CleaverBrooks ClearFire CFH Guide

Model CFH
Gas High-Efficiency Steam Boiler
Operation, Service, and Parts Manual
750-295
07/2020
10-80 HP
ClearFire
®

ii
!DANGER
WARNING
If the information in this manual is not followed ex-
actly, a fire or explosion may result causing prop-
erty damage, personal injury or loss of life.
— Do not store or use gasoline or other flamma-
ble vapors and liquids in the vicinity of this or any
other appliance.
— WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use
any phone in your building.
• Immediately call your gas supplier from a
neighbor's phone. Follow the gas supplier's
instructions.
• If you cannot reach your gas supplier, call the
fire department.
— Installation and service must be performed by
a qualified Cleaver-Brooks service agency or the
gas supplier.
Improper installation, adjustment, service, or
maintenance can cause equipment damage, per-
sonal injury, or death. Refer to the Operation and
Maintenance manual provided with the boiler. In-
stallation and service must be performed by a
qualified Cleaver-Brooks service provider.
!DANGER
WARNING
!DANGER
WARNING
Be sure the fuel supply which the boiler
was designed to operate on is the same
type as specified on the boiler name
plate.
!DANGER
WARNING
Should overheating occur or the gas sup-
ply 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 Cleav-
er-Brooks service representative to in-
spect the boiler and to replace any part of
the control system and any gas control
which has been under water.
!DANGER
WARNING
To minimize the possibility of serious personal in-
jury, fire or damage to the equipment, never vio-
late the following safety rules.
— Always keep the area around the boiler free of
combustible materials, gasoline, and other flam-
mable 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.
This manual must be maintained in legible condi-
tion and kept adjacent to the boiler or in a safe
place for future reference. Contact your local
Cleaver-Brooks representative if additional manu-
als are required.
Notice
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 boiler and its individual shutoff valve
must be disconnected from the gas sup-
ply piping system during any pressure
testing of that system at test pressures in
excess of 1/2 psi (3.5 kPa).
!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

iii
Please direct purchase orders for replacement manuals to your local Cleaver-Brooks authorized representative.
Manual Part No. 750-295
07/2020 Printed in U.S.A.
 Cleaver-Brooks 2020
CLEAVER-BROOKS
Model CFH
ClearFire®Packaged Boiler
Gas High Efficiency Boiler
Operation, Service, and Parts Manual

iv
TO: Owners, Operators and/or Maintenance Personnel
Cleaver-Brooks equipment is designed and engineered for long life and excellent service. The electrical and mechanical
devices supplied as part of the unit were chosen because of their known ability to perform; however, proper operating
techniques and maintenance procedures must be followed at all times. Although these components afford a high degree
of protection and safety, due attention must be given to the dangers and hazards inherent in handling and firing of fuel.
“Automatic” design features, where present, do not relieve the attendant of responsibility. Such features merely eliminate
certain repetitive chores, allowing more time for the proper upkeep of equipment.
Controls and safety devices may vary due to state, local, or other applicable codes.
It is recommended that a boiler room log or record be maintained. Recording of daily, weekly, monthly and yearly main-
tenance activities and recording of any unusual operation will serve as a valuable guide to any necessary investigation.
Most instances of major boiler damage are the result of operation with low water. We cannot emphasize too strongly the
need for the operator to periodically check the low water controls and to follow good maintenance and testing practices.
Cross-connecting piping to low water devices must be internally inspected periodically to guard against any stoppages
which could obstruct the free flow of water to the low water devices.
The waterside condition of the pressure vessel is of extreme importance. Waterside surfaces should be inspected fre-
quently to check for the presence of mud, sludge, scale or corrosion. It is essential to obtain the services of a qualified
water treating company or a water consultant to recommend the proper boiler water treating practices.
The operation of this equipment must comply with all requirements or regulations of the insurance company and/or other
authority having jurisdiction. In the event of any conflict or inconsistency between such requirements and the warnings
or instructions contained herein, please contact Cleaver-Brooks before proceeding.
DO NOT OPERATE, SERVICE, OR REPAIR THIS EQUIPMENT UNLESS YOU FULLY UNDERSTAND ALL
APPLICABLE SECTIONS OF THIS MANUAL.
DO NOT ALLOW OTHERS TO OPERATE, SERVICE, OR REPAIR THIS EQUIPMENT UNLESS THEY FULLY
UNDERSTAND ALL APPLICABLE SECTIONS OF THIS MANUAL.
FAILURE TO FOLLOW ALL APPLICABLE WARNINGS AND INSTRUCTIONS MAY RESULT IN SEVERE
PERSONAL INJURY OR DEATH.
!DANGER
WARNING

v
TABLE OF CONTENTS
Chapter 1 — Introduction
Model CFH Features And Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
The Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
The Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Burner Gas Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Water Level & Steam Pressure Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Chapter 2 — Installation
Boiler Room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Lifting and Moving the Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Boiler Room / Boiler Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Connection Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Electrical Connections & Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Chapter 3 — Flue and Combustion Air Venting
Venting Connections — General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Flue Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Vent Terminal Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Horizontal Thru-Wall Venting, Inside Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Horizontal Thru-Wall, Direct Vent Combustion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Horizontal Thru-Wall Flue Vent Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Vertical Venting, Inside Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Vertical Venting, Direct Vent Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Combustion Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Maximum Vent Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Chapter 4 — Commissioning
Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Filling Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Control Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Water Level Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Model CFH Boiler / Burner Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
CB Falcon Display/Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Controller Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Burner Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Fan Speed Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Operating and High Limit Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Procedures for LP (Propane) Gas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
High Turndown Applications (70 & 80 hp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Initial Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Boil-Out of a New Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Post Start-up Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Falcon Control Functions and Customer Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Chapter 5 — Service and Periodic Maintenance
General ....................................................................................................................................................... 5-2
Blowdown ................................................................................................................................................... 5-2
Water Column Blowdown .............................................................................................................................. 5-3
Fireside Cleaning Procedure/Disassembly ........................................................................................................ 5-5
Ignition Electrodes ......................................................................................................................................... 5-6
UV Scanner .................................................................................................................................................. 5-7
Adjustable Flame Rod.................................................................................................................................... 5-8
Waterside Inspection/Cleaning ....................................................................................................................... 5-9
Safety Valve ................................................................................................................................................. 5-9
Troubleshooting ......................................................................................................................................... 5-10
Lay-up ...................................................................................................................................................... 5-12
Chapter 6 — Parts
Control Panel 10-60 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Control Panel 70-80 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Burner Assembly 10-60 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Burner Assembly 70-80 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Gas Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Boiler Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Recommended Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Sealed Combustion Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Direct Vent Combustion Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29

vi
Safety Precautions
Throughout this manual, procedures or operations that require special attention are emphasized with a cau-
tionary note. The notes are identified by the symbols WARNING! CAUTION! or NOTE, signifying the follow-
ing:
NOTE: Indicates information that is vital to the operation or maintenance of the equipment.
!DANGER
WARNING
Indicates a potentially hazardous situation which, if not
avoided, could result in serious personal injury or death.
!DANGER
CAUTION
Indicates a potentially hazardous situation which, if not
avoided, could result in damage to the equipment.

www.cleaverbrooks.com
Chapter 1
Introduction
Model CFH Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
The Model CFH Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
The Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Burner Gas Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Water Level & Steam Pressure Controls . . . . . . . . . . . . . . . . . . . . . . 1-6
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Chapter 1 — Introduction
1-2 Part No. 750-295
1.1-MODEL CFH FEATURES AND BENEFITS
Compact Firetube Design
The Model CFH boiler is a compact horizontally fired firetube boiler. The extended heating surface tubes
provide for very high levels of performance in a compact space. The Model CFH boiler is designed to fire
natural gas or LP gas. Dual fuel arrangement (natural gas and propane) is also available.
High Efficiency
With the extended heating surface provided by the patented AluFer®tube design (Figure 1-1) the Model
CFH has a nominal fuel to steam efficiency of 85%.
Advanced Construction
Constructed to ASME standards and utilizing AluFer®Tube
technology in a single-pass design, the Model CFH Boiler will
provide many years of trouble free service. Single-pass design
provides excellent thermal shock protection.
Ease of Maintenance
The enclosure is readily removable for access to all key burner
components. A hinged door on the control panel provides access
to all controls.
Quality Construction
ASME construction ensures high quality design, safety, and
reliability.
ISO 9001 certified manufacturing process ensures adherence to
the highest manufacturing standards.
Full Modulation
The burner and combustion fan modulate to provide only the amount of heat required, providing quiet and
efficient operation under all conditions.
Premix Technology
The Model CFH Boiler utilizes “Premix” technology to mix both fuel and combustion air prior to entering the
firing chamber. This technology provides clean, efficient combustion with very low emission levels.
1.2-THE MODEL CFH BOILER
Firetube boilers are rated in boiler horsepower (BHP), which should not be confused with other horsepower
measurements (1 BHP = 33,475 BTU/hr.).
Steam boilers are designed for low pressure or high pressure applications. Low pressure boilers - those
bearing the ASME “H” stamp - are limited to 15 psig maximum design pressure, and are typically used for
heating applications. The CFH minimum operating pressure for acceptable steam quality (99% dry steam)
is 6 psig.
CFH high pressure steam boilers are used for a variety of applications requiring high pressure steam in a
compact footprint, and have a design pressure of 150 psig.
Steam boilers are defined according to design pressure and operating pressure. Design pressure is the
maximum pressure used in the design of the boiler for the purpose of calculating the minimum permissible
thickness or physical characteristics of the pressure vessel parts of the boiler. Typically, the safety valves
are set at or below design pressure. Operating pressure is the pressure of the boiler at which it normally
Figure 1-1 AluFer® tube cross
section

Chapter 1 — Introduction
Part No. 750-295 1-3
operates. In order to prevent the safety valve from opening too frequently during normal operation, the
operating pressure should not exceed 90% of the safety valve setting.
Feedwater equipment should be ready for use upon installing the boiler. Be sure that all valves, piping,
boiler feed pumps, and receivers are installed in accordance with prevailing codes and practices.
As with any boiler, waterside care and maintenance are of critical importance to the Model CFH. Proper
attention to water requirements will pay dividends in the form of longer life, less down-time, and prevention
of costly repairs.
The initial period of service can be especially critical, as the waterside of new boilers may contain oil, grease
or other foreign matter.
The flue side of the Model CFH boiler is virtually maintenance free. Periodic inspection of furnace and Alufer®
tubes is recommended during required service and inspection intervals. See Chapter 5, Maintenance, for
details.
!Caution
Waterside care is of prime importance. For specific information or assistance with your water
treatment requirements, contact your Cleaver-Brooks service and parts representative. Fail-
ure to follow these instructions could result in equipment damage.
Control
Panel
AluFer
Tubes
Flue Gas
Outlet
Safety Relief Valve
Burner Controls
Burner
Burner
Canister
Door
Furnace
Gas Connection
Steam
Outlet
Access Cover
Low Water Cut-Off
Pressure
Gauge
ALWCO
Figure 1-2 CFH cutaway view
Blower

Chapter 1 — Introduction
1-4 Part No. 750-295
1.3-THE BURNER
The CFH burner uses a “premix” design, whereby fuel and air combine prior to entering the burner.
• The burner utilizes a mixing venturi, dual safety shutoff-single body pressure regulating gas valve,
variable speed blower, and Fecralloy metal fiber burner canister (see Figure 1-3).
• Full modulation is provided using the integral variable speed combustion air fan (up to 5:1 turndown;
10:1 for 70-80 HP).
• Solid body radiation of the burner flame provides clean, efficient combustion and low emissions.
• At maximum firing rate, the sound level of the burner is less than 70 dBA, measured in front of the boiler
at a distance of 3 feet. At reduced firing rates, sound levels are even lower.
• Optional sealed or direct vent combustion available.
• Combustion Air Proving Switch standard.
• Air filter for combustion air intake standard.
Figure 1-3 Burner components
1.4-BURNER GAS TRAIN
The gas train assembly (Figure 1-4) is provided
in accordance with UL/cUL certification and
ASME CSD-1. The gas train assembly is factory
assembled and wired, consisting of the
following components:
• Single body, dual safety shutoff gas valve
with integral trim regulator
• Low Gas Pressure Switch
• High Gas Pressure Switch
• (2) Manual Shutoff Valves
• Leak Test Cocks
• Supply pressure regulator (1 psig max)
Shutoff Valve
Figure 1-4 Gas train

Chapter 1 — Introduction
Part No. 750-295 1-5
1.5-CONTROLS
The CB Falcon steam boiler control is an integrated burner management and modulation control with a
touch-screen display/operator interface.
Figure 1-5 Control panel front
Figure 1-6 Control panel interior
FALCON DISPLAY
DEMAND
SWITCH
ALWCO
RESET
OPTIONAL ALARM/LIGHT PKG.
IGNITION
CABLE
IGNITION
TRANSFORMER
BLOWER SIGNAL CABLE
10-60 HP
70-80 HP

Chapter 1 — Introduction
1-6 Part No. 750-295
The controller is capable of the following functions:
• Burner sequencing with safe start check, pre-purge, direct spark ignition, and post purge.
• Electronic ignition.
• Flame Supervision.
• Safety shutdown with time-stamped display of lockout condition.
• Variable speed control of the combustion fan.
• Supervision of low and high gas pressure, air proving, stack back pressure, high limit, and low water.
• First-out annunciator.
• Real-time data trending.
• (3) pump/auxiliary relay outputs.
• Modbus communication capability.
• Remote firing rate or setpoint control
• Setback/time-of-day setpoint
1.6-WATER LEVEL & STEAM PRESSURE CONTROLS
See Chapter 4 for initial settings of the OLC (Operating Limit Control) and HLC (High Limit Control), and
for water column alarm levels and probe lengths.
See Chapter 5 for water column and gauge glass blowdown procedure.
1.7-OPTIONAL EQUIPMENT
Certain options are available for the Model CFH Boiler; normally these will have been specified at the time
of order entry. In addition, some options may have been provided (by others) that are not part of Cleaver-
Brooks scope of supply. In either case, the Cleaver-Brooks authorized representative should be consulted
regarding specific project requirements.
Model CFH optional features
• Boiler Status Lights & Alarm horn
• High Gas Pressure Regulator (>1 psig supply; shipped loose)
• Gas pressure relief valve (>1 psig supply; shipped loose)
Figure 1-7 LWCO & limit controls
ALWCO
STEAM PRESSURE
GAUGE
LWCO &
OLC HLC
COLUMN

Chapter 1 — Introduction
Part No. 750-295 1-7
• Dual fuel gas train (30-80 HP)
• Low gas pressure option (30-60 HP)
• Min. Temp./Hot standby
• Sealed combustion adapter kit - shipped loose
• Direct vent kit - shipped loose
• Chemical Feed System
• Surface Blow-off
• Steam stop valve(s)
• Feedwater system (includes tank, pump, and control) - shipped separately
• Feedwater Valve (on/off)
• Blowdown valves
• Modulating Feedwater Valve & Level Control
• High Water Alarm
• Time clock for setback control - shipped loose
• Warm/Hot Standby control
• Reusable air filter
• Stack thermometer
• Economizer package
• Overflow Drain Trap
• Sample Cooler
• Automatic Surface Blow-off Conductivity control
• Draft Damper control - Isolation or Modulating
• Falcon Lead-Lag control for multiple boiler systems
• ProtoNode Gateway/Translator
• Boiler Monitor - Remote Monitoring, Mobile App

Chapter 1 — Introduction
1-8 Part No. 750-295

www.cleaverbrooks.com
The boiler must be installed such that the gas ignition
system components are protected from water
(dripping, spraying, rain, etc.) during appliance
operation and service. Failure to follow this warning
could result in equipment failure.
!Caution
Chapter 2
Installation
Boiler Room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Lifting and Moving the Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Boiler Room / Boiler Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Connection Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Electrical Connections & Wiring Diagrams . . . . . . . . . . . . . . . . . . . . 2-11
Provisions for combustion and ventilation air must be
in accordance with UL 795, Commercial-Industrial
Gas Heating Equipment, cUL, or applicable provisions
of the local building codes. Failure to follow this
warning could result in personal injury or death
!Warning
If an external electrical source is utilized, the boiler,
when installed, must be electrically bonded to ground in
accordance with the requirements of the authority
having jurisdiction or, in the absence of such
requirements, with the National Electrical Code and/or
UL 795, Commercial-Industrial Gas Heating Equipment.
!Warning

Chapter 2 — Installation
2-2 Part No. 750-295
2.1-BOILER ROOM
The boiler room must comply with all building codes and regulations. An adequate supply of combustion air
and sufficient ventilation are required for safe operation. If the optional direct vent combustion air kit is not
used, ventilation must be provided to meet applicable regulations for air supply.
Clean combustion air is required for optimum efficiency and boiler operation (minimum combustion air 10
cfm per boiler horsepower). Dust and airborne contaminants will adversely effect burner performance.
If conditions dictate, a serviceable filter must be placed at the burner inlet to eliminate airborne contamination
to the burner. If a direct vent air intake is used, the intake and flue venting should be terminated so as to
prevent rain, snow, dust, or debris from entering the intake piping.
Observe proper clearances above and around boiler - see 2.4-.
2.2-LIFTING AND MOVING THE BOILER
The Model CFH boiler is equipped with two lifting lugs extending
from the front and rear tube sheets. These lugs should be used
to lift the boiler.
Note: The boiler should not be lifted by the base, or moved by
pushing, prying, or pulling on any part of the casing.
The boiler must be installed on a non-combustible floor. If the
floor is not level, piers or a raised pad slightly larger in length and width than the boiler base dimensions
will make boiler installation and leveling easier.
The boiler must be installed so that all components remain accessible for inspection, cleaning, or
maintenance. Field-installed piping and electrical connections must be arranged so as to avoid interfering
with removal of the casing panels or with the burner door.
Boiler room ambient conditions
Relative humidity < 85% non-condensing
Ambient temperature range 0 oC to 50 oC / 32oF to 122oF
Storage temperature range -40 oC to 60 oC / -40oF to 140oF
Combustion air temperature 0 oC to 50 oC / 32oF to 122oF
!Warning
The boiler must not be installed
on combustible flooring.
Figure 2-1 Lifting boiler
!Caution
In order to avoid damage to the unit, lifting or
moving the boiler should only be done by
experienced personnel suitably equipped for
moving heavy equipment.

Chapter 2 — Installation
Part No. 750-295 2-3
2.3-WATER TREATMENT
Properly treated boiler water will result in maximum effectiveness and long trouble-free life of the pressure
vessel. Contact your local Cleaver-Brooks representative or water management consultant for complete
information on how to prevent damage resulting from inadequate water treatment. See Table 2-1 below for
water quality guidelines.
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 needs.
The objectives of water treatment in general are to:
1. Prevent hard scale and soft sludge deposits that inhibit heat transfer and that could lead to overheated
metal and costly downtime and repairs.
2. Eliminate corrosive gases in the supply or boiler water.
To accomplish these objectives, the boiler requires proper water treatment before and after introduction of
water into the unit. The selection of pretreatment processes depends upon the water source, its chemical
characteristics, the amount of makeup water needed, system operation practices, etc.
Figure 2-2 Boiler rigging
Important
!

Chapter 2 — Installation
2-4 Part No. 750-295
Because of the variables involved, no single boiler compound can be considered a cure-all; nor is it
advisable to experiment with homemade treating methods. A sound treatment program should include a
periodic analysis of the water in the system.
The internal or waterside surfaces of the pressure vessel
should be inspected at regular intervals for evidence of
corrosion, pitting, contamination, or accumulations of foreign
matter. If any of these conditions are detected, contact your
local Cleaver-Brooks authorized representative for advice on
corrective action. It is recommended that a properly sized
water meter be installed in the raw water makeup line to
accurately determine the amount of raw water admitted to the
boiler.
Surface blow-off is available for steam boilers. This option
allows removal of surface water impurities through a
blowdown line located at the normal operating water level of
the boiler. If allowed to accumulate, surface impurities may
impede steam release and could cause foaming, leading to
priming and carryover in the steam lines.
An optional chemical feed system can be used to introduce
controlled amounts of feedwater treatment chemicals into the boiler.
Refer to Table 2-1 CFH water quality guidelines.
Consult with factory for Reverse Osmosis (RO) applications.
2.4-BOILER ROOM / BOILER CLEARANCES
The boiler room must comply with all building codes and
regulations. An adequate supply of combustion air and sufficient
ventilation are required for safe operation. If the optional direct vent
combustion air kit is not used, ventilation must be provided to meet
applicable regulations for air supply.
Clean combustion air is required for optimum efficiency and boiler operation (minimum combustion air 10
cfm per boiler horsepower). Dust and airborne contaminants will adversely effect burner performance.
If conditions dictate, a serviceable filter must be placed at the burner inlet to eliminate airborne
contamination to the burner.
If a direct vent air intake is used, the intake and flue venting should be terminated so as to prevent rain,
snow, dust, or debris from entering the intake piping.
Notice
Corrosion and sludge deposits in old systems must be removed
prior to installation of a new boiler.
!Warning
Inadequate or improper water treatment will shorten the life
of the boiler, and could result in a hazardous condition.
Table 2-1 CFH water quality guidelines
QUANTITY LIMITS
Oxygen <0.005 ppm
CO2 0 ppm
Hardness <2.0 ppm
Suspended Solids <300 ppm
pH 8.5 - 10.5
Sulfite >50 ppm
Fe <0.1 ppm
Silica <150 ppm
Total Alkalinity <700 ppm
Dissolved Solids <3,000 ppm
!Warning
The boiler must not be installed
on combustible flooring.

Chapter 2 — Installation
Part No. 750-295 2-5
Figure 2-3 Minimum clearances
2.5-CONNECTION LOCATIONS
Figure 2-4 CFH steam boiler connections
2.5.1 Flue Gas Connection
The flue gases from the ClearFire®boiler are removed via a gas-tight,
temperature and corrosion resistant stack. 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 Chapter 3 in this manual for more information.
2.5.2 Condensate Drain
A condensate drain is installed at the bottom of the flue box and should be piped to a drain. A drain trap
with a minimum 6” water leg should be installed to prevent flue gas from entering the boiler room (see
Figure 2-5).
Minimum required service clearances
18”
18”
see table
18”
36”
*Electrical panel clearance - sufficient for burner door swing and tube removal
BOILER SIZE
10 15 20 25 30 40 50 60 70 80
CLEARANCE* 36 36 36 36 36 36 36 36 42 42
STACK OUTLET
OVERFLOW
GAS SUPPLY
STEAM OUTLET
RELIEF VALVE
CHEMICAL FEED
FEED WATER
BLOWDOWN
COMB. AIR/DIRECT VENT
FEED WATER (ALTERNATE )
SURFACE BLOWOFF
CONDENSATE DRAIN
WATER COLUMN
DRAIN
GAUGE GLASS
DRAIN
SPARE
To
Drain
Figure 2-5 Condensate Drain

Chapter 2 — Installation
2-6 Part No. 750-295
2.5.3 Gas Connections
Gas Shut Off Valve and Gas Filter - A manually operated shut-off valve
and pressure regulator are provided as standard on the CFH boiler (Figure
2-6). In some cases, local regulations may require the installation of an
approved gas filter between the gas shut-off valve and the boiler. Please
ask the local gas supply company whether any such regulations apply.
The boiler should be installed so that the gas ignition system
components are protected from water (dripping, spraying, etc.) during
appliance operation and service.
The CFH boiler may operate without a step-down regulator with gas
pressures <1/2 psig (14" w.c.). A step-down regulator is required above
1/2 psig supply pressure. If a step-down regulator includes a vent
connection, proper gas venting will be required and must be piped to a
safe point of discharge. A dedicated gas pressure regulator is
recommended for each boiler to ensure consistent gas pressure at the
boiler. At supply gas pressures above 2 psig, the use of a true lock-up
type regulator with internal relief is highly recommended.
Drip legs are required on any vertical piping at the gas supply to each
boiler so that any dirt, weld slag, or debris can deposit in the drip leg
rather than into the boiler gas train. The bottom of the drip leg should be removable without disassembling any
gas piping. The connected piping to the boiler should be supported from pipe supports and not supported by the
boiler gas train or the bottom of the drip leg.
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.
Before starting the unit(s) all piping must be cleaned of all debris to prevent its'
entrance into the boiler gas train. Piping should be tested as noted in NFPA 54
and the boiler must be isolated during any tests.
After initial startup, the inlet screen to the gas valve should be checked and cleaned for any debris buildup.
Gas Supply Pipe Sizing - For proper operation of a single unit or a multiple unit installation, we recommend that
the gas piping be sized to allow no more than 0.3" w.c. pressure drop from the source (gas header or utility
meter) to the final unit location. Higher supply pressure systems may allow for a greater pressure drop. In ALL
cases, minimum supply pressures must be met for proper operation of the boiler(s). The gas supplier (utility)
should be consulted to confirm that sufficient volume and normal pressure are provided to the building at the
discharge side of the gas meter or supply pipe.
For installations of new boilers into an existing building, gas pressure should be measured with a manometer to
ensure sufficient pressure is available. A survey of all connected gas-using devices should be made. If appliances
other than the boiler or boilers are connected to the gas supply line, then a determination must be made of how
much flow volume (cubic feet per hour) will be demanded at one time and the pressure drop requirement when
all appliances are firing.
The total length of gas piping and all fittings must be considered when sizing the gas piping. Total equivalent
length should be calculated from the utility meter or source to the final unit connection. As a minimum guideline,
gas piping Table 2-2 and Table 2-3 should be used. The data in these tables is from the NFPA 54 source book,
2006 edition.
To verify the input of each device that is connected to the gas piping, obtain the btu/hr input and divide this
input by the calorific value of the gas that will be utilized. For instance, a 40 HP unit with 1,613,253 btu/hr
input divided by a gas calorific value of 1060 will result in a flow of 1,522 cubic feet per hour. The single boiler
is approximately 20 feet from the gas supply header source. And with a measured gas supply pressure of 10"
w.c. we find from Table 2-2 that a supply pipe size of 2" should be used as a minimum.
Figure 2-6 Gas shut-off valve and
step-down regulator
!Warning
A sediment trap must be pro-
vided upstream of the gas
controls.