Cleaver-Brooks ClearFire CFLC-5000 Operation And Maintenance Manual
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Cleaver-Brooks ClearFire CFLC-5000 Operation And Maintenance Manual

Condensing boiler 4,000-12,000 mbtu
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Model CFLC
ClearFire
Condensing Boiler
4,000 - 12,000 MBTU
Operation and Maintenance Manual
750-363
08/2017

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Summary of Contents for Cleaver-Brooks ClearFire CFLC-5000

  • Page 1 Model CFLC ClearFire Condensing Boiler 4,000 - 12,000 MBTU Operation and Maintenance Manual 750-363 08/2017...
  • Page 2 — Installation and service must be performed by Should overheating occur or the gas sup- a qualified Cleaver-Brooks, service agency or the ply valve fail to shut off, do not turn off or gas supplier. disconnect the electrical supply to the boiler.

  • Page 3: Condensing Boiler

    CLEAVER-BROOKS Model CFLC ClearFire Packaged Boiler Condensing Boiler Operation and Maintenance Manual  Cleaver-Brooks 2017 Please direct purchase orders for replacement manuals to your local Cleaver-Brooks authorized representative. Manual Part No. 750-363 Printed in U.S.A. 08/2017...
  • Page 4 Cleaver-Brooks equipment is designed and engineered to give long life and excellent service on the job. The electrical and mechanical devices supplied as part of the unit were chosen because of their known ability to perform; however, proper operating techniques and maintenance procedures must be followed at all times.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Section 1 Introduction CFLC Features and Benefits ..........1-2 Standard Equipment .

  • Page 7: Cflc Features And Benefits

    Section 1 Introduction CFLC Features and Benefits ....... 1-2 Standard Equipment ........1-2 Optional Equipment .

  • Page 8: Standard Equipment

    Section 1 — Introduction 1.1 CFLC FEATURES AND BENEFITS Compact Firetube Design The CFLC boiler is a two pass horizontally 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. High Efficiency With the extended heating surface tubes the boiler can produce fuel to water efficiency of up to 99% depending upon operating conditions.
  • Page 9 Section 1 — Introduction 1.2.2. The Burner The burner utilizes a premix venturi, self-regulating fuel train, variable speed blower modulation, and BURNER CANISTER Fecralloy metal fiber burner head. VENTURI Modulating combustion air fan provides 5:1 turndown. BLOWER ASSEMBLY Combustion canister of the burner is constructed of a Fecralloy-metal fiber for solid body radiation of the burner flame, which provides low emissions.
  • Page 10 Section 1 — Introduction TRANSFORMER, 460/230/208V PRI, 115 V SECONDARY, 350VA, FUSED TOP FALCON CONTROLLER, HYDRONIC WATER LEVEL IGNITION TRANSFORMER TRANSFORMER, 115v/25v CONTROL - LWCO (FAR SIDE) TERMINAL TRACK FUSE, 9 AMP Figure 1-3 Control panel interior 1.2.5. Variable Speed Drive Modulating combustion air fan speed is controlled by a Variable Speed Drive mounted inside the front casing below the Falcon control panel.
  • Page 11 Section 1 — Introduction Air Vent (optional) LWCO probe holder Furnace Water Outlet Safety Valve(s) Gas Train EX Tubes Burner Combustion Assembly gas flow Control Panel Alufer Tubes TO STACK Flue/ condensate collection chamber Water Return (2) Water circulation Boiler Drain Condensate drain Figure 1-5 CFLC Cutaway...
  • Page 12 Section 1 — Introduction Figure 1-7 Return temperature sensor (rear casing & insulation not shown) WATER OUTLET OUTLET TEMP. sensor well COMBUSTION AIR FILTER STACK OUTLET Figure 1-8 Stack Outlet, Water Outlet, and Combustion Air Inlet Part No. 750-363...

  • Page 13: Optional Equipment

    Certain project-specific options may have been supplied with the boiler if these options were specified at the time of order entry. In addition, some options may have been provided (by others) that are not part of Cleaver-Brooks’ scope of supply. In either case, the Cleaver-Brooks authorized representative should be consulted for project specifics.
  • Page 14 Section 1 — Introduction Part No. 750-363...
  • Page 15 Section 2 Installation Assembly ..........2-3 Boiler Room .
  • Page 16 Section 2 — Installation Part No. 750-363...

  • Page 17: Assembly

    2.1 BOILER ASSEMBLY AND PLACEMENT 2.1.1 Packaging The Cleaver-Brooks Model CFLC boiler is shipped fully assembled, ready for installation. 2.1.2 Lifting and moving the boiler The Model CFLC boiler is lifted by means of the holes provided in the upper tube sheets. See rigging diagram below.
  • Page 18 Section 2 — Installation 2.1.3 Boiler placement The boiler or boilers should be mounted in accordance with Figure 2-2 below. Required front, rear, and side clearances are shown. Under special circumstances, reduced side clearance between boilers may be feasible. Contact your C-B authorized representative for assistance. NOTE The boiler assemblies are intended for installation in accordance with the appropriate standards of the National Fire Protection Association and the building code recommended...

  • Page 19: Boiler Room

    The boiler must not be installed on carpeting. 2.4 WATER TREATMENT Cleaver-Brooks ClearFire condensing boilers are suitable for heating systems without significant oxygenation capacity. Systems with continuous oxygenation capacity due to unknown or unseen leaks must be equipped with a system separation or pretreatment device. Closed loop hydronic systems should incorporate air separation, dirt elimination, and air venting.

  • Page 20: Boiler Flush

    The boiler may be flushed with or without heat applied, as deemed appropriate by the chemical treatment company. A traditional steam “Boil Out” is not required on Cleaver-Brooks hot water boilers. Following are some general recommendations to help ensure long boiler life and efficient operation.
  • Page 21 Section 2 — Installation Typically, ethylene glycol is used for freeze protection, but other alternatives exist, such as propylene glycol. Glycol reduces the water-side heat capacity (lower specific heat than 100% water) and can reduce the effective heat transfer to the system. Because of this, design flow rates and pump selections should be sized with this in mind.

  • Page 22: Gas Connections

    Section 2 — Installation 2.7 GAS CONNECTIONS 2.7.1 General The ClearFire Model CFLC gas fired condensing boilers use full modulating burners that require appropriate gas supply pressure and volume for proper operation. The gas requirements specified in this section must be satisfied to ensure efficient and stable combustion.
  • Page 23 Section 2 — Installation 2.7.3 Gas Pressure Requirements For proper and safe operation, each CFLC Series boiler requires a stable gas supply pressure. See table below for pressure requirements. Refer also to APPENDIX C - GAS VALVE Table 2-5 CFLC gas pressure requirements Gas Supply Pressure (at gas regulator outlet) Natural Gas 20ppm Natural Gas 9ppm...
  • Page 24 Section 2 — Installation 2.7.4 Gas Piping A dedicated pressure regulator is recommended for each CFLC boiler when the gas supply exceeds the maximum values in Table 2-5. If below the referenced max. gas supply pressure and no step-down regulator is installed, the CFLC gas train does not require gas venting (the pilot gas regulator may require a vent limiter at its vent connection depending on the local code requirements).
  • Page 25 Section 2 — Installation Figure 2-5 Gas Piping A s required A s required A s required G as header - size for boiler room T O G A S T RA IN capacity and to minimize pressure loss Same or larger than boiler gas connection size D rip leg required for any vertical run of piping...
  • Page 26 Section 2 — Installation Table 2-6: Gas Line Capacity - Schedule 40 Metallic Pipe Pipe Size Nominal 2-1/2" 3" 4" Actual I.D. 2.469" 3.068" 4.026" Length in feet **Maximum Capacity in Cubic Feet of Gas per Hour (cfh) 4,860 8,580 17,500 5,900 12,000...
  • Page 27 Section 2 — Installation 2.7.6 Gas Header Design of a single common gas header with individual takeoffs for a multiple unit installation is recommended. Boiler gas manifold piping should be sized based on the volume requirements and lengths between boilers and the fuel main header. For installations with a mixed sized use, determine the flow of each unit and total the input.

  • Page 28: Boiler Water Piping

    Section 2 — Installation 2.8 BOILER WATER PIPING 2.8.1 General All boiler hot water outlet and return piping is connected at the rear of the boiler. Piping is to be installed per local codes and regulations.The pipelines for the hot water outlet and return may be connected in the usual manner without removing the cladding elements.
  • Page 29 Section 2 — Installation If using only a single (common) return, the low temperature connection should be used. The low temperature connection is on the left when facing the rear of the boiler. Low Temp. High Temp. Return Return Figure 2-8 Dual returns 2.8.4 Pressure drop curves The information in Figure 2-9 and in Tables 2-8 and 2-9 can help in determining pump requirements for Model CFLC installations.
  • Page 30 Section 2 — Installation CFLC 4000 CFLC 5000 Flow rate GPM Flow rate GPM CFLC 6000 CFLC 8000 Flow rate GPM Flow rate GPM CFLC 10000 CFLC 12000 Flow rate GPM Flow rate GPM Figure 2-9 Pressure Drop Curves, CFLC 2-16 Part No.
  • Page 31 Section 2 — Installation Table 2-8: CFLC flow rates @ rated capacity System Temperature Drop Deg F Boiler Size Flow Rate GPM 4000 5000 6000 1128 8000 1504 10000 1880 12000 2255 1128 Flow rates relative to temperature drop so as not to exceed boiler output. Based on 94% nominal efficiency.

  • Page 32: Minimum Boiler Overpressure

    Section 2 — Installation 2.9 MINIMUM BOILER OVERPRESSURE To prevent the occurrence of flash steam within the boiler or system, hot water boilers must operate with proper over-pressure. System over-pressure requirements are shown in Table 2-8. Note: The ASME Code Section IV limits the maximum setting of the excess temperature control to 250 F (121 C). This is to ensure that water temperature will not reach the boiling point (steaming) and therefore, so as not to exceed the maximum limit of this control and in compliance with the Code, the operating limit of 230...
  • Page 33 Section 2 — Installation BOILER REAR WARM WATER RETURN DRAIN CONDENSATE DRAIN A CONDENSATE TRAP IS PIPED WITHIN THE COLD WATER RETURN BOILER. Figure 2-10 Condensate Piped Direct to Drain Note: To ensure compliance with regulations, it is important to contact the responsible authorities prior to the planning and execution of the boiler installation.
  • Page 34 Section 2 — Installation Figure 2-11 Condensate Treatment Tank - external SIZES 10,000-12,000 SIZE 6000-8000 Figure 2-12 Condensate Treatment Tank - internal The neutralization media will require periodic Table 2-8 CFLC Max Condensation replacement, to be determined by pH analysis of Max.

  • Page 35: Electrical Connections

    2.11 ELECTRICAL CONNECTIONS A qualified electrician or service technician must make the electrical connections to the boiler. For specific information on your boiler electrical system refer to the Cleaver-Brooks wiring diagram provided with the boiler. Power is to be run from the top left corner of the boiler to the control panel (see Figure 2-13). AC power is to be connected to the incoming power terminals.
  • Page 36 Section 2 — Installation FALCON Figure 2-13 Electrical Connections CFLC 2-22 Part No. 750-363...

  • Page 37: Wiring Diagram

    Section 2 — Installation 2.12 WIRING DIAGRAM 208V, 230V, 575V 3 PHASE ALSO SUPPORTED Figure 2-14 CFLC 6000 - 12000 Wiring Diagram, single fuel (typical) Note: Wiring diagrams shown examples only. Installations may vary. For specific installations consult the wiring diagram provided with the boiler. Part No.
  • Page 38 Section 2 — Installation 2-24 Part No. 750-363...
  • Page 39 Section 3 Stack and Intake Vent Sizing and Installation Venting Connections - General ........3-2 Vertical Venting / Inside Combustion Air .

  • Page 40: Venting Connections - General

    Section 3 — Stack and Intake Vent Sizing and Installation 3.1 VENTING CONNECTIONS - GENERAL 3.1.1 Appliance Categories Proper installation of flue gas exhaust venting is critical for efficient, reliable, and safe operation of the CFLC boiler. The boiler’s appliance category is a major factor determining venting system design.
  • Page 41 Application-specific information will further determine the material selected. For Category II, III & IV appliance categories, Cleaver-Brooks highly recommends that the flue system be Listed to standard UL 1738 Special Gas Vent and be installed in accordance with the National Fuel Gas Code (NFPA 54) or ANSI Z21.47/ CSA 2.3.
  • Page 42 Section 3 — Stack and Intake Vent Sizing and Installation terminations are suited to moving flue gases and water vapor away from building exterior surfaces and air intakes. 1. Combustion gases can form a white vapor plume in the winter. The plume could obstruct a window view if the termination is installed in close proximity to windows.
  • Page 43 Section 3 — Stack and Intake Vent Sizing and Installation 4. Vent must terminate at least four (4) feet horizontally, and in no case above or below unless four (4) feet horizontal distance is maintained, from electric meters, gas meters, regulators, and relief equipment.

  • Page 44: Vertical Venting / Inside Combustion Air

    Section 3 — Stack and Intake Vent Sizing and Installation Caution Follow items listed below to avoid personal injury or property damage. • Cut nonmetallic vent pipe with fine-toothed hacksaw (34 teeth per inch). • Do not use nonmetallic vent pipe or fittings that are cracked or damaged.

  • Page 45: Vertical Venting / Direct Vent Or Sealed Combustion Air

    Section 3 — Stack and Intake Vent Sizing and Installation 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 46: Venting For Multiple Units

    3.4 VENTING FOR MULTIPLE UNITS Cleaver-Brooks recommends that each model CFLC in a multiple boiler installation be vented individually for safe, reliable, and optimum combustion performance. If common flue venting is the only feasible solution, ensure an unrestricted flow of flue gas from each boiler and a draft within the allowable tolerances.
  • Page 47 Section 3 — Stack and Intake Vent Sizing and Installation EXAMPLE 1 GOOD 26” 26” 26” to roof vent 14” 14” 14” From boilers From boilers EXAMPLE 2 GOOD 20” 14” 14” From boilers From boilers Part No. 750-363...

  • Page 48: Ventilation Requirements

    Section 3 — Stack and Intake Vent Sizing and Installation EXAMPLE 3 GOOD 26” 26” 26” to roof vent 14” 14” 14” 14” 14” 14” From boilers GOOD 14” 14” 14” 16” 24” 30” From Boilers 16” 16” 16” From Boilers 3.5 COMBUSTI0N AIR/BOILER ROOM VENTILATION REQUIREMENTS The boiler(s) must be supplied with adequate quantities of...
  • Page 49 “Sealed combustion” is a special air ducting method that implies a gas-tight ducted connection to the burner’s air intake. Contact your Cleaver-Brooks authorized representative to determine if direct vent or sealed combustion is appropriate for the installation. C-B provides optional Combustion Air Adapter kits which can be used in either Direct Vent or Sealed Combustion configurations.
  • Page 50 Section 3 — Stack and Intake Vent Sizing and Installation 2. The openings must be linked directly (Figure 3-4) or by ducts (Figure 3-5) with the outdoors. 3. Each opening must have a minimum free area of one square inch per 4,000 Btu per hour of total input rating of all equipment in the room, when the opening is directly linked to the outdoors or through vertical ducts.
  • Page 51 Section 3 — Stack and Intake Vent Sizing and Installation VENT VENT 12" MINIMUM OUTLET AIR DUCT INTERIOR WALL EXTERIOR WALL WATER FRESH AIR HEATER CLEARFIRE INLET DUCT BOILER 12" MINIMUM Figure 3-5. Two Opening Ducted Method C. One Opening Method (Figure 3-6) - One permanent opening, commencing within 12 inches of the top of the enclosure, shall be provided.
  • Page 52 Section 3 — Stack and Intake Vent Sizing and Installation VENT VENT 12" MINIMUM FRESH AIR OPENING EXTERIOR WALL WATER HEATER Figure 3-6. One Opening Method 3.5.2 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 53 Section 3 — Stack and Intake Vent Sizing and Installation D. Under no condition should the total area of the air supply openings be less than one square foot. VENT VENT FRESH AIR OPENING FRESH AIR OPENING WATER HEATER EXTERIOR WALL EXTERIOR WALL Figure 3-7.
  • Page 54 Section 3 — Stack and Intake Vent Sizing and Installation • Air Velocity: Up to 7 feet = 250 fpm from 3 above. • Area required: Area = cfm/fpm = 2400/250 = 9.6 square feet total. • Area/Opening: 9.6/2 = 4.8 sq-ft/opening (2 required). Notice Consult local codes, which may supersede these requirements.
  • Page 55 Section 3 — Stack and Intake Vent Sizing and Installation Table 3-2. CFLC Combustion Air and Flue Venting Requirements for Individual Boiler Venting 20ppm NOx Combustion air Minimum duct Max allowable Direct vent Flue diameter Draft tolerance SCFM diameter inches comb.
  • Page 56 Section 3 — Stack and Intake Vent Sizing and Installation 3-18 Part No. 750-363...
  • Page 57 Section 4 Commissioning Operating Conditions ........4-2 Filling Boiler .

  • Page 58: Operating Conditions

    Section 4 — Commissioning 4.1 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-voltage Warning ignition transformers W h e n u s i n g d i r e c t v e n t...

  • Page 59: Model Cflc Boiler / Burner Controller

    Section 4 — Commissioning 4.4 MODEL CFLC BOILER / BURNER CONTROLLER The Model CFLC boiler uses the Falcon hydronic boiler control system. Primary controller functions include: • Flame supervision • Burner sequencing • Heating/modulation control • Hot water system pump control •...

  • Page 60: Falcon Display/Operator Interface

    Section 4 — Commissioning Please review the tables within this Commissioning section to familiarize yourself with the functions and parameters of the Controller. Also see Appendices A and B for details on control configuration and operation. Warning The Model CFLC is factory tested. Nevertheless, all burner safety controls should be checked upon installation, prior to initial firing.
  • Page 61 Section 4 — Commissioning The Demand display will show one of the following: Burner enable off Off (burner switch on but no demand) Central Heat Domestic Hot Water (if configured) Burner state shows the currently active step in the burner operating sequence. The central portion of the display can be toggled between the following: Pumps shows the on/off status of boiler and system pumps.
  • Page 62 Section 4 — Commissioning Figure 4-5 Falcon Display/Interface page flow 4.5.4 Lockouts, Holds, and Alerts To assist in monitoring boiler operation, the Falcon control system employs messages of three types: Lockouts, Holds, and Alerts. • Lockouts and Holds indicate interruptions in boiler operation, whether occurring as part of the normal operating sequence or due to an abnormal condition.

  • Page 63: Controller Configuration

    Section 4 — Commissioning Alarm Banner Figure 4-6 Alarm Banner To obtain more information for a particular message, press that item in the respective history list. For Alerts, burner cycle and hours of operation at the time of occurrence will be displayed. For Lockouts, in addition to cycle and hours the screen will show on/off status of all interlocks at the time of the lockout.
  • Page 64 Section 4 — Commissioning Figure 4-7 Configuration Menu 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. Press <Login> to display the alphanumeric keyboard. Enter password and press <OK> Change parameter settings by selecting the parameter on the page.

  • Page 65: Variable Speed Drive Settings

    Section 4 — Commissioning Confirming Safety Parameter changes 1. Press <Begin> 3. Reset Falcon 2. Press <Yes> 4.6.2 Program Module Falcon parameter information (non-safety parameters only) can be uploaded/ downloaded using the optional Program Module (PIM). When the Program Module is installed, its features are accessible from the Falcon Setup page. Starting from the Home page, press <SETUP>, then <PROGRAM MODULE>.

  • Page 66: Burner Sequence

    The default fan speed settings are intended for typical applications for the various boiler sizes. Please contact your authorized Cleaver-Brooks representative for proper settings in high altitude and direct vent combustion applications.
  • Page 67 Section 4 — Commissioning in pressure due to the venturi effect. The modulating controller of the valve actuator senses air pressure change and accordingly brings about a change in the gas flow proportional to the air pressure. The gas follows the airflow in a set ratio, so that fuel always matches the air as the burner firing rate increases or decreases.
  • Page 68 Section 4 — Commissioning 4.10.2 Power-Up 1. Ensure the boiler is properly wired for the available power supply. Refer to the wiring diagram provided with the boiler or to the appropriate wiring diagram in Section 2 - Installation. 2. Verify the voltage (control voltage is 115V-1Ph) to ensure it is within specifications. 4.10.3 Operation Check: Gas Valve, Gas Pressure Switches, Combustion Air Proving Switch, Ignition Fail Before initial firing of the burner, the gas valve, Low Gas Pressure Switch (LGPS), High Gas Pressure Switch...
  • Page 69 Section 4 — Commissioning CAPS 1. Initiate burner sequence. 2. During purge cycle, set Combustion Air Proving Switch to its max- imum setting. 3. The Falcon should lock out on an airflow failure. The display will show Lockout 65 Interrupted Airflow Switch OFF. Note: If the CAPS fails to open even when set to maximum, test by disconnecting the low-pressure line to the switch and initiating burner sequence.
  • Page 70 Section 4 — Commissioning 4.10.5 Low Water Cutoff Check 1. Hold down the LOW WATER RESET-TEST switch for 3 seconds. 2. Check Annunciation screen. The ILK section (Interlock circuit) should show A3 LOW WATER: OFF 3. Press RESET-TEST switch once to reset. 4.10.6 Low and High Fire Adjustments All CFLC boilers are factory tested firing natural gas at an altitude of 1000 ft ASL.
  • Page 71 Section 4 — Commissioning 4.10.8 Setting Combustion Note: A Combustion Analyzer is required to properly set up the Model CFLC burner. Do not attempt to fire and adjust the burner without this equipment. Note: Ensure boiler is filled with water prior to burner startup. NOTE: Install the combustion analyzer probe as close as possible to the boiler vent connection.
  • Page 72 Section 4 — Commissioning To set combustion: Figure 4-12 Operation screen 1. Check inlet gas pressure and reset low gas pressure switch. 2. At Operation screen set firing rate to low fire. Review burner sequence before proceeding. 3. Turn LOCAL/REMOTE switch to LOCAL. 4.

  • Page 73: Post Start-Up Checkout Procedure

    Section 4 — Commissioning 4.10.9 High Air Pressure Switch Settings The High Air Pressure Switch (HAPS) is used to safely shut down the boiler in case of a blocked flue or blocked condensate condition. The HAPS has a manual reset, similar to the High/Low gas pressure switches.

  • Page 74: Falcon Control Functions And Customer Interface

    Section 4 — Commissioning 4.12 FALCON CONTROL FUNCTIONS AND CUSTOMER INTERFACE Following is a brief overview of the Falcon control features on ClearFire boilers. Please refer to the Falcon Control manual for more detailed explanations. • Set Point • Time-of-Day (TOD) Set Point •...
  • Page 75 Section 4 — Commissioning “LOC” (local) position, the boiler operates on its own set point and ignores any remote signal connections. When in the “REM” (remote) position, the boiler can be enabled and modulated by remote discrete and analog (4-20mA) inputs, respectively. When in the “OFF” position, the boiler will not operate. Refer to Figure 2-10 in this manual or to your specific boiler wiring diagram for remote enable and remote 4-20mA input connections.
  • Page 76 Section 4 — Commissioning Configurable Pump/Aux Relay Contacts The Falcon Pump/Aux Relay outputs are configurable by means of six pre-configured Pump Control Blocks. Each control block is configured for a specific application: 1. Central Heat Pump 2. Boiler Pump (for primary/secondary pumping) 3.

  • Page 77: Service And Maintenance

    Section 5 Service and Maintenance Disassembly for Inspection ............5-2 Reassembly ................5-4 Ignition and Flame Detection Systems ........5-4 Troubleshooting ..............5-6 Extended Shutdown..............5-8 Emergency Shutdown ............. 5-8 Caution Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.Failure to do so may result in equipment failure.

  • Page 78: Disassembly For Inspection

    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. 5.1 DISASSEMBLY FOR INSPECTION 1. Close off the gas supply to the boiler and disconnect electrical power at the primary switch box.
  • Page 79 Section 5 — Service and Maintenance Front Fireside Access Remove the front lower casing panel. R e m o v e c o v e r p l a t e f r o m c o n d e n s a t e c o l l e c t i o n chamber.

  • Page 80: Reassembly

    Section 5 — Service and Maintenance 5.2 REASSEMBLY 1. Assembly is the reverse of the above instructions. 2. Burner gaskets should be replaced; see recommended spare parts list. 3. Replace combustion air filter if dirty. Remove filter retaining rod and install new C-B approved filter media; see recommended spare parts list.
  • Page 81 Section 5 — Service and Maintenance 1/8” 1”E1/16” Figure 5-1 Electrode spacing CFLC Pilot and UV Scanner Maintenance of the UV scanner consists of periodic inspection and cleaning. To inspect, unscrew the UV flame detector from the bracket. Check to ensure that the flame viewing lens is clear and free of dust or debris. Wipe with a clean rag if necessary.

  • Page 82: Troubleshooting

    Section 5 — Service and Maintenance SIGHT PORT SCANNER HOLE HOLE ENSURE GAS HOLES ARE POINTED OUTWARD Figure 5-3 5.4 TROUBLESHOOTING Lockout Conditions 1. Observe lockout code and description - refer to Falcon appendix if necessary. 2. After determining lockout condition, investigate possible causes. 3.
  • Page 83 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 84: Extended Shutdown

    Section 5 — Service and Maintenance 5.5 EXTENDED SHUTDOWN When shutting down the boiler for an extended period of time, use the following general guidelines: 1. Turn the demand switch to the OFF position. 2. Close all main fuel valves. 3.

  • Page 85: Section 6 Parts Recommended Spare Parts List Model Cflc

    Section 6 Parts Recommended Spare Parts List Model CFLC ............6-2 Boiler Mechanical Assembly CFLC 4000/5000 .
  • Page 86 Section 6 — Parts Table 6-1. Recommended Spare Parts List Model CFLC Boiler Size Item 4000 / 5000 6000 8000 Falcon Controller, Hydronic 833-04097 Display/Operator Interface, Falcon System 833-05105 UV Scanner 817-01743 Dual Electrode, Sparking 380-01061 Electrode Gasket 380-01032 Burner Canister 380-01130 380-01145 380-01128...

  • Page 87: Boiler Mechanical Assembly

    Section 6 — Parts Figure 6-1. Boiler Mechanical Assembly CFLC 4000/5000 Part No. 750-363...
  • Page 88 Section 6 — Parts Figure 6-2. Boiler Mechanical Assembly CFLC 6000/8000 Part No. 750-363...
  • Page 89 Section 6 — Parts Figure 6-3. Boiler Mechanical Assembly CFLC 10000/12000 ITEM QTY CFLC 10 000 CFLC 12 000 DESCRIPTION 270-03916-000 270-03743-000 PRESSURE VESSEL ASSEMBLY, CFLC 12M 853-00996-000 853-00996-000 ROPE, FIBERGLASS, 1/2" DIA. X 96-3/4" LG. 429-02038-000 429-01856-000 BURNER ASSEMBLY 20PPM 465-02775-000 465-02775-000 INSULATION &...

  • Page 90: Burner Assembly

    Section 6 — Parts Figure 6-4. Burner Assembly CFLC 4000/5000 UV SCANNER SEE FIGURE 6-7 Part No. 750-363...
  • Page 91 Section 6 — Parts Figure 6-5. Burner Assembly CFLC 6000/8000 UV SCANNER SEE FIGURE 6-7 Part No. 750-363...

  • Page 92: Uv Scanner

    Section 6 — Parts Figure 6-6. Burner Assembly CFLC 10 000/12 000 UV SCANNER SEE FIGURE 6-7 Figure 6-7. UV Scanner Part No. 750-363...

  • Page 93: Gas Train

    Section 6 — Parts Figure 6-8 Gas train CFLC 4000/5000 (standard 20 PPM NOx) ITEM PART NO DESCRIPTION 941-01946-000 BUTTERBALL VALVE, BRONZE, 1-1/2" NPT. 800-00104-000 ADAPTER, PIPE, 1-1/2" NPT. WITH SHUTTER, O-RING AND SCREWS 940-07486-000 VALVE, GAS, COMBO, 120VAC 800-00102-000 ADAPTER, PIPE, 2"...
  • Page 94 Section 6 — Parts Figure 6-9. Gas train CFLC 6000/8000 (standard 20 PPM NOx) ITEM QTY PART NO. DESCRIPTION SEE TABLE ORIFICE NIPPLE 797-07943-000 ACTUATOR 817-02416-000 LGPS 817-02417-000 HGPS 825-00239-000 LEAKAGE TEST COCK, 1/8" NPT. 845-00764-000 CONNECTOR, .25" MPT. x .25" ODC 845-00279-000 ELBOW 157-02747-000 NIPPLE, SIDE OUTLET, 2"...
  • Page 95 Section 6 — Parts Figure 6-10. Gas Train CFLC 6000/8000 (optional 9 PPM NOx) Part No. 750-363 6-11...
  • Page 96 Section 6 — Parts Figure 6-11. Gas train CFLC 10000/12000 (standard 20 PPM NOx) SECTION B-B STD. 36 * CFLC 10,000 CFLC 12,000 VIEW A-A CFLC 10,000 CFLC 12,000 * OPTIONAL SECTION C-C 6-12 Part No. 750-363...
  • Page 97 Section 6 — Parts Figure 6-12. Gas train CFLC 10000/12000 (optional 9 PPM NOx) Part No. 750-363 6-13...
  • Page 98 Section 6 — Parts Figure 6-13. Gas Train CFLC 4000/5000 Propane 6-14 Part No. 750-363...
  • Page 99 Section 6 — Parts Figure 6-14. Gas Train CFLC 6000/8000 Propane Part No. 750-363 6-15...
  • Page 100 Section 6 — Parts Figure 6-15. Gas Train CFLC 10000/12000 Propane 6-16 Part No. 750-363...

  • Page 101: Dual Fuel Gas Trains

    Section 6 — Parts Table 6-2. Dual Fuel Gas Trains SEE ILLUSTRATIONS FOLLOWING PAGES SEE FIGURE 6-15 4000-5000 NATURAL GAS 4000-5000 PROPANE 817-02416-000 SWITCH, LOW GAS PRESSURE 817-02416-000 SWITCH, LOW GAS PRESSURE 817-02420-000 SWITCH, HIGH GAS PRESSURE 817-02420-000 SWITCH, HIGH GAS PRESSURE 825-00239-000 COCK, LEAKAGE TEST 825-00239-000...
  • Page 102 Section 6 — Parts Figure 6-16. Dual Fuel 4000-5000 NATURAL GAS PROPANE 6-18 Part No. 750-363...
  • Page 103 Section 6 — Parts Figure 6-17. Dual Fuel Nat. Gas 6000-12000 OPTIONAL TO VENTURI Figure 6-18. Dual Fuel Propane 6000-12000 OPTIONAL Part No. 750-363 6-19...

  • Page 104: Pilot Gas Train

    Section 6 — Parts Figure 6-19. Pilot Gas Train ITEM DESCRIPTION PART NUMBER COCK, GAS SERVICE, TEE HEAD SEE TABLE VALVE, SOLENOID, GAS PILOT 235-00282 REGULATOR, GAS PRESSURE 918-00356 COCK, GAS SERVICE, TEE HEAD 825-00178 ITEM 1 CFLC 4000 - 5000 CFLC 6000 - 8000 CFLC 10000 - 12000 825-00029...

  • Page 105: Control Panel

    Section 6 — Parts Figure 6-20. Control Panel Part No. 750-363 6-21...

  • Page 106: Cables And Cable Harness

    Section 6 — Parts Figure 6-21. Cables and Cable Harness 6-22 Part No. 750-363...
  • Page 107 Section 6 — Parts Figure 6-22. Casing & Insulation 4000-5000 ITEM QTY PART NO DESCRIPTION ITEM QTY PART NO DESCRIPTION 872-01303-000 INSULATION BLANKET, 1000 F, 2" THICK x 65-1/2" X 117" 105-12384-000 CASING, LEFT SIDE PANEL, CFx 5M 872-01303-000 INSULATION BLANKET, 1000 F, 2" THICK x 65" X 119" 105-12390-000 CASING, MIDDLE SIDE PANEL, CFx 5M 094-01042-000...

  • Page 108: Casing & Insulation

    Section 6 — Parts Figure 6-23. Casing & Insulation 4000-5000 (cont’d) 6-24 Part No. 750-363...
  • Page 109 Section 6 — Parts Figure 6-24. Casing & Insulation 6000-8000 Part No. 750-363 6-25...
  • Page 110 Section 6 — Parts Figure 6-25. Casing & Insulation 6000-8000 (cont’d) 6-26 Part No. 750-363...
  • Page 111 Section 6 — Parts Figure 6-26. Casing & Insulation 10000-12000 Kit ITEM QTY PART NO DESCRIPTION Kit ITEM QTY PART NO DESCRIPTION 872-01303-000 INSULATION BLANKET, 110 1/2" LG. 105-12406-000 CASING, FRONT SIDE PANEL, CFx 12M 872-01303-000 INSULATION BLANKET, 186" LG. 105-12403-000 CASING, FRONT ACCESS PANEL 094-01043-000...
  • Page 112 Section 6 — Parts Figure 6-27. Casing & Insulation 10000-12000 cont’d SECTION A-A REAR CASING INSULATION INSULATION VIEW SEE 607 LEVEL FOR CONTROL PANEL PART NUMBER INSIDE PANEL INSTALLATION INSIDE PANEL PANEL VIEW FROM INSIDE 6-28 Part No. 750-363...

  • Page 113: Optional Parts

    Section 6 — Parts Table 6-3. Optional Parts Condensate Neutralization Tank PART NUMBER DESCRIPTION 195-04787 CONDENSATE TANK W/MEDIA 947-00008 REPLACEMENT MEDIA 880-02719 PARALLEL PIPE KIT, CFLC 8000 - 12000 Sealed Combustion Air Adapter Kits 880-03812 DIRECT VENT KIT CFLC 4000-5000 10” 880-03813 DIRECT VENT KIT CFLC 4000-5000 12”...
  • Page 114 Section 6 — Parts 817-03571 ALARM HORN 817-04403 STACK TEMP. LIMIT SENSOR 940-04920 AUTO AIR VENT (UP TO 150#) 940-02673 AUTO AIR VENT (UP TO 300#) 6-30 Part No. 750-363...
  • Page 115 APPENDIX A Falcon Parameters...
  • Page 117 Appendix A Falcon Parameters Table A-1 CFLC Falcon Parameters Parameter Group Parameter Name Access* Default Setting Max. Parameter Modbus range Range Units Register (dec) System ID & Access Boiler name Service BOILER 1 System ID & Access Installation data Service SERIAL NUMBER System ID &...
  • Page 118 Falcon Parameters Appendix A Table A-1 CFLC Falcon Parameters (Continued) Parameter Group Parameter Name Access* Default Setting Max. Parameter Modbus range Range Units Register (dec) Modulation Configuration DHW forced rate Service 100% Modulation Configuration DHW forced rate time Service 0m 0s mmm ss Modulation Configuration Firing rate control...
  • Page 119 Appendix A Falcon Parameters Table A-1 CFLC Falcon Parameters (Continued) Parameter Group Parameter Name Access* Default Setting Max. Parameter Modbus range Range Units Register (dec) Statistics Configuration Auxiliary 2 pump cycle count Service Cycles High Limits Outlet high limit setpoint Service High Limits Outlet high limit response...
  • Page 120 Falcon Parameters Appendix A Table A-1 CFLC Falcon Parameters (Continued) Parameter Group Parameter Name Access* Default Setting Max. Parameter Modbus range Range Units Register (dec) Annunciation Configuration Annunciator 4 location D:Interlock circuit Annunciation Configuration Annunciator4 short name Annunciation Configuration Annunciator 4 long name HIGH AIR PRESSURE Annunciation Configuration Annunciator 5 location...
  • Page 121 Appendix A Falcon Parameters Table A-1 CFLC Falcon Parameters (Continued) Parameter Group Parameter Name Access* Default Setting Max. Parameter Modbus range Range Units Register (dec) System Configuration Forced recycle interval time Service 0h 0m System Configuration Fan speed error response Service A:Lockout System Configuration...
  • Page 122 Falcon Parameters Appendix A Table A-1 CFLC Falcon Parameters (Continued) Parameter Group Parameter Name Access* Default Setting Max. Parameter Modbus range Range Units Register (dec) Lead Lag Configuration Force lead rotation time Service 168h 0m Lead Lag Configuration Lead lag DHW TOD setpoint User Lead Lag Configuration Boiler off options...
  • Page 123 APPENDIX B Variable Speed Drive Parameters Sections B.1 - B.5: PowerFlex 400 Sections B.6 - B.8: PowerFlex 525...
  • Page 125 Appendix B VSD Parameters B.1 PF 400 Integral Keypad The Variable Speed Drive is programmed using the integral key- pad. Keypad functions are described below. VSD Keypad Functions - PF 400 Name Description Escape Back one step in programming menu. Cancel a change to a parameter value and exit Program Mode.
  • Page 126 VSD Parameters Appendix B B.2 PF 400 LED Status Indicators VSD LED Indicators - PF 400 LED State Description Steady Red Indicates parameter value can be changed. Program Status Flashing Red Indicates that the drive is faulted. Fault Status Steady Green Indicates that the digital speed control keys are enabled.
  • Page 127 Appendix B VSD Parameters The Direction Arrow indicates the commanded direction of rotation. If the Arrow is flashing, the drive has been commanded to change direction, but is still decelerating. Sleep Mode Indication: flashes to indicate that the drive is in sleep mode. Parameter Group and Number: Fault Indication and Fault Number Fault Name...
  • Page 128 VSD Parameters Appendix B Editing VSD Parameters - PF 400 (Continued) Step Key(s) Example Displays 7. Press the Up Arrow or Down Arrow to scroll through the parameters in the group. 8. Press Enter or Sel to view the value of a parameter. If you do not want to edit the value, press Esc to return to the parameter number.
  • Page 129 Appendix B VSD Parameters CFLC VSD Parameters - PF400 (Continued) Par. No. Parameter Name Default Value W/ CFLC Basic Program *P31 Motor NP Volts Rated Volts Motor NPL Volts *P32 Motor NP Hertz 60 Hz Motor NPL Hertz *P33 Motor OL Current Rated Amps Motor NPL F.L.
  • Page 130 VSD Parameters Appendix B CFLC VSD Parameters - PF400 (Continued) Par. No. Parameter Name Default Value W/ CFLC Communic ations C101 Language English C102 Comm Format RTU 8-N-1 C103 Comm Data Rate 9600 C104 Comm Node Addr C105 Comm Loss Action Fault C106 Comm Loss Time...
  • Page 131 Appendix B VSD Parameters CFLC VSD Parameters - PF400 (Continued) Par. No. Parameter Name Default Value W/ CFLC A185 Load Loss Time 0 Secs A186 Stall Fault Time 60 Seconds A187 Bus Reg Mode Enabled A188 Skip Frequency 1 0 Hz A189 Skip Freq Band 1 0.0 Hz...
  • Page 132 Appendix B VSD Parameters B.6 PF 525 Display, Control, and Navigation Keys Menu Parameter Group and Description Basic Display Commonly viewed drive operating conditions. ENET LINK Basic Program Commonly used programmable functions. Terminal Blocks Programmable terminal functions. Communications Programmable communication functions. Logic (PowerFlex 525 only) Programmable logic functions.
  • Page 133 Appendix B VSD Parameters B.7 Viewing and Editing Drive Parameters - PF 525 Editing VSD Parameters - PF 525 Step Key(s) Example Displays 1. When power is applied, the last user-selected Basic Display Group parameter number is briefly displayed with flashing characters. The display then defaults to that parameter’s current value.
  • Page 134 Appendix B VSD Parameters B.8 Drive Parameter List - PF 525 Parameters marked * must be changed from default CFLC VSD Parameters - PF 525 Name Parameter # W/CFLC Output Freq Commanded Freq Output Current Output Voltage Drive Status Fault 1Code Fault 2 Code Fault3 Code Process Display...
  • Page 135 Appendix B VSD Parameters CFLC VSD Parameters - PF 525 (Continued) Name Parameter # W/CFLC Speed Reference2 Start Source 3 Speed Reference3 Average kWh Cost Reset to DefaIts Digln TermBlk 02 DigIn TermBlk 03 2-WireMode DigIn TermBlk 05 DigIn TermBlk 06 Dig!n TermBlk OJl1l Digln TermB!k og\lJ Opto Out1 Se1\1J...
  • Page 136 Appendix B VSD Parameters CFLC VSD Parameters - PF 525 (Continued) Name Parameter # W/CFLC RS485 Data Rate RS485 Node Addr Comm Loss Action Comm Loss Time EN Addr Sel 11 EN IP Addr Cfg 1111 EN IP Addr Cfg 2111 EN IP Addr Cfg 311, EN IP Addr Cfg 411, EN Subnet Cfg 1111...
  • Page 137 Appendix B VSD Parameters CFLC VSD Parameters - PF 525 (Continued) Name Parameter # W/CFLC Stp Logic ollJ Stp Logic 1'11 Stp Logic 1l Stp Logic3"1 Stp Logic 4llJ Stp Logic5l 11 Stp Logic 6"1 Stp Logic Jill Stp Logic Time otlJ Stp Logic Time 111i Stp Logic Time 2(lJ Stp Logic Time 3tlJ...
  • Page 138 Appendix B VSD Parameters CFLC VSD Parameters - PF 525 (Continued) Name Parameter # W/CFLC RdyBit Mode Act Preset Freq O Preset Freq 1 Preset Freq 2 Preset Freq 3 Preset Freq 4 Preset Freq 5 Preset Freq 6 Preset Freq 7 Preset Freq 3llJ Preset Freq 9111 Preset Freq 10111...
  • Page 139 Appendix B VSD Parameters CFLC VSD Parameters - PF 525 (Continued) Name Parameter # W/CFLC PID 1Trim Lo PID 1Trim Sel PIO 1Ref 5el PID 1 Fdback 5el PID 1 Prop Gai n PID 1 lnteg Time Pl01 Oiff Rate PID 1 Setpoint PID 1 Dead band PIO 1 Preload...
  • Page 140 Appendix B VSD Parameters CFLC VSD Parameters - PF 525 (Continued) Name Parameter # W/CFLC Freq 3llJ Freq 3 BW' 11 Freq 1 Kp11J Freq 1 Kil1J Freq 2 Kp11i Freq 2 Ki li Freq 3 Ki111 Boost Select Start Boost Break Voltage Break Frequency Encoder PPR\11...
  • Page 141 Appendix B VSD Parameters CFLC VSD Parameters - PF 525 (Continued) Name Parameter # W/CFLC RdyBit Mode Cfg Fault 4Code Fau!tS Code Fault 6 Codel1J Fault 7 Codel1J Fault 8 Codelli Fault 9 CodellI FaultlO Codel 1 J Fault 1Time-hr Fault 2 Time-hr Fault 3 Time-hr Fault 4 Time-hr...
  • Page 142 Appendix B VSD Parameters CFLC VSD Parameters - PF 525 (Continued) Name Parameter # W/CFLC Fault 2 BusVolts Fault3 BusVolts Fault 4 BusVolts Fault 5 BusVolts Fault6 BusVoltstlJ Fault 7 BusVoltsllJ Fault9 BusVoltst1J FaultlO BusVoltsl1J Status @ Fa ult 1 Status @ Fa ult 2 Status @ Fault 3 Status @ Fault 4...
  • Page 143 Appendix B VSD Parameters CFLC VSD Parameters - PF 525 (Continued) Name Parameter # W/CFLC Orv 1Logic Sts Orv 1 Feedback Orv 2 Logic Cmd Orv 2 Reference Orv 2 Logic Sts Orv 2 Feedback Orv 3 LogicCmd Orv 3 Reference Orv 3 Logic Sts Orv 3 Feedback Orv 4 Logic Cmd...
  • Page 145 APPENDIX C Gas Valve Page C-3 — Siemens Gas Valve Page C-25 — Dungs Gas Valve (CFLC 4000-5000)
  • Page 147 Appendix C Gas Valve...
  • Page 148 Gas Valve Appendix C...
  • Page 149 Appendix C Gas Valve...
  • Page 150 Gas Valve Appendix C...
  • Page 151 Appendix C Gas Valve...
  • Page 152 Gas Valve Appendix C...
  • Page 153 Appendix C Gas Valve...
  • Page 154 Gas Valve Appendix C C-10...
  • Page 155 Appendix C Gas Valve C-11...
  • Page 156 Gas Valve Appendix C C-12...
  • Page 157 Appendix C Gas Valve C-13...
  • Page 158 Gas Valve Appendix C C-14...
  • Page 159 Appendix C Gas Valve C-15...
  • Page 160 Gas Valve Appendix C C-16...
  • Page 161 Appendix C Gas Valve C-17...
  • Page 162 Gas Valve Appendix C C-18...
  • Page 163 Appendix C Gas Valve C-19...
  • Page 164 Gas Valve Appendix C C-20...
  • Page 165 Appendix C Gas Valve C-21...
  • Page 166 Gas Valve Appendix C C-22...
  • Page 167 Appendix C Gas Valve C-23...
  • Page 168 Appendix C Gas Valve C-24...
  • Page 169 Appendix C Gas Valve MBC-SE 1000/2500/4000 ® GasMultiBloc Combined servo pressure regulator and safety shut-off valves Installation Instructions Table of Contents Table of Contents ......Page Valve Leakage Bubble Test (Altern.
  • Page 170 Appendix C Gas Valve MBC- Safety Valve Max. Oper ating Ambient Temperature (CSA) °F Pressure -40 °F ... +140 °F +150 MOP = 5 PSI (360 mbar) (-40 °C … +60 °C) Ambient Temperature (UL) +5 °F ... +140 °F Regulator Oper ating P ressure [PSI]...
  • Page 171 Appendix C Gas Valve Mounting Installation position SE Versions ending in S22/S82/S302 16 12 8 Installation position SE Versions ending in S02 16 12 8 If the w is not in the same dir ection of the arrows, the valves will not operate properly. Setup 1.
  • Page 172 Appendix C Gas Valve Recommended Torque Screw Size [Ib-in] System Accessories 62 lb-in 134 lb-in [Ib-in] Recommended Piping Procedure function may result from excess pipe in the valve body. amount on the male threads only. If pipe sealant lodges on the valve seat, it will prevent proper operation. If using values listed below.
  • Page 173 Appendix C Gas Valve Electrical DIN Connector Ratings Ambient Temperature Rating: -40°F to +175°F Ratings for conduit and conduit Electrical R atings: 120VAC, 24VAC 50/60 Hz, 12 VDC or Temperature: At least 75°C (170°F) 24VDC. Voltage: 300 Volts minimum Maximum Amperage Rating: 6.0 Amps @ 120VAC. Approvals: Enclosure Rating: Type 12...
  • Page 174 Appendix C Gas Valve Electrical DIN Connector assembly & wiring The maximum tor que for the terminal scr ews is 4.4 in-lb Failure to follow the exact instructions belo w ma y result (0.5 Nm). in a valve connector not to valve.
  • Page 175 Appendix C Gas Valve MBC Overview & Impulse Lines Impulse lines must be ordered separately Electrical connection for valves (DIN EN 175 301-803) black Filter Label / Seriel number Cover Test point connection G 1/8 upstream of V1, possible on both sides Test point connection G 1/8 downstream of V2, optional Regulator Outlet Pressure Adjustment Vent connection / Vent limiter G 1/8...
  • Page 176 Appendix C Gas Valve External Impulse line (option) Assembly Instructions Impulse line p must cor - Route Impulse line so that no Secure Impulse line to prevent Test Impulse line for external respond to ≥ DN 4 (1/8”), PN condensate them from being ripped out and leakage.
  • Page 177 Appendix C Gas Valve Outlet Pressure Adjustment MBC...SE S22/82/302 MBC...SE S02 & MBC N • O pen protective slide located at the bottom of the valve. 1. O pen protective slide located at the bottom of the valve. • S ee Fig. 1 & 2 for adjustments. 2.
  • Page 178 Appendix C Gas Valve Changing coil 2. Undo locking screw A, Fig. 1 MBC-1000/2500 Always observe s olenoid 5. R eplace cover B, tighten by o gas s upply and Shut 3. R emove cover B, Fig. 2 No. and voltage! hand, Fig.
  • Page 179 Appendix C Gas Valve MBC-4000 4. C Note: 7. Make electrical connec - o gas s upply and Shut cover, Fig. 3. V1 wire c onnection Coil tions. Assemble in reverse disconnect power s up - 5. Disconnect grounding and black/white order.
  • Page 180 Appendix C Gas Valve Internal Fil ter Inspect lter at least 4. S crew in screws 1-2 without Change the lter , if Δp be - 1. Interrupt gas supply: close using any force and fasten once a year. tween pressure connections upstream ball valve Change the lter , if Δp be -...
  • Page 181 Appendix C Gas Valve Test Ports V2, downstream V2, and on screwed in any of these pres - available on both sides up - sure tap ports. stream V1, between V1 and nipple (P/N 219-008) can be Pressure taps MBC-1000/2500… 6, 7 16 12 8 MBC-4000…...
  • Page 182 Appendix C Gas Valve Valve Leakage Decay Test This test method is an alternative to bubble tightness testing 5) Externally leak test the valve and all piping connected to downstream of the MBC. the manometer connection. DUNGS recommends using Preparation for leak testing: an all purpose liquid leak detector solution (Snoop™...
  • Page 183 Appendix C Gas Valve Valve Leakage Bubble Test (Altern. method) This leak test procedure tests the external sealing and valve ceeding. 2. T hen, de-energize the burner system and verify that both It is required that this test be done on the initial system startup, 3.
  • Page 184 Appendix C Gas Valve Flow Cu rve MBC-1000-... Based on 60 °F 14.65 psia, dry 4,000 7,000 30 40 2,000 10,000 80 100 1,000 MBC-2500-... Curves for equipment selection (in regulated state) with micro Based on 60 °F 14.65 psia, dry 1,000 2,000 4,000...
  • Page 185 Appendix C Gas Valve MBC-4000-... Curves for equipment selection (in regulated state) with micro Based on 60 °F 14.65 psia, dry 1,000 2,000 4,000 7,000 10,000 20,000 40,000 100,000 Pressure Drop for other Gases when using propane, divide the volume (CFH) of propane To determine the pressure drop when using a gas other than required for the application by the calculated value f (f = 0.66 on the next page to determine pressure drop for propane.
  • Page 186 Appendix C Gas Valve C-42...
  • Page 187 APPENDIX D Falcon Alert, Hold, and Lockout Codes...
  • Page 189 Appendix D Falcon Alert, Hold, Lockout Codes Table D-1 Falcon Holds and Lockouts Code Description Note None No lockout/hold Unconfigured safety data Lockout Waiting for safety data verification Lockout Internal fault: Hardware fault Hold Internal fault: Safety Relay key feedback error Hold Internal fault: Unstable power (DCDC) output Hold...
  • Page 190 Falcon Alert, Hold, Lockout Codes Appendix D Table D-1 Falcon Holds and Lockouts (Continued) Internal fault: Safety Key 7 Lockout Internal fault: Safety Key 8 Lockout Internal fault: Safety Key 9 Lockout Internal fault: Safety Key 10 Lockout Internal fault: Safety Key 11 Lockout Internal fault: Safety Key 12 Lockout...
  • Page 191 Appendix D Falcon Alert, Hold, Lockout Codes Table D-1 Falcon Holds and Lockouts (Continued) Outlet T-rise limit Hold / Lockout Exchanger T-rise limit Hold / Lockout Heat exchanger high limit Hold / Lockout Inlet sensor fault Hold Outlet sensor fault Hold DHW sensor fault Hold...
  • Page 192 Falcon Alert, Hold, Lockout Codes Appendix D Table D-1 Falcon Holds and Lockouts (Continued) Internal fault: Flame bias out of range 4 Lockout Internal fault: Flame bias out of range 5 Lockout Internal fault: Flame bias out of range 6 Lockout Flame detected Hold / Lockout...
  • Page 193 Appendix D Falcon Alert, Hold, Lockout Codes Table D-1 Falcon Holds and Lockouts (Continued) Invalid Interlock open response setting Lockout Invalid Interlock start check setting Lockout Invalid LCI enable setting Lockout Invalid lightoff rate setting Lockout Invalid Lightoff rate proving setting Lockout Invalid Main Flame Establishing Period time setting Lockout...
  • Page 194 Falcon Alert, Hold, Lockout Codes Appendix D Table D-1 Falcon Holds and Lockouts (Continued) Invalid S2 (J8-6) connector type setting Lockout Invalid S5 (J8-11) connector type setting Lockout Exchanger sensor not allowed with stack connector setting Lockout Invalid DHW auto detect configuration Lockout Invalid UV with spark interference not compatible with Ignitor on throughout PFEP Lockout...
  • Page 195 Appendix D Falcon Alert, Hold, Lockout Codes Table D-2 Falcon Alerts Code Description None (No alert) Alert PCB was restored from factory defaults Safety configuration parameters were restored from factory defaults Configuration parameters were restored from factory defaults Invalid Factory Invisibility PCB was detected Invalid Factory Range PCB was detected Invalid range PCB record has been dropped EEPROM lockout history was initialized...
  • Page 196 Falcon Alert, Hold, Lockout Codes Appendix D Table D-2 Falcon Alerts (Continued) PCB incompatible with product contained in Program Module Parameter PCB in Program Module is too large for product Range PCB in Program Module was too large for product Alert PCB in Program Module was too large for product IAS start check was forced on due to IAS enabled Low voltage was detected in safety processor...
  • Page 197 Appendix D Falcon Alert, Hold, Lockout Codes Table D-2 Falcon Alerts (Continued) Lead Lag CH 4-20mA water temperature setting was invalid No Lead Lag add stage error threshold was configured No Lead Lag add stage detection time was configured No Lead Lag drop stage error threshold was configured No Lead Lag drop stage detection time was configured RESERVED Modulation output type was invalid...
  • Page 198 Falcon Alert, Hold, Lockout Codes Appendix D Table D-2 Falcon Alerts (Continued) Modulation rate was limited due to anticondensation Fan speed out of range in RUN Modulation rate was limited due to IAS was open Slow start ramp setting of zero will result in no modulation rate change No forced rate was configured for slow start ramp CH demand source was invalid CH P-gain was invalid...
  • Page 199 Appendix D Falcon Alert, Hold, Lockout Codes Table D-2 Falcon Alerts (Continued) DHW storage ON hysteresis was invalid DHW modulation sensor type was invalid DHW modulation sensor was not compatible for Auto mode DHW control was suspended due to fault DHW temperature was invalid DHW inlet temperature was invalid DHW outlet temperature was invalid...
  • Page 200 Falcon Alert, Hold, Lockout Codes Appendix D Table D-2 Falcon Alerts (Continued) Lead Lag slave was discovered Incompatible Lead Lag slave was discovered No base load rate was set for Lead Lag slave Lead Lag slave unable to fire before demand to fire delay expired Adding Lead Lag slave aborted due to add requirement change No Lead Lag slaves available to service demand No Lead Lag active service was set due to demand priority conflicts...
  • Page 201 Appendix D Falcon Alert, Hold, Lockout Codes Table D-2 Falcon Alerts (Continued) CH ODR low water temperature was invalid CH ODR outdoor temperature range was too small CH ODR water temperature range was too small Steam setpoint was invalid Steam time of day setpoint was invalid Steam minimum pressure was invalid CH ODR min water temperature was invalid RESERVED...
  • Page 202 Falcon Alert, Hold, Lockout Codes Appendix D Table D-2 Falcon Alerts (Continued) Abnormal Recycle: Interrupted air flow switch was off during Drive to Purge Rate Abnormal Recycle: Interrupted air flow switch was off during Measured Purge Time Abnormal Recycle: Interrupted air flow switch was off during Drive to Lightoff Rate Abnormal Recycle: Interrupted air flow switch was off during Pre-Ignition test Abnormal Recycle: Interrupted air flow switch was off during Pre-Ignition time Abnormal Recycle: Interrupted air flow switch was off during Main Flame Establishing Period...
  • Page 203 Appendix D Falcon Alert, Hold, Lockout Codes Table D-2 Falcon Alerts (Continued) Abnormal Recycle: Hardware SLO AD linearity Abnormal Recycle: Hardware SLO bias not set Abnormal Recycle: Hardware SLO bias shorted Abnormal Recycle: Hardware SLO electronics Abnormal Recycle: Hardware processor clock Abnormal Recycle: Hardware AC phase Abnormal Recycle: Hardware A2D mismatch Abnormal Recycle: Hardware VSNSR A2D...
  • Page 204 Falcon Alert, Hold, Lockout Codes Appendix D Table D-2 Falcon Alerts (Continued) Abnormal Recycle: Fan Speed Not Proven Abnormal Recycle: Fan Speed Range Low Abnormal Recycle: Fan Speed Range High 383-450 RESERVED Circulator control was invalid Circulator P-gain was invalid Circulator I-gain was invalid Circulator temperature was invalid Circulator outlet temperature was invalid...
  • Page 205 Appendix D Falcon Alert, Hold, Lockout Codes Table D-2 Falcon Alerts (Continued) Internal error: Safety key bit 11 was incorrect Internal error: Safety key bit 12 was incorrect Internal error: Safety key bit 13 was incorrect Internal error: Safety key bit 14 was incorrect Internal error: Safety key bit 15 was incorrect Internal error: Safety relay timeout Internal error: Safety relay commanded off...
  • Page 206 Falcon Alert, Hold, Lockout Codes Appendix D Table D-2 Falcon Alerts (Continued) Mix PID setpoint was invalid STAT may not be a Mix demand source when Remote Stat is enabled 533-539 RESERVED Delta T inlet/outlet enable was invalid Delta T exchanger/outlet enable was invalid Delta T inlet/exchanger enable was invalid Delta T inlet/outlet degrees was out of range Delta T exchanger/outlet degrees was out of range...
  • Page 207 Appendix D Falcon Alert, Hold, Lockout Codes Table D-2 Falcon Alerts (Continued) Auxiliary pump output was invalid System pump output was invalid Mix pump output was invalid 582-589 RESERVED DHW plate preheat setpoint was invalid DHW plate preheat ON hysteresis was invalid DHW plate preheat OFF hysteresis was invalid Tap detect degrees was out of range Tap detect ON hysteresis was invalid...
  • Page 209 APPENDIX E Falcon Lead/Lag INSTALLATION AND STARTUP....page E3 LEAD LAG OPERATION ....page E39 MODBUS FOR EMS COMMUNICATION.
  • Page 211 INSTALLATION AND STARTUP 1- INTRODUCTION The Falcon boiler control in conjunction with Cleaver-Brooks’ ClearFire line of commercial boilers provides a reliable and efficient solution for facilities requiring a modular, multiple-boiler system. The Falcon is uniquely capable of taking advantage of the ClearFire’s characteristic combustion and thermal performance profiles, apportioning the load to individual boilers so as to maximize overall system efficiency.
  • Page 212 (optional). • 833-05105 or 833-03577 display for each boiler.** A Falcon lead lag kit 880-3670 is available from Cleaver-Brooks and includes a system header temperature sensor with thermowell, outdoor air temperature sensor, and Falcon Program Module for copying parameter settings from one Falcon to another.
  • Page 213 • 833-05105 or 833-03577 display for each boiler.** 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.
  • Page 214 Falcon Lead Lag Appendix E 5- PARTS Controls PART NUMBER DESCRIPTION 833-03639 FALCON HYDRONIC CONTROL Model CFC 500-2500 833-04086 FALCON HYDRONIC CONTROL Model CFC 3300 833-03871 FALCON HYDRONIC CONTROL Model CFW 833-04097 FALCON HYDRONIC CONTROL Model CFLC 833-03578 FALCON STEAM CONTROL Models CFH/CFV CFC HYDRONIC CONTROL 833-03639 CFW HYDRONIC CONTROL...
  • Page 215 Appendix E Falcon Lead Lag Display PART NUMBER DESCRIPTION 833-05105 FALCON SYSTEM DISPLAY / OPERATOR INTERFACE 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)
  • Page 216 Falcon Lead Lag Appendix E 6- SYSTEM SETUP <Color>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 217 Appendix E 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 218 Falcon Lead Lag Appendix E NOTE: refer to specific boiler wiring diagram for proper terminal numbers. DEMAND PRESS XMTR (18) FALCON LEAD LAG MASTER ONLY: L-L HEADER PRESSURE XMTR +12VDC Figure 5 - Header press. transmitter (steam) Sensor Configuration (steam) For steam systems the header pressure transmitter input needs to be configured at the Master host.
  • Page 219 Appendix E Falcon Lead Lag 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: • Discrete contact for remote enable - allows a building EMS to send a remote lead lag system enable signal to the Falcon lead lag Master.
  • Page 220 Falcon Lead Lag Appendix E 2. Go to Lead Lag Master Configuration and make any necessary parameter changes. The first set of parameters 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 221 Appendix E Falcon Lead Lag Table 2a - Lead Lag Master Configuration Parameters - Advanced Settings, Hydronic (Continued) Demand switch Stat Terminal Stat Terminal Remote Stat Disabled Setpoint source Local Local 4-20mA Setpoint -40 deg F to 266 deg F (-40 deg C to 130 deg C) Time of day setpoint -40 deg F to 266 deg F (-40 deg C to 130 deg C) 4mA water temperature...
  • Page 222 Falcon Lead Lag Appendix E Table 2b - Lead Lag Master Configuration Parameters - Advanced Settings, Steam Parameter Range CB Default Setting Installation Setting Modulation Parameters S1 (J8-4) Steam Sensor S2 (J8-6) Steam Sensor Modulation sensor S2 (J8-6) Steam Sensor Off hysteresis On hysteresis Hysteresis step time...
  • Page 223 Appendix E Falcon Lead Lag Modulation sensor (steam) - choices are S1 (J8-4) and S2 (J8-6). Default is S2, the system header pressure transmitter. In the event of a header pressure transmitter failure, the local transmitter (S1) can be configured as the lead lag modulation sensor. Note that in steam systems the modulation backup source must be manually configured.
  • Page 224 Falcon Lead Lag Appendix E 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 Lead Lag master Disabled Slave mode Use first Equalize run time Use last...
  • Page 225 Appendix E Falcon Lead Lag Figure 6 - 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 fin- ished, remove the PIM and replace the cover. 4.
  • Page 226 Falcon Lead Lag Appendix E 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 227 Appendix E 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 228 Falcon Lead Lag Appendix E To access the Lead Lag Operation screen: Touch this area Touch <Lead Lag Master> button if visible Figure 8 - 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 229 Appendix E Falcon Lead Lag 10-EXAMPLE SYSTEMS Figure 4 through Figure 8 show piping and network wiring for some typical lead lag network configurations. Systems shown are examples only. Actual installations may vary. Figure 9 - Falcon Lead Lag with outdoor reset and EMS for remote comms/monitoring E-21...
  • Page 230 Falcon Lead Lag Appendix E Figure 10 - Falcon Lead Lag with outdoor reset and EMS for remote enable E-22...
  • Page 231 Appendix E Falcon Lead Lag Figure 11 - Falcon LL with EMS for remote enable/remote setpoint E-23...
  • Page 232 Falcon Lead Lag Appendix E Figure 12 - Falcon Lead Lag with EMS for remote comms/monitoring E-24...
  • Page 233 Appendix E Falcon Lead Lag Figure 13 - Typical Steam System 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. E-25...
  • Page 234 Falcon Lead Lag Appendix E SUPPLY to system System pumps - controlled by others System pump ENABLE signal RETURN to boilers L/L MASTER Boiler 1 Boiler 2 Boiler isolation valve Figure 14 - Primary Pumping Isolation Valve Control At each Slave use Aux 1 Pump control block for isolation valve control (see Figure 17). Assign to Pump B relay.
  • Page 235 Appendix E Falcon Lead Lag SUPPLY to system System pumps - controlled by others Boiler Pump Boiler 1 Boiler 2 Figure 15 - 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.
  • Page 236 Falcon Lead Lag Appendix E Supply Return from boilers to boilers Boiler 1 Boiler 2 Figure 16 - Primary with dedicated system/boiler pumps PCB configuration - same as Figure 10. E-28...
  • Page 237 Appendix E 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 17 - 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 238 Falcon Lead Lag Appendix E 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...

  • Page 239: Boiler Pump

    Appendix E 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 240 Falcon Lead Lag Appendix E 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 241 Appendix E 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 242 Falcon Lead Lag Appendix E Pump Configuration Auxiliary 1 pump AUX 1 Auto Pump control 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...

  • Page 243: Combustion Air Damper

    Appendix E 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...
  • Page 244 Falcon Lead Lag Appendix E 13-Boiler Wiring Diagrams Model CFC ClearFire condensing boiler E-36...
  • Page 245 Appendix E Falcon Lead Lag Model CFW ClearFire hydronic boiler E-37...
  • Page 246 Falcon Lead Lag Appendix E Model CFV/CFH ClearFire steam boiler *‘START PERMISSIVE’ INDICATES CONNECTION MUST BE CLOSED TO ALLOW BOILER START E-38...

  • Page 247: Reference Manual

    Appendix E Falcon Lead Lag LEAD LAG OPERATION Reference Manual Contents General Description of the Lead Lag Application ..E-39 Lead Lag (LL) Master General Operation .......E-39 System Wiring Hookup ............E-42 Lead-Lag Operation............E-43 Slave Operation and setup ..........E-44 Slave Parameters ..............E-45 LL Master Operation and Setup ........E-46 Many of the descriptions used herein refer to functions or tables internal to the Falcon.
  • Page 248 Falcon Lead Lag Appendix E The firing rate is sent to the slaves as a percentage apportioned according to the rate allocation algorithm selected by the Rate Allocation Method parameter. For some algorithms this rate might be common to all slave units that are firing. For others it might represent the total system capacity and be allocated proportionally.
  • Page 249 Appendix E Falcon Lead Lag Add-stage request An Add-stage method implements the criteria for adding another stage. Criteria that may apply are the firing rate of a stage or stages vs. a threshold, the amount of operating point versus setpoint error seen by the master, the rate at which setpoint error is developing, and the rate at which a stage or stages are approaching their maximum or baseload firing rate.
  • Page 250 Falcon Lead Lag Appendix E 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 251 Appendix E Falcon Lead Lag LEAD-LAG OPERATION This is a summary of the functional capability of the embedded lead-lag on the Falcon control. OEM configurable parameters may be adjusted as part of the OEM factory configuration and in the field using the System Display with appropriate password permissions.
  • Page 252 Falcon Lead Lag Appendix E 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...
  • Page 253 Appendix E Falcon Lead Lag Frost protection requests The frost protection in this status register will be set or cleared to match the status generated by the frost protection detection functions. Firing for local frost protection This provides indication to the LL master that although the burner is firing independently, it is doing so for frost protection and thus is still available as a lead/lag slave.
  • Page 254 Falcon Lead Lag Appendix E The Slave Command register is writable but it is mostly ignored, however the Aux pump X, Y, and Z are effective for any setting of the Slave enable parameter. The Enable for Falcon Master option Slave write and Slave read parameters; if "Enable for Falcon Master" is not selected, then these parameters are disabled.

  • Page 255: Overall Control

    Appendix E Falcon Lead Lag • Sequencer - the sequencer determines which unit will be the next one to turn on or turn off. Overall Control LL MASTER ENABLE: DISABLE, ENABLE, LL MASTER MODBUS PORT: MB1, MB2 If Disable is selected then all LL master functions are inactive. If Enable is selected then it acts as the active bus master on the ModBus port it is assigned.

  • Page 256: Slave Status Manager

    Falcon Lead Lag Appendix E Slave Status Manager The LL master keeps track of slave status for each unit that is enabled as a slave device. The slave status manager operates internally for each slave device (up to 8). There is a table entry for each device containing the following data: •...
  • Page 257 Appendix E Falcon Lead Lag SlaveState states Recovering A slave that is recovering is checked once per second. If the slave has recovered the SlaveState table is changed to Available. If the slave has not yet recovered when its recovery timer reaches the RecoveryTimeLimit then: If the slave is not enabled for the LL master its SlaveState table is Set to Unknown (which logically removes it from the slave table).

  • Page 258: Frost Protection

    Falcon Lead Lag Appendix E CH Demand LL CH DEMAND SWITCH: DISABLE, STAT, ENVIRONCOM REMOTE STAT The inputs that can function as the CH demand switch are: STAT, EnvironCOM Remote Stat. If the CH demand switch value is Disable, the LL master does not respond to CH demand. Warm Weather Shutdown WARM WEATHER SHUTDOWN ENABLE: DISABLE, SHUTDOWN AFTER DEMANDS HAVE ENDED, SHUTDOWN IMMEDIATELY...
  • Page 259 Appendix E Falcon Lead Lag Frost protection input to the priority logic is not a heat demand, it is a burner demand (because frost protection always turns on pumps without regard to the priority control - it is a priority item only if it also wants to fire). Master Status MASTER HEAT DEMAND Is a data item which contains the status for the following sources of demand.

  • Page 260: Modulation Sensor

    Falcon Lead Lag Appendix E Modulation Sensor LL MODULATION SENSOR: S5 The LL master's modulation sensor uses the S5 sensor (connector J8 terminal 11 and 12). If the LL master is enabled and its sensor is faulty then an alert will be issued. LL MODULATION BACKUP SENSOR: DISABLE, LEAD OUTLET, SLAVE OUTLET AVERAGE If the sensor chosen by the LL Modulation sensor is faulty then the backup sensor provided here may be used.
  • Page 261 Appendix E Falcon Lead Lag If the setpoint source is S2 4-20mA then the setpoint is determined by the 4-20mA input on S2, and the two param- eters described below. If the 4-20mA signal goes out of range or is invalid, and this persists for a specified time, then the setpoint source reverts to "Local".
  • Page 262 Falcon Lead Lag Appendix E Demand and Rate On/Off Hysteresis Includes hysteresis shifting at turn-on, turn-off LL OFF HYSTERESIS: DEGREES OR NONE LL ON HYSTERESIS: DEGREES OR NONE The LL hysteresis values apply to all setpoint sources. The behavior of the hysteresis function is identical to the behavior of the stand-alone CH hysteresis function, except: •...

  • Page 263: Rate Allocation

    Appendix E Falcon Lead Lag • An add-stage is in-progress and all firing burners are at their limits (max modulation rate or base load) and then the new stage becomes available. This also applies when the system is first starting up, that is, all firing burners are at their limits (zero) because non are firing, and thus when the add-stage is finished the system transitions from no modulation at all, to modulating the first stage.
  • Page 264 Falcon Lead Lag Appendix E When asked for rate overflow the threshold that is used is the upper limit of the modulating stage per the current rate allocation rules. Additionally this threshold may be shifted if the Add-stage method is using a dRate/dt behavior.
  • Page 265 Appendix E Falcon Lead Lag • In between those two extremes the Add-stage and Drop-stage methods determine when staging occurs. The stager handles burner on and burner off events. It operates according to this state transition diagram. The stager has the following variables: StagerState: encodes the current state of the stager.
  • Page 266 Falcon Lead Lag Appendix E Stager Parameters ADD-STAGE INTERSTAGE DELAY: MM:SS This specifies the minimum time that the Stager waits after adding one stage before adding another stage or drop- ping a stage. 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 267 Appendix E Falcon Lead Lag If so then: If the boiler's SlaveState is set to Available. If any slave boiler is firing then StagerState = Active Otherwise StagerState = Idle STAGERSTATE = ACTIVE During this state the stager is ready to manage add-stage and drop-stage requests. If AddStageRequest is true The Stager ask the Sequencer for an available slave.
  • Page 268 Falcon Lead Lag Appendix E - The operating point is below the setpoint by an amount greater than or equal to Add-stage error threshold When the Add-stage condition is false then AddStageDetectTimerN is set to zero. (If the condition is true then AddStageDetectTimerN is not zeroed and thus allowed to run.) If this timer reaches or exceeds LL- Add-stage detection timeN then AddStageRequestN is true.
  • Page 269 Appendix E Falcon Lead Lag LL ALL BOILERS OFF THRESHOLD: TEMPERATURE OR NONE When the LL boiler off options specifies "Enable all boilers off (ABO)" or "Enable both ABO and LDSE" then this parameter provides the boiler off threshold temperature that is used. In this case, if the temperature is the None value then a parameter error lockout occurs.
  • Page 270 Falcon Lead Lag Appendix E As usual, whenever LL master burner demand is turned off by its hysteresis block, it does not recur until the operating point falls below the Burner On threshold. Summary of the burner-off thresholds that are used: LDSE enabled enabled...
  • Page 271 Appendix E Falcon Lead Lag FORCE LEAD ROTATION TIME: HH:MM OR NONE If this parameter is a non-zero time, then it is used to force the rotation of the lead boiler if it stays on longer than the time specified. Sequencer Add Boiler Selection The sequencer selects the next boiler to be added according to a sorted order.
  • Page 272 Falcon Lead Lag Appendix E Example: Before After Notfiring Notfiring Firing Firing Firing Firing Sequencer Drop Lag boiler selection When the stager asks the sequencer for a lag boiler to drop the sequencer looks at the StagingOrder numbers of all Firing boilers.
  • Page 273 Appendix E Falcon Lead Lag 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 274 Falcon Lead Lag Appendix E 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 275 Appendix E Falcon Lead Lag Table 5: 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...
  • Page 276 Falcon Lead Lag Appendix E 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)
  • Page 277 Appendix E Falcon Lead Lag Decimal Parameter Format Description 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 residen- tial & commercial models (see tables 10 & 11). Model type determined by register 176.
  • Page 278 Falcon Lead Lag Appendix E Decimal Parameter Format Description 003A 0058 Active rate override 0=None, 1=Burner control default, 2=Burner control, 3=Manual firing rate, 4=Manual firing rate off 003B 0059 Override rate RPM or % 003C 0060 Demand rate RPM or % CENTRAL HEATING (CH) STATUS 0040 0064...
  • Page 279 Appendix E Falcon Lead Lag Decimal Parameter Format Description 0=None, 1=Burner control, 2=Application, 3=Burner control & application, 4=Clear alert log 00B7 0183 Burner name Variable length string (up to 20 characters) 00B8 0184 Installation data Variable length string (up to 20 characters) MODULATION CONFIGURATION 00C1 0193...
  • Page 280 Falcon Lead Lag Appendix E Decimal Parameter Format Description 0210 0528 CH frost protection enable 0=Disable CH frost protection, 1=Enable CH frost protection 0211 0529 DHW frost protection enable 0=Disable DHW frost protection, 1=Enable DHW frost protection 0212 0530 Outdoor frost protection setpoint -40°-130°...
  • Page 281 Appendix E Falcon Lead Lag Decimal Parameter Format Description 0478- 047D 1144- 1149 Alert log record 5 5th newest alert. 047E-0483 1150- 1155 Alert log record 6 6th newest alert. 0484- 0489 1156- 1161 Alert log record 7 7th newest alert. 048A-048F 1162-1167 Alert log record 8...
  • Page 283 APPENDIX F Falcon Program Module...
  • Page 285 Appendix F Program Module...
  • Page 286 Program Module Appendix F...
  • Page 287 Appendix F Program Module...
  • Page 288 Program Module Appendix F...
  • Page 290 e-mail: info@cleaverbrooks.com Web Address: http://www.cleaverbrooks.com...

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Clearfire cflc-4000Clearfire cflc seriesClearfire cflc-10000Clearfire cflc-12000Clearfire cflc-6000Clearfire cflc-8000

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