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CleaverBrooks CFC-1000, Operation, Service And Parts Manual

The CleaverBrooks CFC-1000 brings reliable heating and steam production for industrial purposes. To ensure efficient operation and easy maintenance, download the comprehensive Operation, Service and Parts Manual from our website. It's the ideal resource, offering detailed instructions and technical information - available for free download at manualshive.com.

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CB FALCON

750-265

66

IMPORTANT 

1. If the system fails to perform properly, note the fault code, 

fault message, equipment status, and sequence time on 
the display. Then refer to the Fault Code section in this 
manual.

2. Repeat all required Checkout tests after all adjust-

ments are made. All tests must be satisfied with the 
flame detector(s) in their final position.

Equipment Recommended

•

833-3577 Display/Operator Interface Module.

•

Volt-ohmmeter (1M ohm/volt minimum sensitivity) with: 
0-300 Vac capability. 0-6000 ohm capability. 0-10 Vdc 
capability.

Checkout Summary

Table 1 provides an overview of checkout steps performed for 
each applicable system.

See the product data sheet for location of component parts 
terminal locations.

Table 32. Checkout steps and applicable systems.

Preliminary Inspection

Perform the following inspections to avoid common problems. 
Make certain that:

1.

Wiring connections are correct and all screws are tight.

2.

Flame detector(s) is clean, installed and positioned prop-
erly. Consult the applicable Instructions.

3.

Combination connector J1 wiring and flame detector(s) 
are correctly used. See product data sheet for wiring.

4.

Burner is completely installed and ready to fire; consult 
equipment manufacturer’s instructions. Fuel lines are 
purged of air.

5.

Combustion chamber and flues are clear of fuel and fuel 
vapor.

6.

Power is connected to the system disconnect switch 
(master switch). 

7.

Lockout is reset (reset button) only if the Falcon unit is 
powered. 

8.

System is in STANDBY condition. STANDBY message is 
displayed on the 833-3577 Falcon Display. 

9.

All limits and interlocks are reset. 

Flame Signal Measurement 

Install a DC voltmeter in the Falcon test jacks. Observe polarity 
when connecting meter leads.

INITIAL LIGHTOFF CHECKS

Proved Pilot Systems

Perform this check on all installations that use a pilot. It should 
immediately follow the preliminary inspection.

NOTE:

Low fuel pressure limits, if used, could be open. If so, 
bypass them with jumpers during this check.

1.

Open the master switch.

2.

Make sure that the manual main fuel shutoff valve(s) is 
closed. Open the manual pilot shutoff valve. If the pilot 
takeoff is downstream from the manual main fuel shutoff 
valve(s), slightly open the manual main valve to supply 
pilot gas flow. Make sure the main fuel is shut off just 
upstream from the burner inlet, or disconnect power from 
the automatic main fuel valve(s).

3.

Close the master switch and start the system with a call 
for heat by raising the setpoint of the operating controller; 
see the operating sequence. The Falcon should start the 
INITIATE sequence.

4.

Let the sequence advance to PILOT IGN (status is 
displayed on the 833-3577 Display/Operator Interface, if 
used). The PILOT valve energizes, ignition spark should 
occur, and the pilot flame should light. If the pilot ignites, 
the FLAME LED is energized. Go to step 7.

5.

If the pilot flame is not established during the PFEP (pilot 
flame establishing period), safety shutdown occurs. Let 
the sequence complete its cycle.

6.

Push the reset pushbutton and let the system recycle 
once. If the pilot flame still does not ignite, make the fol-
lowing ignition/pilot adjustments:

EXTERNAL IGNITION SOURCE

a. Open the master switch and remove the Falcon con-

nector J5.

b. Ensure that both the manual pilot shutoff valve and 

the manual main shutoff valves are closed.

c. On connector J5, jumper power to the ignition termi-

nal J5 terminal 4. Disconnect the leadwire to the pilot 
valve if it is connected to the same terminal.

d. Close the master switch to energize only the ignition 

transformer.

e. If the ignition spark is not strong and continuous, 

open the master switch and adjust the ignition 
electrode spark gap setting to the manufacturer’s 
recommendation.

f.

Make sure the ignition electrodes are clean.

g. Close the master switch and observe the spark.
h. After a continuous spark is obtained, open the 

master switch and add a jumper on the Connector J5 
terminal 2 or reconnect the pilot valve lead wire if it 
was disconnected in step b.

i.

Open the manual pilot shutoff valve.

j.

Close the master switch to energize both the ignition 
transformer and the pilot valve.

Checkout Step

Piloted 

Systems

DSI 

Systems

Flame 

Rod 

Systems

Ultraviolet 

Flame 

Detectors

Preliminary Inspection

X

X

X

X

Flame Signal 
Measurement

X

X

X

X

Initial Lightoff Check for 
Proved Pilot

X

Initial Lightoff Check for 
Direct Spark Ignition

X

Pilot Turndown Test

X

Ignition Interference 
Test

X

Hot Refractory Hold-in 
Test

X

Ignition Spark Pickup

X

Response to Other 
Ultraviolet Sources

X

Flame Signal with Hot 
Combustion Chamber

X

X

X

X

Safety Shutdown Tests

X

X

X

X

Summary of Contents for CFC-1000

Page 1: ...Manual Part No 750 263 07 2010 Model CFC ClearFire Condensing Boiler Operation Service and Parts ...

Page 2: ...ecified 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 boiler Instead turn off the gas supply at a location external to the boiler DANGER WARNING Do not use this boiler if any part has been under water Immediately call your Cleav er Brooks service representative to in spect the bo...

Page 3: ...lation The installation must conform to the re quirements of the authority having juris diction or in the absence of such requirements to the National Fuel Gas Code ANSI Z223 1 and or CAN CSA B149 Installation Codes DANGER WARNING The boiler and its individual shutoff valve must be disconnected from the gas sup ply piping system during any pressure testing of that system at test pressures in exces...

Page 4: ...d to show 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 normal operation will continue indefinitely Malfunctions of controls lead to uneco nomical operation and damage and in most cases these conditions can be traced directly to carelessness and deficien...

Page 5: ...ndensate tank setup options 2 30 Condensate piping for multiple boilers 2 31 Electrical connections 2 32 Wiring diagrams 2 34 Section 3 Stack and Intake Vent Sizing and Installation Venting Connections General 3 2 Appliance Categories 3 2 Vent Stack 3 2 Vent Terminal Location 3 3 Horizontal Thru Wall Venting Inside Combustion Air 3 5 Installation 3 5 Horizontal Thru Wall Stack Vent Termination 3 6...

Page 6: ...tches and CAPS 4 19 Low Water Cutoff Check 4 21 Low and High Fire Adjustments 4 21 Modulation OFF point 4 21 Setting Combustion 4 22 High Air Pressure Switch settings 4 23 Limit Controls Check 4 23 Post start up checkout procedure 4 24 Procedures for LP Propane Gas 4 25 Single Fuel Units 4 25 Units with optional dual fuel gas train 4 26 Falcon Control Functions and Customer Interface 4 28 Section ...

Page 7: ... www cleaver brooks com Section 1 Introduction CFC Features and Benefits 1 2 Standard Equipment 1 3 The Boiler 1 3 The Burner 1 3 Burner Gas Train 1 3 Control 1 4 Component Connection Locations 1 5 Optional Equipment 1 5 ...

Page 8: ...steel enclosures are readily removable for access to all key components A flip down step and hinged burner door provide access to all key components Quality Construction ASME construction 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 combustion fan m...

Page 9: ...provides 5 1 turndown Combustion canister of the burner is constructed of a Fecralloy metal fiber for solid body radiation of the burner flame which provides low emissions At maximum firing rate the sound level of the burner is less than 70 dBA measured in front of the boiler at a distance of 3 feet Provision for direct vent combustion is furnished 3 Burner Gas Train See Figure 1 5 Figure 1 6 The ...

Page 10: ...vision Safety shutdown with time stamped display of lockout condition Variable speed control of the combustion fan Supervision of low and high gas pressure air proving stack back pressure high limit and low water First out annunciator Real time data trending 3 pump auxiliary relay outputs Modbus communication capability Outdoor temperature reset Remote firing rate or setpoint control Setback time ...

Page 11: ...e been supplied with the boiler if these options were specified at the time of order entry In addition some options may have been provided by others that are not part of Cleaver Brooks scope of supply In either case the Cleaver Brooks authorized representative should be consulted for project specifics These are the options that are available for the CFC boiler from Cleaver Brooks A Dual gas train ...

Page 12: ... Component Orientation Combustion Fan and Premix Gas Valve Assembly Control Panel Finned High Efficiency AluFer Tubes Flue Gas Outlet Low Temp Return Hot Water Outlet Safety Relief Valve Insulation Blanket Ignition Electrodes Flame Rod Burner Canister High Temp Return and ...

Page 13: ...ection 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: ...ure 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 Vent Sizing and Installation Figure 1 11 Outlet Temperature Sensor Top of Pressure Vessel Figure 1 12 Stack Right Side viewed from rear ...

Page 15: ...Boiler room 2 14 Gas connections 2 15 General 2 15 Gas train components 2 15 Gas pressure requirements 2 15 Gas piping 2 16 Gas supply pipe sizing 2 17 Gas header 2 20 Boiler water piping 2 22 General 2 22 Safety valve 2 22 Pressure drop curves 2 22 Condensate removal and treatment 2 29 Condensate tank setup options 2 30 Condensate piping for multiple boilers 2 31 Electrical connections 2 32 Wirin...

Page 16: ...ppliance operation and sevice Failure to follow this warning could result in equipment failure Caution The installation must conform to the require ments of the authority having jurisdiction or in the absence of such requirements to the National Fuel Gas Code ANSI Z223 1 and or CAN CSA B149 Installation Codes If an external electrical source is utilized the boiler when installed must be electrical...

Page 17: ...ll piping connections attached prior to installation of the casing 2 Boiler placement The boiler or boilers should be mounted in a space in accordance with Figure 2 1 below Required front rear and side clearances are shown Note If the boiler room is constructed with non combustible walls it is possible to install the units closer to the side walls but the front and rear clearances must be maintain...

Page 18: ...ler When using a crane observe the rigging arrangement shown in Figure 2 3 To install the boiler legs first lift boiler then remove and discard the wooden base Install legs and position the boiler Proceed with step 10 below Figure 2 2 Flat head screwdriver Phillips screwdriver Cordless screwdriver Utility knife Crescent wrench Machine head screw bit Diagonal cutters Fork lift or pallet jack Socket...

Page 19: ...12 Peel backing from any excess length of insulation Tuck excess portion under other end of blanket Place backing over overlapping segments Figure 2 5 and proceed with step 13 13 Use tension springs to hold edges of blanket together Poke end of spring through the fabric of the insulation blanket Figure 2 6 Place one spring at the top and one at the bottom of the blanket Place the remaining two spr...

Page 20: ... of the boiler Figure 2 8 16 Attach electrical supply channels on each side Figure 2 9 17 Attach large side panels to each side fitting on top of the electrical supply channel Fasten loosely using nuts and washers previously removed Do not over tighten You will need these panels to move slightly to fit the other pieces See Figure 2 10 Figure 2 7 Figure 2 8 Figure 2 9 ...

Page 21: ...gure 2 11 Make sure to route sensor wires in wiring channel on left hand side of the boiler see also Figure 2 41 20 Connect control wiring Figure 2 12 Connect flame rod cable A to stand alone electrode on right includes burner ground connection Connect ignition cables B to dual igniter electrode Connect remaining connectors per connection diagram see Figure 2 41 Figure 2 10 Figure 2 11 ...

Page 22: ...r panel Coat sensor with heat conductive compound P N 872 00631 Insert sensor into return pipe sensor well and secure with mounting clamp Figure 2 13 22 Coat outlet feed water temperature sensor the 3 wire sensor with heat conductive compound P N 872 00631 Insert sensor in sensor well behind the burner Figure 2 14 Figure 2 12 A B Figure 2 13 ...

Page 23: ... 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 panels to boiler legs using the supplied cap nuts Figure 2 17 Figure 2 14 Figure 2 15 Figure 2 16 ...

Page 24: ...complete B FLUE GAS COMBUSTION AIR CONNECTIONS The flue gases from the Model CFC boiler should be removed via a gas tight temperature and corrosion resistant flue gas pipeline Only flue gas systems approved and tested by the relevant region or province are to be connected to the boiler Refer to flue piping Figure 2 17 Figure 2 18 ...

Page 25: ... ferrous materials and corrosion resistant stainless steel The chloride content of the heating water must not exceed 30 mg l and the pH level should be between 8 3 to 9 5 after six weeks of operation To maintain the boiler s efficiency and prevent overheating of the heating surfaces the values in Table 2 1 should not be exceeded Water make up during the lifetime of the boiler should not be greater...

Page 26: ...ced to below 7 0 frequently reaching 5 and acid corrosion results Thus when pH levels drop below 7 0 due to glycol degradation the only alternative is to drain flush repassivate and refill with a new inhibited glycol solution The following recommendations should be adhered to in applying ClearFire model CFC boilers to hydronic systems using glycol 1 Maximum allowable antifreeze proportion volume 5...

Page 27: ...33 CFC 1000 175 88 58 44 CFC 1500 263 131 88 66 CFC 1800 316 158 105 79 CFC 2500 438 219 146 110 Notes Limitations 1 Maximum firing rate determined by ClearFire CFC Glycol Firing Rate Limitation chart below Maximum high fire blower speed should be set according to chart 2 Glycol concentration limit of 25 50 Minimum required system operating pressure is 30 psig 3 Maximum system operating temperatur...

Page 28: ...t Vent Combustion Air kits available CFC Maximum Firing Rate vs Glycol Concentration 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 25 30 35 40 50 Glycol Content Maximum Input Rate Max Firing Rate CFC High Fire Speed Setting vs Glycol 3400 3600 3800 4000 4200 4400 4600 4800 5000 5200 5400 25 30 35 40 50 Glycol Content High Fire Speed RPM CFC 500 750 1000 1500 HF RPM CFC 1800 HF RPM CFC 2500 HF R...

Page 29: ... to operate for the highest combustion efficiency for the CFC units 3 Gas Pressure Requirements For proper and safe operation each CFC Series boiler requires a stable gas pressure input See Table 2 3 for pressure requirements Actual gas pressure should be measured when the burner is firing using a manometer at the upstream test port connection on the main gas valve For a multiple unit installation...

Page 30: ...ng gas piping tests If necessary a strainer should be installed upstream of the regulator to remove debris from the gas supply Drip legs are required on any vertical piping 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 disassembling any gas piping The connec...

Page 31: ...nces are firing The total length of gas piping and all fittings must be considered when sizing the gas piping Total equivalent length should be calculated from the utility meter or source to the final unit connection As a minimum guideline see gas piping Tables 2 4 and 2 5 The data in these tables is from the NFPA 54 source book 2006 edition To verify the input of each device that is connected to ...

Page 32: ...0 284 583 873 1 680 2 680 4 740 9 660 40 243 499 747 1 440 2 290 4 050 8 290 50 215 442 662 1 280 2 030 3 590 7 330 60 195 400 600 1 160 1 840 3 260 6 640 70 179 368 552 1 060 1 690 3 000 6 110 80 167 343 514 989 1 580 2 790 5 680 90 157 322 482 928 1 480 2 610 5 330 100 148 304 455 877 1 400 2 470 5 040 125 131 269 403 777 1 240 2 190 4 460 150 119 244 366 704 1 120 1 980 4 050 175 109 209 336 64...

Page 33: ...768 1 150 2 220 3 530 6 250 12 70 0 40 320 657 985 1 900 3 020 5 350 10 90 0 50 284 583 873 1 680 2 680 4 740 9 600 60 257 528 791 1 520 2 430 4 290 8 760 70 237 486 728 1 400 2 230 3 950 8 050 80 220 452 677 1 300 2 080 3 670 7 490 90 207 424 635 1 220 1 950 3 450 7 030 100 195 400 600 1 160 1 840 3 260 6 640 125 173 355 532 1 020 1 630 2 890 5 890 150 157 322 482 928 1 480 2 610 5 330 175 144 29...

Page 34: ... firing Pipe sizes based on Table 2 4 Table 2 6 Multiple Unit Manifold CFC 500 Table 2 7 Multiple Unit Manifold CFC 750 CFC 500 Boilers of Units 1 2 3 4 Pipe Size to Boiler 1 1 1 1 Header Pipe size 1 1 4 1 1 4 1 1 2 2 CFC 750 Boilers of Units 1 2 3 4 Pipe Size to Boiler 1 1 1 1 Header Pipe size 1 1 4 1 1 2 2 2 1 2 Table 2 8 Multiple Unit Manifold CFC 1000 Table 2 9 Multiple Unit Manifold CFC 1500 ...

Page 35: ...Section 2 Installation Part No 750 263 2 21 Figure 2 23 Gas Piping ...

Page 36: ...rial around the valve seat area Apply only a moderate amount of pipe compound to male threads and avoid overtightening which can distort the seats Use only flat jawed wrenches on the flats provided 3 Dual return design The Model CFC features separate high and low temperature return water connections allowing for condensing performance within high temperature hydronic systems With as little as 10 r...

Page 37: ...essure 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 30 8 35 2 39 6 44 48 4 52 8 57 2 61 6 66 70 4 131 Flow GPM Pressure PSI Hydraulic Resistance CFC 500 Metric 0 5 10 15 20 25 30 0 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Flow m3 h Pressure mbar ...

Page 38: ...gure 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 1 3 2 2 2 0 1 3 0 8 3 9 6 4 8 4 5 7 2 6 6 1 3 1 Flow GPM Pressure PSI Hydraulic Resistance CFC 750 Metric 0 5 10 15 20 25 30 0 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Flow m3 h Pressure mbar ...

Page 39: ...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 88 110 132 154 176 Flow GPM Pressure PSI Hydraulic Resistance CFC 1000 0 10 20 30 40 50 60 70 80 0 2 5 10 15 20 25 30 35 40 Flow m3 h Pressure mbar ...

Page 40: ...re 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 8 2 0 8 8 22 44 66 88 110 132 154 176 198 220 242 264 Flow GPM Pressure PSI Hydraulic Resistance CFC 1500 Metric 0 20 40 60 80 100 120 140 0 2 5 10 15 20 25 30 35 40 45 50 55 60 Flow m3 h Pressure mbar ...

Page 41: ...ve 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 8 0 8 8 22 44 66 88 110 132 154 176 198 220 242 264 286 308 330 352 Flow GPM Pressure PSI Hydraulic Resistance CFC 1800 Metric 0 20 40 60 80 100 120 0 2 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 Flow m3 h Pressure mbar ...

Page 42: ...264 286 308 330 352 375 395 420 474 Flow GPM Pressure PSI 10 20 30 40 50 60 70 80 90 100 110 120 500 95 48 33 24 19 16 12 11 10 5 9 8 7 750 131 66 44 33 26 22 19 16 15 13 12 11 1000 176 88 59 44 35 29 25 22 20 18 16 15 1500 260 130 87 65 52 43 37 33 29 26 24 23 1800 351 176 117 88 70 59 50 44 39 35 32 30 2500 470 235 157 118 95 79 67 59 52 48 43 39 Recommended flow rates relative to temperature dr...

Page 43: ...drain systems are determined by the local authorities and municipalities Condensate leaving the boiler normally has a pH of 4 6 The responsible authority will inform you if a higher pH value is required for condensate piped to drain The CFC neutralization system contains the granulate NEUTRALAT a natural compound which acts to increase the pH of the condensate flowing through it The neutralization...

Page 44: ...Figure 2 38 4 bags of neutralization media are sufficient to fill the tank Install the condensate tank cover and slide the complete assembly under the boiler Pipe to the appropriate drain The neutralization media will require periodic replacement to be detemined by pH analysis of condensate If condensate is too acidic pH is below acceptable value the neutralization media should be replaced The neu...

Page 45: ... the connection shown in order to prevent flue gas from entering an idle boiler An internal float in the condensate tank activates the make up water valve Figure 2 39 Condensate Piping for Multiple Boilers Figure 2 40 Condensate Treatment Tank for Multiple Boilers To Drain 1 4 O D Make up Water Supply Condensate Drain Trap Neutralization Tank To Drain Condensate Drain Trap 1 NPT Minimum Header Siz...

Page 46: ... power is to be connected to the incoming power terminals 1 Power wiring right side electrical supply channel 2 Customer connections should be brought in on the right side refer to wiring diagram 3 Temperature sensor wiring left side electrical supply channel Note The following temperature sensor cables should be run through the left side wiring channel Hot water outlet temperature sensor Hot wate...

Page 47: ...Section 2 Installation Part No 750 263 2 33 Figure 2 41 Electrical Connection Diagram ...

Page 48: ...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 provided with the boiler ...

Page 49: ...Section 2 Installation Part No 750 263 2 35 Figure 2 43 CFC Wiring Diagram dual fuel units ...

Page 50: ...Section 2 Installation 2 36 Part No 750 263 ...

Page 51: ... Termination 3 6 Horizontal Thru Wall Venting Direct Vent Combustion Air 3 6 Installation 3 7 Horizontal Thru Wall Stack Vent Termination 3 7 Vertical Venting Inside Combustion Air 3 8 Vertical Venting Direct Vent Combustion Air 3 9 Stack Sizing 3 10 Stack design using room air for combustion 3 10 Stack design using direct vent combustion 3 11 Venting for multiple units 3 12 Combustion Air Boiler ...

Page 52: ...sure and with a vent gas temperature that may cause excessive condensate production in the vent Depending on the application the Model CFC may be considered Category II III or IV The specifying engineer should dictate flue venting as appropriate to the installation For additional information on boiler categorization see appropriate ANSI Z21 Standard and the latest edition Standard of National Fuel...

Page 53: ...outside in cold climates for venting combustion gas 5 Through the wall vents for Category II and IV appliances and non categorized condensing appliances shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of other equipment Where local experience indicates that condensate is a problem with Cat...

Page 54: ...ellings and serves both dwellings 2 Less than 7 ft 2 13m above a paved sidewalk or paved driveway located on public property 3 Within 6 ft 1 8m of a mechanical air supply inlet to any building 4 Above a meter regulator assembly within 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 l...

Page 55: ...oom and the vent is installed horizontally through the wall to the outside Adequate combustion and ventilation air must be supplied to the boiler room in accordance with the National Fuel Gas Code or in Canada the latest edition of CAN CSA B 149 1 and 2 Installation Code for Gas Burning Appliances and Equipment The direct vent cap is not considered in the overall length of the venting system The v...

Page 56: ...uilding The stack vent cap cannot be installed in a well or below grade The stack vent cap must be installed at least one l foot above ground level and above normal snow levels Warning No substitutions of flue pipe or vent cap material are allowed Such substitutions would jeopardize the safety and health of inhabitants The stainless steel direct vent cap must be furnished in accordance with AGA CS...

Page 57: ...s The stack vent is to be insulated through the length of the horizontal run 2 Horizontal Thru Wall Stack Vent Termination The stack vent cap MUST be mounted on the exterior of the building The stack vent cap cannot be installed in a well or below grade The stack vent cap must be installed at least one I foot above ground level and above normal snow levels Multiple stack vent caps should be instal...

Page 58: ...ith AGA CSA requirements D VERTICAL VENTING INSIDE COMBUSTION AIR These installations utilize the boiler mounted blower to vent the combustion products to the outside Combustion air is taken from inside the room and the vent is installed vertically through the roof to the outside Adequate combustion and ventilation air must be supplied to the boiler room in accordance with the National Fuel Figure...

Page 59: ...of flue pipe or vent cap material are allowed Such substitutions would jeopardize the safety and health of inhabitants The Stainless Steel non restricted direct vent cap must be furnished in accordance with AGA CSA requirements E VERTICAL VENTING DIRECT VENT COMBUSTION AIR These installations utilize the boiler mounted blower to draw combustion air from outside and vent combustion products to the ...

Page 60: ...rdance with AGA CSA requirements F STACK SIZING 1 Stack design using room air for combustion Table 3 1 STACK DESIGN SINGLE BOILER USING ROOM AIR Boiler Size Boiler Flue Connection Maximum length of breeching or stack feet CFC 500 6 Standard 80 CFC 750 6 Standard 60 CFC 1000 8 Standard 140 6 Option 80 10 Option 200 CFC 1500 10 Standard 80 8 Option 60 12 Option 120 CFC 1800 12 Standard 100 10 Option...

Page 61: ...dard 4 40 40 6 50 50 CFC1000 8 Standard 6 60 60 6 Option 6 40 40 10 Option 6 80 80 CFC1500 10 Standard 6 40 40 8 60 60 8 Option 6 30 30 8 40 40 12 Option 6 60 60 8 80 80 CFC1800 12 Standard 6 50 50 8 80 80 10 Option 6 40 40 8 55 55 CFC 2500 12 Standard 8 100 100 Each additional 90 elbow equals 5 equivalent feet of ductwork Subtract from the maximum or minimum length accordingly Increasing the diam...

Page 62: ...e connections not tees to connect each boiler to the common breeching see Examples 1 and 2 below Breeching should be sized upward when necessar y to accommodate additional boilers see Example 3 As a rule of thumb the cross sectional area of any ductwork downstream of a wye connection should be equal to or greater than the combined area of the incoming vent sections When multiple boilers are connec...

Page 63: ...ion 3 Stack and Intake Vent Sizing and Installation Part No 750 263 3 13 EXAMPLE 2 EXAMPLE 3 6 10 45o 6 GOOD BAD 6 10 14 6 6 6 From Boilers 6 6 6 6 From Boilers 6 6 GOOD BAD 8 12 16 8 8 8 From Boilers GOOD ...

Page 64: ...ke In accordance with NFPA54 the required volume of indoor air shall be determined in accordance with the Standard Method or Known Air Infiltration Rate Method Where the air infiltration rate is known to be less than 0 40 Air Changes per Hour the Known Air Infiltration Rate Method shall be used see Section 8 3 in the NFPA54 Handbook for additional information 1 Air Supply Unconfined Spaces For U S...

Page 65: ...ngs one terminating within twelve inches from the top and one opening terminating within twelve inches of the bottom of the room 2 The openings must be linked directly Figure 3 5 or by ducts Figure 3 6 with the outdoors 3 Each opening must have a minimum free area of one square inch per 4 000 Btu per hour of total input rating of all equipment in the room when the opening is directly linked to the...

Page 66: ...and 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 rating of all equipment located in the enclosure and not less than the sum of the areas of all vent connectors in the confined space 3 Refer to the NFGC Section 8 3 for additional information GAS VENT ...

Page 67: ...low a height of 7 feet This allows air to sweep the length of the boiler See Figure 3 8 B Air supply openings can be louvered for weather protection but they should not be covered with fine mesh wire as this type of covering has poor air flow qualities and is subject to clogging with dirt and dust C A vent fan in the boiler room is not recommended as it could create a slight vacuum under certain c...

Page 68: ...kBtuh up to 1000 feet elevation Add 3 more per 1000 feet of added elevation 3 Acceptable air velocity in the Boiler 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 Clearfire 1800 boilers at 750 feet elevation The air openings to be 5 feet above floor level Air required 1800 x 2 3600 kBtuh From 2...

Page 69: ...and Maintenance manual 2 Provide for adequate ventilation of the boiler room or mechanical equipment room 3 In cold climates and to mitigate potential freeze up of the intake pipe it is highly recommended that a motorized sealed damper be used to prevent the circulation of cold air through the boiler during non operating hours 4 Refer to Figure 3 2 and Figure 3 4 for suggested piping of direct ven...

Page 70: ...Section 3 Stack and Intake Vent Sizing and Installation 3 20 Part No 750 263 ...

Page 71: ...gs 4 17 Initial start up procedure 4 18 Gas Train and Piping 4 18 Power Up 4 19 Operation Check Gas Valve Gas Press Switches and CAPS 4 19 Low Water Cutoff Check 4 21 Low and High Fire Adjustments 4 21 Modulation OFF point 4 21 Setting Combustion 4 22 High Air Pressure Switch settings 4 23 Limit Controls Check 4 23 Post start up checkout procedure 4 24 Procedures for LP Propane Gas 4 25 Single Fue...

Page 72: ... the initial starting of the boiler After the burner has been properly set minor adjustments to these controls may be necessary for the particular installation For initial starting set the following controls accordingly 1 Combustion Air Proving Switch Set the dial minimum 2 Low Gas Pressure Switch Set the dial minimum 3 High Gas Pressure Switch Set the dial maximum 4 High Air Pressure Switch Set t...

Page 73: ... Central Heating and Domestic Hot Water loop control Password protection of configurable parameters Time of Day dual setpoint control High Stack Temperature limit Remote reset Lead Lag sequencing 3 configurable pump relays Remote modulation remote setpoint Frost protection Please review the tables within this Commissioning section to familiarize yourself with the functions and parameters of the Co...

Page 74: ...rizes boiler status and allows navigation to the configuration operational and diagnostic areas of the CB Falcon interface The Demand display will show one of the following Burner switch off Off burner switch on but no demand Central Heat Domestic Hot Water if configured Burner state shows the currently active step in the burner operating sequence The central portion of the display can be toggled ...

Page 75: ... three types Lockouts Holds and Alerts Lockouts and Holds indicate interruptions in boiler operation whether occurring as part of the normal operating sequence or due to an abnormal condition Lockouts require a manual reset to continue operation while Holds do not A Hold will automatically clear when the hold condition is removed or satisfied The most recent Lockouts are stored in CB Falcon memory...

Page 76: ... to cycle and hours the screen will show on off status of all interlocks at the time of the lockout This information can be used to help pinpoint the cause of a particular Lockout See also Chapter 5 Section E Troubleshooting F CONTROLLER CONFIGURATION The CB Falcon controller should be factory configured for the specific CFC boiler model Prior to starting the boiler verify that the factory default...

Page 77: ...reset enable Service Disabled 0215 Central Heat Configuration CH P gain Service 0 25 400 0216 Central Heat Configuration CH I gain Service 0 25 400 0217 Central Heat Configuration CH D gain Service 0 0 400 0218 Central Heat Configuration CH hysteresis step time Service 0 60 900 seconds 0219 Central Heat Configuration CH setpoint source Service Local SP 0578 Central Heat Configuration CH modulation...

Page 78: ...od PFEP Read Only 4 seconds 0233 Burner Control Ignition Main Flame Est Period MFEP Hidden NA seconds 0234 Burner Control Ignition Flame threshold OEM 0 5 0 8 5 V or μA 0250 Burner Control Flame Failure Ignite failure response Service Lockout 0239 Burner Control Flame Failure Ignite failure retries Service 1 0240 Burner Control Flame Failure Ignite failure delay Service 30 seconds 0241 Burner Cont...

Page 79: ... 0277 Pump Configuration DHW pump overrun time Service 0 60 28800 seconds 0278 Pump Configuration DHW pump frost protection overrun time Service 0 3600 28800 seconds 0279 Pump Configuration DHW pump start delay Service 0 0 28800 seconds 0280 Pump Configuration Boiler pump output Service No assignment 0281 Pump Configuration Boiler pump control Service Auto 0282 Pump Configuration Boiler pump overr...

Page 80: ...ycle time Service 0 60 28800 seconds 0179 System Configuration Alarm silence time Service 0 0 3600 seconds 0180 System Configuration Power up with lockout Read Only Do NOT clear lockout 0181 System Configuration Burner switch User Off 0203 System Configuration Blower HSI function Read Only Blower 0225 System Configuration Flame sensor type OEM Flame rod 0228 System Configuration Forced recycle int...

Page 81: ... response Service Recycle Delay w retry limit 0488 Delta T Limits Delta T enable Exchanger to outlet flow Service Disabled 0489 Delta T Limits Delta T degrees Exchanger to outlet flow Service 14 50 160 F 0490 Delta T Limits Delta T enable Inlet to Exchanger flow Service Disabled 0494 Delta T Limits Delta T degrees Inlet to Exchanger flow Service 14 50 160 F 0495 T rise Limit Outlet T rise enable S...

Page 82: ... OEM LOW WATER 0335 Annunciation Configuration Annunciator 4 location OEM ILK 0345 Annunciation Configuration Annunciator 4 short name OEM A4 0346 Annunciation Configuration Annunciator 4 long name OEM HIGH AIR PRESSURE 0348 Annunciation Configuration Annunciator 5 location OEM ILK 0358 Annunciation Configuration Annunciator 5 short name OEM A5 0359 Annunciation Configuration Annunciator 5 long na...

Page 83: ...d Lag Configuration Lead Lag on hysteresis Service 5 F 0549 Lead Lag Configuration Lead Lag off hysteresis Service 15 F 0550 Lead Lag Configuration Lead Lag hysteresis step time Service 60 seconds 0551 Lead Lag Configuration Lead Lag P gain Service 0 10 400 0552 Lead Lag Configuration Lead Lag I gain Service 0 25 400 0553 Lead Lag Configuration Lead Lag D gain Service 0 0 400 0554 Lead Lag Configu...

Page 84: ...age interstage delay Service 180 900 seconds 0731 Lead Lag Configuration Lead rotation time Service 1 24 hours 0733 Lead Lag Configuration Force lead rotation time Service 1 168 hours 0734 Lead Lag Configuration Boiler off options Service All Boilers Off option disabled 0736 Lead Lag Configuration All boilers off threshold Service 25 F 0737 Lead Lag Configuration Lead Lag CH ODR min outdoor temper...

Page 85: ...alue and press OK press Cancel to leave 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 Parameter Verification page will appear Press Begin to continue 2 The affected parameter group will be displayed showing current parameter values and a prompt Are these...

Page 86: ...Falcon is responsible for flame supervision and burner sequencing The CFC boiler uses direct spark ignition no gas pilot to light the main flame Flame sensing is accomplished with a flame rod or ionization electrode Basic burner sequencing Central Heat 1 Heat request detected Setpoint minus On Hysteresis LCI limits and demand detected terminals J6 3 and J8 3 2 The CH pump is switched on 3 After a ...

Page 87: ...or the forced off time set by the Anti Short Cycle if enabled 16 The pump stays on during the pump overrun time if enabled 17 At the end of the pump overrun time the pump will be switched off H FAN SPEED SETTINGS Because the input is determined by the fan speed fan speed settings may have to be modified for the particular application for high altitudes or when using direct vent combustion Table 4 ...

Page 88: ...e it is properly piped and wired 2 Review available gas pressure to assure it is compatible with the main gas regulators upstream of the Model CFC gas train Note The maximum rated inlet pressure to the CFC gas train is 1 2 psig 14 0 WC An upstream regulator and overpressure protection are required if building supply gas pressure is greater than 1 2 psig 3 To bleed air from the supply pipe open the...

Page 89: ...operation Before proceeding review Section 4 3 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 following safety checks use the CB Falcon Annunciation screen to monitor the status of the circuits involved Press Annunciation on the Operation page to access this screen LGPS Ta...

Page 90: ...low Switch OFF Note If the CAPS fails to open even when set to maximum test by disconnecting the low pressure line to the switch and initiating burner sequence The switch should now break during the purge cycle Reconnect low pressure side after a suc cessful CAPS check 4 Following a successful CAPS check dial the CAPS back to its minimum setting and reset the CB Falcon HGPS and GAS VALVE 1 Open th...

Page 91: ...t screws should initially be set to half way through each setting s range The low fire adjustment screw is accessed by removing the slotted cap on the gas regulator using a blade screwdriver see Figure 4 7 The high fire adjustment screw is accessed by removing the blue plastic cap from the valve cover Figure 4 8 Turn the adjustment screw completely clockwise counting the turns until the screw will...

Page 92: ...n 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 possi ble to the boiler vent connection Sampling too far from the boiler vent can produce false readings due to air diluting the flue gas 1 On the CB Falcon Operation screen press the Firing rate display in the Modulation section 2 A numeric keypad will appear...

Page 93: ... high fire Adjust the gas choke if necessary to obtain desired O2 6 7 7 Modulate to low fire and fine tune offset screw to obtain desired O2 6 7 Verify adjustments by modulating back and forth between low and high fire While setting combustion observe gas pressure at low fire and at high fire Ensure pressure is within limits shown in Table 4 3 8 High Air Pressure Switch settings The High Air Press...

Page 94: ...s 210 deg F The High Limit setting is considered a safety parameter Any changes made will require a password login and reset of the CB Falcon J POST START UP CHECKOUT PROCEDURE 1 Ensure proper air venting to expansion tank 2 Set high gas pressure switch to 50 higher than operating gas pressure at low fire Set low gas pressure switch to 50 lower than operating gas pressure at low fire 3 Check the d...

Page 95: ...e orifice see Table 4 4 Install the vortex breaker CFC 2500 only between venturi and blower with the main body of the vortex breaker in the vertical position Ensure gas train venturi connection is secure and gas tight Ensure venturi blower connection is tight Figure 4 10 LP Gas Setup Single Fuel 3 Connect power to the boiler Power up the controls 4 Access boiler control Configuration menu Press Lo...

Page 96: ...dure Proper combustion settings for LP gas on ClearFire boilers are between 6 5 7 5 O2 Table 4 4 Parts for LP Gas Notice When changing a single fuel unit from LP gas to natural gas the orifice gasket must be removed The vortex breaker may remain in place if desired If the vortex breaker remains installed fan speed settings will need to be adjusted upward from the normal natural gas settings 2 Unit...

Page 97: ...y parameter After changing the speed return to Configuration menu 10 Press Verify to check safety parameter change s Press Begin and check that all changes are correct Press Yes if correct If incorrect press No and return to appropriate parameter configuration menu to correct After all safety parameter changes are checked the controller requires a manual reset Open the panel and reset the control ...

Page 98: ...nt value next to Normal Clear the current value and enter the new value Press OK to establish the new set point The Time of Day TOD or setback set point is an alternative set point that is enabled when a remote contact connected to terminals J10 2 J10 3 is closed Refer to Figure 2 10 CFW wiring diagram When the circuit is open the boiler control reverts back to the normal set point The TOD set poi...

Page 99: ...d input is energized the demand is enabled The boiler operates on its local set point and PID modulating control settings For remote modulation firing rate control both the remote enable and remote 4 20mA input connections must be made The default setting for the 4 20mA remote input is Local This setting should be verified under the Falcon control s Central Heat configuration group Central Heat Mo...

Page 100: ...e to a specific value These functions include Delta T limiting Slow Start and Forced Rate See Appendix A for a complete listing of control functions with detailed descriptions and parametrization instructions Delta T limiting is designed to reduce the firing rate in case of an excessive difference between the inlet and outlet temperatures Sensor connections to the CB Falcon are at J8 4 and 5 inlet...

Page 101: ...ol circuit to provide fault and status messages and also provides first out annunciation for interlock lockouts Eight inputs are available in addition to the Interlock Load Control and Pre Ignition Interlock inputs totalling 11 monitored points Lead Lag Control up to eight boilers Multiple CB Falcon units can be connected in a lead lag system Controllers in a lead lag configuration communicate ove...

Page 102: ...Section 4 CFC Commissioning 4 32 Part No 750 263 ...

Page 103: ...gnition Electrode and Flame Rod 5 3 Troubleshooting 5 3 Caution Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Failure to do so may result in equipment failure Caution Verify proper operation after servicing Failure to do so may result in equipment failure ...

Page 104: ...the head assembly by removing 4 bolts and washers Check the burner head for any damage burn marks or perforations If damage is determined replace the damaged parts If the canister is in good condition clean out any dirt and contaminates with a vacuum cleaner inside and out alternating with compressed air to dislodge any debris of combustion 1 With the burner head and blower removed the combustion ...

Page 105: ...e burner canister D TROUBLESHOOTING Lockout Conditions 1 Observe lockout code and description refer to CB Falcon appendix if necessary 2 After determining lockout condition investigate possible causes 3 When cause is diagnosed remedy condition 4 Reset control Boiler should be able to start normally 5 If lockout recurs further investigation is required Repeat steps 1 through 4 as needed If necessar...

Page 106: ... and the flame rod are not easily adjustable bending the rods can cause damage to the insulation material In addition a bent electrode will return to its original shape when heated If an electrode or flame rod is out of specification replacement is generally required Clean or replace as necessary Also see Troubleshooting Chart below Electrode spacing for the booster ignitor should be 1 8 The dista...

Page 107: ...rain 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 based on all appliances being ON Incorrect fan speed settings increase fan speed by 100 RPM increments until successful lightoff occurs Bad cable connections ignition or flame rod Electrodes fouled o...

Page 108: ...Section 5 Service and Maintenance 5 6 Part No 750 263 ...

Page 109: ...0 3669 Dual Electrode Sparking 380 1061 380 1061 380 1061 380 1061 380 1061 380 1061 Dual Electrode Gasket 380 1032 380 1032 380 1032 380 1032 380 1032 380 1032 Burner Canister 380 1045 380 1045 380 1029 380 1030 380 1030 380 1074 Water Side Gaskets 853 350 853 350 853 350 853 350 853 350 853 350 Falcon Controller Hydronic 833 3639 833 3639 833 3639 833 3639 833 3639 833 3639 Power Supply 12VDC 83...

Page 110: ...Section 6 Parts 6 2 Part No 750 263 Figure 6 1 Boiler Mechanical Assembly I 26 15 20 20 3 10 11 G H ...

Page 111: ...R SIZE 500 750 1000 1500 1800 2500 SINGLE FUEL 507 08324 507 08323 507 08321 507 08320 507 08319 507 08188 DUAL FUEL 185 00703 185 00702 185 00701 185 00700 185 00699 185 00698 BOILER SIZE 500 750 1000 1500 1800 2500 1 NPT KIT 380 01046 1 25 NPT KIT 380 1047 BUTTERBALL VALVE 941 01944 941 01944 941 01944 941 01945 941 01945 941 01945 NIPPLE CLOSED 857 00673 857 00673 857 00673 857 00709 857 00709 ...

Page 112: ...Section 6 Parts 6 4 Part No 750 263 Figure 6 2 Boiler Mechanical Assembly II Table 6 4 Boiler Mechanical Assembly II parts ...

Page 113: ...Section 6 Parts Part No 750 263 6 5 Figure 6 3 Casing Table 6 5 Casing parts ...

Page 114: ...Section 6 Parts 6 6 Part No 750 263 Figure 6 4 Gas train single fuel Table 6 6 Gas train single fuel parts BOILER SIZE ...

Page 115: ... 00013 000 940 07235 000 817 02414 000 857 00758 000 847 00060 000 859 00083 000 859 00109 000 857 01575 000 940 07165 000 857 01642 000 825 00239 000 858 00088 000 859 00077 000 857 01641 000 817 02420 000 847 01172 000 857 01626 000 859 00021 000 857 01643 000 048 00686 000 857 00757 000 857 00710 000 858 00168 000 118 03817 000 118 03816 000 800 00093 000 857 00756 000 223 00013 000 940 07235 0...

Page 116: ...H 2 15 BUSHING 2 16 NIPPLE 4 17 TEE 2 18 NIPPLE 2 19 BUSHING 2 20 UNION 2 21 NIPPLE 2 22 NAMEPLATE TAG NATURAL GAS 1 23 NAMEPLATE TAG PROPANE 1 24 750 500 800 00092 000 857 00645 000 223 00015 000 817 02414 000 800 00095 000 857 00638 000 859 00082 000 859 00107 000 940 07163 000 825 00239 000 858 00088 000 859 00077 000 857 01636 000 859 00103 000 817 02420 000 847 01172 000 857 00719 000 859 000...

Page 117: ...Section 6 Parts Part No 750 263 6 9 Figure 6 7 Electrical assemblies single fuel ...

Page 118: ... Blower Fuse Boiler Size 500 750 1000 1500 1800 2500 119 00429 119 00429 119 00430 119 00431 119 00431 119 00426 Boiler Size Fuse Rating 500 6A 750 6A 1000 6A 1500 12A 1800 15A 2500 15A 832 01881 832 01881 832 01881 832 01887 832 01888 832 01888 See Table See Table 2 881 00348 LATCH PLASTIC 500 1000 ONLY See Fig 6 8 ...

Page 119: ...Section 6 Parts Part No 750 263 6 11 Figure 6 8 Cables and Cable Harness Single Fuel 35 35 82600158 BURNER CABLE HARNESS ...

Page 120: ...ble See Table Item 1 Control Panel Boiler Size 500 750 1000 1500 1800 2500 283 03610 283 03610 283 03609 283 03607 283 03607 283 03606 Item 10 Blower Fuse Boiler Size Fuse Rating 500 6A 750 6A 1000 6A 1500 12A 1800 15A 2500 15A 832 01881 832 01881 832 01881 832 01887 832 01888 832 01888 ...

Page 121: ...Section 6 Parts Part No 750 263 6 13 Figure 6 10 Cables and Cable Harness Dual Fuel 37 38 37 38 1 1 826 00158 000 826 00162 000 CABLE HARNESS BURNER CABLE HARNESS FOR PROPANE GAS TRAIN PANEL ...

Page 122: ...7 OPTIONAL SAFETY VALVE SET 30 PSI 940 478 OUTDOOR TEMP SENSOR INCL EXTERNAL MOUNTING HARDWARE 817 4517 ALARM HORN 817 3571 STACK TEMPERATURE SENSOR 817 4403 HEADER TEMPERATURE SENSOR 817 4468 DHW OUTLET TEMPERATURE SENSOR 817 4403 INLET TEMPERATURE SENSOR 817 4404 PLUG IN MODULE PIM 833 3640 AUX LOW WATER CUTOFF 817 3390 ALARM HORN 817 3571 BOILER AIR VENT VALVE 940 7358 EXTERNAL HIGH LIMIT TEMPE...

Page 123: ...APPENDIX A CB FALCON CONTROLLER ...

Page 124: ......

Page 125: ...ystem instead of a single larger burner or boiler Using boilers in parallel is more efficient costs less reduces emissions improves load control and is more flexible than the traditional large boiler CB Falcon system may consist of 833 3639 3871 or 833 3578 Control Device Touchscreen Display required for setup and Modbus communication Flame Rod or UV flame sensor Temperature Sensor NTC Type Limit ...

Page 126: ...Ignition Table 1 CB Falcon Models Available Model Hydronic Steam Digital I O Modulation Output Flame Sense Burner Type 833 3578 Steam CB Boiler Models CFH CFV 120V PWM FR DSI 833 3639 Hydronic CB Model CFC 120V PWM FR DSI 833 3871 Hydronic CB Model CFW 120V PWM FR DSI ...

Page 127: ...plished using the 833 3577 System Operator Interface Refer to manual 750 241 for the operation and setup screens This document will assist in understanding the parameters being set up The manual contains a worksheet example of Falcon device parameters and how they might be set up to provide a functioning system Note that while the worksheet shows most parameters as being available the actual produ...

Page 128: ...ice Power Hydronic 24 or 120Vac Digital I O models available Steam 120Vac Digital I O Flame Signal test jacks Vdc Three Status LEDs Power Flame Alarm Flame Sensing Ultraviolet C7027 C7035 C7044 Sensors Flame Rod Single Element Internal spark generator and flame sense using the same element Dual Element separate elements for ignition spark and flame sense Inputs Analog Inputs NTC Sensor Inputs 10ko...

Page 129: ...for Header or Outdoor temperature sensors might be available from various sources so parameters are provided to select the input source These parameters determine how temperatures are obtained if where temperature information is stored where a control loop gets its data Sensor Signal Conditioning The analog sensors signal includes filtering to reduce the effect of noise and spurious read events Th...

Page 130: ...ne temperature then this setting must be set up by the installer before the control will operate Modbus ECOM Event Handling The Modbus and ECOM communication system responds to queries and can write new values to the parameters WARNING Explosion Hazard Improper configuration can cause fuel buildup and explosion Improper user operation may result in property loss physical injury or death Safety Con...

Page 131: ...SCREW Pins 7 12 J5 Line Voltage I O Lumberg 3623 07 K01 IDC 3615 1 07 K01 SCREW J6 Line Voltage I O Lumberg 3623 08 K43 IDC 3615 1 04 K185 SCREW Pins 1 4 3615 1 04 K188 SCREW Pins 5 8 J7 Line Voltage I O Lumberg 3623 07 K48 IDC 3615 1 07 K48 SCREW J8 Low Voltage I O Lumberg 3623 06 K127 IDC Pins 1 6 3615 1 06 K127 SCREW Pins 1 6 3623 06 K128 IDC Pins 7 12 3615 1 06 K128 SCREW Pins 7 12 J9 Low Volt...

Page 132: ... UV flame sensor Alarm Output Fig 1 General Falcon hydronic boiler schematic Fig 1 shows two loops of heat control Central Heating CH and an optional second loop for Domestic Hot Water DHW can be configured on each Falcon The DHW loop transfers heat from the boiler outlet to hot water appliances in conjunction with the primary system heat loop Priority assignment to each heat loop can be configure...

Page 133: ...e Nema 1 IP40 Approvals Underwriters Laboratories Inc Component Recognized File No MP268 MCCZ 833 3639 and 833 3578 are certified as UL372 Primary Safety Controls 833 3639 is rated as a UL353 limit rated device when using the dual element limit rated NTC sensors CSD 1 Meets CSD 1 section CF 300 requirements as a Primary Safety Control Meets CSD 1 section CW 400 requirements as a Temperature Operat...

Page 134: ...ure Mounting The Falcon 1 Select a location on a wall burner or electrical panel The Falcon can be mounted directly in the control cabi net Be sure to allow adequate clearance for servicing 2 Use the Falcon as a template to mark the four screw locations Drill the pilot holes 3 Securely mount the Falcon using four no 6 screws NOTE The device can be removed and replaced in the field without rewiring...

Page 135: ...ions Connector J3 1 The ECOM port connectors J3 terminal 1 J3 terminal 2 J3 terminal 3 is not used in CB Falcon aplications Do not connect the display to these connectors 2 Connect the 833 3577 3725 Display to either J3 Modbus port MB1 or MB2 connectors a b c Flame Signal Connector J1 1 Flame Rod Single Element a Connect the Flame rod for both ignition spark and flame sense to the ignition transfo...

Page 136: ...le rated for 25kV at 482F 250C 32004766 001 2 or 003 per foot 3 Grounding Earth ground 1 Earth ground must be capable of conducting enough cur rent to blow the 20A fuse or breaker in the event of an internal short circuit 2 Use wide straps or brackets to provide minimum length maximum surface area ground conductors If a leadwire must be used use 14 AWG copper wire 3 Make sure that mechanically tig...

Page 137: ...ET TEMP INLET TEMP RTN 4 20 mA REMOTE SOURCE OUTLET TEMP A OUTLET TEMP RTN OUTLET TEMP B OUTDOOR TEMP OUTDOOR TEMP RTN DHW TEMP A DHW TEMP RTN DHW TEMP B STACK TEMP A STACK TEMP RTN STACK TEMP B TOD REMOTE RESET 0 10 VDC MA VDC RTN 4 TO 20 MA V I BUILDING AUTOMATION SYSTEM FUTURE System Display TACHOMETER PWM OUT FAN POWER 25 VDC FAN GND MULTIPLE APPLIANCE CONTROLLER GLOBALMODBUS LOCALMODBUS FUTUR...

Page 138: ...24 VAC 24 VAC RTNS STEAM PRESSURE SENSOR 4 20 mA REMOTE SOURCE STACK TEMP A STACK TEMP RTN STACK TEMP B TOD REMOTE RESET 0 10 VDC MA VDC RTN 4 TO 20 MA V I BUILDING AUTOMATION SYSTEM FUTURE System Display TACHOMETER PWM OUT FAN POWER 25 VDC FAN GND MULTIPLE APPLIANCE CONTROLLER GLOBALMODBUS LOCALMODBUS FUTURE UV BLUE WHITE STAT EXTERNALLY POWERED PRESSURE SENSOR 0 15 PSI OR 0 150 PSI 1 1 FALCON ST...

Page 139: ... HZ to power UV J4 7 PUMP A Input 120 VAC 44 4 ALR 7 4 Amps run J4 6 PUMP A Output 120 VAC 44 4 ALR 7 4 Amps run J4 5 PUMP B Input 120 VAC 44 4 ALR 7 4 Amps run J4 4 PUMP B Output 120 VAC 44 4 ALR 7 4 Amps run J4 3 PUMP C Input 120 VAC 44 4 ALR 7 4 Amps run J4 2 PUMP C Output 120 VAC 44 4 ALR 7 4 Amps run J4 1 Not Used J5 7 BLOWER HSI Input 24VAC 120 VAC 44 4 ALR 7 4 Amps run J5 6 BLOWER HSI Outpu...

Page 140: ... from 10K or 12K Ohm NTC temperature sensor J8 12 OUTDOOR TEMP Common a Ground reference for the Outdoor Temp Sensor J9 1 DHW TEMP A S6 a b Supply for and signal input from 10K or 12K Ohm NTC temperature sensor J9 2 DHW Common S6S7 a b Ground reference for the DHW Temp Sensor J9 3 DHW TEMP B S7 a Supply for and signal input from 10K Ohm NTC temperature sensor J9 4 STACK TEMP A S8 b Supply for and ...

Page 141: ...gnition motorized valves with 660 VA inrush 360 VA opening 250 VA holding 65VA pilot duty motorized valves with 3850 VA inrush 700 VA opening 250 VA holding 2 No Load 50VA Pilot Duty 4 5A Ignition 65VA pilot duty motorized valves with 3850 VA inrush 700 VA opening 250 VA holding 3 4 5A Ignition 65VA pilot duty motorized valves with 3850 VA inrush 700 VA opening 250 VA holding 65VA pilot duty motor...

Page 142: ...available parameters to be viewed modified and downloaded This tool allows for building a device working from a spreadsheet Customizing can be done on this along with choosing to have the parameter Hidden Read Only or Level of Password protection When complete this sheet can be saved and or directly downloaded into the Falcon through the Modbus port An example is shown in Table 49 beginning on pag...

Page 143: ...irmed the data or rejected it If the user rejects the data then the process returns to step 2 and when editing again is done the confirmation process begins again Once started the confirmation process is successful only if each safety data item has been con firmed in the order provided by the Falcon 4 After all items are confirmed the Falcon requests the user to press and hold the Reset button on ...

Page 144: ...c Control 10K NTC single non safety 12K NTC single non safety UNCONFIGURED For Steam Control 15 PSI 150 PSI or UNCONFIGURED Designates the type of analog sensor on connector J8 terminals 4 and 5 Outlet Connector Type For Falcon Hydronic Control and Steam Control 10K NTC dual safety connector J8 terminals 8 9 and 10 10K or 12K NTC single non safety connector J8 terminals 8 and 9 Designates the type...

Page 145: ...ecked If it has the highest priority because of either a non zero value in the DHW priority timer which is loaded using the DHW priority time parameter due to the setting in both DHW priority vs LL if Lead Lag Master enable is enabled AND DHW priority vs CH if CH enable is enabled then the anti short cycle delay is ignored and the DHW demand is served Burner name text The Burner Name is a text par...

Page 146: ...ating these scalers is 5000 RPM that is when both the MCBA and the Falcon have a maximum fan speed of 5000 RPM the user programmable P I and D gains used by the MCBA can be directly copied to the corresponding Falcon parameters and the behavior of the Falcon control will then be similar to the MCBA At other values of maximum fan speed the parameters to provide similar behavior can be calculated as...

Page 147: ... IN STANDBY MANUAL IN RUN STANDBY IS ENABLED MIDDLE NOTABOVE AND BC HAS A COMMANDED RATE E G IN STANDBY PURGE IDNITION ETC BOTTOM FIRING BC HAS NO COMMANDED RATE AUTO MODE SELECTED NORMAL MODULATION OFF NO DEMAND 0 OFF NO DEMAND 0 DHW demand priority timer CH PUMP DEMAND DHW PUMP DEMAND SLAVE COMMAND EXISTS CH FROST PROTECT BURNER DEMAND LL SLAVE ENABLE DHW FROST PROTECT BURNER DEMAND DHW FROST PR...

Page 148: ...l exist if the sensor temperature falls below the setpoint minus a hysteresis value Once the burner demand signal is on it remains on until the sensor temperature is above the setpoint plus a hysteresis value or until the other selected demand source input e g Stat Remote Stat if any turns off Pump demand may be driven by the selected demand source input Stat input a remote stat or by the sensor a...

Page 149: ...TPOINT ODR ENABLE SENSOR SENSOR IS OK Table 8 Central Heating Hydronic Parameters Parameter Comment CH demand switch STAT LCI Sensor Only EnviraCOM Remote STAT J7 3 120 Vac The CH demand switch may be selected from four options In all cases for burner demand to exist the sensor must be generating a demand as determined by values When Sensor Only is chosen no other input is considered and pump dema...

Page 150: ...cribed in Outdoor Reset and Boost on page 26 CH off hysteresis CH on hysteresis Degrees or None The off hysteresis is added to the setpoint temperature to determine the temperature at which the demand turns off Similarly the on hysteresis is subtracted from the setpoint to determine the temperature at which demand turns on These may be set to None to indicate that no hysteresis has been defined Th...

Page 151: ...rameter Comment CH ODR low outdoor temperature Degrees or None This parameter determines the X coordinate of one point on the ODR graph At that outdoor temperature the setpoint will be the CH setpoint or the CH TOD setpoint if TOD Is on CH ODR boost time CH ODR boost max burner off point mm ss Degrees or None If CH outdoor reset is not active or if the CH ODR boost time parameter is zero then the ...

Page 152: ...t if any turns off Pump or output demand may be driven by the selected demand source input Stat input a remote stat or by the sensor alone A Proportional Integral Differential PID controller operates to generate the demand source s requested modulation rate The Steam Central Heating function is implemented as shown in Fig 11 CH ODR Parameters LL ODR Parameters Setpoint TOD Setpoint Minimum Outdoor...

Page 153: ...ND SENSOR ONLY 1 2 3 4 20 mA TO pRATE T T T T T T EnviraCOM TOD TOD NO DATA TIMEOUT REVERT TO SETPOINT T NO DATA TIMEOUT REVERT TO PID NO DATA TIMEOUT REVERT TO OFF T T Table 10 Central Heating Steam Parameters Parameter Comment Steam enable Disable Enable Disable enable steam feature Steam demand source STAT and Sensor Remote Stat and Sensor LCI and Sensor Sensor Only The CH demand source may be ...

Page 154: ...is ignored and both of the remote control functions are disabled Modulation When the burner is free to modulate during the Run state the 4 20mA input from the Header input becomes the modulation source where 4mA corresponds to the Minimum modulation rate and 20mA corresponds to the Maximum modulation rate All other behavior remains as it was the setpoint and the on off hysteresis values are still ...

Page 155: ...esis step time parameter The number of steps required to reach the original on hysteresis is the on hysteresis value divided by 2 psi per step for 0 150 PSI 2 psi per step for 0 15 PSI Step Time since turn on Hydronic Turn on threshold 1 0 timer 1T Setpoint 2 On hysteresis 2 1T time 2T Setpoint 2 On hysteresis 1 2 F 3 2T time 3T Setpoint 2 On hysteresis 2 2 F 4 nT time n 1 T Setpoint 2 On hysteres...

Page 156: ...NT SETPOINT ON HYSTERESIS BURNER STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 1 MINUTE SETPOINT 2 ON HYSTERESIS 1 MINUTE OFF ON ANTI SHORT CYCLE DELAY SETPOINT AND HYSTERESIS 2 PSI 2 PSI FOR 0 15 PSI ANTI SHORT CYCLE DELAY TIME TOD SETPOINT SETPOINT ON HYST OFF HYST STEAM PARAMETERS SYSTEM PARAMETER ...

Page 157: ...HROUGH IF PRIORITY DHW STORAGE DOMESTIC HOT WATER DHW DHW HIGH LIMIT ACTIVE SUSPEND DHW DURING DHW HIGH LIMIT CONDITION TO FROM DHW STORAGE DHW MODULATION SENSOR T TOD DATA SERVER DSD DHW TEMP T x P 1 T 0 P 0 T 1 P 0 T P PREHEAT ACTIVE TOD SETPOINT SETPOINT PLATE PREHEAT SETPOINT ON HYST PREHEAT IF PREHEAT IS ACTIVE USE PREHEAT HYSTERESEIS PREHEAT ACTIVE PREHEAT ACTIVE DHW FIRING RATE USE MIN MODE...

Page 158: ...ed in the Plate Heat Exchanger section STAT then the J8 terminal 3 input is the DHW heat demand signal J7 terminal 3 120 Vac DHW setpoint Degrees or None This setpoint is used whenever the time of day switch is off or not connected unused DHW TOD setpoint Degrees or None This setpoint is used when the time of day switch J10 terminal 2 is on DHW off hysteresis DHW on hysteresis Degrees or None The ...

Page 159: ...let temperature to the DHW and Outlet temperatures Because tap demand has two criteria for starting and two other criteria for stopping it is modeled as a Set Clr block driven by two OR gates which in turn are connected to the four criteria sources The tap demand is also modeled to have a force input which forces it to recognize a Set event this is used when Preheat has had control and is now reli...

Page 160: ... IS FALSE IF TAP IS TRUE INHIBIT THIS PREHEAT BLOCK RESET THE ITEMS AND RESET THE PREHEAT DELAY AFTER TAP TIMER IF PREHEAT IS FALSE IT BECOMES TRUE WHEN WHEN THESE HAVE OCCURRED THEN A 1 MINUTE TIMER STARTS WHEN THIS TIME ELAPSES THEN PREHEAT ENDS THE FORCE OUTPUT IS PULSED TO FORCE TAP DETECTION TO START AND PREHEAT IS INHIBITED THIS ALSO OCCURS IMMEDIATELY IF THE 1 MINUTE TIMEOUT IS PENDING BUT ...

Page 161: ...n by this parameter tap demand s Clr input is asserted Tap stop Outlet Inlet degrees Degrees or None The other criteria for asserting Clr is based on the difference between the Outlet and the Inlet temperature calculated as Outlet Inlet When this value is negative or is less than or equal to the degrees given by this parameter tap demand s Clr input is asserted Plate preheat off hysteresis Degrees...

Page 162: ...hey can differ from the values used during normal DHW demand Plate preheat on hysteresis Degrees or None The preheat on threshold is calculated as TON Plate preheat setpoint Plate preheat on hysteresis If the preheat block is False then it is Set becomes True when 1 Tap demand is false AND 2 The preheat delay after tap time has elapsed AND 3 DHW sensor temperature TON AND 4 The above have remained...

Page 163: ...E TAP DETECTION TO START AND PREHEAT IS INHIBITED THIS ALSO OCCURS IMMEDIATELY IF THE 1 MINUTE TIMEOUT IS PENDING BUT PREHEAT ENDS DUE TO ABOVE WHEN PREHEAT TURNS ON ITS MINIMUM ON TIME IS STARTED IF PREHEAT IS TRUE IT BECOMES FALSE WHEN IF TAP IS FALSE ALLOW THE TIMER TO RUN TIME IS EXPIRED AND SET IS FALSE AND CLR IS TRUE TAP DURING PREHEAT IS RECOGNIZED AS TAP HAS BEEN TRUE WHILE PREHEAT WAS TR...

Page 164: ...esis step time behavior which modifies the burner on off thresholds over time The gains used by DHW storage are the normal DHW PID gains This occurs because the DHW PID block is shared by the two demand sources The DHW storage feature when active uses the demand source selected by the normal DHW demand source The DHW storage feature when active provides setpoint information to the normal DHW PID b...

Page 165: ...f demand takes over frost protection is the lowest priority burner demand source or CH Frost protection burner demand ends CH Frost protection burner demand ends when both of these occur 1 the outlet temperature exceeds 50ºF 2 the inlet temperature is greater than 41ºF If the CH control sensor Outlet or Header is invalid e g disconnected then it is ignored by CH frost protection If the Inlet senso...

Page 166: ...the frost protection source generates a burner demand if the DHW temperature is below 38ºF and it requests a minimum modulation firing rate It maintains this demand until some other source of demand takes over frost protection is the lowest priority burner demand source or DHW Frost protection ends DHW Frost protection ends when the DHW temperature exceeds 50ºF If the DHW sensor is invalid e g dis...

Page 167: ...ow Start and Forced Rate are considered to be normal in that they always occur if they are enabled Delta T Limit Rate Limit Only Hydronic only The Delta T limit is designed to reduce the firing rate in case the difference between the following is excessive The Inlet and the Outlet temperature The Inlet and the exchanger temperature The exchanger and the Outlet temperature Each will operate identic...

Page 168: ...ed as the cause of the lockout although each of the reasons for recycling abnormally always generates an alert as usual so the presence of other events will be visible in that log The retry counter is cleared when a normal recycle burner turn off occurs due to satisfying all of the demands A limit of zero is equivalent to selecting lockout Delta T rate limit enable Disable Enable Disable then no m...

Page 169: ...nt Heat exchanger high limit Disable Enable This enables disables temperature rise detection for the heat exchanger sensor S9 J9 terminal 6 If this selection is Enable then the Stack Connector Type must be either 10K single non safety NTC or 12K single non safety NTC If this condition is not met then a lockout occurs because the exchanger input requires using the Stack sensor as two separate senso...

Page 170: ... enable Disable Enable Enable single non safety This parameter enables or disables the entire stack temperature limit function Disable turns off the Limit function Enable turns on the Limit function and requires a 10k dual safety NTC sensor Enable single non safety allows for 10kohm or 12kohm NTC sensor to provide limit non safety function Stack limit setpoint Degrees or None If the stack temperat...

Page 171: ...llowed firing rate is reduced by one stepsize to 80 and thereafter it is reduced by one stepsize every two F until it is reduced to the minimum modulation rate when the 2 F threshold is crossed Assuming that rate limiting has been in effect then the thresholds for returning to a less restrictive step are shifted by 2 F to provide hysteresis I e to go from step 4 to step 5 the threshold occurs at 2...

Page 172: ...ced rate time is zero DHW forced rate time MM SS This parameter determines the duration of the forced rate period when firing for DHW demand If it is set to zero then this forced rate period is disabled DHW forced rate RPM or This parameter provides the firing rate during the DHW forced rate time It is also the initial rate for the DHW slow start period even if the DHW forced rate time is zero PFE...

Page 173: ...provided by subtracting this number of degrees from the setpoint then slow start rate limiting is effective Whenever the outlet temperature is above this value slow start limiting has no effect Slow start ramp RPM or Per Minute When slow start limiting is effective the modulation rate will increase no more than the amount per minute given by this parameter Although provided as a per minute value t...

Page 174: ...for CH and LL demand CH anticondensation setpoint Degrees or None If CH demand anticondensation is enabled and if CH demand or LL slave demand is in control of the burner and the burner is firing and if the temperature of the outlet sensor is below the temperature given by this parameter then the anticondensation subsystem requests the burner s firing rate to be set to the rate given by the CH max...

Page 175: ...arameter specifies the analog output or fan speed used during ignition Firing rate control Auto Manual in Run Manual in Run and Standby If this parameter is set to either of the manual options then the burner s firing rate during modulation in the Run state is the rate given by the Manual firing rate parameter If the Manual in Run and Standby option is chosen the firing rate output is also control...

Page 176: ...he amount of hysteresis applied to the PID output when a non PWM modulation is selected The n value determines how much the PID is required to change in a new direction before the output will change This is somewhat experimental although simulation shows this technique provides better response and also better control of motor reversals than a deadband A typical range is 0 disabled to 10 although h...

Page 177: ...Y CH PUMP OVERUN TIME CH PUMP OPTIONS 2 PUMP EXERCISE CH PUMP CYCLE COUNT CH PUMP CONTROL ON AUTO CH PUMP PUMP CONTROL AND OPTIONS DHW PUMP OPTIONS 1 DHW PUMP START DELAY DHW PUMP OVERUN TIME DHW PUMP OPTIONS 2 DHW PUMP OUTPUT CONNECTION A B C CH PUMP OUTPUT CONNECTION A B C DHW PUMP CYCLE COUNT DHW PUMP CONTROL ON AUTO DHW PUMP BOILER PUMP OPTIONS 1 BOILER PUMP START DELAY BOILER PUMP OVERUN TIME...

Page 178: ... ALL PUMPS EXERCISE WILL NOT RUN IF IT IS FORCED OFF IF TWO OR MORE PUMP CONTROL BLOCKS ARE CONNECTED TO THE SAME PUMP OUTPUT THEN THEIR THREE OUTPUT SIGNALS ON OFF AND DMD ARE OR D TOGETHER THIS PROVIDES THE FOLLOWING BEHAVIOR IF EITHER IS FORCE ON THE PUMP IS ON NORMAL PUMP DEMAND CAN COME FROM EITHER BLOCK EITHER CAN INHABIT NORMAL PUMP DEMAND WITH A FORCE OFF PUMP CONTROL BLOCK PUMP A B OR C 6...

Page 179: ...cur if it is already firing when the pump demand off to on event occurs For a Falcon in slave mode this delay is skipped and does not occur if the Master Service Status defined in the LL specification and noted in the drawing informs the slave unit that some slave burner in the system is already firing when the pump demand off to on event occurs XX pump overrun time mm ss This time indicates how l...

Page 180: ...om a Remote Stat the on condition of the LCI input or may be driven by the sensor status alone The presence of demand causes pump turn on as a primary effect and will cause the burner control to fire only if a setpoint demand signal is also received from the subsystem which is monitoring temperature If burner demand exists then the burner control will attempt to light the burner and if this succee...

Page 181: ... and the ILK is still on then a lockout occurs IAS start check enable Enable Disable If the Interrupted Air Switch Enable parameter is set to Disable then this parameter is ignored Otherwise if the IAS start check is enabled and the fan is off in some cases it can be on during Standby then the control will check the IAS input as it exits the Standby condition in response to demand If this input is...

Page 182: ...red is enforced before the Ignition time begins If the LFS opens during ignition the burner control will react as specified by the equipment setup typically by locking out If set to Fan Speed then the measured fan speed must be within the specified lightoff rate 3 for 3 seconds before the rate is proven and Ignition begins If the fan speed later goes outside of the prepurge rate 10 during ignition...

Page 183: ...ent DBI Direct Burner Ignition Pulsed Preignition time hr mm ss Pilot flame establishing period PFEP 4 10 or 15 seconds This parameter is ignored if DBI is selected Otherwise there are three choices for the duration of PFEP 4 10 or 15 seconds Flame must be on at the end of this period or a response occurs see Ignite failure response on page 60 STANDBY PREPURGE PFEP N U R S 5 1 R O 0 1 4 POSTPURGE ...

Page 184: ...oice for the response If lockout is selected for flame failure during Run However if recycle is selected the burner control shuts off the fuel and recycles back to the beginning of prepurge then continues with the normal burner startup process prepurge ignition then run to light the burner again Fan speed error response Lockout Recycle If fan fails in Run and recycle is selected then the burner co...

Page 185: ...a circuit not related to any of the above The input terminal names Interlock ILK Load Limit Control Input LCI Pre Ignition Interlock PII can be renamed with a long 20 character and short 3 character name that better describes their purpose Three Annunciator terminals may already be assigned functions based on the system parameter setup A1 Will be Interrupted Air Switch IAS if the parameter is enab...

Page 186: ...or display If A7 is defined as a HFS input then the parameter that calls it a Security door would be ignored and the automatic value High Fire Switch is used instead the same would be true for the A8 LFS and A1 IAS FALCON ANNUNCIATOR NAMES MASTER SWITCH WATER LEVEL LIMIT CONTROL MASTER SWITCH WATER LEVEL LIMIT CONTROL LCI ILK A1 L1 A2 STACK VENT FAN HIGH GAS PRESSURE LOW GAS PRESSURE AIRFLOW SWITC...

Page 187: ... event The cause of the alert may be a condition e g something that is causing an abnormal hold but the alert itself in this case is a momentary event generated upon entry to that condition Whether the alarm contact closes or not is programmable for each alert by the OEM Alerts are logged in a 15 item volatile alert history sorted in chronological order Only one instance of each alert code occurs ...

Page 188: ... a No flame is present or flame is lost if enabled lock out b Lockout Interlock opens if enabled c IAS Purge and Ignition enabled and the Interlock opens d Pilot terminal energized if programmed as Inter rupted Pilot e Main valve terminal is not energized f Internal system fault occurred 8 POSTPURGE Period a Preignition Interlock does not close in five seconds b Pilot Valve terminal is energized c...

Page 189: ...6 As soon as the fan rpm is equal to the light off rpm or the Low Fire Switch closes the Trial for Ignition or Pre Ignition Time is started depending on configuration 7 Pre Ignition Time will energize the ignitor and check for flame 8 Trial for Ignition Fig 23 25 on page 59 shows three igni tion options Specifics for timings and device actions are defined by the OEM or installer 9 The ignition and...

Page 190: ...y open the manual main valve to supply pilot gas flow Make sure the main fuel is shut off just upstream from the burner inlet or disconnect power from the automatic main fuel valve s 3 Close the master switch and start the system with a call for heat by raising the setpoint of the operating controller see the operating sequence The Falcon should start the INITIATE sequence 4 Let the sequence advan...

Page 191: ... 5 seconds or the normal lightoff time specified by the equipment manufacturer close the manual main fuel shutoff valve s Check all burner adjustments 14 If the main burner flame is not established after two attempts a Check for improper pilot flame size b Check for excess combustion air at low fire c Check for adequate low fire fuel flow d Check for proper gas supply pressure e Check for proper v...

Page 192: ...ove the jumper between power and J5 terminal 4 Re install the connector J5 to the controller i Open the manual main burner fuel shutoff valve j Close the master switch k Cycle the controller to energize both the ignition source and the main fuel valve l If the main flame does not ignite and if the ignition spark is still continuous adjust the main burner gas pressure regulator until a main flame i...

Page 193: ...RENCE TEST FLAME RODS Ignition interference can subtract from decrease or add to increase the flame signal If it decreases the flame signal enough it causes a safety shutdown If it increases the flame signal it could cause the FLAME LED to come on when the true flame signal is below the minimum acceptable value Start the burner and measure the flame signal with both ignition and pilot or main burn...

Page 194: ...t screen corner back arrow button j Select the Verify button k Select Begin l Follow the prompts on the Operator Interface Response to Other Ultraviolet Sources Some sources of artificial light such as incandescent or fluorescent bulbs and mercury sodium vapor lamps and daylight produce small amounts of ultraviolet radiation Under certain conditions an ultraviolet detector responds to these source...

Page 195: ...ng TROUBLESHOOTING System Diagnostics Troubleshooting control system equipment failures is easier with the Falcon s self diagnostics and first out annunciation In addition to an isolated spst alarm relay audible annunciation the Falcon module provides visual annunciation by displaying a fault code and fault or hold message at the 833 3577 Display Operator Interface The Falcon modules provide many ...

Page 196: ...ndard behavior for a Falcon control in stand alone non slave mode If any slave under LL Master control is in a Run Limited condition then for some algorithms the LL master can apportion to that stage the rate that it is actually firing at Additionally when a slave imposes its own Run limited rate this may trigger the LL Master to add a stage if it needs more capacity or drop a stage if the run lim...

Page 197: ... master the rate at which setpoint error is developing and the rate at which a stage or stages are approaching their minimum firing rate Typically these use Drop stage detection timing to determine how long these things have persisted When all criteria have been met for a sufficient time then an Drop stage request is active Fig 28 Lead lag wiring diagram 2 1 4 5 6 7 8 9 3 12 B A N C GND C 12 N C A...

Page 198: ... configurable actions a Disable No backup will be used b Lead Outlet Outlet temperature of the lead boiler will be used as the backup during firing c Slave Outlet Average Average of the outlet temper atures of all slave boilers that are firing will be used as a backup 2 If the sensor chosen by the above parameter is faulty then the backup sensor provided may be used When burner demand is off and n...

Page 199: ...ollowing parameters are available for OEM configuration and may be adjusted through a System Display or programmed at the OEM production facility Slave Operation and Setup Slave Data Supporting Lead Lag This data is provided by each slave control to support operation when a LL master exists Fig 29 summarizes the slave s registers and data Table 33 OEM Configuration Parameters Master Falcon Slave F...

Page 200: ...to Equalize Runtime then this slave will be staged according to a run time equalization Any units set to Use First will precede any that are set to Equalize Runtime If this parameter is set to Use Last then this slave will be used only after all Use First and Equalize Runtime units have been brought online MASTER EnviraCOM INPUTS SLAVE DATA OUTDOOR S2 4 20mA S5 SENSORS STAT READ BY DISPLAY STAT2 T...

Page 201: ...mbers may be skipped that is 3 will be first if there is no 1 or 2 Note For Equalize Runtime purposes 1 does not mean the unit will be used first every time that will vary over time based on the master s run time equalization scheme In this case the sequence number determines the relative order in which Falcon controls will be used in a round robin scheme If the slave sequence number value is zero...

Page 202: ...nd yes Run off cycle fan no Modulation 0 100 The LL master sends this message to turn the burner on and to assign the burner s firing rate If the commanded modulation rate is less than the burner s minimum modulation rate then the burner should always operate at its minimum rate SlaveState States Recovering A slave that is recovering is checked once per second If any of the following are true Data...

Page 203: ...R SHUTDOWN SETPOINT LL MASTER FROST PROTECT ENABLE DISABLE LL CH STAT EnviraCOM REMOTE STAT MASTER HEAT DEMANDS THE SOURCES ASKING FOR HEAT USED FOR PUMP CONTROL MASTER ACTIVE SERVICE THE DEMAND SOURCE THAT IS CURRENTLY CONTROLLING THE LL MASTER Table 37 CH Demand Parameters Parameter Comment LL CH demand switch Disable STAT EnviraCOM Remote Stat The inputs that can function as the CH demand switc...

Page 204: ... the rate indicated by LL Frost protection rate 0 100 100 represents 100 firing of this boiler and where 0 or any value less than the boiler s minimum firing rate represents the minimum firing rate Warm weather shutdown setpoint Temperature or None When warm weather shutdown is Disabled then it has no effect i e the Warm Weather Shutdown WW SD status shown on the priority diagram is false These tw...

Page 205: ...E SLAVE STATUS EACH SLAVE TELLS LL MASTER WHAT IT IS DOING LL MODULATION BACKUP SENSOR DISABLE LEAD OUTLET OUTLET AVERAGE ON HYSTERESIS I GAIN D GAIN Table 39 Modulation Sensor Parameters Parameter Comment LL Modulation sensor S10 The LL master s modulation sensor uses the S10 sensor wired at J10 terminal 7 and 8 If the LL master is enabled and its sensor is faulty then an alert will be issued LL ...

Page 206: ...ion curve If either of these have the None value are invalid are out of range or are too close for interpolation an alert is issued and the setpoint reverts to Local when it is selected as 4 20mA LL CH setpoint Degrees or None This setpoint is used when the time of day input is off If the ODR function is inactive then the setpoint is used as is If the ODR function is active then this setpoint prov...

Page 207: ...ally allocates the old rate that was saved when the flag was set Examples include The rate allocator has encountered a limit such as base load for a limited rate allocation scheme and this limit is released All stages are at their maximum base load or max modulation and one or more stages are rate limited such as due to slow start or stepped modulation limiting due to high stack temperature etc an...

Page 208: ...ng rate As load decreases As long as all available stages are Firing there is no restriction on the slave s commanded firing rate When at least one stage has been dropped No stage is requested to exceed the common base load rate Modulating stage Since all Firing stages receive the same rate any stage can be considered to be the modulating stage The one with the highest StagingOrder number is consi...

Page 209: ...the current Rate Allocation method asks for the current Overflow rate see the Rate Allocator section Dropping Stages The internal algorithms that generate DropStageRequests are called Drop stage methods One or two methods may be active at any time If two are active then their requests are OR d together All methods work by observing various criteria such as the Firing stages the commanded rate or S...

Page 210: ...s sequence number In all cases if two boilers being compared have the same effective sequence number then the one that is selected is undefined either may prevail Sequencer Add Boiler Selection The sequencer selects the next boiler to be added according to a sorted order This description assumes this is implemented by assigning an ordering number and that the lowest numbers are the first to be add...

Page 211: ...ATA This provides the slave status message to be read by a 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 used prior to using other slave slaves with other values If this parameter is set to Equalize Runtime then this slave will be staged according to a run time equalization Any slaves set to U...

Page 212: ...unction returns a value that indicates no boiler may be dropped Otherwise it returns an identifier for the boiler having the highest StagingOrder number Sequencer 1 Minute Event Part of the sequencer is called by the timing service at a 1 minute rate to implement lead rotation The 1 minute event checks the boiler identified by LeadBoilerSeqNum If it is Firing then the LeadBoilerRunTime is incremen...

Page 213: ...g name The long name up to 20 characters of the A1 annunciator input 61 Annunciator 2 location The location of the contacts monitored by the A2 annunciator input 61 Annunciator 2 long name The long name up to 20 characters of the A2 annunciator input 61 Annunciator 3 location The location of the contacts monitored by the A3 annunciator input 61 Annunciator 3 long name The long name up to 20 charac...

Page 214: ...ity than Stack high limit rate decrease when both of these are active and competing 50 Anti short cycle time Whenever the burner is turned off due to no demand the anti short cycle timer is started and the burner remains in a Standby Delay condition waiting for this time to expire Does not apply however to recycle events or DHW demand 21 BLR function This parameter selects the function for the out...

Page 215: ...ter determines one point on the ODR graph At the maximum outdoor temperature the setpoint will be the minimum water temperature 27 CH ODR minimum outdoor temperature This parameter determines the X coordinate of one point on the ODR graph At that outdoor temperature the setpoint will be the CH setpoint or the CH TOD setpoint if TOD Is on 27 CH ODR minimum water temperature This parameter determine...

Page 216: ...aiting for a delay see the Delta T Limit Delay parameter to expire 44 Delta T retry limit If either the Delta T response or the Delta T inverse limit response specify a retry limit then any recycles due to reaching the corresponding response threshold are counted If this count ever exceeds the n value then a lockout occurs 44 DHW anticondensation enable This parameter enables or disables anti cond...

Page 217: ...ue provided by the parameter 34 DHW priority versus CH This parameters determines the priority of DHW versus the CH call for heat when both of these are enabled and active If DHW has a lower priority it may be boosted to the highest priority temporarily via the DHW Priority Override Time parameter 20 DHW priority versus LL This parameters determines the priority of DHW versus the LL slave call for...

Page 218: ...etection is used to provide Safe Start 58 Frost protection anticondensation enable When Frost Protection is in control either the CH or DWH anticondensation function is enabled 50 Frost protection method Determines what happens when Frost Protection from any source becomes active 42 Heat exchanger high limit This enables disables temperature rise detection for the heat exchanger sensor S9 J9 termi...

Page 219: ...ition 51 Lightoff rate proving This parameter specifies the input used to confirm the Prepurge rate has been reached 58 LL Base load rate This specifies the preferred firing rate of a burner which is used for some types of control 77 LL Demand to firing delay This delay time is needed by the LL master to determine the length of time to wait between requesting a slave unit to fire and detecting tha...

Page 220: ...r Connector Type Designates the Sensor type connected to the control for proper reading 20 Outdoor frost protection setpoint This parameter provides the setpoint for frost protection based on outdoor temperature When the outdoor temperature falls below this threshold then frost protection will be active Outlet Connector Type Designates the Sensor type connected to the control for proper reading 20...

Page 221: ...r revolution The number of pulses per revolution of the fan is provided by this parameter Typically it is the number of Hall effect sensors that the fan contains 52 Pump exercise interval This parameter specifies the maximum number of days that a pump can be off If this limit is reached then the pump is turned on for the specified exercise time If the interval is zero then this exercise function i...

Page 222: ...he setpoint at which this demand turns off or on 30 Steam pressure setpoint Pressure Control setpoint 30 Steam sensor The sensor used for modulation and demand typically a 4 20ma source 29 Steam time of day setpoint Provides the steam pressure setpoint when TOD is on 30 System pump cycles Can be written to a new value e g if the pump or controller is replaced 6 T Rise degrees per second limit For ...

Page 223: ...p can be turned on manually or it can be set to operate automatically If it is turned on then it remains on until changed back to Auto 54 XX pump start delay When the pump demand changes from off to on this delay time is used to delay the start of the pump The pump then starts after the delay expires assuming that the demand is still present A delay time of zero disables the delay For a stand alon...

Page 224: ...ation output Hidden B Demand rate is in units CH maximum modulation rate Read Only 100 RPM DHW maximum modulation rate Read Only 100 RPM Minimum modulation rate Read Only 0 RPM Prepurge rate Read Only 100 RPM Lightoff rate Read Only 25 RPM Postpurge rate Read Only 25 RPM CH forced rate Read Only 25 RPM CH forced rate time Read Only 1m 0s mmm ss DHW forced rate Read Only 25 RPM DHW forced rate time...

Page 225: ...ite failure response Read Only A Lockout Ignite failure retries Read Only A Number of retries not set Ignite failure delay Read Only 5m 0s mmm ss MFEP flame failure response Read Only A Lockout Run flame failure response Read Only A Lockout Pilot test hold Hidden Disabled NTC sensor type Read Only A 10K dual safety Interrupted air switch enable Read Only A no IAS IAS start check enable Hidden Enab...

Page 226: ... Auxiliary ON when CH pump is ON System pump output Read Only A No pump assignment System pump control Read Only A Automatic pump control System pump overrun time Read Only 1m 0s mmm ss Pump exercise interval Read Only 0 Days Pump exercise time Read Only 0m 0s mmm ss Annunciation enable Read Only Enabled Annunciator 1 location Read Only E No annunciation for this terminal Annunciator1 short name R...

Page 227: ...3 chars LCI long name Read Only Load Control Input 20 chars ILK short name Read Only ILK 3 chars ILK long name Read Only Interlock 20 chars DHW enable Read Only Disabled DHW demand source Read Only A DHW sensor only DHW has priority over CH Read Only No False Off DHW has priority over LL Read Only No False Off DHW priority time Read Only 30m 0s mmm ss DHW setpoint Read Only 32 F 0 C 140 F 60 C 240...

Page 228: ...nticondensation enable Read Only Disabled DHW anticondensation setpoint Read Only 32 F 0 C 135 F 57 C 240 F 116 C DHW anticondensation pump force off Read Only Disabled Anticondensation Outlet limit Read Only No False Off Anticondensation Delta T Read Only No False Off Anticondensation Stack limit Read Only No False Off Anticondensation Slow start Read Only Yes True On Anticondensation Forced rate...

Page 229: ...Codes Code Description Recommended Troubleshooting of Lockout Codes NOTE Safety Data Faults 1 Unconfigured safety data 1 New Device complete device configuration and safety verification 2 If fault repeats replace module L 2 Waiting for safety data verification 1 Device in Configuration mode and safety parameters need verification and a device needs reset to complete verification 2 Configuration en...

Page 230: ...k not ON L 19 Internal fault Safety RAM write L 20 Internal fault Flame ripple and overflow H 21 Internal fault Flame number of sample mismatch H 22 Internal fault Flame bias out of range H 23 Internal fault Bias changed since heating cycle starts H 24 Internal fault Spark voltage stuck low or high H 25 Internal fault Spark voltage changed too much during flame sensing time H 26 Internal fault Sta...

Page 231: ...er functioning 3 Check the valve operation 4 Reset and sequence the module monitor the PII status 5 If code persists replace the module H or L 65 Interrupted Airflow Switch OFF 1 Check wiring and correct any possible shorts 2 Check airflow switches to assure proper functioning 3 Check the fan blower operation 4 Reset and sequence the module monitor the airflow status 5 If code persists replace the...

Page 232: ...place the Outlet sensor 3 If previous steps are correct and fault persists replace the module H 93 DHW sensor fault 1 Check wiring and correct any possible errors 2 Replace the DHW sensor 3 If previous steps are correct and fault persists replace the module H 94 Header sensor fault 1 Check wiring and correct any possible errors 2 Replace the header sensor 3 If previous steps are correct and fault ...

Page 233: ...off rate proving failed 1 Check wiring and correct any potential wiring errors 2 Check VFDs ability to change speeds 3 Change the VFD 4 If the fault persists replace the module L 123 Purge rate proving failed L 124 High fire switch OFF 1 Check wiring and correct any potential wiring errors 2 Check High Fire Switch to assure proper function not welded or jumpered 3 Manually drive the motor to the H...

Page 234: ...Specific 1 Sequence returns to standby and restarts sequence at the beginning of Purge after the HF switch opens if flame detected during Safe Start check up to Flame Establishing period H 151 High fire switch ON OEM Specific 1 Check wiring and correct any potential wiring errors 2 Check High Fire Switch to assure proper function not welded or jumpered 3 Manually drive the motor to the High Fire p...

Page 235: ... Purge measure the voltage across the switch Supply voltage should be present If not the Block Intake Switch is defective and needs replacing 5 If the fault persists replace the relay module L 165 Block intake OFF L 166 171 RESERVED Feedback 172 Main relay feedback incorrect Internal Fault 1 Reset Module 2 If fault repeats replace module L 173 Pilot relay feedback incorrect L 174 Safety relay feed...

Page 236: ...ting L 214 Invalid Prepurge time setting L 215 Invalid Purge rate proving setting L 216 Invalid Run flame failure response setting L 217 Invalid Run stabilization time setting L 218 Invalid Stack limit enable setting L 219 Invalid Stack limit response setting L 220 Unconfigured Delta T limit setpoint setting L 221 Unconfigured DHW high limit setpoint setting L 222 Unconfigured Outlet high limit se...

Page 237: ...1 Backup configuration settings was restored from 12 Annunciation configuration was restored from 13 Annunciation configuration was restored from 14 Safety group verification table was restored from 15 Safety group verification table was updated 16 Invalid Parameter PCB was detected 17 Invalid Range PCB was detected System Parameter Errors 18 Alarm silence time exceeded maximum 19 Invalid safety g...

Page 238: ... Table 50 Alerts Continued Code Description 89 RESERVED 90 Modulation output type was invalid 91 Firing rate control parameter was invalid 92 Forced rate was out of range vs min max 93 Forced rate was invalid vs RPM 94 Slow start ramp value was invalid 95 Slow start degrees value was invalid 96 Slow start was ended due to outlet sensor fault 97 Slow start was end due to reference setpoint 98 CH ma...

Page 239: ...on sensor was not compatible for DHW Operation Faults 171 DHW control was suspended due to fault 172 DHW temperature was invalid 173 DHW inlet temperature was invalid 174 DHW outlet temperature was invalid 175 DHW high limit must be disabled for AUTO mode 176 DHW sensortype was not compatible for AUTO 177 DHW priority source setting was invalid 178 DHW priority method setting was invalid CH Operat...

Page 240: ... 251 CH max outdoor setpoint was invalid Table 50 Alerts Continued Code Description 252 CH min outdoor setpoint was invalid 253 CH min water setpoint was invalid 254 CH outdoor temperature range was too small 255 CH water temperature range was too small 256 Steam setpoint was invalid 257 Steam time of day setpoint was invalid 258 Steam minimum pressure was invalid 259 CH ODR min water temperature ...

Page 241: ... Hardware SLO static flame 337 Abnormal Recycle Hardware SLO rod shorted 338 Abnormal Recycle Hardware SLO AD linearity Table 50 Alerts Continued Code Description 339 Abnormal Recycle Hardware SLO bias not set 340 Abnormal Recycle Hardware SLO bias shorted 341 Abnormal Recycle Hardware SLO electronics 342 Abnormal Recycle Hardware processor clock 343 Abnormal Recycle Hardware AC phase 344 Abnormal...

Page 242: ...nternal error Safety key bit 8 was incorrect 487 Internal error Safety key bit 9 was incorrect Table 50 Alerts Continued Code Description 488 Internal error Safety key bit 10 was incorrect 489 Internal error Safety key bit 11 was incorrect 490 Internal error Safety key bit 12 was incorrect 491 Internal error Safety key bit 13 was incorrect 492 Internal error Safety key bit 14 was incorrect 493 Int...

Page 243: ... 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 Heat Exchanger High Limit Errors 570 Heat exchanger high limit setpoint was out...

Page 244: ...CB FALCON 750 265 120 ...

Page 245: ...APPENDIX B CB FALCON PLUG IN MODULE ...

Page 246: ......

Page 247: ...ered from the CB Falcon The 833 3639 3871 CB Falcon Hydronic Control and 833 3578 CB Falcon Steam Control have a backup region that will allow the CB Falcon s programmable data to be backed up and restored This supports both replacement of a controller that has failed and setup of a new controller This process is described below All operations that read and write 833 3640 data are password protect...

Page 248: ...ing with as shown in Fig 3 Fig 3 Program Module Configuration page Button Actions NOTE An installer password will be required to perform the below functions Erase will erase the contents of the installed Program Module for the selected Burner Backup will copy non safety parameter values and Backup Control Header data from the CB Falcon installed in the Burner location noted and save the data to th...

Page 249: ...entered in the Label field This name appears when the Backup Parameters button is pressed If Yes is pressed then a label will be written in the PM memory that will be shown on the 833 3639 Program Module page when the PM is inserted If No is pressed then no label will be written in the PM memory 3 750 244 ...

Page 250: ......

Page 251: ...APPENDIX C GAS VALVE ...

Page 252: ......

Page 253: ...Unit VMU and dc fan are used for modulating premix appliances such as gas bur ners gas boilers rooftop units makeup air units and process ap plications FEATURES Wide modulation range 14 to 100 of burner load 24 Vac and 120 Vac models Main valve body with two shutoff seats double block valve Closing time less than one second Mesh screen strainer between inlet flange and main body Various pressure t...

Page 254: ...4 mBar Note CSA Certification to 1 2 psi Connections 1 8 in 3 mm NPT pressure taps at inlet and outlet flanges Eight flange connections are provided at the main body to mount either a pressure switch high or low or a ValveProving System VPS Torsion and Bending Stress Pipe connections meet EN151 Group 2 requirements Electrical Equipment Standard DIN plug connector with 36 in 914 mm leadwires Valve ...

Page 255: ...wall 3 cu in hr 50 cm3 h at test pressure of 0 87 psi 6 mBar and 7 83 psi 540 mBar First Valve 2 5 cu in hr 40 cm3 h at test pressure of 0 87 psi 6 mBar and 7 83 psi 540 mBar Second Valve 2 4 cu in hr 40 cm3 h at test pressure of 0 87 psi 6 mBar and 7 83 psi 540 mBar High Pressure Test In the OFF condition the valve will withstand 21 75 psi 1 5 Bar inlet pressure without damage Accessories FL02000...

Page 256: ...734C 1 1 Gas Air Servo Regulated Gas Valves 4 EN2R 9074 0612R1 NE Fig 1 V4730C V8730C Gas Valves 1 2 in 13 mm and 3 4 in 19 mm size dimensions in in mm Fig 2 V4730C V8730C Gas Valves 1 in 25 mm size dimensions in in mm ...

Page 257: ... V8730C V4734C 1 1 Gas Air Servo Regulated Gas Valves EN2R 9074 0612R1 NE 5 Fig 3 V4730C V8730C Gas Valves 1 1 4 in 32mm size dimensions in in mm Fig 4 V4734C Gas Valves 1 1 4 in 32mm size dimensions in in mm ...

Page 258: ...R1 NE Fig 5 Venturi 150 335 kW with 1 2 in to 1 in gas valves and valve shutoff kit installed dimensions in in mm See Table 3 for dimensions Table 3 Dimensions in inches millimeters Valve Size in inches A B C D 1 2 3 4 6 1 4 159 15 15 16 405 2 15 16 75 7 7 1 2 191 1 8 5 16 211 ...

Page 259: ...V4730C V8730C V4734C 1 1 Gas Air Servo Regulated Gas Valves EN2R 9074 0612R1 NE 7 Fig 6 Venturi 500kW with V4730 gas vlave and valve shutoff kit installed dimensions in in mm part 1 ...

Page 260: ...V4730C V8730C V4734C 1 1 Gas Air Servo Regulated Gas Valves 8 EN2R 9074 0612R1 NE Fig 7 Venturi 500 kW with V4730 gas valve and valve shutoff kit installed dimensions in in mm part 2 ...

Page 261: ...V4730C V8730C V4734C 1 1 Gas Air Servo Regulated Gas Valves EN2R 9074 0612R1 NE 9 Fig 8 V4734 VMU 500 680 ...

Page 262: ... V4734C 1 1 Gas Air Servo Regulated Gas Valves 10 EN2R 9074 0612R1 NE Fig 9 Capacity curves for V4730C V8730C and VMU 150 Venturi 1 2 in size Fig 10 Capacity curves for V4730C V8730C and VMU 300 Venturi 3 4 in size ...

Page 263: ... V4734C 1 1 Gas Air Servo Regulated Gas Valves EN2R 9074 0612R1 NE 11 Fig 11 Capacity curves for V4730C V8730C and VMU 300 Venturi 1 in size Fig 12 Capacity curves for V4730C V8730C and VMU 335 Venturi 1 1 4 in size ...

Page 264: ...4734C 1 1 Gas Air Servo Regulated Gas Valves 12 EN2R 9074 0612R1 NE Fig 14 Capacity curves for V4734C V8734C and VMU 680 Venturi 1 1 4 in size Fig 13 Capacity curves for V4730C V8730C and VMU 500 Venturi 1 1 4 in size ...

Page 265: ... commissioning the burner check for proper lightoff and verify correct fuel air mix and combustion quality through out the entire firing range from lowest to highest fan speeds used Mounting Locations The distance between the gas valve and the wall ground must be a minimum of 11 5 16 in 30 cm Fig 15 Regulating adjusting screw Main Gas Connection 1 Take care that dirt does not enter the gas valve d...

Page 266: ...ure at first SSOV flange tap 2 inlet pressure at first SSOV P outlet pressure at first SSOV 3 inlet pressure at second SSOV 4 outlet pressure at second SSOV flange tap The following pressures can be measured 1 Inlet pressure tap on inlet flange 1 2 Pressure after inlet screen 2 3 Unregulated intermediate pressure pressure between the two shutoff seats P 4 Regulated intermediate pressure pressure b...

Page 267: ...e rate of bubbles coming through the water stabili zes count the number of bubbles appearing during a ten se cond period Each bubble appearing represents a flow rate of 0 001 cfh 28 cch See Table 4 10 Close the upstream manual gas cock A 11 Remove the leak test tap from the valve body 12 Using a small amount of pipe sealant on the 1 8 in 3 mm NPT plug reinstall the plug in pressure tap point P 13 ...

Page 268: ...a short in the electrical circuit and repair it as ne cessary WARNING Electrical Shock Hazard Can cause severe inju ry death or property damage Use extreme caution when troubleshooting line volta ge is present IMPORTANT Do not replace the valve until all other sources of trouble are eliminated SERVICE INFORMATION Scheduled Inspection and Maintenance Set up and follow a schedule for periodic inspec...

Page 269: ...APPENDIX D CB FALCON MODBUS COMMUNICATION ...

Page 270: ......

Page 271: ...t Modbus Application layer communication protocol standard adopted by the Modbus IDA trade association Recognized as an industry standard protocol for RS 485 serial communication PCB Parameter Control Block Files that customize the user interface with the CB Falcon PCBs reside in the non volatile storage in the Falcon and are uploaded from the controller into the user interface PIM Plug In Module ...

Page 272: ...es 2 register address spaces The holding register map is defined in Fig 1 and Table 4 Except for variable length data items the registers can be accessed as a single register or up to 20 registers for 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 regist...

Page 273: ...URATION DOMESTIC HOT WATER DHW CONFIGURATION ANNUNCIATION CONFIGURATION PUMP CONFIGURATION FAN CONFIGURATION BURNER CONTROL CONFIGURATION CENTRAL HEAT CH CONFIGURATION MODULATION CONFIGURATION PLUGIN MODULE PIM PUBLIC SYSTEM CONFIGURATION LEAD LAG STATUS STATISTICS MIX STATUS PUMP STATUS DOMESTIC HOT WATER DHW STATUS CENTRAL HEAT CH STATUS DEMAND MODULATION STATUS SENSOR STATUS BURNER CONTROL STAT...

Page 274: ... after read Identifies register groups that have new data in them Bit map 15 PCB configuration 14 PIM configuration 13 Reserved 12 Lead Lag configuration 11 Frost protection configuration 10 Outdoor reset configuration 9 Anti condensation configuration 8 Limits configuration 7 DHW configuration 6 Annunciation configuration 5 Pump configuration 4 Fan configuration 3 Burner control configuration 2 C...

Page 275: ...rved 10 OEM alert PCB stored in PIM 9 OEM range PCB stored in PIM 8 OEM parameter PCB stored in PIM 7 3 Reserved always 0 2 Valid copyright 1 Lead Lag enabled 0 PIM installed TREND STATUS 0006 0006 Demand source R U16 Current demand source 0 Unknown 1 No source demand 2 CH 3 DHW 4 Lead Lag slave 5 Lead Lag master 6 CH frost protection 7 DHW frost protection 8 No demand due to burner switch registe...

Page 276: ...l otherwise 4 20 mA 0 1 mA precision Duplicate of register 15 when S2 terminal is 4 20 mA 0016 0022 Active CH pressure setpoint R U16 0 150psi 0 1psi precision 0017 0023 Extended Status Change R U16 Register is cleared all bits zeroed after read Identifies register groups that have new status or configuration data in them Bit map 15 5 Reserved 4 DHW plate heat exchanger configuration 3 DHW plate h...

Page 277: ...t operation S4 J8 10 terminal R U16 40 130 0 1 C precision d or other see register 610 002C 0044 DHW operation S7 J9 3 terminal R U16 40 130 0 1 C precision e or other see register 612 002D 0045 Stack or Heat exchanger operation S9 J9 6 terminal R U16 40 130 0 1 C precision e or other see register 613 002E 0046 Outlet operation sensor S4 J8 10 state R U16 0 None 1 Normal 2 Open 3 Shorted 4 Outside...

Page 278: ...e override R U16 0 None 1 Burner control default 2 Burner control 3 Manual firing rate 4 Manual firing rate off 5 Fan on during off cycle 003B 0059 Override rate R U16 RPM or c 003C 0060 Demand rate R U16 RPM or c 003D 003F 0061 0063 RESERVED CENTRAL HEATING CH STATUS 0040 0064 CH status R U16 0 Unknown 1 Disabled 2 Normal 3 Suspended 0041 0065 CH setpoint source R U16 0 Unknown 1 Normal setpoint ...

Page 279: ...c 0056 0086 DHW frost heat demand R U16 0 Off 1 On 0057 0087 DHW frost burner demand R U16 0 Off 1 On 0058 0088 Active DHW on hysteresis R U16 0 130 0 1 C precision a 0059 0089 Active DHW off hysteresis R U16 0 130 0 1 C precision a 005A 0090 DHW storage time R U16 Elapsed DHW storage time secs 005B 0091 DHW storage heat demand R U16 0 Off 1 On 005C 0092 DHW storage burner demand R U16 0 Off 1 On ...

Page 280: ...n time R U16 Running overrun time for DHW pump due to frost protection seconds 0068 0104 DHW pump idle days count R U16 Number of days that DHW pump has not run sat idle 0069 0105 System pump status R U16 For application build less than 1600 see table 12 For application build 1600 or higher see table 13e 006A 0106 System pump overrun time R U16 Running overrun time for Lead Lag pump seconds 006B 0...

Page 281: ...before auxiliary 1 pump will be turned on DHW PLATE HEAT EXCHANGER STATUS 0098 0152 DHW tap heat demand R U16 0 Off 1 On 0099 0153 DHW preheat demand R U16 0 Off 1 On 009A 0154 DHW change rate R U16 DHW plate heat exchanger temperature change rate degrees second 0 1 C precision 009B 0155 DHW tap on recognition time R U16 Persistent time that DHW tap demand has been recognized seconds 009C 0156 DHW...

Page 282: ...72 Outlet T rise rate R U16 Outlet temperature change rate degrees second 0 1 C precision 00AD 0173 Exchanger T rise rate R U16 Heat exchanger temperature change rate degrees second 0 1 C precision 00AE 0174 S10 sensor reading R U16 40 130 0 1 C precision a 00AF 0175 S10 sensor state R U16 0 None 1 Normal 2 Open 3 Shorted 4 Outside high range 5 Outside low range 6 Not reliable SYSTEM CONFIGURATION...

Page 283: ...set to Installer or higher 00BF 0191 OEM password W To set new OEM password up to 20 characters Requires register access status register 177 set to OEM or higher MODULATION CONFIGURATION 00C0 0192 Modulation output R W U16 SAFETY parameterf 0 Fan PWM 1 0 10V 2 4 20mA 00C1 0193 CH maximum modulation rate R W U16 RPM or c 00C2 0194 DHW maximum modulation rate R W U16 RPM or c 00C3 0195 Minimum modul...

Page 284: ... gain R W U16 0 1000 00D9 0217 CH I gain R W U16 0 1000 00DA 0218 CH D gain R W U16 0 1000 00DB 0219 CH hysteresis step time R W U16 0 64800 seconds 0 Disable hysteresis stepping 00DC 0220 CH pressure setpoint R W U16 0 150psi 0 1psi precision 00DD 0221 CH pressure on hysteresis R W U16 0 150psi 0 1psi precision 00DE 0222 CH pressure off hysteresis R W U16 0 150psi 0 1psi precision 00DF 0223 RESER...

Page 285: ... 00EB 0235 Run stabilization time R W U16 SAFETY parameterf 0 64800 seconds 18 hours 0xFFFF Not configured 00EC 0236 Postpurge time R W U16 SAFETY parameterf 0 64800 seconds 18 hours 0xFFFF Not configured 00ED 0237 Interlock start check enable R W U16 SAFETY parameterf 0 No ILK check 1 ILK check 00EE 0238 Interlock open response R W U16 SAFETY parameterf 0 Lockout 1 Recycle 00EF 0239 Ignite failur...

Page 286: ... PWM frequency R W U16 0 Unknown 1 1000 Hz 2 2000 Hz 3 3000 Hz 4 4000 Hz 0xFFFF Not configured 0103 0259 Fan pulses per revolution R W U16 1 10 0104 0260 Fan speed up ramp R W U16 0 7000 RPM sec 0105 0261 Fan slow down ramp R W U16 0 7000 RPM sec 0106 0262 Fan gain up R W U16 0 65535 0107 0263 Fan gain down R W U16 0 65535 0108 0264 Fan minimum duty cycle R W U16 1 100 b 0109 010F 0265 0271 RESERV...

Page 287: ...xiliary pump Y is set 13 Normal pump demand when auxiliary pump X is set 12 7 Reserved always 0 6 Normal pump demand when DHW service is active 5 Normal pump demand when CH service is active 4 Reserved 3 Normal pump demand when DHW demand 2 Normal pump demand when CH demand 1 Normal pump demand when local burner demand 0 Local demand inhibited for faults 0129 0297 CH pump options 2 R W U16 Bit map...

Page 288: ...ed always 0 8 Force pump off when DHW high limit 7 Force pump off when DHW anti condensation 6 Force pump off when CH anti condensation 5 Force pump off when DHW priority is active 4 Force pump on when DHW frost protection 3 Force pump on when CH frost protection 2 Force pump on when Lead Lag slave demand 1 Force pump on when local burner demand 0 Force pump on when Outlet high limit 012E 0302 Sys...

Page 289: ...1C0 0448 DHW enable R W U16 0 DHW disabled 1 DHW enabled 01C1 0449 DHW demand switch R W U16 Source of DHW demand 0 Modulation sensor only 1 EnviraCOM DHW request 2 DHW switch 3 Unused 4 STAT terminal 5 Reserved 6 Modbus STAT 7 Auto S6 or EnviraCOM DHW request 8 Auto S6 or sensor only 9 Plate heat exchanger 01C2 0450 DHW priority vs CH R W U16 0 CH DHW 1 DHW CH 01C3 0451 DHW priority vs LL R W U16...

Page 290: ...sensors when Delta T limit occurs 0 130 0 1 C precision a 01D8 0472 Delta T response R W U16 0 Lockout 1 Recycle delay 2 Recycle delay with retry limit 01D9 0473 Delta T delay R W U16 0 64800 seconds 18 hours 0xFFFF Not configured 01DA 0474 DHW high limit enable R W U16 SAFETY parameterf 0 Disable DHW high limit 1 Enable dual sensor safety DHW high limit 2 Enable single sensor non safety DHW high ...

Page 291: ...r of recycles due to T rise limit 01EE 0494 Delta T inlet exchanger enable R W U16 Delta T limit for inlet to exchanger flow 0 Disable Delta T limit 1 Enable Delta T limit 2 Enable Inversion detection 3 Enable Delta T limit and Inversion detection 01EF 0495 Delta T inlet exchanger degrees R W U16 Temperature delta between inlet exchanger sensors when Delta T limit occurs 0 130 0 1 C precision a AN...

Page 292: ...ODR maximum outdoor temperature R W U16 40 130 0 1 C precision a 0206 0518 Lead Lag CH ODR minimum outdoor temperature R W U16 40 130 0 1 C precision a 0207 0519 Lead Lag CH ODR low water temperature R W U16 40 130 0 1 C precision a 0208 0520 Lead Lag CH ODR boost time R W U16 0 64800 seconds 18 hours 0xFFFF Not configured 0209 0521 Lead Lag CH ODR maximum off point R W U16 40 130 0 1 C precision ...

Page 293: ...ATION 0220 0544 Lead Lag slave enable R W U16 0 Lead Lag slave disabled 1 Lead Lag simple slave enabled for EnviraCom master 2 Lead Lag simple slave enabled for Global Modbus master 3 Lead Lag full slave enabled for Global Modbus master 0221 0545 Lead Lag master enable R W U16 0 Not a Lead Lag master 1 Lead Lag master 0222 0546 Lead Lag setpoint R W U16 40 130 0 1 C precision a 0223 0547 Lead Lag ...

Page 294: ...ast according to priority 0235 0565 Slave command R W U16 Bit map 15 Slave demand request 14 Slave suspend startup 13 Slave run fan request 12 Turn on auxiliary pump X 11 Turn on auxiliary pump Y 10 Turn on auxiliary pump Z 9 Reserved always 0 8 Commanded rate is binary fraction g 7 0 Commanded rateh 0236 0566 Base load rate R W U16 RPM or c 0237 0567 Fan during off cycle rate R W U16 RPM or c 023...

Page 295: ...mA steam pressure R W U16 Pressure corresponding to 4mA signal input 0 150psi 0 1psi precision 024A 0586 CH 20mA steam pressure R W U16 Pressure corresponding to 4mA signal input 0 150psi 0 1psi precision 024B 024F 0587 0591 RESERVED EXTENDED LIMITS CONFIGURATION 0250 0592 Heat exchanger high limit enable R W U16 0 Disable Heat exchanger high limit 1 Enable Heat exchanger high limit 0251 0593 Heat...

Page 296: ...sor and DHW operation sensor R W U16 SAFETY parameterf 0 Unconfigured 1 Raw A2D counts 2 10K NTC dual temperature 3 10K NTC single temperature 4 12K NTC single temperature 5 0 15 psi pressure 6 0 150 psi pressure 7 4 20 mA 0265 0613 S8S9 J9 4 6 connector type Stack dual sensor Stack limit sensor and Stack operation sensor Stack limit sensor and Heat exchanger sensor R W U16 SAFETY parameterf 0 Unc...

Page 297: ...degrees R W U16 Rate of temperature drop in DHW sensor when tap detection is declared 0 130 second 0 1 C precision a 02B7 0695 Tap detect on hysteresis R W U16 0 130 0 1 C precision a 02B8 0696 Tap detect on recognition time R W U16 0 64800 seconds 18 hours 0xFFFF Not configured 02B9 0697 Tap stop DHW Inlet degrees R W U16 Temperature delta between DHW inlet sensors when tap demand is stopped drop...

Page 298: ... 0725 Drop stage detection time R W U16 0 64800 seconds 18 hours 0xFFFF Not configured 02D6 0726 RESERVED 02D7 0727 Drop stage error threshold R W U16 0 130 0 1 C precision a 02D8 0728 Drop stage rate offset R W U16 100 100 2 0 1 units 02D9 0729 Drop stage error gain R W U16 0 100 02DA 0730 Drop stage rate gain R W U16 0 100 02DB 0731 Drop stage inter stage delay R W U16 0 64800 seconds 18 hours 0...

Page 299: ...and when CH demand 1 Normal pump demand when local burner demand 0 Local demand inhibited for faults 02F8 07600760 Auxiliary 2 pump options 2 R W U16 Bit map 15 Pump used for Lead Lag 14 Pump used for local demand 13 9 Reserved always 0 8 Force pump off when DHW high limit 7 Force pump off when DHW anti condensation 6 Force pump off when CH anti condensation 5 Force pump off when DHW priority is a...

Page 300: ...h units type the parameter has 0 RPM 1 If Modulation Output parameter reg ister 192 doesn t match with the setting of this bit then the parameter setting is invalid d All temperature registers are expressed in C regardless what Temperature units register 179 is set to Temperature range is 40 C to 130 C with values given in 0 1 C units for example 32 0 C 320 A temperature that is NOT applicable in ...

Page 301: ... Annunciator R U16 See register 3 decimal 20 21 Outlet temperature R U16 See register 7 decimal 22 23 Inlet temperature Steam pressure R U16 See register 11 or 20 decimal Data type is dependent on Product type register 176 24 25 DHW temperature R U16 See register 12 decimal 26 27 Outdoor temperature R U16 See register 13 decimal 28 29 Stack temperature R U16 See register 14 decimal 30 31 4 20mA in...

Page 302: ...escription Note 0 None No lockout hold 1 Unconfigured safety data Lockout 2 Waiting for safety data verification Lockout 3 Internal fault Hardware fault Hold 4 Internal fault Safety Relay key feedback error Hold 5 Internal fault Unstable power DCDC output Hold 6 Internal fault Invalid processor clock Hold 7 Internal fault Safety relay drive error Hold 8 Internal fault Zero crossing not detected Ho...

Page 303: ...ut 175 Safety relay open Lockout 176 Main relay ON at safe start check Lockout 177 Pilot relay ON at safe start check Lockout 178 Safety relay ON at safe start check Lockout 179 183 RESERVED Table 8 Falcon lockout and hold codes Table 8 Falcon lockout and hold codes 81 Delta T inlet outlet limit Hold Lockout 82 Stack limit Hold Lockout 83 Delta T exchanger outlet limit Hold Lockout 84 Delta T inle...

Page 304: ...t 221 Unconfigured DHW high limit setpoint setting Lockout 222 Unconfigured Outlet high limit setpoint setting Lockout 223 Unconfigured Stack limit setpoint setting Lockout 224 Invalid DHW demand source setting Lockout Table 8 Falcon lockout and hold codes Table 8 Falcon lockout and hold codes 225 Invalid Flame threshold setting Lockout 226 Invalid Outlet high limit setpoint setting Lockout 227 In...

Page 305: ...as out of range 77 Fan gain down was invalid 78 Fan gain up was invalid 79 Fan minimum duty cycle was invalid Table 10 Falcon alert codes Table 10 Falcon alert codes Code Description 0 None No alert 1 Alert PCB was restored from factory defaults 2 Safety configuration parameters were restored from factory defaults 3 Configuration parameters were restored from factory defaults 4 Invalid Factory Inv...

Page 306: ...nvalid 162 DHW ON hysteresis was invalid 163 DHW hysteresis step time was invalid Table 10 Falcon alert codes Table 10 Falcon alert codes 80 Fan pulses per revolution was invalid 81 Fan PWM frequency was invalid 82 83 RESERVED 84 Lead Lag CH 4 20mA water temperature setting was invalid 85 No Lead Lag add stage error threshold was configured 86 No Lead Lag add stage detection time was configured 87...

Page 307: ...too small 255 CH ODR water temperature range was too small 256 Steam setpoint was invalid Table 10 Falcon alert codes Table 10 Falcon alert codes 164 DHW sensor type was invalid 165 Inlet sensor type was invalid for DHW 166 Outlet sensor type was invalid for DHW 167 DHW storage OFF hysteresis was invalid 168 DHW storage ON hysteresis was invalid 169 DHW modulation sensor type was invalid 170 DHW m...

Page 308: ...0 seconds of RUN 323 Abnormal Recycle Safety Relay off after 10 seconds of RUN 324 Abnormal Recycle Hardware flame bias 325 Abnormal Recycle Hardware static flame Table 10 Falcon alert codes Table 10 Falcon alert codes 257 Steam time of day setpoint was invalid 258 Steam minimum pressure was invalid 259 CH ODR min water temperature was invalid 260 RESERVED 261 DHW setpoint was invalid 262 DHW time...

Page 309: ...26 Abnormal Recycle Hardware flame current invalid 327 Abnormal Recycle Hardware flame rod short 328 Abnormal Recycle Hardware invalid power 329 Abnormal Recycle Hardware invalid AC line 330 Abnormal Recycle Hardware SLO flame ripple 331 Abnormal Recycle Hardware SLO flame sample 332 Abnormal Recycle Hardware SLO flame bias range 333 Abnormal Recycle Hardware SLO flame bias heat 334 Abnormal Recyc...

Page 310: ...ange 571 Heat exchanger high limit response was invalid Table 10 Falcon alert codes Table 10 Falcon alert codes 478 Internal error Safety key bit 0 was incorrect 479 Internal error Safety key bit 1 was incorrect 480 Internal error Safety key bit 2 was incorrect 481 Internal error Safety key bit 3 was incorrect 482 Internal error Safety key bit 4 was incorrect 483 Internal error Safety key bit 5 wa...

Page 311: ...tting 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 579 Auxiliary pump output was invalid 580 System pump output was invalid 581 Mix pump output was invalid 582 589 RESERVED 590 DHW plate preheat ...

Page 312: ...p B On Mix demand 65 Pump C On Mix demand Table 12 Pump status codes application build less than 1600 Table 12 Pump status codes application build less than 1600 Status Description Note 0 Unknown 1 Not connected 2 Not Lead Lag master 3 Pump A Off 4 Pump B Off 5 Pump C Off 6 Pump A Off Anti condensation CH demand 7 Pump B Off Anti condensation CH demand 8 Pump C Off Anti condensation CH demand 9 Pu...

Page 313: ...on timeout for password login See User Interface Data Attribute Table section for more information regarding how access security is determined Two Modbus registers are defined to manage the register data access login 0x00B1 Password 0x0013 Register Access Status The Modbus master writes a password into the Password register to request write access privileges to the data registers Even though this ...

Page 314: ... the Modbus network The Modbus master issues a Report Slave ID request for a specific Modbus address onto the Modbus network and if a Falcon with the requested Modbus address exists it responds to the request If none exists the Modbus master times out and concludes that no Falcon is present with that Modbus address Included in the Falcon response is the following data to further identify it OS num...

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