Cleaver-Brooks ClearFire CFLC-12000, ClearFire CFLC-4000, ClearFire CFLC-6000, ClearFire CFLC-8000, ClearFire CFLC Operation And Maintenance Manual

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Model CFLC

ClearFire

Condensing Boiler

4,000 - 12,000 MBTU

Operation and Maintenance Manual

750-363

08/2017

WARNING

DANGER

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

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

WARNING

DANGER

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

— WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

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

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

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

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

WARNING

DANGER

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

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

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

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

WARNING

DANGER

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

Notice

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

WARNING

DANGER

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

CLEAVER-BROOKS

Model CFLC

ClearFire Packaged Boiler

Condensing Boiler

Operation and Maintenance Manual

 Cleaver-Brooks 2017

Please direct purchase orders for replacement manuals to your local Cleaver-Brooks authorized representative.

Manual Part No. 750-363

08/2017

iii

Printed in U.S.A.

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 REPAIR 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, operation of equipment is not to be considered free from all dangers and hazards inherent in handling and firing of fuel.

Any “automatic” features included in the design do not relieve the attendant of any responsibility. Such features merely 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.

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

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

TABLE OF CONTENTS

Section 1 Introduction

CFLC Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Section 2 Installation

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

Boiler Room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Flue gas/combustion air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Boiler flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Using glycol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Gas connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Boiler water piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Minimum boiler overpressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Condensate removal and treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

Section 3 Stack and Intake Vent Sizing and Installation

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

Vertical Venting / Inside Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Vertical Venting / Direct Vent or Sealed Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Venting for Multiple Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Combustion Air / Boiler Room Ventilation Requirements. . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Section 4 Commissioning

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

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

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

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

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

Controller Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Variable Speed Drive Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Burner Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Fan Speed Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Initial Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Post Start-up Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Falcon Control Functions and Customer Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Section 5 Service and Maintenance

Disassembly for Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Ignition and Flame Detection Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Extended Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Emergency Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Section 6 Parts

Recommended Spare Parts List Model CFLC ................................................................... 6-2

Boiler Mechanical Assembly........................................................................................... 6-3

Burner Assembly .........................................................................................................6-7

UV Scanner ................................................................................................................. 6-9

Gas Train .................................................................................................................. 6-10

Dual Fuel Gas Trains .................................................................................................. 6-18

Pilot Gas Train ..........................................................................................................6-21

Control Panel ............................................................................................................6-22

Cables and Cable Harness ..........................................................................................6-23

Optional Parts ........................................................................................................... 6-24

Casing & Insulation ..................................................................................................... 6-25

Appendix A - Falcon Parameters Appendix B - VSD Parameters Appendix C - Gas Valve Appendix D - Falcon Alert, Hold, and Lockout Codes Appendix E - Falcon Lead Lag Appendix F - Falcon Program Module

Section 1

Introduction

CFLC Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

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Section 1 — Introduction

1.1 CFLC FEATURES AND BENEFITS

Compact Firetube Design

The CFLC boiler is a two pass horizontally 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.

High Efficiency

With the extended heating surface tubes the boiler can produce fuel to water efficiency of up to 99% depending upon operating conditions.

Advanced Construction

Constructed to ASME standards, the CFLC Boiler will provide many years of trouble free service.

First pass tubes are made from SA178A Carbon Steel and are of rifle design for maximum heat transfer. Second pass 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 hinged burner provides access for burner maintenance and fireside inspection.

Quality Construction

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

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

Full Modulation

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

Premix Technology

The CFLC 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 Grade Steel and Stainless Steel materials to provide many years of operating life.

Thermal shock resistant design with large water volume and low pressure drop is ideal for primary variable flow applications.

1.2 STANDARD EQUIPMENT

1.2.1. The Boiler

The boiler is designed for a Maximum Allowable Working Pressure (MAWP) of 160 psig (11 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 144 psig (9.9 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 and temperature gauges, probe type low water control, and Falcon hydronic boiler control with associated sensors.

1-2 Part No. 750-363

1.2.2. The Burner

The burner utilizes a premix venturi, self-regulating fuel train, variable speed blower modulation, and Fecralloy metal fiber burner head.

Modulating 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 85 dBA, measured in front of the boiler at a distance of 3 feet.

Room air for combustion is standard (combustion air filter provided).

A direct vent combustion air adapter kit is available. Refer to Installation and Parts sections in this manual for options and details.

VENTURI

BLOWER ASSEMBLY

Section 1 — Introduction

BURNER CANISTER

HAPS

CAPS

Figure 1-1 Burner Assembly

1.2.3. Burner Gas Train

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 motorized shut-off valves

with POC and regulating actuator D. Manual Shutoff Butterball Valve E. Regulator (optional, based on gas supply pressure) F. Test cocks

1.2.4. Controls

The 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, pilot 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

GAS INLET

TO VENTURI

Figure 1-2 Gas Train (8000 shown)

Part No. 750-363 1-3

Section 1 — Introduction

TRANSFORMER, 460/230/208V PRI, 115 V SECONDARY, 350VA, FUSED TOP

TRANSFORMER, 115v/25v

IGNITION TRANSFORMER (FAR SIDE)

WATER LEVEL CONTROL - LWCO

FALCON CONTROLLER, HYDRONIC

FUSE, 9 AMP

Figure 1-3 Control panel interior

1.2.5. Variable Speed Drive

Modulating combustion air fan speed is controlled by a Variable Speed Drive mounted inside the front casing below the Falcon control panel.

1.2.6. Component/Connection Locations

Figure 1-5 shows the CFLC component orientation and heat flow

path. The return water connections are at the lower vessel and the hot water outlet is at the top of the boiler.

Figure 1-6 shows the locations of the safety valve and air vent connections. Figure 1-7 shows the location of the return water temperature sensor.

The stack is connected on the right side of the boiler when facing the front. The flue gas duct sizes may be reduced at the vent connection. See also Section 3,

Stack and Intake Vent Sizing and Installation.

TERMINAL TRACK

Figure 1-4 VSD (cutaway view)

1-4 Part No. 750-363

Section 1 — Introduction

Gas Train

Burner Assembly

Control Panel

Flue/ condensate collection chamber

Condensate drain

Air Vent (optional)

Water Outlet

TO STACK

Combustion gas flow

LWCO probe holder

Furnace

Water circulation

Safety Valve(s)

EX Tubes

Alufer Tubes

Water Return (2)

Boiler Drain

SAFETY VALVE(S)

Figure 1-5 CFLC Cutaway

AUTO AIR VENT (OPTIONAL)

GATE VALVE

LWCO PROBE HOLDER

Figure 1-6 Boiler safety valve(s) & air vent

Part No. 750-363 1-5

Section 1 — Introduction

Figure 1-7 Return temperature sensor (rear casing & insulation not shown)

WATER OUTLET

OUTLET TEMP. sensor well

COMBUSTION AIR FILTER

STACK OUTLET

Figure 1-8 Stack Outlet, Water Outlet, and Combustion Air Inlet

1-6 Part No. 750-363

Section 1 — Introduction

1.3 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.

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

A. Condensate neutralization tank assembly - consists of neutralizing media, filter, and PVC

condensate holding tank. This assembly is further described in Chapter 2. B. Direct vent combustion air adapter kit C. Outdoor temperature sensor for outdoor reset, frost protection, and warm weather shutdown D. Header temperature sensor for multiple boiler Lead/Lag operation E. Alarm Horn for safety shutdown F. Relays for output signal for burner on, fuel valve open G. Stack Thermometer H. Stack temperature limit-sensor I. Auto air vent J. Boiler drain valve K. Gas pressure relief valve L. Gas pressure gauge M. Water isolation valves N. Hydronic circulating pumps O. Seismic anchoring provisions

For options not listed, consult your authorized CB representative.

Part No. 750-363 1-7

Section 1 — Introduction

1-8 Part No. 750-363

Section 2

Installation

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

Boiler Room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Flue gas / combustion air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Water treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Boiler flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Using glycol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Gas connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Boiler water piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Minimum boiler overpressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Condensate removal and treatment . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

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.

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

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

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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.

Section 2 — Installation

2-2 Part No. 750-363

Section 2 — Installation

2.1 BOILER ASSEMBLY AND PLACEMENT

2.1.1 Packaging

The Cleaver-Brooks Model CFLC boiler is shipped fully assembled, ready for installation.

2.1.2 Lifting and moving the boiler

The Model CFLC boiler is lifted by means of the holes provided in the upper tube sheets. See rigging diagram below.

Caution

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

Figure 2-1 CFLC Rigging

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

Part No. 750-363 2-3

Section 2 — Installation

2.1.3 Boiler placement

The boiler or boilers should be mounted in accordance with Figure 2-2 below. Required front, rear, and side clearances are shown. Under special circumstances, reduced side clearance between boilers may be feasible. Contact your C-B authorized representative for assistance.

NOTE

The boiler assemblies are intended for installation in accordance with the appropriate standards of the National Fire Protection Association and the building code recommended by the American Insurance Association. Local codes may differ. Installation should provide clearances to unprotected combustible material not less than those indicated in the following:

Clearances to adjacent combustible construction not less than 36 inches from control panel front, 24 inches from sides, and 36 inches above and rear. The floor beneath these units may be combustible. In all cases, the flue pipe shall not pass through any floor or ceiling or any combustible wall or partition unless suitably guarded.

Top Clearance = 36”

Figure 2-2 Clearance Required (inches)

2-4 Part No. 750-363

Section 2 — Installation

2.2 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 sealed combustion/direct vent kit is used, ventilation must be provided to meet applicable regulations for air supply.

Note: For further details on sealed combustion/direct vent kits, see Section 3, Stack and Intake Vent Sizing

and Installation and Section 6, Parts.

Clean combustion air is required for optimum efficiency and boiler operation. Dust and airborne contaminants will adversely effect burner performance. An air filter is included to keep airborne contamination from the burner.

If using sealed combustion/direct venting, the air intake should be positioned to keep 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.

2.3 FLUE GAS / COMBUSTION AIR

The flue gases from the Model CFLC boiler should be removed via a gas-tight, temperature and corrosion resistant flue gas pipeline. Only flue gas systems approved and tested by the relevant region or province are to be connected to the boiler. Refer to flue piping manufacturer for proper installation and sealing instructions. See also Chapter 3 of this manual for combustion air and flue gas venting requirements.

Table 2-1. Boiler room environmental limits

Maximum temperature 122 deg F Minimum temperature 32 deg F Humidity 90% RH non condensing

Warning

The boiler must not be installed on carpeting.

2.4 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. Closed loop hydronic systems should incorporate air separation, dirt elimination, and air venting.

Clean, soft water is generally the best heating medium for filling and make-up water in systems utilizing the Model CFLC. 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 both ferrous materials and corrosionresistant stainless steel. The chloride content of the heating water should not exceed 30 ppm and the pH level should be between 8.3 to 10.5 after six weeks of operation.

To maintain the boiler's efficiency and prevent overheating of the heating surfaces, the values in Table 2-2 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 makeup line to monitor makeup water volume.

Should the system require flushing or cleaning after installation of the CFLC, take care that no particulate matter reaches the boiler during the cleaning process.

Part No. 750-363 2-5

Section 2 — Installation

Note: Corrosion and sludge deposits in old systems must be removed

prior to installation of a new boiler.

Table 2-2 Model CFLC Water Chemistry Requirements

Parameter Limit Means of control

Glycol 25-50% Glycol fill/mixing station

pH 8.3 - 10.5 Buffering agent

Nitrates 50 ppm Sulfates 50 ppm Chloride < 250 ppm

Oxygen < 0.1 ppm Air separator/eliminator

Specific Conductivity

< 3500 mmho/cm

Total Hardness < 10 ppm Softener

Table 2-3 Model CFLC Water Temperature Data (Non-Glycol)

Minimum inlet temp. 33 Maximum operating supply set point temp. 230 Maximum design temp. 250 Minimum supply set point temperature 130 Max allowable Delta T 100

Chemical additives

2.5 BOILER FLUSH

Cleaver-Brooks recommends cleaning in accordance with the recommendations of the boiler owner’s water treatment company for each individual site. The boiler may be flushed with or without heat applied, as deemed appropriate by the chemical treatment company. A traditional steam “Boil Out” is not required on Cleaver-Brooks hot water boilers.

Following are some general recommendations to help ensure long boiler life and efficient operation.

NOTE: these are recommendations only. The chemical treatment supplier should recommend a procedure based on the site conditions and quality of water being used to fill the system.

If the entire system is being flushed THROUGH the boiler, weld slag and deposits from the piping system may settle in the boiler. The boiler is typically a low velocity zone where these deposits tend to accumulate. The boiler should be drained periodically during the flushing process to keep any deposit build up to a minimum. When the system flush is complete, drain the boiler completely and open water side inspection ports for visual inspection. Any deposits should be manually flushed out.

If the boiler is isolated during the system flush, or if this is an equipment replacement only where minimal amounts of system piping have been replaced, there should be minimal manufacturing deposits inside the boiler and no boiler flush is required.

To provide the longest life of the equipment it is recommended but not mandatory to chemically treat the boiler prior to start-up. The owner’s water treatment company should determine needed course of action for each installation.

2.6 USING GLYCOL

The Model CFLC 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.

2-6 Part No. 750-363

Section 2 — Installation

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 CFLC boilers to hydronic systems using glycol:

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

2) Glycol minimum temperature rating 300 deg F (149 deg C).

3) Maximum allowable boiler outlet/supply temperature: 200 deg F (93 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, regular water circulation through each boiler is required

while the boiler is operating (requires a dedicated boiler pump if in a primary/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 200 deg F (93 deg C), a minimum operating pressure of 30 psig (2.1 bar) is required.

6) pH level should be maintained between 8.3 and 10.5

Table 2-4 Glycol Application Guidelines — ClearFire Model CFLC

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

ClearFire Model-Size

CFLC-4000

CFLC-5000

CFLC-6000

CFLC-8000

CFLC-10000

CFLC-12000

Notes/Limitations:

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

2. Maximum system operating temperature of 200 ˚F. Maximum ΔT of 40˚.

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

4. Standard altitude (<2000' ASL). Contact C-B for high altitude applications.

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

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

ΔT = 10˚ ΔT = 20˚ ΔT = 30˚ ΔT = 40˚

813 407 271 203

1016 508 339 254

1220 610 374 281

1626 813 499 368

2033 1016 624 468

2439 1220 749 562

System ΔT (˚F)

Part No. 750-363 2-7

Section 2 — Installation

2.7 GAS CONNECTIONS

2.7.1 General

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

2.7.2 Gas Train Components

CFLC 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 CFLC units.

Leak test cocks

Manual shutoff valve (MSOV)

High pressure regulator (optional)

Gas valve, top view

Low gas press. switch

Figure 2-3 CFLC Gas Train (typical)

MSOV

High gas press. switch

Double-body gas valve

2-8 Part No. 750-363

Section 2 — Installation

2.7.3 Gas Pressure Requirements

For proper and safe operation, each CFLC Series boiler requires a stable gas supply pressure. See table below for pressure requirements. Refer also to

Table 2-5 CFLC gas pressure requirements

Gas Supply Pressure (at gas regulator outlet)

Natural Gas 20ppm Natural Gas 9ppm Propane

Boiler

size 4000 9 14 10 14 9 14 3-5 5000 9 14 10 14 9 14 3-5 6000 35 56 35 56 31 56 3-5 8000 35 56 42 56 31 56 3-5

10000 38 56 38 56 35 56 3-5 12000 38 56 40 56 35 56 3-5

Min

(“WC)

Max*

(“WC)

Min

(“WC)

*Listed max. pressures are without the use of a step-down regulator. The CFLC can accommodate higher supply pressures with the addition of an upstream regulator:

CFLC 4000 - 5000 >1/2 psig requires step-down regulator

>5 psig requires overpressure protection

CFLC 6000 - 12000 >2 psig requires step-down regulator

>7 psig requires overpressure protection

When an upstream regulator is installed, required minimum pressures will be higher due to the pressure drop across the regulator.

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 supply pressure drop is not more than 7" w.c. and never below the required pressure. Fluctuating gas pressure readings could be indicative of a faulty supply regulator or improper gas train piping to the boiler. Refer to Tables 2-6 and 27 for gas piping recommendations.

APPENDIX C - GAS VALVE.

Max*

(“WC)

Min

(“WC)

Max

(“WC)

Gas pilot pressure

(“WC)

To measure pilot gas pressure, use the test port on the pilot solenoid valve.

VALVESOLENOID PILOT

COCKGAS SERVICE

Test Port

Figure 2-4 Pilot train

Part No. 750-363 2-9

Section 2 — Installation

2.7.4 Gas Piping

A dedicated pressure regulator is recommended for each CFLC boiler when the gas supply exceeds the maximum values in Table 2-5. If below the referenced max. gas supply pressure and no step-down regulator is installed, the CFLC gas train does not require gas venting (the pilot gas regulator may require a vent limiter at its vent connection depending on the local code requirements).

The regulator for each boiler must be installed outside the boiler enclosure with at least 2 feet of pipe between the regulator and the boiler gas valve connection. The discharge range of the regulator must be able to maintain steady gas pressures as noted in Table 2-5.

For buildings or boiler rooms with gas supply pressure exceeding 14” WC (CFLC 4000/5000) or 2 psi (CFLC 6000-12000) a “full lock-up” type regulator is required.

In addition to the regulator, a full port 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.

It is recommended that a strainer be installed upstream of the regulator or boiler gas connection 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.

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 that may have resulted from installation.

See Figure 2-5 for a typical piping configuration.

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).

2-10 Part No. 750-363

Figure 2-5 Gas Piping

Section 2 — Installation

TO GAS TRAIN

As required

Same or large r tha n boiler ga s connect ion size

As required

Ga s header - size for boiler room

capacity and to minimize press ure loss

Dr ip le g r e quir e d f or a ny ver t ic a l ru n of pipi ng

2.7.5 Gas Supply Pipe Sizing

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

For installations of new boilers into an existing building, gas pressure should be measured with a manometer to ensure sufficient pressure is available. A survey of all connected gas-using devices should be made. If appliances other than the boiler or boilers are connected to the gas supply line, then a determination must be made of how much flow volume (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 2-6 and 2-7. 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 4,000,000 btu/hr input divided by a gas calorific value of 1060 will result in a flow of 3774 cfh. The single boiler is approximately 20 feet from the gas supply header source. And with a measured gas supply pressure of 10" w.c. we find from Table 2-6 that a supply pipe size of 3" should be used as a minimum.

Part No. 750-363 2-11

Section 2 — Installation

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

Pipe Size Nominal 2-1/2" 3" 4" Actual I.D. 2.469" 3.068" 4.026" Length in feet **Maximum Capacity in Cubic Feet of Gas per Hour (cfh) 10 4,860 8,580 17,500 20 5,900 12,000 30 9,660 40 8,290 50 7,330 60 6,640 70 6,110 80 5,680 90 5,330 100 5,040 125 4,460 150 4,050 175 200 **Fuel: Natural Gas **Inlet Pressure: Less than 2.0 psi

**Pressure Drop: 0.30" w.c.

**Specific Gravity: 0.60

Table 2-7: Gas Line Capacity - Schedule 40 Metallic Pipe

Pipe Size Nominal 2" 2-1/2" 3" 4" Actual I.D. 2.067" 2.469" 3.068" 4.026" Length in feet **Maximum Capacity in Cubic Feet of Gas per Hour (cfh) 10 4,020 6,400 11,300 23,100 20 4,400 7,780 15,900 30 6,250 12,700 40 5,350 10,900 50 4,740 9,600 60 4,290 8,760 70 8,050 80 7,490 90 7,030 100 6,640 125 5,890 150 5,330 175 4,910 200 4,560 **Fuel: Natural Gas **Inlet Pressure: Less than 2.0 psi

**Pressure Drop: 0.50" w.c.

**Specific Gravity: 0.60

2-12 Part No. 750-363

Section 2 — Installation

2.7.6 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.

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.

Figure 2-6 Gas header piping

From Meter

Manua l Shut Off

Gas Strainer

Re g ula to r See Note 1

Gas Hea der Piping, Typical

Header Pipe

Re lie f Valve See Note 5

NOTES:

1. Dedicated gas pressure regula tor required for each boiler if gas supply greater than max. pressure in Table 1

2. Refer to local fuel gas codes when applicable.

3. Header to be sized for room capacit y.

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

5. Ove rpre ss ur e prote ct ion re quired if gas supply press ure > 5 ps ig.

Part No. 750-363 2-13

Section 2 — Installation

2.8 BOILER WATER PIPING

2.8.1 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.

2.8.2 Safety valve

The pressure relief valve (safety valve) should be piped from the coupling on top of the boiler (see Figure 2-7). Use pipe sealing compound and a flat sided wrench when securing the Safety relief valve. Do not use

a pipe wrench and do not over tighten the relief valve. The safety valve must be mounted in a vertical position so that discharge piping and code-required drains can be properly piped to prevent buildup of back pressure and accumulation of foreign material around the valve seat area. Apply only a moderate amount of pipe compound to male threads and avoid overtightening, which can distort the seats. Use only flatjawed wrenches on the flats provided.

Figure 2-7 Safety 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.

2.8.3 Dual return design

The Model CFLC 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 CFLC will achieve condensing performance, with associated gains in efficiency.

2-14 Part No. 750-363

Section 2 — Installation

If using only a single (common) return, the low temperature connection should be used. The low temperature connection is on the left when facing the rear of the boiler.

Low Temp. Return

High Temp. Return

Figure 2-8 Dual returns

2.8.4 Pressure drop curves

The information in Figure 2-9 and in Tables 2-8 and 2-9 can help in determining pump requirements for Model CFLC installations.

Part No. 750-363 2-15

Section 2 — Installation

CFLC 4000 CFLC 5000

Pressure PSI

Flow rate GPM

CFLC 6000

Flow rate GPM

Pressure PSI

Flow rate GPM

CFLC 8000

Pressure PSI

Flow rate GPM

Pressure PSI

CFLC 10000

Pressure PSI

Flow rate GPM

CFLC 12000

Flow rate GPM

Figure 2-9 Pressure Drop Curves, CFLC

2-16 Part No. 750-363

Section 2 — Installation

Table 2-8: CFLC flow rates @ rated capacity

System Temperature Drop Deg F

10 20 40 60 80 100

Boiler Size

4000 752 376 188 125 94 75

5000 940 470 235 157 117 94

6000 1128 564 282 188 141 113

8000 1504 752 376 251 188 150

10000 1880 940 470 313 235 188

12000 2255 1128 564 376 282 226

Flow rates relative to temperature drop so as not to exceed boiler output. Based on 94% nominal efficiency.

Flow Rate GPM

Table 2-9: CFLC flow rates (metric)

System Temperature Drop Deg C

6 1122334456

Boiler Size

4000 171 85 43 28 21 17

5000 213 107 53 36 27 21

6000 256 128 64 43 32 26

8000 341 171 85 57 43 34

10000 427 213 107 71 53 43

12000 512 256 128 85 64 51

Flow rates relative to temperature drop so as not to exceed boiler output. Based on 94% nominal efficiency.

Flow Rate m3/hr

Part No. 750-363 2-17

Section 2 — Installation

2.9 MINIMUM BOILER OVERPRESSURE

To prevent the occurrence of flash steam within the boiler or system, hot water boilers must operate with proper over-pressure. System over-pressure requirements are shown in Table 2-8.

Note: The ASME Code Section IV limits the maximum setting of the excess temperature control to 250 F (121 C). This is to ensure

that water temperature will not reach the boiling point (steaming) and therefore, so as not to exceed the maximum limit of this control and in compliance with the Code, the operating limit of 230 F (110 C) is set for normal boiler operation.

While proper overpressure is required, a means to relieve excess pressure at or beyond the design pressure of the boiler must be provided. As boiler water is heated, expansion occurs. And this expansion must be accounted for either with an expansion tank (air filled) or with a bladder type tank. These devices permit the water pressure to expand outside of the boiler and not impact the pressure vessel or pressure relieving device. In accordance with code, each boiler is equipped with an ASME approved safety relieving device should pressure build-up occur.

Table 2-10: Model CFLC Minimum Over Pressure Requirements (100% water)

Outlet Water Temperature Minimum System Pressure

(°F) (°C) PSIG Bar

130-180 54-82 12 0.83

181-185 83-85 15 1.03

186-205 86-96 18 1.24

206-215 97-101 24 1.66

216-225 102-107 30 2.07

226-240 108-116 42 2.90

2.10 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.

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

Notice

The condensate occurring during operation in both the boiler and the flue gas pipeline should 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.

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 CFLC neutralization system contains a compound which acts to increase the pH of the condensate flowing through it. The neutralization system comprises the plastic neutralization tank with condensate inlet, granulate chamber and condensate outlet. The system is installed per Figure 2-11.

2-18 Part No. 750-363

DRAIN

Section 2 — Installation

BOILER REAR

WARM WATER RETURN

CONDENSATE DRAIN

COLD WATER RETURN

A CONDENSATE TRAP IS PIPED WITHIN THE BOILER.

Figure 2-10 Condensate Piped Direct to Drain

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 20 to 80 GPH can be expected depending on boiler size and return water temperature.

2.10.1 Condensate tank setup options

(1) Condensate direct to drain - The condensate is piped directly to a drain through the piping and water trap supplied during installation (see Figure 2-10).

(2) Condensate to treatment tank - The condensate is held in a condensate tank(s) under or near the boiler.

The condensate is neutralized as it passes through a bed of granular material. The neutralized condensate is then piped to the drain.

• To install the system, assemble the tank and fittings per instructions supplied with tank. Neutralization media are already installed in tank.

• For CFLC 4000/5000 the tank must be installed external to the boiler (Figure 2-11). For sizes 6000-12000 the tank(s) may be mounted internally or externally.

• Install the condensate tank cover and connect tank to boiler condensate discharge.

Pipe to an appropriate drain.

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

Part No. 750-363 2-19

Section 2 — Installation

Figure 2-11 Condensate Treatment Tank - external

SIZE 6000-8000

SIZES 10,000-12,000

Figure 2-12 Condensate Treatment Tank - internal

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

The number of condensate treatment tanks required depends on the total amount of condensate produced by the system. As a general rule, CB recommends one tank per boiler for sizes 4,000 -

Table 2-8 CFLC Max Condensation

CFLC Model BTU/hr

4000 4,000,000 27 5000 5,000,000 34 6000 6,000,000 41

8000 8,000,000 54 10000 10,000,000 68 12000 12,000,000 82

Condensation

Max.

GPH

8,000 and two tanks for sizes 10,000 - 12,000.

2-20 Part No. 750-363

Section 2 — Installation

2.11 ELECTRICAL CONNECTIONS

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

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 top left corner of the boiler to the control panel (see Figure 2-13). AC power is to be connected to the incoming power terminals.

Note: The following temperature sensor cables should not be run near the three phase incoming power

wiring.

• Hot water outlet temperature sensor.

• Hot water return temperature sensor.

• Stack temperature sensor (optional).

• Outdoor temperature sensor (optional).

• Header water temperature sensor (optional).

Warning

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

Part No. 750-363 2-21

Section 2 — Installation

FALCON

Figure 2-13 Electrical Connections CFLC

2-22 Part No. 750-363

2.12 WIRING DIAGRAM

208V, 230V, 575V 3 PHASE ALSO SUPPORTED

Section 2 — Installation

Figure 2-14 CFLC 6000 - 12000 Wiring Diagram, single fuel (typical)

Note: Wiring diagrams shown are examples only.

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

Part No. 750-363 2-23

Section 2 — Installation

2-24 Part No. 750-363

Section 3

Stack and Intake Vent Sizing and Installation

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

Vertical Venting / Inside Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Vertical Venting / Direct Vent or Sealed Combustion Air . . . . . . . . . . . . . . . . . . 3-7

Venting for multiple units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

Combustion Air / Boiler Room Ventilation Requirements . . . . . . . . . . . . . . . . . . 3-10

www.cleaverbrooks.com

Section 3 — Stack and Intake Vent Sizing and Installation

3.1 VENTING CONNECTIONS - GENERAL

3.1.1 Appliance Categories

Proper installation of flue gas exhaust venting is critical for efficient, reliable, and safe operation of the CFLC 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 CFLC may be considered Category II, III, or IV. The specifying engineer should dictate flue venting as appropriate to the installation. CFLC condensing applications will typically utilize Category IV venting.

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.

3.1.2 Flue Venting System Design

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

Flue venting should be supported by the building structure. The maximum load that the boiler flue connection can support is 500 lbs.

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

3-2 Part No. 750-363

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.

For Category II, III & IV appliance categories, Cleaver-Brooks highly recommends that the flue system be Listed to standard UL 1738 Special Gas Vent and be installed in accordance with the National Fuel Gas Code (NFPA 54) or ANSI Z21.47/ CSA 2.3. Type B Vent shall not be allowed for positive pressure (forced draft burner) or condensing vent systems.

Draft calculations should be performed for any condensing boiler flue system. It is good practice to perform calculations at several operating conditions to ensure draft tolerances are maintained.

For best performance, individual, through-the-roof vertical flue venting is recommended for CFLC boilers. Cleaver-Brooks recommends vertical straight flue (no loss) or velocity cone flue termination.

Note:Traditional rain caps should not be used, as moist,

condensing flue gases can be directed downward toward the building and air intakes. In cold climates and freezing ambient temperatures, rain caps can lead to ice formation, air intake blockage, and flue blockage that result from condensing water vapor in the flue gases.

Cleaver-Brooks discourages the use of horizontal through-the-wall flue termination with CFLC boilers. Vertical flue terminations are recommended for optimum combustion performance and building exterior maintenance.

An active draft inducer may be necessary for a horizontal flue arrangement that exceeds the allowable draft tolerance.

Contact the Cleaver-Brooks authorized representative for consideration of horizontal flue termination with CFLC boilers.

3.1.3 Draft Tolerances

For Individual flue vented boilers:

Maximum allowed pressure at vent connection is minus 0.25 inches to plus 0.10 to WC.

Recommended maximum design pressure at vent connection is minus 0.10 to plus 0.10 inches WC.

For common flue vented boilers: Maximum allowed pressure at vent connection is minus 0.25 inch

to 0.0 inch WC. Recommended maximum design pressure at vent connection is

minus 0.10 to 0.0 inch WC.

3.1.4 Vent Terminal Location

Give special attention to the location of the vent termination to avoid possibility of property damage, compromised performance, or personal injury. For best results with condensing boilers, use vertical straight (no loss) flue discharge or velocity cone termination. These

Figure 3-1 Vent Terminations

Part No. 750-363 3-3

Section 3 — Stack and Intake Vent Sizing and Installation

terminations are suited to moving flue gases and water vapor away from building exterior surfaces and air intakes.

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, as well as 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. Extend the termination at least 2” from exterior surface.

10. DO NOT extend exposed stack pipe outside of building. In

winter conditions condensate could freeze and block stack pipe.

During winter months check the vent cap and make sure no

Note:

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.

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

Vent termination requirements are as follows:

1. Flue vent must terminate at least eight (8) feet above or eight (8)

feet horizontal from any HVAC air inlet to the building, including combustion air intakes. Vent must terminate at least three (3) feet above any door or window.

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.

3-4 Part No. 750-363

Section 3 — Stack and Intake Vent Sizing and Installation

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 veranda, porch or deck, unless:

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

• The distance between the top of the vent termination and the underside of the veranda, 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.

Venting Installation Tips

Support piping:

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

• Vertical runs - use braces.

• Under or near elbows

Part No. 750-363 3-5

Section 3 — Stack and Intake Vent Sizing and Installation

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.

3.2 VERTICAL VENTING / INSIDE COMBUSTION AIR

Caution

10'-0" or Less

24"

Minimum

Flue Gas Vent Termination

48"

Minimum

Figure 3-2 Vertical Stack with Inside Combustion Air

3-6 Part No. 750-363

Section 3 — Stack and Intake Vent Sizing and Installation

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

149.2 Installation Code for Gas Burning Appliances and Equipment.

To prevent accumulation of condensation in the vent, it is required to install the horizontal portion of vent with a slight slope of at least 1/4” per foot of horizontal run, pitched either back to the boiler or to a low point equipped with suitable condensate trap and drain.

Warning

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

3.3 VERTICAL VENTING / DIRECT VENT OR SEALED COMBUSTION AIR

Vent Termination

Minimum

48"

48" Minimum

12"

Minimum above roof or snow line

Air Intake (w/Screen)

24" Minimum

Vent Termination

36" Minimum above intake

48" Minimum

Air Intake (w/Screen)

12" Minimum

above parapet or snow line

With parapet wall

Figure 3-3 Vertical Stack with Direct Venting/Sealed Combustion

Part No. 750-363 3-7

Section 3 — Stack and Intake Vent Sizing and Installation

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

3.4 VENTING FOR MULTIPLE UNITS

Cleaver-Brooks recommends that each model CFLC in a multiple boiler installation be vented individually for safe, reliable, and optimum combustion performance. If common flue venting is the only feasible solution, ensure an unrestricted flow of flue gas from each boiler and a draft within the allowable tolerances.

To help maintain balanced draft conditions in common flue vented CFLC boiler systems, isolation dampers (flue or combustion air) with “prove open” switches are required. The damper prove must be wired in the boiler's safety interlock circuit.

When there is insufficient (or excessive) vertical flue stack to ensure neutral draft, active draft controls are recommended for common flue vented CFLC boilers.

Ductwork sizing, layout, and connections require special attention in common flue venting systems. Good design practice should be followed such as the use of 45 degree wye connections (not 'tees') for boiler branch connections into common flue duct. The number of elbows should be kept to a minimum.

Common flue venting should always be larger than the boiler branch connection joining it. As a rule-of-thumb, the cross-sectional area of any ductwork downstream of a wye branch connection should be equal to or greater than the combined area of the incoming vent sections.

See Examples 1-3 below for suggested venting arrangements.

When multiple CFLC boiler are connected in a Falcon Lead-Lag network, a 'Fan rate during off cycle' feature is available. When enabled, a boiler that goes off line and completes its post purge will continue to operate the combustion air blower at a user-selectable rate. This feature provides a further measure when needed to prevent flue gases from flowing back into the boiler and room.

To ensure safe and reliable operation of multiple CFLC boilers in a common flue venting system, please contact the Cleaver-Brooks authorized representative. Cleaver-Brooks offers proven flue systems for all Cleaver-Brooks models through its Exhaust Solutions group.

3-8 Part No. 750-363

EXAMPLE 1

Section 3 — Stack and Intake Vent Sizing and Installation

GOOD

BAD



26”

14” 14”

From boilers

26”

to roof vent

14”

EXAMPLE 2

GOOD

14”

20”

From boilers



14”

BAD

From boilers

Part No. 750-363 3-9

Section 3 — Stack and Intake Vent Sizing and Installation

EXAMPLE 3

GOOD



26”

14” 14”

From boilers

16”

16” 16”

From Boilers

26”

24”

26”

30”

14”

16”

to roof vent

BAD



14”

14” 14”

From Boilers

14”

Combustion air methods

ROOM AIR

Air is drawn from the boiler room.

DIRECT VENTING

Air is ducted from the outdoors to the burner cabinet. No direct connection to burner air intake.

SEALED COMBUSTION

Outside air is ducted directly to the burner air intake.

3.5 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 boiler room venting, where ambient combustion air is drawn from the area immediately surrounding the boiler (boiler room must be positive pressure*), or with air ducted from the outdoors to the burner cabinet (direct venting) or burner air intake (sealed combustion). 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.

*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 wall louvered air intake.

3-10 Part No. 750-363

Section 3 — Stack and Intake Vent Sizing and Installation

“Sealed combustion” is a special air ducting method that implies a gas-tight ducted connection to the burner’s air intake. Contact your Cleaver-Brooks authorized representative to determine if direct vent or sealed combustion is appropriate for the installation.

C-B provides optional Combustion Air Adapter kits which can be used in either Direct Vent or Sealed Combustion configurations.

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).

3.5.1 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. 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.

Part No. 750-363 3-11

Section 3 — Stack and Intake Vent Sizing and Installation

2. The openings must be linked directly (Figure 3-4) or by

3. Each opening must have a minimum free area of one

4. The minimum free area required for horizontal ducts is

ducts (Figure 3-5) with the outdoors.

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.

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 3-4 Two Opening Outside Wall Method

12" MINIMUM

FRESH AIR OPENING

INTERIOR WALL

FRESH AIR OPENING

12" MINIMUM

3-12 Part No. 750-363

Section 3 — Stack and Intake Vent Sizing and Installation

CLEARFIRE BOILER

GAS VENT

WATER

HEATER

INTERIOR WALL

EXTERIOR WALL

Figure 3-5. Two Opening Ducted Method

12" MINIMUM

OUTLET AIR DUCT

FRESH AIR INLET DUCT

12" MINIMUM

C. One Opening Method (Figure 3-6) - 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.

Part No. 750-363 3-13

Section 3 — Stack and Intake Vent Sizing and Installation

GAS

VENT

GAS VENT

12" MINIMUM

FRESH AIR OPENING

EXTERIOR WALL

WATER

HEATER

Figure 3-6. One Opening Method

3.5.2 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 3-7.

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.

3-14 Part No. 750-363

Section 3 — Stack and Intake Vent Sizing and Installation

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

openings be less than one square foot.

FRESH AIR OPENING

EXTERIOR WALL

GAS VENT

WATER HEATER

FRESH AIR OPENING

EXTERIOR WALL

Figure 3-7. 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) CFLC 4000 boilers at 750 feet elevation. The air openings to be 5 feet above floor level.

• Air required: 4000 x 2 = 8000 kBtuh. From 2C above, 8000 x 0.3 = 2400 cfm.

Table 3-1 Boiler room air

CFLC 20 ppm

4000 1000 200 1200

5000 1250 250 1500

6000 1500 300 1800

8000 2000 400 2400

10000 2500 500 3000

12000 3000 600 3600

CFLC 9 ppm

4000 1075 200 1275

5000 1350 250 1600

6000 1625 300 1925

8000 2150 400 2550

10000 2700 500 3200

12000 3225 600 3825

Combustion

air SCFM

Combustion

air SCFM

Vent air

SCFM

Vent air

SCFM

Total

room air

SCFM

Total

room air

SCFM

Part No. 750-363 3-15

Section 3 — Stack and Intake Vent Sizing and Installation

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

• Area required: Area = cfm/fpm = 2400/250 = 9.6 square feet total.

• Area/Opening: 9.6/2 = 4.8 sq-ft/opening (2 required).

Consult local codes, which may supersede these requirements.

Direct Venting/Sealed Combustion

If combustion air will be drawn directly from the outside by means of a duct connected to the burner cabinet (Direct Venting) or air intake (Sealed Combustion), use the following as a guide:

1. Install combustion air vent 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 extremely cold climates, to mitigate the potential for freezing and to reduce standby losses, a motorized isolation damper is necessary to prevent the circulation of cold air through the boiler during non-operating hours.

4. Refer to Figure 3-3 for suggested piping of direct vent/sealed combustion installations. Figure 3-8 shows the optional kit providing easy adaptation of the contractor supplied air duct to boiler connection. Table 3-2 shows vent sizing information.

Notice

Caution

Combustion air ductwork should be securely attached to the boiler casing. No weight should be supported by the venturi. Venting should be installed to allow easy disconnection for burner service. For best results, the CleaverBrooks direct vent/sealed combustion kit is recommended. See T able 6-2 for kit part numbers.

For Direct Vent use, omit the flexible duct connector and air intake collar.

For Sealed Combustion, assemble all components as shown.

Figure 3-8. Optional Direct Vent/Sealed Combustion Kit

3-16 Part No. 750-363

Section 3 — Stack and Intake Vent Sizing and Installation

Table 3-2. CFLC Combustion Air and Flue Venting Requirements for Individual Boiler Venting

20ppm NOx Combustion air

SCFM

CFLC 4000 1000 10 0.25 10” or 12” 14” -0.25/+0.10” CFLC 5000 1250 12 0.25 12” 14” -0.25/+0.10” CFLC 6000 1500 14 0.25 14” or 16” 16” -0.25/+0.10” CFLC 8000 2000 14 0.25 14” or 16” 16” -0.25/+0.10” CFLC 10000 2500 16 0.50 16” or 18” 20” -0.25/+0.10” CFLC 12000 3000 18 0.50 18” 20” -0.25/+0.10”

9ppm NOx

CFLC 4000 1075 10 0.25 10” or 12” 14” -0.25/+0.10” CFLC 5000 1350 12 0.25 12” 14” -0.25/+0.10” CFLC 6000 1625 14 0.25 14” or 16” 16” -0.25/+0.10” CFLC 8000 2150 16 0.25 14” or 16” 16” -0.25/+0.10” CFLC 10000 2700 16 0.50 16” or 18” 20” -0.25/+0.10” CFLC 12000 3225 18 0.50 18” 20” -0.25/+0.10”

Minimum duct

diameter inches

Max allowable

comb. air pressure

drop (inches WC)

Direct vent adapter kit

options

Flue diameter Draft tolerance

(inches WC)

Part No. 750-363 3-17

Section 3 — Stack and Intake Vent Sizing and Installation

3-18 Part No. 750-363

Section 4

Commissioning

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

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

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

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

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

Controller Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Variable Speed Drive Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Burner Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Fan Speed Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Initial start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Post start-up checkout procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Falcon Control Functions and Customer Interface . . . . . . . . . . . . . . . 4-18

Warning

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

www.cleaverbrooks.com

Section 4 — Commissioning

4.1 OPERATING CONDITIONS

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

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

• Control panel must be connected to earth ground.

• Refer to Section 3 in this manual for combustion air requirements.

When using direct vent combustion in cold climates, special care must be taken to

Warning

observe combustion air temperature limits. Failure to

Boiler room ambient conditions

Relative humidity Ambient temperature range 0 Storage temperature range -40 Combustion air temperature 0

< 85% non-condensing

C to 50 oC / 32oF to 122oF

C to 60 oC / -40oF to 140oF

C to 50 oC / 32oF to 122oF

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

4.2 FILLING BOILER

The system should be flushed, preferably with the boiler isolated, before operating the boiler.

When filling the boiler and/or hydronic system, water should be circulated to allow entrapped air to escape at appropriate air venting provisions. Check to ensure that no leaks appear at any pipe connections and correct if water leaks are noticed. When no air remains in the boiler, it will be possible to reset the low water cutoff. If the low water cutoff can not be reset, it is likely that some air remains in the boiler.

4.3 CONTROL SETPOINTS

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

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

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

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

4. High Air Pressure Switch - Set the dial @ maximum (for operational settings see Table 4-2).

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

Note:Ensure that the post-startup checkout procedure (section 4.11) is observed following

commissioning.

4-2 Part No. 750-363

4.4 MODEL CFLC BOILER / BURNER

CONTROLLER

The Model CFLC boiler uses the 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.

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

Section 4 — Commissioning

Figure 4-1 Opening control panel

Figure 4-2 Controller status LEDs and reset button

• High Stack Temperature limit

• Remote reset

• Lead/Lag sequencing and modulation

• (3) configurable pump relays

• Remote modulation/remote setpoint

• Frost protection

• Warm weather shutdown

Part No. 750-363 4-3

Section 4 — Commissioning

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.

Warning

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

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

Figure 4-3 Falcon Display/Operator Interface

4.5 FALCON DISPLAY/OPERATOR INTERFACE

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

4.5.1 Home Page

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

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

4.5.2 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 Falcon interface.

Home page

4-4 Part No. 750-363

Status page

Section 4 — Commissioning

The Demand display will show one of the following:

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

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.

4.5.3 Operation Page

The operation page (Figure 4-4) displays the 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.

Figure 4-4 Operation Page

Part No. 750-363 4-5

Section 4 — Commissioning

Figure 4-5 Falcon Display/Interface page flow

4.5.4 Lockouts, Holds, and Alerts

To assist in monitoring boiler operation, the 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 15 most recent Lockouts are stored in 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 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 4-6). Press this banner to access the Alert or Lockout History, where a list of the most recently occurring Alerts/Lockouts can be viewed.

4-6 Part No. 750-363

Section 4 — Commissioning

Alarm Banner

Figure 4-6 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 Section 5 - Service and Maintenance.

4.6 CONTROLLER CONFIGURATION

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

Falcon configuration is organized 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

4.6.1 Changing Falcon Parameter Settings

See APPENDIX A for Falcon parameter list

• Anti-condensation Configuration

• Frost Protection Configuration

• Annunciation Configuration

• Burner Control Interlocks

• Burner Control Timings & Rates

• Burner Control Ignition

• Burner Control Flame Failure

• System Configuration

• Fan Configuration

• Lead Lag Configuration

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

Part No. 750-363 4-7

Section 4 — Commissioning

Figure 4-7 Configuration Menu

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

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 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.

4-8 Part No. 750-363

Confirming Safety Parameter changes

1. Press <Begin>

Section 4 — Commissioning

3. Reset Falcon

2. Press <Yes>

4.6.2 Program Module

Falcon parameter information (non-safety parameters only) can be uploaded/ downloaded using the optional Program Module (PIM). 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>.

Figure 4-8 PIM

4.7 VARIABLE SPEED DRIVE SETTINGS

The Variable Speed Drive is pre-configured at the factory. Should it become necessary to change the drive’s configuration, VSD parameters can be viewed and changed using the drive’s integral keypad/display. See APPENDIX B - Variable Speed Drive Parameters for parameter list; if necessary refer also to the appropriate Allen-Bradley PowerFlex user manual.

Part No. 750-363 4-9

Section 4 — Commissioning

4.8 BURNER SEQUENCE

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

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).

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 5 seconds into pilot ignition.

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.

4.9 FAN SPEED SETTINGS

Because the input is determined by the fan speed, the factory fan speed settings may have to be modified for the particular application, for high altitudes, or when using direct vent combustion. The default fan speed settings are intended for typical applications for the various boiler sizes. Please contact your authorized Cleaver-Brooks representative for proper settings in high altitude and direct vent combustion applications.

4.10 INITIAL START-UP PROCEDURE

Warning

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

4.10.1 Gas Train and Piping

The ClearFire burner is equipped with a combination servo-regulated gas valve and venturi mixing unit. The gas valve consists of a single body and regulating actuator with safety shutoff. The blower speed is controlled by the Falcon with airflow directly proportional to the speed of the fan. The airflow creates a drop

4-10 Part No. 750-363

Section 4 — Commissioning

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 supply pressure to ensure that it is compatible with the ClearFire’s gas train and

regulator. Refer to Table 4-1 for minimum required supply pressure and maximum allowable supply pressure.

3. To bleed air from the supply pipe, open the manual gas shut off valve upstream of the burner gas train

and bleed air from the piping by loosening the union in the upstream piping.

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

5. Gas Pressure Regulator - Using the adjusting screw on the main gas regulator, adjust the gas valve inlet

pressure to within the recommended levels in Table 4-1.

Figure 4-9 Premix Burner Technology - Full Modulation

Table 4-1 CFLC gas pressure requirements

Gas Supply Pressure (at gas regulator outlet)

Natural Gas 20ppm Natural Gas 9ppm Propane

Boiler

size 4000 9 14 10 14 9 14 3-5 5000 9 14 10 14 9 14 3-5 6000 35 56 35 56 31 56 3-5 8000 35 56 42 56 31 56 3-5

10000 38 56 38 56 35 56 3-5 12000 38 56 40 56 35 56 3-5

*Listed max. pressures are without the use of a step-down regulator. The CFLC can accommodate higher supply pressures with the addition of an upstream regulator. *When an upstream regulator is installed, required minimum pressures will be higher due to the pressure drop across the regulator. CFLC 4000-5000 >1/2 psig requires step-down regulator

CFLC 6000-12000 >2 psig requires step-down regulator

Part No. 750-363 4-11

Min

(“WC)

Max*

(“WC)

>5 psig requires overpressure protection

>7 psig requires overpressure protection

Min

(“WC)

Max*

(“WC)

Min

(“WC)

Max

(“WC)

Gas pilot pressure

(“WC)

Section 4 — Commissioning

4.10.2 Power-Up

1. Ensure the boiler is properly wired for the available power supply. Refer to the wiring diagram provided

with the boiler or to the appropriate wiring diagram in Section 2 - Installation.

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

4.10.3 Operation Check: Gas Valve, Gas Pressure Switches, Combustion Air Proving Switch, Ignition Fail

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 C - 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 Falcon Annunciation screen to monitor the status of the circuits involved. Press <Annunciation> on the Operation page to access this screen.

Figure 4-10 Annunciation Screen

LGPS

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

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

3. Turn the LGPS setting to maximum.

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

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

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

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Section 4 — Commissioning

CAPS

1. Initiate burner sequence.

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

imum setting.

3. The Falcon should lock out on an airflow failure. The display will

show Lockout 65 Interrupted Airflow Switch OFF.

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

CAPS low pressure connection

4. Following a successful CAPS check, dial the CAPS back to its min-

imum setting and reset the 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, indi-

cating both safety shutoff valves open.

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

5. Reset Falcon.

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

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

IGNITION FAILURE CHECK

1. A test of the UV scanner circuit can also be performed at this time. Shut off pilot gas manual valve and attempt to start the burner. The Falcon should lock out, indicating Lockout 109 Ignition Failure.

2. Reopen pilot gas manual valve.

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

4.10.4 PIlot Tests

PILOT FAIL CHECK

Close the gas pilot shutoff valve. Also shut off main fuel supply. Attempt to start the burner. There should be an ignition spark, but no pilot flame. The Falcon will lock out, indicating pilot failure.

Reset the Falcon, open the pilot shutoff valve, and re-establish fuel supply before continuing.

PILOT HOLD TEST

On the Falcon display, go to Configure>Ignition and turn <Pilot Hold> to ON. Open the manual valve on the pilot gas train, keeping the downstream main gas valve closed. Initiate the burner sequence. The burner will go through prepurge and will go to trial for pilot ignition. Once the pilot is lit, check for flame signal on the Falcon display and visually inspect the pilot flame through the sight port on top of the boiler. Once a good pilot flame has been established, open the downstream main gas shutoff valve and turn the Pilot Hold setting to OFF. The Falcon will proceed to main flame trial for ignition.

Part No. 750-363 4-13

Section 4 — Commissioning

4.10.5 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

3. Press RESET-TEST switch once to reset.

4.10.6 Low and High Fire Adjustments

All CFLC boilers are factory tested firing natural gas at an altitude of 1000 ft ASL. Operating under different conditions may require re-adjustment of the gas valve. See figure below for low and high fire adjusting screw locations. Observe the markings on the gas valve to ensure correct direction of adjustment.

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

High Fire

Low Fire

CFLC 6000-12000CFLC 4000-5000

Figure 4-11 Gas Valve Adjustments

4.10.7 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.

4-14 Part No. 750-363

Section 4 — Commissioning

4.10.8 Setting Combustion

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

and adjust the burner without this equipment.

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

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.

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 Falcon Control. Setting combustion will require manually modulating the burner via the 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.

1. On the Falcon Operation screen, press the Fir- ing rate display.

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.

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

Part No. 750-363 4-15

Section 4 — Commissioning

To set combustion:

Figure 4-12 Operation screen

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

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

3. Turn LOCAL/REMOTE switch to LOCAL.

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

12). 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 4-1 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% (5%

- 8.5%).

7. Modulate to low fire and fine tune offset screw to obtain desired O2% (6% - 8.5%).

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 4-1.

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Section 4 — Commissioning

4.10.9 High Air Pressure Switch Settings

The High Air Pressure Switch (HAPS) is used to safely shut down the boiler in case of a blocked flue or blocked condensate condition. The HAPS has a manual reset, similar to the High/Low gas pressure switches.

Table 4-2 HAPS Settings

Boiler Size Setting (inches WC)

20 ppm 9 ppm

4000 5 5

5000 6 7

6000 11 16

8000 21 21

10000 15 8

12000 9 9

Note: In the event of a HAPS lockout, investigate possible causes before attempting to restart boiler.

4.10.10 Limit Controls Check

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

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

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

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

Specific settings are determined by application. Maximum High Limit for Model CFLC is 250 deg F.

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

4.11 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 4-1.

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.

Part No. 750-363 4-17

Section 4 — Commissioning

4.12 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 manual for more detailed explanations.

• Set Point

• Time-of-Day (TOD) Set Point

• Hysteresis On and Hysteresis Off

• PID modulation control

• Remote Enable and Remote 4-20mA Input

• Remote Modulation

• Remote Set Point

• Rate Limiting/Override

• Configurable pump/auxiliary relay contacts

• Annunciator

• Diagnostics

• Lockout/Alarm History

• Trend Analysis

• Modbus communications

• Lead/Lag Control for up to 8 boilers

• DHW demand priority

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 CFLC 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 may be 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 5 deg F and 15 deg F, respectively.

The PID (Proportional-Integral-Derivative) load control operates on 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 single boiler heating applications.

Decreasing the PID gain values slows down the controller’s response to a change in load demand. Increasing the gain values causes more aggressive control, though setting the values too high can lead to ‘overshoot’ and unnecessary cycling.

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

4-18 Part No. 750-363

Section 4 — Commissioning

“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 then 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 “20mA water temperature” parameter determines the value for 20mA; “4mA water temperature” determines the value for 4mA.

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 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 caused by a mismatch between water flow rate and boiler firing rate. Sensor connections to the 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 userspecifiable threshold. Slow Start can help reduce set point overshoot, high limit trips, and frequent cycling.

Part No. 750-363 4-19

Section 4 — Commissioning

Configurable Pump/Aux Relay Contacts

The Falcon Pump/Aux Relay outputs are configurable by means of six pre-configured Pump Control Blocks. Each control block is configured for a specific application:

1. Central Heat Pump

2. Boiler Pump (for primary/secondary pumping)

3. DHW pump

4. System Pump

5. “Aux 1 Pump” - used for a boiler isolation valve

6. “Aux 2 Pump” - used for a boiler Start Permissive Interlock

Each pump control block has seven parameters (for details see Falcon Lead Lag appendix):

Pump Options (2 parameter blocks) - determine pump on/off conditions Start Delay - if burner is just starting up, timer will delay pump turning on Overrun Time - keeps the pump running for a short time after the input turns off or demand is satisfied Output Connection - selects Pump A, B, or C (refer to WD, Figure 2-10) Cycle Count - one cycle counter for each pump output; can be reset if a pump is replaced Pump Control - selects Auto or Manual control

A Pump Exercise routine helps to prevent pumps from freezing up due to long periods of inactivity. Configurable parameters are Pump Exercise Interval (days) and Pump Exercise Time (minutes). Any pump that remains off for the Pump Exercise Interval will be turned on for the duration given by Pump Exercise Time.

The relays may be configured for various other functions, including freeze protection, isolation valves, damper interlocks, operating status, etc.

Annunciator

The Annunciator monitors the Falcon control circuit to provide fault and status messages, and also provides first out annunciation for interlock lockouts. Eight inputs are available in addition to the Interlock, Load Control, and Pre-Ignition Interlock inputs, totaling 11 monitored points. Annunciator points can be accessed via the Falcon display Operation screen.

Lead/Lag Control (up to eight boilers)

Multiple Falcon units can be connected in a lead/lag

MASTER

system. Controllers in a lead/lag configuration communicate over the Falcon’s MB2 Modbus network.

One Falcon in the lead/lag network hosts the Lead Lag Master function, which coordinates the activities of the

SLAVE SLAVE SLAVE SLAVE

Slave units (individual Falcons, including the one hosting the Master) via Modbus. The Master uses its host controller’s header sensor to receive control input information and to maintain the optimum setpoint. An

Figure 4-13 Falcon Lead/Lag

outdoor temperature sensor can also be connected for Lead Lag outdoor reset control.

Boiler sequencing, on/off staging, and firing rate allocation are user-configurable. The Falcon’s default lead lag parameter settings have been optimized specifically for ClearFire-C condensing boiler operation.

Refer to the Falcon Lead/Lag appendix in this manual for additional information.

Modbus Communication

For remote enable / remote setpoint (see above) and for remote monitoring through a building EMS, the Falcon uses the Modbus communication protocol. For more information on Modbus setup and implementation, see the Falcon Lead Lag appendix in this manual.

4-20 Part No. 750-363

Section 5

Service and Maintenance

Disassembly for Inspection ...................................................... 5-2

Reassembly .......................................................................... 5-4

Ignition and Flame Detection Systems ...................................... 5-4

Troubleshooting .................................................................... 5-6

Extended Shutdown................................................................ 5-8

Emergency Shutdown ............................................................. 5-8

Caution

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

Caution

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

www.cleaverbrooks.com

Section 5 — Service and Maintenance

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

5.1 DISASSEMBLY FOR INSPECTION

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

2. Remove the front upper and front left side casing panels.

3. Remove the gas train and set aside.

4. Disconnect the electrical connections to the blower assembly.

5. Disconnect scanner, ignition, and pilot cables.

6. Remove air filter (or direct vent coupling if supplied).

7. Remove the vent section between the flue collection chamber and the casing roof.

8. Remove the nuts securing the blower to the adapter plate.

9. The blower will swing out and to the left on its hinge.

10. The burner head can be separated by removing the nuts and washers holding the adapter plate to the dry oven.

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

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

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

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

Caution

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

5-2 Part No. 750-363

Front Fireside Access

Remove the front lower casing panel.

Remove cover plate from condensate collection chamber.

After fireside inspection/ maintenance, replace cover plate gasket with 853-01531 silicone tape.

Rear Fireside Access

Section 5 — Service and Maintenance

Remove rear casing panels.

Remove upper/lower rear smokebox cover plate.

After fireside inspection/ maintenance, replace cover plate gaskets with 872-00622 rope.

Part No. 750-363 5-3

Section 5 — Service and Maintenance

5.2 REASSEMBLY

1. Assembly is the reverse of the above instructions.

2. Burner gaskets should be replaced; see recommended spare parts list.

3. Replace combustion air filter if dirty. Remove filter retaining rod and install new C-B approved filter media; see recommended spare parts list. Replace rod to hold filter in place.

Overlap filter media and clamp under threaded rod in the housing. Sticky side should be towards the perforated sheet.

Filter Housing

Filter Assembly

5.3 IGNITION AND FLAME DETECTION SYSTEMS

Ignition Electrode

The ignition electrode should be replaced annually, or more frequently if conditions require. Inspect the electrode periodically for signs of fouling, displacement, or other damage.

Observe the dimensions below when replacing:

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

1” from ignitor electrode to the burner canister.

5-4 Part No. 750-363

Section 5 — Service and Maintenance

1”E1/16”

1/8”

Figure 5-1 Electrode spacing CFLC

Pilot and UV Scanner

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

When replacing the scanner, verify an unobstructed line of sight through the scanner bracket to the burner canister.

Figure 5-2

The CFLC uses an interrupted gas pilot in lieu of direct spark ignition. Ensure pilot is installed with the holes facing outward (towards the burner can).

Part No. 750-363 5-5

Section 5 — Service and Maintenance

5.4 TROUBLESHOOTING

Lockout Conditions

SCANNER HOLESIGHT PORT

HOLE

ENSURE GAS HOLES ARE POINTED OUTWARD

Figure 5-3

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

2. After determining lockout condition, investigate possible causes.

3. When cause is diagnosed, remedy condition.

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

5. If lockout recurs, further investigation is required. Repeat steps 1 through 4 as needed. If necessary, contact your

CB service representative for technical support.

EXAMPLE: Lockout 79 Outlet Temperature High Limit

1. Before resetting control to clear lockout, check for sufficient water flow through boiler. Possible sources of insuffi-

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

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

2. Remedy condition that caused lockout to occur.

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

Light-off Problems

Check electrode positioning according to Section 5.3 above.

The dimensions on the ignition electrodes are not easily adjustable - bending the rods can cause damage to the insulation material. In addition, a bent electrode will return to its original shape when heated. If an ignitor is out of specification, replacement is generally required. Clean or replace as necessary.

Also see Troubleshooting Chart below.

5-6 Part No. 750-363

Section 5 — Service and Maintenance

Troubleshooting Chart

Symptom/Fault Indication Possible Causes

Erratic display/controller behavior Faulty electrical ground - Check ground terminals in control panel. System

should be grounded firmly to metal casing. External ground wiring may be necessary.

Touch screen not working properly Screen out of calibration - from Falcon home page, go to Setup/Advanced

Setup/Diagnostics. Under “Touch Screen” press <Calibrate> and follow instructions on screen.

Burner can failure; High Gas Pressure lockouts

Lightoff problems • Wrong gas pressure. Check regulated gas pressure and ensure it agrees

Outlet Temperature High Limit lockout • Insufficient water flow through boiler - closed water valves, insufficient

Incorrect gas pressure:

• Check regulated gas pressure and ensure it agrees with Table 4-3. Check other equipment connected to gas main - regulator and gas supply piping sizings should be based on all appliances being ON.

• A dedicated, properly sized gas pressure regulator is required for each boiler.

• Customer connection should reduce to boiler gas train.

with Table 4-3. Check other equipment connected to gas main regulator and gas supply piping sizings should be based on all appliances being ON.

• Incorrect fan speed settings - increase fan speed by 100 RPM increments until successful lightoff occurs.

• Bad cable connections (ignition)

• Electrodes fouled or improperly spaced - electrodes should be cleaned or replaced and spacing adjusted.

• Debris on burner canister. To clean the unit, remove the burner can and blow compressed air from the outside in. Vacuum up the residue.

• Electrical ground problem

pump speed

• Air trapped in boiler

• Modulation set point and off point too close to outlet high limit setting

Interrupted Air Switch lockout • Blower not running

• Blocked blower inlet

• CAPS switch defective or improperly wired

Loss of flame • Debris on burner

• Blocked condensate drain

• Combustion improperly set

• Flame scanner soiled, obstructed, or out of position

5-7 Part No. 750-363

Section 5 — Service and Maintenance

5.5 EXTENDED SHUTDOWN

When shutting down the boiler for an extended period of time, use the following general guidelines:

1. Turn the demand switch to the OFF position.

2. Close all main fuel valves.

3. If the boiler operates in a damp environment, cover electrical components in plastic to protect from moisture.

To restart after an extended period, follow the initial startup instructions in Chapter 4.

5.6 EMERGENCY SHUTDOWN

In case of emergency, shut down the boiler by turning the demand switch to the OFF position. Shut off the main manual fuel shutoff valves on the fuel supply line. The unit can also be shut down with the main electrical power disconnect. Inspect and troubleshoot the boiler before attempting to restart. Follow instructions in Chapter 4 for restart and continued operation.

5-8 Part No. 750-363

Section 6

Parts

Recommended Spare Parts List Model CFLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Boiler Mechanical Assembly CFLC 4000/5000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Boiler Mechanical Assembly CFLC 6000/8000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Boiler Mechanical Assembly CFLC 10000/12000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Burner Assembly CFLC 4000/5000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Burner Assembly CFLC 6000/8000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Burner Assembly CFLC 10 000/12 000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

UV Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Gas train CFLC 4000/5000 (standard 20 PPM NOx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

Gas train CFLC 6000/8000 (standard 20 PPM NOx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

Gas Train CFLC 6000/8000 (optional 9 PPM NOx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

Gas train CFLC 10000/12000 (standard 20 PPM NOx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

Gas train CFLC 10000/12000 (optional 9 PPM NOx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

Gas Train CFLC 4000/5000 Propane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

Gas Train CFLC 6000/8000 Propane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

Gas Train CFLC 10000/12000 Propane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

Dual Fuel Gas Trains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

Dual Fuel 4000-5000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19

Dual Fuel Nat. Gas 6000-12000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

Dual Fuel Propane 6000-12000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

Pilot Gas Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

Cables and Cable Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

Optional Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24

Casing & Insulation 4000-5000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25

Casing & Insulation 6000-8000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27

Casing & Insulation 10000-12000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29

www.cleaverbrooks.com

Section 6 — Parts

Table 6-1. Recommended Spare Parts List Model CFLC

Boiler Size

Item Qty 4000 / 5000 6000 8000

Falcon Controller, Hydronic 1 833-04097 Display/Operator Interface, Falcon System 1 833-05105 UV Scanner 1 817-01743 Dual Electrode, Sparking 1 380-01061 Electrode Gasket 3 380-01032 Burner Canister 1 380-01130 380-01145 380-01128 Water Side Gaskets 5 853-00934 Transformer, 115V/25V 1 832-00235 Relay, DPDT, 115VAC Coil 1 833-03532 Gasket, Burner Canister 2 380-01118 Gasket, Adapter to Blower 1 380-01121 N/A 380-01121 Cable, Gas Pilot 1 826-00262 Ignition Cable (2) 1 826-00298 Burner Sight Glass 1 851-00026 Gasket, Sight Glass 2 853-00213 Filter Media, Air Filter 2 332-00091 332-00094

Fuse (5A), Control Circuit 2 832-01811 Fuse (4A), Control Circuit 1 832-01810 Fuse (2A), 24VAC Secondary 1 832-02051 UV Heat Block 1 001-01584

6-2 Part No. 750-363

Figure 6-1. Boiler Mechanical Assembly CFLC 4000/5000

Section 6 — Parts

Part No. 750-363 6-3

Section 6 — Parts

Figure 6-2. Boiler Mechanical Assembly CFLC 6000/8000

6-4 Part No. 750-363

Figure 6-3. Boiler Mechanical Assembly CFLC 10000/12000

CFLC 10 000

QTY

ITEM

270-03916-000 853-00996-000

429-02038-000

465-02775-000

426-03302-000

1 426-03302-000

8 1 426-03303-000

426-03303-000

426-03304-000

11 1 872-00622-000

872-00622-000

16 1 185-01247-000 GAS TRAIN, MAIN GAS, SIEMENS

185-01393-000

17 1

185-01248-000

507-09839-000

31 1 656-10231-000 INSTALLATION, PRESSURE GAUGE & THERMOMETER

656-10231-000

283-03650-000

189-01434-000

41 1

826-00296-000

42 1 090-04723-000 TUBING, AIR SENSING LINE

090-04723-000

45 1

940-01267-000

46 1 940-02952-000

940-02952-000

47 1 940-01265-000

940-01265-000

940-00985-000

940-00811-000

49 50 2 940-00962-000

940-00811-000

880-02715-000

462-00286-000

833-03494-000

1 833-03494-000 CONDUIT KIT, VSD

484950

CFLC 12 000 270-03743-000 PRESSURE VESSEL ASSEMBLY, CFLC 12M 853-00996-000 ROPE, FIBERGLASS, 1/2" DIA. X 96-3/4" LG. 429-01856-000 BURNER ASSEMBLY 20PPM

465-02775-000 INSULATION & LAGGING ASSEMBLY

426-03304-000 DUCT, STACK SUPPORT, 20" DIA.

185-01248-000 PIPING, PILOT GAS TRAIN, CFLC 10M-12M 833-03366-000 DRIVE, VARIABLE SPEED, POWERFLEX 400, 20HP MOTOR 507-09839-000 PIPING, AIR VENT AND LWCO PROBE HOLDER

283-03650-000 CONTROL PANEL 189-01434-000 PIPING, CONDENSATE DRAIN 817-00405-000 WELL, SEPARABLE, HONEYWELL, 1/2" NPT. W/CLAMP 826-00296-000 CABLE HARNESS, MALE END

940-01267-000

940-00985-000 SAFETY VALVE, 60 PSI, 2" X 2-1/2" (OPTIONAL, SHIP LOOSE) 940-00811-000

880-02715-000 KIT, AIR FILTER, CFLC 10M-12M 462-00247-000 HINGE ASSEMBLY, BLOWER

DESCRIPTION

DUCT, STACK STARTER SECTION, 20" DIA. DUCT, STACK REMOVABLE SECTION, 20" DIA. W/BANDS

ROPE, FIBERFAX, 2300 DEG. 1/2" DIA. x 65" LG.

SAFETY VALVE, 160 PSI, 1-1/2" X 2" (STANDARD, SHIP LOOSE) SAFETY VALVE, 125 PSI, 2" X 2-1/2" (OPTIONAL, SHIP LO OSE) SAFETY VALVE, 100 PSI, 2" X 2-1/2" (OPTIONAL, SHIP LO OSE)

SAFETY VALVE, 60 PSI, 1" X 1-1/4" (OPTIONAL, SHIP LOOSE) SAFETY VALVE, 30 PSI, 2" X 2-1/2" (OPTIONAL, SHIP LOOSE)

Section 6 — Parts

DRY OVEN DETAIL

Part No. 750-363 6-5

Section 6 — Parts

Figure 6-4. Burner Assembly CFLC 4000/5000

UV SCANNER SEE FIGURE 6-7

6-6 Part No. 750-363

Figure 6-5. Burner Assembly CFLC 6000/8000

UV SCANNER SEE FIGURE 6-7

Section 6 — Parts

Part No. 750-363 6-7

Section 6 — Parts

Figure 6-6. Burner Assembly CFLC 10 000/12 000

UV SCANNER SEE FIGURE 6-7

Figure 6-7. UV Scanner

6-8 Part No. 750-363

Figure 6-8 Gas train CFLC 4000/5000 (standard 20 PPM NOx)

Section 6 — Parts

9 10 18

GAS PILOT TRAIN CONNECTION

29 30

1 1 1

1 4

800-00104-00018

800-00102-000 918-00637-000 157-00425-000119

817-02420-000128

800-00103-000 825-00239-000331 845-00217-000135

DESCRIPTIONPART NOQTYITEM BUTTERBALL VALVE, BRONZE, 1-1/2" NPT.941-01946-000 ADAPTER, PIPE, 1-1/2" NPT. WITH SHUTTER, O-RING AND SCREWS VALVE, GAS, COMBO, 120VAC940-07486-000 ADAPTER, PIPE, 2" NPT. WITHOUT SHUTTER REGULATOR, GAS PRESSURE, MAXITROL #210E, 2" NPT, 4"-12" WC (VIOLET) NIPPLE, SIDE OUTLET, 2" NPT. x 9" LG. x 1/2" NPT. VALVE, BUTTERBALL, 2" NPT.941-01947-000

HIGH GAS PRESSURE SWITCH, 3-21"WC RANGE, MR, 1/4" NPT MOUNT LGPS, 3-21"WC RANGE, MR, 1/4" NPT MOUNT817-02416-000 ADAPTER, 1/8 BSPT (MALE) x 1/8" NPT (FEMALE) LEAKAGE TEST COCK, 1/8" NPT. FITTING, COMP. 90 DEG. ELBOW, 1/8" NPT. x 1/4" ODC

VIEW B-B

30 31

DETAIL A

VENTURI

ASSEMBLY P/N 185-01245-000 185-01419-000 185-01420-000

185-01421-000

"A"

WHERE USED CFLC 5000, 20PPM CFLC 5000, 9PPM CFLC 4000, 20PPM CFLC 4000, 9PPM

ADJUST SHUTTER TO DIMENSION PRIOR TO ASSEMBLING TO VALVE

DIM "A"

.730" .657" .734" .665"

DETAIL ITEM 8

Part No. 750-363 6-9

Section 6 — Parts

Figure 6-9. Gas train CFLC 6000/8000 (standard 20 PPM NOx)

STD.

SECTION A-A

ITEM QTY CFLC 6000 CFLC 8000 DESCRIPTION

29 1 157-02627-000

STD.

32 1 857-04322-000

*OPTIONAL

ITEM QTY PART NO. DESCRIPTION

11 SEE TABLE

797-07943-000 ACTUATOR

817-02416-000 4 1 817-02417-000 5

3 825-00239-000 LEAKAGE TEST COCK, 1/8" NPT. 1

845-00764-000 CONNECTOR, .25" MPT. x .25" ODC 7

1 845-00279-000 14 1 18 19 2 941-01947-000 20 1 945-00236-000

26 2 849-01586-000 VALVE END, THREADED, 2" NPT 29 1

STD.

* *

33 1

CFLC 6000

CFLC 8000

157-02744-000 157-02724-000

918-00653-000

157-02747-000 NIPPLE, SIDE OUTLET, 2" NPS x 6" x 1/2"

939-00661-000 TUBING, ALUMINUM

21 1 949-00448-000

32 1

ASS'Y PART NO 185-01389-000

185-01260-000

157-02769-000

918-00682-000 857-04375-000

ORIFICE NIPPLE

LGPS HGPS

ELBOW

VALVE, BUTTERBALL, 2" NPT. ACTUATOR, GAS VALVE, W/ POC VALVE BODY, GAS, 2"

SEE TABLE

NATURAL GAS, 20PPM

NIPPLE, SIDE OUTLET, 2" x 34.875" x 1/2"

NIPPLE, SIDE OUTLET, 2" NPS x 9" x 1/2"

REGULATOR, GAS PRESS NIPPLE

WHERE USED

ITEM 1

048-00893-000

048-00888-000

CFLC 6000

ORIFICE

CFLC 8000

ORIFICE DETAIL

ITEM 33 MSOV 941-01947-000 VALVE, BUTTERBALL, 2” NPT 223-00030-000 VALVE, BALL, 2-1/2” THREADED

6-10 Part No. 750-363

Figure 6-10. Gas Train CFLC 6000/8000 (optional 9 PPM NOx)

Section 6 — Parts

Part No. 750-363 6-11

Section 6 — Parts

Figure 6-11. Gas train CFLC 10000/12000 (standard 20 PPM NOx)

STD.

VIEW A-A

SECTION B-B

1816

CFLC 10,000 CFLC 12,000 CFLC 10,000 CFLC 12,000

19 16

* OPTIONAL

SECTION C-C

6-12 Part No. 750-363

Figure 6-12. Gas train CFLC 10000/12000 (optional 9 PPM NOx)

Section 6 — Parts

Part No. 750-363 6-13

Section 6 — Parts

Figure 6-13. Gas Train CFLC 4000/5000 Propane

6-14 Part No. 750-363

Figure 6-14. Gas Train CFLC 6000/8000 Propane

Section 6 — Parts

Part No. 750-363 6-15

Section 6 — Parts

Figure 6-15. Gas Train CFLC 10000/12000 Propane

6-16 Part No. 750-363

Cleaver-Brooks ClearFire CFLC-12000, ClearFire CFLC-4000, ClearFire CFLC-6000, ClearFire CFLC-8000, ClearFire CFLC Operation And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual