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Cleaver-Brooks ClearFire CFLC Series Operation And Maintenance Manual Download Page 206

Falcon Alert, Hold, Lockout Codes

Appendix D

D-20

531

Mix PID setpoint was invalid

532

STAT may not be a Mix demand source when Remote Stat is enabled

533-539

RESERVED

540

Delta T inlet/outlet enable was invalid

541

Delta T exchanger/outlet enable was invalid

542

Delta T inlet/exchanger enable was invalid

543

Delta T inlet/outlet degrees was out of range

544

Delta T exchanger/outlet degrees was out of range

545

Delta T inlet/exchanger degrees was out of range

546

Delta T response was invalid

547

Delta T inversion limit response was invalid

548

Delta T rate limit enable was invalid

549

Delta T exchanger/outlet wasn't allowed due to stack limit setting

550

Delta T inlet/outlet limit was exceeded

551

Delta T exchanger/outlet limit was exceeded

552

Delta T inlet/exchanger limit was exceeded

553

Inlet/outlet inversion occurred

554

Exchanger/outlet inversion occurred

555

Inlet/exchanger inversion occurred

556

Delta T exchanger/outlet wasn't allowed due to stack connector setting

557

Delta T inlet/exchanger wasn't allowed due to stack limit setting

558

Delta T inlet/exchanger wasn't allowed due to stack connector setting

559

Delta T delay was not configured for recycle response

560

Outlet T-rise enable was invalid

561

Heat exchanger T-rise enable was invalid

562

T-rise degrees was out of range

563

T-rise response was invalid

564

Outlet T-rise limit was exceeded

565

Heat exchanger T-rise limit was exceeded

566

Heat exchanger T-rise wasn't allowed due to stack limit setting

567

Heat exchanger T-rise wasn't allowed due to stack connector setting

568

Outlet T-rise wasn't allowed due to outlet connector setting

569

T-rise delay was not configured for recycle response

570

Heat exchanger high limit setpoint was out of range

571

Heat exchanger high limit response was invalid

572

Heat exchanger high limit was exceeded

573

Heat exchanger high limit wasn't allowed due to stack limit setting

574

Heat exchanger high limit wasn't allowed due to stack connector setting

575

Heat exchanger high limit delay was not configured for recycle response

576

CH pump output was invalid

577

DHW pump output was invalid

578

Boiler pump output was invalid

Table D-2 Falcon Alerts (Continued)

Summary of Contents for ClearFire CFLC Series

Page 1: ...Model CFLC ClearFire Condensing Boiler Operation and Maintenance Manual 750 363 08 2017 4 000 12 000 MBTU...

Page 2: ...is the same type as specified on the boiler name plate DANGER WARNING Should overheating occur or the gas sup ply valve fail to shut off do not turn off or disconnect the electrical supply to the boil...

Page 3: ...acement manuals to your local Cleaver Brooks authorized representative Manual Part No 750 363 08 2017 Printed in U S A Cleaver Brooks 2017 CLEAVER BROOKS Model CFLC ClearFire Packaged Boiler Condensin...

Page 4: ...ow how a basic burner operates Operating controls will normally function for long periods of time and we have found that some operators become lax in their daily or monthly testing assuming that norma...

Page 5: ...Setpoints 4 2 Model CFLC Boiler Burner Controller 4 3 Falcon Display Operator Interface 4 4 Controller Configuration 4 7 Variable Speed Drive Settings 4 9 Burner Sequence 4 10 Fan Speed Settings 4 10...

Page 6: ...vi...

Page 7: ...www cleaverbrooks com Section 1 Introduction CFLC Features and Benefits 1 2 Standard Equipment 1 2 Optional Equipment 1 7...

Page 8: ...ensures high quality design safety and reliability ISO 9001 certified manufacturing process ensures the highest degree of manufacturing standards is always followed Full Modulation The burner and com...

Page 9: ...al reset B High Gas Pressure Switch manual reset C Single body dual safety motorized shut off valves with POC and regulating actuator D Manual Shutoff Butterball Valve E Regulator optional based on ga...

Page 10: ...e boiler Figure 1 6 shows the locations of the safety valve and air vent connections Figure 1 7 shows the location of the return water temperature sensor The stack is connected on the right side of th...

Page 11: ...Air Vent optional LWCO probe holder Safety Valve s EX Tubes Alufer Tubes Control Panel Gas Train Burner Assembly Water Return 2 Water circulation Combustion gas flow Furnace Flue condensate collection...

Page 12: ...1 6 Part No 750 363 Figure 1 7 Return temperature sensor rear casing insulation not shown Figure 1 8 Stack Outlet Water Outlet and Combustion Air Inlet STACK OUTLET COMBUSTION AIR FILTER WATER OUTLET...

Page 13: ...tion tank assembly consists of neutralizing media filter and PVC condensate holding tank This assembly is further described in Chapter 2 B Direct vent combustion air adapter kit C Outdoor temperature...

Page 14: ...Section 1 Introduction 1 8 Part No 750 363...

Page 15: ...th The boiler must be installed such that the gas ignition system components are protected from water dripping spraying rain etc during appliance operation and sevice Failure to follow this warning co...

Page 16: ...Section 2 Installation 2 2 Part No 750 363...

Page 17: ...the boiler The Model CFLC boiler is lifted by means of the holes provided in the upper tube sheets See rigging diagram below Figure 2 1 CFLC Rigging Caution In order to avoid damage to the unit lifti...

Page 18: ...he National Fire Protection Association and the building code recommended by the American Insurance Association Local codes may differ Installation should provide clearances to unprotected combustible...

Page 19: ...lers are suitable for heating systems without significant oxygenation capacity Systems with continuous oxygenation capacity due to unknown or unseen leaks must be equipped with a system separation or...

Page 20: ...tem flush or if this is an equipment replacement only where minimal amounts of system piping have been replaced there should be minimal manufacturing deposits inside the boiler and no boiler flush is...

Page 21: ...ed in such a way that the temperature difference between the boiler outlet supply and inlet return is a maximum of 40 deg F 22 deg C defined as DT Delta T A DT Limit algorithm should be enabled in the...

Page 22: ...follow these guidelines and those of any local authorities having installation jurisdiction 2 7 2 Gas Train Components CFLC boilers are equipped with a gas train that meets the requirements of ASME C...

Page 23: ...red when the burner is firing using a manometer at the upstream test port connection on the main gas valve For a multiple unit installation gas pressure should be set for a single unit first then the...

Page 24: ...ping at the gas supply to each boiler so that any dirt weld slag or debris can deposit in the drip leg rather than into the boiler gas train The bottom of the drip leg should removable without disasse...

Page 25: ...made of how much flow volume cfh will be demanded at one time and the pressure drop requirement when all appliances are firing The total length of gas piping and all fittings must be considered when s...

Page 26: ...el Natural Gas Inlet Pressure Less than 2 0 psi Pressure Drop 0 30 w c Specific Gravity 0 60 Table 2 7 Gas Line Capacity Schedule 40 Metallic Pipe Pipe Size Nominal 2 2 1 2 3 4 Actual I D 2 067 2 469...

Page 27: ...ine length of run from the source and determine what size header will be needed for the flow of all units firing Figure 2 6 Gas header piping R egulator H eader Pipe M eter From G as H eader Piping T...

Page 28: ...ge piping and code required drains can be properly piped to prevent buildup of back pressure and accumulation of foreign material around the valve seat area Apply only a moderate amount of pipe compou...

Page 29: ...on should be used The low temperature connection is on the left when facing the rear of the boiler 2 8 4 Pressure drop curves The information in Figure 2 9 and in Tables 2 8 and 2 9 can help in determ...

Page 30: ...9 Pressure Drop Curves CFLC CFLC 4000 CFLC 5000 CFLC 6000 CFLC 8000 CFLC 10000 CFLC 12000 Pressure PSI Pressure PSI Pressure PSI Pressure PSI Pressure PSI Pressure PSI Flow rate GPM Flow rate GPM Flo...

Page 31: ...150 10000 1880 940 470 313 235 188 12000 2255 1128 564 376 282 226 Flow rates relative to temperature drop so as not to exceed boiler output Based on 94 nominal efficiency System Temperature Drop Deg...

Page 32: ...10 Model CFLC Minimum Over Pressure Requirements 100 water 2 10 CONDENSATE REMOVAL AND TREATMENT The condensate generated during normal boiler operation must be removed in accordance with local codes...

Page 33: ...ructions supplied with tank Neutralization media are already installed in tank For CFLC 4000 5000 the tank must be installed external to the boiler Figure 2 11 For sizes 6000 12000 the tank s may be m...

Page 34: ...uired depends on the total amount of condensate produced by the system As a general rule CB recommends one tank per boiler for sizes 4 000 8 000 and two tanks for sizes 10 000 12 000 Figure 2 11 Conde...

Page 35: ...top left corner of the boiler to the control panel see Figure 2 13 AC power is to be connected to the incoming power terminals Note The following temperature sensor cables should not be run near the t...

Page 36: ...Section 2 Installation 2 22 Part No 750 363 Figure 2 13 Electrical Connections CFLC FALCON...

Page 37: ...DIAGRAM Figure 2 14 CFLC 6000 12000 Wiring Diagram single fuel typical Note Wiring diagrams shown are examples only Installations may vary For specific installations consult the wiring diagram provide...

Page 38: ...Section 2 Installation 2 24 Part No 750 363...

Page 39: ...Vent Sizing and Installation Venting Connections General 3 2 Vertical Venting Inside Combustion Air 3 6 Vertical Venting Direct Vent or Sealed Combustion Air 3 7 Venting for multiple units 3 8 Combust...

Page 40: ...and with a vent gas temperature that may cause excessive condensate production in the vent Depending on the application the Model CFLC may be considered Category II III or IV The specifying engineer...

Page 41: ...rain caps can lead to ice formation air intake blockage and flue blockage that result from condensing water vapor in the flue gases Cleaver Brooks discourages the use of horizontal through the wall f...

Page 42: ...ccidental contact by people and pets 7 DO NOT terminate vent in window well alcove stairwell or other recessed area unless previously approved by local authority 8 DO NOT terminate above any door wind...

Page 43: ...3 ft 900mm horizontally of the vertical center line of the regulator 5 Within 6 ft 1 8m if any gas service regulator vent outlet 6 Less than 1 ft 300mm above grade level 7 Within 3 ft 1m of a window...

Page 44: ...acksaw 34 teeth per inch Do not use nonmetallic vent pipe or fittings that are cracked or damaged Do not use nonmetallic vent fittings if they are cut or altered Do not drill holes or use screws or ri...

Page 45: ...tion of condensation in the vent it is required to install the horizontal portion of vent with a slight slope of at least 1 4 per foot of horizontal run pitched either back to the boiler or to a low p...

Page 46: ...aft active draft controls are recommended for common flue vented CFLC boilers Ductwork sizing layout and connections require special attention in common flue venting systems Good design practice shoul...

Page 47: ...Stack and Intake Vent Sizing and Installation Part No 750 363 3 9 EXAMPLE 1 EXAMPLE 2 From boilers 45 o 26 26 26 14 14 14 3 From boilers to roof vent GOOD BAD From boilers 14 20 45o 14 3 From boilers...

Page 48: ...iately surrounding the boiler boiler room must be positive pressure or with air ducted from the outdoors to the burner cabinet direct venting or burner air intake sealed combustion All installations m...

Page 49: ...not equipped with direct vent combustion and the boiler is located in an unconfined space use the following guidelines 1 The mechanical equipment room must be provided with two permanent openings link...

Page 50: ...hour of total input rating of all equipment in the room when the opening is directly linked to the outdoors or through vertical ducts 4 The minimum free area required for horizontal ducts is one squa...

Page 51: ...nd 6 inches from the front of the appliance 2 The opening shall directly communicate with the outdoors and shall have a minimum free area of 1 square inch per 3000 BTU s per hour of the total input ra...

Page 52: ...ded Locate one at each end of the boiler room preferably below a height of 7 feet This allows air to sweep the length of the boiler See Figure 3 7 B Air supply openings can be louvered for weather pro...

Page 53: ...iler Room fpm A From floor to 7 feet high 250 fpm B Above 7 feet above floor 500 fpm Example Determine the area of the boiler room air supply openings for 2 CFLC 4000 boilers at 750 feet elevation The...

Page 54: ...e potential for freezing and to reduce standby losses a motorized isolation damper is necessary to prevent the circulation of cold air through the boiler during non operating hours 4 Refer to Figure 3...

Page 55: ...ches WC CFLC 4000 1000 10 0 25 10 or 12 14 0 25 0 10 CFLC 5000 1250 12 0 25 12 14 0 25 0 10 CFLC 6000 1500 14 0 25 14 or 16 16 0 25 0 10 CFLC 8000 2000 14 0 25 14 or 16 16 0 25 0 10 CFLC 10000 2500 16...

Page 56: ...Section 3 Stack and Intake Vent Sizing and Installation 3 18 Part No 750 363...

Page 57: ...splay Operator Interface 4 4 Controller Configuration 4 7 Variable Speed Drive Settings 4 9 Burner Sequence 4 10 Fan Speed Settings 4 10 Initial start up procedure 4 10 Post start up checkout procedur...

Page 58: ...3 CONTROL SETPOINTS Preliminary settings of the burner boiler safety controls are necessary for the initial starting of the boiler After the burner has been properly set minor adjustments to these co...

Page 59: ...ignals to the controller Additional features include User friendly touchscreen interface Modbus communication capability Alarm lockout messaging with history last 15 messages Annunciation Outdoor rese...

Page 60: ...r to the boiler The Home page will appear on the Falcon display Each Falcon in the hydronic system is represented on the Home page by an icon and name 4 5 2 Status Page Pressing the Falcon icon takes...

Page 61: ...and Override rates Setpoints shows the ON Modulation and OFF temperature setpoints 4 5 3 Operation Page The operation page Figure 4 4 displays the Falcon running operation including setpoint and firin...

Page 62: ...he Lockout History Holds are not logged in memory Note Before attempting to restart the boiler after a Lockout identify and correct the Lockout condition Alerts indicate conditions or events which whi...

Page 63: ...rect for your application Please refer to CB default settings APPENDIX A and make any changes at this time if needed Falcon configuration is organized into the following functional groups 4 6 1 Changi...

Page 64: ...the parameter unchanged Safety Parameters When configuring safety parameters an additional verification step is required to confirm the changes 1 When a safety parameter is changed the Safety Paramet...

Page 65: ...press SETUP then PROGRAM MODULE 4 7 VARIABLE SPEED DRIVE SETTINGS The Variable Speed Drive is pre configured at the factory Should it become necessary to change the drive s configuration VSD parameter...

Page 66: ...d Rate and Slow Start Enable if the water is colder than the threshold 13 Release to modulation 14 At the end of the CH heat request the burner is switched off and the fan stays on until post purge is...

Page 67: ...ed before placing the boiler into operation 5 Gas Pressure Regulator Using the adjusting screw on the main gas regulator adjust the gas valve inlet pressure to within the recommended levels in Table 4...

Page 68: ...review Section C Control Setpoints for initial LGPS HGPS and CAPS settings Note Close the downstream manual gas shut off valve before checking pressure switches and CAPS While performing the followin...

Page 69: ...N FAILURE CHECK 1 A test of the UV scanner circuit can also be performed at this time Shut off pilot gas manual valve and attempt to start the burner The Falcon should lock out indicating Lockout 109...

Page 70: ...ft ASL Operating under different conditions may require re adjustment of the gas valve See figure below for low and high fire adjusting screw locations Observe the markings on the gas valve to ensure...

Page 71: ...ating the burner via the Falcon from low fire to high fire two or more times to ensure a consistent air fuel ratio NOTE Install the combustion analyzer probe as close as possible to the boiler vent co...

Page 72: ...the low fire offset screw may also be tried Check that gas pressure to gas valve inlet is sufficient to fire burner see Table 4 1 for gas pressure requirements 5 After burner lights maintain in low f...

Page 73: ...lation OFF point higher than the High Limit setting Restore Modulation OFF and High Limit to operational settings after testing Specific settings are determined by application Maximum High Limit for M...

Page 74: ...l Heat Configuration parameter group Service level password login may be required to change this parameter The hysteresis on and hysteresis off points can only be changed under the Central Heat Config...

Page 75: ...the value for 4mA 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 beca...

Page 76: ...ting status etc Annunciator The Annunciator monitors the Falcon control circuit to provide fault and status messages and also provides first out annunciation for interlock lockouts Eight inputs are av...

Page 77: ...4 Troubleshooting 5 6 Extended Shutdown 5 8 Emergency Shutdown 5 8 Caution Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Failu...

Page 78: ...swing out and to the left on its hinge 10 The burner head can be separated by removing the nuts and washers holding the adapter plate to the dry oven Check the burner head for any damage burn marks o...

Page 79: ...cover plate from condensate collection chamber After fireside inspection maintenance replace cover plate gasket with 853 01531 silicone tape Rear Fireside Access Remove rear casing panels Remove upper...

Page 80: ...old filter in place 5 3 IGNITION AND FLAME DETECTION SYSTEMS Ignition Electrode The ignition electrode should be replaced annually or more frequently if conditions require Inspect the electrode period...

Page 81: ...that the flame viewing lens is clear and free of dust or debris Wipe with a clean rag if necessary When replacing the scanner verify an unobstructed line of sight through the scanner bracket to the b...

Page 82: ...d in boiler inadequate air venting or modulation set point and off point close to outlet high limit setting The Falcon system display interface provides extensive boiler diagnostic data at the time of...

Page 83: ...in Lightoff problems Wrong gas pressure Check regulated gas pressure and ensure it agrees with Table 4 3 Check other equipment connected to gas main regulator and gas supply piping sizings should be b...

Page 84: ...nts in plastic to protect from moisture To restart after an extended period follow the initial startup instructions in Chapter 4 5 6 EMERGENCY SHUTDOWN In case of emergency shut down the boiler by tur...

Page 85: ...000 8000 standard 20 PPM NOx 6 11 Gas Train CFLC 6000 8000 optional 9 PPM NOx 6 12 Gas train CFLC 10000 12000 standard 20 PPM NOx 6 13 Gas train CFLC 10000 12000 optional 9 PPM NOx 6 14 Gas Train CFLC...

Page 86: ...ter 1 380 01130 380 01145 380 01128 Water Side Gaskets 5 853 00934 Transformer 115V 25V 1 832 00235 Relay DPDT 115VAC Coil 1 833 03532 Gasket Burner Canister 2 380 01118 Gasket Adapter to Blower 1 380...

Page 87: ...Section 6 Parts Part No 750 363 6 3 Figure 6 1 Boiler Mechanical Assembly CFLC 4000 5000...

Page 88: ...Section 6 Parts 6 4 Part No 750 363 Figure 6 2 Boiler Mechanical Assembly CFLC 6000 8000...

Page 89: ...EPARABLE HONEYWELL 1 2 NPT W CLAMP 41 1 826 00296 000 CABLE HARNESS MALE END 42 1 090 04723 000 TUBING AIR SENSING LINE 45 1 940 01267 000 SAFETY VALVE 160 PSI 1 1 2 X 2 STANDARD SHIP LOOSE 46 1 940 0...

Page 90: ...Section 6 Parts 6 6 Part No 750 363 Figure 6 4 Burner Assembly CFLC 4000 5000 UV SCANNER SEE FIGURE 6 7...

Page 91: ...Section 6 Parts Part No 750 363 6 7 Figure 6 5 Burner Assembly CFLC 6000 8000 UV SCANNER SEE FIGURE 6 7...

Page 92: ...Section 6 Parts 6 8 Part No 750 363 Figure 6 6 Burner Assembly CFLC 10 000 12 000 Figure 6 7 UV Scanner UV SCANNER SEE FIGURE 6 7...

Page 93: ...000 1 19 VALVE BUTTERBALL 2 NPT 941 01947 000 1 21 HIGH GAS PRESSURE SWITCH 3 21 WC RANGE MR 1 4 NPT MOUNT 817 02420 000 1 28 LGPS 3 21 WC RANGE MR 1 4 NPT MOUNT 817 02416 000 1 29 ADAPTER 1 8 BSPT MA...

Page 94: ...1586 000 VALVE END THREADED 2 NPT 29 1 30 1 31 1 32 1 A A 3 7 1 21 3 20 7 4 33 30 31 32 32 20 29 31 STD STD 14 19 26 26 14 1 19 27 30 1 14 ORIFICE 2 4 6 18 6 18 7 6 18 5 185 01260 000 NATURAL GAS 20PP...

Page 95: ...Section 6 Parts Part No 750 363 6 11 Figure 6 10 Gas Train CFLC 6000 8000 optional 9 PPM NOx...

Page 96: ...11 Gas train CFLC 10000 12000 standard 20 PPM NOx VIEW A A SECTION B B SECTION C C A A B B C C D D OPTIONAL 24 1 29 11 35 34 STD 16 14 12 9 10 19 16 16 22 21 22 18 16 19 16 1 33 36 8 4 4 13 19 18 CFL...

Page 97: ...Section 6 Parts Part No 750 363 6 13 Figure 6 12 Gas train CFLC 10000 12000 optional 9 PPM NOx...

Page 98: ...Section 6 Parts 6 14 Part No 750 363 Figure 6 13 Gas Train CFLC 4000 5000 Propane...

Page 99: ...Section 6 Parts Part No 750 363 6 15 Figure 6 14 Gas Train CFLC 6000 8000 Propane...

Page 100: ...Section 6 Parts 6 16 Part No 750 363 Figure 6 15 Gas Train CFLC 10000 12000 Propane...

Page 101: ...LVE W POC 7 945 00236 000 ACTUATOR GAS VALVE W POC 11 949 00448 000 VALVE GAS MOTORIZED 8 949 00448 000 VALVE GAS MOTORIZED 10000 NATURAL GAS 10000 PROPANE 1 048 00914 000 ORIFICE NATURAL GAS LINE 1 0...

Page 102: ...Section 6 Parts 6 18 Part No 750 363 Figure 6 16 Dual Fuel 4000 5000 1 PROPANE NATURAL GAS 2 3 3 3 4 5 6 7 8 9 10 10 11 12 13 14...

Page 103: ...Section 6 Parts Part No 750 363 6 19 Figure 6 17 Dual Fuel Nat Gas 6000 12000 Figure 6 18 Dual Fuel Propane 6000 12000 1 5 11 10 4 TO VENTURI OPTIONAL 2 6 2 7 7 7 6 8 2 6 7 4 3 5 5 5 1 OPTIONAL...

Page 104: ...EM DESCRIPTION PART NUMBER 1 COCK GAS SERVICE TEE HEAD SEE TABLE 2 VALVE SOLENOID GAS PILOT 235 00282 3 REGULATOR GAS PRESSURE 918 00356 4 COCK GAS SERVICE TEE HEAD 825 00178 ITEM 1 CFLC 4000 5000 CFL...

Page 105: ...Section 6 Parts Part No 750 363 6 21 Figure 6 20 Control Panel...

Page 106: ...Section 6 Parts 6 22 Part No 750 363 Figure 6 21 Cables and Cable Harness...

Page 107: ...868 00137 000 CAPSCREW HEX HD 1 4 20 UNC 2A X 1 LG 19 8 952 00294 000 WASHER FLAT PLAIN 3 4 O D X 5 16 20 1 105 12389 000 CASING FRONT LOWER PANEL CFx 5M 21 1 105 12392 000 CASING FRONT UPPER PANEL C...

Page 108: ...Section 6 Parts 6 24 Part No 750 363 Figure 6 23 Casing Insulation 4000 5000 cont d...

Page 109: ...Section 6 Parts Part No 750 363 6 25 Figure 6 24 Casing Insulation 6000 8000...

Page 110: ...Section 6 Parts 6 26 Part No 750 363 Figure 6 25 Casing Insulation 6000 8000 cont d...

Page 111: ...CFLC 10M 12M 20 1 105 12408 000 CASING FRONT UPPER PANEL CFLC 10M 12M 21 4 105 12393 000 CASING ACCESS COVER CFx 22 12 952 00294 000 WASHER FLAT PLAIN 3 4 O D X 5 16 I D X 16 GA 23 8 868 00137 000 CAP...

Page 112: ...INSULATION VIEW REAR CASING INSULATION SECTION A A VIEW FROM INSIDE PANEL INSTALLATION A A 3 2 37 1 36 4 5 35 29 30 8 10 9 7 33 34 31 32 31 9 7 8 10 17 22 23 23 22 22 26 INSIDE PANEL 26 22 22 23 INSI...

Page 113: ...8000 12000 Sealed Combustion Air Adapter Kits 880 03812 DIRECT VENT KIT CFLC 4000 5000 10 880 03813 DIRECT VENT KIT CFLC 4000 5000 12 880 03816 DIRECT VENT KIT CFLC 6000 8000 12 880 03815 DIRECT VENT...

Page 114: ...Section 6 Parts 6 30 Part No 750 363 817 03571 ALARM HORN 817 04403 STACK TEMP LIMIT SENSOR 940 04920 AUTO AIR VENT UP TO 150 940 02673 AUTO AIR VENT UP TO 300...

Page 115: ...APPENDIX A Falcon Parameters...

Page 116: ......

Page 117: ...temperature Service 80 oF 514 Outdoor Reset Configuration CH ODR boost time Service 30m 0s mmm ss 515 Outdoor Reset Configuration CH ODR boost maximum off point Service 180 230 oF 516 Outdoor Reset Co...

Page 118: ...on System pump overrun time Service 15m 0s mmm ss 289 Pump Configuration Pump exercise interval Service 0 Days 290 Pump Configuration Pump exercise time Service 0m 0s mmm ss 291 Pump Configuration CH...

Page 119: ...anticondensation enable Service Enabled 499 Anticondensation Configuration DHW anticondensation setpoint Service 130 230 oF 500 Anticondensation Configuration Anticondensation Forced rate User Yes Tr...

Page 120: ...ly A Lockout 238 Interlocks Interrupted air switch enable OEM xBCx C Enable IAS during purge ignition 246 Interlocks LCI enable Read Only Enabled 248 Interlocks PII enable OEM Enabled 249 Interlocks I...

Page 121: ...ch User No False Off 555 Lead Lag Configuration Lead lag CH demand switch Service B STAT terminal 556 Lead Lag Configuration Lead lag CH setpoint source Service A Local setpoint is used 557 Lead Lag C...

Page 122: ...tion Slave sequence order Service 0 1 to 8 568 Lead Lag Configuration Lead lag slave demand to firing delay Service 1m 0s 3m 0s mmm ss 570 Lead Lag Configuration LL CH ODR max outdoor temperature Serv...

Page 123: ...APPENDIX B Variable Speed Drive Parameters Sections B 1 B 5 PowerFlex 400 Sections B 6 B 8 PowerFlex 525...

Page 124: ......

Page 125: ...Up Arrow Down Arrow Increase decrease the value of a flashing digit Scroll through groups and parameters Enter Advance one step in programming menu Save a change to a parameter value Digital Speed In...

Page 126: ...njection is commanded VSD LED Indicators PF 400 LED LED State Description Program Status Steady Red Indicates parameter value can be changed Fault Status Flashing Red Indicates that the drive is fault...

Page 127: ...Display Group parameter number is displayed with flashing characters The display then defaults to that parameter s current value Example shows the value of b001 Output Freq with the drive stopped 2 P...

Page 128: ...LED will turn off Or Press Enter to save a change The digit will stop flashing and the Program LED will turn off 13 Press Esc to return to the parameter list Continue to press Esc to back out of the...

Page 129: ...Not Used T58 Relay 1 On Time 0 0 Secs OK T59 Relay 1 Off Time 0 0 Secs OK T60 Relay Out 2 Select Motor Running Above Freq 006 T61 Relay Out 2 Level 0 0 40 T62 Not Used T63 Relay 2 On Time 0 0 Secs OK...

Page 130: ...PID Setpoint 0 0 OK A158 PID Deadband 0 0 OK A159 PID Preload 0 0 Hz OK A160 Process Factor 30 0 OK A161 Not Used A162 Not Used A163 Auto Restart Tries 0 2 A164 Auto Restart Delay 1 0 Secs 2 A165 Star...

Page 131: ...ed Display d301 Control Source Read Only d302 Contrl In Status Read Only d303 Comm Status Read Only d304 PID Setpnt Displ 0 0 d305 Analog In 1 0 0 d306 Analog In 2 0 0 d307 Fault 1 Code Read Only d308...

Page 132: ...iewed drive operating conditions Basic Program Commonly used programmable functions Terminal Blocks Programmable terminal functions Communications Programmable communication functions Logic PowerFlex...

Page 133: ...rrow to scroll through the parameter list 7 Press Enter to view the value of the parameter Or Press Esc to return to the parameter list 8 Press Enter or Sel to enter Program Mode and edit the value Th...

Page 134: ...ower Saved 018 Elapsed Run Time 019 Average Power 020 Elapsed kWh 021 Elapsed MWh 022 Energy Saved 023 Accum kWh Sav 024 Accum Cost Sav 025 Accum C02 Sav 026 Drive Temp 027 Control Temp 028 Control SW...

Page 135: ...1On Time 079 Relay 1 Off Time 080 Relay Out2 Sel lJ 081 6 Relay 0ut2 level111 082 15 Relay 2 On Time11l 084 Relay 2 Off TimetlJ 085 EM Brk Off Delay 086 EM Brk On Delay 087 Analog Out Sel u 088 Analo...

Page 136: ...omm Flt ActnllJ 143 EN Idle Flt Actn111 144 EN FltCfg Logic11i 145 EN FltCfg Ret 11 146 EN Flt Cfg DL 11 1 147 EN FltCfg DL Jl1i 148 EN FltCfg DLJ111 149 EN FltCfg DL411 150 EN Data In 1 lJ 153 EN Dat...

Page 137: ...3111 206 Step Units 4111 208 Step Units 5llJ 210 Step Units 611l 212 Step Units 7tli 214 Analog In 0 10V 360 Analog In 4 20mA 361 Elapsed Time hr 362 Elapsed Time min 363 Counter Status 364 Timer Sta...

Page 138: ...set Sel 428 MOP Preload 429 MOP Time 430 Jog Frequency 431 Jog Accel Decel 432 Purge Frequency 433 DC Brake Time 434 DC Brake Level 435 DC Brk Time Strt 436 DB Resistor Sel 437 DB Threshold 438 S Curv...

Page 139: ...75 PIO 2 Setpoint1li 476 PID 2 DeadbandtlJ 477 PIO 2 Preload 11 478 PID 2 I nvert Err111 479 Process Disp Lo 481 Process Disp Hi 482 Testpoint Sel 483 Current Limit 1 484 Current Limit 21 485 Shear Pi...

Page 140: ...le 544 Flying Start En 545 FlyStrtCurlimit 546 Compensation 547 Power Loss Mode 548 Half Bus Enable 549 Bus Reg Enable 550 Fault Clear 551 Program Lock 552 Program Lock Mod 553 Orv Ambient Sel 554 Res...

Page 141: ...22 Fault3 Time min 623 Fault 4 Time min 624 Fault S Time min 625 Fault6 Time min11J 626 Fault7Time minl11 627 Fault 8 Time min11J 628 Fault 9 Time minl11 629 Faultl O Time min 111 630 Fault 1 Freq 631...

Page 142: ...pt 682 Com Sts Emb Enet 1J 683 EN Addr Src11 684 EN Rate Actl l 685 OSI 1 0 Act 686 HW Add r111l 687 HW Add r zl11 688 HW Addr3v 689 HW Addr 4111 690 HW Addr5111 691 HW Addr 6 11 692 EN IP Addr Act 11...

Page 143: ...ic Cmd 721 Orv 4 Reference 722 Drv 4Logic Sts 723 Orv 4 Feedback 724 EN Rx Overruns lJ 725 EN Rx Packets1lJ 726 EN Rx Errors 11 727 ENTx Packets11J 728 EN Tx Errorsl11 729 EN Missed 10 Pkt111 730 OSI...

Page 144: ......

Page 145: ...APPENDIX C Gas Valve Page C 3 Siemens Gas Valve Page C 25 Dungs Gas Valve CFLC 4000 5000...

Page 146: ......

Page 147: ...Appendix C Gas Valve C 3...

Page 148: ...Gas Valve Appendix C C 4...

Page 149: ...Appendix C Gas Valve C 5...

Page 150: ...Gas Valve Appendix C C 6...

Page 151: ...Appendix C Gas Valve C 7...

Page 152: ...Gas Valve Appendix C C 8...

Page 153: ...Appendix C Gas Valve C 9...

Page 154: ...Gas Valve Appendix C C 10...

Page 155: ...Appendix C Gas Valve C 11...

Page 156: ...Gas Valve Appendix C C 12...

Page 157: ...Appendix C Gas Valve C 13...

Page 158: ...Gas Valve Appendix C C 14...

Page 159: ...Appendix C Gas Valve C 15...

Page 160: ...Gas Valve Appendix C C 16...

Page 161: ...Appendix C Gas Valve C 17...

Page 162: ...Gas Valve Appendix C C 18...

Page 163: ...Appendix C Gas Valve C 19...

Page 164: ...Gas Valve Appendix C C 20...

Page 165: ...Appendix C Gas Valve C 21...

Page 166: ...Gas Valve Appendix C C 22...

Page 167: ...Appendix C Gas Valve C 23...

Page 168: ...Appendix C Gas Valve C 24...

Page 169: ...re installing or operating K eep the instruction in a safe place You the instruction also at www dungs com If these instructions are not heeded the result may be personal injury or damage to property...

Page 170: ...2 1 s MBC PSI V A Hz VA Gas F 0 40 150 Electrical Connection DIN connectorwith1 2 NPTconduit Order separately for CSA Versions Power Consumption with all coils energized see table below NEMA Enclosur...

Page 171: ...ded Procedure to Mount the Flanges 1 Unpack the MBC valve and remove the socket cap head screws from white plastic cover For MBC 1000 use 5 mm hex wrench for M6 screws For MBC 2500 4000 use 6 mm hex w...

Page 172: ...ipe in the valve body values listed below It is not recommended that this valve be painted Painting covers date codes and other labels that identify this valve Ifthevalveneedstobepainted apaintfreeofv...

Page 173: ...nduit and 1 2 Conduit Fitting Select one conduit type and its suitable conduit from the following table Type FLEX MC Flexible Metal Clad Standard thickness steel or aluminum Flexible Metal Clad Condui...

Page 174: ...the wires to the terminals on the T Block see FIG A above 4 Strip no mor e than 1 4 of insulation from each wire 5 Wiring to the corr ect terminal is critical The terminals are labeled next to the ter...

Page 175: ...2 3 4 Filter 5 Label Seriel number 6 Cover 7 Test point connection G 1 8 upstream of V1 possible on both sides 8 Test point connection G 1 8 downstream of V2 optional 9 Regulator Outlet Pressure Adju...

Page 176: ...ter a cer tion with the burner boiler Close internal Impulse line with grub scr ew See Fig 1 Route Impulse line so that no condensate the MBC SE See Fig 2 1 2 1 2 MBC 1000 2500 Fig 1 MBC 4000 SecureIm...

Page 177: ...as air ratio concentration for the application T T 3 Verify that products of combustion are within the operating range as Low Fire setting using MBC regulator 1 W I Theminimumnegativesignaltozerogover...

Page 178: ...MBC 1000 2500 1 Shut o gas s upply and disconnect power s up ply 2 UndolockingscrewA Fig 1 3 R emove cover B Fig 2 4 E xchange solenoid Fig 3 Always observe s olenoid No and voltage 5 R eplacecoverB...

Page 179: ...power s up ply 2 UndolockingscrewA Fig 1 3 R emove cover B Fig 2 1 2 3 4 5 6 B A B A 7 Note Coil V1 wire connection black white Coil V2 wire connection red blue Replacement s olenoid is complete assem...

Page 180: ...For production date codes May 2007 or newer this feature is present 1 Internal Fil ter Change the lter if p be tween pressure connections 1 and 2 is twice as high com pared to the last inspection 1 I...

Page 181: ...essure taps MBC 1000 2500 1 2 3 4 5 G 1 8 Screw plug 2 0 1 6 1 2 8 4 p B r 20 16 12 8 4 pBr 4 5 4 3 1 2 3 1 2 6 7 3 4 4 5 3 1 2 2 6 7 MBC 4000 6 Air pressure signal 7 Combustion chamber pressure MBC S...

Page 182: ...ressurereadingonthemanometer whichshould be zero 5 With a stopwatch ready de energize valve 2 and imme diately start the timer Watch the manometer for pressure change 6 As soon as the test time e xpir...

Page 183: ...downstream manual ball valve 4 Usingascrewdriver slowlyopentheV1testnipple port2 byturningitcounterclockwisetodepressurizethevolume to the test nipple 5 S lowlyopentheupstreammanualballvalve andthenpr...

Page 184: ...200 400 600 2 000 10 000 4 000 7 000 800 1 000 NPT 1 2 NPT 3 4 NPT 1 1 1 4 Based on 60 F 14 65 psia dry MBC 1000 MBC 2500 Curves for equipment selection in regulated state with micro 100 200 400 600...

Page 185: ...xt page to determine pressure drop for propane Density of Natural gas Density of gas used f Type of gas Density kg m 3 s g f Natural gas 0 81 0 65 1 00 Butane 2 39 1 95 0 58 Propane 1 86 1 50 0 66 Air...

Page 186: ...Appendix C Gas Valve C 42...

Page 187: ...APPENDIX D Falcon Alert Hold and Lockout Codes...

Page 188: ......

Page 189: ...ockout 17 Internal fault Safety relay test failed due to safety relay not OFF Lockout 18 Internal fault Safety relay test failed due to feedback not ON Lockout 19 Internal fault Safety RAM write Locko...

Page 190: ...56 57 RESERVED 58 Internal fault HFS shorted to IAS Lockout 59 Internal fault Mux pin shorted Lockout 60 Internal fault HFS shorted to LFS Lockout 61 Anti short cycle Hold 62 Fan speed not proved Hold...

Page 191: ...ailure occurred Hold 111 Flame current lower than WEAK threshold Hold 112 Pilot test flame timeout Lockout 113 Flame circuit timeout Lockout 114 121 RESERVED 122 Lightoff rate proving failed Lockout 1...

Page 192: ...ack incorrect Lockout 173 Pilot relay feedback incorrect Lockout 174 Safety relay feedback incorrect Lockout 175 Safety relay open Lockout 176 Main relay ON at safe start check Lockout 177 Pilot relay...

Page 193: ...re response setting Lockout 217 Invalid Run stabilization time setting Lockout 218 Invalid Stack limit enable setting Lockout 219 Invalid Stack limit response setting Lockout 220 Unconfigured Delta T...

Page 194: ...ompatible with Ignitor on throughout PFEP Lockout 244 Internal fault Safety relay test invalid state Lockout 245 Invalid Outlet connector type setting for T rise Lockout 246 4 20mA cannot be used for...

Page 195: ...15 Safety group verification table was updated 16 Invalid Parameter PCB was detected 17 Invalid Range PCB was detected 18 Alarm silence time exceeded maximum 19 Invalid safety group verification table...

Page 196: ...brown out reset occurred 57 Safety processor watchdog reset occurred 58 Alarm was reset by the user at the control 59 Burner control firing rate was absolute max rate 60 Burner control firing rate wa...

Page 197: ...modulation range max minus min was too small 4 or 40 RPM 104 Min modulation rate was absolute min rate 105 Min modulation rate was invalid vs RPM 106 Manual rate was invalid vs RPM 107 Slow start ena...

Page 198: ...as invalid 146 CH control was suspended due to fault 147 CH header temperature was invalid 148 CH Outlet temperature was invalid 149 CH steam pressure was invalid 150 Steam setpoint source parameter w...

Page 199: ...enable was invalid 189 Lead Lag hysteresis step time was invalid 190 No Lead Lag Modbus port was assigned 191 Lead Lag base load common setting was invalid 192 Lead Lag DHW demand switch setting was i...

Page 200: ...down was not checked due to invalid outdoor temperature 229 Lead Lag slave communication timeout 230 RESERVED 231 Lead Lag CH setpoint was invalid 232 Lead Lag CH time of day setpoint was invalid 233...

Page 201: ...ff during Drive to Purge Rate 276 Abnormal Recycle LCI off during Measured Purge Time 277 Abnormal Recycle LCI off during Drive to Lightoff Rate 278 Abnormal Recycle LCI off during Pre Ignition test 2...

Page 202: ...Stuck reset switch 313 Run was terminated due to fan failure 314 Abnormal Recycle Fan failed during Drive to Purge Rate 315 Abnormal Recycle Fan failed during Measured Purge Time 316 Abnormal Recycle...

Page 203: ...Abnormal Recycle fault inlet sensor 360 Abnormal Recycle Check Parameters Failed 361 Internal error No factory parameters were detected in control 362 Internal error PID iteration frequency was inval...

Page 204: ...ernal error EEPROM cycle count address was invalid 469 Internal error EEPROM days count address was invalid 470 Internal error EEPROM hours count address was invalid 471 Internal error Lockout record...

Page 205: ...ceeds normal setpoint 507 Mix ODR max outdoor temperature was invalid 508 Mix ODR min outdoor temperature was invalid 509 Mix ODR low water temperature was invalid 510 Mix ODR outdoor temperature rang...

Page 206: ...a T inlet exchanger wasn t allowed due to stack limit setting 558 Delta T inlet exchanger wasn t allowed due to stack connector setting 559 Delta T delay was not configured for recycle response 560 Ou...

Page 207: ...hysteresis was invalid 592 DHW plate preheat OFF hysteresis was invalid 593 Tap detect degrees was out of range 594 Tap detect ON hysteresis was invalid 595 Inlet DHW tap stop degrees was out of range...

Page 208: ......

Page 209: ...APPENDIX E Falcon Lead Lag INSTALLATION AND STARTUP page E3 LEAD LAG OPERATION page E39 MODBUS FOR EMS COMMUNICATION page E65...

Page 210: ......

Page 211: ...cially the sections pertaining to multiple boiler installations See also the latest revisions of 750 265 Falcon Boiler Control 750 241 Falcon Display Operator Interface 750 308 Falcon Modbus 750 244 F...

Page 212: ...d to an available Falcon sensor input for outdoor reset control optional 833 05105 or 833 03577 display for each boiler A Falcon lead lag kit 880 3670 is available from Cleaver Brooks and includes a s...

Page 213: ...by one of the Falcon units in the network The lead lag Master is not a separate controller and no additional control panels or devices are required to configure and operate a Falcon lead lag network T...

Page 214: ...V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V V O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O L L L L L L L L L L L L L...

Page 215: ...EMPERATURE SENSOR HEADER SUPPLY 10K NTC THERMISTOR 817 00405 THERMOWELL 817 04517 OUTDOOR TEMP SENSOR 833 03640 FALCON PROGRAM MODULE PART NUMBER DESCRIPTION 817 04385 PRESSURE TRANSMITTER HEADER SUPP...

Page 216: ...reset 6 1 Lead Lag Modbus Network Falcon controllers should be connected in a daisy chain manner see Color Figure 2 over the MB2 bus using 18 AWG 2 conductor shielded or twisted pair cable Connections...

Page 217: ...See Figure 4a NOTE refer to specific boiler wiring diagram for proper terminal numbers 6 3 Header Pressure Transmitter steam systems Determine which boiler will be the lead lag Master host and connec...

Page 218: ...le boiler in the network other than the boiler hosting the Master Once configured the sensor will be recognized by the lead lag Master Sensor Configuration hot water The Outdoor Reset Warm Weather Shu...

Page 219: ...lead lag network and a building EMS for purposes of remote system monitoring or data acquisition Connection to the lead lag Modbus network is made at control panel terminals 41 and 42 on each boiler c...

Page 220: ...Lag Master Configuration Parameters Hydronic Parameter Range CB Default Setting Installation Setting Master enable Enabled Disabled Disabled CH setpoint 40 to 266 deg F 40 to 130 deg C 150 deg F CH t...

Page 221: ...orithms Parameters Lead selection method Sequence order Measured run time Sequence order Lag selection method Sequence order Measured run time Sequence order Lead rotation time day hr min 120 hrs Forc...

Page 222: ...0 25 D gain 0 400 0 Steam Parameters Demand switch Stat Terminal Mod Sensor Disabled Stat Terminal Setpoint source Local Local 4 20mA Not compatible with Falcon steam lead lag Setpoint 0 135 psi 10 Ti...

Page 223: ...Defines the temperature range if S2 4 20mA selected as setpoint source Outdoor Reset hot water only if enabled uses the current outdoor temperature to determine setpoint outdoor temperature sensor re...

Page 224: ...purge rate prepurge time transition to lightoff rate all ignition timings and some extra margin Fan rate during off cycle This determines if or at what rate the fan is to operate during the standby p...

Page 225: ...place the cover 8 Repeat steps 4 7 with the remaining boilers 9 IMPORTANT after parameterizing all boilers remember to give each one a unique Modbus address Each boiler s MB1 and MB2 addresses must be...

Page 226: ...curve In the example Minimum outdoor temperature 0 deg F CH setpoint 180 deg F Maximum outdoor temperature 80 deg F Low water temperature 70 deg F The end points x1 y1 and x2 y2 of the ODR curve are...

Page 227: ...d Lag Master to access the Lead Lag Operation screen Turn the Lead Lag Operation screen switch ON The system should now start when a demand is present 9 MONITORING SYSTEM PERFORMANCE Press VIEW LEAD L...

Page 228: ...tate of any slave is Unknown it will be removed from the display Note If during operation an alert NO SLAVES AVAILABLE FOR LEAD LAG occurs While not a lockout condition this alert will close the alarm...

Page 229: ...S Figure 4 through Figure 8 show piping and network wiring for some typical lead lag network configurations Systems shown are examples only Actual installations may vary Figure 9 Falcon Lead Lag with...

Page 230: ...Falcon Lead Lag Appendix E E 22 Figure 10 Falcon Lead Lag with outdoor reset and EMS for remote enable...

Page 231: ...Appendix E Falcon Lead Lag E 23 Figure 11 Falcon LL with EMS for remote enable remote setpoint...

Page 232: ...Falcon Lead Lag Appendix E E 24 Figure 12 Falcon Lead Lag with EMS for remote comms monitoring...

Page 233: ...HYDRONIC PIPING DIAGRAMS Figure 9 through Figure 12 below show some typical hydronic systems Examples of Pump Control Block PCB parameters for these and other systems can be found in Figure 13 throug...

Page 234: ...ump enable to Falcon Pump C relay terminals This configuration will ensure that as long as Falcon Lead Lag is enabled the lead boiler isolation valve will remain open When Lead Lag is disabled any pro...

Page 235: ...ach slave Use Boiler Pump control block Figure 14 assign to Pump B relay Use Aux 1 Pump Figure 17 assign to Pump C relay Figure 15 Primary Secondary Piping Boiler 1 Boiler 2 SUPPLY to system System pu...

Page 236: ...Falcon Lead Lag Appendix E E 28 PCB configuration same as Figure 10 Figure 16 Primary with dedicated system boiler pumps Boiler 1 Boiler 2 Supply from boilers Return to boilers...

Page 237: ...s lead lag Home page When DHW demand is satisfied the boiler will again be available to the lead lag network At each Slave use Aux 1 Pump Figure 17 for isolation valve assign Pump B At Master host us...

Page 238: ...p Logout Control Settings Pump Configuration On options Force on Force off Misce Central Heat DHW Local Lead Lag Frost Protection Aux pump Local burner demand Demand Demand Pump demand Central Heat X...

Page 239: ...ead Lag Frost Protection Aux pump Local burner demand Demand Demand Pump demand Central Heat X is set Z is set Y is set Service active Service active Service active DHW This setting may be inhibited d...

Page 240: ...g Frost Protection Aux pump Local burner demand Demand Demand Pump demand Central Heat X is set Z is set Y is set Service active Service active Service active DHW This setting may be inhibited due to...

Page 241: ...Lag Frost Protection Aux pump Local burner demand Demand Demand Pump demand Central Heat X is set Z is set Y is set Service active Service active Service active DHW This setting may be inhibited due t...

Page 242: ...rost Protection Aux pump Local burner demand Demand Demand Pump demand Central Heat X is set Z is set Y is set Service active Service active Service active DHW This setting may be inhibited due to bur...

Page 243: ...Aux pump Local burner demand Demand Demand Pump demand Central Heat X is set Z is set Y is set Service active Service active Service active DHW This setting may be inhibited due to burner fault or di...

Page 244: ...Falcon Lead Lag Appendix E E 36 13 Boiler Wiring Diagrams Model CFC ClearFire condensing boiler...

Page 245: ...Appendix E Falcon Lead Lag E 37 Model CFW ClearFire hydronic boiler...

Page 246: ...Falcon Lead Lag Appendix E E 38 Model CFV CFH ClearFire steam boiler START PERMISSIVE INDICATES CONNECTION MUST BE CLOSED TO ALLOW BOILER START...

Page 247: ...g to the slave Falcon controls via Modbus Falcon devices utilize two ModBus ports MB1 and MB2 for communications One port will be designated to support a system display and the other port will support...

Page 248: ...even cross over each other Certainly it is incorrect to do this and it would take a very deliberate and non accidental act to accomplish it But there are two points in this 1 LL master does not preven...

Page 249: ...e persisted When all criteria have been met for a sufficient time then an Add stage request is active Drop stage method Drop stage detection timing Drop stage request A Drop stage method implements th...

Page 250: ...a b c a LL MASTER SLAVE 1 SLAVE 2 a SLAVE 4 SLAVE 3 MB1 MB2 MB1 MB2 MB1 MB2 MB1 MB2 J3 J3 J3 J3 b c a b c a b c a b c b c a b c a Display wiring typical for remaining slaves Bldg EMS 3rd Party MODBUS...

Page 251: ...d setting calculation settings will be based only on available boilers e Master boiler lockout If the master boiler is in lock out then its burner control function will be skipped in the rotation the...

Page 252: ...con control to support operation when a LL master exists The illustration below summarizes the slave s registers and data LL Slave Some slave changes relate to pump control frost protection and also a...

Page 253: ...paring to fire to serve that demand Otherwise it will be clear Aux Pump X Y and Z The pump control in the Slave can be used by previously existing command devices to create the same behavior However b...

Page 254: ...ed to start It should be set to the total time normally needed for the burner to transition from Standby to Run including such things as transition to purge rate prepurge time transition to ligh toff...

Page 255: ...purge rate prepurge time transition to lightoff rate all ignition timings and some extra margin f CT Burner run time This parameter will be needed if measured run time equalization is being used Slave...

Page 256: ...master to the slave Features common to all states Whenever a slave device is not in an expected condition then a recovery function is used to set up timers to give a faulty slave minimum time that it...

Page 257: ...the AddStage state remains that way until the ProcessSlaveStatus moves it to Firing or some other state or the Stager times out and moves it into the Recovering state if it fails to fire SuspendStage...

Page 258: ...CH demand to end If WWSD is true then when the Outdoor temperature is below the value provided by Warm weather shutdown setpoint minus 4 F 2 2 C then WWSD becomes false When warm weather shutdown is...

Page 259: ...is inhibiting CH demand if any MASTER SERVICE STATUS Is a data item used by pump control logic that combines the Master Heat Demand and Master Active Service data It is implemented as described by th...

Page 260: ...Outlet is selected then the outlet temperature of the lead boiler will be used as the backup during firing If Slave Outlet Average is selected then average of the outlet temperatures of all slave boil...

Page 261: ...ime of Day has one sources of control a switch contact Closed TOD is an on condition open then TOD is off OUTDOOR RESET AND BOOST BOOST IS FUTURE The outdoor reset and boost functions for the LL CH fu...

Page 262: ...he examples below are ways in which this may occur but in implementation what is necessary first of all is to use a rate allocator that assigns rate to each slave and can detect when all of the assign...

Page 263: ...what to do about that or if it is not firing it will remain off Disabled same as Available Recovering same as Available It next runs a rate allocator that depends upon the rate allocation method This...

Page 264: ...ve the same firing rate Only the Base load common parameter is used for base loading the individual slave s base load values are ignored As load increases Until all stages are Firing No stage is reque...

Page 265: ...operates according to this state transition diagram The stager has the following variables StagerState encodes the current state of the stager StagerTimer multipurpose 1 second timer used by states wh...

Page 266: ...rced to be Idle When burner demand becomes true Call for Heat the stager checks the sequencer to identify the lead boiler That boiler is given a command to start The stager resets to verify it is at 0...

Page 267: ...e or DropStage request Add Stage Methods Various methods can be used to determine when a new stage should be added The internal algorithms that generate AddStageRequests are called Add stage methods A...

Page 268: ...this the current Rate Allocation method asks for the current Overflow rate see the Rate Allocator section Drop Stage Methods Various methods can be used to determine when a stage should be dropped Th...

Page 269: ...stage condition will occur when the last stage is at the minimum modulation rate rate offset 20 The Drop stage condition will occur if the last stage is at minimum modulation and there is 20 less rat...

Page 270: ...abled and the lead is firing solo then simply reaching the drop stage threshold causes a dropstage event that causes the lead to turn off and rf3259 which thus ends LL master demand until the operatin...

Page 271: ...ed by LeadBoilerSeqNum is neither Available nor Firing i e it has a fault or is OnLeave or the LeadBoilerRunTime value exceeds Lead rotation time In either of these cases the algorithm performed is If...

Page 272: ...e slave status message to be read by a CB Falcon Master It includes all of the data that is read from a slave SLAVE MODE USE FIRST EQUALIZE RUNTIME USE LAST If set to Use First then this slave will be...

Page 273: ...ngle Modbus address to service the requests of the Modbus Master on the RS 485 network Definitions The following definitions apply in this appendix Modbus Application layer communication protocol stan...

Page 274: ...changed here if necessary selectable between 38400 19200 or 9600 4 Go to the Gateway tab Make sure Enable Modbus Gateway is checked Select Gateway on COM2 port NOTE The Modbus Gateway must be enabled...

Page 275: ...writes and 125 registers for reads Data is mapped into logical groups with room for future expansion so some gaps exist in the register map Data organization is intended to allow for efficient registe...

Page 276: ...tection 8 No demand due to burner switch register 199 turned off 9 DHW storage 10 Mix 0007 0007 Outlet Limit channel R U16 40 130 0 1 C precision 0008 0008 Firing rate R U16 Actual firing rate or RPM...

Page 277: ...Pressure 17 Annunciator 7 18 Annunciator 8 0025 0037 Annunciator hold R U16 Source for burner control hold condition see Hold code 0 None or undetermined 1 ILK 2 PII 3 LCI 11 Annunciator 1 Interrupted...

Page 278: ...1 0065 0101 DHW pump start delay time R U16 Count down seconds when DHW pump is delayed from starting 0066 0102 DHW pump overrun time R U16 Running overrun time for DHW pump seconds 0067 0103 DHW FP o...

Page 279: ...HW disabled 1 DHW enabled 01C5 0453 DHW setpoint R W U16 40 130 0 1 C precision 01C6 0454 DHW time of day setpoint R U16 40 130 0 1 C precision Setpoint when Time Of Day switch is on 01C7 0455 DHW on...

Page 280: ...Turn on System pump with overrun 11 Turn on System pump with no overrun 10 Turn on Auxiliary pump 9 Reserved always 0 8 Commanded rate is binary fraction 7 0 Commanded rate 0236 0566 Base load rate R...

Page 281: ...73 Alert log record 9 R U16 9th newest alert 0496 049B 1174 1179 Alert log record 10 R U16 10th newest alert 049C 04A1 1180 1185 Alert log record 11 R U16 11th newest alert 04A2 04A7 1186 1191 Alert l...

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Page 283: ...APPENDIX F Falcon Program Module...

Page 284: ......

Page 285: ...Appendix F Program Module F 3...

Page 286: ...Program Module Appendix F F 4...

Page 287: ...Appendix F Program Module F 5...

Page 288: ...Program Module Appendix F F 6...

Page 289: ......

Page 290: ...e mail info cleaverbrooks com Web Address http www cleaverbrooks com...

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