CleaverBrooks ClearFire SFH Installation and operation manual

www.cleaverbrooks.com
ClearFire®Model CFH
Horizontal Steam Boiler
Startup Guide
750-293

CFH Startup Guide
2Part 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-
signedtooperateonis the same typeas 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.ImmediatelycallyourCleaver-Brooksservice
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 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 CFH manual.
Figure 1 CFH Connections
Boiler room ambient conditions
Relative humidity < 85% non-condensing
Ambient temperature range 0 oC to 50 oC / 32oF to 122oF
Storage temperature range -20 oC to 60 oC / -4oF to 140oF
Combustion air temperature 0 oC to 50 oC / 32oF to 122oF
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
When using direct vent
combustion in cold climates,
special care must be taken to
observe combustion air
temperature limits. Failure to
follow this precaution may lead
to equipment damage or unsafe
operation.

CFH Startup Guide
4Part 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 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.
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
10 7.2" w.c.
28” 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 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 5
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
BlowerSignal
Cable
Flame Rod Cable
Cable Harness
BlowerPower
Cable
(Panel cover removed)
Customer
connections
and power
wiring
Ignition
Tran sfo rme r
(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
6Part 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 Control
w/Reset
LWCO & Pump Control
CB FalconController
Control panel interior
LWCO
ALWCO

CFH Startup Guide
Part No. 750-293 7
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
The Model CFH 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.
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
8Part 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 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 11).
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 left 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 9
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
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>.
1
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
10 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 11
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
•ReviewChapter 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 O2. To ensure optimum combustion throughout the firing
range, the O2% 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 O2%. 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
12 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 13
Figure 16 CFH Wiring Diagram