CleaverBrooks CFC-500 Operation, Service And Parts Manual

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[Page 1] CleaverBrooks CFC-500

Manual Part No. 750-263 07/2010 Model CFC ClearFire Condensing Boiler Operation, Service, and Parts ...

[Page 2] CleaverBrooks CFC-500

ii ! DANGER WARNING If the information in this manual is not fol- lowed exactly, a fire or explosion may re- sult causing property damage, personal injury or loss of life. — Do not store or use gasoline or other flammable vapors and liquids in the ...

[Page 3] CleaverBrooks CFC-500

iii ! DANGER WARNING A hot water boiler installed above radia- tion level or as required by the Authority having jurisdiction, must be provided with a low water cutoff device either as a part of the boiler or at the time of boiler instal- lation. The...

[Page 4] CleaverBrooks CFC-500

iv 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...

[Page 5] CleaverBrooks CFC-500

v TABLE OF CONTENTS Section 1 — Introduction Clearfire Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

[Page 6] CleaverBrooks CFC-500

vi Section 4 — Commissioning Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Filling Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

[Page 7] CleaverBrooks CFC-500

Milwaukee, Wisconsin www.cleaver-brooks.com Section 1 Introduction CFC Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

[Page 8] CleaverBrooks CFC-500

Section 1 — Introduction 1-2 Part No. 750-263 A. CFC FEATURES AND BENEFITS Compact Firetube Design (Figure 1-1 & Figure 1-2) The CFC boiler is a single pass down fired durable Firetube boiler. The extended heating surface tubes provide for very...

[Page 9] CleaverBrooks CFC-500

Section 1 — Introduction Part No. 750-263 1-3 B. STANDARD EQUIPMENT 1. The Boiler The boiler is designed for a Maximum Allowable Working Pressure (MAWP) of 125 psig (8.6 Bar) in accordance with the ASME Code for Low Pressure Section IV Hot Water Bo...

[Page 10] CleaverBrooks CFC-500

Section 1 — Introduction 1-4 Part No. 750-263 4. Control (See Figure 1-7) The CB Falcon hydronic control is an integrated burner management and modulation control with a touch-screen display/operator interface. The controller is capable of the foll...

[Page 11] CleaverBrooks CFC-500

Section 1 — Introduction Part No. 750-263 1-5 5. Component/Connection Locations Figure 1-8 shows the CFC component orientation and heat flow path. Note the downfired design of the burner and the orientation of the hot water outlet and return connec...

[Page 12] CleaverBrooks CFC-500

Section 1 — Introduction 1-6 Part No. 750-263 Figure 1-8 CFC Heat Flow and Component Orientation Combustion Fan and Premix Gas Valve Assembly Control Panel “Finned” High Efficiency AluFer Tubes Flue Gas Outlet Low Temp. Return Hot Water Out...

[Page 13] CleaverBrooks CFC-500

Section 1 — Introduction Part No. 750-263 1-7 Figure 1-9 Boiler Controls Figure 1-10 Return Temperature Sensor Mounting Low Water Cutoff Safety Valve (shipped loose) Probe Auto air vent (optional; shipped loose) ...

[Page 14] CleaverBrooks CFC-500

Section 1 — Introduction 1-8 Part No. 750-263 The stack can be mounted on the right (Figure 1-12) or left side on the back of the boiler base. The flue gas duct sizes may be reduced at the vent connection. See also Chapter 4 - Stack and Intake Ven...

[Page 15] CleaverBrooks CFC-500

Milwaukee, Wisconsin www.cleaver-brooks.com Section 2 Installation Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

[Page 16] CleaverBrooks CFC-500

Section 2 — Installation 2-2 Part No. 750-263 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 c...

[Page 17] CleaverBrooks CFC-500

Section 2 — Installation Part No. 750-263 2-3 A. ASSEMBLY 1. Packaging The Cleaver-Brooks Model CFC boiler is shipped in three parcels. The pressure vessel assembly mounted on a skidded crate, the control panel in a box, and the outer casing with i...

[Page 18] CleaverBrooks CFC-500

Section 2 — Installation 2-4 Part No. 750-263 3. Casing assembly To assemble the CFC casing, the following tools are required: 1. Remove all packing material and open all boxes shipped with the boiler. 2. Remove all casing panels from box and group...

[Page 19] CleaverBrooks CFC-500

Section 2 — Installation Part No. 750-263 2-5 6. Attach the boiler front legs. 7. Lift up the back of the boiler using the jack and remove the wooden skid side beams. 8. Attach the rear boiler mounting legs. 9. Lifting eyes are provided for moving...

[Page 20] CleaverBrooks CFC-500

Section 2 — Installation 2-6 Part No. 750-263 15.Using a 10mm socket, or by hand, remove 3 nuts and washers from the mounting studs extending from each side of the top plate of the boiler (Figure 2-8). 16.Attach electrical supply channels on each...

[Page 21] CleaverBrooks CFC-500

Section 2 — Installation Part No. 750-263 2-7 18.Remove control panel from box. Uncoil sensor wires and route wires out of left-hand side of panel. 19.Mount control panel on front of boiler (Figure 2-11). Make sure to route sensor wires in wiri...

[Page 22] CleaverBrooks CFC-500

Section 2 — Installation 2-8 Part No. 750-263 21.Route return water sensor (the 2-wire sensor) to the lower pipe on back of boiler, and install lower panel. Coat sensor with heat-conductive compound P/N 872-00631. Insert sensor into return pipe s...

[Page 23] CleaverBrooks CFC-500

Section 2 — Installation Part No. 750-263 2-9 23.Install rear center panels (Figure 2-15). 24.Install C-clips on upper side panels, then install panels on boiler (Figure 2-16). 25.Install top rear panel and top center panel. 26.Attach side skirt p...

[Page 24] CleaverBrooks CFC-500

Section 2 — Installation 2-10 Part No. 750-263 27.Attach front skirt panel to the side panels. 28.Install front panel. Assembly is now complete. B. FLUE GAS / COMBUSTION AIR CONNECTIONS The flue gases from the Model CFC boiler should be removed vi...

[Page 25] CleaverBrooks CFC-500

Section 2 — Installation Part No. 750-263 2-11 manufacturer for proper installation and sealing instructions. See also Chapter 3 of this manual for combustion air and flue gas venting requirements. C. WATER TREATMENT Cleaver-Brooks ClearFire conden...

[Page 26] CleaverBrooks CFC-500

Section 2 — Installation 2-12 Part No. 750-263 D. USING GLYCOL The Model CFC boiler may be operated with a solution of glycol and water. Where glycols are added, the system must first be cleaned and flushed. Correct glycol selection and regular mo...

[Page 27] CleaverBrooks CFC-500

Section 2 — Installation Part No. 750-263 2-13 secondary loop arrangement.) Refer to table below for minimum boiler circulation rates. 5) Minimum over-pressure at the boiler: For outlet temperatures up to the maximum of 185 deg F (85 deg C), a min...

[Page 28] CleaverBrooks CFC-500

Section 2 — Installation 2-14 Part No. 750-263 E. BOILER ROOM The boiler room must comply with all building codes and regulations. An adequate supply of combustion air is required for safe operation. If the optional direct vent combustion air kit (...

[Page 29] CleaverBrooks CFC-500

Section 2 — Installation Part No. 750-263 2-15 Clean combustion air is required for optimum efficiency and boiler operation. Dust and airborne contaminants will adversely effect burner performance. If conditions dictate, a serviceable filter must b...

[Page 30] CleaverBrooks CFC-500

Section 2 — Installation 2-16 Part No. 750-263 4. Gas Piping CFC units are not standardly equipped with an upstream gas pressure regulator. Therefore, a regulator must be installed at each CFC unit. Do not use a common regulator to regulate pressur...

[Page 31] CleaverBrooks CFC-500

Section 2 — Installation Part No. 750-263 2-17 5. Gas Supply Pipe Sizing For proper operation of a single unit or a multiple unit installation, we recommend that the gas piping be sized to allow no more than 0.3" w.c. pressure drop from the so...

[Page 32] CleaverBrooks CFC-500

Section 2 — Installation 2-18 Part No. 750-263 Table 2-4: Gas Line Capacity - Schedule 40 Metallic Pipe Pipe Size Nominal 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4" Actual I.D. 1.04 9 1.380" 1.610" 2.067" 2.4...

[Page 33] CleaverBrooks CFC-500

Section 2 — Installation Part No. 750-263 2-19 Table 2-5: Gas Line Capacity - Schedule 40 Metallic Pipe Pipe Size Nominal 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4" Actual I.D. 1.049" 1.380" 1.610" 2.067"...

[Page 34] CleaverBrooks CFC-500

Section 2 — Installation 2-20 Part No. 750-263 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 ...

[Page 35] CleaverBrooks CFC-500

Section 2 — Installation Part No. 750-263 2-21 Figure 2-23 Gas Piping ...

[Page 36] CleaverBrooks CFC-500

Section 2 — Installation 2-22 Part No. 750-263 G. BOILER WATER PIPING 1. General All boiler hot water outlet and return piping is connected at the rear of the boiler. Piping is to be installed per local codes and regulations.The pipelines for the h...

[Page 37] CleaverBrooks CFC-500

Section 2 — Installation Part No. 750-263 2-23 Figure 2-25 Pressure Drop Curve, CFC 500, U.S. Flow Rates Figure 2-26 Pressure Drop Curve, CFC 500, Metric Flow Rates Hydraulic Resistance CFC 500 0 0.2 0.4 0.6 0.8 1 1.2 1.4 0 8.8 13.2 17.6 22 26.4 ...

[Page 38] CleaverBrooks CFC-500

Section 2 — Installation 2-24 Part No. 750-263 Figure 2-27 Pressure Drop Curve, CFC 750, U.S. Flow Rates Figure 2-28 Pressure Drop Curve, CFC 750, Metric Flow Rates Hydraulic Resistance CFC 750 0 0.2 0.4 0.6 0.8 1 1.2 1.4 0 13.2 2 2 . 01 3 0 . 8 ...

[Page 39] CleaverBrooks CFC-500

Section 2 — Installation Part No. 750-263 2-25 Figure 2-29 Pressure Drop Curve, CFC 1000, U.S. Flow Rates Figure 2-30 Pressure Drop Curve, CFC 1000, Metric Flow Rates Hydraulic Resistance CFC 1000 0 0.2 0.4 0.6 0.8 1 1.2 0 8.8 22 44 66 88 110 13...

[Page 40] CleaverBrooks CFC-500

Section 2 — Installation 2-26 Part No. 750-263 Figure 2-31 Pressure Drop Curve, CFC 1500, U.S. Flow Rates Figure 2-32 Pressure Drop Curve, CFC 1500, Metric Flow Rates Hydraulic Resistance CFC 1500 U.S. Standards 0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1....

[Page 41] CleaverBrooks CFC-500

Section 2 — Installation Part No. 750-263 2-27 Figure 2-33 Pressure Drop Curve, CFC 1800, U.S. Flow Rates Figure 2-34 Pressure Drop Curve, CFC 1800, Metric Flow Rates Hydraulic Resistance CFC 1800 U.S. Standards 0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1....

[Page 42] CleaverBrooks CFC-500

Section 2 — Installation 2-28 Part No. 750-263 Table 2-12: Maximum flow rate through ClearFire boilers (U.S. flow rates) Figure 2-35 Pressure Drop Curve, CFC 2500, U.S. Flow Rates Hydraulic Resistance CFC 2500 U.S. Standards 0 0.2 0.4 0.6 0.8 1 1....

[Page 43] CleaverBrooks CFC-500

Section 2 — Installation Part No. 750-263 2-29 Table 2-13: Maximum flow rate through ClearFire boilers (metric flow rates) H.CONDENSATE REMOVAL AND TREATMENT The condensate generated during normal boiler operation must be removed in accordance with...

[Page 44] CleaverBrooks CFC-500

Section 2 — Installation 2-30 Part No. 750-263 1. Condensate tank setup options The boiler is supplied with boiler legs (standard) which are sized to permit the installation of the condensate collection tank. There are two (2) condensate removal op...

[Page 45] CleaverBrooks CFC-500

Section 2 — Installation Part No. 750-263 2-31 2. Condensate Piping for Multiple Boilers More than one Model CFC boiler can be piped into a common condensate neutralization tank. See Figure 2-39 and Figure 2-40 for the suggested layout. A drain tra...

[Page 46] CleaverBrooks CFC-500

Section 2 — Installation 2-32 Part No. 750-263 I. ELECTRICAL CONNECTIONS A qualified electrician or service technician must make the electrical connections to the boiler. For typical CFC electrical component mounting see the electrical diagram moun...

[Page 47] CleaverBrooks CFC-500

Section 2 — Installation Part No. 750-263 2-33 Figure 2-41 Electrical Connection Diagram ...

[Page 48] CleaverBrooks CFC-500

Section 2 — Installation 2-34 Part No. 750-263 I. WIRING DIAGRAMS Figure 2-42 CFC Wiring Diagram - single fuel units Note: Wiring diagrams shown are examples only. Installations may vary. For specific installations consult the wiring diagram provi...

[Page 49] CleaverBrooks CFC-500

Section 2 — Installation Part No. 750-263 2-35 Figure 2-43 CFC Wiring Diagram - dual fuel units ...

[Page 50] CleaverBrooks CFC-500

Section 2 — Installation 2-36 Part No. 750-263 ...

[Page 51] CleaverBrooks CFC-500

Milwaukee, Wisconsin www.cleaver-brooks.com Section 3 Stack and Intake Vent Sizing and Installation Venting Connections - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Appliance Categories . . . . . . . . . . . . . . . . ...

[Page 52] CleaverBrooks CFC-500

Section 3 — Stack and Intake Vent Sizing and Installation 3-2 Part No. 750-263 Notice A. VENTING CONNECTIONS - GENERAL 1. Appliance Categories Proper installation of flue gas exhaust venting is critical for the efficient and safe operation of the C...

[Page 53] CleaverBrooks CFC-500

Section 3 — Stack and Intake Vent Sizing and Installation Part No. 750-263 3-3 Vent material should be appropriate for the Appliance Category. Application-specific information will further determine the material selected. In some cases, PVC/CPVC m...

[Page 54] CleaverBrooks CFC-500

Section 3 — Stack and Intake Vent Sizing and Installation 3-4 Part No. 750-263 1. Vent must terminate at least four (4) feet below, four (4) feet horizontally, or one (1) foot above any door, window or gravity air inlet to the building. 2. The v...

[Page 55] CleaverBrooks CFC-500

Section 3 — Stack and Intake Vent Sizing and Installation Part No. 750-263 3-5 ! Caution Follow items listed below to avoid personal injury or property damage. • Cut nonmetallic vent pipe with fine-toothed hacksaw (34 teeth per inch). • Do not...

[Page 56] CleaverBrooks CFC-500

Section 3 — Stack and Intake Vent Sizing and Installation 3-6 Part No. 750-263 • The vent be installed with a slight upward slope of not more than 1/4" per foot of horizontal run to the vent terminal. In this case, an approved condensate t...

[Page 57] CleaverBrooks CFC-500

Section 3 — Stack and Intake Vent Sizing and Installation Part No. 750-263 3-7 1. Installation These installations utilize the boiler mounted blower to draw combustion air from outside and vent combustion gases to the outside. The sealed combustion...

[Page 58] CleaverBrooks CFC-500

Section 3 — Stack and Intake Vent Sizing and Installation 3-8 Part No. 750-263 Notice If the boiler is vented directly out through the sidewall with no elbows and less than 6 feet of vent pipe, a restricted direct vent cap should be utilized. Notic...

[Page 59] CleaverBrooks CFC-500

Section 3 — Stack and Intake Vent Sizing and Installation Part No. 750-263 3-9 Gas Code or, in Canada, the latest edition of CAN/CSA-B 149.1 and .2 Installation Code for Gas Burning Appliances and Equipment. To prevent the condensation accumulation...

[Page 60] CleaverBrooks CFC-500

Section 3 — Stack and Intake Vent Sizing and Installation 3-10 Part No. 750-263 not more than 1/4" per foot of horizontal run and an approved condensate trap must be installed per applicable codes. ! Warning No substitutions of flue pipe or ve...

[Page 61] CleaverBrooks CFC-500

Section 3 — Stack and Intake Vent Sizing and Installation Part No. 750-263 3-11 2. Stack design using direct vent combustion Table 3-2 STACK SIZING USING OUTSIDE AIR FOR COMBUSTION Boiler Boiler Flue Connection Combustion Air Duct Connection Ma...

[Page 62] CleaverBrooks CFC-500

Section 3 — Stack and Intake Vent Sizing and Installation 3-12 Part No. 750-263 G. VENTING FOR MULTIPLE UNITS Cleaver-Brooks recommends that each Model CFC in a multiple boiler installation be vented individually. If it becomes necessary to connect...

[Page 63] CleaverBrooks CFC-500

Section 3 — Stack and Intake Vent Sizing and Installation Part No. 750-263 3-13 EXAMPLE 2 EXAMPLE 3 6” 10” 45 o 6”   GOOD BAD 6” 10” 14” 6” 6” 6” From Boilers  6” 6” 6” 6” From Boilers 6” 6”  GOOD BAD 8” ...

[Page 64] CleaverBrooks CFC-500

Section 3 — Stack and Intake Vent Sizing and Installation 3-14 Part No. 750-263 H. COMBUSTI0N AIR/BOILER ROOM VENTILATION REQUIREMENTS The boiler(s) must be supplied with adequate quantities of uncontaminated air to support proper combustion and e...

[Page 65] CleaverBrooks CFC-500

Section 3 — Stack and Intake Vent Sizing and Installation Part No. 750-263 3-15 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, Se...

[Page 66] CleaverBrooks CFC-500

Section 3 — Stack and Intake Vent Sizing and Installation 3-16 Part No. 750-263 Figure 3-6. Two Opening Ducted Method C. One Opening Method (Figure 3-7) - One permanent opening, commencing within 12 inches of the top of the enclosure, shall be prov...

[Page 67] CleaverBrooks CFC-500

Section 3 — Stack and Intake Vent Sizing and Installation Part No. 750-263 3-17 Figure 3-7. One Opening Method 2. Air Supply - Engineered Method When determining boiler room air requirements for an unconfined space, the size of the room, airflow, a...

[Page 68] CleaverBrooks CFC-500

Section 3 — Stack and Intake Vent Sizing and Installation 3-18 Part No. 750-263 Figure 3-8. Two Opening Engineered Method E. Size the openings by using the formula: Area in square feet = cfm/fpm Where cfm = cubic feet per minute of air Where fpm = ...

[Page 69] CleaverBrooks CFC-500

Section 3 — Stack and Intake Vent Sizing and Installation Part No. 750-263 3-19 • Area required: Area = cfm/fpm = 1,080/250 = 4.32 square feet total. • Area/Opening: 4.32/2 = 2.16 sq-ft/opening (2 required). Notice Consult local codes, which m...

[Page 70] CleaverBrooks CFC-500

Section 3 — Stack and Intake Vent Sizing and Installation 3-20 Part No. 750-263 ...

[Page 71] CleaverBrooks CFC-500

Milwaukee, Wisconsin www.cleaver-brooks.com Section 4 CFC Commissioning Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Filling Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

[Page 72] CleaverBrooks CFC-500

Section 4 — CFC Commissioning 4-2 Part No. 750-263 A. OPERATING CONDITIONS • The installation site should be as free as possible from vibration, dust, and corrosive media • The controllers should be located as far as possible from sources of ...

[Page 73] CleaverBrooks CFC-500

Section 4 — CFC Commissioning Part No. 750-263 4-3 D. MODEL CFC BOILER / BURNER CONTROLLER The Model CFC boiler uses the CB Falcon hydronic boiler control system. Primary controller functions include: • Flame supervision • Burner sequencing •...

[Page 74] CleaverBrooks CFC-500

Section 4 — CFC Commissioning 4-4 Part No. 750-263 E. CB FALCON DISPLAY/OPERATOR INTERFACE The CB Falcon display/operator interface is mounted at the left side of the control panel for convenient access to all operating controls. 1. Home Page Appl...

[Page 75] CleaverBrooks CFC-500

Section 4 — CFC Commissioning Part No. 750-263 4-5 3. Operation Page The operation page displays the CB Falcon running operation, including setpoint and firing rate values. From this page the user can change setpoints, manually control the boiler�...

[Page 76] CleaverBrooks CFC-500

Section 4 — CFC Commissioning 4-6 Part No. 750-263 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 ...

[Page 77] CleaverBrooks CFC-500

Section 4 — CFC Commissioning Part No. 750-263 4-7 • Burner Control Interlocks • Burner Control Timings & Rates • Burner Control Ignition • Burner Control Flame Failure • System Configuration • Fan Configuration • Lead Lag Configu...

[Page 78] CleaverBrooks CFC-500

Section 4 — CFC Commissioning 4-8 Part No. 750-263 Domestic HW Configuration DHW setpoint User 32 130 180 °F 0453 Domestic HW Configuration DHW TOD setpoint Service 32 120 180 °F 0454 Domestic HW Configuration DHW on hysteresis Service 2 5 80 °F...

[Page 79] CleaverBrooks CFC-500

Section 4 — CFC Commissioning Part No. 750-263 4-9 Modulation Configuration CH max. mod. rate Service 2000 5000 6000 RPM 0193 Modulation Configuration DHW max. mod. rate Service 2000 5000 6000 RPM 0194 Modulation Configuration Minimum mod. rate Ser...

[Page 80] CleaverBrooks CFC-500

Section 4 — CFC Commissioning 4-10 Part No. 750-263 Pump Configuration Boiler pump options 2 Service 0xC0DF 0301 Pump Configuration System pump options 1 Service 0xE36C 0302 Pump Configuration System pump options 2 Service 0x801D 0303 Pump Configur...

[Page 81] CleaverBrooks CFC-500

Section 4 — CFC Commissioning Part No. 750-263 4-11 Fan Configuration Fan speed up ramp Service 0 0 1000 RPM/sec 0260 Fan Configuration Fan speed down ramp Service 0 0 1000 RPM/sec 0261 Fan Configuration Fan gain up Service 0 30 100 0262 Fan Config...

[Page 82] CleaverBrooks CFC-500

Section 4 — CFC Commissioning 4-12 Part No. 750-263 Plate HX Preheat Plate preheat OFF hysteresis Service 5 °F not used 0692 Plate HX Preheat Plate preheat minimum on time Service 60 seconds not used 0693 Plate HX Preheat Tap detect degrees per ...

[Page 83] CleaverBrooks CFC-500

Section 4 — CFC Commissioning Part No. 750-263 4-13 Anti-condensation Configuration CH anti-condensation pump force off Service Disabled 0498 Anti-condensation Configuration DHW anti-condensation enable Service Disabled 0499 Anti-condensation Con...

[Page 84] CleaverBrooks CFC-500

Section 4 — CFC Commissioning 4-14 Part No. 750-263 *Access Levels: Read Only = parameter not configurable OEM = manufacturer only Service = password required (default password is 9220) User = no password required Lead Lag Configuration Lead Lag ad...

[Page 85] CleaverBrooks CFC-500

Section 4 — CFC Commissioning Part No. 750-263 4-15 1. Changing Parameter Settings To access the CB Falcon configuration menu, press <Configure> on the Status page. Some parameters require a password entry before allowing changes. The <Log...

[Page 86] CleaverBrooks CFC-500

Section 4 — CFC Commissioning 4-16 Part No. 750-263 2. Program Module CB Falcon parameter information (non-safety parameters only) can be uploaded/downloaded using the optional Program Module. When the Program Module is installed, its features are ...

[Page 87] CleaverBrooks CFC-500

Section 4 — CFC Commissioning Part No. 750-263 4-17 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. p...

[Page 88] CleaverBrooks CFC-500

Section 4 — CFC Commissioning 4-18 Part No. 750-263 I. INITIAL START-UP PROCEDURE NOTE: For LP gas-fired units or boilers with optional dual-fuel gas train, see section K - Procedures for LP gas. 1. Gas Train and Piping The ClearFire burner is equi...

[Page 89] CleaverBrooks CFC-500

Section 4 — CFC Commissioning Part No. 750-263 4-19 2. Power-Up 1. Ensure blower motor is properly wired for the available power supply. 2. Verify the voltage (control voltage is 115V-1Ph.-60Hz) to ensure it is within specifications. 3. Operation ...

[Page 90] CleaverBrooks CFC-500

Section 4 — CFC Commissioning 4-20 Part No. 750-263 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 C...

[Page 91] CleaverBrooks CFC-500

Section 4 — CFC Commissioning Part No. 750-263 4-21 IGNITION FAILURE CHECK 7. A test of the flame rod circuit can also be performed at this time. Disconnect the flame rod cable and attempt to start the burner. The CB Falcon should lock out, indicat...

[Page 92] CleaverBrooks CFC-500

Section 4 — CFC Commissioning 4-22 Part No. 750-263 7. Setting Combustion Note: A Combustion Analyzer is required to properly set up the Model CFC burner. Do not attempt to fire and adjust the burner without this equipment. Note: Ensure boiler is f...

[Page 93] CleaverBrooks CFC-500

Section 4 — CFC Commissioning Part No. 750-263 4-23 To set combustion: 1. Check inlet gas pressure and reset low gas pressure switch. 2. At Operation screen set firing rate to low fire. Review burner sequence before proceeding. 3. Turn LOCAL/REMOT...

[Page 94] CleaverBrooks CFC-500

Section 4 — CFC Commissioning 4-24 Part No. 750-263 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 set...

[Page 95] CleaverBrooks CFC-500

Section 4 — CFC Commissioning Part No. 750-263 4-25 K. PROCEDURES FOR LP (PROPANE) GAS • Minimum LP gas pressure required is 11" W.C. at 700' ASL. Pressure correction required for high altitudes. • Maximum gas pressure rating of the ...

[Page 96] CleaverBrooks CFC-500

Section 4 — CFC Commissioning 4-26 Part No. 750-263 modulation rate according to Tabl e 4-1 . Return to Configuration menu. 6. Select Burner Control Ignition configuration. Adjust ignition, or lightoff, rate according to Ta b l e 4-1 . A warning wi...

[Page 97] CleaverBrooks CFC-500

Section 4 — CFC Commissioning Part No. 750-263 4-27 7. Access boiler control Configuration menu. Press <Login>. Enter service level password: 9220. Press <OK>. 8. Select Modulation configuration. Adjust CH and DHW maximum modulation ra...

[Page 98] CleaverBrooks CFC-500

Section 4 — CFC Commissioning 4-28 Part No. 750-263 L. FALCON CONTROL FUNCTIONS AND CUSTOMER INTERFACE Following is a brief overview of the Falcon control features on ClearFire boilers. Please refer to the Falcon Control operating instructions in...

[Page 99] CleaverBrooks CFC-500

Section 4 — CFC Commissioning Part No. 750-263 4-29 The PID (Proportional-Integral-Derivative) load control operates to generate the demand source’s modulation rate. Under Central Heat configuration, the PID gain values can be adjusted to match t...

[Page 100] CleaverBrooks CFC-500

Section 4 — CFC Commissioning 4-30 Part No. 750-263 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...