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Cleaver-Brooks CFV Startup Manual

Made by: Cleaver-Brooks
Type: Startup Guide
Category: Boiler
Pages: 16
Size: 1.38 MB

 

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www.cleaverbrooks.com

ClearFire

®

 

Model CFV

Vertical Steam Boiler

Startup Guide

750-288

 


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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-
signed to operate on is the same type as specified
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 
combustible materials, gasoline, and other flammable 
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

The installation must conform to 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.

 


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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

W h e n  u s i n g  d i r e c t  v e n t
combustion in cold climates,
special care must be taken to
o b s e r v e  c o m b u s t i o n  a i r
temperature limits.

 Failure to

follow this precaution may lead
to equipment damage or unsafe
operation.

 


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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

o

C to 50 

o

C / 32

o

F to 122

o

F

Storage temperature range

-20 

o

C to 60 

o

C / -4

o

F to 140

o

F

Combustion air temperature

o

C to 50 

o

C / 32

o

F to 122

o

F

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.

 


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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

5

6

7

1

2

3

4

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 plug into blower
4. Plug DC blower control harness plug into blower
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.

 


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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

 

 


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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

 

 


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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

 


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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.

1

2

3

4

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.

 


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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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CFV Startup Guide

Part No. 750-288

11

1.On the CB Falcon 

Operation

 screen, press the 

Firing Rate

display in the Modulation section.

2. A numeric keypad will appear, showing the current firing rate
and operating mode.*

3. Under 

Firing rate control 

select 

Manual in Run

.

4. Press <Clear> to clear the current RPM value.

5. Enter the desired RPM setting using the numeric
keypad.

6. Press <OK>. The display will return to the Operation
screen and the burner will modulate to the chosen firing
rate.

*Use 

Manual in Run

 for normal manual operation. In 

Manual in Run

and Standby

 mode, the burner will not operate. Use this mode for

testing blower operation without firing the boiler.

If any of the following conditions occur:

• Loss of flame
• Excessive or unusual noise
• Flame appears irregular when viewed through sight glass
• Frequent low water shutdowns

Cease boiler operation. See the Troubleshooting section in the CFV manual or consult your authorized CB
representative.

Repeated nuisance low water shutdowns may indicate a problem with the boiler feed system and/or water
level controls.

4 - POST STARTUP

• Review 

Chapter 4 - Commissioning 

in the CFV manual. Ensure all safety checks have been performed 

according to instructions.

• Set high gas pressure switch to 50% higher than operating gas pressure at low fire. Set low gas pressure 

switch to 50% lower than operating gas pressure at low fire.

• Check the draft on the outlet stack and compare to acceptable limits (-0.25 to +0.25 inches WC). 

Operating outside of acceptable limits could result in light off and flame failure problems.

• Verify gas pressure remains within limits shown in Table 1.

• A new boiler should be cleaned by boil-out prior to being placed into service. See Chapter 4 of the CFV 

manual for boil-out procedure.

Figure 13  

Notice

The CFV has been factory tested at 1000’ ASL and tuned for 5-6% excess
O

2

. To ensure optimum combustion throughout the firing range, the O

2

%

should be verified and if necessary adjusted to the proper levels. This
procedure involves manually firing the burner while using a combustion
analyzer to monitor O

2

%. Low and high fire adjustments are made at the

main gas valve. See the CFV Operation and Maintenance manual for a
detailed procedure.

Note: If an alarm or lockout occurs

during startup or operation, see
t h e  b o i l e r  O p e r a t i o n  a n d
Maintenance manual.

 


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CFV Startup Guide

12

Part No. 750-288

5 - LOCKOUTS, HOLDS, AND ALERTS

To assist in monitoring boiler operation, the CB Falcon control system employs messages of three types:

Lockouts

,

 Holds

,

 

and

 Alerts

.

Lockouts

 and 

Holds

 indicate interruptions in boiler operation, whether occurring as part of the normal 

operating sequence or due to an abnormal condition. Lockouts require a manual reset to continue operation, 
while Holds do not. A Hold will automatically clear when the hold condition is removed or satisfied. 

The most recent Lockouts are stored in CB Falcon memory and may be accessed through the Lockout
History. Holds are not logged in memory.

Note:

 

Before attempting to restart the boiler after a Lockout, identify and correct the Lockout condition.

Alerts

 indicate conditions or events which, while not preventing boiler operation, may nevertheless be of 

interest in evaluating boiler performance or operating conditions. Examples include certain operator actions, 
out-of-range configuration data, controller internal status reports (e.g. timers, counters, memory read/write 
activity), and recycle events. Alerts require no operator acknowledgment and are for informational purposes 
only.

The most recently occurring message (Lockout, Hold, or Alert) is displayed in the alarm banner on the
Overview screen (see 

Figure 14

). Press this banner to access the Alert or Lockout History, where a list of

the most recently occurring Alerts/Lockouts can be viewed.

To obtain more information for a particular message, press that item in its respective history list. For Alerts,
burner cycle and hours of operation at the time of occurrence will be displayed. For Lockouts, in addition
to cycle and hours the screen will show on/off status of all interlocks at the time of the lockout. This
information can be used to help pinpoint the cause of a particular Lockout.

If the boiler is left unattended after a startup, the Alert/Lockout History can be consulted to determine
whether the boiler has been running normally or if operation has been interrupted due to a fault condition.

Figure 14  Alarm Banner

Alarm Banner

 


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CFV Startup Guide

Part No. 750-288

13

Figure 15  CFV Wiring Diagram

DENOTES CONTROL PANEL TERMINAL

5

LGPS

HGPS

(1)

(2)

MR

FUSE

BLOWER

OFF

ON

CNTRL

CIRC

5 AMP

BLOWER

AC POWER

CONNECTOR

CONNECTOR

G

L

N

G

LL1

115V/1PH AC FUSED

POWER SUPPLY W/

J2

3

4

VALVE

GAS

(3)

(2)

ELECTRODES

IGNITION

IGNITION

IONIZATION

ELECTRODE

TRANSFORMER

12

11

9

7

8

J4

3

6

4

1

2

FALCON

J1

4

CFV STEAM

MR

MR

GROUND

ALWCO

(COM)

(L2)

(L1)

(NO)

W

BK

GROUNDED NEUTRAL

TRANSFORMER

4

24 VAC

2

5

7

6

9

8

10

12

10

5

11

1

2

3

4

24

N

J8

1

J3

7

5

2

1

4

6

3

J5

J9

4

5

3

1

2

4

6

5

7

6

3

5

7

4

2

J6

8

1

5

2

4

6

3

1

J7

7

CANISTER

BURNER

J10

J11

DC CONTROL

2

CAPS

LCI

INTLK

EXT IGN

3

FUEL VALVE

PRE-IGN INTLK

9

10

11

ALARM

14

13

(COM)

(NO)

POWER

DEMAND

REM

LOC

(G)

(L1)

LWCO DF16

(L2)

4

(H)

PROBES

(8)

(7)

RESET

(MOM)

PB

1

9

COMMS

PS

(L)

(N)

(G) (V+) (V-)

4

12 VDC

8

ANNUN #1/IAS
ANNUN #2/LWCO

8

NOTES:

TERMINALS:  LL1,N,G,1,2,3,4-4-4,5-5-5,6,7,8,9,10,11,12,13,14,15,16,

CUSTOMER CONNECTIONS:

REMOTE ON-OFF   24 & 25

(24V 1A)

53

52

56

80

81

DASHED LINES INDICATE CUSTOMER CONNECTIONS

C1

C2

3C 18AWG

1 AMP

DISPLAY

51

12

ANNUN #3/ALWCO

PS FUSE

9

10

ANNUN #4/HLC

ANNUN #5/HGPS

ANNUN #6/LGPS

(R)

(C)

BL

W

11

6

7

5

4

3

2

1

6

7

5

4

3

2

1

8

ALARM

HLC

(4)

(1)

REMOTE

WH

BLK

RED

4

50

49

REMOTE ON-OFF

FUSE

(NC)

SHIELDED

21

29

30

22

23

24

25

26

28

27

14

15

16

17

18

19

20

10

11

12

13

8

9

6

7

4

5

2

3

1

REMOTE 4-20MA INPUT  26 & 27

(REF. 14)

(REF. 15)

(REF. 15)

(REF. 8)

(REF. 8)

(REF. 8)

(REF. 8)

BK

W

(REF. 8)

(REF. 9)

(REF. 15)

(REF. 15)

BLOWER MOTOR FUSE SELECTION

CFV HP

BLOWER MODEL

RATING, CLASS CC

10 - 30

G1G170-AB05-20

6 A

40

G3G200-GN26-01

12 A

50 - 60

G3G250-GN39-01

15 A

(REF. 8)

57

(6)

RLY1

(COM)

(NO)

RLY2

6

7

FW PUMP

FW PUMP ON/OFF  6 & 7

PROBE

(LLCO)

54

(L)

55

(A) (B) (C)

OLC

8

DATA +

DATA -

COMMON

A

C

B

GLOBAL MODBUS

CONNECTIONS

14 GAUGE

ALL CONTROL WIRE IS #18 AWG UNLESS OTHERWISE NOTED

REMOTE

26

+

-

XMTR

BK

BR

PRESS

-

+

4-20MA

23

25

(V-) (V+)

27

(REF. 25)

24

25

16

15

26,27,

23,24,25,

OFF

MODBUS RS485  J3-MB2 - A,B,C

REMOTE ALARM   15 & 16

(NC)

PR

BL

BL

BK

(G)

R

B/R

W

G

G

R

B/R

W

G

G

GY

OR

DISPLAY

Y

G

+ -

A

C

B

MB1

MB2

LOCAL

(REF. 7)

(REF. 8)

 


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CFV Startup Guide

14

Part No. 750-288

 


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CFV Startup Guide

Part No. 750-288

15

 


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