CleaverBrooks ClearFire SFH Startup Manual - User Manual

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ClearFire

Model CFH

Horizontal Steam Boiler

Startup Guide

750-293

CFH Startup Guide

Part No. 750-293

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 com-
bustible materials, gasoline, and other flammable liq-
uids 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

The installation must conform to the requirements
of the authority having jurisdiction or, in the ab-
sence of such requirements, to UL 795 Commer-
cial-Industrial Gas Heating Equipment and/or the
National Fuel Gas Code, ANSI Z223.1

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

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

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

The boiler and its gas connection must be
leak tested before placing the boiler in
operation.

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 CFH Operation and Maintenance Manual

CB Part Number 750-295

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

DANGER

WARNING

CFH Startup Guide

Part No. 750-293

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 CFH manual.

Figure 1 CFH Connections

Boiler room ambient conditions

Relative humidity

< 85% non-condensing

Ambient temperature range

C to 50

C / 32

F to 122

Storage temperature range

-20

C to 60

C / -4

F to 140

Combustion air temperature

C to 50

C / 32

F to 122

Specifications

Input power

115 VAC single phase 60Hz

Recommended operating steam
pressure

Up to 135 psig (150# design)
Up to 13.5 psig (15# design)

Gas pressure requirements

See Table 1

GAS SUPPLY

CHEMICAL FEED

FEED WATER

COMB. AIR/

DIRECT VENT

WATER COLUMN DRAIN

GAUGE GLASS

DRAIN

CHEMICAL FEED

STEAM OUTLET

STACK OUTLET

SURFACE

BLOWOFF

BLOWDOWN

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.

CFH Startup Guide

Part No. 750-293

1.2 Gas Piping

A manually operated shut-off valve and pressure regulator are provided as standard on the Model CFH 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 CFH 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 CFH Operation and Maintenance manual.

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 prop erly piped to prevent buildup of back pressure an d
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.

Connections are provided for optional chemical feed, surface blowoff,
and overflow.

Table 1 CFH gas pressure requirements

Boiler HP

Minimum pressure required

at gas train connection

Max. pressure

7.2" w.c.

28” w.c.

7.3" w.c.

7.5" w.c.

7.7" w.c.

8.5" w.c.

11.0" w.c.

10.0" w.c.

Note: To measure supply pressure

at the CFH gas valve, use the
test port on the valve inlet
flange (see below). Do not
use the leak test cocks to
measure gas pressure.

Figure 2 Pressure Relief Valve

CFH Startup Guide

Part No. 750-293

1.5 Electrical Connections

Refer to

Figure 3

and

Figure 4

for CFH 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 CFH 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 4 CFH wiring and cable connections

Figure 3 Control panel cable connections

Blowe

Sig

Cable

Fla

e Rod Cable

Cable Ha

ess

Blowe

Powe

Cable

(Panel cover removed)

Customer

connections
and power
wiring

Ignition
Transformer

(Burner Controls)

CB Falcon

NOTICE

The blower signal wiring
must be isolated from the
blower power wiring and the
high voltage ignition cables.

CFH Startup Guide

Part No. 750-293

1.6 Safety Controls

Users should take note of the safety controls installed as standard on the Model CFH. 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 CFH 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 5

) 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.

Figure 5 Combustion Safety Controls at Burner

Water Level Controls

(see

Figure 6

)

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 6 Water Level Controls

Low Gas Pressure Switch

High Gas Pressure Switch

Combustion Air
Proving Switch

Flame Rod
(Ionization Electrode)

Dual SSOV

ALWCO Co

w/Reset

LWCO & P

p Co

CB Falco

olle

Control panel interior

LWCO

ALWCO

CFH Startup Guide

Part No. 750-293

Limit Controls

(see

Figure 7

)

The operating and high pressure limit controls are
externally mounted to the boiler casing. For control
settings and testing instructions, see the boiler
operation manual.

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 the CC-BLOWER
switch (see

Figure 8

) in the OFF position. Open the boiler vent valve

(see

Figure 9

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.

Warning

T h e M o d e l C F H i s f a c t o r y t e s t e d .
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.

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.

Figure 9 Filling the Boiler

OLC

HLC

Figure 7 Limit Controls

Figure 8 Control Panel

Switches

Important

Vent Valve

Gauge
Glass

Feedwater
Inlet

CFH Startup Guide

Part No. 750-293

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 10

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.

2.1 Controller Configuration

The CB Falcon controller is factory pre-configured with default
parameter settings for the Model CFH. Prior to starting the boiler,
verify that the factor y 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

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 Home Page; Falcon power indicator

HOME PAGE

POWER

Falcon

controller

icon

LED

Note:

The “Home” icon at the
upper lef t of the display
screen always returns to the
Home Page.

The “Back” icon at the upper
right displays the previous
screen.

CFH Startup Guide

Part No. 750-293

Figure 11 Changing the setpoint

2.2 Initiating Burner Sequence

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

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

Figure 12 Operation 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.

BURNER
SWITCH

button

Warning

Before initial startup, check for
blockages in the flue venting or
vent terminations. Inspect the
burner and furnace for any con-
tamination or blockages.

CFH Startup Guide

Part No. 750-293

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 13

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:

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.

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 13 Burner Sequence

Figure 14

CFH Startup Guide

Part No. 750-293

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 CFH 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 CFH 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 CFH

manual for boil-out procedure.

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.

Notice

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

. To ensure optimum combustion throughout the firing

range, the O

% 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

%. Low and high

fire adjustments are made at the main gas valve. See the CFH
Operation and Maintenance manual for a detailed procedure.

Note:

If an alarm or lockout occurs

during startup or operation, see the
boiler Operation and Maintenance
manual

CFH Startup Guide

Part No. 750-293

•

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 15

). 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 15 Alarm Banner

Alarm Banner

CFH Startup Guide

Part No. 750-293

Figure 16 CFH Wiring Diagram

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