CleaverBrooks ClearFire CFC-E Installation Manual
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CleaverBrooks ClearFire CFC-E Installation Manual

Condensing boiler
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Model CFC-E
®
ClearFire
Condensing Boiler
Installation Manual
Manual Part No. 750-459
1/2023

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Summary of Contents for CleaverBrooks ClearFire CFC-E

  • Page 1 Model CFC-E ® ClearFire Condensing Boiler Installation Manual Manual Part No. 750-459 1/2023...
  • Page 2 ! DANGER WARNING ! DANGER WARNING If the information in this manual is not followed ex- Improper installation, adjustment service or main- actly, a fire or explosion may result causing prop- tenance can cause equipment damage, personal erty damage, personal injury or loss of life. injury or death.
  • Page 3 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 UNDER- STAND ALL APPLICABLE SECTIONS OF THIS MANUAL. FAILURE TO FOLLOW ALL APPLICABLE WARNINGS AND INSTRUCTIONS MAY RESULT IN SEVERE PERSONAL INJURY OR DEATH.

  • Page 4: Table Of Contents

    CFC-E INSTALLATION MANUAL CONTENTS GENERAL INSTALLATION REQUIREMENTS........1-1 Boiler Placement .

  • Page 5: General Installation Requirements

    National Electrical Code ANSI/NFPA 70 and/or the Canadian Electrical Code Part I CSA C22.1. www.cleaverbrooks.com...

  • Page 6: Boiler Placement

    CFC-E Installation Manual 1.1 - Boiler Placement The Model CFC-E boiler is shipped fully assembled, ready for installation. There may be accessories that ship loose for field installation and wiring. Refer to specific order information for details. For handling instructions specific to larger sizes (3500-6000) see document CB-8597. 1.1.1 - Lifting by the base The boiler can be lifted by the base using a suitable fork lift or pallet jack.
  • Page 7 CFC-E Installation Manual 3.Remove 15-pole wire harness, 12-pole wire harness, and (2 each) ignition cables. Store cables in safe location. 4.Remove (4 each) star grasps which are used to secure burner door to boiler. 5.With burner door propped open, disconnect and remove (2 each) gas springs. 6.Carefully close burner door.
  • Page 8 CFC-E Installation Manual Figure 1-4 Standard rigging arrangement, 500-3000 1.1.3 - Lifting with crane (3500-6000) It is not necessary to remove the burner or lower casing. After removing the top casing sections the boiler can be lifted using the lifting lugs provided. Use of a spreader beam is recommended (and often necessary) to reduce the required length of the rigging chains.
  • Page 9 CFC-E Installation Manual 1.1.4 - Placing the boiler If the floor is not level, a raised pad slightly larger in length and width than the boiler base dimensions will make boiler installation and leveling easier. The boiler must be installed so that all components remain accessible for inspection, cleaning, or maintenance.

  • Page 10: Boiler Room Requirements

    CFC-E Installation Manual 1.2 - Boiler Room Requirements The boiler room must comply with all building codes and regulations. An adequate supply of combustion air is required for safe operation. Table 1-1: Boiler Room Requirements Temperature Range 32 to 122 deg F Boiler room (0 to 50 deg C) environmental...

  • Page 11: Using Glycol

    CFC-E Installation Manual A pre-start “boil out” of the vessel is not required; the interior boiler surfaces are cleaned following production of the pressure vessel. 1.3.2 - Retrofit Installations Older hydronic systems often contain impurities due to deteriorating piping, fittings, and other hydronic specialties.
  • Page 12 CFC-E Installation Manual High temperature glycol recommended. The glycol concentration determines the maximum allowable firing rate and output of the boiler(s). Please refer to the firing rate limitation and corresponding high fire speed settings vs. glycol% in the charts below. Maximum allowable boiler outlet/supply temperature: 185°...
  • Page 13 CFC-E Installation Manual CFC-E High Fire Blower Speed Se ng vs. % Glycol CFC-E 750 CFC-E 500/1000 6200 CFC-E 1500 6100 CFC-E 2000 6000 CFC-E 2500 5900 CFC-E 3000 5800 CFC-E 3500 5700 CFC-E 4000 5600 CFC-E 5000 5500 CFC-E 6000 5400 5300 5200...

  • Page 14: Gas Connections

    CFC-E Installation Manual 1.5 - Gas Connections COMBUSTION AIR INLET 1.5.1 - General Model CFC-E gas fired condensing boilers are full modulating input units that require appropriate gas supply pressure and volume for proper operation. The gas requirements specified in ELECTRICAL ELECTRICAL RACEWAY...
  • Page 15 CFC-E Installation Manual 1.5.4 - Gas Piping Gas Pressure Regulator Do not use a common regulator to regulate gas pressure for a multiple unit installation. Use a dedicated regulator for each CFC-E boiler. Note: Gas connection is at the rear of Shutoff Valve the boiler, left hand side as you face the rear of the boiler.
  • Page 16 CFC-E Installation Manual PRESSURE TEST 500/750/1000 1500/2000 LEAK TEST LEAK TEST LEAK TEST LEAK TEST PRESSURE TEST LEAK TEST LEAK TEST LEAK TEST (NOT SHOWN) LEAK TEST (NOT SHOWN) PRESSURE TEST 4000-5000 PRESSURE TEST 2500-3500 MAIN GAS VALVE PROOF-OF-CLOSURE VALVE LEAK TEST (NOT SHOWN) PRESSURE TEST...
  • Page 17 CFC-E Installation Manual 1.5.5 - Gas Supply Pipe Sizing For proper operation of a single unit or a multiple unit installation, we recommend that the gas piping be sized to allow no more than 0.3" w.c. pressure drop from the source (gas header or utility meter) to the final unit location.
  • Page 18 CFC-E Installation Manual Table 1-6: Gas Line Capacity - Schedule 40 Metallic Pipe Pipe Size Nominal 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4" Actual I.D. 1.049 1.380" 1.610" 2.067" 2.469" 3.068" 4.026" Length in feet **Maximum Capacity in Cubic Feet of Gas per Hour (cfh) 1,060 1,580 3,050...
  • Page 19 CFC-E Installation Manual Table 1-7: Gas Line Capacity - Schedule 40 Metallic Pipe Pipe Size Nominal 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4" Actual I.D. 1.049" 1.380" 1.610" 2.067" 2.469" 3.068" 4.026" Length in feet **Maximum Capacity in Cubic Feet of Gas per Hour (cfh) 1,390 2,090 4,020...
  • Page 20 CFC-E Installation Manual 1.5.6 - 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 headerFigure . Table 1-8 indicates the proper sizing for multiple units, and assumes <...
  • Page 21 CFC-E Installation Manual Figure 1-12 Gas Piping Part No. 750-459 1-17...

  • Page 22: Boiler Water Piping

    CFC-E Installation Manual 1.6 - Boiler Water Piping 1.6.1 - 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 23: Condensate Removal And Treatment

    CFC-E Installation Manual Table 1-9: Maximum flow rate through CFC-E boilers (U.S. flow rates) Temperature Differential (°F) Size Flow Rate GPM 1000 1500 2000 2500 3000 3500 4000 5000 6000 1130 Recommended flow rates relative to temperature drop so as not to exceed boiler output. Based on 94% nominal effficiency and maximum firing capacity Based on water only Table 1-10: Maximum flow rate through CFC-E boilers (metric flow rates)
  • Page 24 CFC-E Installation Manual 1.7.1 - Options The CFC-E uses one of several condensate removal options, depending on the application: (1) Condensate direct to drain (not recommended) - The condensate is piped directly to a drain through the piping and water trap supplied during installation (see Figure 1-16). •...
  • Page 25 CFC-E Installation Manual Pipe to the appropriate drain. Drain trap Neutralization tank Condensate To drain Float valve for makeup water Neutralization media Figure 1-17 Combo Trap/Tank The purpose of the integral water trap is to prevent flue gases from entering the boiler room. If cold water is not piped to the tank for integral trap functionality, then an external trap is required.
  • Page 26 CFC-E Installation Manual 1.7.2 - Condensate Piping for Multiple Boilers The number of condensate treatment tanks required for multiple boiler installations depends on the total amount of condensate produced by the system. As a general rule, CB recommends a maximum of 4 boilers per tank, with total BTU per tank not to exceed 8,000,000.

  • Page 27: Electrical Connections

    CFC-E Installation Manual 1.8 - Electrical Connections A qualified electrician or service technician must make the electrical connections to the boiler. For typical CFC-E electrical component mounting see the electrical diagram mounted on the inside of the removable front panel. For specific information on your boiler electrical system refer to the Cleaver-Brooks wiring diagram provided with the boiler.
  • Page 28 CFC-E Installation Manual LWCO, GAS VALVE, LGPS, HGPS, HAPS, CAPS RETURN TEMP, OUTLET TEMP, PWM UV SCANNER IGNITION CABLE Figure 1-21 Electrical Connections CFC-E 500-2000 1-24 Part No. 750-459...
  • Page 29 CFC-E Installation Manual 6000 only LWCO, GAS VALVE, LGPS, HGPS, HAPS, CAPS RETURN TEMP, OUTLET TEMP, PWM, UV SCANNER PILOT, DAMPER (DAMPER ONLY FOR 2500) IGNITION CABLE BLOWER Figure 1-22 Electrical Connections CFC-E 2500-6000 Part No. 750-459 1-25...

  • Page 30: Wiring Diagrams

    CFC-E Installation Manual 1.9 - Wiring Diagrams Figure 1-23 CFC-E Standard Wiring Diagram (500-2000) Note: Wiring diagrams shown are examples only. Installations may vary. For specific installations consult the wiring diagram provided with the boiler. sht. 1 of 2 1-26 Part No.
  • Page 31 CFC-E Installation Manual CFC-E Standard Wiring Diagram (500-2000) cont’d SEE NOTE 1 NOTES: OPTIONAL SIGNAL SPLITTER 880-10061 PROVIDES AN ADDITIONAL ANALOG OUTPUT AT J10 sht. 2 of 2 Part No. 750-459 1-27...
  • Page 32 CFC-E Installation Manual Figure 1-24 CFC-E Standard Wiring Diagram (2500) (REMOVE JUMPER) CONTROL 24VAC TRANSFORMER Blower BLOWER CC TIME DELAY CAPS HAPS HGPS LGPS LWCO Probe PUMP PUMP BOILER STATUS IGNITION TFMR ELECTRODES START PERMISSIVE (REMOVE JUMPER) INTERLOCK PROVE DEMAND SWITCH LOW WATER RESET / TEST CR-1...
  • Page 33 CFC-E Installation Manual CFC-E Standard Wiring Diagram (2500) cont’d Blower TACH 24 VDC + PWM OUTPUT OUTLET TEMP RETURN TEMP DEMAND SWITCH REMOTE 4-20mA HEADER or OUTDOOR TEMP DHW DEMAND REMOTE SET POINT OR REMOTE MOD REMOTE ENABLE (REMOVE JUMPER) 24 VAC TRANSFORMER LEAD-LAG NETWORK...
  • Page 34 CFC-E Installation Manual sht. 1 of 2 1-30 Part No. 750-459...
  • Page 35 CFC-E Installation Manual CFC-E Standard Wiring Diagram (3000-6000) cont’d sht. 2 of 2 Part No. 750-459 1-31...

  • Page 36: Seismic Mounting

    CFC-E Installation Manual 1.10 - Seismic Mounting Kits are available for seismic mounting. Seismic base dimensions shown below. Attach the 4 seismic brackets to the boiler as shown using the screws provided. Anchor the brackets using the pre-drilled holes. 500/750/1000 1500-3000 3500/4000 5000/6000...

  • Page 37: Stack And Intake Venting

    Category II, III or IV vent system. Using improper venting materials can result in property damage, personal injury, or death. Notice A vent cap is not recommended for condensing applications. Condensate can freeze on the vent cap, resulting in a blocked flue. See below for more information. www.cleaverbrooks.com...
  • Page 38 CFC-E Installation Manual 2.1.2 - Flue Venting The vent should be supported to maintain proper clearances from combustible materials. Use insulated vent pipe spacers where the vent passes through combustible roofs and walls. Cleaver-Brooks recommends the use of flue venting systems that are certified to UL 1738 or ULC S636. Vent material should be appropriate for the Appliance Category.
  • Page 39 CFC-E Installation Manual Canada Installations (refer also to the latest edition of CAN/CSA-B149.1 and B149.2): A vent shall not terminate: • Directly above a paved sidewalk or driveway which is located between two single family dwellings and serves both dwellings. •...

  • Page 40: Horizontal Through-Wall Venting / Inside Combustion Air

    CFC-E Installation Manual 2.1.4 - Boiler Air Inlet The boiler ships with both an air inlet screen and a direct vent collar (see illustration below). If room air will be used for combustion, install the air inlet screen; the collar may be discarded.
  • Page 41 CFC-E Installation Manual 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 horizontally through the wall to the outside. Adequate combustion and ventilation air must be supplied to the boiler room in accordance with the National Fuel Gas Code or, in Canada, the latest edition of CAN/CSA-B 149.1 and 149.2 Installation Code for Gas Burning Appliances and Equipment.

  • Page 42: Horizontal Through-Wall Venting / Direct Vent Combustion Air

    CFC-E Installation Manual 2.3 - Horizontal Thru-Wall Venting / Direct Vent Combustion Air Flue Gas Vent (w/Screen) 24” Minimum 18” Minimum Air Intake (w/Screen) 24” Minimum Figure 2-4 Horizontal Thru-wall Direct Venting System (Direct Vent Combustion Air/Stack Venting) 2.3.1 - Installation These installations utilize the boiler mounted blower to draw combustion air from outside and vent combustion gases to the outside.
  • Page 43 CFC-E Installation Manual 2.3.2 - Horizontal Thru-Wall Stack Vent Termination The stack vent cap MUST be mounted on the exterior of the building. The stack termination cannot be installed in a well or below grade. The stack termination must be installed at least one (I) foot above ground level and above normal snow levels.

  • Page 44: Vertical Venting / Inside Combustion Air

    CFC-E Installation Manual 2.4 - Vertical Venting / Inside Combustion Air THIS DRAWING IS DIAGRAMMATIC AND DOES NOT REPRE- SENT THE FULL EXTENT OF VENT- ING LAYOUT REQUIREMENTS. FINAL VENT ROUT- ING SHALL BE COORDINATED WITH GAS PIPING, COMBUSTION AIR DUCTING (IF APPLI- CABLE) AND OTHER INTERFERENCES...

  • Page 45: Vertical Venting / Direct Vent Combustion Air

    CFC-E Installation Manual 2.5 - Vertical Venting / Direct Vent Combustion Air THIS DRAWING IS DIAGRAMMATIC AND DOES NOT REPRESENT THE FULL WITH EXTENT OF VENTING LAYOUT REQUIREMENTS. FINAL VENT ROUTING SHALL BE COORDINATED WITH GAS PIPING, COMBUSTION AIR DUCTING PARAPET (IF APPLICABLE) AND OTHER INTERFERENCES THAT ARE POSSIBLE IN WALL...

  • Page 46: Stack & Combustion Air Duct Sizing

    CFC-E Installation Manual 2.6 - Stack & Combustion Air Duct Sizing Table 2-1 STACK & COMB. AIR DUCT SIZING Combustion Air Duct Flue Duct Connec- Max. Comb. Air Duct Max. Flue Duct Length* Boiler Connection (inches tion (inches diame- Length (equivalent feet) (equivalent feet) diameter) ter)
  • Page 47 CFC-E Installation Manual Use ‘wye’ connections (not ‘tees’) to connect each boiler to the common breeching (see Examples 1 and 2 below). Breeching should be sized upward when necessary to accommodate additional boilers (see Example 3). As a rule of thumb, the cross-sectional area of any ductwork downstream of a wye connection should be equal to or greater than the combined area of the incoming vent sections.
  • Page 48 CFC-E Installation Manual EXAMPLE 2 GOOD 10” 6” 6” EXAMPLE 3 GOOD 6” 10” 14” 6” 6” 6” 6” 6” 6” From Boilers GOOD 6” 6” 6” 8” 12” 16” From Boilers 8” 8” 8” From Boilers 2-12 Part No. 750-459...

  • Page 49: Combustion Air/Boiler Room Ventilation Requirements

    CFC-E Installation Manual 2.8 - Combustion Air/Boiler Room Ventilation Requirements The boiler(s) must be supplied with adequate quantities of uncontaminated air to support proper combustion and equipment ventilation. Air shall be free of chlorides, halogens, fluorocarbons, construction dust or other contaminants that are detrimental to the burner/boiler. If these contaminants are present, we recommend the use of direct vent combustion provided the outside air source is uncontaminated.
  • Page 50 CFC-E Installation Manual Figure 2-7 Two Opening Outside Wall Method Figure 2-8 Two Opening Ducted Method 2-14 Part No. 750-459...
  • Page 51 CFC-E Installation Manual C. One Opening Method (Figure 2-9) - One permanent opening, commencing within 12 inches of the top of the enclosure, shall be provided. 1. The equipment shall have clearances of at least 1 inch from the sides and back and 6 inches from the front of the appliance.
  • Page 52 CFC-E Installation Manual Figure 2-10 Two Opening Engineered Method E. Size the openings by using the formula: Area in square feet = cfm/fpm where cfm = cubic feet per minute of air fpm = feet per minute of air 2. Amount of Air Required (cfm). A.
  • Page 53 CFC-E Installation Manual Direct Vent Combustion If combustion air will be drawn directly from the outside by means of a duct connected to the boiler casing, use the following as a guide: 1. Provide for adequate ventilation of the boiler room or mechanical equipment room. 2.

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