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Cleaver-Brooks ClearFire CFLC Series - User Manual

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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 2 Installation

Boiler Assembly and Placement

Covers packaging, lifting, moving, and placement requirements, including clearances to combustible materials and building codes.

Flue Gas; Combustion Air

Covers flue gas removal via gas-tight pipeline and combustion air supply according to codes and standards.

Water Treatment

Discusses heating medium quality, chloride content, pH levels, and water make-up volume for efficiency and preventing overheating.

Gas Connections

Details gas supply pressure/volume, gas train components, and specifications for efficient, stable combustion.

Boiler Water Piping

Covers piping for hot water outlet/return, safety valve installation, and dual return design for condensing performance.

Electrical Connections

Outlines requirements for qualified personnel for electrical connections, power routing, and sensor cable placement near power wiring.

Section 3 Stack and Intake Vent Sizing and Installation

Combustion Air;Boiler Room Ventilation Requirements

Specifies need for adequate, uncontaminated air for combustion/ventilation, detailing methods like room air, direct, and sealed combustion.

Section 4 Commissioning

Control Setpoints

Details preliminary settings for safety controls like gas pressure switches, air proving, and high pressure switches before startup.

Model CFLC Boiler; Burner Controller

Explains the Falcon control system and its functions: flame supervision, burner sequencing, heating/pump control, and high limit.

Controller Configuration

Guides on verifying defaults and configuring parameters for system ID, heating, reset, DHW, modulation, and limits.

Initial Start-up Procedure

Covers pre-firing steps: gas train/piping check, power-up, and operation checks for gas valves, pressure switches, and ignition.

Post Start-up Checkout Procedure

Outlines post-startup checks: air venting, gas switch settings, draft verification, auto operation monitoring, and HAPS switch operation.

Section 5 Service and Maintenance

Disassembly for Inspection

Details steps for disassembling boiler/burner for inspection: casing, gas train, blower, and burner head removal.

Troubleshooting

Guides on resolving lockout conditions, light-off problems, and issues with temperature, airflow, and flame detection.

Emergency Shutdown

Outlines emergency shutdown: turn off demand, close fuel valves, disconnect electrical power.

Appendix A Falcon Parameters

CFLC Falcon Parameters

Comprehensive table of Falcon parameters for CFLC boiler: groups, names, access, ranges, units, and Modbus registers.

APPENDIX C Gas Valve

APPENDIX D Falcon Alert, Hold, and Lockout Codes

Falcon Holds and Lockouts

Lists Falcon system holds and lockouts: codes, descriptions, and notes for identifying and resolving abnormal conditions.

Falcon Alerts

Comprehensive list of Falcon alerts: codes, descriptions, and notes for resolving operational or performance issues.

APPENDIX E Falcon Lead;Lag

System Wiring Hookup

Illustrates network wiring for multi-boiler lead lag using Falcon controllers and Modbus communication.

Cleaver-Brooks ClearFire CFLC Series Specifications

General IconGeneral
Fuel TypeNatural Gas, Propane
Design Pressure160 psi
Modulation10:1
ConstructionStainless Steel Heat Exchanger
ApplicationCommercial Heating

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