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CleaverBrooks CFC-E 1000, Manual

The CleaverBrooks CFC-E 1000 is a high-quality industrial boiler designed for energy efficiency and reliability. For easy installation and maintenance, users can simply download the free manual from our website. Ensure optimal performance with step-by-step instructions and helpful tips. Download the manual at manualshive.com.

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BOILER BOOK CFC-E

2

Table of Contents

FEATURES AND BENEFITS   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PRODUCT OFFERING   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DIMENSIONS AND RATINGS   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PERFORMANCE DATA  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ENGINEERING DATA  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
STACK/BREECHING SIZE CRITERIA   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
CB FALCON CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
EXAMPLE SYSTEM SCHEMATICS  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

List of Figures

Fireside Access  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Premix Burner Technology   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ClearFire CE Control Panel   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Model CFC-E Dimensional Views  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Efficiencies  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  15-16
Waterside Pressure Drop   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  19-20
High Fire Speed Settings vs. % Glycol   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Maximum Firing Rate vs. % Glycol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Condensate Piped Direct to Drain   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Neutralization Capsule  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Combo Trap/Tank   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Treatment Tank  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Condensate Piping for Multiple Boilers  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Tank Detail, Multiple Boilers  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Gas Piping Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Gas Header Piping  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Model CFC-E Minimum Room Clearance Dimensions  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
CFC-E Seismic Mounting   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Two Opening Outside Wall Method   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Two Opening Ducted Method   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
One Opening Method  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Two Opening Engineered Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Boiler Air Inlet  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Horizontal through-wall venting using inside air for combustion  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Horizontal flue through-wall with direct vent combustion intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Inside Air - Vertical Vent  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Vertical Stack with Direct Vent Combustion Air  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
CFC-E Rear Connections  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
CB Falcon Pinout  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Primary/Secondary Piping Schematic, Single Boiler   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Primary/Secondary Piping Schematic, Two Boilers  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Primary/Secondary Piping Schematic, Three Boilers  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Primary Variable Flow Piping Schematic, Single Boiler  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Primary Variable Flow Piping Schematic, Two Boilers   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Primary Variable Flow Piping Schematic, Three Boilers   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Primary Variable Flow Piping Schematic, Single Boiler with Heat Exchanger  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Primary Variable Flow Piping Schematic, Single Boiler with Heat Exchanger and Dual Return . . . . . . . . . . . . . . . . . . . . . . 59

List of Tables

U.S. Standard Dimensions Model CFC-E Boiler  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Dimensions (Metric) Model CFC-E  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Model CFC-E Boiler Ratings (Sea Level to 2000 Feet)   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Altitude Correction for Input Capacity at Various Altitude Levels   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CFC-E Efficiencies  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Emissions  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Noise level (dBA) measured 3 feet in front of boiler  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Flow Rates  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Summary of Contents for CFC-E 1000

Page 1: ...CFC E ClearFire Condensing Boiler Boiler Book 02 2018...

Page 2: ...Boiler Air Inlet 39 Horizontal through wall venting using inside air for combustion 42 Horizontal flue through wall with direct vent combustion intake 43 Inside Air Vertical Vent 45 Vertical Stack wi...

Page 3: ...mum Flow Recommendations for ClearFire Model CFC E Boiler 24 Condensate piping for multiple boilers 28 Model CFC E Minimum and Maximum Gas Pressure 31 Model CFC E Minimum Required Gas Pressure Altitud...

Page 4: ...the extended heating surface tubes the CFC E boiler will provide fuel to water efficiency of up to 99 at low fire and 95 at high fire with 80 degrees F return water temperature Ease of Maintenance Th...

Page 5: ...outdoor reset controls radiant floor heating snow melt systems ground source heat pump systems and systems that utilize variable speed circulating pumps It may also be employed in standard hot water s...

Page 6: ...Cutoff manual reset NTC negative temp coefficient sensor for hot water supply temperature NTC sensor for hot water return temperature ASME Safety Relief Valve set 125 psig 8 6 Bar Optional SRV set poi...

Page 7: ...on the burner is capable of direct vent combustion G Ignition of the main flame is via direct spark utilizing high voltage electrodes and a UV scanner for flame supervision H To ensure adequate combus...

Page 8: ...door control E Header temperature sensor for multiple boiler Lead Lag operation F Auxiliary Low Water Control shipped loose for field piping by others into the system piping G Alarm Horn for safety sh...

Page 9: ...BOILER BOOK CFC E DIMENSIONS AND RATINGS 9 Figure 4 Model CFC E Dimensional Views OPTIONAL ADJUSTABLE FEET ALLOW FOR 1 56 TO 3 88 ADDITIONAL HEIGHT...

Page 10: ...RF Flange 2 1 2 2 1 2 2 1 2 4 4 Z Air Vent NPT 1 1 2 1 1 2 1 1 2 1 1 2 1 1 2 AA Vessel Drain NPT 1 1 2 1 1 2 1 1 2 1 1 2 1 1 2 BB Flue Gas Outlet Standard Nominal 6 6 8 8 8 Option Nominal 8 8 6 10 10...

Page 11: ...192 N Rear of Base to Flue Outlet 165 165 165 190 190 P Casing Depth 921 921 921 1077 1077 Q Casing Height 1703 1703 1703 1749 1749 R Floor to Lower Return Connection 428 428 428 428 428 S Floor to Up...

Page 12: ...39 53 KW 129 193 258 387 516 MAWP psi 125 125 125 125 125 Bar 8 6 8 6 8 6 8 6 8 6 MAWT F 210 210 210 210 210 C 99 99 99 99 99 Maximum Operating Setpoint F 194 194 194 194 194 C 90 90 90 90 90 Water Co...

Page 13: ...ficiencies The tables below list the operating efficiencies of each size Model CFC E boiler including radiation losses As the Model CFC E is a fully condensing boiler maximum efficiency is obtained wh...

Page 14: ...emperature F C 68 80 100 120 130 140 160 20 27 38 49 55 60 72 20 99 0 98 8 97 0 93 3 90 7 88 9 88 0 50 97 8 96 9 94 7 91 5 89 8 88 5 87 7 75 96 9 95 4 92 7 90 0 89 0 88 2 87 5 100 95 9 93 8 90 8 88 6...

Page 15: ...turn Water Temperature 40 F Temperature Di eren al CFC E 500 Efficiency Curve 20 Firing Rate 50 Firing Rate 75 Firing Rate 100 Firing Rate F 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 60 70 80 90 1...

Page 16: ...Return Water Temperature F 40 F Temperature Di eren al CFC E 1000 Efficiency Curve 20 Firing Rate 50 Firing Rate 75 Firing Rate 100 Firing Rate 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 60 70 80 9...

Page 17: ...ls and is virtually vibration free Thus it is very suitable in applications that demand low noise levels Table 7 Noise level dBA measured 3 feet in front of boiler POLLUTANT UNITS CO ppm 20 lb MMBTU 0...

Page 18: ...sidered when sizing the system flow so that the flow does not exceed the capacity of the boiler or the demand Flow Rates and Pressure Drops To maintain rated capacity of the boiler recommended flow ra...

Page 19: ...ATA 19 Figure 10 Waterside Pressure Drop CFC E 500 Figure 11 Waterside Pressure Drop CFC E 750 0 0 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 1 0 1 1 1 2 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 9...

Page 20: ...BOILER BOOK CFC E ENGINEERING DATA 20 Figure 12 Waterside Pressure Drop CFC E 1000 Figure 13 Waterside Pressure Drop CFC E 1500...

Page 21: ...d for either with an expansion tank air filled or with a bladder type tank These devices permit the water pressure to expand outside of the boiler and not impact the pressure vessel or pressure reliev...

Page 22: ...Outlet NPT Valve Capacity MBH CFC E 500 3 4 1 2270 CFC E 750 3 4 1 2270 CFC E 1000 3 4 1 2270 CFC E 1500 3 4 1 2270 CFC E 2000 3 4 1 2270 75 psig Model Inlet NPT Outlet NPT Valve Capacity MBH CFC E 5...

Page 23: ...n inhibitors are added to glycol systems However all glycols tend to oxidize over time in the presence of oxygen and when heated form aldehydes acids and other oxidation products Whenever inadequate l...

Page 24: ...ning a boiler isolation valve once a day or turning on a boiler circulating pump Table 12 Glycol Minimum Flow Recommendations for ClearFire Model CFC E Boiler Minimum required boiler circulation rate...

Page 25: ...mum Firing Rate vs Glycol 4000 4100 4200 4300 4400 4500 4600 4700 4800 4900 5000 5100 5200 5300 5400 5500 5600 5700 5800 5900 6000 6100 6200 20 25 30 35 40 45 50 55 High Fire Blower Speed rpm Glycol C...

Page 26: ...densate water trap 5 required 2 Neutralization Capsule A compact corrosion resistant capsule is piped to the condensate drain downstream of the water trap Capsule is filled with a replaceable neutrali...

Page 27: ...pH analysis of condensate If condensate is too acidic pH is below acceptable value the neutralization media should be replaced The neutralizing media should be gently agitated periodically to ensure e...

Page 28: ...f 4 boilers per tank with total BTU per tank not to exceed 8 000 000 See figures below for suggested piping When using the combo tank supply make up water at the connection shown An internal float in...

Page 29: ...connections made to the boiler must be arranged so that all components are accessible for inspection cleaning and maintenance A drip leg should be installed in the supply line before the connection to...

Page 30: ...traverse the top of the boiler B Table 14 shows the gas pressure required at the inlet of the gas line Note a pressure regulator is not furnished and if gas pressure exceeds 14 W C a pressure regulat...

Page 31: ...Maximum gas train pressure rating Natural Gas LP Gas UL cUL CSA 500 7 11 14 WC 1 2 psig 1 psig 1 2 psig 750 7 11 1000 7 11 1500 7 11 2000 7 11 R egulator H eader Pipe M eter G as H eader Piping T ypi...

Page 32: ...be leveled side to side and front to back using the supply and return nozzles for horizontal and vertical positions If shims are required to level the boiler the weight of the boiler must be evenly d...

Page 33: ...mum Room Clearance Dimensions Seismic Legs Seismic mounting details shown below Figure 26 CFC E Seismic Mounting FRONT VIEW PLAN VIEW DETAIL A A B A C C Q 7 16 HOLE DIM 750 1000 1500 2000 A 34 35 34 3...

Page 34: ...r 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 Handboo...

Page 35: ...gs 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 or by ducts with the outdoors 3 E...

Page 36: ...es of at least 1 inch from the sides and back 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 inc...

Page 37: ...boiler room preferably below a height of 7 feet This allows air to sweep the length of the boiler See Figure 30 B Air supply openings can be louvered for weather protection but they should not be cove...

Page 38: ...0 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 supp...

Page 39: ...e that avoids excessive condensate production in the vent Category II A boiler which operates with a non positive vent static pressure and with a vent gas temperature that may cause excessive condensa...

Page 40: ...uct a window view if the termination is installed in close proximity to windows 2 Prevailing winds could cause freezing of Condensate and water ice buildup on building plants or roof 3 The bottom of t...

Page 41: ...property 3 Within 6 feet 1 8m of a mechanical air supply inlet to any building 4 Above a meter regulator assembly with 3 feet 900mm horizontally of the vertical centerline of the regulator 5 Within 6...

Page 42: ...freezing climates it is recommended that 1 The vent shall be installed with a slight upward slope of not more than 1 4 per foot of horizontal run to the vent termination In this case an approved Cond...

Page 43: ...be installed to prevent the potential accumulation of Condensate in the stack pipes It is recommended that 1 The vent shall be installed with a slight downward slope of not more than 1 4 per foot of h...

Page 44: ...e non warrantable problems with components and poor operation of the unit due to the recirculation of flue products Table 15 STACK SIZING USING OUTSIDE AIR FOR COMBUSTION DIRECT VENT Boiler Combustion...

Page 45: ...Vertical Venting Inside Combustion Air See Figure 34 Figure 34 Inside Air Vertical Vent As noted in Paragraph A above these installations use air from within the boiler room for combustion The same r...

Page 46: ...tion See Figure 35 Figure 35 Vertical Stack with Direct Vent Combustion Air As noted in Paragraph B above these installations use air from outside the building for combustion The same recommendations...

Page 47: ...BOOK CFC E STACK BREECHING SIZE CRITERIA 47 Boiler Rear Connections Figure 36 CFC E Rear Connections COMBUSTION ELECTRICAL RACEWAY ELECTRICAL RACEWAY HIGH TEMPERATURE RETURN LOW TEMPERATURE RETURN AIR...

Page 48: ...h history last 15 messages Annunciation Outdoor reset Central Heating and Domestic Hot Water loop control Password protection of configurable parameters High Stack Temperature limit Remote reset Lead...

Page 49: ...Optional Header Temperature 9 System Configuration CB Falcon configuration is arranged into the following functional groups Table 18 CB Falcon burner sequence Central Heat 1 Heat request detected CH d...

Page 50: ...2 FLAME STRENGTH LOCAL MODBUS A B C GLOBAL MODBUS A B C POWER FLAME ALARM RESET PIM 1 2 3 4 5 6 CB FALCON HYDRONIC CONTROL J1 J2 J1 J3 ENVIRACOM D R C L1 L2 FOR 120VAC OR 24VAC RETURN OPTOS EGND EX I...

Page 51: ...SYSTEM SCHEMATICS Typical piping arrangements using the CFC E are shown in the figures that follow Note These diagrams are generic and are not intended for use in a specific design without consultati...

Page 52: ...BOILER BOOK CFC E EXAMPLE SYSTEM SCHEMATICS 52 Figure 38 Primary Secondary Single Boiler...

Page 53: ...BOILER BOOK CFC E EXAMPLE SYSTEM SCHEMATICS 53 Figure 39 Primary Secondary Two Boilers...

Page 54: ...BOILER BOOK CFC E EXAMPLE SYSTEM SCHEMATICS 54 Figure 40 Primary Secondary Three Boilers...

Page 55: ...BOILER BOOK CFC E EXAMPLE SYSTEM SCHEMATICS 55 Figure 41 Primary Variable Flow Single Boiler...

Page 56: ...BOILER BOOK CFC E EXAMPLE SYSTEM SCHEMATICS 56 Figure 42 Primary Variable Flow Two Boilers...

Page 57: ...BOILER BOOK CFC E EXAMPLE SYSTEM SCHEMATICS 57 Figure 43 Primary Variable Flow Three Boilers...

Page 58: ...BOILER BOOK CFC E EXAMPLE SYSTEM SCHEMATICS 58 Figure 44 Primary Variable Flow Single Boiler with Heat Exchanger...

Page 59: ...BOILER BOOK CFC E EXAMPLE SYSTEM SCHEMATICS 59 Figure 45 Primary Variable Flow Single Boiler with Heat Exchanger and Dual Return...

Page 60: ...BOILER BOOK CFC E EXAMPLE SYSTEM SCHEMATICS 60...

Page 61: ...BOILER BOOK CFC E e mail info cleaverbrooks com Web Address http www cleaverbrooks com...

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