Cleaver-Brooks ClearFire CFLC-4000 Manuals

Manuals and User Guides for Cleaver-Brooks ClearFire CFLC-4000. We have 1 Cleaver-Brooks ClearFire CFLC-4000 manual available for free PDF download: Operation And Maintenance Manual

Cleaver-Brooks ClearFire CFLC-4000 Operation And Maintenance Manual

Cleaver-Brooks ClearFire CFLC-4000 Operation And Maintenance Manual (291 pages)

Condensing Boiler 4,000-12,000 MBTU

Brand: Cleaver-Brooks | Category: Boiler | Size: 12 MB

Table of Contents

What to Do if You Smell Gas
2
Table of Contents
5
Section 1 Introduction

7
- Compact Firetube Design
  8
- High Efficiency
  8
- Advanced Construction
  8
- CFLC Features and Benefits
  8
- Standard Equipment
  8
  - The Burner
    9
  - Burner Gas Train
    9
  - Controls
    9
  - Gas Train
    9
  - Variable Speed Drive
    10
  - Component/Connection Locations
    10
  - Control Panel Interior
    10
  - VSD (Cutaway View)
    10
  - CFLC Cutaway
    11
  - Boiler Safety Valve(S) & Air Vent
    11
  - Return Temperature Sensor (Rear Casing & Insulation Not Shown)
    12
  - Stack Outlet, Water Outlet, and Combustion Air Inlet
    12
- Optional Equipment
  13
- Installation
  15
Section 2 Installation

16
- Boiler Assembly and Placement
  17
- Lifting and Moving the Boiler
  17
- Boiler Placement
  18
- Clearance Required (Inches)
  18
- Boiler Room
  19
- Flue Gas/Combustion Air
  19
  - Flue Gas / Combustion Air
    19
- Water Treatment
  19
- Boiler Flush
  20
- Using Glycol
  20
  - Glycol Application Guideline
    21
  - Notes/Limitations
    21
- Gas Connections
  22
  - General
    22
  - Gas Train Components
    22
  - CFLC Gas Train (Typical)
    22
  - Gas Pressure Requirements
    23
  - CFLC Gas Pressure Requirements
    23
  - Pilot Train
    23
  - Gas Piping
    24
  - Gas Supply Pipe Sizing
    25
  - Gas Line Capacity - Schedule 40 Metallic Pipe
    26
  - Gas Header
    27
  - Gas Header Piping
    27
- Boiler Water Piping
  28
  - Safety Valve
    28
  - Safety Relief Valve Piped to Safe Point of Discharge
    28
  - Dual Return Design
    28
  - Pressure Drop Curves
    29
  - Dual Returns
    29
  - Pressure Drop Curves, CFLC
    30
  - CFLC Flow Rates
    31
- Minimum Boiler Overpressure
  32
- Model CFLC Minimum over Pressure Requirements (100% Water)
  32
- Condensate Removal and Treatment
  32
- Electrical Connections
  35
- Electrical Connections CFLC
  36
- Wiring Diagram
  37
  - CFLC 6000 - 12000 Wiring Diagram, Single Fuel (Typical)
    37
  - Stack and Intake Vent Sizing and Installation
    39
- Venting Connections - General
  40
  - Appliance Categories
    40
  - Flue Venting System Design
    40
Section 3 Stack and Intake Vent Sizing and Installation

40
- Draft Tolerances
  41
- Vent Terminal Location
  41
- Vent Terminations
  41
- Venting Installation Tips
  43
- Support Piping
  43
- Vertical Venting / Inside Combustion Air
  44
- Vertical Venting / Direct Vent or Sealed Combustion Air
  45
- Venting for Multiple Units
  46
- Combustion Air / Boiler Room Ventilation Requirements
  48
  - Combustion Air Methods
    48
  - Air Supply - Unconfined Spaces
    49
  - Two Opening Outside Wall Method
    50
  - Two Opening Ducted Method
    51
  - Air Supply - Engineered Method
    52
  - One Opening Method
    52
  - Two Opening Engineered Method
    53
  - Boiler Room Air
    53
  - Direct Venting/Sealed Combustion
    54
  - Optional Direct Vent/Sealed Combustion Kit
    54
  - Commissioning
    57
- Operating Conditions
  58
- Filling Boiler
  58
- Control Setpoints
  58
Section 4 Commissioning

58
- Commissioning
  58
- Model CFLC Boiler / Burner Controller
  59
  - Opening Control Panel
    59
  - Controller Status Leds and Reset Button
    59
- Falcon Display/Operator Interface
  60
  - Home Page
    60
  - Status Page
    60
  - Operation Page
    61
  - Lockouts, Holds, and Alerts
    62
  - Falcon Display/Interface Page Flow
    62
- Controller Configuration
  63
  - Changing Falcon Parameter Settings
    63
  - Alarm Banner
    63
  - Configuration Menu
    64
  - Safety Parameters
    64
  - Confirming Safety Parameter Changes
    65
- Variable Speed Drive Settings
  65
- Program Module
  65
- Burner Sequence
  66
- Basic Burner Sequencing (Central Heat)
  66
- Fan Speed Settings
  66
- Initial Start-Up Procedure
  66
  - Premix Burner Technology - Full Modulation
    67
  - Power-Up
    68
  - Operation Check
    68
  - Lgps
    68
  - Annunciation Screen
    68
  - Caps
    69
  - HGPS and GAS VALVE
    69
  - Ignition Failure Check
    69
  - Pilot Fail Check
    69
  - Low Water Cutoff Check
    70
  - Low and High Fire Adjustments
    70
  - Modulation off Point
    70
  - Gas Valve Adjustments
    70
  - Setting Combustion
    71
  - Operation Screen
    72
  - High Air Pressure Switch Settings
    73
  - HAPS Settings
    73
  - Limit Controls Check
    73
- Post Start-Up Checkout Procedure
  73
- Falcon Control Functions and Customer Interface
  74
  - Remote Enable and Remote 4-20Ma Input
    74
  - Rate Limiting/Override
    75
  - Configurable Pump/Aux Relay Contacts
    76
  - Annunciator
    76
  - Lead/Lag Control (up to Eight Boilers)
    76
  - Modbus Communication
    76
  - Service and Maintenance
    77
- Disassembly for Inspection
  78
Section 5 Service and Maintenance

78
- Front Fireside Access
  79
- Rear Fireside Access
  79
- Reassembly
  80
- Ignition and Flame Detection Systems
  80
  - Ignition Electrode
    80
  - Pilot and UV Scanner
    81
  - Electrode Spacing CFLC
    81
- Troubleshooting
  82
  - Lockout Conditions
    82
  - Lockout 79 Outlet Temperature High Limit
    82
  - Light-Off Problems
    82
  - Troubleshooting Chart
    83
- Extended Shutdown
  84
- Emergency Shutdown
  84
- Parts
  85
- Recommended Spare Parts List Model CFLC
  86
Section 6 Parts

86
- Boiler Mechanical Assembly CFLC 4000/5000
  87
- Boiler Mechanical Assembly CFLC 6000/8000
  88
- Boiler Mechanical Assembly CFLC 10000/12000
  89
- Burner Assembly
  89
  - Burner Assembly CFLC 4000/5000
    90
  - Burner Assembly CFLC 6000/8000
    91
- Burner Assembly CFLC 10 000/12 000
  92
- UV Scanner
  92
- Dual Fuel Gas Trains
  101
  - Gas Train CFLC 10000/12000 Propane
    101
  - Dual Fuel 4000-5000
    102
  - Dual Fuel Nat. Gas 6000-12000
    103
- Pilot Gas Train
  104
- Control Panel
  105
- Cables and Cable Harness
  106
  - Cable Harness Layout
    106
  - Casing & Insulation 4000-5000
    107
  - Casing & Insulation 6000-8000
    109
  - Casing & Insulation 10000-12000
    111
- Optional Parts
  113
Appendix A - Falcon Parameters

115
- A-1 CFLC Falcon Parameters
  117
- Variable Speed Drive Parameters
  123
- PF 400 Integral Keypad
  125
- VSD Keypad Functions - PF 400
  125
Appendix B - VSD Parameters

125
Appendix C - Gas Valve

145
- Application
  148
- Ordering Information
  148
- Accessories
  149
- Product Numbers
  149
- Specifications
  150
- Description
  159
- Features
  159
- Approvals
  169
- Explanation of Symbols
  169
- Specification
  170
- Power Consumption Table
  170
- Mounting
  171
- Installation Position
  171
- SE Versions Ending in S22/S82/S302
  171
- Painting Valve
  172
- Protection from Radiant Heat
  172
- Electrical DIN Connector Ratings
  173
- Initial Setup
  173
- DIN Connector
  173
- Electrical DIN Connector Assembly & Wiring
  174
- MBC Overview & Impulse Lines
  175
- External Impulse Line (Option)
  176
- Assembly Instructions
  176
- Outlet Pressure
  177
- Low Fire Setting Using MBC Regulator
  177
- High Fire Setting Using Shutter
  177
- Changing Coil
  178
- Internal Filter
  180
- Test Ports
  181
- Pressure Taps
  181
- Valve Leakage Decay Test
  182
- Preparation for Leak Testing
  182
- Procedure for Testing Valve #1
  182
- After Completing the above Tests
  182
- Valve Leakage Bubble Test (Altern. Method)
  183
- Leak Test Procedure
  183
- Flow Cu Rve
  184
Appendix D - Falcon Alert, Hold, and Lockout Codes

187
- Falcon Holds and Lockouts
  189
- Falcon Alerts
  195
- Falcon Lead/Lag
  209
- Installation and Startup
  211
- Introduction
  211
Appendix E Falcon Lead Lag

211
Appendix F - Falcon Program Module

211
- Hydronic Systems
  212
- Steam Systems
  212
- System Requirements
  212
- Header Press. Transmitter (Steam)
  218
- Outdoor Temperature Sensor
  218
- Sensor Configuration (Steam)
  218
- Connecting to a Building Energy Management System
  219
- Lead Lag Master Configuration
  219
- Lead Lag Master Configuration Parameters (Hydronic)
  220
- Lead Lag Master Configuration Parameters (Steam)
  220
- Lead Lag Master Configuration Parameters - Advanced Settings, Hydronic
  220
- Demand Switch
  223
- Lead Lag Slave Configuration
  223
- On, off Hysteresis
  223
- PID Gain
  223
- Copying Parameters to Remaining Slaves
  224
- Lead Lag Slave Configuration Parameters
  224
- Loading a PIM
  225
- Enable Master
  226
- Outdoor Reset Configuration
  226
- Monitoring System Performance
  227
- ODR Curve
  227
- Startup
  227
- To Start the Lead Lag System
  227
- Lead Lag Home Page
  228
- Example Systems
  229
- Falcon LL with EMS for Remote Enable/Remote Setpoint
  231
- Falcon Lead Lag with EMS for Remote Comms/Monitoring
  232
- Typical Steam System
  233
- Isolation Valve Control
  234
- Primary Pumping
  234
- System Pump Enable (Optional)
  234
- Primary/Secondary Piping
  235
- Primary with Dedicated System/Boiler Pumps
  236
- Domestic Hot Water Priority on Slave
  237
- Pump Control Block (Pcb) Examples
  238
- Boiler Pump
  239
- DHW Pump
  240
- Central Heat Pump
  241
- Aux 1 Pump
  242
- Aux 2 Pump
  243
- Boiler Wiring Diagrams
  244
- Model CFC Clearfire Condensing Boiler
  244
- Model CFW Clearfire Hydronic Boiler
  245
- Model CFV/CFH Clearfire Steam Boiler
  246
- General Description of the Lead Lag Application
  247
- Lead Lag (Ll) Master General Operation
  247
- Lead Lag Operation
  247
- Assumptions
  248
- System Wiring Hookup
  250
  - Typical Falcon L/L Wiring with 4 Slaves
    250
  - Basic Operation
    251
  - Field Installation Configuration
    251
  - Lead-Lag Operation
    251
    
    Rotation
    251
    
    LL Slave
    252
    
    Slave Data Supporting Lead Lag
    252
  - Slave Operation and Setup
    252
    
    Aux Pump X, Y, and Z
    253
    
    Firing for Local Frost Protection
    253
    
    Frost Protection Requests
    253
  - Slave Parameters
    253
  - Ll Master Operation and Setup
    254
    
    Slave Mode: Use First, Equalize Runtime, Use Last
    254
    
    Slave Sequence Order: 0-255
    254
  - Overall Control
    255
  - Periodic Data Polling Messages
    255
  - Slave Control
    255
  - Data Poll Response Handling
    256
  - Features Common to All States
    256
  - Slave Status Manager
    256
  - Valid Response Message
    256
  - Demand and Priority
    257
  - Slavestate States
    257
  - CH Demand
    258
  - Frost Protection
    258
  - Priority Control
    258
  - Warm Weather Shutdown
    258
  - Master Active Service
    259
  - Master Heat Demand
    259
  - Master Service Status
    259
  - Master Status
    259
  - Modulation Sensor
    260
  - Setpoints
    260
  - Ll Ch Odr Minimum Water Temperature: Degrees or None
    261
  - Ll Ch Tod Setpoint: Degrees or None
    261
  - Outdoor Reset and Boost (Boost Is Future)
    261
  - Time of Day
    261
  - Demand and Rate
    262
  - Integrator Compensation
    262
  - Lead Lag Pid
    262
  - Rate Adjustment
    262
  - Common Features
    263
  - Lead Lag Burner Demand
    263
  - Rate Allocation
    263
  - Rate Allocation Parameters
    263
  - Modulating Stage
    264
  - Parallel Common-Base Limited
    264
  - Rate Allocation Methods
    264
  - Stager
    264
  - Burner Demand
    266
  - Stager Parameters
    266
  - Stager States
    266
  - Add Stage Methods
    267
  - Add-Stage Methods
    267
  - Adding Stages Parameters
    267
  - Add-Stage Condition
    268
  - Drop Stage Methods
    268
  - Dropping Stages Parameters
    268
  - Rate Threshold
    268
  - Boiler off Options
    269
  - Drop-Stage Methods
    269
  - Error Threshold
    269
  - Lead Drop-Stage on Error - Ldse
    270
  - Sequencer
    270
  - Sequencer Parameters
    270
  - Sequencer Add Boiler Selection
    271
  - Sequencer Ordering Function
    271
  - Voluntary Lead Rotation
    271
  - Forced Lead Rotation:
    272
  - Sequencer 1 Minute Event
    272
  - Sequencer Drop Lag Boiler Selection
    272
  - Slave Write: Data
    272
  - Building Energy Management System (EMS) Interface
    273
  - Modbus
    273
  - Wiring
    273
  - Enabling Modbus Communications
    274
  - Interface
    274
  - Physical Layer
    274
  - Application Layer
    275
  - RS-485 Message Format
    275
  - Modbus Registers
    276
  - Product Data
    285
  - Button Actions
    286
  - Operation
    286
  - Backup Data
    287
  - Backup Data Settings
    287

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