CleaverBrooks ClearFire CFH Operation, Service And Parts Manual
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CleaverBrooks ClearFire CFH Operation, Service And Parts Manual

Gas high-efficiency steam boiler 10-80 hp
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Model CFH
ClearFire
®
Gas High-Efficiency Steam Boiler
10-80 HP
Operation, Service, and Parts Manual
750-295
07/2020

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  • Page 1 Model CFH ClearFire ® Gas High-Efficiency Steam Boiler 10-80 HP Operation, Service, and Parts Manual 750-295 07/2020...
  • Page 2 ! DANGER WARNING ! DANGER WARNING If the information in this manual is not followed ex- Improper installation, adjustment, service, or actly, a fire or explosion may result causing prop- maintenance can cause equipment damage, per- sonal injury, or death. Refer to the Operation and erty damage, personal injury or loss of life.
  • Page 3 CLEAVER-BROOKS Model CFH ClearFire ® Packaged Boiler Gas High Efficiency Boiler Operation, Service, and Parts Manual  Cleaver-Brooks 2020 Please direct purchase orders for replacement manuals to your local Cleaver-Brooks authorized representative. Manual Part No. 750-295 Printed in U.S.A. 07/2020...
  • 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 FULLY 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 Chapter 1 — Introduction Model CFH Features And Benefits ............1-2 The Boiler .
  • Page 6 Safety Precautions Throughout this manual, procedures or operations that require special attention are emphasized with a cau- tionary note. The notes are identified by the symbols WARNING! CAUTION! or NOTE, signifying the follow- ing: ! DANGER WARNING Indicates a potentially hazardous situation which, if not avoided, could result in serious personal injury or death.
  • Page 7 Optional Equipment ........1-6 www.cleaverbrooks.com...

  • Page 8: Chapter 1 - Introduction

    Chapter 1 — Introduction 1.1-MODEL CFH FEATURES AND BENEFITS Compact Firetube Design The Model CFH boiler is a compact horizontally fired firetube boiler. The extended heating surface tubes provide for very high levels of performance in a compact space. The Model CFH boiler is designed to fire natural gas or LP gas.
  • Page 9 Chapter 1 — Introduction operates. In order to prevent the safety valve from opening too frequently during normal operation, the operating pressure should not exceed 90% of the safety valve setting. Caution Waterside care is of prime importance. For specific information or assistance with your water treatment requirements, contact your Cleaver-Brooks service and parts representative.

  • Page 10: The Boiler

    Chapter 1 — Introduction 1.3-THE BURNER The CFH burner uses a “premix” design, whereby fuel and air combine prior to entering the burner. • The burner utilizes a mixing venturi, dual safety shutoff-single body pressure regulating gas valve, variable speed blower, and Fecralloy metal fiber burner canister (see Figure 1-3). •...

  • Page 11: Controls

    Chapter 1 — Introduction 1.5-CONTROLS The CB Falcon steam boiler control is an integrated burner management and modulation control with a touch-screen display/operator interface. FALCON DISPLAY DEMAND SWITCH ALWCO OPTIONAL ALARM/LIGHT PKG. RESET Figure 1-5 Control panel front BLOWER SIGNAL CABLE 10-60 HP IGNITION IGNITION...

  • Page 12: Water Level & Steam Pressure Controls

    Chapter 1 — Introduction The controller is capable of the following functions: • Burner sequencing with safe start check, pre-purge, direct spark ignition, and post purge. • Electronic ignition. • Flame Supervision. • Safety shutdown with time-stamped display of lockout condition. •...
  • Page 13 Chapter 1 — Introduction • Dual fuel gas train (30-80 HP) • Low gas pressure option (30-60 HP) • Min. Temp./Hot standby • Sealed combustion adapter kit - shipped loose • Direct vent kit - shipped loose • Chemical Feed System •...
  • Page 14 Chapter 1 — Introduction Part No. 750-295...
  • Page 15 National Electrical Code and/or UL 795, Commercial-Industrial Gas Heating Equipment. www.cleaverbrooks.com...

  • Page 16: Chapter 2 - Installation

    Chapter 2 — Installation 2.1-BOILER ROOM The boiler room must comply with all building codes and regulations. An adequate supply of combustion air and sufficient ventilation are required for safe operation. If the optional direct vent combustion air kit is not used, ventilation must be provided to meet applicable regulations for air supply.

  • Page 17: Water Treatment

    Chapter 2 — Installation Figure 2-2 Boiler rigging 2.3-WATER TREATMENT Properly treated boiler water will result in maximum effectiveness and long trouble-free life of the pressure vessel. Contact your local Cleaver-Brooks representative or water management consultant for complete information on how to prevent damage resulting from inadequate water treatment. See Table 2-1 below for water quality guidelines.

  • Page 18: Boiler Room / Boiler Clearances

    Chapter 2 — Installation Because of the variables involved, no single boiler compound can be considered a cure-all; nor is it advisable to experiment with homemade treating methods. A sound treatment program should include a periodic analysis of the water in the system. Warning Inadequate or improper water treatment will shorten the life of the boiler, and could result in a hazardous condition.

  • Page 19: Connection Locations

    Chapter 2 — Installation 18” 36” 18” 18” BOILER SIZE 10 15 20 25 30 40 50 60 70 80 CLEARANCE* 36 36 36 36 36 36 36 36 42 42 *Electrical panel clearance - sufficient for burner door swing and tube removal see table Minimum required service clearances Figure 2-3 Minimum clearances...
  • Page 20 Chapter 2 — Installation 2.5.3 Gas Connections Gas Shut Off Valve and Gas Filter - A manually operated shut-off valve and pressure regulator are provided as standard on the CFH boiler (Figure 2-6). In some cases, local regulations may require the installation of an approved gas filter between the gas shut-off valve and the boiler.
  • Page 21 Chapter 2 — Installation Table 2-2 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* 1,060 1,580 3,050...
  • Page 22 Chapter 2 — Installation Gas Header - For multiple unit installations, a single common gas header is recommended with individual takeoffs for each boiler (See Figure 2-7). Boiler gas manifold piping should be sized based on volume requirements and lengths between each boiler and the fuel main header. Table 2-4 indicates the proper sizing for multiple units of equal size (assuming <...
  • Page 23 Chapter 2 — Installation G as header - size for boiler room capacity and to minimize pressure loss D rip leg required for any vertical run of piping Figure 2-8 Example gas piping <1 psig Table 2-4 Pipe sizing for multiple units 10HP 15HP 20HP...
  • Page 24 Chapter 2 — Installation 2.5.4 Boiler Water-Side Connections A pressure relief valve (Safety Valve), provided with the boiler, must be installed in the mounting provided. Use pipe sealing compound and a flat sided wrench when securing the Safety relief valve. Do not use a pipe wrench and do not over tighten the relief valve.

  • Page 25: Electrical Connections & Wiring Diagrams

    Chapter 2 — Installation 2.6-ELECTRICAL CONNECTIONS & WIRING DIAGRAMS Notice The blower signal wiring must be isolated from the blower power wiring and the high voltage ignition cables. Refer to Figure 2-10 for CFH wiring and cable connections. A qualified electrician or service technician must make the electrical connections to the boiler; all local electrical and building codes should be adhered to.
  • Page 26 Chapter 2 — Installation Figure 2-10 CFH wiring and cable connections 2-12 Part No. 750-295...
  • Page 27 Chapter 2 — Installation Figure 2-10 CFH wiring diagram, typical 10-60 HP Part No. 750-295 2-13...
  • Page 28 Chapter 2 — Installation Figure 2-11 CFH wiring diagram, typical 70-80 HP BLOWER/CCT FUSE 2-14 Part No. 750-295...
  • Page 29 Combustion Air Requirements ......3-9 Maximum Vent Lengths ....... . 3-13 www.cleaverbrooks.com...

  • Page 30: Chapter 3 - Flue And Combustion Air Venting

    Chapter 3 — Flue and Combustion Air Venting 3.1-VENTING CONNECTIONS — GENERAL ® Proper installation of flue gas exhaust venting is critical for the efficient and safe operation of the ClearFire boiler. Definition of Appliance Categories Boilers are divided into four categories based on the pressure and temperature produced in the exhaust stack and the likelihood of condensate production in the vent.

  • Page 31: Vent Terminal Location

    Chapter 3 — Flue and Combustion Air Venting 3.3-VENT TERMINAL LOCATION Give special attention to the location of the vent termination to avoid possibility of property damage or personal injury. 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 32 Chapter 3 — Flue and Combustion Air Venting 6. Less than 1 ft. (300mm) above grade level. 7. Within 3 ft. (1m) of a window or door which can be opened in any building, any non-mechanical air supply inlet to any building to the combustion air inlet of any other appliance. 8.

  • Page 33: Horizontal Thru-Wall Venting, Inside Air

    Chapter 3 — Flue and Combustion Air Venting 3.4-HORIZONTAL THRU-WALL VENTING, INSIDE AIR (Category III) For boilers connected to gas vents or chimneys, vent installations shall be in accordance with Part 7, Venting of Equipment, of the latest edition of National Fuel Gas Code, or in Canada, the latest edition of CAN/CGA-B 149.1 and.2 Installation Code for Gas Burning Appliances and Equipment, or applicable...

  • Page 34: Horizontal Thru-Wall Flue Vent Termination

    Chapter 3 — Flue and Combustion Air Venting • Vent be installed with a slight downward slope of at least 1/8” per foot of horizontal run to the stack terminal. • The flue venting is to be insulated through the length of the horizontal run.

  • Page 35: Vertical Venting, Inside Air

    Chapter 3 — Flue and Combustion Air Venting 3.7-VERTICAL VENTING, INSIDE AIR (Category III) Central Heating Figure 3-4 Vertical stack, 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 36: Vertical Venting, Direct Vent Combustion Air

    Chapter 3 — Flue and Combustion Air Venting 3.8- VERTICAL VENTING, DIRECT VENT COMBUSTION AIR (Category III) WITH PARAPET WALL Figure 3-5 Vertical stack with direct vent combustion air These installations utilize the boiler mounted blower to draw combustion air from outside and vent combustion products to the outside.

  • Page 37: Combustion Air Requirements

    Chapter 3 — Flue and Combustion Air Venting 3.9-COMBUSTION AIR REQUIREMENTS Warning COMBUSTION AIR TEMPERATURE RANGE: C to 50 C / 32 F to 122 When using direct vent combustion in cold climates, special care must be taken to observe combustion air temperature RELATIVE HUMIDITY: limits.
  • Page 38 Chapter 3 — Flue and Combustion Air Venting inches from the bottom of the room. See Figure 3-6; refer to the NFGC for additional information. All Air From Outdoors - If all combustion VENT air will be received from outside the building (the mechanical room is linked with outdoors),...
  • Page 39 Chapter 3 — Flue and Combustion Air Venting Engineered Design When determining boiler room air requirements for an unconfined space the “Engineered Design” method may be used. Following this method, consideration must be given to the size of the room, airflow and velocity of air as follows: A.
  • Page 40 Chapter 3 — Flue and Combustion Air Venting Example of required air openings (Engineered Method): Determine the area of the boiler room air supply openings for (2) 60 horsepower Model CFH boilers at 750 feet elevation. The air openings will be 5 feet above the floor level. Total boiler horsepower (bhp): 60 x 2 = 120 bhp From F.3 above, total air required = 120 bhp x 10 = 1200 cfm.

  • Page 41: Maximum Vent Lengths

    Chapter 3 — Flue and Combustion Air Venting 48" M inimum A ir Intake (w/ Screen) Flue G as V ent (w/ Screen) 48" M inimum 12" M inimum ClearFire ® Boiler Figure 3-10 Direct vent combustion 3.10-MAXIMUM VENT LENGTHS Based on horizontal venting.
  • Page 42 Chapter 3 — Flue and Combustion Air Venting 3-14 Part No. 750-295...
  • Page 43 Falcon Control Functions and Customer Interface ....4-25 Warning The boiler and its gas connection must be leak tested before placing the boiler in operation. www.cleaverbrooks.com...

  • Page 44: Chapter 4 - Commissioning

    Chapter 4 — Commissioning 4.1-OPERATING CONDITIONS Warning When using direct vent combustion in cold climates, special care must be taken to observe combustion air temperature limits. Failure to follow this precaution may lead to equipment damage or unsafe operation. • The installation site should be as free as possible from vibration, dust, and corrosive media •...

  • Page 45: Water Level Controls

    Chapter 4 — Commissioning 4.4-WATER LEVEL CONTROLS The LWCO/pump control and ALWCO control boards are located in the boiler control panel. The LWCO control is connected to conductance probes mounted within the external water column. This column has 4 probes used for the following functions: low water cut-off, pump on, pump off, and high water alarm (optional).

  • Page 46: Model Cfh Boiler / Burner Controls

    Chapter 4 — Commissioning 4.5-MODEL CFH BOILER / BURNER CONTROLS The Model CFH boiler uses the Falcon boiler control system. Primary controller functions include: • Flame supervision • Burner sequencing • PID Modulation control • Operating LImit Control Additional features include: •...
  • Page 47 Chapter 4 — Commissioning 4.6.1 Display Setup When power is turned on (Control Circuit-Blower Switch is ON), the Note: The “Home” icon at the upper Home page will appear on the CB Falcon display. left of the display screen always returns to the Home Page.
  • Page 48 Chapter 4 — Commissioning After making changes, press <Save> and cycle power to the controller. 4.6.2 Boiler Status Pressing the Falcon icon on the Home Page takes the user to the Status page, which summarizes boiler status and allows navigation to the configuration, operational, and diagnostic areas of the CB Falcon interface.
  • Page 49 Chapter 4 — Commissioning The Demand display will show one of the following: Burner switch off Off (burner switch on but no demand) Steam 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 status of the pump/auxiliary relay contacts Modulation shows fan speed RPM settings for Demand, Limited, and Override rates Setpoints shows the ON, Modulation, and OFF setpoints.
  • Page 50 Chapter 4 — Commissioning The user will be notified when a password is required to make changes. Press the Login button to enter the password. The default Service level password can be changed in the System Identification and Access section under the Configuration menu. LOGIN The burner is enabled from the Operation page by turning the <Burner switch>...

  • Page 51: Controller Configuration

    Chapter 4 — Commissioning • Whether the alarm contact closes or not is programmable for each alert by the OEM. Alerts are logged in a 15-item volatile alert history sorted in chronological order. Only one instance of each alert code occurs in the history, corresponding to the most recent occurrence of that alert. See also Chapter 5, Section 5.10 - Troubleshooting.
  • Page 52 Chapter 4 — Commissioning Table 4-3 CB Falcon factory parameter settings - Model CFH (Continued) Modulation Configuration Steam forced rate time Service minutes Modulation Configuration Steam forced rate Service 1000 2000 6500 Modulation Configuration Analog input hysteresis Service Modulation Configuration* Burner switch User Modulation Configuration* Firing rate control User...
  • Page 53 Chapter 4 — Commissioning Table 4-3 CB Falcon factory parameter settings - Model CFH (Continued) Annunciation Configuration Annunciator 6 location Annunciation Configuration Annunciator 6 short name Annunciation Configuration Annunciator 6 long name LOW GAS PRES- Annunciation Configuration Annunciator 7 location Service Unused Annunciation Configuration Annunciator 7 short name...
  • Page 54 Chapter 4 — Commissioning Table 4-3 CB Falcon factory parameter settings - Model CFH (Continued) Burner Control Interlocks PII enable Service Disabled Burner Control Interlocks LCI enable Read Only Enabled Burner Control Interlocks Interrupted air switch (IAS) Read Only Enable during purge & Burner Control Interlocks ILK/IAS open response Read Only...
  • Page 55 Chapter 4 — Commissioning 4.7.1 Changing Parameter Settings To access the CB Falcon configuration menu, press <Configure> on the Status page. From the Configuration Menu, select the parameter group to be changed. 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.

  • Page 56: Burner Sequence

    Chapter 4 — Commissioning Safety Parameters When configuring safety parameters an additional verification step is required to confirm the changes. 1. When a safety parameter is changed, a lockout will result: “Waiting for safety data verification”. Silence alarm if desired and press <OK> to continue. 2.

  • Page 57: Fan Speed Settings

    Chapter 4 — Commissioning Basic burner sequencing: 1. Heat request detected (Setpoint minus On Hysteresis); LCI limits and steam demand detected (terminals J6 3 and J8 2. The Auxiliary Start Interlock relay is switched on (relay contact closes). 3. After a system Safe Start Check, the Blower (combustion air fan) is started 4.

  • Page 58: Operating And High Limit Controls

    Chapter 4 — Commissioning 4.10-OPERATING AND HIGH LIMIT CONTROLS The operating (OLC) and high pressure limit (HLC) controls are OLC HLC externally mounted to the control panel. The setting of the OLC should be slightly higher than the configured set point plus the hysteresis off value set in the CB Falcon control.

  • Page 59: High Turndown Applications (70 & 80 Hp)

    Chapter 4 — Commissioning 5. Depress gas pressure switches to reset. 6. Measure gas pressure at inlet to LP gas valve – should be 11”w.c. minimum. 7. Access boiler control Configuration menu. Press <Login>. Enter service level password. Press <OK>. 8.
  • Page 60 Chapter 4 — Commissioning 2. Review available gas pressure to assure it is compatible with the main gas regulators upstream of the Model CFH gas train. Note: The maximum rated inlet pressure to the CFH gas train is 1 psig (28"...
  • Page 61 Chapter 4 — Commissioning • Before proceeding, review Section 4.3 - Control Setpoints for initial LGPS, HGPS, and CAPS settings. Note: Close the downstream manual gas shut-off valve before checking pressure switches and CAPS. While performing the following safety checks, use the CB Falcon Annunciation screen to monitor the status of the circuits involved.
  • Page 62 Chapter 4 — Commissioning HGPS and GAS VALVE 1. Open the upstream manual shutoff valve and wait a few moments for gas pressure to rise. 2. Lower the switch setting to minimum. 3. Initiate burner sequence. During the main flame establishing period, verify gas valve LEDs energize, indi- cating both safety shutoff valves open.
  • Page 63 Chapter 4 — Commissioning 4.13.5 Low and High Fire Adjustments All CFH 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. Adjustments are made using a TORX® T40 (low fire adjustment) and 3 mm hex wrench (main gas choke).
  • Page 64 Chapter 4 — Commissioning Figure 4-20 High fire adjustment - low gas pressure option 4.13.6 Modulation OFF point Prior to setting combustion, the steam pressure off hysteresis point should be adjusted upward to avoid nuisance shutdowns while the burner is under manual control. This parameter is located under Steam Configuration.
  • Page 65 Chapter 4 — Commissioning Manual Modulation - use the procedure below to change the burner firing rate manually. 1. On the CB Falcon Operation screen, press the 2. A numeric keypad will appear, Firing rate display. showing the current firing rate and operating mode.* 3.

  • Page 66: Boil-Out Of A New Unit

    Chapter 4 — Commissioning 7. Modulate to low fire and fine tune offset screw to obtain desired O2% (6.0% - 7.0%). Verify adjustments by modulating back and forth between low and high fire. While setting combustion observe gas pressure at low fire and at high fire. Ensure pressure is within limits shown in Table 4-5.

  • Page 67: Post Start-Up Checkout Procedure

    Chapter 4 — Commissioning 13. After closing the handholes and reinstalling safety or relief valves, fill the boiler and fire it until the water is heated to at least 180 F to drive off any dissolved gases. Table 4-6 CFH Boiler Water Capacity Boiler Horsepower 10-15 HP 20-25 HP...
  • Page 68 Chapter 4 — Commissioning Set Point, TOD Set Point, Hysteresis On, Hysteresis Off, and PID load control The set point is the value that the boiler’s PID load control attempts to maintain in order to meet the steam demand. The modulating set point can be adjusted at the Operation page or under the Steam Configuration parameter group.
  • Page 69 Chapter 4 — Commissioning needs to be established. The steam set point determines the value for 20mA; “minimum steam pressure” determines the value for 4mA. Depending on the quality of the remote input signal, the modulation rate or operating set point may fluctuate unnecessarily because of small changes in the measured current signal.
  • Page 70 Chapter 4 — Commissioning Figure 4-21 Trend Screen Control Snapshot For diagnostic purposes, the Falcon display is able to store a record of the control status and/or configuration parameter settings. To use this feature: 1. From the Home screen press <Setup>. 2.
  • Page 71 Chapter 4 — Commissioning Figure 4-23 Control Snapshot Screen 4. When the chosen snapshot appears, press <Save>, select a name, and press <OK> to save the snapshot to the Falcon display internal memory. Press the back arrow to return to the Control Snapshot List screen.
  • Page 72 Chapter 4 — Commissioning Modbus for CFH Steam Decimal Parameter R/W Format Description 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) 8=Interlock (ILK) 7=Alarm 6=Main valve...
  • Page 73 Chapter 4 — Commissioning Modbus for CFH Steam (Continued) Decimal Parameter R/W Format Description 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 50=Ignition 51=Firing 52=Postpurge 0021 0033 Burner control state Burner control sequence (I/O) state. Different states exist between res- idential &...
  • Page 74 Chapter 4 — Commissioning Modbus for CFH Steam (Continued) Decimal Parameter R/W Format Description 1=ILK 2=PII 3=LCI 11=Annunciator 1 12=Annunciator 2 13=Annunciator 3 14=Annunciator 4 15=Annunciator 5 16=Annunciator 6 17=Annunciator 7 18=Annunciator 8 0026 0038 Sequence time Running time for timed burner control operation (seconds) 0027 0039 Delay time...
  • Page 75 Chapter 4 — Commissioning Modbus for CFH Steam (Continued) Decimal Parameter R/W Format Description 1=Lead/Lag simple slave enabled for EnviraCom master, 2=Lead/Lag simple slave enabled for Global Modbus master, 3=Lead/Lag full slave enabled for Global Modbus master 0235 0565 Slave command R/W U16 Bit map: 15=Slave demand request, 14=Slave suspend startup, 13=Slave run fan request, 12=Turn on System pump with overrun,...
  • Page 76 Chapter 4 — Commissioning Modbus for CFH Steam (Continued) Decimal Parameter R/W Format Description EXTENDED CH CONFIGURATION 0240 0576 CH modulation backup sensor R/W U16 Alternative modulation sensor when primary CH sensor is bad: 0=No backup sensor, 1=Header sensor 0241 0577 CH Modbus STAT R/W U16...
  • Page 77 Lay-up ..........5-12 www.cleaverbrooks.com...

  • Page 78: Chapter 5 - Service And Periodic Maintenance

    Chapter 5 — Service And Periodic Maintenance 5.1-GENERAL A well-planned maintenance program will help avoid unnecessary downtime or costly repairs, and will promote safety and aid boiler inspectors. It is recommended that a boiler room log or record be maintained. Recording of daily, weekly, monthly, and yearly maintenance activities will help to obtain economical and lengthy service from the equipment.

  • Page 79: Water Column Blowdown

    Chapter 5 — Service And Periodic Maintenance Manual Blowdown Procedure Blowdown is most effective when the boiler is under a light load, and when the water level is at the Normal Operating Water Level. Be sure the blowdown piping is in proper operating condition. Waste should be piped to a point of safe discharge. Open the quick-opening valve.
  • Page 80 Chapter 5 — Service And Periodic Maintenance Open Open Closed 1. Open Water Column blowdown valve (5 to 3. Close upper gauge glass isolation valve. 10 sec.) to discharge water from WC. 4. Open gauge glass blowdown valve to 2. Close WC blowdown valve. discharge water from gauge glass.

  • Page 81: Fireside Cleaning Procedure/Disassembly

    Chapter 5 — Service And Periodic Maintenance Use a proper size rubber packing. Do not use loose packing, which could be forced below the glass and possibly plug the valve opening. Close the valves when replacing the glass. Slip a packing nut, packing washer, and packing ring onto each end of the glass.

  • Page 82: Ignition Electrodes

    Chapter 5 — Service And Periodic Maintenance If any adverse conditions are observed during operation or inspection, contact your authorized Cleaver-Brooks service representative. When inspection and servicing are completed, reassemble the burner in reverse order. When re-fastening burner door: 1) Coat bolt threads with anti-seize compound. 2) Tighten bolts gradually in a diagonal pattern to ensure a secure fit (see Figure 5-5).

  • Page 83: Uv Scanner

    Chapter 5 — Service And Periodic Maintenance Caution The dimensions on the ignition electrodes are not easily adjustable. Bending the rods can cause dam- age to the insulating material. In addition, a bent electrode will have a tendency to return to its original shape when heated.

  • Page 84: Adjustable Flame Rod

    Chapter 5 — Service And Periodic Maintenance 5.7-ADJUSTABLE FLAME ROD (10-60HP) AXIAL ROTATIONAL A low-fire flame signal of 5-15 and above is considered good. If the flame signal Adjustment Adjustment is lower, try rotating the flame rod slightly or adjusting the axial position to obtain a stronger signal.

  • Page 85: Waterside Inspection/Cleaning

    Chapter 5 — Service And Periodic Maintenance 5.8-WATERSIDE INSPECTION/CLEANING Waterside inspection frequency may depend upon the local jurisdiction and inspector but it is recommended that after the first year of operation, a waterside inspection take place. To inspect the boiler on the waterside, first shut off the electric power to the burner.

  • Page 86: Troubleshooting

    Chapter 5 — Service And Periodic Maintenance Avoid excessive operation of the safety valve; a valve that is opened too frequently can develop leaks. Safety valves should be operated only often enough to assure that they are in good working order. When a pop test is required, raise the operating pressure to the set pressure of the valve, allowing it to open and reseat as it would in normal service.
  • Page 87 Chapter 5 — Service And Periodic Maintenance Table 5-1 CFH Troubleshooting Problem Possible Cause Suggested Remedy Touch screen does not work prop- Screen out of calibration Calibrate touch screen. From Home page, erly; screen buttons malfunctioning press <Setup>, <Advanced Setup>, <Diagnostics>...

  • Page 88: Lay-Up

    Chapter 5 — Service And Periodic Maintenance Display Diagnostics For problems specific to the Falcon display/operator interface, diagnostic functions are available under the Advanced Setup menu. To access display diagnostics: 1. Press <Setup> on the Home Page. 2. Press <Display Diagnostics> on the Setup Page. Date and Time The Setup menu also allows access to system date and time settings.
  • Page 89 Chapter 5 — Service And Periodic Maintenance tive to minimize corrosion. Internal water pressure should be maintained at greater than atmospheric pres- sure. Nitrogen is often used to pressurize the vessel. Whichever method of lay-up is used, a periodic re-check of fireside and waterside conditions is recom- mended during lay-up.
  • Page 91 Sealed Combustion Kits ........29 Direct Vent Combustion Kits ....... . 29 www.cleaverbrooks.com...

  • Page 92: Control Panel 10-60 Hp

    Chapter 6 — Model CFH Parts 6.1-CONTROL PANEL 10-60 HP Part No. 750-295...

  • Page 93: Control Panel 70-80 Hp

    Chapter 6 — Model CFH Parts 6.1-CONTROL PANEL 70-80 HP Part No. 750-295...

  • Page 94: Burner Assembly 10-60 Hp

    Chapter 6 — Model CFH Parts 6.2-BURNER ASSEMBLY 10-60 HP 78” 78” 85” 85” 110” 110” 130” 130” *50-60 HP - if burner door manufactured prior to 03/2019 use 853-00982 Part No. 750-295...

  • Page 95: Burner Assembly 70-80 Hp

    Chapter 6 — Model CFH Parts 6.3-BURNER ASSEMBLY 70-80 HP ITEM PART NO DESCRIPTION 132-00592-000 DOOR, TOP INSULATED 380-01115-000 GASKET, ADAPTER PLATE TO DOOR 380-01208-000 BURNER CAN 380-00011-000 ADAPTER PLATE, CFH 70-80HP 380-01038-000 GASKET, ADAPTER PLATE TO BLOWER (380C01038) SEE TABLE BLOWER, COMBUSTION AIR, 240V, 50/60HZ 853-01476-000 O-RING, BUNA-N, 70 DUROMETER, PARKER #2-365...

  • Page 96: Gas Train

    Chapter 6 — Model CFH Parts 6.4-GAS TRAIN Standard gas train 10 HP ITEM PART NO. DESCRIPTION 940-07162-000 VALVE, GAS, COMBO, 120V, .5" NPT. C/W .5" ADAPTER 800-00092-000 ADAPTER, 1" NPT PIPE 941-01944-000 VALVE, BUTTERBALL, BRONZE, 1" NPT. 817-02414-000 LOW GAS PRESSURE SWITCH 817-02420-000 HIGH GAS PRESSURE SWITCH 918-00032-000...
  • Page 97 Chapter 6 — Model CFH Parts Standard gas train 15 HP ITEM PART NO. DESCRIPTION 940-07163-000 VALVE, GAS, 120V , .75" NPT. C/W .75" ADAPTER. 800-00092-000 ADAPTER, 1" NPT PIPE 941-01944-000 VALVE, BUTTERBALL, BRONZE, 1" NPT. 825-00239-000 LEAKAGE TEST COCK, .125" NPT 918-00032-000 GAS PRESSURE REGULATOR, MAXITROL #RV61, 1"...
  • Page 98 Chapter 6 — Model CFH Parts Standard gas train 20 HP ITEM PART NO. DESCRIPTION 800-00092-000 ADAPTER, 1" NPT PIPE 941-01944-000 *Varies* 940-07163-000 VALVE, GAS, 120V , .75" NPT. C/W .75" ADAPTER. 817-02414-000 LOW GAS PRESSURE SWITCH 817-02420-000 HIGH GAS PRESSURE SWITCH 918-00032-000 GAS PRESSURE REGULATOR, MAXITROL #RV61, 1"...
  • Page 99 Chapter 6 — Model CFH Parts Standard gas train 25 HP ITEM PART NUMBER DESCRIPTION 800-00092-000 ADAPTER, 1" NPT Pipe 941-01944-000 VALVE, BUTTERBALL, BRONZE, 1" NPT. 940-07164-000 VALVE, GAS, COMBO, 120V, 1" NPT. C/W 1" ADAPTER 817-02414-000 LOW GAS PRESSURE SWITCH 817-02420-000 HIGH GAS PRESSURE SWITCH 918-00032-000...
  • Page 100 Chapter 6 — Model CFH Parts Standard gas train 30 HP 6-10 Part No. 750-295...
  • Page 101 Chapter 6 — Model CFH Parts Standard gas train 40 HP ITEM PART NO. DESCRIPTION 817-02414-000 LOW GAS PRESSURE SWITCH 817-02420-000 HIGH GAS PRESSURE SWITCH 941-01945-000 VALVE, BUTTERBALL, 1-1/4" NPT. 800-00093-000 ADAPTER, 1.25" NPT PIPE 940-07165-000 VALVE, GAS, COMBO, 120V, 1.25" NPT. C/W 1.25" ADAPTER 825-00239-000 LEAKAGE TEST COCK, .125"...
  • Page 102 Chapter 6 — Model CFH Parts Standard gas train 50-60 HP ITEM PART NO. DESCRIPTION 800-00093-000 ADAPTER, 1.25" NPT PIPE 941-01945-000 BUTTER BALL VALVE, 1-1/4" NPT. 941-01946-000 BUTTERBALL VALVE, BRONZE, 1-1/2" NPT. 918-00730-000 GAS PRESSURE REGULATOR 940-07235-000 GAS VALVE, COMBO, 120VAC 1.25" NPT. C/W 1.25" ADAPTER 817-02420-000 HIGH GAS PRESSURE SWITCH 817-02414-000...
  • Page 103 Chapter 6 — Model CFH Parts Standard gas train 70-80 HP ITEM PART NO DESCRIPTION 800-00103-000 ADAPTER 800-00101-000 ADAPTER, PIPE 800-00102-000 ADAPTER, PIPE 939-00642-000 BULK TUBING, ALUMINUM 825-00030-000 COCK, GAS SERVICE, TEE HEAD 825-00029-000 COCK, GAS SERVICE, TEE HEAD 845-00468-000 CONNECTOR 845-00312-000 CONNECTOR...

  • Page 104: Low Gas Pressure Option

    Chapter 6 — Model CFH Parts 6.4.1 Low Gas Pressure Option PART NO 30-40 HP 50-60 HP ITEM DESCRIPTION 800-00092-000 ADAPTER 800-00103-000 ADAPTER 800-00101-000 ADAPTER 800-00107-000 800-00105-000 ADAPTER 939-01129-000 BULK STEEL TUBING 941-01945-000 941-01946-000 VALVE, BUTTERBALL 845-03379-000 CONNECTOR 817-02420-000 HIGH GAS PRESSURE SWITCH 825-00239-000 LEAKAGE TEST COCK 798-06720-000...

  • Page 105: Gas Train, Dual Fuel

    Chapter 6 — Model CFH Parts 6.4.2 Gas Train, Dual Fuel 30 HP dual fuel Part No. 750-295 6-15...
  • Page 106 Chapter 6 — Model CFH Parts 40 HP dual fuel 6-16 Part No. 750-295...
  • Page 107 Chapter 6 — Model CFH Parts 50-60 HP dual fuel Part No. 750-295 6-17...
  • Page 108 Chapter 6 — Model CFH Parts 70-80 HP dual fuel ITEM PART NO DESCRIPTION 800-00103-000 ADAPTER 800-00101-000 ADAPTER, PIPE 800-00093-000 ADAPTER 800-00102-000 ADAPTER, PIPE 939-00642-000 BULK TUBING, 11.19" LG. 939-00642-000 BULK TUBING, 18.25" LG. 939-00642-000 BULK TUBING, 23.63" LG. 825-00029-000 COCK, GAS SERVICE, TEE HEAD 825-00030-000 COCK, GAS SERVICE, TEE HEAD...

  • Page 109: Gas Train, Dual Fuel, W/Low Gas Pressure Option

    Chapter 6 — Model CFH Parts 6.4.3 Gas Train, Dual Fuel, w/Low Gas Pressure Option 30 HP (dual fuel lgp) Part No. 750-295 6-19...
  • Page 110 Chapter 6 — Model CFH Parts 40 HP (dual fuel lgp) 6-20 Part No. 750-295...
  • Page 111 Chapter 6 — Model CFH Parts 50-60 HP (dual fuel lgp) Part No. 750-295 6-21...

  • Page 112: Gas Train, Propane

    Chapter 6 — Model CFH Parts 6.4.4 Gas Train, Propane 30 HP propane 6-22 Part No. 750-295...
  • Page 113 Chapter 6 — Model CFH Parts 40 HP propane Part No. 750-295 6-23...
  • Page 114 Chapter 6 — Model CFH Parts 50-60 HP propane 6-24 Part No. 750-295...
  • Page 115 Chapter 6 — Model CFH Parts 70-80 HP propane ITEM PART NO DESCRIPTION 800-00103-000 ADAPTER 800-00101-000 ADAPTER, PIPE 800-00102-000 ADAPTER, PIPE 939-00642-000 BULK TUBING 27.50" LG. 825-00030-000 COCK, GAS SERVICE, TEE HEAD 825-00029-000 COCK, GAS SERVICE, TEE HEAD 845-00468-000 CONNECTOR 845-00312-000 CONNECTOR 845-00221-000...

  • Page 116: Boiler Controls

    Chapter 6 — Model CFH Parts 6.5-BOILER CONTROLS - NOT SHOWN 5105 5105 - NOT SHOWN - NOT SHOWN SEE TABLE SAFETY RELIEF VALVE ITEM 9 - SAFETY RELIEF VALVE Boiler HP 15-20 25-30 940-5073 940-5073 940-5072 940-4993 940-4993 940-5297 940-5297 940-5632 150#...

  • Page 117: Recommended Spare Parts List

    Chapter 6 — Model CFH Parts 6.6-RECOMMENDED SPARE PARTS LIST see table UV SCANNER see next page ADJUSTABLE FLAME ROD *LENGTHS ITEM 15 10-15 HP 20-25 HP 30-40 HP 50-60 HP 70-80 HP 78” 85” 110” 130” 140” 70-80HP 380-01115 380-01208 Part No.

  • Page 118: Uv Scanner

    Chapter 6 — Model CFH Parts 6.6.1 UV Scanner PART NO. DESCRIPTION 008-04052-000 BRACKET, MOUNTING, UV SCANNER 380-01032-000 GASKET, ELECTRODE 817-01743-000 SCANNER ASSEMBLY - UV 847-00420-000 BUSHING, HEX HD. 868-00209-000 CAPSCREW, SOCKET HD 952-00117-000 LOCK WASHER, #10 PLAIN STEEL 952-00144-000 WASHER, FLAT, 3/16"...

  • Page 119: Sealed Combustion Kits

    Chapter 6 — Model CFH Parts 6.7-SEALED COMBUSTION KITS Boiler HP Minimum Kit part number connection size 10-15 4” 880-02678 20-25 4” 880-02042 4” x 6” 880-02679 6” 880-02043 50-60 6” x 8” 880-02680 70-80 6” x 8” 880-04495 BLOWER VENTURI 6.8-DIRECT VENT COMBUSTION KITS Boiler HP...
  • Page 120 Web Address: http://www.cleaverbrooks.com...

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