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CleaverBrooks CFC User Manual
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Manual P
art No. 750-263
07/2008
Clearfire
Condensing Boiler
Model CFC
Gas High Efficiency Boiler
Operation, Service,
and Part
s Manual
T
a
ble Of Content
s
CLEAVER-BROOKS
MILWAUKEE, WISCO
NSIN
ANSI STANDARD Z21.13b-2004
—
CSA 4.9b-2004 LOW PRESS
URE BOILER
ANSI STANDARD
Z21.13b-2005 — CSA 4.9b-2005
2
Table of Contents
Table of Contents
5
CFC Features and Benefits
8
Burner Gas Train
9
Chapter 1
9
Standard Equipment
9
The Boiler
9
The Burner
9
Component/Connection Locations
10
Control
10
Optional Equipment
11
Section 2 Installation
15
Section 2 - Installation
16
Assembly
17
Packaging
17
Boiler Room
17
Mounting Legs
18
Insulation
18
Casing Assembly
20
Base Mounting
22
Boiler Room
23
Flue Gas / Combustion Air Connections
23
Flue Gas/Combustion Air Connections
23
Water Treatment
23
Gas Connections
24
General
24
Gas Train Components
24
Gas Pressure Requirements
24
Gas Piping
25
Gas Supply Pipe Sizing
26
Gas Header
32
Boiler Water Piping
34
General
34
Water Temperature Sensors
34
Safety Valve
34
Pressure Drop Curves
34
Condensate Removal and Treatment
41
Condensate Tank Installation
41
Condensate Tank Setup Options
42
Condensate Take-Off and Neutralization
42
Condensate Discharge into Local Drain
42
Piping Treated Condensate to Drain
42
Installation
43
Condensate Piping for Multiple Boilers
44
Electrical Connections
45
Wiring Diagrams
47
Chapter 3 Stack and Intake Vent Sizing and Installation
49
Appliance Categories
50
Stack and Intake Vent Sizing and Installation
50
Vent Stack
50
Venting Connections - General
50
Vent Terminal Location
51
Horizontal Thru-Wall Venting / Inside Combustion Air
54
Installation
54
Horizontal Thru-Wall Stack Vent Termination
54
Horizontal Thru-Wall Venting / Direct Vent Combustion Air
55
Installation
55
Horizontal Thru-Wall Stack Vent Termination
56
Vertical Venting / Inside Combustion Air
57
Vertical Venting / Direct Vent Combustion Air
58
Chapter 4 Cfc Commissioning
63
Control Setpoints
64
Filling Boiler
64
Model CFC Boiler / Burner Controller
64
Operating Conditions
64
CB Falcon Display/Operator Interface
65
Home Page
65
Status Page
65
Operation Page
66
Controller Configuration
67
Lockouts and Alerts
67
Changing Parameter Settings
73
Burner Sequence
74
Fan Speed Settings
75
Initial Start-Up Procedure
75
Gas Train and Piping
75
Power-Up
76
LOW WATER CUTOFF Check
78
Low and High Fire Adjustments
78
Modulation off Point
79
Setting Combustion
79
High Air Pressure Switch Settings
81
Limit Controls Check
81
Post Start-Up Checkout Procedure
82
Chapter 5 Service and Maintenance
83
Service and Maintenance
83
Cleaning Procedure / Disassembly
84
Assembly
85
Condensate Neutralization
85
Ignition Electrode and Flame Rod
86
Troubleshooting
86
Chapter 6 Parts
89
Boiler Mechanical Assembly
90
Boiler Mechanical Assembly Parts List
91
Connection Sizes
91
Gas Train
92
Gas Train Parts List
92
MSOV Kit
92
Electrical Assemblies
93
Blower Fuse
94
Control Panel
94
Electrical Assemblies Parts List
94
Appendix A - CB Falcon Hydronic Control
97
Table of Contents
101
Communications and Displays
105
Overview
105
Installation
107
Wiring
107
Parameter Control Blocks (PCB)
114
Startup
114
Programming Safety Parameters
115
Burner Control
133
Boiler Pump
143
Annunciator
146
Fault Handling
149
Lockouts and Alerts
149
Alarms for Alerts
149
Sensor Signal Conditioning
149
Burner Control Operation
150
Safety Shutdown of Burner Control Functions
150
Operational Sequence
150
Parameter Glossary
152
Global Modbus
161
Appendix B - Falcon Display/Operator Interface
197
833-3577 Cb-Falcon System Operator Interface
199
Preface
200
Safety Features
201
Installation Instructions
201
Wiring
201
Quick Setup
202
Starting the Display
202
Page Navigation
203
Configuration Password
205
Configuration
213
Monitoring
226
833-3639 Diagnostics
238
Display Setup and Diagnostics
240
Advanced Setup
246
System Time
248
Appendix C - Gas Valve
251
Application
253
Specifications
254
Ordering Information
255
Installation
265
Electrical Connections
266
Adjustments and Final Checkout
266
Operation
267
Troubleshooting
268
Service Information
268
4
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CleaverBrooks CFC Specifications
General
Brand
CleaverBrooks
Model
CFC
Category
Boiler
Language
English
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