CleaverBrooks CFC ClearFire Operation & User’s Manual

Text of CleaverBrooks CFC ClearFire User Guide:

• CleaverBrooks CFC ClearFire, Model CFC ClearFire Commercial Boilers 3 Rev. 05-2012 MODEL CFC FEATURES AND BENEFITS Compact Firetube Design The Model CFC boiler is a single pass, vertical down fired durable firetube boiler. The internal extended-heating surface tubes provide very high levels of performance in a compact space, offering over 10 square feet of heating surface per boiler horsepower, providing many years of trouble free performance. Advanced Technology Tubes and tube sheets are constructed from UNS S32101 duplex stainless steel. Tubes feature AluFer tube inserts for optimal heat transfer. Advanced Construction The extended heating surf

• CleaverBrooks CFC ClearFire, Figure B5-36. Two Boilers and Three Variable Temperature Zones (No Primary 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

• CleaverBrooks CFC ClearFire, Figure B5-43. ‘Hybrid’ Boilers with Domestic Water CFC 1 BOILER OUTLET (SUPPLY) 2 BOILER INLET (RETURN) 3 SECONDARY CONNECTION 4 ISOLATION VALVES 5 PURGE COCKS 6 AIR SEPARATOR WITH 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 Retur n FLX 2 4 1 8 4 130 F 150 F Sensor Hot Water Outl

• Model CFC ClearFire Commercial Boilers 2 Rev. 05-2012 Zoning with Zone Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Domestic Water with 2 Boilers and 2 Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

• Figure B5-41. Domestic Water with On/Off and 3-Way Valves ClearFire Full Condensing ClearFire Full Condensing To Condensate Drain To Sanitary Drain System Returns Domestic Co l 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 Ma

• CleaverBrooks CFC ClearFire, Model CFC ClearFire Commercial Boilers 30 Rev. 05-2012 Table B5-21. Model CFC Maximum Condensation As prescribed by local codes, this condensate may be discharged directly to the drain or treated using an optional treatment assembly. Figure B5-21 depicts piping without the treatment assembly and Figure B5-22 shows the optional treatment assembly. Condensate Piping for Multiple Boilers The number of condensate treatment tanks required for multiple boiler installations depends on the total amount of condensate produced by the system. As a general rule, CB recommends one tank per 5 million BTU/hr of boiler capacity (5.0 MMBTU/hr). Model CFC capacities are in Table B5-22. See Fig

• CleaverBrooks CFC ClearFire, Model CFC ClearFire Commercial Boilers 57 Rev. 05-2012 2. The vent must be at least seven feet above grade when located adjacent to public walkways. 3. Terminate vent at least three feet above any forced air inlet located within ten feet. 4. Vent must terminate at least four feet horizontally, and in no case above or below unless four feet horizontal distance is maintained, from electric meters, gas meters, regulators, and relief equipment. 5. Terminate vent at least six feet from adjacent walls. 6. DO NOT terminate

• CleaverBrooks CFC ClearFire, Figure B5-35. Zoning with Zone Valves CFC 1 BOILER OUTLET (SUPPLY) 2 BOILER INLET (RETURN) 4 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)

• CleaverBrooks CFC ClearFire, Model CFC ClearFire Commercial Boilers 8 Rev. 05-2012 • Low Gas Pressure Interlock, manual reset. • High Gas Pressure Interlock, manual reset. • ASME CSD-1 Test Cocks. • Downstream manual ball type shutoff cock. • Single body dual safety shutoff gas valve. Optional Equipment For option details, contact the local authorized Cleaver-Brooks representative. In summary, here are some of the options that can be provided with the boiler: A. Dual gas train for quick and easy fuel switchover. B. Reusable air filter. C. Condensate neutralization tank assembly - consists of neutralizing media, filter, and PVC condensate holding tank with integral drain trap. This assembly ca

• CleaverBrooks CFC ClearFire, Figure B5-37. Two-Pipe Primary/Secondary Piping with Domestic Hot Water Boiler Heating Load A Heating Load B Heating Load C 1 BOILER OUTLET (SUPPLY) 2 BOILER INLET (RETURN) 3 SECONDARY CONNECTION 4 ISOLATION VALVES 5 PURGE COCKS 6 AIR SEPARATOR WITH AUTOMATIC AIR VENT 7 DIAPHRAGM EXPANSION TANK WITH FILL VALVE 8 BALANCING VALVES (SQUARE HEAD COCKS) 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 (FI

• CleaverBrooks CFC ClearFire, Model CFC ClearFire Commercial Boilers 21 Rev. 05-2012 (90.5 C) is set for normal boiler operation. While proper overpressure is required, a means to relieve excess pressure at or beyond the design pressure of the boiler must be provided. As boiler water is heated, expansion occurs. And this expansion must be accounted for either with an expansion tank (air filled) or with a bladder type tank. These devices permit the water pressure to expand outside of the boiler and not impact the pressure ve

• CleaverBrooks CFC ClearFire, Model CFC ClearFire Commercial Boilers 15 Rev. 05-2012 Table B5-7. CFC 1000 ClearFire Efficiency Table B5-8. CFC 1500 ClearFire Efficiency Table B5-9. CFC 1800 ClearFire Efficiency Table B5-10. CFC 2500 ClearFire Efficiency Table B5-11. CFC 3300 ClearFire Efficiency Firing Rate % Return Water Temperature F 0 (C) 68 80 100 120 130 140 160 (20) (27) (38) (49) (55) (60) (72) 20 99 97.8 94.3 92.4 90.1 88.5 88 50 98.5 96.5 93.5 90.8 89.5 88.5 87.5 75 97.5 96.2 92.5 89.5 88.3 88 87.3 100 96.5 95.8 91.5 88.9

• CleaverBrooks CFC ClearFire, Model CFC ClearFire Commercial Boilers 67 Rev. 05-2012 CB FALCON CONTROLLER 1. Control Description - The CB Falcon hydronic control is an integrated burner management and modulation control with a touch-screen display/operator interface. 2. Functionality - The controller is capable of the following functions: • Flame supervision • Burner sequencing • Heating/modulation control • Hot water system pump control • High Limit temperature control • Thermowell-mounted NTC temperature sensors to provide measured process variable signals to the controller. • User-friendly touchscreen interface �

• CleaverBrooks CFC ClearFire, Model CFC ClearFire Commercial Boilers 20 Rev. 05-2012 Noise Level The Model CFC is extremely quiet at all operating levels, does not require any sound level modifications to provide ultra low noise levels, and is virtually vibration free. Thus, it is very suitable in applications that demand low noise levels. Table B5-11 shows the noise levels of the Clearfire at various firing rates. Table B5-11. Noise Level (dBA) measured 3 feet in front of boiler ENGINEERING DATA Boiler Information The Model CFC boiler is designed for service in any closed hydronic system and can be used to augment any hot water system. It can be put into operation as a single stand-alone u

• CleaverBrooks CFC ClearFire, Model CFC ClearFire Commercial Boilers 51 Rev. 05-2012 Figure B5-45. Two Opening Outside Wall Method B. All Air From Outdoors - If all combustion air will be received from outside the building (the mechanical room equipment is linked with the outdoors), the following methods can be used: 1. Two Opening Method (Figure B5-45) - The mechanical equipment room must be provided with two permanent openings, one terminating within twelve inches from the top, and one opening terminating within twelve inches of the bottom of the room. 2. T

• CleaverBrooks CFC ClearFire, Model CFC ClearFire Commercial Boilers 33 Rev. 05-2012 Figure B5-26. Gas Piping Schematic Consideration of volume and pressure requirements must be given when selecting gas supply piping. Connections to the burner gas train must include a union so that the burner may be opened for inspection and maintenance. A. Gas supply connection is at the rear of the boiler near the top. To permit burner opening, gas piping must not traverse the top of the boiler. B. Table B5-23 shows the gas pressure required at

• CleaverBrooks CFC ClearFire, Model CFC ClearFire Commercial Boilers 36 Rev. 05-2012 Figure 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

• Figure B5-42. Piping ‘Hybrid’ Boilers CFC 1 BOILER OUTLET (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 Retur n FLX 2 3 1 7 3 130 F 150 F Sensor 3 3 3 3 3 3 7

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