CleaverBrooks CFC-500 Operation, Service And Parts Manual
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CB FALCON 35 750-265 Plate Heat Exchanger Plate heat exchanger demand for DHW comes from one of two sources: • Tap Demand - detected primarily as a temperature decrease rate when hot water is “tapped”, e.g. when a tap is turned on. • Preheat demand - used to keep a plate exchanger preheated so it is warm enough to be ready to provide hot water, and also so t
CleaverBrooks CFC-500, Section 4 — CFC Commissioning Part No. 750-263 4-15 1. Changing Parameter Settings To access the CB Falcon configuration menu, press <Configure> on the Status page. Some parameters require a password entry before allowing changes. The <Login> button will appear when any password- protected parameter is displayed on the screen. Default service level password is 9220. Press <Login> to display the alphanumeric keyboard. Enter password and press <OK> Change parameter settings by selecting the parameter on the page. A dialog box appears with controls allowing the user to change
CleaverBrooks CFC-500, CB FALCON 71 750-265 simulate a flame signal for 10 seconds to 30 seconds for PREPURGE. b. *Flame Detected out of sequence* fault is displayed on the Operator Interface Module. c. Safety shutdown occurs. 4. Failure to ignite pilot or Main Burner (DBI setup). a. Close pilot and main fuel manual shutoff valve(s). b. Cycle burner on. c. Automatic pilot valve(s) or main valves (DBI) should be energized but the pilot or main burner (DBI) can- not ignite. d. *Ignition Failure* fault is displayed on the Operator Interface to indicate the fault. e. Safety shutdown occurs. 5. Failure
CleaverBrooks CFC-500, V4730C/V8730C/V4734C 1:1 Gas/Air Servo Regulated Gas Valves EN2R-9074 0612R1-NE 11 Fig. 11: Capacity curves for V4730C/V8730C and VMU 300 Venturi, 1 in. size. Fig. 12: Capacity curves for V4730C/V8730C and VMU 335 Venturi, 1-1/4 in. size.
CleaverBrooks CFC-500, Section 4 — CFC Commissioning 4-14 Part No. 750-263 *Access Levels: Read Only = parameter not configurable OEM = manufacturer only Service = password required (default password is 9220) User = no password required Lead Lag Configuration Lead Lag add stage detection time 1 Service 60 300 seconds 0716 Lead Lag Configuration Lead Lag add stage error threshold Service 5 °F 0718 Lead Lag Configuration Lead Lag add stage rate offset Service -100 20% 100 % 0719 Lead Lag Configuration Lead Lag add stage interstage delay Service 180 900 seco
CleaverBrooks CFC-500, CB FALCON MODBUS COMMUNICATION 27 Table 4. CB Falcon Modbus register map 0272 0626 Outdoor temperature source R/W U16 0=Unconfigured, 1=S5 connector, 2=S10 connector, 3=Modbus, 4=EnviraCOM sensor 0273 0627 Warm weather shutdown enable R/W U16 0=Disable, 1=Enable 0274 0628 Warm weather shutdown setpoint R/W U16 -40°-130° (0.1°C precision) a 0275 0629 Use STAT with EnviraCOM remote stat R/W U16 0=Disable, 1=Enable 0276-02AF 0630-0687 RESERVED DHW PLATE HEAT EXCHANGER CONFIGURATION 02B0 0688 Plate preheat delay after tap R/W U16 0-64800 seconds (18 hours), 0xFFFF=Not configured 02B1 0689 Plate
CleaverBrooks CFC-500, CB FALCON 107 750-265 50 Modulation fault Internal sub-system fault. 1. Review alert messages for possible trends. 2. Correct possible problems. 3. If fault persists, replace module. H 51 Pump fault H 52 Motor tachometer fault H 53 AC inputs phase reversed 1. Check the Module and display connections. 2. Check the Module power supply and make sure that both frequency and voltage meet the specifications. 3. On 24Vac applications, assure that J4-10 and J8-2 are connected together. L 54 Safety GVT model ID doesn't match application's model ID L 55 Application configuration data block CRC errors L 56-57 RESERVED 58 Internal fault: HFS
Section 4 — CFC Commissioning 4-10 Part No. 750-263 Pump Configuration Boiler pump options 2 Service 0xC0DF 0301 Pump Configuration System pump options 1 Service 0xE36C 0302 Pump Configuration System pump options 2 Service 0x801D 0303 Pump Configuration Auxiliary 1 pump overrun time Service 0 300 28800 seconds 0752 Pump Configuration Auxiliary 1 pump options 1 Service 0x0003 0753 Pump C
CleaverBrooks CFC-500, CB FALCON MODBUS COMMUNICATION 17 Table 4. CB Falcon Modbus register map 011B 0283 Boiler pump overrun time R/W U16 0-64800 seconds (18 hours), 0xFFFF=Not configured 011C 0284 Auxiliary 1 pump output R/W U16 0=None, 1=Pump A, 2=Pump B, 3=Pump C 011D 0285 Auxiliary 1 pump control R/W U16 0=Auto, 1=On 011E 0286 RESERVED 011F 0287 System pump output R/W U16 0=None, 1=Pump A, 2=Pump B, 3=Pump C 0120 0288 System pump control R/W U16 0=Auto, 1=On 0121 0289 System pump overrun time R/W U16 0-64800 seconds (18 hours), 0xFFFF=Not configured 0122 0290 Pump exercise interval R/W U16 Days 0123 0291 Pump exercise time R/W U16 0-64800 seco
CB FALCON 49 750-265 DHW High Limit (Hydronic Control) If DHW high limit enable is enabled then whenever the DHW high limit has been reached the DHW pump will be forced off. It will remain off until the DHW input temperature is lower than the DHW high limit temperature minus 5°F. The DHW high limit pump inhibit function is not a safety function. CH slow start en
CleaverBrooks CFC-500, CB FALCON 750-265 36 Fig. 15. Plate heat exchanger subsystem. Table 12. Plate Heat Exchanger Parameters. Parameter Comment Tap detect degrees per second Degrees or None This tap demand “set” criteria depends on rate of change of the DHW sensor. The rate of change of this temperature is monitored. If it falls at a rate faster than specified degrees per second then the Tap demand block is “Set” (Tap demand becomes true and the minimum on timer is started). Tap detect on hysteresis Degrees or None The second tap demand “set” criteria depends on the value of the DHW sensor. If the
CleaverBrooks CFC-500, Section 4 — CFC Commissioning Part No. 750-263 4-23 To set combustion: 1. Check inlet gas pressure and reset low gas pressure switch. 2. At Operation screen set firing rate to low fire. Review burner sequence before proceeding. 3. Turn LOCAL/REMOTE switch to LOCAL. 4. Initiate burner firing sequence. The burner switch is accessed via the CB Falcon Operation page (Figure 4-9). If the burner does not ignite, adjust choke counterclockwise slightly until you can see a slight yellow flame at the burner during ignition. Clockwise adjustments to t
Section 4 — CFC Commissioning 4-28 Part No. 750-263 L. FALCON CONTROL FUNCTIONS AND CUSTOMER INTERFACE Following is a brief overview of the Falcon control features on ClearFire boilers. Please refer to the Falcon Control operating instructions in Appendix A for more detailed explanations. •Set Point • Time-of-Day (TOD) Set Point •Hysteresis On and
CleaverBrooks CFC-500, CB FALCON 750-265 88 Sequencer Drop Lag Boiler Selection When the stager asks the sequencer for a lag boiler to drop the sequencer looks at the StagingOrder numbers of all Firing boilers. If only one Firing boiler is found, or none are found, then this selection function returns a value that indicates no boiler may be dropped. Otherwise it returns an identifier for the boiler having the highest StagingOrder number. Sequencer 1 Minute Event Part of the sequencer is called by the timing service at a 1 minute rate to implement
CleaverBrooks CFC-500, iv TO: Owners, Operators and/or Maintenance Personnel This operating manual presents information that will help to properly operate and care for the equipment. Study its contents carefully. The unit will provide good service and continued operation if proper operating and maintenance instructions are fol- lowed. No attempt should be made to operate the unit until the principles of operation and all of the components are thoroughly understood. Failure to follow all applicable instructions and warnings may result in severe person
CleaverBrooks CFC-500, CB FALCON MODBUS COMMUNICATION 13 Table 4. CB Falcon Modbus register map 00B4 0180 Alarm silence time R/W U16 0-600 minutes 00B5 0181 Power up with lockout R/W U16 SAFETY parameter f : 0=Clear lockout on power-up (reset), 1=Do not clear lockout on power-up (preserve) 00B6 01820182 Reset and restart W U16 Force soft reset of Falcon subsystems: 0=None, 1=Burner control, 2=Application, 3=Burner control & application, 4=Clear alert log Successful login required before request is granted. 00B7 0183 Burner name R/W Variable length string
CleaverBrooks CFC-500, CB FALCON MODBUS COMMUNICATION 32 33 Internal fault: Safety Key 1 Lockout 34 Internal fault: Safety Key 2 Lockout 35 Internal fault: Safety Key 3 Lockout 36 Internal fault: Safety Key 4 Lockout 37 Internal fault: Safety Key 5 Lockout 38 Internal fault: Safety Key 6 Lockout 39 Internal fault: Safety Key 7 Lockout 40 Internal fault: Safety Key 8 Lockout 41 Internal fault: Safety Key 9 Lockout 42 Internal fault: Safety Key 10 Lockout 43 Internal fault: Safety Key 11 Lockout 44 Internal fault: Safety Key 12 Lockout 45 Internal f
CleaverBrooks CFC-500, Section 4 — CFC Commissioning Part No. 750-263 4-21 IGNITION FAILURE CHECK 7. A test of the flame rod circuit can also be performed at this time. Disconnect the flame rod cable and attempt to start the burner. The CB Falcon should lock out, indicating Lockout 109 Ignition Failure. 8. Replace flame rod electrode and grounding tab. After verifying proper operation of LGPS, HGPS, CAPS, and Gas Valve, re-open the downstream manual shut-off valve. 4. LOW WATER CUTOFF Check 1. Hold down the LOW WATER RESET-TEST switch for 3 seconds. 2. Check Annunciation screen. The ILK section (Interlock circuit) should show A3 LOW
CleaverBrooks CFC-500, Section 2 — Installation Part No. 750-263 2-31 2. Condensate Piping for Multiple Boilers More than one Model CFC boiler can be piped into a common condensate neutralization tank. See Figure 2-39 and Figure 2-40 for the suggested layout. 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 2-39 Condensate Piping for Multiple Boilers Figure 2-40 Condensate Treatment Tank for Multiple Boilers To Drain 1/4" O.D. Make-up Water Supply Condensate Drain Trap Neutralization Tank To Drain C
CleaverBrooks CFC-500, Section 2 — Installation Part No. 750-263 2-25 Figure 2-29 Pressure Drop Curve, CFC 1000, U.S. Flow Rates Figure 2-30 Pressure Drop Curve, CFC 1000, Metric Flow Rates Hydraulic Resistance CFC 1000 0 0.2 0.4 0.6 0.8 1 1.2 0 8.8 22 44 66 88 110 132 154 176 Flow - GPM Pressure - PSI Hydraulic Resistance CFC 1000 0 10 20 30 40 50 60 70 80 0 2 5 10152025303540 Flow m3/h Pressure mbar
CleaverBrooks CFC-500, Section 4 — CFC Commissioning 4-4 Part No. 750-263 E. CB FALCON DISPLAY/OPERATOR INTERFACE The CB Falcon display/operator interface is mounted at the left side of the control panel for convenient access to all operating controls. 1. Home Page Apply power to the boiler. The Home page will appear on the CB Falcon display. Each CB Falcon in the hydronic system is represented on the Home page by an icon and name. 2. Status Page Pressing the Falcon icon takes the user to the Status page, which summarizes boiler status and allows navigation to the configuration, operational, and diagnostic areas of the CB Falcon interface. The Dem
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