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Cleaver-Brooks ClearFire CFLC-5000 - User Manual

Cleaver-Brooks ClearFire CFLC-5000
290 pages
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Model CFLC
ClearFire
Condensing Boiler
Operation and Maintenance Manual
750-363
08/2017
4,000 - 12,000 MBTU

Table of Contents

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Summary

Section 1 Introduction

CFLC Features and Benefits

Details on the boiler's design, efficiency, construction, and technology.

Standard Equipment

Lists the standard components included with the CFLC boiler.

Optional Equipment

Lists available optional components for the CFLC boiler.

Section 2 Installation

Boiler Assembly and Placement

Instructions for assembling and positioning the boiler unit.

Boiler Room Requirements

Guidelines for installing the boiler in a dedicated room, including air supply.

Flue Gas; Combustion Air

Requirements for venting flue gases and supplying combustion air.

Water Treatment

Guidelines for boiler water quality, chemistry, and treatment.

Gas Connections

Procedures and requirements for connecting the gas supply to the boiler.

Boiler Water Piping

Details on connecting hot water outlet and return piping, including safety valve installation.

Minimum Boiler Overpressure

Requirements for maintaining adequate system overpressure in hot water boilers.

Condensate Removal and Treatment

Procedures for handling and neutralizing boiler condensate.

Electrical Connections

Instructions for making proper electrical connections to the boiler system.

Wiring Diagram

Provides schematic diagrams for boiler electrical connections.

Section 3 Stack and Intake Vent Sizing and Installation

Venting Connections - General

Critical information on flue gas exhaust venting categories and system design.

Vertical Venting; Inside Combustion Air

Details on installing vertical vent stacks using inside combustion air.

Vertical Venting; Direct Vent or Sealed Combustion Air

Guidelines for direct vent or sealed combustion air intake and flue termination.

Venting for Multiple Units

Recommendations for venting multiple CFLC boilers together.

Combustion Air; Boiler Room Ventilation Requirements

Specifies requirements for supplying uncontaminated air for combustion and ventilation.

Section 4 Commissioning

Operating Conditions

Specifies site requirements and controller placement for optimal operation.

Filling Boiler

Procedures for filling the boiler and hydronic system with water.

Control Setpoints

Preliminary settings for burner safety controls before initial boiler startup.

Model CFLC Boiler; Burner Controller

Overview of the Falcon hydronic boiler control system and its primary functions.

Falcon Display;Operator Interface

Describes the user interface, including Home, Status, and Operation pages.

Controller Configuration

Details on verifying factory default settings and configuring the Falcon controller.

Variable Speed Drive Settings

Information on changing Variable Speed Drive configuration parameters.

Burner Sequence

Explains the basic burner sequencing controlled by the Falcon.

Initial Start-up Procedure

Comprehensive steps for safely starting up the boiler for the first time.

Post Start-up Checkout Procedure

Essential checks to perform after initial boiler startup to ensure proper operation.

Falcon Control Functions and Customer Interface

Overview of Falcon control features like set points, PID control, and remote inputs.

Configurable Pump;Aux Relay Contacts

Details on configuring pump and auxiliary relay outputs for various applications.

Lead;Lag Control (up to eight boilers)

Information on connecting multiple Falcon units for lead/lag operation.

Modbus Communication

Explains the use of Modbus for communication with building EMS and for remote monitoring.

Section 5 Service and Maintenance

Disassembly for Inspection

Step-by-step instructions for disassembling the boiler for inspection and cleaning.

Reassembly

Guidelines for reassembling boiler components after service.

Ignition and Flame Detection Systems

Maintenance procedures for ignition electrodes, pilot, and UV scanners.

Troubleshooting

Guidance on diagnosing and resolving common boiler issues and lockout conditions.

Extended Shutdown

General guidelines for shutting down the boiler for extended periods.

Emergency Shutdown

Procedures for safely shutting down the boiler in case of an emergency.

Section 6 Parts

Recommended Spare Parts List Model CFLC

A list of recommended spare parts for the CFLC model boiler.

Boiler Mechanical Assembly (by model size)

Exploded views and part lists for the boiler mechanical assemblies.

Burner Assembly (by model size)

Exploded views and part lists for the burner assemblies.

Gas Train (by model size and NOx)

Diagrams and part lists for various gas train configurations.

Optional Parts

Lists available optional components for the boiler system.

Casing & Insulation (by model size)

Diagrams and part lists for boiler casing and insulation components.

APPENDIX A Falcon Parameters

APPENDIX B Variable Speed Drive Parameters

PF 400 Integral Keypad

Description of keypad functions for programming the PF 400 VSD.

PF 400 LED Status Indicators

Explanation of the LED status indicators on the PF 400 VSD.

VSD LCD Display - PF 400

Overview of the PF 400 Variable Speed Drive's LCD display elements.

Viewing and Editing Drive Parameters - PF 400

Step-by-step guide for navigating and modifying PF 400 VSD parameters.

Drive Parameter List - PF 400

A comprehensive list of parameters for the PF 400 VSD, including default and CFLC values.

PF 525 Display, Control, and Navigation Keys

Description of display, control, and navigation keys for the PF 525 VSD.

Viewing and Editing Drive Parameters - PF 525

Guide for viewing and editing parameters on the PF 525 VSD.

Drive Parameter List - PF 525

A list of parameters for the PF 525 VSD, including default and CFLC values.

APPENDIX C Gas Valve

Siemens Gas Valve

Technical details and specifications for Siemens VG and VGD series gas valves.

Dungs Gas Valve (CFLC 4000-5000)

Information on DUNGS MBC-SE gas valves used with CFLC boilers.

SKP Series Actuators

Details on SKP75...U... Air/Gas Ratio Controlling Valve Actuators.

Gas Flow Charts

Charts for sizing single and double gas valves based on flow and pressure drop.

Dimensions

Dimensional data for VGG and VGD series gas valves.

APPENDIX D Falcon Alert, Hold, and Lockout Codes

APPENDIX E Falcon Lead;Lag

INSTALLATION AND STARTUP

Instructions for installing and starting up the Falcon lead/lag system.

LEAD LAG OPERATION

Details on operating the Falcon lead lag system, including master and slave functions.

MODBUS FOR EMS COMMUNICATION

Information on connecting the Falcon system to a Building Energy Management System via Modbus.

SYSTEM SETUP

Guidance on setting up the Falcon lead lag network, including Modbus and sensor connections.

COMMISSIONING

Steps for commissioning the lead lag system, including master and slave configuration.

MODBUS REGISTERS

Table of Modbus registers for boiler/burner status monitoring and control.

APPENDIX F Falcon Program Module

SPECIFICATIONS

Product data and specifications for the Falcon Program Module.

APPLICATION

Information on the application and use of the Falcon Program Module.

FEATURES

Key features of the Falcon Program Module.

Back up parameters to PROGRAM MODULE

Procedure for backing up Falcon control parameters to the Program Module.

Restore parameters from the 833-3640 PROGRAM MODULE

Instructions for restoring parameters from the Program Module to the Falcon controller.

OPERATION

Steps for operating the Falcon Program Module.

Button Actions

Explanation of the button functions available on the Program Module.

Backup Data

Guide to backing up and managing data using the Program Module.

Cleaver-Brooks ClearFire CFLC-5000 Specifications

General IconGeneral
ModelCFLC-5000
CategoryBoiler
Modulation5:1
Fuel TypeNatural gas or Propane
Input MBH5000
Output MBH4750
Thermal Efficiency95%
Operating PressureUp to 160 psi
Firing RateFully Modulating

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