Page 1 Model CFC ClearFire Condensing Boiler Operation, Service, and Parts Manual Part No. 750-263 05/2015...
Page 2 WARNING ! DANGER WARNING ! DANGER If the information in this manual is not fol- Improper installation, adjustment service lowed exactly, a fire or explosion may re- or maintenance can cause equipment damage, personal injury or death. Refer sult causing property damage, personal injury or loss of life.
Page 3 WARNING ! DANGER WARNING ! DANGER A hot water boiler installed above radia- The installation must conform to the re- tion level or as required by the Authority quirements of the authority having juris- diction or, in the absence of such having jurisdiction, must be provided with a low water cutoff device either as a part requirements, to the National Fuel Gas...
Page 4 WARNING ! DANGER DO NOT OPERATE, SERVICE, OR REPAIR THIS EQUIPMENT UNLESS YOU FULLY UNDERSTAND ALL APPLICABLE SECTIONS OF THIS MANUAL. DO NOT ALLOW OTHERS TO OPERATE, SERVICE, OR REPAIR THIS EQUIPMENT UNLESS THEY FUL- LY UNDERSTAND ALL APPLICABLE SECTIONS OF THIS MANUAL. FAILURE TO FOLLOW ALL APPLICABLE WARNINGS AND INSTRUCTIONS MAY RESULT IN SEVERE PERSONAL INJURY OR DEATH.
Page 5: Table Of Contents
TABLE OF CONTENTS Section 1 — Introduction Clearfire Features and Benefits ........1-2 Standard Equipment .
Page 6: Table Of Contents
Control Setpoints ..........4-2 Model CFC Boiler / Burner Controller ....... 4-3 CB Falcon Display/Operator Interface .
Page 7: Table Of Contents
Introduction CFC Features and Benefits ....... . 1-2 Standard Equipment ........1-3 The Boiler .
Page 8: Cfc Features And Benefits
A. CFC FEATURES AND BENEFITS Compact Firetube Design The CFC boiler is a single pass down fired durable Firetube boiler. The extended heating surface tubes provide for very high levels of performance in a compact space. The boiler is designed to fire natural gas or propane.
Page 9: Standard Equipment
Section 1 — Introduction B. STANDARD EQUIPMENT 1. The Boiler The boiler is designed for a Maximum Allowable Working Pressure (MAWP) of 125 psig (8.6 Bar) in accordance with the ASME Code for Low Pressure Section IV Hot Water Boilers and is stamped accordingly.
Page 10: Control
Section 1 — Introduction 4. Control (See Figure 1-7) The CB Falcon hydronic control is an integrated burner management and modulation control with a touch-screen display/operator interface. The controller is capable of the following functions: • Two (2) heating loops with PID load control. •...
Page 11: Component/Connection Locations
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 for quick and easy fuel switchover.
Page 12 Blower and Gas Valve Safety Relief Valve Burner Assembly Canister Air Vent Connection Control Panel Hot Water Outlet “Finned” High High Temp. Efficiency AluFer Return Tubes Low Temp. Return Insulation Blanket Flue Gas Outlet Figure 1-8 CFC Cutaway View Part No. 750-263...
Page 13 Section 1 — Introduction Air vent Safety Valve (optional; shipped (shipped loose) loose) Figure 1-9 Boiler safety valve & air vent Figure 1-10 Return Temperature Sensor Mounting Part No. 750-263...
Page 14 Section 1 — Introduction Figure 1-11 Outlet Temperature Sensor, Top of Pressure Vessel The stack can be mounted on the right (Figure 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 3 - Stack and Intake Vent Sizing and Installation.
Page 15 Wiring diagrams ........2-34 www.cleaverbrooks.com...
Page 16 Section 2 — Installation Warning Caution Provisions for combustion and ventilation air must The boiler must be installed such that the gas be in accordance with the National Fuel Gas ignition system components are protected from Code, ANSI Z223.1, or the CAN/CSA B149 water (dripping, spraying, rain, etc.) during Installation Codes, or applicable provisions of the appliance operation and sevice.
Page 17: Assembly
Section 2 — Installation ASSEMBLY 1. Packaging The Cleaver-Brooks Model CFC boiler is shipped in three parcels - the pressure vessel assembly mounted on a skidded crate, the control panel in a box, and the outer casing with insulation in a skidded box.
Page 18: Casing Assembly
3. Locate boiler legs and attaching nuts/bolts (Figure 2-2). Ensure all four (six on CFC 3300) leg height adjusters are at the same level before installing legs. 4. Remove the wooden skid cross beam from the front of the boiler Figure 2-2 5.
Page 19 Section 2 — Installation 6. Attach the boiler front legs. 7. Lift up the back of the boiler using the jack and remove the wooden skid side beams. 8. Attach the rear boiler mounting legs. 9. Lifting eyes are provided for moving and positioning the boiler. 10.Before installing insulation, level the boiler using a level placed against the side of the vessel.
Page 20 Section 2 — Installation Figure 2-7 15.Using a 10mm socket, or by hand, remove 3 nuts and washers from the mounting studs extending from each side of the top plate of the boiler (Figure 2-8). Figure 2-8 16.Attach electrical supply channels on each side (Figure 2-9). Figure 2-9 17.Attach large side panels to each side, fitting on top of the electrical supply channel.
Page 21 Section 2 — Installation Figure 2-10 18.Remove control panel from box. Uncoil sensor wires and route wires out of left-hand side of panel. 19.Mount control panel on front of boiler (Figure 2-11). Make sure to route sensor wires in wiring channel on left-hand side of the boiler (see also Figure 2-38).
Page 22 Section 2 — Installation Flame Rod/Direct urner ignition UV Scanner/ Plot ignition Figure 2-12 21.Route return water sensor (the 2-wire sensor) to the lower pipe on back of boiler, and install lower 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).
Page 23 24.Install C-clips on upper side panels, then install panels on boiler (Figure 2-16). 25.(CFC 3300 only) the main gas train and pilot train ship loose and should be connected before installing the casing top. 26.Install front panel and top panel.* *Sizes 500/750 top/front is 1 piece.
Page 24: Flue Gas/Combustion Air Connections
Figure 2-18 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 2-10 Part No.
Page 25: Water Treatment
Untreated drinking water is generally the best heating medium as filling and make-up water for a system that utilizes the Model CFC. If the water available from the main system is not suitable for use, then demineralization and/or treatment with inhibitors is necessary.
Page 26: Using Glycol
Maximum design temp. D. USING GLYCOL The Model CFC boiler may be operated with a solution of glycol and water. Where glycols are added, the system must first be cleaned and flushed. Correct glycol selection and regular monitoring of the...
Page 27 CFC-3300 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.
Page 28: Boiler Room
2. Gas Train Components Alternate Flue Gas CFC boilers are equipped with a gas train that meets the Flue Gas Vent Connection requirements of ASME CSD-1, FM and XL-GAP (formerly IRI). The Condensate Drain gas train and its components have been designed and tested to operate for the highest combustion efficiency for the CFC units.
Page 29: Gas Pressure Requirements
6.8" 11" 5 psi *Pilot gas pressure CFC 3300: Natural gas 3-5” WC, LP gas 3-4” WC NOTE: The pressure test port is Actual gas pressure should be measured when the burner is firing located at the gas valve inlet using a manometer at the upstream test port connection on the flange (see Figure 2-23).
Page 30: Gas Connections
Leak Test For buildings or boiler rooms with gas supply pressure exceeding 28" w.c. (or 5 psi for CFC 3300) a "full lock-up" type regulator is required as well as overpressure protection (e.g. relief valve). In addition to the regulator, a plug type or "butterball” type gas shutoff valve must be installed upstream of the regulator for use as a service valve.
Page 31: Gas Supply Pipe Sizing
Section 2 — Installation See Figure 2-24 for a typical piping configuration. 5. 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"...
Page 32 Section 2 — Installation Table 2-4: Gas Line Capacity - Schedule 40 Metallic Pipe Pipe Size Nominal 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4" Actual I.D. 1.04 1.380" 1.610" 2.067" 2.469" 3.068" 4.026" Length in feet **Maximum Capacity in Cubic Feet of Gas per Hour (cfh) 1,060 1,580 3,050...
Page 33 Section 2 — Installation Table 2-5: Gas Line Capacity - Schedule 40 Metallic Pipe 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 (cfh) 1,390 2,090 4,020...
Page 34: Gas Header
With the total input, determine length of run from the source and determine what size header will be needed for the flow of all units firing. Pipe sizes based on Table 2-4. Table 2-6: Multiple Unit Manifold, CFC 500 Table 2-7: Multiple Unit Manifold, CFC 750...
Page 35 Section 2 — Installation Figure 2-24 Gas Piping From Meter Header Pipe Gas Strainer Manual Shut Off Regulator See Note 1 Relief Valve See Note 5 Model Model Model Model NOTES: 1. Dedicated gas pressure regulator required for each boiler. Gas Header Piping, Typical 2.
Page 36: General
With as little as 10% return water at or below 120 deg F, the Model CFC will achieve condensing performance, with associated gains in efficiency. If using only a single (common) return, the lower return connection should be used.
Page 37: Pressure Drop Curves
The information in Figure 2-26 through Figure 2-31 and in Tables 2-13 and 2-14 can help in determining pump requirements for Model CFC installations. Figure 2-26 Pressure Drop Curve, CFC 500 Figure 2-27 Pressure Drop Curve, CFC 750 Part No. 750-263...
Page 38 Section 2 — Installation Figure 2-28 Pressure Drop Curve, CFC 1000 Figure 2-29 Pressure Drop Curve, CFC 1500 2-24 Part No. 750-263...
Page 39 Section 2 — Installation Figure 2-30 Pressure Drop Curve, CFC 1800 Figure 2-31 Pressure Drop Curve, CFC 2500 Part No. 750-263 2-25...
Page 40 Section 2 — Installation Hydraulic Resistance CFC 3300 Figure 2-32 Pressure Drop Curve, CFC 3300 Table 2-13: Maximum flow rate through ClearFire boilers (U.S. flow rates) System Temperature Drop Deg F Boiler Flow Rate GPM Size 10.5 1000 1500 1800...
Page 41: Condensate Removal And Treatment
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.
Page 42: Condensate Tank Setup Options
Section 2 — Installation 1. Condensate tank setup options The boiler is supplied with boiler legs (standard) which are sized to Note: To ensure compliance permit the installation of the condensate collection tank. There are with regulations, it is two (2) condensate removal options available: important to contact the responsible authorities (1) Condensate direct to drain - The condensate is piped directly to...
Page 43: Condensate Piping For Multiple Boilers
The number of condensate treatment tanks required for multiple boiler installations depends on the total amount of condensate produced by the system. As a general rule, CB recommends one tank per 5-6 million BTU/hr of total boiler capacity. Model CFC capacities are as follows: CFC Model BTU/hr Max.
Page 44 Section 2 — Installation 1/4" O.D. Make-up Water Supply Condensate Drain Trap Neutralization Tank To Drain Figure 2-36 Condensate Piping for Multiple Boilers 1" NPT Minimum Header Size (Use PVC Pipe or other Nonferrous Material) Condensate Drain Trap Neutralization Tank Neutralization Media 12”...
Page 45 A qualified electrician or service technician must make the electrical connections to the boiler. For typical CFC electrical component mounting see the electrical diagram mounted on the inside of the removable front panel. For specific information on your boiler electrical system refer to the Cleaver-Brooks wiring diagram provided with the boiler.
Page 46: Electrical Connections
Section 2 — Installation Figure 2-38 Electrical Connections CFC 500-2500 2-32 Part No. 750-263...
Page 47 Section 2 — Installation Figure 2-39 Electrical Connections CFC 3300 Part No. 750-263 2-33...
Page 48: Wiring Diagrams
Section 2 — Installation I. WIRING DIAGRAMS Figure 2-40 CFC Wiring Diagram 500-2500, single fuel Note: Wiring diagrams shown examples only. Installations may vary. For specific installations consult the wiring diagram provided with the boiler. 2-34 Part No. 750-263...
Page 49 Section 2 — Installation Figure 2-41 CFC Wiring Diagram 500-2500, dual fuel Part No. 750-263 2-35...
Page 50 Section 2 — Installation Figure 2-42 CFC 3300 Wiring Diagram 2-36 Part No. 750-263...
Page 51 Section 2 — Installation Figure 2-43 CFC 3300 Wiring Diagram - Dual Fuel Part No. 750-263 2-37...
Page 52 Section 2 — Installation Figure 2-44 Transformer Detail, CFC 3300 2-38 Part No. 750-263...
Page 53 Air Supply - Unconfined Spaces ......3-14 Air Supply - Engineered Method ......3-17 www.cleaverbrooks.com...
Page 54: Venting Connections - General
A. VENTING CONNECTIONS - GENERAL 1. Appliance Categories Proper installation of flue gas exhaust venting is critical for the efficient and safe operation of the CFC boiler. The boiler’s appliance category is a major factor determining venting system design. Definitions:...
Page 55: Vent Terminal Location
Section 3 — Stack and Intake Vent Sizing and Installation Vent material should be appropriate for the Appliance Category. Application-specific information will further determine the material selected. In some cases, PVC/CPVC material meeting ULC Type BH Class IIB specifications may be used. Use of PVC/CPVC depends on operating conditions, specific vent suppliers, and any local codes having jurisdiction.
Page 56 Section 3 — Stack and Intake Vent Sizing and Installation Vent termination requirements are as follows: 1. Vent must terminate at least four (4) feet below, four (4) feet horizontally, or one (1) foot above any door, window or gravity air inlet to the building.
Page 57: Horizontal Thru-Wall Venting / Inside Combustion Air
Section 3 — Stack and Intake Vent Sizing and Installation Venting Installation Tips Support piping: • Horizontal runs- at least every five (5) feet. • Vertical runs - use braces. • Under or near elbows Caution Follow items listed below to avoid personal injury or property damage.
Page 58: Horizontal Thru-Wall Stack Vent Termination
Section 3 — Stack and Intake Vent Sizing and Installation 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.
Page 59: Installation
Section 3 — Stack and Intake Vent Sizing and Installation Care must be taken during assembly that all joints are sealed properly and are airtight for both the combustion air intake and the exhaust stack piping system. The stack vent must be installed to prevent the potential accumulation of condensate in the stack pipes.
Page 60: Vertical Venting / Inside Combustion Air
24" Minimum 48" Minimum CFC Boiler Figure 3-3 Vertical Stack with 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.
Page 61: Vertical Venting / Direct Vent Combustion Air
Section 3 — Stack and Intake Vent Sizing and Installation 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 non-restricted direct vent cap must be furnished in accordance with AGA/CSA requirements.
Page 62: Stack Sizing
Flue Connection Air Filter Kit No. Combustion Air Boiler Flue/Stack Flue Gas Vent in Connection Part No. (optional) Required (CFM) Size Feet* CFC 500 6" Standard 6" 039-01704 880-01858 CFC 750 6" Standard 6" 039-01704 880-01858 CFC1000 6" Option 6"...
Page 63: Stack Design Using Direct Vent Combustion
Boiler Connection Intake Duct & Flue/Stack Flue Gas Vent in Air Intake Duct in Combustion Air Kit Part No. Connection Size Feet* Feet** CFC 500 6" Standard 4" 6" 880-01312 039-01704 CFC 500 6" Standard 6" 6" 880-03736 039-01704 CFC750 6"...
Page 64: Venting For Multiple Units
Section 3 — Stack and Intake Vent Sizing and Installation G. VENTING FOR MULTIPLE UNITS Cleaver-Brooks recommends that each Model CFC in a multiple boiler installation be vented individually. If it becomes necessary to connect multiple boilers to a common breeching, measures should be taken to ensure an unrestricted flow of flue gas from each boiler.
Page 65 Section 3 — Stack and Intake Vent Sizing and Installation EXAMPLE 2 GOOD 10” 6” 6” EXAMPLE 3 GOOD 6” 10” 14” 6” 6” 6” 6” 6” 6” From Boilers GOOD 6” 6” 6” 8” 12” 16” From Boilers 8” 8”...
Page 66: Air Supply - Unconfined Spaces
Section 3 — Stack and Intake Vent Sizing and Installation H. COMBUSTI0N AIR/BOILER ROOM VENTILATION REQUIREMENTS The boiler(s) must be supplied with adequate quantities of uncontaminated air to support proper combustion and equipment ventilation. Air shall be free of chlorides, halogens, fluorocarbons, construction dust or other contaminants that are detrimental to the burner/boiler.
Page 67 Section 3 — Stack and Intake Vent Sizing and Installation 3. One opening must terminate within twelve inches of the top, and one opening must terminate within twelve inches of the bottom of the room. 4. Refer to the NFGC, Section 8.3 for additional information.
Page 68 Section 3 — Stack and Intake Vent Sizing and Installation VENT VENT 12" MINIMUM OUTLET AIR DUCT INTERIOR WALL EXTERIOR WALL CLEARFIRE WATER BOILER FRESH AIR HEATER INLET DUCT 12" MINIMUM Figure 3-6. Two Opening Ducted Method C. One Opening Method (Figure 3-7) - One permanent opening, commencing within 12 inches of the top of the enclosure, shall be provided.
Page 69: Air Supply - Engineered Method
Section 3 — Stack and Intake Vent Sizing and Installation VENT VENT 12" MINIMUM FRESH AIR OPENING EXTERIOR WALL CLEARFIRE WATER BOILER HEATER Figure 3-7. One Opening Method 2. Air Supply - Engineered Method When determining boiler room air requirements for an unconfined space, the size of the room, airflow, and velocity of air must be reviewed as follows: 1.
Page 70 Section 3 — Stack and Intake Vent Sizing and Installation VENT VENT FRESH AIR OPENING FRESH AIR OPENING CLEARFIRE WATER BOILER HEATER EXTERIOR WALL EXTERIOR WALL Figure 3-8. Two Opening Engineered Method E. Size the openings by using the formula: Area in square feet = cfm/fpm Where cfm = cubic feet per minute of air Where fpm = feet per minute of air...
Page 71 Section 3 — Stack and Intake Vent Sizing and Installation • Area required: Area = cfm/fpm = 1,080/250 = 4.32 square feet total. • Area/Opening: 4.32/2 = 2.16 sq-ft/opening (2 required). Notice Consult local codes, which may supersede these requirements. Direct Vent Combustion If combustion air will be drawn directly from the outside by means of a duct connected to the burner air intake, use the following as a...
Page 72 Section 3 — Stack and Intake Vent Sizing and Installation 3-20 Part No. 750-263...
Page 73 Control Setpoints ........4-2 Model CFC Boiler / Burner Controller ......4-3 CB Falcon Display/Operator Interface .
Page 74: Operating Conditions
Section 4 — CFC Commissioning A. OPERATING CONDITIONS • The installation site should be as free as possible from vibration, dust, and corrosive media • The controllers should be located as far as possible from sources of electromagnetic fields, such as frequency converters or high-...
Page 75: Model Cfc Boiler / Burner Controller
Section 4 — CFC Commissioning D. MODEL CFC BOILER / BURNER CONTROLLER The Model CFC boiler uses the CB Falcon hydronic boiler control system. Primary controller functions include: • Flame supervision • Burner sequencing • Heating/modulation control • Hot water system pump control •...
Page 76: Cb Falcon Display/Operator Interface
Section 4 — CFC Commissioning E. CB FALCON DISPLAY/OPERATOR INTERFACE The CB Falcon display/operator interface is mounted at the left side of the control panel for convenient access to all operating controls. 1. Home Page Apply power to the boiler. The Home page will appear on the CB Falcon display.
Page 77: Operation Page
Section 4 — CFC Commissioning 3. Operation Page The operation page (Figure 4-5) displays the CB Falcon running operation, including setpoint and firing rate values. From this page the user can change setpoints, manually control the boiler’s firing rate, manually turn pumps on, view annunciation information, and switch between heating loops (Central Heat and Domestic Hot Water).
Page 78: Controller Configuration
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 settings are correct for your application. Please refer to CB default settings, Table 4-1, and make any changes at this time if needed.
Page 79 Section 4 — CFC Commissioning • High Limits • Stack Limit • Other Limits • Anti-condensation Configuration • Frost Protection Configuration • Annunciation Configuration • Burner Control Interlocks • Burner Control Timings & Rates • Burner Control Ignition • Burner Control Flame Failure •...
Page 80 Section 4 — CFC Commissioning Table 4-1 CFC Falcon Parameters (Continued) Modbus Min. Max. Paramet Default Setting - Default Setting - Parameter Group Parameter Name Access Installation Setting Register Range Range er Units CFC-500 to -2500 CFC-3300 (dec) Outdoor Reset Config-...
Page 81 Section 4 — CFC Commissioning Table 4-1 CFC Falcon Parameters (Continued) Modbus Min. Max. Paramet Default Setting - Default Setting - Parameter Group Parameter Name Access Installation Setting Register Range Range er Units CFC-500 to -2500 CFC-3300 (dec) Modulation Configura-...
Page 82 Section 4 — CFC Commissioning Table 4-1 CFC Falcon Parameters (Continued) Modbus Min. Max. Paramet Default Setting - Default Setting - Parameter Group Parameter Name Access Installation Setting Register Range Range er Units CFC-500 to -2500 CFC-3300 (dec) Pump Configuration...
Page 83 Section 4 — CFC Commissioning Table 4-1 CFC Falcon Parameters (Continued) Modbus Min. Max. Paramet Default Setting - Default Setting - Parameter Group Parameter Name Access Installation Setting Register Range Range er Units CFC-500 to -2500 CFC-3300 (dec) Delta-T Limits...
Page 84 Section 4 — CFC Commissioning Table 4-1 CFC Falcon Parameters (Continued) Modbus Min. Max. Paramet Default Setting - Default Setting - Parameter Group Parameter Name Access Installation Setting Register Range Range er Units CFC-500 to -2500 CFC-3300 (dec) Annunciation Configu-...
Page 85 Section 4 — CFC Commissioning Table 4-1 CFC Falcon Parameters (Continued) Modbus Min. Max. Paramet Default Setting - Default Setting - Parameter Group Parameter Name Access Installation Setting Register Range Range er Units CFC-500 to -2500 CFC-3300 (dec) Burner Control Inter-...
Page 86 Section 4 — CFC Commissioning Table 4-1 CFC Falcon Parameters (Continued) Modbus Min. Max. Paramet Default Setting - Default Setting - Parameter Group Parameter Name Access Installation Setting Register Range Range er Units CFC-500 to -2500 CFC-3300 (dec) Sensor Configuration...
Page 87: Changing Parameter Settings
Section 4 — CFC Commissioning 1. Changing Parameter Settings To access the CB Falcon configuration menu, press <Configure> on the Status page. Some parameters require a password entry before allowing changes. The <Login> button will appear when any password- protected parameter is displayed on the screen. Default service level password is 9220.
Page 88: Program Module
Figure 4-3 Falcon Program responsible for flame supervision and burner sequencing. Module The CFC boiler uses direct spark ignition (gas pilot on 3300) to light the main flame. Flame sensing is accomplished with a flame rod, or ionization electrode (UV scanner on 3300).
Page 89: Fan Speed Settings
9. The ignition and the gas valve are switched on. 10.The ignition is turned off at the end of the direct burner ignition period (5 seconds into pilot ignition, CFC 3300). 11.The fan is kept at the lightoff rate during the stabilization timer, if any.
Page 90: Initial Start-Up Procedure
CSA Canadian regulations may limit the maximum allowable gas supply pressure to 1/2 psig). CFC 500-2500 CFC 3300 maximum allowable gas supply pressure to its gas train is 5 psig. 3. To bleed air from the supply pipe, open the manual gas shut off valve upstream of the burner gas train and bleed air from the piping by loosening the union in the upstream piping.
Page 91: Power-Up
5 psi *Sizes 1500-2500 for low gas pressure applications see Table 4-4 **Pilot gas pressure CFC 3300: Natural gas 3-5” WC, LP gas 3-4” WC CFC sizes 1500-2500 can accommodate lower gas supply pressures when equipped with the 940-07482 gas valve. Dual fuel units retain the standard valve for LP gas operation.
Page 92 Section 4 — CFC Commissioning 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 1. To check the Low Gas Pressure Switch, first close the upstream manual shutoff valve (both manual shutoff valves should now be closed).
Page 93: Pilot Tests
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. PILOT TESTS (CFC 3300 ONLY) Figure 4-6 Low Water Cutoff test PILOT FAIL CHECK Close the gas pilot shutoff valve.
Page 94: Low And High Fire Adjustments
Section 4 — CFC Commissioning 6. Low and High Fire Adjustments All CFC boilers are factory tested firing natural gas at an altitude of 1000 ft ASL. Operating under different conditions may require re- adjustment of the gas valve. CFC 500-2500 Adjustments are made using a TORX®...
Page 95: Modulation Off Point
Note: A Combustion Analyzer is required to properly set up the analyzer probe as close as possi- ble to the boiler vent connection. Model CFC burner. Do not attempt to fire and adjust the burner without this equipment. Sampling too far from the boiler vent can produce false readings Note: Ensure boiler is filled with water prior to burner startup.
Page 96: High Air Pressure Switch Settings
The High Air Pressure witch (HAPS) is used to safely shut down the boiler in case of a blocked flue or blocked condensate condition. The HAPS switch setting for each model CFC can be found below: Table 4-5 HAPS Settings...
Page 97: Limit Controls Check
Restore Modulation OFF and High Limit to operational settings after testing. Specific settings are determined by application. Maximum High Limit for Model CFC is 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.
Page 98: Procedures For Lp (Propane) Gas
2. Install orifice gasket provided by replacing the existing venturi- gas train connection gasket with appropriate orifice (see Table 4-6). 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.
Page 99: Units With Optional Dual-Fuel Gas Train
Section 4 — CFC Commissioning 5. Select Modulation configuration. Adjust CH and DHW maximum modulation rates according to Table 4-2. Adjust minimum modulation rate according to Table 4-2. Return to Configuration menu. 6. Select Burner Control Ignition configuration. Adjust ignition, or lightoff, rate according to Table 4-2.
Page 100 Section 4 — CFC Commissioning 7. Access boiler control Configuration menu. Press <Login>. Enter service level password: 9220. Press <OK>. 8. Select Modulation configuration. Adjust CH and DHW maximum modulation rates according to Table 4-2. Adjust minimum modulation rate according to Table 4-2. Return to Configuration menu.
Page 101: Falcon Control Functions And Customer Interface
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 CFC wiring diagram). When the circuit is open, the boiler control reverts back to the normal set point.
Page 102 Section 4 — CFC Commissioning The PID (Proportional-Integral-Derivative) load control operates on the demand source’s modulation rate. Under Central Heat configuration, the PID gain values can be adjusted to match the desired modulation response. The default gain value settings of P=25, I=25 &...
Page 103 Section 4 — CFC Commissioning to “S2 (J8-6) 4-20mA”. Next, the span of the 4-20mA needs to be established. The “20mA water temperature” parameter determines the value for 20mA; “4mA water temperature” determines the value for 4mA. Depending on the quality of the remote input signal, the modulation...
Page 104 Section 4 — CFC Commissioning 1. Central Heat Pump 2. Boiler Pump (for primary/secondary pumping) 3. DHW pump 4. System Pump 5. “Aux 1 Pump” - used for a boiler isolation valve 6. “Aux 2 Pump” - used for a boiler Start Permissive Interlock...
Page 105 Section 4 — CFC Commissioning receive control input information and to maintain the optimum setpoint. An outdoor temperature sensor can also be connected for Lead Lag outdoor reset control. Boiler sequencing, on/off staging, and firing rate allocation are user- configurable. The Falcon’s default lead lag parameter settings have been optimized specifically for ClearFire-C condensing boiler operation.
Page 107: Service And Maintenance
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. www.cleaverbrooks.com...
Page 108: Cleaning Procedure / Disassembly
Section 5 — Service and Maintenance On an annual basis the boiler vessel and burner combustion system must be checked and cleaned. This work is to be carried out by an authorized Cleaver-Brooks Service Technician. A. CLEANING PROCEDURE / DISASSEMBLY 1.
Page 109: Reassembly
2. A new rope gasket should be installed on the burner door; see recommended spare parts list. C. IGNITION AND FLAME DETECTION SYSTEMS Electrode and Flame Rod (CFC 500-2500) The ignition and ionization electrodes should be replaced annually, or more frequently if conditions require. Inspect the electrodes periodically for signs of fouling, displacement, or other damage.
Page 110 Section 5 — Service and Maintenance When replacing the adjustable flame rod: • While holding the flame rod in position, tighten the bracket nut until you cannot twist the flame rod. This can be done by slightly wiggling the flame rod back and forth when tightening. You should also begin to feel tension in the nut while tightening.
Page 111 REFRACTORY UV Scanner Figure 5-7 The CFC 3300 uses an interrupted gas pilot in lieu of direct spark ignition. The dual ignition electrode is the same component used in direct spark models; it should be inspected regularly and cleaned or replaced as needed.
Page 112: Troubleshooting
Section 5 — Service and Maintenance 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.
Page 113 Section 5 — Service and Maintenance Troubleshooting Chart Symptom/Fault Indication Possible Causes Erratic display/controller behavior Faulty electrical ground - Check ground terminals in control panel. System should be grounded firmly to metal casing. External ground wiring may be necessary. Touch screen not working properly Screen out of calibration - from Falcon home page, go to Setup/Advanced Setup/Diagnostics.
Page 114 Section 5 — Service and Maintenance Part No. 750-263...
Page 115 Vent (Flue) Connections ................. . 6-23 Table 6-1. Recommended Spare Parts List Model CFC...
Page 116 Section 6 — Parts Figure 6-1. Boiler Mechanical Assembly CFC 500-2500 Part No. 750-263...
Page 117 Section 6 — Parts Table 6-2. Boiler Mechanical Assembly CFC 500-2500 BOILER SIZE 1000 1500 1800 2500 380 01104 380 01104 380 01105 380 01106 380 01099 380 01100 880 02529 880 02525 880 02525 880 02526 880 02527 880 02528...
Page 118 Section 6 — Parts Figure 6-2. Boiler Mechanical Assembly CFC 3300 SECTION B-B TOP PLATE OF VESSEL DETAIL A Part No. 750-263...
Page 119 Section 6 — Parts Table 6-4. Boiler Mechanical Assembly CFC 3300 NOTES ITEM PART NO DESCRIPTION 380-01116-000 VESSEL, PRESSURE, CFC-3300 SHIP LOOSE 880-02708-000 KIT, CASING ASSEMBLY (CASING, LEGS AND INSULATION) 429-01783-000 BURNER & DOOR ASSEMBLY 185-01140-000 GAS TRAIN, MAIN GAS AND PILOT 961-00089-000 GAS SPRING, PUSH TYPE, 10.2"...
Page 120 Section 6 — Parts Figure 6-3. Vessel 3300 132-02800 BURNER DRAWER ASSY. SEE BURNER DRAWER INSULATION BLANKET, TOP 872-01247 872-01248 872-01249 872-01249 872-01250 872-01551 INSULATION BLANKET, SHELL 872-01237 872-01238 872-01239 872-01239 872-01241 872-01242 872-01234 872-01234 872-01235 STRAP 872-01235 872-01236 872-01236 872-01233 872-01233 872-01233 872-01233 872-01233 872-01233 BUCKLES Part No.
Page 121 Section 6 — Parts Figure 6-4. Casing Part No. 750-263...
Page 122 Section 6 — Parts Figure 6-5. Burner Door Assembly CFC 500-2500 1000 1500 1800 2500 132-02637 132-02637 132-02282 132-02384 132-02384 132-02385 872-01252 872-01252 872-01254 872-01253 872-01255 872-01254 380 01053 380 01053 380 01033 380-01052 380-01052 380-01035 380-01082 380-01037 380-01076 380-01037...
Page 123 Section 6 — Parts Figure 6-6. Burner Door Assembly CFC 3300 INSULATION SUPPLIED WITH ITEM# 1 ITEM PART NO DESCRIPTION ITEM PART NO DESCRIPTION 132-02800-000 DOOR, TOP INSULATED 090-04464-000 TUBE, GAS PILOT ----------- ---------------------------------------------- 853-00213-000 SIGHT GLASS GASKET, .0625" x 1.438" ID x 1.719" OD...
Page 124 Section 6 — Parts Figure 6-7 Gas train - single fuel 500-2500 BOILER SIZE ITEM 1000 1500 1800 2500 DESCRIPTION GAS VALVE, C/W 1" ADAPTER 940-07163-000 940-07164-000 940-07165-000 940-07235-000 817-02420-000 817-02420-000 HIGH GAS PRESSURE SWITCH (HGPS) 817-02420-000 817-02420-000 817-02414-000 817-02414-000 817-02414-000 LOW GAS PRESSURE SWITCH (LGPS) 817-02414-000...
Page 125 Section 6 — Parts Figure 6-8. Gas train, dual fuel: CFC 1000 - 2500 (PROPANE) (NATURAL GAS) (PORT P) (PORT P) SECTION A-A (PORT 4) (PORT 1) (PORT 2) ITEM PART NO. DESCRIPTION 800-00093-000 ADAPTER 800-00093-000 800-00093-000 800-00093-000 800-00092-000 223-00013-000...
Page 126 Section 6 — Parts Figure 6-9. Gas train, dual fuel: CFC 500 - 750 (PORT P) (NATURAL GAS) (PROPANE) (PORT P) (PORT 4) (PORT 4) SECTION A-A (PORT 2) (PORT 2) (PORT 1) (PORT 1) ITEM DESCRIPTION 800-00092-000 800-00092-000 Adapter...
Page 127 Section 6 — Parts Figure 6-10. Gas train, single fuel - CFC 3300 ITEM PART NO DESCRIPTION 941-01946-000 BALL VALVE, 1-1/2" NPT. 800-00101-000 ADAPTER, PIPE, 1" NPT. W/ SHUTTER, O-RING & SCREWS 940-07482-000 VALVE, GAS, 110VAC 800-00102-000 ADAPTER, PIPE, 2" NPT. WITHOUT SHUTTER 918-00637-000 REGULATOR, GAS PRESS., 2"...
Page 128 Section 6 — Parts Figure 6-11. Gas train, dual fuel - CFC 3300 ITEM PART NO DESCRIPTION 223-00013-000 BALL VALVE, 3-WAY, BRASS, 1-1/2" NPT. 800-00101-000 ADAPTER, PIPE, 1" NPT. WITH SHUTTER, O-RING AND SCREWS 940-07482-000 VALVE, GAS, 110VAC 800-00102-000 ADAPTER, PIPE, 2" NPT. WITHOUT SHUTTER 918-00637-000 REGULATOR, GAS PRESSURE, MAXITROL #210E, 2"...
Page 129 Section 6 — Parts Figure 6-12. Electrical assemblies - single fuel 500-2500 Part No. 750-263 6-15...
Page 130 Section 6 — Parts Table 6-5. Electrical assemblies single fuel 500-2500 PART NUMBER SEE TABLE SEE TABLE SEE TABLE SEE FIGURE 6-13 *OPTIONAL Table 6-6. Item 1 Control Panel Boiler Size 1000 1500 1800 2500 119-00429 119-00429 119-00430 119-00431 119-00431 119-00426 Table 6-7.
Page 131 Section 6 — Parts Figure 6-13. Cables and Cable Harness - Single Fuel 500-2500 82600158 BURNER CABLE HARNESS Part No. 750-263 6-17...
Page 132 Section 6 — Parts Figure 6-14. Electrical Assemblies - Dual Fuel 500-2500 PART NUMBER PART NUMBER SEE TABLE SEE TABLE SEE FIGURE 6-15 SEE TABLE (OPTIONAL) ITEM 1 CONTROL PANEL BOILER SIZE 1000 1500 1800 2500 PART # 119-00429 119-00429 119-00430 119-00431 119-00431...
Page 133 Section 6 — Parts Figure 6-15. Cables and Cable Harness - Dual Fuel 500-2500 , PANEL CABLE HARNESS, BURNER 826-00158-000 CABLE HARNESS FOR PROPANE GAS TRAIN 826-00162-000 Part No. 750-263 6-19...
Page 134 Section 6 — Parts Figure 6-16. Electrical Assemblies - CFC 3300 ITEM QTY PART NO DESCRIPTION 119-00435-000 CONTROL PANEL (119C00435) 833-05105-000 DISPLAY, SYSTEM 833-04086-000 FALCON CONTROLLER, HYDRONIC 832-00235-000 TRANSFORMER, 115v/25v 832-02451-000 IGNITION TRANSFORMER 880-02343-000 PLUG, CONNECTOR KIT, FALCON 833-03547-000 CONTROLLER, LWCO...
Page 135 Section 6 — Parts Figure 6-17. Cables and Cable Harness - CFC 3300 ITEM PART NO DESCRIPTION 826-00156-000 CABLE, IGNITION 832-02434-000 CABLE, BLOWER SIGNAL 826-00160-000 CABLE HARNESS, FEMALE END 826-00257-000 CABLE, BLOWER POWER 826-00211-000 CABLE, UV SCANNER TO FALCON J1...
Page 136 Section 6 — Parts OPTIONAL PARTS Table 6-9. Air Filter BOILER VENTURI DESCRIPTION PART NO. SIZE CONNECTION SIZE 4” AIR FILTER KIT* 880-01858 4” AIR FILTER KIT* 880-01858 1000 4” AIR FILTER KIT* 880-01858 1500 6” AIR FILTER KIT* 880-02005 1800 6”...
Page 137 OUTDOOR TEMP . SENSOR W/WEATHERPROOF ENCLOSURE 817-4517 HEADER TEMPERATURE SENSOR (FOR LEAD LAG) 817-4468 THERMOWELL, 1/2” NPT W/CLAMP 817-00405 PLUG-IN MODULE (PIM) - FOR CLONING AND BACKUP 833-3640 Table 6-12. Vent (Flue) Connections Model CFC Connection Size 1000 1500 1800 2500 3300 6” 039-1704...
Page 138 Section 6 — Parts 6-24 Part No. 750-263...
Page 139 Appendix A — CB Falcon Hydronic Control ...
Page 141 CB Falcon Boiler Control System 833-3578 Steam 833-3639 & 833-3871 Hydronic INSTALLATION AND OPERATION APPLICATION The CB Falcon is a boiler control system available for steam or hydronic applications. The Falcon is able to provide heat control, flame supervision, circulation pump control, fan control, boiler control, and electric ignition function.
Page 142 Flame Sense/Burner Type 833-3578 Steam (CB Boiler 120V FR - DSI Models CFH, CFV) 833-3639 Hydronic (CB Model 120V FR - DSI CFC) 833-3871 Hydronic (CB Model 120V FR - DSI CFW) FR = Flame Rod DSI = Direct Spark Ignition 750-265...
Page 143 CB FALCON TABLE OF CONTENTS Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 Operational Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 Communications and Displays - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9...
Page 144 CB FALCON FEATURES • Flame • Alarm • Flame Sensing Safety and Boiler Protection • Ultraviolet (C7027, C7035, C7044 Sensors) Hydronic Control • Flame Rod • Frost Protection, Slow Start, Anti-condensate, Boiler Delta- • Single Element (Internal spark generator T, Stack Limit, Boiler Limit, DHW Limit, Outlet T-Rise Limit and flame sense using the same element) Steam Control •...
Page 145: Lockouts And Alerts
CB FALCON OPERATIONAL FEATURES Sensor Select Inputs for Header or Outdoor temperature sensors might be available from various sources, so parameters are provided to Self Test select the input source. These parameters determine: The Safety Processor performs Dynamic Self Checks that •...
Page 146: Temperature Settings
CB FALCON Cycle and Time History Modbus/ECOM Event Handling The non-volatile memory contains the following parameters The Modbus and ECOM communication system responds to and status values related to cycle counts and elapsed queries and can write new values to the parameters. operation time: •...
Page 147 CB FALCON 880-2343 Connector Kit Device Mates with … Plug # Description Manf. Part Number Flame Detection Molex 0050841060 (Shell), 0002082004 (Pin, 14-20 AWG) Interface PWM Combustion Molex 0039012040 (Shell), 0039000059 (Pin, 18-24 AWG) Blower Interface Comm. Interface EDZ1100/9 (SCREW) Line Voltage I/O Lumberg 3623 06 K129...
Page 148: Communications And Displays
CB FALCON OVERVIEW Functions provided by the Falcon include automatic boiler • Digital inputs for room limit control, high limit control, sequencing, flame supervision, system status indication, firing Air pressure switch, Gas pressure switch, low water rate control, load control, CH/DHW control, limit control, cutoff, valve proof of closure switch.
Page 149 CB FALCON Vibration: 0.0 to 0.5g Continuous (V2 level) SPECIFICATIONS Enclosure: Nema 1/IP40. Electrical Ratings: Operating voltage Approvals: 24Vac (20 to 30 Vac, 60 Hz ±5%) Underwriters Laboratories, Inc. Component Recognized: File Connected Load for Valve and annunciator functions: No. MP268 (MCCZ). 833-3639 and 833-3578 are certified 24Vac, 60Hz as UL372 Primary Safety Controls.
Page 150 CB FALCON 5. Disconnect the power supply before beginning installa- tion to prevent electrical shock and equipment damage. Table 1. NTC Sensors (temperature versus resistance). More than one disconnect may be involved. 6. All wiring must comply with applicable local electrical 12K NTC (kOhm)* 10K NTC (kOhm)* codes, ordinances and regulations.
Page 151 CB FALCON 3. Ground to central ground terminal, not to Ground on A ground return wire is required in the appliance to reduce the J4 terminal 12. high frequency components of the actual return current. Limit String and Annunciator inputs and Communications: Connector J3 1.
Page 152 CB FALCON Table 2. Wire Sizes. (Continued) Maximum Leadwire Distance (in Application Recommended Wire Size Recommended Part Number(s) feet) Modulating 22 AWG two-wire twisted Beldon 8443 or equivalent Output Signal pair, insulated for low voltage Modbus 22 AWG two-wire twisted 22 AWG two-wire twisted pair, insulated for low voltage communication pair, insulated for low voltage...
Page 153 CB FALCON FALCON HYDRONIC CONTROL PLUG CONNECTORS BLUE FAN POWER (25 VDC) FAN GND WHITE PWM OUT TACHOMETER 24 VAC EGND 24 VAC RTN L2 FOR 120VAC OR STAT 24VAC RETURN (OPTOS) INLET TEMP INLET TEMP RTN PUMP A 4-20 mA REMOTE SOURCE OUTLET TEMP A PUMP B OUTLET TEMP RTN...
Page 154 CB FALCON FALCON STEAM CONTROL PLUG CONNECTORS BLUE FAN POWER (25 VDC) FAN GND WHITE PWM OUT TACHOMETER 24 VAC EGND 24 VAC RTNS STAT L2 FOR 120VAC OR 24VAC RETURN (OPTOS) STEAM PRESSURE – SENSOR 4-20 mA REMOTE SOURCE PUMP A –...
Page 155 CB FALCON Table 3. Falcon Contact. Connector Term. Function Description and Rating (All Models) FLAME ROD INPUT FLAME ROD COMMON UV COMMON TACH Tachometer Input (Tach) Tachometer input. Electronic Blower Motor Power (25 VDC) Digital modulation (PWM) Output Digital modulation signal out. Ground pin for Fan interface and power Modbus MB1 RS-485 + Modbus MB1 RS-485 -...
Page 156 CB FALCON Table 3. Falcon Contact. (Continued) Connector Term. Function Description and Rating (All Models) Annunc2 24VAC, 120 VAC: 2 mA maximum Not Used Annunc3 24VAC, 120 VAC: 2 mA maximum Annunc4 24VAC, 120 VAC: 2 mA maximum Annunc5 24VAC, 120 VAC: 2 mA maximum Annunc6 24VAC, 120 VAC: 2 mA maximum Annunc7/HFS...
Page 157 CB FALCON Table 3. Falcon Contact. (Continued) Connector Term. Function Description and Rating (All Models) Spark 8kV minimum open circuit voltage; 2.8mJ at the igniter Plug In Module (PM7910) Flame + FS + Testpoint for Flame signal. 0 to 10 VDC Flame - FS - Testpoint for Flame signal - Ground...
Page 158 CB FALCON STARTUP Parameter Control Blocks (PCB) The Falcon Parameters are managed using control blocks. There are three parameter control blocks (PCB) that may be The Falcon is shipped in the unconfigured condition, so when installed into the memory of the Falcon: power is applied, all safety loads are off and the burner status 1.
Page 159 CB FALCON one or more of the items in the list. If a parameter is not modified section of safety data. However it is not yet listed in this PCB, then it is restricted by the factory installed accepted and written into memory, nor does the Falcon limits.
Page 160 CB FALCON Table 6. System Operation Settings. (Continued) Parameter Comment Warm Weather Shutdown Temperature, None Setpoint Lead Lag slave enable Enable, Disable (hydronic only) Lead Lag Master enable Enable, Disable (hydronic only) DHW priority vs LL These parameters determine the priority of DHW versus other sources of calls-for-heat, when more DHW priority vs CH than one source is enabled.
Page 161 CB FALCON Table 7. General Configuration Settings. Parameter Comment Temperature Units F, C This parameter determines whether the temperature is represented in units of Fahrenheit or Celsius degrees. Anti short cycle time mm:ss 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.
Page 162 CB FALCON The chosen fan speed for calibrating these scalers is 5000 Demand and Rate RPM, that is, when both the MCBA and the Falcon have a The Demand and Rate subsystem produces 3 outputs: maximum fan speed of 5000 RPM, the user-programmable P, I, and D gains used by the MCBA can be directly copied to the •...
Page 163 CB FALCON CH ENABLE DEMAND SENSOR TERMINALS DHW ENABLE PRIORITY INPUT OUTPUT SLAVE COMMAND EXISTS CONTROL PARAMETER LL SLAVE ENABLE CH PUMP DEMAND “pRATE” = 0 TO 99.99% OF CAPACITY PRIORITY: CH <>DWH LL<>DHW DHW PUMP DEMAND RELOAD “mRATE” = ANALOG% OR RPM CH FROST PROTECT BURNER DEMAND DHW PRIORITY OVERRIDE TIME demand...
Page 164 CB FALCON The burner demand priority control block implements a priority scheme according to the descriptions of the parameters shown as providing input to this block. The implementation is: DETERMINE IF DHW DEMAND SHOULD IGNORE AN ANTI SHORT CYCLE (ASC) DELAY... Fig.
Page 165 CB FALCON The Hydronic Central Heating function is implemented as shown in Fig. 8. CH DEMAND SOURCE CH ENABLE STAT ENVIRACOM REMOTE SETTINGS ARE: STAT (ON/OFF TOP: STAT AND SENSOR MESSAGE, WITH REMOTE STAT AND SENSOR CH PUMP TIMEOUT) LCI AND SENSOR DEMAND BOTTOM: SENSOR ONLY...
Page 166 CB FALCON Table 8. Central Heating Hydronic Parameters. (Continued) Parameter Comment Modulation sensor Inlet (S1), Outlet (S3, S4), S5 The selected input provides the temperature for modulation control. As a startup check, if the CH Loop is enabled for a hydronic system, then if the select sensor is not a temperature input (i.e.
Page 167 CB FALCON (min outdoor, Setpoint) Should be higher than setpoint Boost max setpoint step °F (min outdoor, TOD Setpoint) (max outdoor, min water) OUTDOOR TEMPERATURE Fig. 9. Outdoor reset with TOD and boost. Table 9. Outdoor Reset and Boost Parameters. Parameter Comment CH ODR low outdoor...
Page 168 CB FALCON CH ODR Parameters LL ODR Parameters Setpoint Setpoint TOD Setpoint TOD Setpoint Minimum Outdoor Temp Minimum Outdoor Temp Maximum Outdoor Temp Maximum Outdoor Temp Minimum Water Temp Minimum Water Temp Boost Time Boost Time Boost Max Setpoint Boost Max Setpoint Boost step Boost step Boost recovery step time...
Page 169 CB FALCON INPUT STEAM ONLY CH DEMAND SWITCH PARAMETER OUTPUT STEAM HEATING PARAMETER STAT (CH) “pRATE” = 0 TO 99.99% OF CAPACITY EnviraCOM REMOTE STAT CH ENABLE NO DATA TIMEOUT REVERT TO OFF CH MODULATION SENSOR STAT2 IGNORED: S1 IS ALWAYS USED AS THE CH SENSOR FOR STEAM MODULUS STAT CH HEAT...
Page 170 CB FALCON Table 10. Central Heating Steam Parameters. (Continued) Parameter Comment Steam pressure setpoint PSI or None This setpoint is used when the time-of-day input is off. Steam time-of-day pressure PSI or None setpoint This setpoint is used when the time-of-day input (J10 terminal 2) is on. Steam Pressure off hysteresis PSI or None Steam Pressure on hysteresis...
Page 171 CB FALCON Whenever the burner turns off, the turn-on threshold is lowered Setpoint and Hysteresis (Steam by doubling the on hysteresis, and then increasing it by 2 Control) degrees F per step until it reaches its original value. The Steam and LL master each have similar setpoint and The time of each step is provided by the hysteresis step time hysteresis functions.
Page 172 CB FALCON STEAM PARAMETERS OFF HYST. SETPOINT TOD SETPOINT ON HYST. SETPOINT AND HYSTERESIS STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 SETPOINT + OFF HYSTERESIS 1 MINUTE SETPOINT SETPOINT - ON HYSTERESIS 1 MINUTE 2 PSI (.2 PSI FOR 0-15 PSI) SETPOINT - 2 * ON HYSTERESIS BURNER ANTI-SHORT-CYCLE DELAY...
Page 173 CB FALCON is above the setpoint plus a hysteresis value, or until the other DHW Loop Demand and Rate selected demand source input (i.e. Remote Stat or DHW (Hydronic only) Switch), if any, turns off. The Domestic Hot Water (DHW) Demand and Rate source Pump demand may be driven by the a remote stat, or by the compares a sensor to a setpoint.
Page 174 CB FALCON Table 11. Domestic Hot Water Parameters. Parameter Comment DHW demand switch DHW Sensor Only, DHW Switch, Auto-Sensor Only, EnviraCOM DHW Request, STAT, Auto and EnviraCOM DHW, Plate Heat Exchanger, J7-3 120 Vac This parameter selects the source of demand for the DHW system. •...
Page 175 CB FALCON Table 11. Domestic Hot Water Parameters. (Continued) Parameter Comment DHW modulation sensor Inlet (S1), Outlet (S3S4), DHW (S6S7), Auto DHW (S6) or Inlet(S1), Auto DHW (S6) or Outlet This parameter selects the source of modulation control for the DHW system. If the selected input is not a temperature (e.g.
Page 176 CB FALCON DHW MODULATION SENSOR PRIORITY WHENEVER SET CHANGES FROM OFF TO ON, TAP OUTPUT IS TRUE FOR AT LEAST THE TAP DETECT MINIMUM ON TIME TRUE WHILE DHW IS DROPPING FASTER THAN TAP DEMAND ENDS WHEN: IF DHW PLATE TIMER •TIME IS EXPIRED, AND DEMAND LOSES...
Page 177 CB FALCON Table 12. Plate Heat Exchanger Parameters. (Continued) Parameter Comment Tap detect minimum on time hr:mm:ss or None Once a tap detect event has occurred, and the Tap demand block is Set, it remains true for at least the time provided by this parameter. If DHW loses control due to priority, the timer is restarted, so that when Tap demand again gains control of the burner it remains in this condition for the full minimum on time.
Page 178 CB FALCON Table 13. Preheat Demand Parameters. (Continued) Parameter Comment Plate preheat on hysteresis Degrees or None The preheat on threshold is calculated as: = Plate preheat setpoint - Plate preheat on hysteresis If the preheat block is False, then it is Set (becomes True) when: 1.
Page 179 CB FALCON DHW MODULATION SENSOR PRIORITY WHENEVER SET CHANGES FROM OFF TO ON, TAP OUTPUT IS TRUE FOR AT LEAST THE TAP DETECT MINIMUM ON TIME TRUE WHILE DHW IS DROPPING FASTER THAN TAP DEMAND ENDS WHEN: IF DHW PLATE TIMER •TIME IS EXPIRED, AND DEMAND LOSES...
Page 180 CB FALCON storage time has expired then DHW storage demand ends and DHW Storage Operation does not recur until a normal DHW demand has recurred and When the DHW storage feature is enabled, whenever any ends. The DHW setpoint and hysteresis are used in the same normal DHW call-for-heat is satisfied (i.e.
Page 181 CB FALCON Table 16. CH Frost Protection Parameters. Parameter Comment CH Frost protection enable Enable, Disable When enabled, regardless of whether the boiler is firing or not or whether CH is in control or not: • The CH pump is turned on if the CH control temperature is below 45ºF, using the active CH sensor: Header or Outlet •...
Page 182 CB FALCON Table 17. DHW Frost Protection Parameters. Parameter Comment DHW frost protection enable Enable, Disable The DHW frost protection feature is enabled or disabled by this parameter. See Fig. 18. DHW frost protection will use the DHW sensor, if the DHW demand source parameter selects a switch instead of a sensor.
Page 183 CB FALCON So the rate limit priority scheme uses the following steps, Rate Limits and Override where “active” means that the rate override is both enabled The Limit and Override subsystem consists of three separate and requesting its rate: concepts: 1.
Page 184 CB FALCON Table 18. Delta-T Limit Parameters. (Continued) Parameter Comment Delta-T inlet/exch degrees Degrees, none Delta-T exch/outlet degrees Degrees, none This is the temperature at which a Delta-T response occurs, measured as the signed value (hi-lo) if the result is negative then it is treated as zero (inversion detection may be enabled to handle this, but that is a different function which does not use this parameter).
Page 185 CB FALCON Table 19. T-Rise Parameters. (Continued) Parameter Comment T-Rise degrees per second limit Degrees or None For any input that has T-rise detection enabled, this parameter provides the maximum rate of temperature increase that will be allowed. If the temperature increases at a rate greater than this, and this rate of increase persists for 4 seconds then the response specified by T-rise response occurs.
Page 186 CB FALCON Stack limit (Safety limit and Rate limit) Table 21. Limits and Rate Override: Stack Limit Parameters. Parameter Comment Stack limit 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.
Page 187 CB FALCON Thus there are 5 steps in the modulation limiting: step 0: unlimited (max is 100%) step 1: max is 80% of range STEPPED MODULATION RATE LIMITING step 2: max is 60% of range MAXIMUM step 3: max is 40% of range MODULATION RATE (NO LIMIT) step 4: max is 20% of range...
Page 188 CB FALCON Slow Start and Forced Rate limits (Hydronic Control) The Forced Rate limit causes the burner to stay at a fixed firing rate immediately after lightoff, just after the end of the Run Stabilization time (if any). This is optionally followed by a slow start function that limits the ramp-up speed of the firing rate when the water is colder than a threshold, as shown in the following diagram.
Page 189 CB FALCON Table 23. Limits and Rate Override: Slow Start Limit Parameters. (Continued) Parameter Comment CH slow start enable Enable, Disable This parameter enables or disables the slow start limit function for CH and LL demand sources. It uses the CH forced rate parameter as the starting point for the slow start. If the forced rate parameter is invalid or zero and slow start is enabled, then the slow start function does not occur and an alert is issued.
Page 190 CB FALCON The pump corresponding to that source will usually be on; Anticondensation (Hydronic Control) however, to warm the heat exchanger more quickly, that pump The anticondensation function reduces condensation effects may be forced off when anticondensation is active. when the temperature is below a threshold by increasing the firing rate and optionally shutting off the pump.
Page 191 CB FALCON Table 26. Modulation Output Parameters. Parameter Comment Modulation output Fan Speed, 4-20mA, 0-10V This parameter selects the type of modulation output. The Falcon software responds by driving the appropriate circuit to provide modulation of firing rate. This parameter also affects the interpretation or the type of all parameters which specify rates.
Page 192 CB FALCON Table 27. Fan Speed Modulation Parameters. (Continued) Parameter Comment PWM frequency 1000Hz, 2000Hz, 3000Hz, 4000Hz, This parameter provides the frequency used by the PWM output to control the fan. Pulses per revolution 0-10 Typically is the number of sensors that the fan contains. Fan gain up 0-100 This is the gain for speeding up the fan.
Page 193: Pump Control
CB FALCON The pump names are: PUMP CONTROL • Boiler • CH There are six identical pump control blocks. Each has a • DHW different name but are entirely equal in features and • Aux1 capabilities. For example, if the block named CH Pump were •...
Page 194 CB FALCON • Force On conditions: These bits enable or disable Fig. 22 shows how a pump control block works when reasons why the pump may be forced on. A force on connected to a pump output. The Pump On Options determine condition flows to the “Force On”...
Page 195 CB FALCON Table 29. Pump Control Block Parameters. (Continued) Parameter Comment XX pump start delay mm:ss 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.
Page 196 CB FALCON monitoring temperature. If burner demand exists, then the The Burner Control Uses: burner control will attempt to light the burner and if this succeeds, release control to the modulation source. However if a hold condition exists, then the burner control will remain in Inputs the hold condition until that condition reverts to normal.
Page 197 CB FALCON Table 31. Burner Control Safety Parameters. Parameter Comment NTC sensor type 10K dual safety, 12K single non-safety, 10K single non-safety This parameter determines whether 10K or 12K sensors are used for the Inlet, Outlet, DHW header, Stack, and Outdoor analog sensor inputs. Falcon Steam Control has Stack sensor option only.
Page 198 CB FALCON Table 31. Burner Control Safety Parameters. (Continued) Parameter Comment Purge rate proving None, High Fire Switch, Fan Speed This parameter determines the input used to confirm the purge rate has been reached. It is unused and ignored if the Prepurge time is set to zero. If set to None, the purge rate is commanded during prepurge but purge timing begins immediately without waiting for any feedback.
Page 199 CB FALCON IGNITER MAY BE ON THROUGHOUT PFEP, OR ONLY DURING FIRST HALF. IGNITER PILOT FLAME REQUIRED. FAILURE TO IGNITE OPTIONS: MAIN • LOCKOUT • COUNT RECYCLES, THEN LOCKOUT • COUNT RECYCLES, THEN DELAY MM:SS • RECYCLE (NO LIMIT) RUN STABILIZATION (MAY BE ZERO) PFEP STANDBY...
Page 200 CB FALCON Table 31. Burner Control Safety Parameters. (Continued) Parameter Comment Main flame establishing period 5, 10, or 15 Seconds (MFEP) This parameter only appears if Pilot type is Interrupted. Three choices of the MFEP time are provided: 5, 10, or 15 seconds. Flame must remain on throughout the MFEP, otherwise a response occurs (see “MFEP flame failure response”...
Page 201 CB FALCON Table 31. Burner Control Safety Parameters. (Continued) Parameter Comment Postpurge time 0 seconds to 5 minutes (MM:SS) This parameter sets the burner control’s postpurge time. Setting this parameter to zero disables postpurge. • Unused: not used ANNUNCIATOR • Other: Used to Monitor a circuit, not related to any of the above.
Page 202 CB FALCON TERMINAL TABLE FALCON J6 TERMINAL 2 J6 TERMINAL 1 ANNUNCIATOR NAMES J6 TERMINAL 3 J7 TERMINAL 6 J7 TERMINAL 5 J7 TERMINAL 4 MASTER SWITCH J5 TERMINAL 1 J7 TERMINAL 3 J6 TERMINAL 5 J7 TERMINAL 2 WATER LEVEL J7 TERMINAL 1 LIMIT CONTROL MASTER...
Page 203 CB FALCON alert may be a condition, e.g. something that is causing an FAULT HANDLING 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 Lockouts and Alerts for each alert by the OEM.
Page 204: Burner Control Operation
CB FALCON a. No flame is present, or flame is lost (if enabled-lock- BURNER CONTROL out). b. Lockout Interlock opens) if enabled). OPERATION c. IAS Purge and Ignition enabled and the Interlock opens. d. Pilot terminal energized (if programmed as Inter- Safety Shutdown of Burner Control rupted Pilot).
Page 205: Central Heating
CB FALCON 10. The ignition is turned off at the end of the direct burner Central Heating ignition period, or for a system that does use a pilot, at Start-up sequence central heating request (system in standby): the end (or optionally at the middle) of the Pilot Flame 1.
Page 206 CB FALCON 7. Lockout is reset (reset button) only if the Falcon unit is IMPORTANT powered. 1. If the system fails to perform properly, note the fault code, 8. System is in STANDBY condition. STANDBY message is fault message, equipment status, and sequence time on displayed on the 833-3577 Falcon Display.
Page 207 CB FALCON k. If the pilot flame does not ignite and if the ignition 14. If the main burner flame is not established after two attempts: spark is still continuous, adjust the pilot gas pressure a. Check for improper pilot flame size. regulator until a pilot flame is established.
Page 208 CB FALCON 9. When the fuel valve turns on during the ignition period, If the main flame does not ignite and if the ignition spark is still continuous, adjust the main burner gas make sure that the main burner flame is established. If it is, go to step 14.
Page 209 CB FALCON NOTE: If the sequence does not stop, reset the system and Start the burner and measure the flame signal with both make sure that you selected the Pilot Test. ignition and pilot (or main burner) on, and then with only the pilot (or main burner) on.
Page 210 CB FALCON 1. Open the master switch. Response to Other Ultraviolet 2. Close the pilot and main burner manual fuel shut-off Sources valve(s). 3. Close the master switch Some sources of artificial light (such as incandescent or — Go to the 833-3577 Display/Operator Interface. fluorescent bulbs, and mercury sodium vapor lamps) and —...
Page 211 CB FALCON simulate a flame signal for 10 seconds to 30 seconds TROUBLESHOOTING for PREPURGE. b. *Flame Detected out of sequence* fault is displayed on the Operator Interface Module. System Diagnostics c. Safety shutdown occurs. 4. Failure to ignite pilot or Main Burner (DBI setup). Troubleshooting control system equipment failures is easier a.
Page 212: Lead Lag
CB FALCON By adjusting the parameters in an extreme way it is possible to LEAD LAG define add-stage and drop-stage conditions that overlap or even cross over each other. Certainly it is incorrect to do this, Falcon devices contain the ability to be a stand-alone control, and it would take a very deliberate and non-accidental act to operate as a Lead Lag Master control (which also uses the accomplish it.
Page 213 CB FALCON Add-stage method, Add-stage detection Drop-stage method, Drop-stage detection timing, timing, Drop-stage request A Drop-stage method implements the criteria for dropping a Add-stage request stage. Criteria that may apply are the firing rate of a stage (or An Add-stage method implements the criteria for adding stages) vs.
Page 214 CB FALCON either “Lead Outlet” or “Slave Outlet Average”, the lead Lead-Lag Operation boiler's outlet temperature is used to monitor for burner OEM Configurable parameters may be adjusted as part of the demand. OEM factory configuration and in the field using the System Display with appropriate password permissions (see Local Display Configuration and Operation “Passwords”...
Page 215 CB FALCON • See Falcon Modbus specification for details. Slave Operation and Setup Typical values: 2-15 (3) BL = Baseload common Slave Data Supporting Lead Lag (a)“BL” for baseload (b)User selection 0 – 100 % This data is provided by each slave control to support (4) Use existing timeout, Done button, and Next but- operation when a LL master exists.
Page 216 CB FALCON MASTER SLAVE DATA DEMAND MASTER COMPATIBILITY TO BURNER CONTROL SUSPEND FIRING RATE TO FAN CONTROL OFF CYCLE FAN SLAVE PUMP X, Y, AND Z CONTROL SLAVE COMMAND WRITE SLAVES HAVE DEMAND SLAVES ARE FIRING MASTER’S HEAT DEMAND STAT MASTER SERVICE STATUS CH FROST DHWFROST...
Page 217 CB FALCON Table 34. Slave Data Supporting Lead Lag Parameters. (Continued) Parameter Comment LL - Slave priority sequence order 0-255 Slave sequence order is used to determine the order in which the slaves will be used (staged on) for those Falcons with the same Slave mode setting. Numbers may be skipped, that is 3 will be first if there is no 1 or 2.
Page 218 CB FALCON A polled slave unit is read to determine the values of the Periodic Data Polling Messages following data items: The LL master will poll to discover all the slave devices when it a. The slave's type (compatibility) as indicated by the starts up.
Page 219 CB FALCON OnLeave A slave in the OnLeave state remains that way until Disabled A slave in the Disabled state remains that way until the ProcessSlaveStatus moves it to some other state. the ProcessSlaveStatus moves it to Recovering. Demand and Priority LL MASTER DEMAND SOURCES CENTRAL HEAT LL CH DEMAND SWITCH...
Page 220 CB FALCON Table 38. Warm Weather Shutdown (WW-SD) Parameters. (Continued) Parameter Comment 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 two parameters are shared by the stand-alone Falcon control and the LL master and have the same effect for either control.
Page 221 CB FALCON Modulation HEADER ModBus MASTER SERVICE LL MODULATION TEMPERATURE STATUS MASTER ACTIVE SERVICE ALL SLAVES KNOW WHAT MASTER HEAT DEMAND THE MASTER IS DOING. USED FOR LL MODULATION BACKUP SENSOR PUMP CONTROL DISABLE LEAD OUTLET OUTLET AVERAGE LL MASTER FROST PROTECTION SLAVES FROST PROTECTION RATE LL SLAVE DEMAND...
Page 222 CB FALCON Setpoints Table 40. Setpoint Parameters. Parameter Comment LL CH Setpoint source Local, S2 4-20mA If the setpoint source is Local then the Falcon control's local setpoint system is used. This setting enables the normal use of the CH setpoint, CH TOD setpoint, and the CH outdoor reset parameters and functions.
Page 223 CB FALCON • All stages are at their maximum (base load, or max RATE ADJUSTMENT modulation) and one or more stages are rate-limited (such When the LL - Slave dropout/return compensation parameter as due to slow-start or stepped modulation limiting due to specifies a rate adjustment and a rate compensation event high stack temperature, etc.) and the rate limited stage occurs (a slave leaves while firing, or a slave returns) then rate...
Page 224 CB FALCON Table 42. Rate Allocation Parameters. Parameter Comment LL - Base load common 0-100% If set to zero, this parameter is disabled. For any non-zero value, it uses the individual base load rates of each slave to be ignored by the LL master's routines and this common value to be used instead.
Page 225 CB FALCON Table 43. Stager Parameters. Parameter Comment LL - Add-stage interstage delay mm:ss This specifies the minimum time that the Stager waits after adding one stage before adding another stage or dropping a stage. LL -Drop-stage interstage delay mm:ss This parameter specifies the minimum time that the Stager waits after dropping one stage before dropping another stage or adding a stage.
Page 226 CB FALCON Table 45. Dropping Stages Parameters. (Continued) Parameter Comment LL - Drop-stage error threshold degrees This provides the error threshold as defined by the methods below. LL - Drop-stage rate offset -100% to +100% This provides the rate offset threshold as defined by the methods below. rate offset = 0% The Drop-stage condition will occur when Drop-stage Methods the last stage is at the minimum modulation rate.
Page 227 CB FALCON • If this parameter is “Measured run time” then they are SLAVE MODE: USE FIRST, EQUALIZE RUNTIME, USE ordered according to their reported run time. If two have the LAST same measured run time, then either may be selected. •...
Page 228 CB FALCON Sequencer Drop Lag Boiler Selection Sequencer 1 Minute Event When the stager asks the sequencer for a lag boiler to drop the Part of the sequencer is called by the timing service at a 1 sequencer looks at the StagingOrder numbers of all Firing minute rate to implement lead rotation.
Page 229 CB FALCON APPENDIX A: PARAMETER GLOSSAR Table 47. Parameter Glossary. Parameter Name Short Description Ref. Page 20 mA CH pressure PSI or None Establishes the pressures for the end points of the 4-20 mA inputs 4 mA water Degrees temperature Establishes temperature for 4 mA input 20 mA water Degrees...
Page 230 CB FALCON Table 47. Parameter Glossary. Parameter Name Short Description Ref. Page Annunciator 1 short The short (3 letter) name of the contacts monitored by the A1 annunciator input. name Annunciator 2 short The short (3 letter) name of the contacts monitored by the A2 annunciator input. name Annunciator 3 short The short (3 letter) name of the contacts monitored by the A3 annunciator input.
Page 231 CB FALCON Table 47. Parameter Glossary. Parameter Name Short Description Ref. Page CH forced rate For CH demand, if the CH forced rate time is non-zero, then the firing rate will be held at the rate specified here during that time. This parameter is also needed as the starting point for Slow State, even if the forced rate time is zero.
Page 232 CB FALCON Table 47. Parameter Glossary. Parameter Name Short Description Ref. Page CH TOD setpoint This Setpoint is used when the time-of-day input is on. If the ODR function is active, this Setpoint provides one coordinate for the shifted (because TOD is on) outdoor reset curve, as described for the CH Outdoor Reset parameter.
Page 233 CB FALCON Table 47. Parameter Glossary. Parameter Name Short Description Ref. Page DHW high limit If Recycle && hold is selected, the burner control recycles and waits for the DHW response temperature to fall. It will remain in this holding condition until the DHW temperature is lower than the DHW high limit temperature minus 5 degrees F.
Page 234 CB FALCON Table 47. Parameter Glossary. Parameter Name Short Description Ref. Page Exchanger T-Rise This enables/disables temperature rise detection for the heat exchanger sensor S9 (J9 enable terminal 6). Fan during off cycle If this parameter is non-zero for a control that is enabled as a LL slave, then it provides the rate modulation rate (e.g.
Page 235 CB FALCON Table 47. Parameter Glossary. Parameter Name Short Description Ref. Page ILK bounce Enable, Disable detection enable ILK long name The long name (up to 20 characters) of the ILK annunciator input. ILK short name The short (3 letter) name of the contacts monitored by the ILK annunciator input. Inlet Connector Designates the sensor type connected to the control for proper reading.
Page 236 CB FALCON Table 47. Parameter Glossary. Parameter Name Short Description Ref. Page LL - Slave write This allows the slave to accept command messages from a master. Manual firing rate This parameter specifies the analog output or fan speed during burner modulation, when the Firing rate control parameter specifies Manual mode.
Page 237 CB FALCON Table 47. Parameter Glossary. Parameter Name Short Description Ref. Page Plate preheat off The preheat off threshold is calculated as: hysteresis = Plate preheat setpoint + Plate preheat off hysteresis If the preheat block is True, then it becomes False when: •...
Page 238 CB FALCON Table 47. Parameter Glossary. Parameter Name Short Description Ref. Page Speed up ramp Whenever the burner is firing it will be commanded to increase its RPM no faster than the rate provided by this parameter. Stack Connector Designates the Sensor type connected to the control for proper reading. Type Stack limit delay This parameter provides the delay time for the Stack limit.
Page 239 CB FALCON Table 47. Parameter Glossary. Parameter Name Short Description Ref. Page Tap detect on The second tap demand “set” criteria depends on the value of the DHW sensor. If the hysteresis temperature is less than or equal to the threshold given by subtracting this parameter from the normal DHW setpoint, and if this condition has persisted for the time specified by the Tap detect recognition time parameter, the Tap demand block is “Set”...
Page 240 CB FALCON APPENDIX B: HYDRONIC DEVICE PARAMETER WORKSHEET EXAMPLE Table 48. Example of a Completed Device Parameter Worksheet. Customer Choice - Hidden, Read Only or Password Parameter Name protected Minimum Range Default Setting Maximum Range Parameter Units Burner cycle count Read Only Cycles Burner run time...
Page 241 CB FALCON Table 48. Example of a Completed Device Parameter Worksheet. (Continued) Customer Choice - Hidden, Read Only or Password Parameter Name protected Minimum Range Default Setting Maximum Range Parameter Units CH P gain Read Only CH I gain Read Only CH D gain Read Only CH hysteresis step time...
Page 242 CB FALCON Table 48. Example of a Completed Device Parameter Worksheet. (Continued) Customer Choice - Hidden, Read Only or Password Parameter Name protected Minimum Range Default Setting Maximum Range Parameter Units Fan min duty cycle Read Only 0-100% CH pump output Read Only A:No pump assignment...
Page 243 CB FALCON Table 48. Example of a Completed Device Parameter Worksheet. (Continued) Customer Choice - Hidden, Read Only or Password Parameter Name protected Minimum Range Default Setting Maximum Range Parameter Units Annunciator 4 location Read Only A:No annunciation for this terminal Annunciator4 short name Read Only 3 chars...
Page 244 CB FALCON Table 48. Example of a Completed Device Parameter Worksheet. (Continued) Customer Choice - Hidden, Read Only or Password Parameter Name protected Minimum Range Default Setting Maximum Range Parameter Units Stack limit delay Read Only 5m 0s mmm:ss Delta-T enable Read Only Disabled Delta-T degrees...
Page 245 CB FALCON Note Column: H= Hold message; L=Lockout message; H or L= APPENDIX C: LOCKOUT AND HOLD either Hold or Lockout depending on Parameter Configuration CODES To support the recommended Troubleshooting, the Falcon has an Alert File. Review the Alert history for possible trends that may have been occurring prior to the actual Lockout.
Page 246 CB FALCON Table 49. Falcon Lockout and Hold Codes. (Continued) Code Description Recommended Troubleshooting of Lockout Codes NOTE Internal fault: Hardware fault Internal Fault. 1. Reset Module. Internal fault: Safety Relay key feedback 2. If fault repeats, replace module. error Internal fault: Unstable power (DCDC) output Internal fault: Invalid processor clock...
Page 247 CB FALCON Table 49. Falcon Lockout and Hold Codes. (Continued) Code Description Recommended Troubleshooting of Lockout Codes NOTE Modulation fault Internal sub-system fault. 1. Review alert messages for possible trends. Pump fault 2. Correct possible problems. Motor tachometer fault 3. If fault persists, replace module. AC inputs phase reversed 1.
Page 248 CB FALCON Table 49. Falcon Lockout and Hold Codes. (Continued) Code Description Recommended Troubleshooting of Lockout Codes NOTE DHW high limit 1. Check wiring and correct any possible errors. H or L 2. Replace the DHW high limit. 3. If previous steps are correct and fault persists, replace the module.
Page 249 CB FALCON Table 49. Falcon Lockout and Hold Codes. (Continued) Code Description Recommended Troubleshooting of Lockout Codes NOTE 101-104 RESERVED Flame Operation Faults Flame detected out of sequence 1. Check that flame is not present in the combustion H or L chamber.
Page 250 CB FALCON Table 49. Falcon Lockout and Hold Codes. (Continued) Code Description Recommended Troubleshooting of Lockout Codes NOTE Interrupted Airflow Switch failed to close 1. Check wiring and correct any possible wiring errors. 2. Check Interrupted Airflow switch(es) to assure proper function.
Page 251 CB FALCON Table 49. Falcon Lockout and Hold Codes. (Continued) Code Description Recommended Troubleshooting of Lockout Codes NOTE Combustion pressure and Flame ON OEM Specific H or L 1. Check that flame is not present in the combustion Combustion pressure and Flame OFF chamber.
Page 252 CB FALCON Table 49. Falcon Lockout and Hold Codes. (Continued) Code Description Recommended Troubleshooting of Lockout Codes NOTE Invalid ignite failure response setting 1. Return to Configuration mode and recheck selected parameters, reverify and reset module. Invalid ignite failure retries setting 2.
Page 253 CB FALCON Table 49. Falcon Lockout and Hold Codes. (Continued) Code Description Recommended Troubleshooting of Lockout Codes NOTE Invalid S2 (J8-6) connector type setting Invalid S5 (J8-11) connector type setting Exchanger sensor not allowed with stack connector setting Invalid DHW auto detect configuration Invalid UV with spark interference not compatible with Ignitor on throughout PFEP Internal fault: Safety relay test invalid state...
Page 254 CB FALCON Table 50. Alerts. (Continued) Table 50. Alerts. (Continued) Code Description Code Description Low line frequency occurred RESERVED Invalid subsystem reset request occurred Modulation output type was invalid Write large enumerated Modbus register value Firing rate control parameter was invalid Maximum cycle count was reached Forced rate was out of range vs.
Page 255 CB FALCON Table 50. Alerts. (Continued) Table 50. Alerts. (Continued) Code Description Code Description CH parameter Errors DHW modulation sensor was not compatible for DHW Operation Faults CH demand source was invalid DHW control was suspended due to fault CH P-gain was invalid DHW temperature was invalid CH I-gain was invalid DHW inlet temperature was invalid...
Page 256 CB FALCON Table 50. Alerts. (Continued) Table 50. Alerts. (Continued) Code Description Code Description Too many Lead Lag slaves were detected CH min outdoor setpoint was invalid Lead Lag slave was discovered CH min water setpoint was invalid Incompatible Lead Lag slave was discovered CH outdoor temperature range was too small No base load rate was set for Lead Lag slave CH water temperature range was too small...
Page 257 CB FALCON Table 50. Alerts. (Continued) Table 50. Alerts. (Continued) Code Description Code Description Abnormal Recycle: Interrupted air flow switch Abnormal Recycle: Hardware SLO bias not set Abnormal Recycle: Interrupted air flow switch Abnormal Recycle: Hardware SLO bias shorted Abnormal Recycle: Interrupted air flow switch Abnormal Recycle: Hardware SLO electronics Abnormal Recycle: Interrupted air flow switch Abnormal Recycle: Hardware processor clock...
Page 258 CB FALCON Table 50. Alerts. (Continued) Table 50. Alerts. (Continued) Code Description Code Description Abnormal Recycle: Fan Speed Range Low Internal error: Safety key bit 10 was incorrect Abnormal Recycle: Fan Speed Range High Internal error: Safety key bit 11 was incorrect 383-450 RESERVED Internal error: Safety key bit 12 was incorrect...
Page 259 CB FALCON Table 50. Alerts. (Continued) Table 50. Alerts. (Continued) Code Description Code Description Mix PID setpoint was invalid Heat exchanger high limit was exceeded STAT may not be a Mix demand source when Heat exchanger high limit wasn't allowed due to Remote Stat is enabled stack limit setting 533-539...
Page 260 CB FALCON 750-265...
Page 261 Appendix B — CB Falcon Display/Operator Interface ...
Page 263: Replacement Parts
Falcon System Display 833-05105 PRODUCT DATA APPLICATION The 833-5105 is a microprocessor-based color touch-screen Operator Interface (OI) display that provides an operator PREFACE interface for monitoring and configuring parameters in the Falcon hydronic control and steam control systems. This User Guide is intended to provide a general overview of The 833-5105 can be used to monitor an individual boiler but is the 833-5105 Operator Interface (OI) Displays.
Page 264: Installation Instructions
9-7/16 (240) 8-15/16 (227) 3-1/2 (89) 6-21/32 (169) 1-27/32 (47) PANEL HOLE CUTOUT SIZE FOR FRONT PANEL MOUNT: 8 (203) WIDE X 5-1/2 (140) HIGH. M32735 PANEL HOLE CUTOUT SIZE FOR REAR PANEL MOUNT: 7-1/8 (181) WIDE X 4-11/16 (119) HIGH. Fig.
Page 265 6. Secure the display to the panel with four #6-32 screws and nuts provided. Table 1. 8-pin Connector Terminals. 7. Wire the 24 Vac power supply and the RS-485 cables Pin # Function using the wiring diagram in Fig. 2. 8.
Page 266 83 3-510 5 OI DISPLAY 24 VAC COM 1 COM 2 POWER FA LCON LL MASTER AND SLAVE 1 FA LCON SLAVE 2 FA LCON SLAVE 3 DISPLAY CAN ALSO BE CONNECTED TO MB2; A, B, C AND THE SLAVES NEED TO BE WIRED TO MB1. CONTROLLER HAS TWO AVAILABLE MODBUS CONNECTIONS: THIS CONFIGURATION REQUIRES ONE FOR CONTROL LEAD LAG COMMUNICATION AND ONE...
Page 267 COM 2 COM 2 COM 2 833-5105 833-5105 833-5105 COM 1 COM 1 COM 1 UP TO 8 FALCONS FALCON FALCON FALCON FALCON FALCON EACH FALCON IN THE BAS WILL HAVE A DIFFERENT MODBUS ADDRESS. M32738 Fig. 4. 83 3-51 05 in a Building Automation System. BUILDING AUTOMATION STARTING THE S7999D OI SYSTEM (BAS)
Page 268: Page Navigation
On System applications, each Falcon Control is represented Up to 8 systems can be displayed on the Home page. The on the Home page by an icon and name. Pressing the icon name of each boiler is displayed next to the Falcon icon button. allows the user to zoom in on that boiler and see its specific When Lead Lag is enabled, the system header temperature details.
Page 269: Configuration Password
The initial status page displayed contains summary status No specific order for configuration is required. All parameters information as shown in Fig. 7. Any status information not are enabled for editing, though some may not be applicable applicable for the installation is grayed/blanked out on the (e.g., a configuration parameter may disable a control screen.
Page 270: Change Parameter Settings
NOTE: Each boiler in a multi-boiler configuration has its own should be pressed when the user is done entering the text set of installer and OEM passwords. To avoid user input. The Cancel button on the bottom of the screen allows confusion, the passwords should be changed to the the user to ignore any text changes that have been made and same password in each control, but there is no...
Page 271 Verify button is enabled that allows the installer to conduct verification sessions (the example of the Verify button in Fig. 8 is not yet enabled because the installer hasn’t logged in). NOTE: When the installer proceeds with the safety parame- ter configuration, the control unlocks the safety parameters in this group and marks them unusable.
Page 272 The lockout history can be displayed by pressing on the History button. The state information about each lockout is displayed along with the date/time that the lockout occurred (see Table 2). Current date/time stamp is a display setup feature. Table 2. Sola Control Lockout History. Data Comment Lockout time...
Page 273 The Clear Lockout button allows the user to acknowledge and clear (reset) the lockout when in lockout state, much the same as pressing the reset button on the front of the Sola Control. The user can toggle between displaying the controls’ lockout history and alert log by pressing the Alerts or Lockouts button on the bottom of the pages.
Page 274 Operation Button The operation button displays the Falcon Control running operation, including setpoint and firing rate values. From this page the user can change setpoints, manually control the boiler’s firing rate, manually turn pumps on, view annunciation information, and switch between hydronic heating loops (Central Heat and Domestic Hot Water).
Page 275 Table 4. Functional Configuration Groups. Hydronic Control Steam Control Modulation Configuration Statistics Configuration Pump Configuration Stack Limit Statistics Configuration Annunciation Configuration High Limit Burner Control Interlocks Stack Limit Burner control Timings and Rates Delta T Limits T-Rise Limit Heat Exchanger High Limit Anti-condensation Burner Control Flame Failure Frost Protection...
Page 276 WARNING Table 6. System Identification Information. Explosion Hazard. Status Comment Improper configuration can cause fuel buildup and Product Type Type of product that the burner is explosion. Improper user operation may result in PROPERTY OS Number Model number associated with burner LOSS, PHYSICAL INJURY or DEATH.
Page 277 Table 7. Central Heat Hydronic Table 8. Steam Configuration Parameters Configuration Parameters. (Continued) Parameter Comment Parameter Comment Steam P Gain Gain applied for the P portion of the Time of day setpoint Setpoint when Time Of Day switch is PID equation on.
Page 278 Table 10. Domestic Hot Water (DHW) Configuration Parameters. (Continued) Parameter Comment DHW priority vs Which system has priority: Lead Lag Lead Lag over Domestic Hot Water, Domestic Hot Water over Lead Lag DHW P-gain Gain applied for the P portion of the PID equation 0-400 DHW I-gain...
Page 279 Demand Priority Configuration Table 12. DHW Plate Heat Exchanger Configuration Parameters. (Continued) Parameters Parameter Comment Fig. 32 displays R7910A Hydronic Control Demand Priority Plate preheat on -0 °F to 180 °F (-17 °C to 82 °C) configuration options. Press the arrows to change the priority hysteresis order.
Page 280 Modulation Configuration Table 14. R7910A Hydronic Control Modulation Configura- tion Parameters. (Continued) Parameters Parameter Comment Table 14 displays Hydronic Control Modulation configuration parameters. DHW forced rate time 0-600 seconds DHW forced rate RPM or % CH slow start enable Enabled Disabled DHW slow start Enabled...
Page 281 NOTE: The Falcon Steam Control does not have pumps, but Pump Configuration Parameters the outputs are available to operate air dampers or Table 16 displays Pump configuration parameters. Use the left accessories. CH Pump, Boiler Pump and System and right arrows to switch between Central Heat, Boiler, DHW, Pump are used for these output options.
Page 282 Statistics Configuration Parameters High Limit Configuration Parameters Table 17 displays Statistics configuration parameters. (Hydronic Control Only) Table 18 displays outlet high limit configuration parameters. Fig. 35. Statistics configuration. Fig. 36. High Limits configuration. Table 17. Statistics Configuration Parameters. Parameter Comment Table 18.
Page 283 Stack Limit Configuration Delta T Limit Configuration Parameters Parameters Table 19 displays stack limit configuration parameters. (Hydronic Control Only) Table 20 displays other limit parameters. Use the left and right arrows to switch between Inlet to Outlet Flow and Exchanger to Outlet Flow.
Page 284 T-Rise Limit Configuration Anti-Condensation Configuration Parameters Parameters ( Hydronic Table 21 displays T-Rise limit parameters. Control Only) Table 23 displays anti-condensation parameters. Use the left and right arrows to switch between Central Heat, Domestic Table 21. T-Rise Limit Configuration Parameters. Hot Water, Frost Protection, and Priority parameters.
Page 285 Frost Protection Parameters Annunciation Configuration (Hydronic Control Only) Parameters Table 24 displays frost protection parameters. Table 25 displays annunciation configuration parameters. Fig. 40. Frost Protection configuration. Fig. 41. Annunciation configuration example. Table 24. Frost Protection Configuration Parameters. Table 25. Annunciation Configuration Parameters. Parameter Comment Parameter...
Page 286 Table 27. Burner Control Timings and Rates Configura- tion. Parameter Comment Prepurge rate RPM or % Prepurge time ___hour ___min ___sec Run stabilization time ___hour ___min ___sec Standby Rate RPM or % Postpurge rate RPM or % Postpurge time ___hour ___min ___sec Forced recycle ___day ___hour ___min interval time...
Page 287 Fig. 45. Burner Control Flame Failure configuration. Fig. 46. Safety verification lockout. The user must log in before verification can be completed, as shown in Fig. 47. Table 29. Burner Control Flame Failure Configuration. Parameter Comment Ignite failure Lockout response Recycle Recycle &...
Page 288 After all safety parameter groups have been verified, the user must press the Reset button on the control within 30 seconds to confirm the correct device. See Fig. 52. Fig. 49. Confirm safety parameter settings. After the first safety parameter group has been confirmed by the user (by pressing the Yes button), the next safety parameter group waits for verification as shown in Fig.
Page 289 Individual Table 31. System Configuration Parameters. (Continued) Configuration Parameters Parameter Comment Table 30 and Table 31 displays system configuration parameters for individual controls. Anti short cycle time ___hour ___min ___sec Alarm silence time ___day ___hour ___min Power up with lockout Clear lockout Do NOT clear lockout Inlet connector type...
Page 290 Use the left and right arrows to switch between Modulation, Lead Lag Slave Configuration CH, DHW, Frost Protection, Warm Weather Shutdown, Parameters (Hydronic Control Only) Algorithms, Rate Allocation, Add stage and Drop stage parameters. Table 33 displays Lead Lag Slave Configuration parameters. Fig.
Page 291 Table 36. Lead Lag Master Configuration Table 40. Lead Lag Master Configuration Advanced Settings: Central Heat Parameters. Advanced Settings: Algorithms Parameters. Parameter Comment Parameter Comment Demand switch Stat Lead selection Sequence order Remote Stat method Measured run time ModBus Stat Lag selection method Sequence order Disabled Measured run time...
Page 292 DETAILS Status Data in Tables 44–Table 55 are displayed on the Hydronic or Steam status pages. A complete list of Details of the hydronic or steam system is accomplished Status tables can be found in Table 59 on page 41. through the detail status pages.
Page 293 Table 45. DHW Hydronic Status. (Continued) Data Comment DHW requested rate RPM or % DHW sensor state None, Normal, Open, Shorted, Outside high range, Outside low range, Not reliable (None = no outlet sensor) DHW OFF setpoint Setpoint plus hysteresis DHW setpoint Temp setting between -40 °F to 266 °F (-40 °C to 130 °C)
Page 294 Fig. 67. Burner Control Status menu (top). Fig. 66. DHW Hydronic Status menu (bottom). Burner Control Status The Burner Control status page will display the status data shown in Table 46. Table 46. Burner Control Status. Data Comment Alarm reason Description for alarm being on (maybe lockout or a hold message) Annunciator first out...
Page 295 The bar graph displayed for this status is the outlet sensor Fan Status temperature. Table 49 displays the status page data for the fan in the control. Table 49. Control Fan Status. Data Comment Fan speed % or RPM (current fan speed) Maximum fan speed Setpoint of maximum fan speed (% or RPM) Minimum fan speed...
Page 296 Table 52. Control Statistics Status. Data Comment Burner cycles Number of cycles Burner run time Duration of run time CH pump cycles Number of cycles System pump cycles Number of cycles Controller cycles Number of cycles Controller run time Duration of run time The bar graph displayed for this status is the outlet sensor temperature.
Page 297 Table 54. Lead Lag Slave. Data Comment Type Slave Command Received Yes/No Demand Request Rate Burner Control Standby Modulating Priority Lead Lag Master Status - Hydronic Fig. 75. Diagnostic digital I/O page. Only Temperature sensors or pressure sensors also display the Table 55 shows the status page data for Lead Lag Master.
Page 298 “On” status is indicated by a green LED and “Off” status is indicated by a gray LED. Table 57. Control Analog I/O Data. Data Comment Outlet Inlet If enabled Firing rate % or RPM Flame signal Fan speed RPM (if applicable). Should match with firing rate.
Page 299 • Modbus address range 1-N: Sets the Modbus address for the connected device (range is 1 to 250). • Modbus baud rate: Select the baud rate (38400, 19200 or 9600 bps) Fig. 80. Setup page. Press the Display Setup page to display various options that can be set by the user (see Fig.
Page 300 Fig. 87. Trend analysis menu page. Fig. 85. Setup page - Language setup. The status variable with the largest range (minimum to Trend Analysis Page maximum) is used as the Y-axis range in the graph. Trend analysis of FAlcon status data can be viewed As the status variables are selected they are listed in a trend on the display.
Page 301 NOTE: For system trend analysis graphs the Clear button isn’t present, so no status variables can be cleared. A snapshot of the trend analysis graph can be taken and saved to the display. The user is asked to confirm the save before it occurs.
Page 302 Table 58. R7910/R7911 Trend Analysis Data. (Continued) Data Comment DHW setpoint (R7910 only) Actual DHW setpoint based on TOD. Central Heat Operation Analysis Domestic Hot Water Operation Analysis (R7910 only) Vessel Analysis Trend Analysis Snapshot The trend analysis snapshot file is stored in Comma Separated Value (CSV) format in the 833-5105 so it can be Fig.
Page 303 Display Reset NOTE: It’s important that the time be set in the Display so correct timestamps are given to Falcon The user can reset the display and force a power-up by lockouts. The display’s time and date need pressing the Display Reset button. A pop-up dialog box to be set should power be interrupted to the dis- confirming the reset request displays (Fig.
Page 304 Parameters Table 60. Configurable Parameters. (Continued) A complete list of configurable parameters is shown in Table Table Page Parameter Comment CH enable Disable or Enable Central Heating Loop Table 60. Configurable Parameters. CH demand Sensor for Central Heat switch demand: Table Page Sensor only...
Page 305 Table 60. Configurable Parameters. (Continued) Table 60. Configurable Parameters. (Continued) Table Page Table Page Parameter Comment Parameter Comment Steam Disable/enable steam feature DHW enable Disable or Enable Domestic Hot enable Water Loop Steam Sensor and LCI Sensor for Central Heat demand Sensor and Remote Stat demand...
Page 306 Table 60. Configurable Parameters. (Continued) Table 60. Configurable Parameters. (Continued) Table Page Table Page Parameter Comment Parameter Comment DHW storage Enabled, Disabled CH maximum RPM or % enable modulation rate Storage time ___hour ___min ___sec RPM or % Setpoint -40 °F to 266 °F maximum (-40 °C to 130 °C) modulation...
Page 307 Table 60. Configurable Parameters. (Continued) Table 60. Configurable Parameters. (Continued) Table Page Table Page Parameter Comment Parameter Comment Auxiliary Auto DHW high Enabled pump control limit Disabled Auxiliary CH pump is ON DHW high Suspend DHW pump is on Slave command limit Recycle &...
Page 308 Table 60. Configurable Parameters. (Continued) Table 60. Configurable Parameters. (Continued) Table Page Table Page Parameter Comment Parameter Comment Heat Enabled CH frost Enabled exchanger Disabled protection Disabled high limit enable enable DHW frost Enabled Heat -40 °F to 266 °F protection Disabled exchanger...
Page 309 Table 60. Configurable Parameters. (Continued) Table 60. Configurable Parameters. (Continued) Table Page Table Page Parameter Comment Parameter Comment PII enable Enabled Pilot test hold On Disabled LCI enable Enabled Ignition Hot Surface Igniter Disabled source External ignition Internal ignition Interrupted Enable during purge and air switch ignition...
Page 310 Table 60. Configurable Parameters. (Continued) Table 60. Configurable Parameters. (Continued) Table Page Table Page Parameter Comment Parameter Comment Flame sensor Flame rod Absolute type UV power tube maximum fan UV power tube with spark speed interference Absolute None minimum fan Modulation 4-20mA speed...
Page 311 Table 60. Configurable Parameters. (Continued) Table 60. Configurable Parameters. (Continued) Table Page Table Page Parameter Comment Parameter Comment Modulation Lead outlet sensor Lead Sequence order backup Slave outlet sensor average selection Measured run time sensor Disabled method 0 °F to 234 °F Lag selection Sequence order hysteresis...
Page 312 Fig. 96. 8 33-5105 front-mount cutout template.
Page 313 Fig. 97. 833-5105 rear-mount cutout template.
Page 315 Appendix C — CB Falcon Plug-In Module ...
Page 317 Program Module 833-3640 for the 833-3639 / 833-3871 Hydronic Control or 833-3578 Steam Control PRODUCT DATA SPECIFICATIONS Supply Voltage: Power is supplied by the 833-3639/3871 or 833-3578 Ambient Storage Temperature: -40 to 150°F (-40 to 65°C) Ambient Operating Temperature: -40 to 150°F (-40 to 65°C) Indicator LEDs: One (Status LED) Blinking LED indicated the Program Module is properly seated and powered from the CB Falcon..
Page 318 833-3640 PROGRAM MODULE 6. Press the Program Module button on the Setup screen, OPERATION as shown in Fig. 2. 7. Select the burner that contains the Program Module you Remove the dust cover from the CB Falcon Hydronic or will be working with, as shown in Fig. 3. CB Falcon Steam Control and install the 833-3640 Program Module.
Page 319 833-3640 PROGRAM MODULE A 20 character label, date, and time can be entered in the Backup Data 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.
Page 321 Appendix D — Gas Valve ...
Page 323 V4730C/V8730C/V4734C 1:1 Gas/Air Servo Regulated Gas Valves Product data CONTENTS Application ............1 Features ..............1 Specifications ............2 Ordering Information..........3 Installation ............13 Electrical Connections ........14 Adjustments and Final Checkout ......14 Operation ............15 Troubleshooting..........16 Service Information ..........16 Note: Photo shows valve with manual safety shutoff valve and venturi installed.
Page 324 V4730C/V8730C/V4734C 1:1 Gas/Air Servo Regulated Gas Valves SPECIFICATIONS The specifications in this section are related to the Venturi Mixing Unit (VMU) and Combination Gas Valve. Models: See Table 1 Table 1: Model Information Model Number Size (in.) Voltage/Frequency V1 + V2 Total Current Capacity (Natural Gas 0.64sp.gr) V4730C1006 120 Vac, 50/60 Hz...
Page 325: Ordering Information
V4730C/V8730C/V4734C 1:1 Gas/Air Servo Regulated Gas Valves ORDERING INFORMATION When purchasing replacement and modernization products from Accessories: your TRADELINE® wholesaler or distributor, refer to the FL020008 Mesh Screen. TRADELINE® Catalog or price sheets for complete ordering Flange Kits (see Table 2). number.
Page 326 V4730C/V8730C/V4734C 1:1 Gas/Air Servo Regulated Gas Valves 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). EN2R-9074 0612R1-NE...
Page 327 V4730C/V8730C/V4734C 1:1 Gas/Air Servo Regulated Gas Valves 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). EN2R-9074 0612R1-NE...
Page 328 V4730C/V8730C/V4734C 1:1 Gas/Air Servo Regulated Gas Valves 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 1/2, 3/4 6 - 1/4 (159)
Page 329 V4730C/V8730C/V4734C 1:1 Gas/Air Servo Regulated Gas Valves Fig. 6: Venturi 500kW, with V4730 gas vlave and valve shutoff kit installed, dimensions in in. (mm), part 1. EN2R-9074 0612R1-NE...
Page 330 V4730C/V8730C/V4734C 1:1 Gas/Air Servo Regulated Gas Valves Fig. 7: Venturi, 500 kW, with V4730 gas valve and valve shutoff kit installed, dimensions in in. (mm), part 2 EN2R-9074 0612R1-NE...
Page 331 V4730C/V8730C/V4734C 1:1 Gas/Air Servo Regulated Gas Valves Fig. 8: V4734 + VMU 500/680 EN2R-9074 0612R1-NE...
Page 332 V4730C/V8730C/V4734C 1:1 Gas/Air Servo Regulated Gas Valves 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 EN2R-9074 0612R1-NE...
Page 333 V4730C/V8730C/V4734C 1:1 Gas/Air Servo Regulated Gas Valves 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. EN2R-9074 0612R1-NE...
Page 334 V4730C/V8730C/V4734C 1:1 Gas/Air Servo Regulated Gas Valves Fig. 13: Capacity curves for V4730C/V8730C and VMU 500 Venturi, 1-1/4 in. size. Fig. 14: Capacity curves for V4734C/V8734C and VMU 680 Venturi, 1-1/4 in. size. EN2R-9074 0612R1-NE...
Page 335 V4730C/V8730C/V4734C 1:1 Gas/Air Servo Regulated Gas Valves INSTALLATION When Installing This Product... Mounting Locations 1. Read these instructions carefully. Failure to follow them could The distance between the gas valve and the wall/ground must be damage the product or cause a hazardous condition. a minimum of 11-5/16 in.
Page 336 V4730C/V8730C/V4734C 1:1 Gas/Air Servo Regulated Gas Valves ELECTRICAL CONNECTIONS WARNING Electrical Shock Hazard. Can cause severe injury or death. Disconnect the power supply before beginning wiring to prevent electrical shock. More than one disconnect may be involved. Wiring 1. Use 14, 16 or 18 AWG copper conductor, 600 volt insulation, moisture-resistant wire for line voltage connections.
Page 337 V4730C/V8730C/V4734C 1:1 Gas/Air Servo Regulated Gas Valves OPERATION The V4730C/V8730C/V4734C are normally closed valves. The 13. To test the second SSOV, remove the 1/8 in. (3 mm) NPT plug from the flange pressure tap point 4. valves open when energized and close when power is removed. 14.
Page 338 V4730C/V8730C/V4734C 1:1 Gas/Air Servo Regulated Gas Valves TROUBLESHOOTING 3. If there is still no voltage at the valve leadwires or terminal WARNING block, make sure all appropriate contacts in the thermostat Electrical Shock Hazard. Can cause severe inju- or controller, limits and flame safeguard control are closed. If ry, death or property damage.
Page 340 Dungs Gas Valve DUNGS Gas Valve (CFC 3300) Test point connection downstream Electrical DIN connection for valves of V2 possible on both sides Setting screw Input ﬂange for p burner pressure Pressure connection upstream Vent nozzle of ﬁlter Pressure connection...
Page 341 Dungs Gas Valve Setting the pressure controller Pressure controller is provisionally set at the factory. The setting values must be locally adapted to machine conditions. Important: Follow Ensure optimum com - the instructions of the burner bustion and ignition reli- manufacturer! ability! 1.
Page 342 Dungs Gas Valve Inspect the ﬁlter at least once a year. Change the ﬁlter, if Δp between pres - sure connections 1 and 2 > 10 mbar. Change the ﬁlter, if Δp between pressure connections 1 and 2 is twice as high compared to the last inspection.
Page 343 Appendix E — CB Falcon Lead Lag Operation ...
Page 345 Figure 1 shows efficiency data for the ClearFire CFC condensing boiler. Note that the CFC operates most efficiently at low fire (20% firing rate). While different model ClearFire boilers will differ somewhat in their operational characteristics, all share a tendency to reach peak efficiencies at lower firing rates.
Page 346 122° 140° 158° Return Water Temperature Figure 1 - CFC Efficiencies 2- SYSTEM REQUIREMENTS Hydronic Systems • 2-8 boilers equipped with 833-03639 Falcon hydronic controls. All Falcon controllers in a Lead/ Lag network must have compatible software versions.* To check the software version on a particular Falcon controller, use the touchscreen display and go to Configure>System...
Page 347 CB Falcon Lead/Lag A Falcon lead lag kit (880-3755 for 15# steam or 880-3756 for 150# steam) is available from Cleaver- Brooks and includes a system header pressure transmitter and Falcon Program Module for copying parameter settings from one Falcon to another. * Software version 3468.2550 or later required.
Page 348 FALCON HYDRONIC CONTROL Model CFC 3300 833-03871 FALCON HYDRONIC CONTROL Model CFW 833-03578 FALCON STEAM CONTROL Models CFH/CFV CFC HYDRONIC CONTROL 833-03639 CFW HYDRONIC CONTROL 833-03871 (CFW panel interior) (CFC control panel interior) CFH STEAM CONTROL 833-03578 (CFH panel interior)
Page 349 CB Falcon Lead/Lag Lead Lag Kits Hydronic (kit number 880-03670): PART NUMBER DESCRIPTION 817-04468 TEMPERATURE SENSOR, HEADER SUPPLY, 10K NTC THERMISTOR 817-00405 THERMOWELL 817-04517 OUTDOOR TEMP. SENSOR 833-03640 FALCON PROGRAM MODULE 15# Steam (kit number 880-3755) PART NUMBER DESCRIPTION 817-04385 PRESSURE TRANSMITTER*, HEADER SUPPLY, 4-20mA, 2-WIRE, 0-15# PRESSURE TRANSMITTER...
Page 350 CB Falcon Lead/Lag 6- SYSTEM SETUP Figure 2 shows a basic Falcon lead lag system consisting of a 4-boiler network with remote enable and outdoor air temperature reset. Figure 2 - Four Boiler Lead Lag System 6.1 - Lead Lag Modbus Network Falcon controllers should be connected in a ‘daisy-chain’...
Page 351 CB Falcon Lead/Lag 24 VAC 24 VAC RTN Figure 3 - Falcon communication wiring 6.2 - Header Temperature Sensor (hot water systems) Determine which boiler will be the lead lag Master host and connect the header temperature sensor to this boiler at the appropriate control panel terminals.
Page 352 CB Falcon Lead/Lag 6.3 - Header Pressure Transmitter (steam systems) Determine which boiler will be the lead lag Master host and connect the header pressure transmitter to this boiler at the appropriate control panel terminals. Pressure transmitter (steam) - 2-wire, 4-20mA: Terminals 26 and 28 (Falcon terminals J8-6 and power supply VDC+;...
Page 353 CB Falcon Lead/Lag 1. Starting from the display home page, go to VIEW INDIVIDUAL>CONFIGURE>Sensor Configuration. 2. Under Outdoor temperature source Select ‘S5 (J8-11) Sensor’. Once configured, the sensor will be recognized by the lead lag Master over the Modbus network. 6.4 - Connecting to a Building Energy Management System (EMS) A Falcon lead lag network may be connected to a building EMS by several means: •...
Page 354 CB Falcon Lead/Lag Logging in: 2. Go to Lead Lag Master Configuration and make any necessary parameter changes. The first set of param- eters shown will be the following: Master Enable should be left at Disabled for now. CH (steam) setpoint is the system header temperature (pressure) that the lead lag system will attempt to maintain.
Page 355 CB Falcon Lead/Lag Table 2a - Lead Lag Master Configuration Parameters - Advanced Settings, Hydronic Parameter Range CB Default Setting Installation Setting Modulation Parameters Lead outlet sensor Slave outlet sensor Modulation backup sensor Slave outlet sensor average average Disabled Off hysteresis 0 deg F to 234 deg F (-17 deg C to 112 deg C) On hysteresis 0 deg F to 234 deg F (-17 deg C to 112 deg C)
Page 356 CB Falcon Lead/Lag Table 2a - Lead Lag Master Configuration Parameters - Advanced Settings, Hydronic (Continued) Boiler off options Disabled All boilers off threshold deg F Table 2b - Lead Lag Master Configuration Parameters - Advanced Settings, Steam Parameter Range CB Default Setting Installation Setting Modulation Parameters...
Page 357 CB Falcon Lead/Lag Slave Outlet Average is selected then average of the outlet temperatures of all slave boilers that are firing will be used as a backup. Modulation sensor (steam) - choices are S1 (J8-4) and S2 (J8-6). Default is S2, the system header pressure transmitter.
Page 358 CB Falcon Lead/Lag 2. Available parameters are shown in Table 3. Make any necessary changes at this time. Table 3 - Lead Lag Slave Configuration Parameters Parameter Range CB Default Setting Installation Setting Slave enable Enable slave for built-in Lead Disabled Lag master Enable slave for third party...
Page 359 CB Falcon Lead/Lag Figure 1 - Loading a PIM 2. From the Home page go to SETUP> PROGRAM MODULE. 3. Press <Backup Parameters>. The display will indicate when uploading is complete. When finished, remove the PIM and replace the cover. 4.
Page 360 CB Falcon Lead/Lag Caution After cloning parameters with the PIM: If using boilers of different sizes/models, it will be neces- sary to reset the min/max modu- lation speed settings. Once the lead lag Master host has been configured and enabled, an additional pushbutton <VIEW LEAD LAG>/ <VIEW INDIVIDUAL>...
Page 361 CB Falcon Lead/Lag Min. Outdoor Temp. Setpoint Max. Outdoor Temp. Setpoint Deg F Low Water Temp. SEE NOTE Outdoor Temp. Deg F NOTE: A ‘Minimum boiler water temperature’ parameter is available which sets an absolute lower limit to the ODR setpoint. The slope of that portion of the ODR curve above the minimum setpoint is not affected.
Page 362 CB Falcon Lead/Lag To access the Lead Lag Operation screen: Touch this area Touch <Lead Lag Master> button if visible Figure 3 - Lead Lag Home Page This page shows the system setpoint, actual header temperature, and status of each slave boiler. The possible Slave states are: •...
Page 363 CB Falcon Lead/Lag Figure 4 - Falcon Lead Lag with outdoor reset and EMS for remote comms/monitoring 750-322...
Page 364 CB Falcon Lead/Lag Figure 5 - Falcon Lead Lag with outdoor reset and EMS for remote enable 750-322...
Page 365 CB Falcon Lead/Lag Figure 6 - Falcon LL with EMS for remote enable/remote setpoint 750-322...
Page 366 CB Falcon Lead/Lag Figure 7 - Falcon Lead Lag with EMS for remote comms/monitoring 750-322...
Page 367 CB Falcon Lead/Lag Figure 8 - Typical Steam System 750-322...
Page 368 CB Falcon Lead/Lag 11-EXAMPLE HYDRONIC PIPING DIAGRAMS Figure 9 through Figure 12 below show some typical hydronic systems. Examples of Pump Control Block (PCB) parameters for these and other systems can be found in Figure 13 through Figure 18. SUPPLY to system System pumps - controlled by others...
Page 369 CB Falcon Lead/Lag SUPPLY to system System pumps - controlled by others Boiler Pump Boiler 1 Boiler 2 Figure 10 - Primary/Secondary Piping At each slave: Use Boiler Pump control block (Figure 14) - assign to Pump B relay. Use Aux 1 Pump (Figure 17) - assign to Pump C relay. 750-322...
Page 370 CB Falcon Lead/Lag Supply Return from boilers to boilers Boiler 1 Boiler 2 Figure 11 - Primary with dedicated system/boiler pumps PCB configuration - same as Figure 10. 750-322...
Page 371 CB Falcon Lead/Lag To system City water To boilers Tank System Pumps (controlled by others) Aquastat Sys. pump ENABLE signal DHW Pump Master Host Slave 2 Slave 1 Boiler 1 Boiler 2 To building Figure 12 - Domestic Hot Water priority on slave In this example one boiler (NOT the lead lag Master host) has been enabled for Domestic Hot Water service.
Page 372 CB Falcon Lead/Lag 12-PUMP CONTROL BLOCK (PCB) EXAMPLES Examples shown are the system defaults and are the settings referred to in figures 9-12 above. For information on programming the Pump Control Blocks see the Falcon manual 750-265. Pump Configuration System pump SYSTEM Pump control PUMP...
Page 373: Boiler Pump
CB Falcon Lead/Lag Pump Configuration Boiler pump BOILER Pump control Auto PUMP Pump B Pump output 10 sec Pump start delay 3 min Overrun time (L/L Slave) Use for local (Stand-alone) demands Use for Lead Lag Master demands Advanced Logout Settings>>...
Page 374 CB Falcon Lead/Lag Pump Configuration DHW pump Pump control Auto PUMP Pump B or None Pump output 1 min Pump start delay (L/L Slave) 1 min Overrun time Use for local (Stand-alone) demands Use for Lead Lag Master demands Advanced Logout Settings>>...
Page 375 CB Falcon Lead/Lag Pump Configuration CH PUMP CH pump Pump control Auto (L/L Slave None Pump output or L/L Master) 10 sec Pump start delay 5 min Overrun time Use for local (Stand-alone) demands Use for Lead Lag Master demands Advanced Logout Settings>>...
Page 376 CB Falcon Lead/Lag Pump Configuration Auxiliary 1 pump AUX 1 Pump control Auto PUMP Pump C Pump output 0 sec Pump start delay 5 min 30 sec Overrun time Isolation valve Use for local (Stand-alone) demands (LL Slave) Use for Lead Lag Master demands Advanced Logout Settings>>...
Page 377: Combustion Air Damper
CB Falcon Lead/Lag Pump Configuration AUX 2 Auxiliary 2 pump PUMP Pump control Auto Pump A Pump output Start Permissive 0 sec Pump start delay 3 min Overrun time Interlock (e.g. Use for local (Stand-alone) demands combustion air damper) Use for Lead Lag Master demands L/L Slave Advanced Logout...
Page 378 CB Falcon Lead/Lag 13-Boiler Wiring Diagrams Model CFC ClearFire condensing boiler 750-322...
Page 379 CB Falcon Lead/Lag Model CFW ClearFire hydronic boiler 750-322...
Page 380 CB Falcon Lead/Lag Model CFV/CFH ClearFire steam boiler 750-322...
Page 381: Reference Manual
LEAD LAG OPERATION Reference Manual from the LL Master with its slaves. The diagram on page 4 shows a simplified wiring diagram with a 4 system Lead Lag arrangement. The Lead Lag master is a software service that is hosted by a falcon control.
Page 382 750-322 CB FALCON LEAD/LAG The LL master may be aware of slave falcons minimum firing • if its add-stage action has been triggered, it will rate and use this information for some of its algorithms, but remain in this condition until either a stage has been when apportioning rate it may also assign rates that are less added, than this.
Page 383 750-322 CB FALCON LEAD/LAG SYSTEM WIRING HOOKUP 833-5105 SYSTEM DISPLAY COM1 COM2 24 VAC com power MODBUS Bldg EMS 3rd Party 24 VAC 120 VAC 24 VAC RTN LEAD LAG MODBUS NETWORK WIRING KEY LINE VOLTAGE LOW VOLTAGE DATA/COMMS LL MASTER &...
Page 384 750-322 CB FALCON LEAD/LAG e. Master boiler lockout – If the master boiler is in lock- LEAD-LAG OPERATION out then its burner control function will be skipped in the rotation the same as the slave controllers. How- This is a summary of the functional capability of the ever, the master boiler function will continue to oper- embedded lead-lag on the falcon control.
Page 385 750-322 CB FALCON LEAD/LAG SLAVE OPERATION AND SETUP Slave Data Supporting Lead Lag This data is provided by each slave falcon control to support operation when a LL master exists. The illustration below summarizes the slave's registers and data: LL Slave Some slave changes relate to pump control, frost protection, and also are available to 3 party (non falcon) LL master devices.
Page 386 750-322 CB FALCON LEAD/LAG Frost protection requests SLAVE PARAMETERS The frost protection in this status register will be set or cleared to match the status generated by the frost protection detection SLAVE ENABLE: DISABLE, ENABLE VIA MODBUS, functions. ENABLE FOR FALCON MASTER It enables or disables the "LL Slave"...
Page 387: Overall Control
750-322 CB FALCON LEAD/LAG If set to Use Last, then this burner will be used only after all • Modulation - each demand source has one or more Use First and Equalize Runtime falcons have been brought setpoints that may be active and an operation sensor. online.
Page 388: Slave Status Manager
750-322 CB FALCON LEAD/LAG • RecoveryTime: Saves how long the slave must be OK to Slave Control recover. The LL master sends each active slave a command and also • RecoveryTimer: Used to measure the slaves recovery performs a slave status read for each known slave device. It time also sends a Master status broadcast that is heard by all •...
Page 389 750-322 CB FALCON LEAD/LAG AddStage A slave in the AddStage state remains that way SlaveState states until the ProcessSlaveStatus moves it to Firing or some Recovering A slave that is recovering is checked once per other state, or the Stager times out and moves it into the second.
Page 390 750-322 CB FALCON LEAD/LAG These two parameters are shared by the stand-alone 100% firing of this boiler, and where 0% or any value less control and the LL master and have the same effect for than the boiler's minimum firing rate represents the either control.
Page 391 750-322 CB FALCON LEAD/LAG Modulation Each demand source has one or more setpoints that may be active and an operation sensor. These are used to detect turn-on and turn-off conditions. The difference between operating point and setpoint determines the LL master's firing rate When the burner demand is off and no burners are firing Modulation Sensor then, for either Lead Outlet or Slave Outlet Average, the...
Page 392 750-322 CB FALCON LEAD/LAG If this parameter is invalid or None then the outdoor reset LL CH 20MA WATER TEMPERATURE: TEMPERATURE function will be inhibited and will not run: if it is enabled OR NONE then an alert is issued. CH 4MA WATER TEMPERATURE: TEMPERATURE OR NONE Demand and Rate...
Page 393 750-322 CB FALCON LEAD/LAG heat than that, note that this has occurred by setting The rate allocator first generates the Slave Command. a flag and also record total rate that the system Except for the Firing state, the value ultimately depends absorbed (the total of the commanded maximums, only upon the SlaveState.
Page 394 750-322 CB FALCON LEAD/LAG shifted if the Add-stage method is using a dRate/dt There is no restriction on the slave's commanded behavior. Rate overflow is a positive or negative per- firing rate. centage offset from the threshold. For example: As load decreases: If the modulating stage is at the staging threshold posi- As long as all available stages are Firing There is no tion but the...
Page 395 750-322 CB FALCON LEAD/LAG The stager has the following variables: DROP-STAGE INTERSTAGE DELAY: MM:SS StagerState: encodes the current state of the stager. This parameter specifies the minimum time that the Stager StagerTimer: multipurpose 1 second timer used by states waits after dropping one stage before dropping another which measure time.
Page 396 750-322 CB FALCON LEAD/LAG If any slave boiler is firing then StagerState = Active STAGERSTATE = IDLE WITH SLAVES ACTIVE Otherwise StagerState = Idle If the stager runs and its state is Idle, it checks the status of all slaves. If any of these have SlaveState=AddStage, Sus- pendStage, or Firing then these are set to Available (this STAGERSTATE = ACTIVE will cause the Rate Allocator to turn them all off).
Page 397 750-322 CB FALCON LEAD/LAG Add-stage methods Drop-Stage method: Disable, Error threshold, ERROR THRESHOLD Rate threshold, For error threshold staging, a stage is added when the dError/dt and threshold, error becomes excessive based on degrees away from dRate/dt and threshold setpoint, and time. DROP-STAGE ERROR THRESHOLD: DEGREES ADD-STAGE CONDITION: This provides the error threshold as defined by the...
Page 398 750-322 CB FALCON LEAD/LAG Examples: ALL BOILERS OFF - ABO: rate offset = 20% The Drop-stage condition will occur The ABO temperature provides a Burner Off threshold that when the last stage is less than a threshold that is the essentially replaces the normal Burner Off threshold as minimum modulation rate plus another 20%.
Page 399 750-322 CB FALCON LEAD/LAG In all cases, if a boiler sequence number is needed and Voluntary Lead Rotation Slave sequence order is 0, then the boiler's ModBus The current lead boiler is identified by the LeadBoilerSeq- address is used as its sequence number. Num value.
Page 400 750-322 CB FALCON LEAD/LAG Example: SLAVE READ: DATA Before After This provides the slave status message to be read by a CB Notfiring Falcon Master. It includes all of the data that is read from a Notfiring slave. Firing Firing SLAVE MODE: USE FIRST, EQUALIZE RUNTIME, USE Firing LAST...
Page 401 MODBUS Building Energy Management System (EMS) interface The following is used as a reference in this document: MODBUS Application Protocol Specification V1.1a, June 4, 2004, http://www.Modbus-IDA.org. This appendix describes the interface to the CB Falcon boiler controller on either the MB1 or MB2 Modbus port and the Falcon display COM 2 port.
Page 402 ENABLING MODBUS COMMUNICATIONS To establish communications with a building EMS, each Falcon display in the lead lag network must have its COM 2 Modbus port enabled. Use the following steps to enable: 1. On the display Home page press <SETUP>. 2.
Page 403 Table 2: RS-485 message format Coding system 8-bit binary Number of data bits per character 10 = 1 start bit 8 data bits No parity bit 1 stop bit Bit transfer rate 38400 bps Duplex Half duplex Error checking 2 byte CRC-16 polynomial Bit transfer order LSB first End of message...
Page 404 MODBUS REGISTERS Bolded registers are typical boiler/burner status monitoring points. Highlighted registers are allowed Modbus read/write points. Decimal Parameter Format Description CONTROLLER STATUS 0002 0002 Digital I/O Bit map: 15=Safety relay 14=Time of Day 13=STAT (Demand) 12=High Fire Switch (HFS) 11=Low Fire Switch (LFS) 10=Load Control Input(LCI) 9=Pre-ignition interlock (PII)
Page 405 Bolded registers are typical boiler/burner status monitoring points. 0=Disabled 1=Locked out 4=Anti-short cycle 5=Unconfigured safety data 34=Standby Hold 35=Standby Delay 48=Normal Standby 49=Preparing/Pre-purge/Ignition 50=Firing 51=Postpurge 0021 0033 Burner control state Burner control sequence (I/O) state. Different states exist between residential & commercial models (see tables 10 & 11).
Page 406 Bolded registers are typical boiler/burner status monitoring points. 002D 0045 Stack OP channel (J9-6) -40°-130° (0.1°C precision) or other (see register 613) DEMAND & MODULA- TION STATUS 0038 0056 Active rate limiter 0=None, 1=Outlet high limit, 2=Delta T limit, 3=Stack limit, 4=Slow start limit, 5=Anti-condensation, 6=Minimum modulation, 7=Forced rate 0039...
Page 407 Bolded registers are typical boiler/burner status monitoring points. 0084- 0085 0132- 0133 CH pump cycle count 0-999,999 0086- 0087 0134- 0135 DHW pump cycle count 0-999,999 0088- 0089 0136- 0137 System pump cycle count 0-999,999 008A-008B 0138- 0139 Boiler pump cycle count 0-999,999 008C- 008D 0140- 0141...
Page 408 Bolded registers are typical boiler/burner status monitoring points. 0200 0512 CH ODR maximum out- -40°-130° (0.1°C precision) door temperature 0201 0513 CH ODR minimum outdoor -40°-130° (0.1°C precision) temperature 0202 0514 CH ODR low water tem- -40°-130° (0.1°C precision) perature 0203 0515 CH ODR boost time...
Page 409 Bolded registers are typical boiler/burner status monitoring points. 0236 0566 Base load rate RPM or % (applicable for Base Load sequencing type only) 0237 0567 Fan during off cycle rate RPM or % 0238 0568 Slave sequence order 0-255 EXTENDED CH CONFIGU- RATION 0240 0576...
Page 411 Appendix F — CB Falcon Modbus Communication ...
Page 413 CB Falcon Modbus Communication INTRODUCTION Reference The following is used as a reference in this document: This document describes the interface to the CB Falcon MODBUS Application Protocol Specification V1.1a, June 4, boiler controller on either the MB1 or MB2 Modbus port. 2004, http://www.Modbus-IDA.org.
Page 414 CB FALCON MODBUS COMMUNICATION • 12K NTC single temperature non-safety sensor Application Layer • 0-15 psi pressure sensor The Falcon Modbus interface supports the following • 0-50 psi pressure sensor function codes: • 4-20 mA analog input • 03 (0x03) Read Holding Registers •...
Page 415 CB FALCON MODBUS COMMUNICATION ALERT LOG LOCKOUT HISTORY SAFETY VERIFICATION MIX FLOW CONFIGURATION NEW IN 2.3 MIX CONFIGURATION NEW IN 2.3 EXTENDED SYSTEM CONFIGURATION NEW IN 2.1 LEAD LAG CONFIGURATION STEAM CONFIGURATION NEW IN 2.0 FROST PROTECTION CONFIGURATION DHW STORAGE CONFIGURATION NEW IN 2.2 OUTDOOR RESET (ODR) CONFIGURATION PLUGIN...
Page 416 CB FALCON MODBUS COMMUNICATION Table 4. CB Falcon Modbus register map Address Register Read/ (hex) (dec) Parameter Write Format Note SYSTEM STATUS 0000 0000 Status Change Register is cleared (all bits zeroed) after read. Identifies register groups that have new status in them. Bit map: 15-11=Reserved (always 1) 10=Alert log...
Page 417 CB FALCON MODBUS COMMUNICATION Table 4. CB Falcon Modbus register map 0003 0003 Annunciation I/O Only applicable when Annunciation is enabled Bit map: 15-8=Reserved (always 0) 7=Annunciator 8/LFS 6=Annunciator 7/HFS 5=Annunciator 6 4=Annunciator 5 3=Annunciator 4 2=Annunciator 3 1=Annunciator 2 0=Annunciator 1/IAS 0004 0004...
Page 418 CB FALCON MODBUS COMMUNICATION Table 4. CB Falcon Modbus register map 000F 0015 4-20 mA remote control 4-20 mA (0.1 mA precision) or other (see register 609) input (S2) terminal 0010 0016 Active CH setpoint -40°-130° (0.1°C precision) Setpoint determined by CH setpoint source (register 65). 0011 0017 Active DHW setpoint...
Page 419 CB FALCON MODBUS COMMUNICATION Table 4. CB Falcon Modbus register map 0024 0036 Annunciator first out Source for annunciator first out: 0=None or undetermined, 1=ILK, 2=PII, 11=Annunciator 1, 12=Annunciator 2, 13=Annunciator 3, 14=Annunciator 4, 15=Annunciator 5, 16=Annunciator 6, 17=Annunciator 7, 18=Annunciator 8 0025 0037...
Page 420 CB FALCON MODBUS COMMUNICATION Table 4. CB Falcon Modbus register map 0035 0053 4-20mA remote control 0=None, 1= Normal, 2=Open, 3=Shorted, 4=Outside input(S2=J8-6) state high range, 5=Outside low range, 6=Not reliable 0036 0054 Pressure sensor (S1=J8-4) 0=None, 1= Normal, 2=Open, 3=Shorted, 4=Outside state high range, 5=Outside low range, 6=Not reliable 0037...
Page 421 CB FALCON MODBUS COMMUNICATION Table 4. CB Falcon Modbus register map DOMESTIC HOT WATER (DHW) STATUS 0050 0080 DHW status 0=Unknown, 1=Disabled, 2=Normal, 3=Suspended 0051 0081 DHW setpoint source 0=Unknown, 1=Normal setpoint, 2=TOD setpoint, 5=DHW tap setpoint, 6=DHW preheat setpoint 0052 0082 DHW priority count...
Page 422 CB FALCON MODBUS COMMUNICATION Table 4. CB Falcon Modbus register map 005E 0094 Pump B status Bit map: Demand: 15-14=Reserved, 13=Auxiliary 2 pump demand, 12=Auxiliary 1 pump demand, 11=System pump demand, 10=Boiler pump demand, 9=DHW pump demand, 8=CH pump demand Reason: 7=Reserved, 6=Pump assigned to logical pump,...
Page 423 CB FALCON MODBUS COMMUNICATION Table 4. CB Falcon Modbus register map STATISTICS 0080-0081 0128-0129 Burner cycle count 0-999,999 0082-0083 0130-0131 Burner run time Hours 0084-0085 0132-0133 CH pump cycle count 0-999,999 0086-0087 0134-0135 DHW pump cycle count 0-999,999 0088-0089 0136-0137 System pump cycle count 0-999,999 008A-008B 0138-0139 Boiler pump cycle count 0-999,999...
Page 424 CB FALCON MODBUS COMMUNICATION Table 4. CB Falcon Modbus register map 00A3 0163 Lead Lag master heat 0=Off, demand 1=On 00A4 0164 Lead Lag slave burner 0=Off, demand 1=On 00A5 0165 Lead Lag slave requested RPM or % rate EXTENDED PUMP STATUS 00A8 0168...
Page 425 CB FALCON MODBUS COMMUNICATION Table 4. CB Falcon Modbus register map 00B4 0180 Alarm silence time 0-600 minutes 00B5 0181 Power up with lockout SAFETY parameter 0=Clear lockout on power-up (reset), 1=Do not clear lockout on power-up (preserve) 00B6 01820182 Reset and restart Force soft reset of Falcon subsystems: 0=None,...
Page 426 CB FALCON MODBUS COMMUNICATION Table 4. CB Falcon Modbus register map 00CF 0207 Standby rate SAFETY parameter RPM or % CH CONFIGURATION 00D0 0208 CH enable 0=Disable Central Heating, 1=Enable Central Heating 00D1 0209 CH demand switch Source for CH demand: 0=Modulation sensor only, 1=STAT terminal, 2=EnviraCOM remote Stat,...
Page 427 CB FALCON MODBUS COMMUNICATION Table 4. CB Falcon Modbus register map 00E5 0229 Purge rate proving SAFETY parameter 0=None, 1=High Fire Switch (HFS), 2=Fan speed 00E6 0230 Lightoff rate proving SAFETY parameter 0=None, 1=(Low Fire Switch) LFS, 2=Fan speed, 3=Fan speed, except during ignition 00E7 0231 Prepurge time...
Page 428 CB FALCON MODBUS COMMUNICATION Table 4. CB Falcon Modbus register map 00F6 0246 Interrupted air switch (IAS) SAFETY parameter enable 0=Disable, 1=Enable during purge, 2=Enable during purge & ignition, 3=Enable during all states 00F7 0247 IAS start check enable SAFETY parameter 0=Disable, 1=Enable 00F8 0248...
Page 429 CB FALCON MODBUS COMMUNICATION Table 4. CB Falcon Modbus register map 011B 0283 Boiler pump overrun time 0-64800 seconds (18 hours), 0xFFFF=Not configured 011C 0284 Auxiliary 1 pump output 0=None, 1=Pump A, 2=Pump B, 3=Pump C 011D 0285 Auxiliary 1 pump control 0=Auto, 1=On 011E 0286...
Page 430 CB FALCON MODBUS COMMUNICATION Table 4. CB Falcon Modbus register map 012B 0299 DHW pump options 2 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 active, 4=Force pump on when DHW frost protection,...
Page 431 CB FALCON MODBUS COMMUNICATION Table 4. CB Falcon Modbus register map ANNUNCIATION CONFIGURATION 0130 0304 Annunciation enable 0=Annunciation disabled, 1=Annunciation enabled 0131 0305 Annunciator mode 0=Fixed, 1=Programmable 0132-013E 0306-0318 Annunciator 1 configuration R/W See table 6. 013F-014B 0319-0331 Annunciator 2 configuration R/W See table 6.
Page 432 CB FALCON MODBUS COMMUNICATION Table 4. CB Falcon Modbus register map 01CE 0462 RESERVED 01CF 0463 DHW priority source 0=Disable DHW priority, 1=DHW priority begins when DHW heat demand starts LIMITS CONFIGURATION 01D0 0464 Outlet high limit setpoint SAFETY parameter -40°-130°...
Page 433 CB FALCON MODBUS COMMUNICATION Table 4. CB Falcon Modbus register map 01E5 0485 Delta-T retry limit Maximum number of recycles due to Delta-T or inversion limit. 01E6 0486 Delta-T rate limit enable 0=Do not limit modulation rate, 1=Limit modulation rate when approaching Delta-T threshold 01E7 0487...
Page 434 CB FALCON MODBUS COMMUNICATION Table 4. CB Falcon Modbus register map DHW STORAGE CONFIGURATION 01F8 0504 DHW storage enable 0=DHW storage disabled, 1=DHW storage enabled 01F9 0505 DHW storage time 0-64800 seconds (18 hours), 0xFFFF=Not configured 01FA 0506 DHW storage setpoint -40°-130°...
Page 435 CB FALCON MODBUS COMMUNICATION Table 4. CB Falcon Modbus register map 0214 0532 Lead Lag frost protection 0=Disable Lead Lag frost protection, enable 1=Enable Lead Lag frost protection 0215 0533 Lead Lag frost protection 0-100% (in 0.1% units) rate 0216-0217 0534-0535 RESERVED EXTENDED MODULATION CONFIGURATION 0218...
Page 436 CB FALCON MODBUS COMMUNICATION Table 4. CB Falcon Modbus register map 022D 0557 Lead Lag CH setpoint 0=Local setpoint source (register 546), 1=Modbus setpoint (register 562), 2=4-20mA setpoint (register 15) 022E 0558 Lead Lag modulation sensor R/W Sensor used for Lead Lag modulation: 0=S5 sensor, 1=S10 sensor 022F...
Page 437 CB FALCON MODBUS COMMUNICATION Table 4. CB Falcon Modbus register map 0242 0578 CH setpoint source Source for CH setpoint: 0=Local setpoint (registers 211, 212, etc.), 1=Modbus setpoint (register 579), 2=4-20mA remote control (register 15) 0243 0579 CH Modbus setpoint -40°-130°...
Page 438 CB FALCON MODBUS COMMUNICATION Table 4. CB Falcon Modbus register map 0261 0609 S2 (J8-6) connector type(4- SAFETY parameter 20mA remote control input) 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 0262...
Page 439 CB FALCON MODBUS COMMUNICATION Table 4. CB Falcon Modbus register map 0272 0626 Outdoor temperature source R/W 0=Unconfigured, 1=S5 connector, 2=S10 connector, 3=Modbus, 4=EnviraCOM sensor 0273 0627 Warm weather shutdown 0=Disable, enable 1=Enable 0274 0628 Warm weather shutdown -40°-130° (0.1°C precision) setpoint 0275 0629...
Page 440 CB FALCON MODBUS COMMUNICATION Table 4. CB Falcon Modbus register map 02C9 0713 Slave dropout/return 0=No slave compensation, compensation 1=Replace dropout immediately, 2=Adjust rate for remaining slaves, 3=Both replace dropout & adjust rate 02CA 0714 Add stage method 0=Do not add stage, 1=Use error threshold, 2=Use firing rate threshold, 3=Use error rate change &...
Page 441 CB FALCON MODBUS COMMUNICATION Table 4. CB Falcon Modbus register map 02F2 0754 Auxiliary 1 pump options 2 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 active,...
Page 442 CB FALCON MODBUS COMMUNICATION Table 4. CB Falcon Modbus register map 040A-041A 1034-1050 Lockout history record 11 newest lockout. See Table 5. 041B-042B 1051-1067 Lockout history record 12 newest lockout. See Table 5. 042C-043C 1068-1084 Lockout history record 13 newest lockout. See Table 5. 043D-044D 1085-1101 Lockout history record 14 newest lockout.
Page 443 CB FALCON MODBUS COMMUNICATION Each lockout history record has the format described in Table 5. Table 5. CB Falcon lockout history record Byte Offset Parameter Read/Write Format Note Lockout code See register 34 (decimal). Annunciator first out See register 36 (decimal). Burner control state See register 33 (decimal).
Page 444 CB FALCON MODBUS COMMUNICATION Table 8. Falcon lockout and hold codes Table 8. Falcon lockout and hold codes Internal fault: Safety Key 1 Lockout Code Description Note Internal fault: Safety Key 2 Lockout None No lockout/ Internal fault: Safety Key 3 Lockout hold Internal fault: Safety Key 4...
Page 445 CB FALCON MODBUS COMMUNICATION Table 8. Falcon lockout and hold codes Table 8. Falcon lockout and hold codes Delta T inlet/outlet limit Hold/ Fan speed failed during prepurge Hold/ Lockout Lockout Stack limit Hold/ Fan speed failed during preignition Hold/ Lockout Lockout Delta T exchanger/outlet limit...
Page 446 CB FALCON MODBUS COMMUNICATION Table 8. Falcon lockout and hold codes Table 8. Falcon lockout and hold codes Invalid BLOWER/HSI output setting Lockout Invalid Flame threshold setting Lockout Invalid Delta T limit enable setting Lockout Invalid Outlet high limit setpoint setting Lockout Invalid Delta T limit response setting Lockout...
Page 447 CB FALCON MODBUS COMMUNICATION Table 10. Falcon alert codes Table 10. Falcon alert codes Program Module safety parameter revision differs from safety processor Code Description None (No alert) PCB incompatible with product contained in Program Module Alert PCB was restored from factory defaults Parameter PCB in Program Module is too large for Safety configuration parameters were restored from product...
Page 448 CB FALCON MODBUS COMMUNICATION Table 10. Falcon alert codes Table 10. Falcon alert codes Fan pulses per revolution was invalid Modulation commanded rate was > DHW max modulation rate Fan PWM frequency was invalid Modulation commanded rate was < min modulation 82-83 RESERVED rate...
Page 449 CB FALCON MODBUS COMMUNICATION Table 10. Falcon alert codes Table 10. Falcon alert codes DHW sensor type was invalid Too many Lead Lag slaves were detected Inlet sensor type was invalid for DHW Lead Lag slave was discovered Outlet sensor type was invalid for DHW Incompatible Lead Lag slave was discovered DHW storage OFF hysteresis was invalid No base load rate was set for Lead Lag slave...
Page 450 CB FALCON MODBUS COMMUNICATION Table 10. Falcon alert codes Table 10. Falcon alert codes Steam time of day setpoint was invalid Abnormal Recycle: Flame was lost early in Run Steam minimum pressure was invalid Abnormal Recycle: Flame was lost during Run CH ODR min water temperature was invalid Abnormal Recycle: Leakage test failed RESERVED...
Page 451 CB FALCON MODBUS COMMUNICATION Table 10. Falcon alert codes Table 10. Falcon alert codes Abnormal Recycle: Hardware flame current invalid Internal error: Lead Lag master PID P-scaler was invalid Abnormal Recycle: Hardware flame rod short Internal error: Lead Lag master PID I-scaler was Abnormal Recycle: Hardware invalid power invalid Abnormal Recycle: Hardware invalid AC line...
Page 452 CB FALCON MODBUS COMMUNICATION Table 10. Falcon alert codes Table 10. Falcon alert codes Internal error: Safety key bit 0 was incorrect Mix modulation sensor type was invalid Internal error: Safety key bit 1 was incorrect Mix ODR min water temperature setpoint was invalid Internal error: Safety key bit 2 was incorrect Mix circulator sensor was invalid Internal error: Safety key bit 3 was incorrect...
Page 453 CB FALCON MODBUS COMMUNICATION Table 10. Falcon alert codes Table 11. Burner control states Heat exchanger high limit was exceeded State Name Initiate Heat exchanger high limit wasn't allowed due to stack limit setting Standby Delay Heat exchanger high limit wasn't allowed due to Standby stack connector setting Safe Startup...
Page 454 CB FALCON MODBUS COMMUNICATION Table 12. Pump status codes Table 12. Pump status codes (application build less than 1600) (application build less than 1600) Pump C On – DHW demand Status Description Note Pump A On – DHW frost protection Unknown Pump B On –...
Page 455 CB FALCON MODBUS COMMUNICATION Some holding registers contain variable length data, e.g., Table 13. Pump status codes register 186 (OS number), that bend the normal Modbus (application build 1600 or higher) access for holding registers. Only a single register address is Status Description Note...
Page 456 CB FALCON MODBUS COMMUNICATION 17 (0x11) Report Slave ID 16 (0x10) Write Multiple Registers This function is used to locate and identify the Falcons This function is used to write data into multiple Falcon connected on the Modbus network. The Modbus master registers with a single request.

CleaverBrooks CFC Operation, Service & Parts Manual

Section 1 - Introduction

Section 2 - Installation

Section 3 - Stack and Intake Vent Sizing and Installation

Section 4 - Commissioning

Section 5 - Service and Maintenance

Section 6 - Parts

Appendix A - CB Falcon Hydronic Control

Quick Links

Troubleshooting

Related Manuals for CleaverBrooks CFC

Summary of Contents for CleaverBrooks CFC

Table of Contents