Cleaver-Brooks CFV, ClearFire CFV Startup Manual
ClearFire® Model CFV
Vertical Steam Boiler
Startup Guide
750-288
www.cleaverbrooks.com
CFV Startup Guide
!
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.
!
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.
NOTE to equipment owners, operators, and maintenance
personnel: This guide is not a short-cut to safe and effi-
cient boiler operation. Operating an improperly commissioned boiler can result in increased fuel costs and may
shorten the life of the equipment or produce a hazardous
condition. All personnel involved in operating or maintaining the boiler should read the manual in its entirety.
!
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.
!
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
Refer to CFV Operation and Maintenance
Manual - CB Part Number 750-269
2 Part No. 750-288
!
WARNING
DANGER
The boiler and its individual shutoff valve must be
disconnected from the gas supply piping system
during any pressure testing of that system at test
pressures in excess of 1/2 psi (3.5 kPa).
!
WARNING
DANGER
The boiler and its gas connection must be leak
tested before placing the boiler in operation.
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.
CFV Startup Guide
1 - BEFORE STARTUP
Your Cleaver-Brooks boiler has been factory fire-tested and the control system pre-configured for a troublefree startup. To help ensure a successful lightoff and reliable operation, certain initial conditions should be
observed.
Do not attempt to place the boiler into service without verifying that all connections - fuel, steam and
water piping, electrical connections, stack, and combustion air provisions - have been installed properly
and in accordance with any applicable codes or regulations.
COMBUSTION AIR INLET
RELIEF VALVE
STEAM
OUTLET
GAS SUPPLY
SURFACE
BLOWOFF
Figure 1 CFV Connections
1.1 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. For electrical
wiring requirements, see wiring diagram provided with the boiler or
in the CFV manual.
GAUGE GLASS DRAIN
WATER COLUMN DRAIN
FEEDWATER
STACK
BLOWDOWN
!
CONDENSATE DRAIN
Warning
OUTLET
When using direct vent
combustion in cold climates,
special care must be taken to
observe combustion air
temperature limits. Failure to
follow this precaution may lead
to equipment damage or unsafe
operation.
Part No. 750-288 3
CFV Startup Guide
Boiler room ambient conditions
Relative humidity
Ambient temperature range 0
Storage temperature range -20
Combustion air temperature 0
Specifications
Input power 115 VAC single phase 60Hz
Recommended operating steam
pressure
Gas pressure requirements See Table 1
< 85% non-condensing
o
C to 50 oC / 32oF to 122oF
o
C to 60 oC / -4oF to 140oF
o
C to 50 oC / 32oF to 122oF
75-135 psig
1.2 Gas Piping
A manually operated shut-off valve and pressure regulator are provided
as standard on the Model CFV boiler. It is recommended to install an
approved gas filter or strainer in the gas supply line to the boiler. Please
inquire with the local gas supply company.
The boiler shall be installed such that the gas ignition system
components are protected from water (dripping, spraying, etc.) during
appliance operation and service.
If building supply gas pressure is greater than 1 psig (27.8” WC), an
upstream regulator with overpressure protection and proper gas venting
will be required and must be piped to a safe point of discharge.
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.
See Table 1 for CFV gas pressure requirements.
Table 1 CFV gas pressure requirements
Boiler HP Minimum pressure required
at gas train connection
9.5 7.2" w.c.
10 7.2" w.c.
15 7.3" w.c.
20 7.5" w.c.
25 7.7" w.c.
30 8.5" w.c.
40 11.0" w.c.
50 10.0" w.c.
60 10.0" w.c.
Max. pressure
28” w.c.
Note: To measure supply pressure
at the CFV gas valve, use the
test port on the valve inlet
flange (see below). Do not
use the leak test cocks to
measure gas pressure.
1.3 Flue Gas Connection
The flue gases from the ClearFire boiler are 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 ClearFire boiler. Refer to flue piping manufacturer for proper installation and sealing instructions.
See also Chapter 3 in the CFV Operation and Maintenance manual.
4 Part No. 750-288
CFV Startup Guide
1.4 Boiler Water-Side Connections
A pressure relief valve (safety valve; Figure 2), provided with the
boiler, must be installed in the mounting provided and piped to a safe
point of discharge. 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 coderequired drains can be properly piped to prevent buildup of back
pressure and accumulation of foreign material around the valve seat
area.
Connection to the main steam header is made at the nozzle projecting
upward from the boiler shell.
Feedwater is introduced through the piping assembly installed on the
side of the boiler vessel.
Figure 2 Pressure Relief Valve
Safety
Valve
1.5 Electrical Connections
Refer to Figure 3 for CFV wiring and cable connections. See also wiring diagram on page 13.
A qualified electrician or service technician must make the electrical connections to the boiler; all local
electrical and building codes should be adhered to.
Refer to wiring diagram provided with the boiler or in the CFV manual. Ensure all required customer
connections are properly made. Main power (115 VAC single phase 60Hz) and any remote wiring should be
brought to the left side of the control panel and terminated at the appropriate terminals provided. Controls for
the boiler feed pump (or feedwater valve if applicable) should be wired to control panel terminals 6 and 7.
Figure 3 CFV wiring and cable connections
7
6
5
4
1
2
1. Connect UV Scanner to threaded connection on dry oven
2. Connect spark cables to dual electrode and ignition transformer
3. Plug AC pow er harnes s plug in to b lower
4. Plug D C blow er c ontrol harn es s pl ug in to blower
5. Connect incoming AC power per wiring diagram
6. Connect optional heat request inputs per wiring diagram
7. Connect pump controls per wiring diagram
The blower signal wiring must be isolated
from the blower power wiring and the
high voltage ignition cables.
3
Notice
Part No. 750-288 5
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