 1500

CFC-E 1000

CFC-E 750

CFC-E 500

** Ratings assume 35% excess air, 80F combustion air.
Blower speed adjustments should be made to match performance and local conditions accordingly.
For minimum gas supply pressures see Table 14. Altitude corrections for supply pressure should be made per Table 15
Natural gas heating value of 1000 BTU/SCF assumed.

2000 2000 1883 1747 1619 1552
1500 1500 1500 1500 1500 1472
1000 1000 945 877 813 779

750 750 750 707 655 628
500 500 473 438 406 389

LP Gas MBTU/h at various altitudes

700' ASL 2000' 4000' 6000' 8000' 10000'

CFC-E 2000

CFC-E 1500

CFC-E 1000

CFC-E 750

CFC-E 500

** Ratings assume 40% excess air, 80F combustion air.
Blower speed adjustments should be made to match performance and local conditions accordingly.
For minimum gas supply pressures see Table 14. Altitude corrections for supply pressure should be made per Table 15\
LP (propane) gas heating value of 2500 BTU/SCF assumed.

2000 2000 2000 1867 1730 1659
1500 1500 1500 1500 1500 1500
1000 1000 1000 926 858 822

750 750 750 750 724 694
500 500 500 472 437 419

PERFORMANCE DATA

Efficiency

The Model CFC-E is a “full condensing” boiler realizing efficiency gain at variable operating
conditions. It is designed to extract the latent heat of condensation over a greater range than other
designs. The nominal point of condensation is approximately 132
its more efficient heat transfer design and lower stack temperature, is able to capture the latent heat
of condensation over a broader range.

Fuel-to-water efficiency is relative to specific operating conditions. Operating efficiency will be greater
in the “condensing” mode of operation as noted above, yet with its inherently greater heat transfer
surfaces and superior premix burner, the ClearFire’s efficiency under “traditional” hot water
conditions is also outstanding. Table 5 shows the guaranteed efficiencies at various operating
conditions and firing rates for Natural Gas. It should be noted that the efficiency is exceptional at
high fire and low fire versus other designs where high efficiency is realized only with low fire or
minimal firing rates and low temperature returns.

ClearFire Efficiencies

The tables below list the operating efficiencies of each size Model CFC-E boiler, including radiation losses. As
the Model CFC-E is a fully condensing boiler, maximum efficiency is obtained when operating within the
condensing mode, utilizing the latent heat of condensation.

 F (55.5 C). The ClearFire, due to

13

BOILER BOOK CFC-E PERFORMANCE DATA

Table 5. CFC-E Efficiencies

CFC-E 500 Efficiency

Return Water Temperature °F ( °C )

% Firing Rate

20% 99.0 97.8 96.1 92.4 90.4 88.9 88.1
50% 97.9 96.7 94.7 91.5 89.9 88.6 87.9
75% 97.2 95.7 93.6 90.8 89.4 88.4 87.7

100% 96.5 94.8 92.5 90.0 89.0 88.1 87.6

% Firing Rate

20% 98.5 97.4 95.6 92.1 90.3 88.8 88.0
50% 97.2 95.7 93.6 90.8 89.4 88.4 87.7
75% 96.1 94.3 92.0 89.7 88.7 88.0 87.5

100% 95.0 92.9 90.3 88.6 88.0 87.6 87.3

% Firing Rate

20% 99.0 98.8 97.0 93.3 90.7 88.9 88.0
50% 97.8 96.9 94.7 91.5 89.8 88.5 87.7
75% 96.9 95.4 92.7 90.0 89.0 88.2 87.5

100% 95.9 93.8 90.8 88.6 88.2 87.9 87.3

68 80 100 120 130 140 160

(20) (27) (38) (49) (55) (60) (72)

CFC-E 750 Efficiency

Return Water Temperature °F ( °C )

68 80 100 120 130 140 160

(20) (27) (38) (49) (55) (60) (72)

CFC-E 1000 Efficiency

Return Water Temperature °F ( °C )

68 80 100 120 130 140 160

(20) (27) (38) (49) (55) (60) (72)

CFC-E 1500 Efficiency

Return Water Temperature °F ( °C )

% Firing Rate

20% 98.5 97.6 95.2 91.8 90.1 88.8 88.0
50% 97.1 95.9 93.4 90.6 89.3 88.3 87.8
75% 96.0 94.4 91.9 89.6 88.6 87.9 87.5

100% 94.9 93.0 90.4 88.6 87.9 87.5 87.3

% Firing Rate

20% 98.0 97.1 94.5 91.4 90.0 88.9 88.0
50% 96.6 95.5 93.0 90.5 89.3 88.5 87.7
75% 95.5 94.1 91.7 89.6 88.8 88.2 87.5

100% 94.3 92.7 90.5 88.8 88.3 87.8 87.2

Conditions:

Natural Gas
40% Excess Air
Relative Humidity = 50%
ΔT = 40°F
R & C Loss = 0.2% of rated capacity

68 80 100 120 130 140 160

(20) (27) (38) (49) (55) (60) (72)

CFC-E 2000 Efficiency

Return Water Temperature °F ( °C )

68 80 100 120 130 140 160

(20) (27) (38) (49) (55) (60) (72)

14

BOILER BOOK CFC-E PERFORMANCE DATA

Figure 5. Efficiency 500

CFC-E 500 Eciency Curve

100

99

98

97

96

95

94

93

Eĸciency (%)

92

91

90

89

88

87

60 70 80 90 100 110 120 130 140 150 160 170

Return Water Temperature (

40° F Temperature DiīerenƟal

°F)

20% Firing Rate

50% Firing Rate

75% Firing Rate

100% Firing Rate

Figure 6. Efficiency 750

CFC-E 750 Eciency Curve

100

99

98

97

96

95
94

93

92

Eciency (%)

91

90

89
88

87

86

60 70 80 90 100 110 120 130 140 150 160 170

Return Water Temperature ( °F)

40°F Temperature DiīerenƟal

20% Firing Rate

50% Firing Rate

75% Firing Rate

100% Firing Rate

15

BOILER BOOK CFC-E PERFORMANCE DATA

Figure 7. Efficiency 1000

CFC-E 1000 Eciency Curve

100

99

98

97

96

95
94

93

92

Eciency (%)

91

90

89
88

87

86

60 70 80 90 100 110 120 130 140 150 160 170

Return Water Temperature ( °F)

40°F Temperature DiīerenƟal

20% Firing Rate

50% Firing Rate

75% Firing Rate

100% Firing Rate

Figure 8. Efficiency 1500

CFC-E 1500 Eciency Curve

100

99

98

97

96

95
94

93

92

Eciency (%)

91

90

89
88

87

86

60 70 80 90 100 110 120 130 140 150 160 170

Return Water Temperature ( °F)

40°F Temperature DiīerenƟal

20% Firing Rate

50% Firing Rate

75% Firing Rate

100% Firing Rate

16

BOILER BOOK CFC-E PERFORMANCE DATA

Figure 9. Efficiency 2000

CFC-E 2000 Eciency Curve

99
98

97
96

95
94

93
92

91

Eciency (%)

90
89

88
87

86

60 70 80 90 100 110 120 130 140 150 160 170

Return Water Temperature ( °F)

40°F Temperature DiīerenƟal

20% Firing Rate

50% Firing Rate

75% Firing Rate

100% Firing Rate

Emissions

By means of the Pre-mix burner, the Clearfire boiler provides environmentally friendly emissions
when firing natural gas; emission data are shown below.

Table 6. Emissions

POLLUTANT UNITS

CO

NOx

SOx

HC/VOC

PM

*ppm levels are given on a dry volume basis and corrected to 3% oxygen (15% excess air)

ppm* <20

lb/MMBTU <0.014

ppm* <20

lb/MMBTU <0.024

ppm* <1

lb/MMBTU <0.001

ppm* <4

lb/MMBTU <0.0016

ppm* -

lb/MMBTU <0.01

Noise Level

The Model CFC-E is extremely quiet at all operating levels, does not require any sound level
modifications to provide ultra low noise levels, and is virtually vibration free. Thus, it is very suitable
in applications that demand low noise levels.

Table 7.

CFC-E 500 43 56 61

CFC-E 750 41 51 60

CFC-E 1000 43 56 61

CFC-E 1500 46 56 66

CFC-E 2000 46 61 70

Noise level (dBA) measured 3 feet in front of boiler

20% Input 60% Input 100% Input

17

BOILER BOOK CFC-E ENGINEERING DATA

ENGINEERING DATA

Boiler Information

The Model CFC-E boiler is designed for service in any closed hydronic system. It can be put into
operation as a single stand-alone unit with 5:1 turndown or in multiple units for larger turndown and
capacity.

Clearfire boilers may be utilized in water heating systems with temperatures from 40
194

 F (90 C); ideal for systems such as ground water source heat pump applications. Because the

Clearfire is a full condensing boiler, low water temperature (below the dewpoint) restrictions do not
apply. In fact, the lower the return the better the fuel savings.

Variable temperature differentials can be designed to make use of changing outdoor conditions and
thus, the Clearfire is not restricted to a nominal 20

 F (10 C) differential. The boiler is designed to

withstand thermal stresses with supply and return temperature differences up to 100
without the use of a boiler-circulating pump, blend pump or minimum water flow.

Note: The Clearfire does not require a minimum flow or continuous flow through it during operation. However, the load

imposed on the boiler must be considered when sizing the system flow so that the flow does not exceed the capacity
of the boiler or the demand.

Flow Rates and Pressure Drops

To maintain rated capacity of the boiler, recommended flow rates should not be exceeded as the flow
will remove the heat beyond the capacity of the boiler.

 F (4.4 C) to

 F (55 C),

Table 8. Flow Rates

CFC-E Flow Rates

Temperature Differential (°F)

10 20 30 40 50 60 70 80 90 100 110 120
Size Flow Rate GPM
500 94 47 31 24 19 16 13 12 10 9 9 8
750 141 71 47 35 28 24 20 18 16 14 13 12

1000 188 94 63 47 38 31 27 24 21 19 17 16
1500 283 141 94 71 57 47 40 35 31 28 26 24
2000 377 188 126 94 75 63 54 47 42 38 34 31

Recommended flow rates relative to temperature drop so as not to exceed boiler output.
Based on 94% nominal effficiency and maximum firing capacity
Based on water only

CFC-E Flow Rates [metric]

Temperature Differential (°C)

6 1117222833394450566167

Size
500 21.4 10.7 7.1 5.3 4.3 3.6 3.1 2.7 2.4 2.1 1.9 1.8

750 32.1 16.0 10.7 8.0 6.4 5.3 4.6 4.0 3.6 3.2 2.9 2.7

1000 42.8 21.4 14.3 10.7 8.6 7.1 6.1 5.3 4.8 4.3 3.9 3.6
1500 64.1 32.1 21.4 16.0 12.8 10.7 9.2 8.0 7.1 6.4 5.8 5.3
2000 85.5 42.8 28.5 21.4 17.1 14.3 12.2 10.7 9.5 8.6 7.8 7.1

Recommended flow rates relative to temperature drop so as not to exceed boiler output.
Based on 94% nominal efficiency and maximum firing capacity
Based on water only

Flow Rate m

3

/hr

18

BOILER BOOK CFC-E ENGINEERING DATA

Figure 10. Waterside Pressure Drop CFC-E 500

1.2

1.1

1.0

0.9

0.8

0.7

0.6

Pressure (psi)

0.5

0.4

0.3

0.2

0.1

0.0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95

Flow Rate (gpm)

Figure 11. Waterside Pressure Drop CFC-E 750

19