Initial Lightoff Checks; Checkout Summary; Preliminary Inspection; Proved Pilot Systems - CleaverBrooks CFC Operation, Service & Parts Manual

CB FALCON
IMPORTANT
1. If the system fails to perform properly, note the fault code,
fault message, equipment status, and sequence time on
the display. Then refer to the Fault Code section in this
manual.
2. Repeat all required Checkout tests after all adjust-
ments are made. All tests must be satisfied with the
flame detector(s) in their final position.
Equipment Recommended
• 833-3577 Display/Operator Interface Module.
• Volt-ohmmeter (1M ohm/volt minimum sensitivity) with:
0-300 Vac capability. 0-6000 ohm capability. 0-10 Vdc
capability.

Checkout Summary

Table 1 provides an overview of checkout steps performed for
each applicable system.
See the product data sheet for location of component parts
terminal locations.
Table 32. Checkout steps and applicable systems.
Piloted
Checkout Step Systems

Preliminary Inspection

Flame Signal
Measurement
Initial Lightoff Check for
Proved Pilot
Initial Lightoff Check for
Direct Spark Ignition
Pilot Turndown Test
Ignition Interference
Test
Hot Refractory Hold-in
Test
Ignition Spark Pickup
Response to Other
Ultraviolet Sources
Flame Signal with Hot
Combustion Chamber
Safety Shutdown Tests
Preliminary Inspection
Perform the following inspections to avoid common problems.
Make certain that:
1. Wiring connections are correct and all screws are tight.
2. Flame detector(s) is clean, installed and positioned prop-
erly. Consult the applicable Instructions.
3. Combination connector J1 wiring and flame detector(s)
are correctly used. See product data sheet for wiring.
4. Burner is completely installed and ready to fire; consult
equipment manufacturer's instructions. Fuel lines are
purged of air.
5. Combustion chamber and flues are clear of fuel and fuel
vapor.
6. Power is connected to the system disconnect switch
(master switch).
750-265
Flame Ultraviolet
DSI Rod Flame
Systems Systems Detectors
X X X
X X X
X
X
X
X
X X X
X X X
7. Lockout is reset (reset button) only if the Falcon unit is
powered.
8. System is in STANDBY condition. STANDBY message is
displayed on the 833-3577 Falcon Display.
9. All limits and interlocks are reset.
Flame Signal Measurement
Install a DC voltmeter in the Falcon test jacks. Observe polarity
when connecting meter leads.

INITIAL LIGHTOFF CHECKS

Proved Pilot Systems

Perform this check on all installations that use a pilot. It should
immediately follow the preliminary inspection.
NOTE: Low fuel pressure limits, if used, could be open. If so,
bypass them with jumpers during this check.
1. Open the master switch.
2. Make sure that the manual main fuel shutoff valve(s) is
closed. Open the manual pilot shutoff valve. If the pilot
takeoff is downstream from the manual main fuel shutoff
valve(s), slightly open the manual main valve to supply
pilot gas flow. Make sure the main fuel is shut off just
upstream from the burner inlet, or disconnect power from
X
the automatic main fuel valve(s).
3. Close the master switch and start the system with a call
X
for heat by raising the setpoint of the operating controller;
see the operating sequence. The Falcon should start the
INITIATE sequence.
4. Let the sequence advance to PILOT IGN (status is
displayed on the 833-3577 Display/Operator Interface, if
used). The PILOT valve energizes, ignition spark should
occur, and the pilot flame should light. If the pilot ignites,
the FLAME LED is energized. Go to step 7.
5. If the pilot flame is not established during the PFEP (pilot
flame establishing period), safety shutdown occurs. Let
the sequence complete its cycle.
X
6. Push the reset pushbutton and let the system recycle
once. If the pilot flame still does not ignite, make the fol-
X
lowing ignition/pilot adjustments:
X
EXTERNAL IGNITION SOURCE
a. Open the master switch and remove the Falcon con-
nector J5.
X
b. Ensure that both the manual pilot shutoff valve and
the manual main shutoff valves are closed.
X
c. On connector J5, jumper power to the ignition termi-
nal J5 terminal 4. Disconnect the leadwire to the pilot
valve if it is connected to the same terminal.
d. Close the master switch to energize only the ignition
transformer.
e. If the ignition spark is not strong and continuous,
open the master switch and adjust the ignition
electrode spark gap setting to the manufacturer's
recommendation.
f. Make sure the ignition electrodes are clean.
g. Close the master switch and observe the spark.
h. After a continuous spark is obtained, open the
master switch and add a jumper on the Connector J5
terminal 2 or reconnect the pilot valve lead wire if it
was disconnected in step b.
i. Open the manual pilot shutoff valve.
j. Close the master switch to energize both the ignition
transformer and the pilot valve.
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