CleaverBrooks CFV Benutzerhandbuch

www.cleaverbrooks.com

ClearFire®Model CFV

Vertical Steam Boiler

Startup Guide

750-288

CFV Startup Guide

2 Part No. 750-288

Improper installation, adjustment, service, or main-

tenance can cause equipment damage, personal

injury, or death. Refer to the Operation and Mainte-

nance manual provided with the boiler.

!DANGER

WARNING

Be sure the fuel supply which the boiler was de-

signedtooperateonisthesametypeasspecified

on the boiler name plate.

!DANGER

WARNING

To minimize the possibility of serious personal injury,

fire or damage to the equipment, never violate the fol-

lowing safety rules.

— Always keep the area around the boiler free of

combustiblematerials,gasoline,andotherflammable

liquids and vapors

— Never cover the boiler, lean anything against it,

stand on it, or in any way block the flow of fresh air to

the boiler.

!DANGER

WARNING

Where required by the authority having jurisdic-

tion, the installation must conform to the Standard

for Controls and Safety Devices for Automatically

Fired Boilers, ANSI/ASME CSD-1.

Notice

Theinstallationmustconformto the requirements of

the authority having jurisdiction or, in the absence of

such requirements, to UL 795 Commercial-Industri-

al Gas Heating Equipment and/or the National Fuel

Gas Code, ANSI Z223.1

!DANGER

WARNING

NOTE to equipment owners, operators, and maintenance

personnel: This guide is not a short-cut to safe and effi-

cient boiler operation. Operating an improperly commis-

sioned boiler can result in increased fuel costs and may

shorten the life of the equipment or produce a hazardous

condition. All personnel involved in operating or main-

taining the boiler should read the manual in its entirety.

Refer to CFV Operation and Maintenance

Manual - CB Part Number 750-269

Do not use this boiler if any part has been under

water. Immediately call your Cleaver-Brooks service

representative to inspect the boiler and to replace

any part of the control system and any gas control

which has been under water.

!DANGER

WARNING

Should overheating occur or the gas supply valve

fail to shut off, do not turn off or disconnect the

electrical supply to the boiler. Instead turn off the

gas supply at a location external to the boiler.

!DANGER

WARNING

The boiler and its individual shutoff valve must be

disconnected from the gas supply piping system

during any pressure testing of that system at test

pressures in excess of 1/2 psi (3.5 kPa).

!DANGER

WARNING

!DANGER

WARNING

The boiler and its gas connection must be leak

tested before placing the boiler in operation.

CFV Startup Guide

Part No. 750-288 3

1 - BEFORE STARTUP

Your Cleaver-Brooks boiler has been factory fire-tested and the control system pre-configured for a trouble-

free startup. To help ensure a successful lightoff and reliable operation, certain initial conditions should be

observed.

Do not attempt to place the boiler into service without verifying that all connections - fuel, steam and

water piping, electrical connections, stack, and combustion air provisions - have been installed properly

and in accordance with any applicable codes or regulations.

1.1 Operating Conditions

• The installation site should be as free as possible from vibration,

dust, and corrosive media

• The controllers should be located as far as possible from sources of

electromagnetic fields, such as frequency converters or high-voltage

ignition transformers

• Control panel must be connected to earth ground. For electrical

wiring requirements, see wiring diagram provided with the boiler or

in the CFV manual.

Figure 1 CFV Connections

RELIEF VALVE

STEAM

OUTLET

SURFACE

BLOWOFF

GAS SUPPLY

FEEDWATER

BLOWDOWN

STACK

OUTLET

CONDENSATE DRAIN

COMBUSTION AIR INLET

GAUGE GLASS DRAIN

WATER COLUMN DRAIN

!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.

CFV Startup Guide

4 Part No. 750-288

1.2 Gas Piping

A manually operated shut-off valve and pressure regulator are provided

as standard on the Model CFV boiler. It is recommended to install an

approved gas filter or strainer in the gas supply line to the boiler. Please

inquire with the local gas supply company.

The boiler shall be installed such that the gas ignition system

components are protected from water (dripping, spraying, etc.) during

appliance operation and service.

If building supply gas pressure is greater than 1 psig (27.8” WC), an

upstream regulator with overpressure protection and proper gas venting

will be required and must be piped to a safe point of discharge.

All gas piping and components to the boiler gas train connection must

comply with NFPA 54, local codes, and utility requirements as a

minimum. Only gas approved fittings, valves, or pipe should be used.

Standard industry practice for gas piping is normally Schedule 40

black iron pipe and fittings.

See Table 1 for CFV gas pressure requirements.

1.3 Flue Gas Connection

The flue gases from the ClearFire boiler are removed via a gas-tight, temperature and corrosion resistant flue

gas pipeline. Only flue gas systems approved and tested by the relevant region or province are to be connected

to the ClearFire boiler. Refer to flue piping manufacturer for proper installation and sealing instructions.

See also Chapter 3 in the CFV Operation and Maintenance manual.

Boiler room ambient conditions

Relative humidity < 85% non-condensing

Ambient temperature range 0 oC to 50 oC / 32oF to 122oF

Storage temperature range -20 oC to 60 oC / -4oF to 140oF

Combustion air temperature 0 oC to 50 oC / 32oF to 122oF

Specifications

Input power 115 VAC single phase 60Hz

Recommended operating steam

pressure

75-135 psig

Gas pressure requirements See Table 1

Table 1 CFV gas pressure requirements

Boiler HP Minimum pressure required

at gas train connection

Max. pressure

9.5 7.2" w.c.

28” w.c.

10 7.2" w.c.

15 7.3" w.c.

20 7.5" w.c.

25 7.7" w.c.

30 8.5" w.c.

40 11.0" w.c.

50 10.0" w.c.

60 10.0" w.c.

Note: To measure supply pressure

at the CFV gas valve, use the

test port on the valve inlet

flange (see below). Do not

use the leak test cocks to

measure gas pressure.

CFV Startup Guide

Part No. 750-288 5

1.4 Boiler Water-Side Connections

A pressure relief valve (safety valve; Figure 2), provided with the

boiler, must be installed in the mounting provided and piped to a safe

point of discharge. 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. The safety valve must

be mounted in a vertical position so that discharge piping and code-

required drains can be properly piped to prevent buildup of back

pressure and accumulation of foreign material around the valve seat

area.

Connection to the main steam header is made at the nozzle projecting

upward from the boiler shell.

Feedwater is introduced through the piping assembly installed on the

side of the boiler vessel.

1.5 Electrical Connections

Refer to Figure 3 for CFV wiring and cable connections. See also wiring diagram on page 13.

A qualified electrician or service technician must make the electrical connections to the boiler; all local

electrical and building codes should be adhered to.

Refer to wiring diagram provided with the boiler or in the CFV manual. Ensure all required customer

connections are properly made. Main power (115 VAC single phase 60Hz) and any remote wiring should be

brought to the left side of the control panel and terminated at the appropriate terminals provided. Controls for

the boiler feed pump (or feedwater valve if applicable) should be wired to control panel terminals 6 and 7.

Figure 3 CFV wiring and cable connections

Safety

Valve

Figure 2 Pressure Relief Valve

1. Connect UV Scanner to threaded connection on dry oven

2. Connect spark cables to dual electrode and ignition transformer

3. Plug AC power harness pl ug into blower

4. Plug DC blow er control harness plug in to b lower

5. Connect incoming AC power per wiring diagram

6. Connect optional heat request inputs per wiring diagram

7. Connect pump controls per wiring diagram

Notice

The blower signal wiring must be isolated

from the blower power wiring and the

high voltage ignition cables.

CFV Startup Guide

6 Part No. 750-288

1.6 Safety Controls

Users should take note of the safety controls installed as standard on the Model CFV. Minor adjustments to

the initial factory settings of some controls may be necessary for your particular installation.

It is required to test all controls for proper functioning prior to starting the boiler for the first time. Step-

by-step procedures for testing the controls can be found in the CFV manual (Chapter 4 - Commissioning).

The primary flame safety control is the CB Falcon, which monitors the flame signal by means of an

ionization electrode installed in proximity to the burner canister.

Other Combustion Safety Controls (see Figure 4) include the following:

• Combustion Air Proving Switch

• Low Gas Pressure Switch

• High Gas Pressure Switch

• Dual Safety Shut-off Valve (SSOV)

Depress all manual reset buttons for all controls prior to starting the boiler.

Water Level Controls (see Figure 5)

The primary Low Water Cutoff and pump control level probes are mounted in an external water column.

The Auxiliary Low Water Cutoff is mounted in the boiler vessel or optional external column. Control boards

for the LWCO and ALWCO are located in the boiler control panel. The ALWCO includes a panel-mounted

reset/test switch.

Figure 4 Combustion Safety Controls at Burner

!Warning

The Model CFV is factory tested. Nevertheless, all burner safety

controls should be checked upon installation, prior to initial firing.

Failure to verify burner control functioning could result in severe

bodily injury or death.

For detailed procedures on how to test the safety controls, see the

boiler Operation and Maintenance Manual.

Dual SSOV

CFV Startup Guide

Part No. 750-288 7

Limit Controls (see Figure 6)

The operating and high pressure limit controls are

externally mounted to the control trim piping. For

control settings and testing instructions, see the

boiler operation manual.

Figure 6 Limit Controls

1.7 Filling Boiler

Ensure that all feedwater equipment is properly installed and any feed

pumps, valves, etc. are in good working order.

Begin with the control panel DEMAND switch and CC/BLOWER switch (see

Figure 7) in the OFF position. Open the boiler vent valve (see Figure 8).

Turn the Control Circuit/Blower Switch ON to enable the feedwater control

circuit. If the CB Falcon icon does not appear on the display when the CC/

Blower switch is turned on, see STARTING THE BOILER below.

With the vent valve open, entrapped air will be allowed to escape while the

boiler fills with water. Do not close the vent valve until water is visible in

the gauge glass. The feed pump will shut off when water reaches the ‘Pump

Off’ probe level.

Check to ensure that no leaks appear at any pipe connections and correct

if water leaks are noticed.

Figure 5 Water level controls

CB FALCON

CONTROLLER

ALWCO CONTROLLER

LWCO CONTROLLER / PUMP CONTROL

Control panel interior

Figure 7 Control Panel Switches

CFV Startup Guide

8 Part No. 750-288

Important

The use of soft water is highly recommended. Failure to observe this recommendation can lead to dangerous

operating conditions, and may result in damage to the boiler. If necessary, your Cleaver-Brooks

representative can provide additional information regarding your water softening requirements.

2 - STARTING THE BOILER

Ensure boiler has been filled with water (see above - 1.7 Filling Boiler). The DEMAND switch should be in

the OFF position.

When the Control Circuit/Blower switch is turned ON, the Home page will appear on the CB Falcon display,

showing the boiler control icon. It may take a short time for the display/controller to initialize before the

Falcon icon appears.

If the Falcon icon does not appear, open the control panel and verify that the controller is receiving power.

The green ‘POWER’ LED should be lit (see Figure 9).

If the controller is powered on but still does not appear on the display, refer to manual. If unable to resolve

the problem, contact your CB representative.

Figure 8 Filling the Boiler

Figure 9 Home Page; Falcon power indicator

Vent Valve

Gauge Glass

HOME PAGE

POWER

Falcon

controller

icon

LED

CFV Startup Guide

Part No. 750-288 9

2.1 Controller Configuration

The CB Falcon controller is factory pre-configured with default parameter

settings for the Model CFV. Prior to starting the boiler, verify that the

factory default settings are correct for your application. See the boiler

operation manual (Chapter 4 - Commissioning) for the parameter list and

parameter change procedure.

Changing the Setpoint

The default steam pressure setpoint should be changed at this time to

suit your application. Press the CB Falcon icon on the Home page. The

Overview screen will appear. On the bottom row of screen buttons press

<Operation> to access the Operation screen (Figure 10).

Press the yellow highlighted setpoint display. A numeric keypad will appear. Press <Clear> to clear the

current value, enter the appropriate setting using the numeric keypad, and press <OK>.

Figure 10 Changing the setpoint

2.2 Initiating Burner Sequence

When ready to start the boiler, navigate to the Operation screen (see “Changing the Setpoint” above).

Note: The “Home” icon at the

upper left of the display

screen always returns to the

Home Page.

The “Back” icon at the upper

right displays the previous

screen.

To change the steam pressure setpoint: 1. Press the yellow highlighted setpoint display window.

2. Clear the current value.

3. Enter the desired value.

4. Press <OK>.

Note: Some features of the CB Falcon controls are password

protected. Service level password = 9220.

!Warning

Before initial startup, check for blockages in the flue vent-

ing or vent terminations. Inspect the burner and furnace

for any contamination or blockages.

CFV Startup Guide

10 Part No. 750-288

Turn the <Burner switch> screen button to ON. The burner is now

enabled.

Turn the control panel DEMAND switch to LOC (local). The burner

sequence should now begin. To verify that the sequence is in

progress, check the ‘Burner state’ display on the Operation screen.

If operating normally, the controller should advance through the

steps in the burner sequence (see Figure 12).

Note: The <Burner switch> screen button enables the burner, but

will not by itself start the lightoff sequence. In order for the burner

to start, the following must be true:

• <Burner switch> screen button is ON

• All control circuit interlocks are satisfied

• A demand for steam exists (example: DEMAND switch is on LOC

and steam pressure is below setpoint)

Once started, the boiler will continue running until demand is met,

an alarm condition occurs, or until manually shut down.

Before leaving the boiler unattended, ensure all safety controls

have been checked and boiler operational settings are properly

set,

As part of the initial safety checks, a flame failure test should also be performed to verify that the controls

are able to respond properly to a loss of flame: Disconnect the flame rod cable and attempt to start the

burner. The CB Falcon should lock out, indicating Lockout 109 Ignition Failure. Reconnect flame rod cable

after test.

The CB Falcon requires a manual reset to resume operation after a lockout.

3 - MANUAL OPERATION

Certain circumstances - such as setting combustion - require operating the boiler in manual mode. To enter

manual mode, use the following procedure:

Figure 11 Operation screen

BURNER

SWITCH

button

Burner Sequence:

STANDBY (burner switch off or no demand)

SAFE STARTUP

PREPURGE DRIVE TO PURGE (prove fan

purge rate)

PREPURGE MEASURED PURGE TIME

(30 sec default)

PREPURGE DRIVE TO LIGHTOFF (prove

lightoff rate)

PREIGNITION TEST

DIRECT BURNER IGNITION

RUN (release to modulating control)

Figure 12 Burner Sequence

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