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CleaverBrooks CFC ClearFire, User Manual

The CleaverBrooks CFC ClearFire is a cutting-edge industrial boiler system, designed for superior performance and energy efficiency. Enhance your user experience by downloading our free User Manual from 88.208.23.73:8080, providing you with comprehensive instructions and valuable insights to utilize this advanced product to its fullest potential.

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1

Rev. 05-2012

 

Table of Contents

MODEL CFC FEATURES AND BENEFITS   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
MODEL CFC PRODUCT OFFERING   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
PERFORMANCE DATA   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
ENGINEERING DATA   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
STACK/BREECHING SIZE CRITERIA  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
CB FALCON CONTROLLER  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

List of Figures

AluFer Inserts   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Fireside Access   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Premix Burner Technology  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Model CFC Heat Flow and Component Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
ClearFire Control Panel  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Model CFC Dimensional Views  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Competitive Condensation Analysis  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Emissions Data Clearfire  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-19
Pressure Drop Curves   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22-25
Condensate Piping Direct To Drain   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Optional Condensate Treatment Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Condensate Piping for Multiple Boilers   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Condensate Treatment Tank for Multiple Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Gas Piping Schematic  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Gas Header Piping  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Model CFC Minimum Room Clearance Dimensions  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
CFC Seismic Mounting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
No Primary Loop with Domestic Water and 2-Way Divert Valve  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Two Boilers and Three Variable Temperature Zones (No Primary Loop)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Two-Pipe Primary/Secondary Piping with Domestic Hot Water  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Two-Pipe Primary/Secondary Piping   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
No Primary Loop  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Domestic Water Heating, No Primary Loop  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Domestic Water with On/Off and 3-Way Valves  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Piping ‘Hybrid’ Boilers  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
‘Hybrid’ Boilers with Domestic Water  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
2 Pipe System, Typical (reverse-return)   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Model CFC ClearFire Condensing Boiler

Summary of Contents for CFC ClearFire

Page 1: ...30 Optional Condensate Treatment Assembly 31 Condensate Piping for Multiple Boilers 31 Condensate Treatment Tank for Multiple Boilers 32 Gas Piping Schematic 33 Gas Header Piping 34 Model CFC Minimum Room Clearance Dimensions 36 CFC Seismic Mounting 36 No Primary Loop with Domestic Water and 2 Way Divert Valve 38 Two Boilers and Three Variable Temperature Zones No Primary Loop 39 Two Pipe Primary ...

Page 2: ...r Ratings Sea Level to 2000 Feet 12 Altitude Correction for Input Capacity at Various Altitude Levels 13 ClearFire Efficiency 14 15 Noise Level 20 CFC Flow Rates 21 CFC Flow Rates Metric 22 Model CFC Minimum Over Pressure Requirements 26 Model CFC Boiler Safety Valve Information 125 PSIG 26 Model CFC Boiler Safety Valve Information 60 PSIG 26 Model CFC Water Chemistry Requirements in accordance wi...

Page 3: ...ng surface tubes the CFC boiler will provide fuel to water efficiency of up to 99 at low fire and 97 at high fire with 80 degrees F return water temperature Ease of Maintenance The powder coated steel casing is designed for easy removal and re assembly As shown in Figure B5 2 the burner is hinged and is provided with hydraulic pistons for simple opening for service of the spark electrode inspectio...

Page 4: ...shows the counter flow heat exchanger design that gives optimal heat transfer The design also prevents hot spots does not require a minimum flow for thermal shock protection and does not require a minimum return water temperature In fact the design carries a 20 year thermal shock warranty Because of its design characteristics the Model CFC is well suited for applications utilizing indoor outdoor r...

Page 5: ...operation on Natural Gas or LP Gas only Installation is for indoor use only Dimensions ratings and product information may change to meet current market requirements and product improvements Therefore use this information as a guide Combustion Fan and Premix Gas Valve Assembly Control Panel Finned High Efficiency AluFer Tubes ASME Code Pressure Vessel Flue Gas Outlet High Temp Return Hot Water Out...

Page 6: ...upply temperature NTC sensor for hot water return temperature ASME Safety Relief Valve set 125 psig 8 6 Bar Combination Temperature Pressure Gauge 3 Burner Control A The CB Falcon is an integrated burner management and modulation control with a touch screen display operator interface Its functions include the following Two 2 heating loops with PID load control Burner sequencing with safe start che...

Page 7: ...main flame is via direct spark utilizing high voltage electrodes and a separate electrode for flame supervision CFC 3300 uses gas pilot ignition and UV scanner for flame supervision H To ensure adequate combustion air is present prior to ignition and to ensure the fan is operating a combustion air proving switch is furnished I A High Air Pressure Switch is provided to ensure burner lockout if exce...

Page 8: ...and return water drain and vent The performance ratings for the boiler are shown in Table B5 3 Altitude Relative to the ratings shown installation of the boiler above 2000 feet elevation will result in input capacity reduction Please refer to Table B5 4 for input ratings of the boiler at various elevations PERFORMANCE DATA Efficiency The Model CFC is a full condensing boiler realizing efficiency g...

Page 9: ...Model CFC ClearFire Commercial Boilers 9 Rev 05 2012 Figure B5 6 Model CFC Dimensional Views I ...

Page 10: ...ing Height 56 2 56 2 60 0 65 4 65 4 65 4 67 0 P Air Vent Line Projection from Rear of Casing 7 8 7 8 7 3 8 1 8 1 8 7 4 7 Q Floor to Centerline of Lower Return 19 5 19 5 19 6 20 7 21 3 22 4 24 1 R Floor to Centerline of Upper Return 28 2 28 7 30 5 20 3 32 3 33 8 35 5 S Floor to Centerline of Supply Connec tion 54 3 54 3 56 2 57 1 56 2 56 2 59 1 T Floor to Centerline of Air Vent 59 9 59 9 62 3 63 1 ...

Page 11: ... Height 1427 1427 1524 1661 1661 1661 1702 P Air Vent Line Projection from Rear of Casing 198 198 185 206 206 221 119 Q Floor to Centerline of Lower Return 495 495 498 526 541 569 612 R Floor to Centerline of Upper Return 716 729 775 516 820 859 902 S Floor to Centerline of Supply Connection 1379 1379 1427 1450 1427 1427 1501 T Floor to Centerline of Air Vent 1521 1521 1582 1603 1603 1615 1687 AA ...

Page 12: ...51 90 113 99 126 209 Liters 193 193 341 428 375 477 791 Weight w o Water Pounds 1 160 1 160 1 795 2 225 2 505 3 640 4 835 Kg 526 526 814 1009 1136 1651 2193 Operating Weight Pounds 1 585 1 585 2 545 3 165 3 325 4 685 6 570 Kg 719 719 1154 1436 1508 2125 2980 Weight Shipping Pounds 1 210 1 210 1 850 2 300 2 600 3 725 5 000 Kg 549 549 839 1043 1179 1690 2268 Fireside Heating Surface ft2 185 185 307 ...

Page 13: ...minimum gas supply pressures see Table B5 24 Altitude corrections for supply pressure should be made per Table B5 25 Natural gas heating value of 1000 BTU SCF assumed LP Gas 700 ASL 2000 4000 6000 8000 10000 CFC 3300 3300 kBTU h 3300 3300 3300 3057 2930 CFC 2500 2500 2500 2339 2169 2010 1927 CFC 1800 1800 1800 1800 1704 1579 1514 CFC 1500 1500 1500 1500 1500 1390 1332 CFC 1000 1000 1000 1000 1000 ...

Page 14: ...ion Table B5 5 CFC 500 ClearFire Efficiency Table B5 6 CFC 750 ClearFire Efficiency Competitor 1 Competitor 2 Clearfire Firing Rate Return Water Temperature F0 C 68 80 100 120 130 140 160 20 27 38 49 55 60 72 20 99 0 98 8 97 5 94 8 92 0 88 5 88 0 50 97 4 96 2 95 0 92 2 90 5 88 5 88 0 75 97 0 95 6 93 0 90 5 89 0 88 5 88 0 100 96 0 94 6 92 0 89 0 88 5 88 4 87 9 Firing Rate Return Water Temperature F...

Page 15: ...55 60 72 20 99 98 96 2 94 91 88 7 88 2 50 98 2 97 5 94 3 92 90 88 5 88 2 75 98 96 5 92 1 91 89 88 5 88 2 100 97 95 3 91 5 90 88 1 87 8 87 5 Firing Rate Return Water Temperature F0 C 68 80 100 120 130 140 160 20 27 38 49 55 60 72 20 99 98 96 5 94 91 88 5 88 50 98 3 96 93 8 91 89 8 88 5 87 6 75 98 95 93 89 5 88 9 88 3 87 3 100 97 2 94 91 5 88 9 88 87 5 87 Firing Rate Return Water Temperature F0 C 68...

Page 16: ...h Coast Air Quality Management District SCAQMD Rule 1146 Meeting the requirements of SCAQMD also qualifies the boiler for meeting the NOx requirements in the state of Texas By means of the Pre mix burner the Clearfire boiler provides environmentally friendly emissions when firing natural gas emission data are shown in Figure B5 8 through Figure B5 13 Figure B5 8 Emissions Data Clearfire Model CFC ...

Page 17: ...Model CFC ClearFire Commercial Boilers 17 Rev 05 2012 Figure B5 9 Emissions Data ClearFire Model CFC 750 Figure B5 10 Emissions Data ClearFire Model CFC 1000 ...

Page 18: ...Model CFC ClearFire Commercial Boilers 18 Rev 05 2012 Figure B5 11 Emissions Data ClearFire Model CFC 1500 Figure B5 12 Emissions Data ClearFire Model CFC 1800 ...

Page 19: ...Model CFC ClearFire Commercial Boilers 19 Rev 05 2012 Figure B5 13 Emissions Data ClearFire Model CFC 2500 Figure B5 14 Emissions Data ClearFire Model CFC 3300 ...

Page 20: ...rences up to 100 F 55 C without the use of a boiler circulating pump blend pump or minimum water flow Note The Clearfire does not require a minimum flow or continuous flow through it during operation However the load imposed on the boiler must be considered when sizing the system flow so that the flow does not exceed the capacity of the boiler or the demand Flow Rates and Pressure Drops To maintai...

Page 21: ...5 15 Air Venting The elimination of entrained air is required It is recommended that each unit be piped to an expansion tank If this is not possible then an auto air vent should be provided on the vent connection of the boiler The caveat in using an auto vent is that free oxygen can be introduced to the vesel as the boiler cools or in some instances the vent can become plugged Table B5 12 CFC Flow...

Page 22: ...w Rate m3 hr 500 21 6 10 9 7 5 5 4 4 3 3 6 2 7 2 5 2 3 2 1 8 1 6 750 29 75 15 10 7 5 6 5 4 3 3 6 3 4 2 9 2 7 2 5 1000 40 20 14 10 8 7 6 5 4 5 4 3 6 3 4 1500 59 29 5 20 15 12 10 8 4 7 5 6 6 6 5 4 5 2 1800 80 40 27 20 16 13 11 3 10 9 8 7 3 6 8 2500 106 7 53 4 36 7 26 8 21 6 17 9 15 2 13 4 11 8 10 9 9 8 8 8 3300 141 70 47 35 28 23 20 18 16 14 13 12 Flow rate as a function of Delta T at 94 efficiency ...

Page 23: ...Model CFC ClearFire Commercial Boilers 23 Rev 05 2012 Figure B5 16 Pressure Drop Curve ClearFire Boiler Size 750 Figure B5 17 Pressure Drop Curve ClearFire Boiler Size 1000 ...

Page 24: ...Model CFC ClearFire Commercial Boilers 24 Rev 05 2012 Figure B5 18 Pressure Drop Curve ClearFire Boiler Size 1500 Figure B5 19 Pressure Drop Curve ClearFire Boiler Size 1800 ...

Page 25: ...Model CFC ClearFire Commercial Boilers 25 Rev 05 2012 Figure B5 20 Pressure Drop Curve ClearFire Boiler Size 2500 Figure B5 21 Pressure Drop Curve ClearFire Boiler Size 3300 ...

Page 26: ...3 181 185 83 85 15 1 03 186 195 86 91 18 1 24 Boiler Size ValveConnection Boiler Valve Setting 125 psig Relie Valve Capacity MBH No Valves Req d Outlet Size 500 3 4 1 1 3364 750 3 4 1 1 3364 1000 3 4 1 1 3364 1500 3 4 1 1 3364 1800 3 4 1 1 3364 2500 3 4 1 1 3364 3300 3 4 1 1 3364 Boiler Size ValveConnection Boiler Valve Setting 60 psig Relief Valve Capacity MBH No Valves Req d Outlet Size 500 3 4 ...

Page 27: ...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 Generally corrosion inhibitors are added to glycol systems However all glycols tend to oxidize over time in the presence o...

Page 28: ...ratures up to the maximum of 185 deg F 85 deg C a minimum operating pressure of 30 psig 2 1 bar is required 6 pH level should be maintained between 8 3 and 9 5 Table B5 18 Glycol Application Guidelnes Model CFC Minimum required boiler circulation rate gpm at maximum firing rate ClearFire System ΔT F Model Size ΔT 10 ΔT 20 ΔT 30 ΔT 40 CFC 500 88 44 29 22 CFC 750 131 66 44 33 CFC 1000 175 88 58 44 C...

Page 29: ...t any time when the return water temperature is below the dew point or approximately 132 F 55 5 C The condensation collects in the lower portion of the boiler from the tube surfaces and from the stack and must be discharged to a drain A Condensate trap must be piped on the boiler and must be field piped to either a drain or to the optional condensate treatment kit Table B5 21 provides the amount o...

Page 30: ...boiler capacity 5 0 MMBTU hr Model CFC capacities are in Table B5 22 See Figure B5 23 and Figure B5 24 for suggested piping A drain trap is built into the condensate tank Make up water must be supplied at the connection shown in order to prevent flue gas from entering an idle boiler An internal float in the condensate tank activates the make up water valve Figure B5 22 Condensate Piping Direct To ...

Page 31: ... the front of the boiler must be provided for servicing the assembly and for periodically adding the neutralizing granules Figure B5 24 Condensate Piping for Multiple Boilers Neutralization media To drain Neutralization tank Drain trap Condensate in Float valve for makeup water To Drain 1 4 O D Make up Water Supply Condensate Drain Trap Neutralization Tank ...

Page 32: ...nd regulatory codes All connections made to the boiler must be arranged so that all components are accessible for inspection cleaning and maintenance A drip leg should be installed in the supply line before the connection to the boiler The drip leg should be at least as large as the gas piping connection on the boiler See Figure B5 25 and Figure B5 26 for piping suggestions To Drain Condensate Dra...

Page 33: ...p To permit burner opening gas piping must not traverse the top of the boiler B Table B5 23 shows the gas pressure required at the inlet of the gas line Note a pressure regulator is not furnished and if gas pressure exceeds 14 W C a pressure regulator is recommended C Table B5 24 shows the correction factors for gas pressure at elevations at 2000 feet and higher above sea level Same or larger than...

Page 34: ...as Header Piping Typical Gas Strainer Relief Valve See Note 5 Manual Shut Off See Note 1 NOTES 1 Dedicated gas pressure regulator required for each boiler 2 Refer to local fuel gas codes when applicable 3 Header to be sized for room capacity 4 Provision required for measuring gas supply pressure at boiler 5 Relief valve required if gas supply pressure 1 psig ...

Page 35: ...g Once the boiler is placed it must be leveled side to side and front to back using the supply and return nozzles for horizontal and vertical positions If shims are required to level the boiler the weight of the boiler must be evenly distributed at all points of support The legs may also be used for leveling Clearances The boiler must be installed so that all components remain accessible ensure no...

Page 36: ...e B5 28 Model CFC Minimum Room Clearance Dimensions Seismic Legs Seismic mounting details shown below Figure B5 29 CFC Seismic Mounting DIM Inches Top Clearance A 14 Side Clearance B 20 Backway C 20 Front D 36 Between Boilers E 3 C B D B E CFC 500 2500 CFC 3300 ...

Page 37: ...its design is such that no minimum flow is required variable speed or on off pumps may be employed in the piping scheme Typical piping arrangements are shown in figures B5 33 through B5 45 Note These diagrams are generic and are not intended for use in a specific design without consultation with your local Cleaver Brooks sales representative ...

Page 38: ...ire Full Condensing To Condensate Drain To Sanitary Drain System Returns Domestic Cold Water In Domestic Water Domestic Water Pump Return Header Boiler Drain Domestic Water Supply Heating System Pumps System Supply Returns System Supply Header Expansion Tank Water Makeup 2 Way Diverting Valve On Off Valve ...

Page 39: ...ry Loop ClearFire ClearFire P P T T BV1 B1 T T BV1 B1 T T BV1 B1 CWS Filling Loop Removable Tank Expansion Return Return Run condensate drain to adjacent drain or via optional condensate pumping unit Drain Flow Prefabricated Header Back Pressure Radiant Heating Load Valve ...

Page 40: ... CIRCULATOR 10 SECONDARY CIRCULATORS INJECTION PUMP 11 FLOW CHECK VALVES TO PREVENT GRAVITY 10 11 8 10 5 8 8 3 5 10 3 11 10 5 8 3 5 1 2 6 9 4 7 FIXED OR VARIABLE SPEED OR PRESSURE DROP INDUCED FLOW IN SECONDAY CIRCUITS 12 MAX APART AT ALL SECONDARY CONNECTIONS TO PREVENT FORCED FLOW IN SECONDARY CAUSED BY PRESSURE DROP THROUGH PIPING BETWEEN CONNECTIONS TEMPERATURE CONTROL BY SECONDARY CIRCULATION...

Page 41: ...S 9 SYSTEM CIRCULATOR 10 SECONDARY CIRCULATORS INJECTION PUMP 11 FLOW CHECK VALVES TO PREVENT GRAVITY 10 11 8 10 5 8 8 3 5 10 3 11 10 5 8 3 5 1 2 6 9 4 7 FIXED OR VARIABLE SPEED OR PRESSURE DROP INDUCED FLOW IN SECONDAY CIRCUITS 4 12 MAX APART AT ALL SECONDARY CONNECTIONS TO PREVENT FORCED FLOW IN SECONDARY CAUSED BY PRESSURE DROP THROUGH PIPING BETWEEN CONNECTIONS TEMPERATURE CONTROL BY SECONDARY...

Page 42: ...Drain To Sanitary Drain System Returns Return Header Boiler Drain Heating System Pumps System Supply Returns System Supply Header Expansion Tank Water Makeup Y10 2 Y10 1 VK 1 VK 2 Y10 1 Motorized Shutoff Y10 2 Motorized Shutoff VK 1 3 Way Mixed Circuit VK 2 3 Way Mixed Circuit Back Pressue Valve ...

Page 43: ...ater Heating No Primary Loop ClearFire Full Condensing ClearFire Full Condensing To Condensate Drain To Sanitary Drain System Returns Boiler Drain Expansion Tank Water Makeup Air Vent Line Primary Pump Standby Pump Surge Tank ...

Page 44: ...arFire Full Condensing To Condensate Drain To Sanitary Drain System Returns Domestic Col Water In Domestic Water Domestic Water Pump Return Header Boiler Drain Domestic Water Supply Heating System Pumps System Supply Returns System Supply Header Expansion Tank Water Makeup On Off Valves ...

Page 45: ... SUPPLY 2 BOILER INLET RETURN 3 ISOLATION VALVES 4 PURGE COCKS 5 AIR SEPARATOR WITH AUTOMATIC AIR VENT 6 DIAPHRAGM EXPANSION TANK WITH FILL VALVE 7 FLOW CHECK VALVES 8 SYSTEM CIRCULATOR 3 4 5 8 6 Supply Return FLX 2 3 1 7 3 130 F 150 F Sensor 3 3 3 3 3 3 7 ...

Page 46: ...TH AUTOMATIC AIR VENT 7 DIAPHRAGM EXPANSION TANK WITH FILL VALVE 8 FLOW CHECK VALVES 9 SYSTEM CIRCULATOR 5 6 9 7 3 12 MAX APART AT ALL SECONDARY CONNECTIONS TO PREVENT FORCED FLOW IN SECONDARY CAUSED BY PRESSURE DROP THROUGH PIPING BETWEEN CONNECTIONS Supply Return FLX 2 4 1 8 4 130 F 150 F Sensor Hot Water Outlet Cold Water Supply 10 DOMESTIC PUMP 4 4 4 4 4 1 2 8 10 4 3 ...

Page 47: ...Figure B5 34 2 Pipe System Typical reverse return CFC 2 1 1 PRIMARY ZONE WITH THERMOSTAT THERMOSTAT CONTROLS BOILER AND CIRCULATOR 2 HEATING UNITS WITH THERMOSTATIC VALVES ...

Page 48: ... 5 11 6 3 4 1 2 8 5 4 9 7 3 SECONDARY CONNECTION BOILER CIRCUIT 4 ISOLATION VALVES 5 PURGE COCKS HOSE BIBB 6 AIR SEPARATOR WITH AUTOMATIC AIR VENT 7 DIAPHRAGM EXPANSION TANK 8 COMBINATION FILL VALVE 9 ZONE VALVES 10 ZONE CIRCULATORS CIRCULATOR ZONING 11 SYSTEM CIRCULATOR ZONE VALVE SYSTEM ...

Page 49: ... Out Thermometer Pipe To Safe Location Top Relief Pipe Per Code Cold In Air Purger with Vent PRV and Expansion Tank Reducers Auto Air Vent It High Point Reverse Return For Balanced Flow Boiler 2 Boiler 1 Circulators Tube Bundles Can Be In Any Location Exce On Top Of Each Othe Supply Supply Return Heating Domestic Water with 2 Boilers and 2 Coils Return ...

Page 50: ... Known Air Infiltration Rate Method Where the air infiltration rate is known to be less than 0 40 Air Changes per Hour the Known Air Infiltration Rate Method shall be used See Section 8 3 in the NFPA54 Handbook for additional information Combustion Air Supply Unconfined Spaces For U S Installations Only A All Air From Inside the Building If additional combustion air is drawn from inside the buildi...

Page 51: ... top and one opening terminating within twelve inches of the bottom of the room 2 The openings must be linked directly or by ducts 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 4 The minimum free area required fo...

Page 52: ...es from the front of the appliance 2 The opening shall directly communicate with the outdoors and shall have a minimum free area of 1 square inch per 3000 BTU s per hour of the total input rating of all equipment located in the enclosure and not less than the sum of the areas of all vent connectors in the confined space 3 Refer to the NFGC Section 8 3 for additional information GAS VENT CLEARFIRE ...

Page 53: ...t of 7 feet This allows air to sweep the length of the boiler See Figure B5 48 B Air supply openings can be louvered for weather protection but they should not be covered with fine mesh wire as this type of covering has poor air flow qualities and is subject to clogging with dirt and dust C A vent fan in the boiler room is not recommended as it could create a slight vacuum under certain conditions...

Page 54: ...elevation 3 Acceptable air velocity in the Boiler Room fpm A From floor to 7 feet high 250 fpm B Above 7 feet above floor 500 fpm Example Determine the area of the boiler room air supply openings for 2 Clearfire 1800 boilers at 750 feet elevation The air openings to be 5 feet above floor level Air required 1800 x 2 3600 kBtuh From 2C above 3600 x 0 3 1 080 cfm Air Velocity Up to 7 feet 250 fpm fro...

Page 55: ...SIZE CRITERIA General 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 Category I A boiler which operates with a non positive vent static pressure and with a vent gas temperature that avoids excessive condensate production in the vent Category II A boiler which operates with a non po...

Page 56: ...on 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 2 Prevailing winds could cause freezing of Condensate and water ice buildup on building plants or roof 3 The bottom of the vent termination and the air intake shall be located at least 12 inches above grade including the normal snow line 4 Non ins...

Page 57: ...horizontally of the vertical centerline of the regulator 5 Within 6 feet 1 8m of any gas service regulator vent outlet 6 Less than 1 foot 300mm above grade level 7 Within 3 feet 1m of a window or door which can be opened in any building any non mechanical air supply inlet to any building or to the combustion air inlet of any other appliance 8 Underneath a Verandah porch or deck unless A The Verand...

Page 58: ...light upward slope of not more than 1 4 per foot of horizontal run to the vent termination In this case an approved Condensate trap must be installed per applicable codes 2 The vent must be insulated through the length of horizontal run The stack vent cap MUST be mounted on the exterior of the building The stack vent cap cannot be installed in a well or below grade The stack vent cap must be insta...

Page 59: ... horizontal run Note For installations in freezing climates it is recommended that 1 The stack vent shall be installed with a slight upward slope of not more than 1 4 per foot of horizontal run to the vent termination In this case an approved Condensate trap must be installed per applicable codes 2 The stack vent is to be insulated through the length of the horizontal run Note For Horizontal Stack...

Page 60: ... Room Combustion Air Required CFM Air Filter Kit No optional CFC 500 6 Standard 6 80 039 01704 125 880 01858 CFC 750 6 Standard 6 60 039 01704 190 880 01858 CFC1000 6 Option 6 80 039 01646 250 880 01858 CFC1000 8 Standard 8 140 039 01647 250 880 01858 CFC1000 10 Option 10 200 039 01705 250 880 01858 CFC1500 8 Option 8 60 039 01645 375 880 02005 CFC1500 10 Standard 10 80 039 01644 375 880 02005 CFC...

Page 61: ... 10 Option 6 10 80 80 880 03736 039 01705 CFC1500 8 Option 6 8 30 30 880 01313 039 01645 CFC1500 8 Option 8 8 40 40 880 02451 039 01645 CFC1500 10 Standard 6 10 40 40 880 01313 039 01644 CFC1500 10 Standard 8 10 60 60 880 02451 039 01644 CFC1500 12 Option 6 12 60 60 880 01313 039 01688 CFC1500 12 Option 8 12 80 80 880 02451 039 01688 CFC1800 10 Option 6 10 40 40 880 01313 039 01644 CFC1800 10 Opti...

Page 62: ...de Air Vertical Vent As noted in Paragraph A above these installations use air from within the boiler room for combustion The same recommendations apply as noted in Paragraph A above and also the recommendations on flue vent sizing according to Table B5 25 CFC Boiler Flue Gas Vent 24 Minimum 10 0 or Less 48 Minimum Termination ...

Page 63: ...ue vent sizing according to Table B5 26 ELECTRICAL Voltage requirements for the Fan Motor are 115 120 1 60 Control Circuit voltage is 120 1 60 for all boiler sizes Refer to Table B5 3 Ratings for ampacity requirements Refer to Figure B5 54 through Figure B5 56 for wiring connections and control locations Boiler Vent Termination Air Intake w Screen 48 Minimum 48 Minimum 12 Minimum above roof or sno...

Page 64: ...Model CFC ClearFire Commercial Boilers 64 Rev 05 2012 Figure B5 54 Electrical Connections CFC 500 2500 ...

Page 65: ...Model CFC ClearFire Commercial Boilers 65 Rev 05 2012 Figure B5 55 Electrical Connections CFC 3300 ...

Page 66: ...Model CFC ClearFire Commercial Boilers 66 Rev 05 2012 Figure B5 56 CFC Rear Connections ...

Page 67: ... with history last 15 messages Annunciation Outdoor reset Central Heating and Domestic Hot Water loop control Password protection of configurable parameters High Stack Temperature limit Remote reset Lead Lag sequencing 3 configurable pump relays Remote modulation remote setpoint Frost protection Time of Day dual setpoint control Three levels of access to control configuration End user Installer Se...

Page 68: ... System Configuration CB Falcon configuration is arranged into the following functional groups Table B5 29 CB Falcon burner sequence Central Heat 1 Heat request detected CH demand 2 CH pump switched on 3 Safe Start Check dynamic ILK input test if enabled blower switched on 4 If ILK input and CAPS switch closed and purge rate fan speed achieved begin 15 second prepurge 5 When purge complete blower ...

Page 69: ...MODBUS A B C GLOBAL MODBUS A B C POWER FLAME ALARM RESET PIM 1 2 3 4 5 6 HYDRONIC CONTROL J1 J2 J3 ECOM D R C L1 L2 FOR 120VAC OR 24VAC RETURN OPTOS EGND BLOWER HSI EX IGNITION ALARM MAIN VALVE PILOT VALVE ANNUN 1 IAS ANNUN 2 ANNUN 3 ANNUN 4 ANNUN 5 ANNUN 6 PRE IGN INTLK INTERLOCK P P P LCI PUMP A PUMP B PUMP C ANNUN 7 HFS ANNUN 8 LFS 24 VAC 24 VAC RTN INLET TEMP INLET TEMP RTN 4 20 mA REMOTE SOUR...

Page 70: ...Model CFC ClearFire Commercial Boilers 70 Rev 05 2012 ...

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