CleaverBrooks ClearFire CFH Operation, Service And Parts Manual Download

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Chapter 6

Model CFH Parts

Control Panel 10-60 HP   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Control Panel 70-80 HP   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Burner Assembly 10-60 HP  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Burner Assembly 70-80 HP  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Gas Train  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Low Gas Pressure Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Gas Train, Dual Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Gas Train, Dual Fuel, w/Low Gas Pressure Option . . . . . . . . . . . . . 19
Gas Train, Propane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Boiler Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Recommended Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

UV Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Adjustable Flame Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Sealed Combustion Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Direct Vent Combustion Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Summary of Contents for ClearFire CFH

Page 1: ...Model CFH Gas High Efficiency Steam Boiler Operation Service and Parts Manual 750 295 07 2020 10 80 HP ClearFire ...

Page 2: ...n 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 boiler and to replace any part of the control system and any gas control which has been under water DANGER WARNING To minimize the possibility of serious personal in jury fire or damage to the equipment never vio late the follo...

Page 3: ...ent manuals to your local Cleaver Brooks authorized representative Manual Part No 750 295 07 2020 Printed in U S A Cleaver Brooks 2020 CLEAVER BROOKS Model CFH ClearFire Packaged Boiler Gas High Efficiency Boiler Operation Service and Parts Manual ...

Page 4: ...strongly the need for the operator to periodically check the low water controls and to follow good maintenance and testing practices Cross connecting piping to low water devices must be internally inspected periodically to guard against any stoppages which could obstruct the free flow of water to the low water devices The waterside condition of the pressure vessel is of extreme importance Watersid...

Page 5: ...tions 4 2 Filling Boiler 4 2 Control Setpoints 4 2 Water Level Controls 4 3 Model CFH Boiler Burner Controls 4 4 CB Falcon Display Operator Interface 4 4 Controller Configuration 4 9 Burner Sequence 4 14 Fan Speed Settings 4 15 Operating and High Limit Controls 4 16 Procedures for LP Propane Gas 4 16 High Turndown Applications 70 80 hp 4 17 Initial Start up Procedure 4 17 Boil Out of a New Unit 4 ...

Page 6: ...NING CAUTION or NOTE signifying the follow ing NOTE Indicates information that is vital to the operation or maintenance of the equipment DANGER WARNING Indicates a potentially hazardous situation which if not avoided could result in serious personal injury or death DANGER CAUTION Indicates a potentially hazardous situation which if not avoided could result in damage to the equipment ...

Page 7: ...verbrooks com Chapter 1 Introduction Model CFH Features and Benefits 1 2 The Model CFH Boiler 1 2 The Burner 1 4 Burner Gas Train 1 4 Controls 1 5 Water Level Steam Pressure Controls 1 6 Optional Equipment 1 6 ...

Page 8: ...o provide only the amount of heat required providing quiet and efficient operation under all conditions Premix Technology The Model CFH Boiler utilizes Premix technology to mix both fuel and combustion air prior to entering the firing chamber This technology provides clean efficient combustion with very low emission levels 1 2 THE MODEL CFH BOILER Firetube boilers are rated in boiler horsepower BH...

Page 9: ...The initial period of service can be especially critical as the waterside of new boilers may contain oil grease or other foreign matter The flue side of the Model CFH boiler is virtually maintenance free Periodic inspection of furnace and Alufer tubes is recommended during required service and inspection intervals See Chapter 5 Maintenance for details Caution Waterside care is of prime importance ...

Page 10: ...he sound level of the burner is less than 70 dBA measured in front of the boiler at a distance of 3 feet At reduced firing rates sound levels are even lower Optional sealed or direct vent combustion available Combustion Air Proving Switch standard Air filter for combustion air intake standard Figure 1 3 Burner components 1 4 BURNER GAS TRAIN The gas train assembly Figure 1 4 is provided in accorda...

Page 11: ...tegrated burner management and modulation control with a touch screen display operator interface Figure 1 5 Control panel front Figure 1 6 Control panel interior FALCON DISPLAY DEMAND SWITCH ALWCO RESET OPTIONAL ALARM LIGHT PKG IGNITION CABLE IGNITION TRANSFORMER BLOWER SIGNAL CABLE 10 60 HP 70 80 HP ...

Page 12: ...OLS See Chapter 4 for initial settings of the OLC Operating Limit Control and HLC High Limit Control and for water column alarm levels and probe lengths See Chapter 5 for water column and gauge glass blowdown procedure 1 7 OPTIONAL EQUIPMENT Certain options are available for the Model CFH Boiler normally these will have been specified at the time of order entry In addition some options may have be...

Page 13: ...ntrol shipped separately Feedwater Valve on off Blowdown valves Modulating Feedwater Valve Level Control High Water Alarm Time clock for setback control shipped loose Warm Hot Standby control Reusable air filter Stack thermometer Economizer package Overflow Drain Trap Sample Cooler Automatic Surface Blow off Conductivity control Draft Damper control Isolation or Modulating Falcon Lead Lag control ...

Page 14: ...Chapter 1 Introduction 1 8 Part No 750 295 ...

Page 15: ...ical Connections Wiring Diagrams 2 11 Provisions for combustion and ventilation air must be in accordance with UL 795 Commercial Industrial Gas Heating Equipment cUL or applicable provisions of the local building codes Failure to follow this warning could result in personal injury or death Warning If an external electrical source is utilized the boiler when installed must be electrically bonded to...

Page 16: ...fting lugs extending from the front and rear tube sheets These lugs should be used to lift the boiler Note The boiler should not be lifted by the base or moved by pushing prying or pulling on any part of the casing The boiler must be installed on a non combustible floor If the floor is not level piers or a raised pad slightly larger in length and width than the boiler base dimensions will make boi...

Page 17: ...y result in damage to the boiler If necessary your Cleaver Brooks representative can provide additional information regarding your water softening needs The objectives of water treatment in general are to 1 Prevent hard scale and soft sludge deposits that inhibit heat transfer and that could lead to overheated metal and costly downtime and repairs 2 Eliminate corrosive gases in the supply or boile...

Page 18: ... 2 1 CFH water quality guidelines Consult with factory for Reverse Osmosis RO applications 2 4 BOILER ROOM BOILER CLEARANCES The boiler room must comply with all building codes and regulations An adequate supply of combustion air and sufficient ventilation are required for safe operation If the optional direct vent combustion air kit is not used ventilation must be provided to meet applicable regu...

Page 19: ... information 2 5 2 Condensate Drain A condensate drain is installed at the bottom of the flue box and should be piped to a drain A drain trap with a minimum 6 water leg should be installed to prevent flue gas from entering the boiler room see Figure 2 5 Minimum required service clearances 18 18 see table 18 36 Electrical panel clearance sufficient for burner door swing and tube removal BOILER SIZE...

Page 20: ...ust be isolated during any tests After initial startup the inlet screen to the gas valve should be checked and cleaned for any debris buildup Gas Supply Pipe Sizing For proper operation of a single unit or a multiple unit installation we recommend that the gas piping be sized to allow no more than 0 3 w c pressure drop from the source gas header or utility meter to the final unit location Higher s...

Page 21: ...175 109 209 336 648 1 030 1 820 3 720 200 102 185 313 602 960 1 700 3 460 Fuel Natural Gas Inlet Pressure Less than 2 0 psi Pressure Drop 0 30 w c Specific Gravity 0 60 Pipe Size Nominal 1 1 1 4 1 1 2 2 2 1 2 3 4 Actual I D 1 049 1 380 1 610 2 067 2 469 3 068 4 026 Length in feet Maximum Capacity in Cubic Feet of Gas per Hour 10 678 1 390 2 090 4 020 6 400 11 300 23 100 20 466 957 1 430 2 760 4 40...

Page 22: ...ngth of run from the source and determine what size header will be needed for the flow of all units firing Pipe sizes are based on Table 2 2 with boiler gas line take off at 20 feet from the header For systems with 1 psig or greater supply pressure the gas supply header piping should be sized for not more than 1 2 psi drop at 100 installed capacity Figure 2 7 Typical gas header piping R egulator H...

Page 23: ...1 2 3 4 Pipe Size To Boiler 1 1 2 1 1 2 1 1 2 1 1 2 2 2 2 2 2 2 2 2 Header Pipe Size 1 1 2 2 2 1 2 3 2 2 1 2 3 3 2 2 1 2 3 4 50HP 60HP 70HP of Units 1 2 3 4 1 2 3 4 1 2 3 4 Pipe Size To Boiler 2 2 2 2 2 2 2 2 2 1 2 2 1 2 2 1 2 2 1 2 Header Pipe Size 2 3 3 4 2 1 2 3 4 4 2 1 2 3 4 6 80HP of Units 1 2 3 4 Pipe Size To Boiler 2 1 2 2 1 2 2 1 2 2 1 2 Header Pipe Size 2 1 2 3 4 6 Figure 2 8 Example gas ...

Page 24: ...steam header This valve should be located as close as possible to the boiler to facilitate venting and pressure testing A suitably rated gate valve is recommended for this purpose Feedwater is introduced through the piping assembly installed on the side of the boiler vessel A stop valve and check valve are optional equipment Figure 2 9 The feedwater supply should provide sufficient pressure to mee...

Page 25: ...ctrical and building codes should be adhered to Main power and any remote wiring should be brought to the left side of the control panel and terminated at the appropriate terminals provided For specific information on your boiler electrical control system see Figure 2 10 or refer to the Cleaver Brooks wiring diagram provided with the boiler Notice The blower signal wiring must be isolated from the...

Page 26: ...Chapter 2 Installation 2 12 Part No 750 295 Figure 2 10 CFH wiring and cable connections 1 2 3 4 5 6 7 ...

Page 27: ...Chapter 2 Installation Part No 750 295 2 13 Figure 2 10 CFH wiring diagram typical 10 60 HP ...

Page 28: ...Chapter 2 Installation 2 14 Part No 750 295 Figure 2 11 CFH wiring diagram typical 70 80 HP BLOWER CCT FUSE ...

Page 29: ...g 3 2 Vent Terminal Location 3 3 Horizontal Thru Wall Venting Inside Air 3 5 Horizontal Thru Wall Direct Vent Combustion 3 5 Horizontal Thru Wall Flue Vent Termination 3 6 Vertical Venting Inside Air 3 7 Vertical Venting Direct Vent Combustion Air 3 8 Combustion Air Requirements 3 9 Maximum Vent Lengths 3 13 ...

Page 30: ...ry II III or IV boiler as deemed appropriate for the application For additional information on boiler categorization see latest edition standard of National Fuel Gas Code or in Canada the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment or applicable provisions of local building codes During winter months check the flue termination and make sure no blo...

Page 31: ...st resistant sheet metal backing plate against brick or masonry surfaces 10 Minimize exposed flue venting outside of building in extreme cold climates In winter conditions condensate could freeze and block the flue pipe or termination 11 Ensure combustion air intake s are a sufficient distant away from any exhaust terminations to avoid drawing in flue gases or other contaminants U S Installations ...

Page 32: ...lations where the air is piped in from outside a protective screen on the air inlet termination elbow must be used to act as an inlet screen 3 3 1 Venting Installation Tips Support piping horizontal runs at least every five 5 feet vertical runs use braces under or near elbows Caution To avoid personal injury or property damage To cut nonmetallic vent pipe use a fine toothed hacksaw 34 teeth per in...

Page 33: ...in the vent pipes It is recommended that 1 Vent be installed with a slight downward slope of at least 1 4 per foot of horizontal run to the vent terminal 2 The vent be insulated through the length of the horizontal run For appliances installed in extreme cold climate it is recommended that 1 The vent be installed with a slight upward slope of at least 1 4 per foot of horizontal run to the vent ter...

Page 34: ...e termination should not be installed in a well or below grade The flue termination must be installed at least one I foot above ground level and above normal snow levels Combustion air supplied from outdoors must be free of particulate and chemical contaminants To avoid a restricted combustion air or blocked flue condition keep all air intakes and flue terminations clear of snow ice leaves debris ...

Page 35: ...ically through the roof 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 CGA B 149 1 AND 2 Installation Code for Gas Burning Appliances and Equipment To prevent condensation accumulation in extended horizontal runs It is required to install the horizontal portion of the fl...

Page 36: ...to the outside A positive pressure venting system is required To prevent condensation accumulation in extended horizontal runs it is required to install the horizontal portion of the flue venting with a slight upward slope of at least 1 8 per foot of horizontal run a drain with condensate trap must be installed per applicable codes Combustion air venting can be constructed of steel stainless steel...

Page 37: ... be used see the NFPA Handbook for additional information All Air From Inside the Building If combustion air is drawn from inside the building the mechanical equipment room does not receive air from outside via louvers or vent openings and the boiler is not equipped with direct vent and the boiler is located in an unconfined space use the following guidelines The mechanical equipment room must be ...

Page 38: ...oors or through vertical ducts C The minimum free area required for horizontal ducts is one square inch per 2 000 Btu per hour of total input rating of all the equipment in the room One Opening Method Figure 3 8 One permanent opening commencing within 12 inches of the top of the room shall be provided A The equipment shall have clearances of at least 1 inch from the sides and back and 6 inches fro...

Page 39: ...ubject 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 conditions and cause variations in the quantity of combustion air This can result in unsafe burner performance D It is forbidden to have the total area of the air supply openings at less than one square foot E Size the openings by using the formula Area in ft2 c...

Page 40: ... in accordance with local codes and the boiler operating and maintenance manual Provide for adequate ventilation of the boiler room or mechanical equipment room Duct material can be PVC or metallic vent material It should be air tight to prevent in leakage of air during operation Maximum pressure drop for the duct shall not exceed 0 25 w c negative If this pressure drop is exceeded a larger size d...

Page 41: ...rance at boiler flue connection during operation is 0 25 W C Use 0 10 when designing venting system Maximum vent length assumes horizontal run and sidewall terminations Larger diameter venting vertical flue runs and vertical flue termination may allow for longer vent lengths than indicated here provided the engineered draft calculations are within the allowable operational tolerance of 0 25 W C Bo...

Page 42: ...Chapter 3 Flue and Combustion Air Venting 3 14 Part No 750 295 ...

Page 43: ...nfiguration 4 9 Burner Sequence 4 14 Fan Speed Settings 4 15 Operating and High Limit Controls 4 16 Procedures for LP Propane Gas 4 16 High Turndown Applications 70 80 hp 4 17 Initial Start up Procedure 4 17 Boil Out of a New Unit 4 24 Post Start up Checkout Procedure 4 25 Falcon Control Functions and Customer Interface 4 25 The boiler and its gas connection must be leak tested before placing the ...

Page 44: ...POINTS Preliminary settings of the burner boiler controls are necessary for 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 Operating and High Limit Controls Set the dial maximum Combustion Air Proving Switch Set the dial minimum...

Page 45: ... The ALWCO includes a panel mounted manual reset test switch Table 4 2 Water Levels 15 Steam 150 Steam 10 15 HP 20 25 HP 30 40 HP 50 60 HP 70 80 HP 10 15 HP 20 25 HP 30 40 HP 50 60 HP 70 80 HP A 1 1 16 1 16 0 1 1 16 1 16 0 1 1 16 1 16 0 1 1 16 1 16 0 3 1 16 1 16 0 3 1 16 1 16 0 3 1 16 1 16 0 3 1 16 1 16 0 3 1 16 1 16 0 3 1 16 1 16 0 B 9 10 1 16 10 1 16 11 3 4 15 1 4 11 12 1 16 12 1 16 13 3 4 15 1 ...

Page 46: ...Lag for multiple boiler systems Warm Hot standby minimum temperature control Please review the tables within this Commissioning section to familiarize yourself with the functions and parameters of the Controller Also see Appendices A and B for details on control configuration and operation 4 6 FALCON DISPLAY OPERATOR INTERFACE The CB Falcon display operator interface is mounted at the right side o...

Page 47: ...play verify the connections shown in Figure 4 4 Once communication is established the display will synchronize with the controller Figure 4 4 Falcon communications wiring After powering up the system for the first time it is recommended to verify the following under Setup Display Setup In the COM 1 tab change Modbus address range maximum to 10 Note The Home icon at the upper left of the display sc...

Page 48: ...s Save and cycle power to the controller 4 6 2 Boiler Status Pressing the Falcon icon on the Home Page takes the user to the Status page which summarizes boiler status and allows navigation to the configuration operational and diagnostic areas of the CB Falcon interface ...

Page 49: ...will be annunciated here Pressing the banner allows access to the Lockout and Alert history logs In the case of a lockout alarm the lockout can be cleared by navigating to the Lockout History and pressing Clear Lockout The steam pressure modulation setpoints can be changed from the Status page by pressing the current displayed value A numeric keypad will pop up allowing entry of new values 4 6 3 B...

Page 50: ...e not preventing boiler operation may nevertheless be of interest in evaluating boiler performance or operating conditions Examples include certain operator actions out of range configuration data controller internal status reports e g timers counters memory read write activity and recycle events Alerts require no operator acknowledgment and are for informational purposes only LOCKOUT A lockout ca...

Page 51: ...ag configuration Table 4 3 CB Falcon factory parameter settings Model CFH Parameter Group Parameter Name Access Min Range Default Setting Max Range Parameter Units Installation Setting System ID Access Boiler Name Service Boiler 1 System ID Access Installation data Service MB00xxxx System ID Access Installer password Service 9220 System ID Access Modbus address Service 0 1 250 System ID Access Fac...

Page 52: ... Burner run time Read Only 0 999 999 Statistics Configuration CH pump cycle count Read Only 0 999 999 Statistics Configuration System pump cycle count Read Only 0 999 999 Statistics Configuration Boiler pump cycle count Read Only 0 999 999 Statistics Configuration Auxiliary pump cycle count Read Only 0 999 999 Stack Limit Stack limit enable Service Disabled Stack Limit Stack limit delay Service 0 ...

Page 53: ...nciator7 Annunciation Configuration Annunciator 8 location Service Unused Annunciation Configuration Annunciator 8 short name Service A8 Annunciation Configuration Annunciator 8 long name Service Annunciator8 Annunciation Configuration PII short name OEM PII Annunciation Configuration PII long name OEM Pre Ignition ILK Annunciation Configuration LCI short name OEM LCI Annunciation Configuration LC...

Page 54: ... Control Flame Fail Ignite failure retries Service Unknown Burner Control Flame Fail Run flame failure response Read Only Lockout System Configuration Modulation Output Read Only Fan PWM System Configuration Temperature units Service Fahrenheit System Configuration Antishort cycle time Service 0 1 480 minutes System Configuration Alarm silence time Service 0 0 60 minutes System Configuration Inlet...

Page 55: ...ear when any password protected parameter is displayed on the screen The default service level password is 9220 Press Login to display the alphanumeric keyboard Enter password and press OK Change parameter settings by selecting the parameter on the page A dialog box appears with controls allowing the user to change the selected value Press Clear to clear the current value Enter the new value and p...

Page 56: ... the verification steps do not need to be completed immediately 4 7 2 Program Module CB Falcon parameter information non safety parameters only can be uploaded downloaded using the optional Program Module When the Program Module is installed its features are accessible from the Falcon Setup page See Appendices for instructions 4 8 BURNER SEQUENCE In addition to providing modulation control the CB ...

Page 57: ...ked temporarily for the forced off time set by the Anti Short Cycle if enabled 15 The pump relay remains energized during the pump overrun time if enabled 16 At the end of the pump overrun time the pump will be switched off 4 9 FAN SPEED SETTINGS The boiler firing rate is determined by the combustion air fan speed Accordingly fan speed settings may have to be modified for the particular applicatio...

Page 58: ...Disconnect power from the boiler 2 Connect power to the boiler Power up the controls 3 Access boiler control Configuration menu Press Login Enter service level password default is 9220 Press OK 4 Select Modulation configuration Adjust CH and DHW maximum modulation rates and minimum modulation rate according to Table 4 4 Return to Configuration menu 5 Select Burner Control Ignition configuration Ad...

Page 59: ...a damper and actuator cam assembly downstream of the venturi All settings for high turndown operation are made at the factory no further adjustments are required For verification of Falcon settings Analog Rate Tracking in Modulation Configuration should be enabled for PWM to 4 20mA 4 13 INITIAL START UP PROCEDURE 4 13 1 Gas Train and Piping The ClearFire burner is equipped with a combination servo...

Page 60: ... 115V 1Ph 60Hz to ensure it is within specifications 3 To power the control and blower circuits turn the CC Blower switch to the ON position 4 When the control and blower circuits are powered commissioning may begin Turn the Demand switch to the LOC Local position On the Operation page the Demand status should indicate Steam The boiler will now start if the LCI and ILK circuits are satisfied and t...

Page 61: ... screen will indicate Lockout 67 ILK OFF 6 Reset the controller and change the LGPS setting back to minimum to proceed CAPS Interrupted Airflow Switch 1 Initiate burner sequence 2 During purge cycle set Combustion Air Proving Switch to its maximum setting 3 The CB Falcon should lock out on an airflow failure The dis play will show Lockout 65 Interrupted Airflow Switch OFF Note If the CAPS fails to...

Page 62: ... Ignition Failure 2 Replace flame rod electrode and grounding tab After verifying proper operation of LGPS HGPS CAPS and Gas Valve re open the downstream manual shut off valve 4 13 4 LWCO and ALWCO Check Before testing low water controls disconnect power to the feed pump LWCO 1 To verify proper LWCO operation conduct a blowdown of the water column refer to Chapter 5 Section 5 3 Water Column Blowdo...

Page 63: ...kwise half the number of turns counted when turning clockwise NOTE When adjusting low fire offset clockwise adjustments increase gas flow and counterclockwise adjustments decrease gas flow When adjusting the main gas choke clockwise adjustments decrease gas flow and counterclockwise adjustments increase gas flow CFH 70 80 HP and Low Gas Pressure Option See figures below for low and high fire adjus...

Page 64: ...3 7 Setting Combustion Note A Combustion Analyzer is required to properly set up the Model CFH burner Do not attempt to fire and adjust the burner without this equipment Note Ensure boiler is filled with water prior to burner startup The burner does not have need of linkages for fuel air adjustment nor is a separate manual auto switch provided for burner positioning All firing rate adjustments are...

Page 65: ...g main choke on gas valve and a combustion analyzer set O2 level within 3 8 O2 6 Manually modulate the burner to high fire Adjust the gas choke if necessary to obtain desired O2 6 0 7 0 for optimum combustion 1 On the CB Falcon Operation screen press the Firing rate display 2 A numeric keypad will appear showing the current firing rate and operating mode 3 Under Firing rate control select Manual i...

Page 66: ... flow pipe should be attached to one of the top boiler openings and routed to a safe point of discharge A relief or safety valve tapping can be used for this purpose 4 Water relief valves and steam safety valves must be removed before adding the boilout solution to avoid contaminating the valves Use caution when removing and reinstalling these devices 5 All valves in the piping leading to or from ...

Page 67: ...cceptable limits 25 to 25 W C and record in start up form 7 Switch to automatic operation and monitor flue gas to ensure consistent excess air 8 Reassemble all panels and covers that were removed and replace any plugs that were removed to check gas pressure 9 If boiler is equipped with a High Air Pressure Switch check switch operation 10 Verify with customer that softened water is being used and t...

Page 68: ...typical steam boiler applications Remote Enable and Remote 4 20mA Input Remote enable and Remote 4 20mA input allow the boiler to be sequenced and or controlled from a separate boiler room controller or building management system The 3 position Demand switch at the front of the control panel determines whether the boiler is off in local or under remote control When in the LOC local position the bo...

Page 69: ...ns These functions may include combustion air damper or exhaust fan interlocks feed pump on off for constant running pump with modulating feedwater valve etc Contact your CB representative for further information Annunciator The Falcon features an annunciator to monitor boiler safety controls and to provide first out lockout annunciation The annunciator status screen is accessed from the boiler op...

Page 70: ...onnected to this display will appear on the right side of the Control Snapshot List screen 3 Select one of the following Show Status Only will display information about the current state of the system including active holds alarms analog and digital I O status burner control status run time cycles and alarm history Show Configuration will show the current Falcon configuration parameter settings Sh...

Page 71: ...display USB slot Highlight the snapshot in the Snapshots list and press Copy to USB To view rename or delete a saved snapshot highlight it in the Snapshots list and press the appropriate screen button Modbus Communication The Falcon uses the Modbus RTU protocol for communication with a Building Management System or other devices Modbus register mapping for CFH steam boilers is given below Addition...

Page 72: ...r 3 Auxiliary Low Water 1 Annunciator 2 Low Water 0 Annunciator 1 Interrupted Air Switch 0008 0008 Firing rate R U16 Actual firing rate or RPM 0009 0009 Fan speed R U16 RPM 000A 0010 Flame signal R U16 0 01V or 0 01A precision 0 00 50 00V 0013 0019 Register Access Status R U16 Register data write access status 0 No register writes allowed 1 Installer register writes allowed 2 OEM register writes a...

Page 73: ...eignition Test 8 Preignition Time 9 Pilot Flame Establishing Period Main Trial for Ignition with DSI 10 Main Flame Establishing Period Not used with DBI 12 Run 13 Postpurge 14 Lockout 255 Safety Processor Offline 0022 0034 Lockout code Active R U16 0 No lockout 1 4096 refer to Table 44 Falcon Lockout and Hold Codes 0024 0036 Annunciator first out R U16 Source for annunciator first out 0 None or un...

Page 74: ...te R W U16 RPM or 00C3 0195 Minimum modulation rate R W U16 RPM or 00C5 0197 Lightoff rate R W U16 SAFETY parameter RPM or 00C6 0198 Postpurge rate R W U16 SAFETY parameter RPM or 00C7 0199 CH forced rate R W U16 RPM or 00C8 0200 CH forced rate time R W U16 0 64800 seconds 18 hours 0xFFFF Not configured 00CB 0203 Burner switch R W U16 0 Off 1 On Used to enable disable burner control 00CC 0204 Firi...

Page 75: ...r Global Modbus master 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 System pump with overrun 11 Turn on System pump with no overrun 10 Turn on Auxiliary pump 9 Reserved always 0 8 Commanded rate is binary fraction 7 0 Commanded rate Modbus for CFH Steam Continued Hex Decimal Parameter R W Format Description ...

Page 76: ...istory record 8 R 0 1 byte 8th newest lockout See Table 4 03E8 03F8 1000 1016 Lockout history record 9 R 0 1 byte 9th newest lockout See Table 4 03F9 0409 1017 1033 Lockout history record 10 R 0 1 byte 10th newest lockout See Table 4 040A 041A 1034 1050 Lockout history record 11 R 0 1 byte 11th newest lockout See Table 4 041B 042B 1051 1067 Lockout history record 12 R 0 1 byte 12th newest lockout ...

Page 77: ...Maintenance General 5 2 Blowdown 5 2 Water Column Blowdown 5 3 Fireside Cleaning Procedure Disassembly 5 5 Ignition Electrodes 5 6 UV Scanner 5 7 Adjustable Flame Rod 5 8 Waterside Inspection Cleaning 5 9 Safety Valve 5 9 Troubleshooting 5 10 Lay up 5 12 ...

Page 78: ...gh not necessarily scheduled for periods of normal boiler downtime such as an off season This period can be used to accomplish maintenance replacement or repairs that cannot easily be done at other times While the inspection pertains primarily to the waterside and fireside surfaces of the pressure vessel the inspection period provides operators with an opportunity for a detailed check of all boile...

Page 79: ...he water level is at the Normal Operating Water Level Be sure the blowdown piping is in proper operating condition Waste should be piped to a point of safe discharge 1 Open the quick opening valve 2 Crack the second or downstream valve slightly to allow the lines to warm then continue opening slowly to its fully open posi tion The duration of each blowdown should be determined by water analysis A ...

Page 80: ...ced at once Open Open Closed 1 2 3 4 5 6 7 8 1 Open Water Column blowdown valve 5 to 10 sec to discharge water from WC 2 Close WC blowdown valve 3 Close upper gauge glass isolation valve 4 Open gauge glass blowdown valve to discharge water from gauge glass 5 Close lower gauge glass isolation valve 6 Open upper gauge glass isolation valve 7 Open lower gauge glass isolation valve to discharge steam ...

Page 81: ...ct the ignition cables and flame sensor cable from the electrodes 6 a If using room combustion air remove air filter Inspect and clean as necessary NOTE Do not discard the air filter It may be cleaned and re used Contact Cleaver Brooks for cleaning kits b Remove the air combustion piping at the inlet to the fan air intake if supplied with direct vent combustion 7 Disconnect the burner gas train fr...

Page 82: ...rque bolts to 11 ft lbs 132 in lbs Ensure that all connections are tight and secure before reconnecting power or fuel supply After turning the gas supply on reset the gas pressure switches 5 5 IGNITION ELECTRODES The ignition electrodes should be checked on an annual basis or as needed if ignition problems are encountered Replacement should be accomplished as shown in Figure 5 6 with the electrode...

Page 83: ...f place gasket or the boiler refractory dry oven can all potentially obstruct the scanner To verify a line of sight unscrew the UV scanner from the mounting bracket and ensure that it is possible to sight through the bracket to the burner can without obstruction Figure 5 8 shows the UV scanner wiring connections to the CFH control panel Caution The dimensions on the ignition electrodes are not eas...

Page 84: ...an acceptable flame signal can not be produced open the boiler door and check the flame rod settings with respect to the boiler drawings To avoid proximity of the flame rod to the ignition electrodes any rotational adjustments should be made on the side opposite the ignitor exception on larger CFH sizes this distance is not critical AXIAL Adjustment ROTATIONAL Adjustment Figure 5 9 Flame rod adjus...

Page 85: ...emove the equalizing piping plugs remove all probes and inspect Clean as necessary being sure to remove any debris or blockages If a waterside sludge buildup is noticed flush the waterside and drain Again consult with the water treatment company or technician on cleaning After inspection install new gaskets close the handholes replace probes tighten plugs and allow water to fill the boiler while k...

Page 86: ...eign material from the seat area and then allow the valve to snap shut 5 10 TROUBLESHOOTING The Falcon lockout and alert histories contain information which can help in determining the cause of problems To view the lockout or alert history start from the Status screen First press the alarm banner then press the appropriate button in the pop up window The alert or lockout list will appear showing d...

Page 87: ... Incorrect fan speed Increase fan speed by 100 RPM incre ments until successful lightoff occurs Bad cable connections Check connections Electrodes fouled or out of position Electrodes should be cleaned and replaced annually and spacing periodically checked Dust or debris on burner canister Precautions should be taken in dusty envi ronments to ensure the burner canister remains free of dust particl...

Page 88: ...event rust To prevent condensation from forming in the control cabinet keep the control circuit energized For extended layup periods especially where high humidity or large swings in ambient temperature occur the control should be removed and stored in a dry atmosphere Dry Lay up Dry lay up is generally used when the boiler will be out of service for a lengthy time period or where the boiler might...

Page 89: ...itrogen is often used to pressurize the vessel Whichever method of lay up is used a periodic re check of fireside and waterside conditions is recom mended during lay up Table 6 Waterside Volume CFH Boiler Horsepower 10 15 HP 20 25 HP 30 HP 40 HP 50 60 HP 70 HP 80 HP Capacity gallons flooded 140 170 260 300 386 559 547 Waterside Volume cu ft 18 7 22 7 34 8 40 1 51 6 74 7 73 1 ...

Page 90: ......

Page 91: ...10 60 HP 4 Burner Assembly 70 80 HP 5 Gas Train 6 Low Gas Pressure Option 14 Gas Train Dual Fuel 15 Gas Train Dual Fuel w Low Gas Pressure Option 19 Gas Train Propane 22 Boiler Controls 26 Recommended Spare Parts List 27 UV Scanner 28 Adjustable Flame Rod 28 Sealed Combustion Kits 29 Direct Vent Combustion Kits 29 ...

Page 92: ...Chapter 6 Model CFH Parts 6 2 Part No 750 295 6 1 CONTROL PANEL 10 60 HP ...

Page 93: ...Chapter 6 Model CFH Parts Part No 750 295 6 3 6 1 CONTROL PANEL 70 80 HP ...

Page 94: ...Chapter 6 Model CFH Parts 6 4 Part No 750 295 6 2 BURNER ASSEMBLY 10 60 HP 78 78 85 85 110 110 130 130 50 60 HP if burner door manufactured prior to 03 2019 use 853 00982 ...

Page 95: ...01476 000 1 7 DAMPER ASSEMBLY AIR INLET 427 03759 000 1 8 VENTURI COMBUSTION AIR GAS HOVAL 048 00811 000 1 9 KIT AIR FILTER 880 02745 000 1 10 GASKET ELECTRODE DWG 380 01032 000 380 01032 000 2 12 ELECTRODE DUAL CLEARFIRE IGNITION 380 01061 000 1 13 TUBE GAS PILOT 090 04464 000 1 14 ADAPTER HEAT BLOCK UV SCANNER 001 01584 000 1 15 SCANNER ASSEMBLY UV 1 16 SIGHT GLASS GASKET 0625 x 1 438 ID x 1 719...

Page 96: ...5 NPT C W 5 ADAPTER 940 07162 000 1 1 ADAPTER 1 NPT PIPE 800 00092 000 2 2 VALVE BUTTERBALL BRONZE 1 NPT 941 01944 000 2 3 LOW GAS PRESSURE SWITCH 817 02414 000 1 4 HIGH GAS PRESSURE SWITCH 817 02420 000 1 5 GAS PRESSURE REGULATOR MAXITROL RV61 1 NPS 918 00032 000 1 6 LEAKAGE TEST COCK 125 NPT 825 00239 000 3 7 3 6 4 1 2 7 3 2 7 5 7 7 ...

Page 97: ...5 ADAPTER 940 07163 000 1 1 ADAPTER 1 NPT PIPE 800 00092 000 2 2 VALVE BUTTERBALL BRONZE 1 NPT 941 01944 000 2 3 LEAKAGE TEST COCK 125 NPT 825 00239 000 3 4 GAS PRESSURE REGULATOR MAXITROL RV61 1 NPS 918 00032 000 1 5 LOW GAS PRESSURE SWITCH 817 02414 000 1 6 HIGH GAS PRESSURE SWITCH 817 02420 000 1 7 3 6 1 2 5 7 2 3 4 4 4 4 4 ...

Page 98: ...PIPE 800 00092 000 2 1 Varies 941 01944 000 2 2 VALVE GAS 120V 75 NPT C W 75 ADAPTER 940 07163 000 1 3 LOW GAS PRESSURE SWITCH 817 02414 000 1 4 HIGH GAS PRESSURE SWITCH 817 02420 000 1 5 GAS PRESSURE REGULATOR MAXITROL RV61 1 NPS 918 00032 000 1 6 LEAKAGE TEST COCK 125 NPT 825 00239 000 3 7 2 6 7 5 7 4 3 1 2 1 7 7 ...

Page 99: ...92 000 2 1 VALVE BUTTERBALL BRONZE 1 NPT 941 01944 000 2 2 VALVE GAS COMBO 120V 1 NPT C W 1 ADAPTER 940 07164 000 1 3 LOW GAS PRESSURE SWITCH 817 02414 000 1 4 HIGH GAS PRESSURE SWITCH 817 02420 000 1 5 GAS PRESSURE REGULATOR MAXITROL RV61 1 NPT 918 00032 000 1 6 LEAKAGE TEST COCK 125 NPT 825 00239 000 3 7 2 6 7 5 7 4 3 1 2 7 7 1 ...

Page 100: ...Chapter 6 Model CFH Parts 6 10 Part No 750 295 Standard gas train 30 HP ...

Page 101: ...M LOW GAS PRESSURE SWITCH 817 02414 000 1 1 HIGH GAS PRESSURE SWITCH 817 02420 000 1 2 VALVE BUTTERBALL 1 1 4 NPT 941 01945 000 2 3 ADAPTER 1 25 NPT PIPE 800 00093 000 2 5 VALVE GAS COMBO 120V 1 25 NPT C W 1 25 ADAPTER 940 07165 000 1 7 LEAKAGE TEST COCK 125 NPT 825 00239 000 3 8 8 2 8 8 A A 7 5 1 8 2 8 7 5 3 3 ...

Page 102: ...ALVE 1 1 4 NPT 941 01945 000 1 2 BUTTERBALL VALVE BRONZE 1 1 2 NPT 941 01946 000 1 6 GAS PRESSURE REGULATOR 918 00730 000 1 8 GAS VALVE COMBO 120VAC 1 25 NPT C W 1 25 ADAPTER 940 07235 000 1 9 HIGH GAS PRESSURE SWITCH 817 02420 000 1 10 LOW GAS PRESSURE SWITCH 817 02414 000 1 11 LEAKAGE TEST COCK 125 NPT 825 00239 000 3 12 A B 9 1 11 6 8 12 1 12 9 2 1 12 10 DETAIL A ...

Page 103: ... 817 02420 000 1 18 LEAKAGE TEST COCK 1 8 NPT 825 00239 000 3 19 LGPS 817 02416 000 1 20 REGULATOR GAS PRESSURE 918 00356 000 1 40 TUBING ALUMINUM 939 00265 000 1 43 VALVE BUTTERBALL 1 1 2 NPT 941 01946 000 1 46 VALVE BUTTERBALL BRONZE 2 NPT 941 01947 000 1 47 VALVE GAS COMBO 110VAC 940 07482 000 1 48 VALVE SOLENOID GAS PILOT 3 8 235 00282 000 1 49 A A 9 47 48 18 19 2 1 19 19 3 20 LGPS HGPS ADJUST...

Page 104: ...E BUTTERBALL 7 1 845 03379 000 CONNECTOR 8 1 817 02420 000 HIGH GAS PRESSURE SWITCH 9 3 825 00239 000 LEAKAGE TEST COCK 10 1 798 06720 000 LOW GAS PRESSURE SWITCH 11 1 941 01944 000 VALVE BUTTERBALL 12 1 940 07570 000 VALVE GAS 13 1 918 00730 000 GAS PRESSURE REGULATOR DETAIL ITEM 3 2 10 7 4 8 3 11 5 12 6 1 ADJUST SHUTTER TO DIMENSION PRIOR TO ASSEMBLING TO VALVE NOTE 30 40 HP REGULATOR NOT REQUIR...

Page 105: ...Chapter 6 Model CFH Parts Part No 750 295 6 15 6 4 2 Gas Train Dual Fuel 30 HP dual fuel ...

Page 106: ...Chapter 6 Model CFH Parts 6 16 Part No 750 295 40 HP dual fuel ...

Page 107: ...Chapter 6 Model CFH Parts Part No 750 295 6 17 50 60 HP dual fuel ...

Page 108: ... CONNECTOR TEE 845 01147 000 1 17 HIGH GAS PRESSURE SWITCH 817 02420 000 2 27 PRESSURE SWITCH 817 02414 000 1 28 LGPS 817 02416 000 1 29 LEAKAGE TEST COCK 825 00239 000 5 30 NUT SHORT 845 00224 000 4 59 TUBING 8 1 2 LG 939 00265 000 2 66 BALL VALVE 3 WAY 223 00013 000 1 69 VALVE BUTTERBALL 2 NPT 941 01947 000 2 70 VALVE GAS 940 07235 000 1 71 VALVE GAS COMBO 940 07482 000 1 72 REGULATOR GAS PRESSU...

Page 109: ...Chapter 6 Model CFH Parts Part No 750 295 6 19 6 4 3 Gas Train Dual Fuel w Low Gas Pressure Option 30 HP dual fuel lgp ...

Page 110: ...Chapter 6 Model CFH Parts 6 20 Part No 750 295 40 HP dual fuel lgp ...

Page 111: ...Chapter 6 Model CFH Parts Part No 750 295 6 21 50 60 HP dual fuel lgp ...

Page 112: ...Chapter 6 Model CFH Parts 6 22 Part No 750 295 6 4 4 Gas Train Propane 30 HP propane ...

Page 113: ...Chapter 6 Model CFH Parts Part No 750 295 6 23 40 HP propane ...

Page 114: ...Chapter 6 Model CFH Parts 6 24 Part No 750 295 50 60 HP propane ...

Page 115: ... CONNECTOR 845 00312 000 1 11 CONNECTOR 845 00221 000 1 12 HIGH GAS PRESSURE SWITCH 817 02420 000 1 18 LEAKAGE TEST COCK 825 00239 000 3 19 LGPS 817 02416 000 1 20 NUT SHORT 845 00224 000 2 37 REGULATOR GAS PRESSURE 918 00356 000 1 40 TUBING 8 1 2 LG 939 00265 000 1 43 VALVE BUTTERBALL 941 01946 000 1 46 VALVE BUTTERBALL 941 01947 000 1 47 VALVE GAS 940 07482 000 1 48 VALVE SOLENOID GAS PILOT 235 ...

Page 116: ...WN NOT SHOWN NOT SHOWN 9 SAFETY RELIEF VALVE SEE TABLE ITEM 9 SAFETY RELIEF VALVE Boiler HP 10 15 20 25 30 40 50 60 70 80 15 940 5073 940 5073 940 5072 940 4993 940 4993 940 5297 940 5297 940 5632 150 940 5602 940 5602 940 5500 940 5500 940 5453 940 5453 940 5453 940 5405 5105 5105 ...

Page 117: ...ts Part No 750 295 6 27 6 6 RECOMMENDED SPARE PARTS LIST UV SCANNER ADJUSTABLE FLAME ROD see table see next page LENGTHS ITEM 15 1 1 1 10 15 HP 20 25 HP 30 40 HP 50 60 HP 70 80 HP 78 85 110 130 140 70 80HP 380 01115 380 01208 ...

Page 118: ...PART NO 851 00646 000 032 00994 000 GASKET DESCRIPTION PART NO QTY ITEM FLAME ROD ADJUSTABLE 873 00571 000 1 1 BRACKET ADJUSTABLE FLAME ROD 008 04093 000 1 2 GASKET ELECTRODE DWG 380 01032 000 380 01032 000 1 3 O RING ROUND 3 8 x 1 2 PTFE EXTRA HARD 133 00041 000 1 4 NUT COMPRESSION 3 8 TUBING 9 16 20 UN THREAD 845 01303 000 1 5 WASHER FLAT 3 16 952 00144 000 2 6 LOCK WASHER 10 PLAIN STEEL 952 001...

Page 119: ... COMBUSTION KITS Boiler HP Minimum connection size Kit part number 10 15 4 880 02678 20 25 4 880 02042 30 4 x 6 880 02679 40 6 880 02043 50 60 6 x 8 880 02680 70 80 6 x 8 880 04495 Boiler HP Connection size Kit part number 10 25 4 880 04494 30 60 6 880 04496 70 80 8 880 02748 BLOWER VENTURI ...

Page 120: ...e mail info cleaverbrooks com Web Address http www cleaverbrooks com ...

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