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Model CFH w/ CB90-RWF40 – 750-222, 5/2007 or 11/2008 edition

1. ITEM QTY PART NUMBER DESCRIPTION 1 1 132 02490 INSULATED FRONT DOOR ASSEMBLY 2 1 853 00982 GASKET ROPE 1 1 4 DIA X 85 LG 3 2 380A01033 GASKET ADAPTER PLATE TO DOOR 4 1 380 01029 BURNER CANISTER 5 1 380 01035 ADAPTER PLATE BLOWER TO DOOR 6 4 869 00030 NUT HEX 3 8 16 7 1 380A01037 GASKET ADAPTER PLATE TO BLOWER 8 1 894 04076 BLOWER UNIT 115V 9 1 048 00655 VENTURI AIR GAS PREMIX C W SENSING LINES 10 2 380A01032 GASKET ELECTRODE C W ITEMS 11 AND 12 11 1 380 01061 ELECTRODE DOUBLE 12 1 380 01060 ELECTRODE SINGLE 13 1 065C00879 RETAINER SIGHT PORT 14 1 851 00026 SIGHT GLASS PYREX 1875 X 1 75 OD 15 2 853 00213 SIGHT GLASS GASKET 0625 X 1 438 ID X 1 719 C 16 3 860 00097 MACHINE SCREW 8 32 UNC X 75 LG 17 1 817 03468 COMBUSTION AIR PROVING SWITCH 18 2 845 00468 CONNECTOR 125 NPT X 25 OD 19 1 1939 00661 TUBING ALUMINUM 25 OD X 035 WALL X 25 LC 20 4 928 00228 CABLE RING LOOP 21 4 860 00033 MACHINE SCREW 10 32 UNF X 375 LG 22 1 507C08099 PIPING GAS TRAIN 23 1 869 00036 NUT HEX 5 16 18 UNC 24 1 880C01858 _ AIR FILTER KIT 4 25 4 952 00145 WASHER 1 4 FLAT 26 1 800 00098 VENTURI GASKET 27 1 008C03620 BRACKET JUNCTION BOX 28 4 868 00536 SOCKET HEAD SCREW 10 24 UNC X 1 LG 29 4 869 00061 NUT HEX MACHINE SCREW 10 24 UNC 30 4 993 16083 CAPSREW HEX 10 32 x 1 2 Lg 3
2. 4 2 1 3 EEEE 17 A E E E E E P 4 2 1 1 renis 4 2 2 How to configure your 40 5 2 3 HOw adjust EO 6 2 4 How to change a setpoint SP1 7 2 5 How to display the software version and 5 8 2 6 m 9 2 7 Auto Tune Self setting 10 2 8 Setting up a standard temperature 11 2 9 Setting up a standard pressure 12 2 10 How to unlock RWFAO 13 3 l 13 3 1 00112511 01 18 EO D Dem 13 3 2 List of values for User settings Parameters and Configurations 14 1 Introduction to hints manual 1 1 1 How to use this manual This RWF40 hint manual is intended to supplement the RWF40 User Manual Please read the RFW40 User Manual before applying power to the controller 1 1 2 Symbols used in this manual These symbols represent the four buttons on the controller FX If a combination of key
3. 48 Logstat represents the current software module the CB90 is currently executing They named as close to the logic module the actual burner sequence is in For instance in the CB90 MPURGE rep resents High Fire Purge where MPOSTPURGE represents low fire start purge MSHUTDWNI rep resents the post purge period after a complete cycle or the cool down period after a lockout MIDLE or STANDBY is the period of time where the operating control is open or the control is in lockout waiting for reset On instances of false flame during the purge period the control algorithm forces the control back to STANDBY until false flame ceases or lockout occurs MPREPURGE1 is the period of time prior to PURGE where the control checks the status of the air flow interlocks or in the case of the Flame Monitor high fire proving switch D 8 If found open the control will remain in this state until the respective switch closes or lockout occurs represents the pilot ignition stage of a burner sequence represents the main trial for ignition period where main fuel is introduced along with pilot MAUTO is the run period of the burner sequence MPOSTIDLE and MSHTDWNQ are small periods of time where certain internal tests are conducted and general cleanup before and after a cycle is performed PROGTYP is represented by 1 data word The upper byte identifies the family and the lower byte represents the pro
4. FLAME DETECTION FLAME ROD _ 11 NTON 4 2 Q IGNITION TRANSFORMER 3 F B 222 MAIN CAS VALVES FUEL ALVE LICHT TO MOD RELAY H RMR SE T0 57 X 57 60 MODULATE UP X 77 LRS A 1 FR ae REMOTE FIRING RATE RELAY 40 Q 42 93 01 14 fT UU T BL l 25 _ 6 e Y 24 42 JS 7 i g 7 2 NOTE 1 FLAME B s 29 10 R p9 1 OR IR BR _ BL 33 ENABLE 28 ES 15 NOT FURNISHED BY 3 R MOL w EILDED CABLE ONE END ONLY C OF ABBREVIATED DEVICES 2 8 Part No 750 222 CLEAVER BROOKS Chapter 3 Stack and Intake Vent Sizing and Installation Venting Connections General 3 2 seis de E 3 2 Vent Terminal Location 2020200 0 3 3 Horizontal Thru Wall Venting Inside 3 5 Horizontal Thru wall Direct Venting 3 6 Horizontal Thru wall
5. NAA 6 9 Gas man 55 ncc 6 11 H 6 12 6 13 Gas 6 14 6 15 04 ul TET 6 16 81 20 0051 6 17 Burner Assembly 10 vd ot eh Po ed vob i Puis 6 18 Burner Assembly 15 6 19 Assembly oc Fu 6 20 Burner Assembly 25 6 21 Burner Assembly 30 1 6 22 Burner Assembly 40 6 23 Burner Assembly 50 60 6 24 tu tpe 6 25 Recommended Spare Parts 5 6 26 Appendix A Gas Valve Installation and Maintenance Appendix B RWF40 User Hints Appendix C CB90 Flame Safety viii CLEAVER BROOKS Chapter 1 Introduction Model Features And Benefits 1 2 The Boller 1 3 The RED 1 4 Burner Gas 1 4 CONTOS os xung dor Ra x Eure ROGO Ec E Rr 1 5 Compone
6. Capscrew Hex Hd 3 8 16 UNC x 4 Lg Retainer Ring TruArc 5 Shaft Washer Fender 3 8 Bolt 19 6 _ 860 00596 Setscrew Flat Pnt 3 8 16 UNC x 5 Lg Plug 5 NPT 24 Name Plate Drain Plug Front Burner Housing Removed For Clari 6 8 Not Ensure door is centered over furnace Adjust item 19 as required to align door Apply grease to pin prior to installation DETAIL B Add extra item 17 s as required L MATERIAL SIZES ON BILL OF MA L ARE FOR REFERENCE CLEAVER BROOKS The power of commitment HIGH LEVEL ASSEMBLY 2 12 2007 50 60HP 150 ST BOILER Peal v 146 00543 ONLY DRAWING DIME INS MUST BE FOLLOWED lo TOLERANCE UNLESS OTHERWISE SPECIFIED FRACTIONAL DECIMAL e HOLE LOCATIONS GLES DRILLED PUNCHED OR SLOTTED HOLES Part No 750 222 Chapter 6 ClearFire H Parts 8 Control Panel sheet 1 of 2 Part No 750 222 6 9 Chapter 6 ClearFire H Parts Control Panel sheet 2 of 2 ock Single Pole te Burner OFF with 1 Double Pole Fuse Block P N 848 01479 and add 2 6 Amp Fuses for Item 16 6 10 Part No 750 222 CCC OGL ON Hed IT 9 29 25 Supplied with Item 1 10 313 9 Gas Train 10 HP Notes NO B 0 PN All Piping To Be SA106 Gr B Sch 80 All
7. Lavd 1511 sued 9PTOODTT9 1971403 cv 0708088 uonsnquioo 9 111 51609949 Yue pedid pue suondo 6 4 Chapter 6 ClearFire H Parts 4 High Level Assembly 20 25 HP a 2_ 940 05073 940 05602 94005072 94005500 e i 283003333 28303533 28309333 Contol Pan e i 118803638 118803638 118803630 118803638 labi CFH Boiler Pan 5 i 18368 11840364 11840363 118403634 Data Plate CFH Boilers 8 95200359 95200392 95200392 95200192 Waserfener3t Bat i ueni S SO 27 28 29 See Table Handhole Cover Assembly Handhole Items Notes PART NUMBER DESCRIPTION Ensure door is centered over furnace Adjust item 21 as required to align door Apply grease to pin prior to installation 317 00057 HANDHOLE COVER STUD AND WASHER ASSEMBLY 953 00048 HANDHOLE YOKE 2 PRONG FORGED 853 00934 HANDHOLE GASKET 2 3 4 x 3 1 2 DETAIL B Add extra item 18 s as required CLEAVER BROOKS The power of commitment 10 10 2006 HIGH LEVEL ASSEMBLY 20HP 15 ST BOILER N T S 146 00530 04 Part No 750 222 6 5 Chapter 6 ClearFire H Parts 5 High Level Assembly 30 40 HP ITEM QTY 30 HP 152 ST 30 150 ST JOHP 152 ST 40HP 150 ST DESCRIPTION T 77 mer
8. CONNECTION TO 1 2 INCH FLEXIBLE ELECTRICAL Fig 3 Electrical Connection Diagram CONDUIT ONLY MAXIMUM TORQUE 85 INCH POLUNDS Fig 2 Four Pin Electrical Plug Connector ADJUSTMENTS AND FINAL CHECKOUT The following procedures are related to the adjustments on the main gas valve For adjustments of the other devices 1 6 pressure switches refer to the instructions supplied with the applicable device WARNING Fire or Explosion Hazard Can cause severe injury death or property damage Only fully qualified expe rienced flame safeguard technicians should make adjustments on the valve Pressure Tap Points Fig 4 The V4730C V8730C Valves have a number of connection points 1 8 in 3 mm NPT plugs mea suring pressure and or mounting a pressure switch The pressure tap points are 1 inlet pressure at first SSOV flange tap 2 inlet pressure at first SSOV P outlet pressure at first SSOV 3 inlet pressure at second SSOV 4 outlet pressure at second SSOV flange tap 4 SWITCH Fig 4 Pressure Tap Points The following pressures can be measured 1 Inlet pressure tap on inlet flange 1 2 Pressure after inlet screen 2 3 Unregulated intermediate pressure pressure between the two shutoff seats P 4 Regulated intermediate pressure pressure between the shutoff valves 3 5 Outlet pressure tap from flange 4 The corresponding numbers 2 3 can be found on the side of the valve NOTE
9. 2 Ma Burner Canister Figure 5 10 Part No 750 222 5 7 Chapter 5 Service And Periodic Maintenance 6 51 INSPECTION CLEANING Waterside inspection frequency may depend upon the local jurisdiction and inspector but it is recommended that after the first year of operation a waterside inspection take place To inspect the boiler on the waterside first shut off the electric power to the burner Close all waterside stop and shutoff valves Close the manual gas shutoff valve After allowing the boiler to cool open the bottom blowdown valve crack the air vent valve and drain the boiler While the boiler is draining note the condition of the water When the water has drained from the boiler remove the handhole covers and examine the waterside surfaces Use a good flashlight and where necessary a swivel mirror with an extension Discuss any scale sludge or other buildup on the surfaces with the water treatment company or technician Remove the equalizing piping plugs remove all probes and inspect Clean as necessary being sure to remove any debris or blockages Figure 5 11 Handholes If a waterside sludge buildup is noticed flush the waterside and drain Again consult with the water treatment company or Important technician on cleaning After inspection install new gaskets close the handholes replace probes tighten plugs and allow water to fill Clean probes are essential the boiler while
10. Figure 4 7 Control circuitry LWCO and ALWCO 20 25 HP 20 25 HP 30 40 HP 30 40 HP 50 60 HP 50 60 HP 15 Steam 150 Steam 15 Steam 150 Steam 15 Steam 150 Steam 3 1 16 1 16 0 1 1 16 116 07 3 1 16 1 16 0 12 1 16 11 3 4 13 3 4 6 1 16 8 E 1 16 6 1 4 E 1 16 Chapter 4 Commissioning Figure 4 8 Limit Controls Warning Before initial startup check for blockages in the flue venting or vent terminations Inspect the burner and furnace for any contamination or blockages Figure 4 9 Blower Housing Gas Valve amp Mixing Venturi E Operating and High Limit Controls The operating OLC and high pressure limit HLC controls are externally mounted to the control trim piping The setting of the OLC should be slightly higher than the configured set point plus the differential off SPx HYS3 value of the RWF40 modulating control The setting of the HLC should be slightly higher than the OLC For example RWF40 SP1 100 0 psig HYS3 5 0 psig OLC could be set to 110 psig HLC set to 120 psig Specific settings are determined by application and system control scheme After all settings are verified and with boiler controls at proper settings the boiler can be connected to power and the burner commissioning can be initiated 4 5 Initial start up procedure A Gas Train and Piping The ClearFire burner is equipped with a combination servo regulated gas valve
11. 2 Prevailing winds could cause freezing of condensate and water ice buildup on building plants or roof 3 The bottom of the vent terminal and the air intake shall be at least 24 inches above grade including normal snow ine 4 Un insulated single wall metal vent pipe shall not be used outside in cold climates for venting combustion gas 5 Through the wall vents for Category 11 and IV appliances and non categorized condensing appliances shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of other equipment Where local experience indicates that condensate is a problem with Category appliances this provision shall also apply 6 Locate and guard vent termination to prevent accidental contact by people and pets 7 DONOT terminate vent in window well alcove stairwell or other recessed area unless previously approved by local authority 8 DO NOT terminate above any door window or gravity air intake Condensate can freeze causing ice formations 9 Locate or guard vent to prevent condensate from damaging exterior finishes Use a 2 x 2 rust resistant sheet metal backing plate against brick or masonry surfaces 10 DO NOT extend exposed stack pipe outside of building In winter conditions condensate could freeze and block stack pipe 11 Multiple direct stack installations require a four 4 foot clearance betwe
12. Assembly p di Door Burner Controls Gas Connection Access Cover Ignition Electrodes Flame Rod Figure 1 10 Model CFH Steam Boiler 1 6 Part No 750 222 Chapter 1 Introduction 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 steam boilers Flame Safety Control display on front panel Lights amp Alarm horn w silencing circuit Remote modulation sequencing boiler status Modbus communications RS 485 e High Gas Pressure Regulator gt 1 psig supply shipped loose Gas pressure relief valve gt 1 psig supply shipped loose e Min Temp Hot standby Sealed combustion direct vent kit shipped loose Chemical Feed System e Surface Blow off Integral feedwater system includes tank pump and control shipped separately e Feedwater Valve on off Blowdown valves e Modulating Feedwater Valve amp Level Control e High Water Alarm e Economizer package 150 steam only e Time clock for setback control shipped loose Part No 750 222 1 7 Chapter 2 Installatio
13. 960 800 T Zz 434 OST aaavasH 39NV14 000 18010 698 92 99960 81 1 9114 41914 000 999 0 8TT T Sz V vid 5 9 04 000 90610 848 T vc 96200 811 NOLLO3dSNI 31V d3AVN 000 96Z00 8TT T EZ VAOVNVO NI 138v1 000 69520 811 T 22 SLON HLIM 1109 N 000 22110 1 8 TC 009505800 ONIdId SVD 1 3 000 00920 800 T OZ 97 5 X 91 8 LNIOd 1 14 Mau2S13S 000 96500 098 9 61 a 62002940 40OQ LNOUS 000 26Z00 950 81 lJVHS 167 OUV NYL YANIVLIY 000 6000 rT6 ZT 031 14 000 11100 256 2 91 se X ONN 91 8 2 264 2 000 05700 898 8 ST 5 91 1108 8 i3HSVM 000 26600 256 8 e jeuondo 562202451 SNL 44 JDVAUNS 000 29220 251 T ET a d vlad jeuondo STT809Z0S 9NIdId 44OMO1d JOVAUNS 000 51180 205 T ZT jeuondo 166109405 DNIdId NNOQMO T8 WOLLOS 000 15640 205 T TT I jeuondo 280809405 14 1 000 78080 205 T OT 0 8 sJejog e3eld 000 2920 811 6 869608811 Jajiog H49 Ileqe1 000 82920 811 T 8 9 08811 Burse sajlog H40 Ileqe1 000 22920 811 2 Z 2 555509586 14 IOULNOD 000 22220 282 T 9 s09702S9P A18A3SSV SNIO9V1 ANY NOLLVINSNI
14. CLEAVE BROOKS BROOKS The power of commitment Model ClearFire Packaged Boiler Gas High Efficiency Boiler Operation Service and Parts Manual 750 222 11 08 US LISTED A WARNING If the information in this manual is not fol lowed exactly a fire or explosion may re sult causing property damage personal injury or loss of life Do not store or use gasoline or other flammable vapors and liquids in the vicin ity 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 e f you cannot reach your gas supplier call the fire department Installation and service must be per formed by a qualified Cleaver Brooks service agency or the gas supplier A WARNING To minimize the possibility of serious per sonal injury fire or damage to the equip ment never violate the following safety rules Always keep the area around the boiler free of combustible materials gasoline and other flammable 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 Notice Where required by the authority having jurisdiction the installation must conform to the Standard for Controls and Safety D
15. input Axxx mverted sw function fie all K6 OH amp K5 OFF are reversed SP 1 w 80 AL 5 H YSt hystersis 2 Upper Limit i i C112 input HHE setpoint as shown nornal sw function C112 K6 input xxx KB sw function fe all amp K6 OFF reversed SP 4 tw 80 AL init alarm 75 HYSt hystersis 2 C112 input 1 7 xxx C112 input 2 C112 input 3 as shown nornral sw function Absolute function NOT related to setpoint C112 KS input 1 Sxxx C112 KS input 2 112 input 3 Cuxx Kb mverted swtunction Kb OH 8 K6 OFF are reversed 13 St AL 88 HY St 84 SP 1 80 H St 76 AL 75 74 0 SP 1 80 H St 76 AL 75 H St 74 HYSt 85 AL 85 HYSt 81 SP 1 Ww 30 H St 76 AL 74 0 Acc SP 80 shown for reference AL value is absol te independent of SP 1 K6 AL function Terminals Q64 amp Q65 Ik1 thru Ik8 Pressure or Temperature HYSt 2 Pressure or Temperature Pressure or Temperature Pressure or Temperature if Input 1 Ext Setpoint Setpoint Shift if Input 2 Ambient Temperature if Input 3 3 Notes 3 2 Your record of values RWF40 Man Ref Sec 8 1
16. 85701350 Nppe 1 0 1 19 2 85700638 2 sued H ell4Je9 9 4939 47 91 9 giv 31 3 4 REF 14 4 3 4 OT 20 10 1 2 PT Port MAOO i Sit AS gt x M D YOO E Port 2 CCC OGL ON Hed 14 Gas Train 40 HP 23 24 23 22 13 15 ITEM QTY DESCRIPTION 3 3 8572202 Nipple amp 3 80000093 Adapter 12 O 8 1 85900109 Elbow Street 90 9 1 94007165 Gas 120V 125 O Gas Pressure Regulator 1 25 RV81 Tee Notes 1 All Piping To Be SA106 Gr B Sch 40 Or Better 2 All Fittings To 150 M I Unless Otherwise Specified 3 Plug All Unused Openings 4 Use Pipe Joint Compoud On All Threaded Joints 5 Use Gaskets O Rings Where Applicable 6 All Joints Must Be Gas Tight 17 18 16 10 19 12 111 101 11117 Install union with nut side towards regulator sued H aJl4Je9 9 4939 47 CCC 0GL ON Hed 9 32 1 2 Ref 10 1 2 a faf id d 17 Ne 15 Gas Train 50 60 HP 940 07235 Valve Gas 120VAC 1 1 4 Ball Valve Leakage Test Cock Elbow Street 90 1 25 859 00021 125 Bushing Bulk Pipe 1 Ee ele o A V sm os 1 JA Notes 1 All Pipi
17. 868 00450 Capscrew Hex Hd 3 8 16 UNC x 4 0 Lg 2 2 Lys KA 1 LO LO e Part No 750 222 Smoke Box Drain Plug amp Tag ALL MATERIAL SIZES ON BILL OF MATERIAL ARE FOR REFERENCE ONLY DRAWING DIMENSIONS MUST BE FOLLOWED TOLERANCE UNLESS OTHERWISE SPECIFIED FRACTIONAL DECIMAL e HOLE LOCATIONS ANGLES DRILLED PUNCHED OR SLOTTED HOLES Chapter 6 ClearFire H Parts DETAIL A CLEAVER CHECKED BY BR BROO 2 9 10 19 2007 HIGH LEVEL ASSEMBLY 0 15 2007 15HP 15 ST BOILER REV 6 3 Chapter 6 ClearFire H Parts V 11 14 p nb se 5 51 493 5 Ajddy gq wey 3sn py JAAO pasa UBd SI JOOP aJnsu3 5910 3 High Level Assembly 15 HP 150 St XOGOYOWS uone jesu 49211023 104 10015 104 14044 2 Part No 750 222 9620078 NOLLO3dSNI 31V 1d3lAVN 000 96200 8TT zz NI 138v1 000 69520 811 1 92 9996078 NIVUC 31vid3lvN 000 99960 811 Sz LAN S 000 070 858 T PE9E0V8TT 5831108 HAD ALV1d YLYA 000 6960 811 T
18. 9 4939 47 203 CCC OGL ON Hed Attach Using Spray Adhesive or Pins Clips SECTION A A 21 Burner Assembly 40 HP DETAIL D ocate Grounding Tab Here Sensing Line CB P N 380 01069 C W 9 Parts List ITEM QTY PART NUMBER DESCRIPTION 1 1 1132 02500 INSULATED FRONT DOOR ASSEMBLY 2 1 1853 00982 GASKET 1 1 4 DIA X 85 LG 3 2 380 401034 GASKET ADAPTER PLATE TO DOOR 4 1 1380 01030 BURNER CANISTER 5 1 1380401082 ADAPTER PLATE BLOWER TO DOOR 6 4 1869 00030 NUT 3 8 16 UNC 7 1 1380401076 GASKET ADAPTER PLATE TO BLOWER 8 1 1894 04111 BLOWER UNIT 115V 9 1 1048 00656 VENTURI AIR GAS PREMIX C W SENSING LINES 10 380A01032 GASKET ELECTRODE INCLUDED WITH ITEM 11 12 11 1 380 01061 ELECTRODE DOUBLE C W GASKET 12 1 380 01060 ELECTRODE SINGLE C W GASKET 13 1 1065000879 RETAINER SIGHT PORT 14 1 1851 00026 SIGHT GLASS 1875 X 1 75 OD 15 2 1853 00213 SIGHT GLASS GASKET 0625 X 1 138 X 1 719 OD 16 3 1860 00097 MACHINE SCREW 8 32 UNC X 75 LG 17 1 1857 00681 NIPPLE 25 SCH 80 X 5 LG 18 1 1817 03468 COMBUSTION AIR PROVING SWITCH 19 2 1845 00468 CONNECTOR 125 X 25 OD 20 1 1939 00661 TUBING ALUMINUM 25 OD X 035 WALL X 34 LG 21 4 928 00228 CABLE RING LOOP MCMASTER C
19. NE DETAIL C SECTION B B SECTION A A sued H ell4Je9 9 4939 47 Chapter 6 ClearFire H Parts 23 Boiler Controls Gauge Glass Valve Set 825 00132 825 00132 Sight Glass Kit Glass Tubular Pyrex 851 00199 851 00199 Gauge Glass Protector Set 912 00085 912 00085 Part No 750 222 6 25 Chapter 6 ClearFire H Parts RECOMMENDED SPARE PARTS LIST ClearFire H ITEM Electrode Dual Sparking 380 01061 Electrode Single lonization 380 01062 380 01060 Electrode Gasket 380 01032 6 26 Part No 750 222 APPENDIX A Gas Valve installation and maintenance Honeywell V4 30C V8 30C 1 1 Gas Air Servo Regulated Gas Valves NOTE Proto shows valve weh manual valve ang venur stalled APPLICATION The V47390C 87 1 1 Regulated Gas Values with Ee addition of he Ventas Mixing Unit MU and an are used for modulating premix appliances such as Ges bomers gas boilers anis makeup air ns and procpss INSTALLATION When Installing This Product 1 PRODUCT DATA FEATURES Wide modulation range 1495 to 100 of burner load 24 and 120 Vac models Mam valve body with two shutoff seats double black valve Closing time less than one second Mesh screen strainer between inlet fange and main body Various pressure tap points available at main body when no additional valves or pressure switches are
20. all surfaces should be completely dried before lay up Dry Lay up Dry lay up is generally used when the boiler will be out of service for a lengthy time period or where the boiler might be subject to freezing temperatures The boiler must be thoroughly dried before dry storage as any moisture could cause corrosion Both fireside and waterside surfaces must be cleaned of all scale deposits soot etc A desiccant such as quick lime or silica gel should be placed in suitable containers inside the boiler vessel Wet Lay up Wet storage is generally used when a boiler may be needed on short notice or in cases where dry storage is not practical Before wet storage the vessel should be drained thoroughly cleaned and refilled to overflowing with treated water If deaerated water is not available the unit should be fired to boil the water for a short period of time Whichever method of lay up is used a periodic re check of fireside and waterside conditions is recommended during lay up Part No 750 222 CLEAVER BROOKS Chapter 6 ClearFire H Parts Description Page High Level Assembly 10 HP 15 Steam 6 2 High Level Assembly 15 HP 15 Steam 6 3 High Level Assembly 15 HP 150 Steam 6 4 High Level Assembly 20 25 6 5 High Level Assembly 30 40 6 6 High Level Assembly 50 60 HP 15 Steam 6 7 High Level Assembly 50 60 HP 150 Steam 6 8 6 9 DOE
21. 000 50920 59 T S 51000297 431934 AL3dVS 000 6 080 096 T 01 eseaJb lt 8780040 lt 04409 000 58180 205 T se 6 3snfpy 8PL00DTT9 uonejjessu Jeziuuruo23 NIVUL SVO ATEWASSYV 000 81970 62 T 5 JOOP 151 4 20202088 1 000 2 A18W3SSV 13SS3A 33f1SS33d 000 0 0 7 T T 21111 51609959 padid pue NOLLdTH2S3d Lavd ALO 9 0 6 2 2 High Level Assembly 15 HP 15 St Parts List 5 1 465C02605 Insulation and Lagging Assembly 283C03333 Control Panel 2 118 03637 Label CFH Boiler Casing 1 118B03638 Label CFH Boiler Panel 118403634 Data Plate Boilers OJ D 10 1 12 1 1 16 2 17 1 18 1 20 1 008 03600 Bracket Gas Train 841 01122 U Bolt with Nuts 22 1 118 02569 Label Made in Canada 23 1 118A00296 Nameplate Inspection 858 01304 Plug 5 NPT 25 1 118 03666 Name Plate Drain Plug 849 01031 Flange Threaded 150 4 008 03643 Blowdown Piping 28 6 1939 01134 Bulk Copper Tubing 14 8 1952 00392 Washer Fender 3 8 Bolt 15 8
22. 24 CLEAVER BROOKS Wiring Arrangements FIGURE 4 WIRING ARRANGEMENT FOR SPARK IGNITED BURNERS USING 833 3163 or CB90 PROGRAMMERS FLAME SCANNER AIR FLOW OPERATING a INTERLOCK KL WATCHDOG 1 FLAME AMPLIFIER IGNITION 120VAC SPEED 50 60Hz EN E RELAY KP located on daughter e board ALARM BLOWER MOTOR MAIN VALVE SPARK RELEASE TO OR IGNITION MODULATE CONTACTOR SUGGESTED GROUNDING RULES The CB90 system being microprocessor based requires a ground system that provides a zero volt age reference The voltage measured from L2 to all other terminals except L1 should be 0 volts 1 The most effective ground is to run the ground wire in the same raceway as the hot and neutral from the main distribution service panel not intermediate sub panels to the burner control panel and insure that this ground wire is well bonded to the control panel 2 The wiring base of the CB90 must have earth ground providing a connection between the sub base and the control panel or the burner 3 The earth ground wire must be capable of conducting the current to blow the 20A fuse in event of an internal short circuit A number 14 AWG copper conductor is adequate wide straps or brackets are preferred rather than lead wires 4 The ground path needs to be low impedance less than 1 ohm to the equipment frame which in tu
23. 3 7 OFF2 Actual value correction 0 input 2 8 3 8 OFF2 Actual value correction 0 input 3 8 3 9 Df1 Digital filter time constant 0 Analog input 1 8 3 10 11 Set parameters See Hint section 2 3 How to adjust parameters The actual value display 0 shows the current parameter value The setpoint display AL shows the parameter item you are adjusting Increase ry or decrease 14 the value accept it by waiting 2 seconds Once it flashes proceed to the next parameter HYSt by pressing and releasing Adjust all of the parameters as shown below Parameter level values Value Description Sec 160 AL Limit value for comparator 9 2 5 HYSt Switching differential for limit comparator 8 2 10 Pb 1 SPE setpoint external 9 2 80 dt Derivative time 22 350 rt Integral action time 9 2 5 HYS1 5 F below setpoint 55 1 3 HYS2 Burner off 2 stage 5 24 5 HYS3 Burner off 5 F above setpoint 5 5 1 0 q Response threshold 5 6 1 Heating curve slope 5 5 1 0 P Parallel displacement 5 5 Set user level values See Hint section3 4 How to change a setpoint You may enter the user level directly from the basic display Press and release The actual value display 180 shows the current user level item value The setpoint display SP 1 shows the user level item you are adjusting Increase rN or decrease the value accept it by wai
24. 5 16 3 55 150 1 4 18 2 857 00726 Nipple 25 NPT SCH 80 x 1 5 LG 19 1 857 00679 Nipple 25 NPT SCH 80 x 3 LG 20 1 817 03468 Combustion Air Proving Switch 21 1 817 02420 Switch High Air Pressure 22 2 845 00468 Connector 125 NPT x 25 OD 23 1 939 00661 Tubing Aluminum 25 OD x 035 Wall x 25 LG 24 4 928 00228 Cable Ring Loop McMaster Carr 7572K17 Self Closing 25 4 860 00033 Machine Screw 10 32 UNF x 375 LG 26 1 507C07932 Piping Gas Train 27 4 869 00036 Nut Hex 5 16 18 UNC 28 1 880 01858 Air Filter Kit 4 29 4 952 00145 Washer 1 4 Flat 30 1 800 00098 Venturi Gasket 31 4 868 00536 Socket Head Cap Screws 10 24 UNC x 1 LG 32 1 008 03620 Bracket Junction Box 33 4 869 00061 Nut Hex Machine Screw 10 24 UNC 34 4 993 16083 Capscrew Hex 10 32 x 1 2 LG 35 11 993 15760 External Lock Washer 10 36 1 872 00381 Board Insulation 1 TH x 3 5 8 x 72 1 4 LG 37 1 848 00157 Terminal Ignition Straight Spring Snap 7mm Cable Sensing Line CB P N 380 01069 C W Item 9 4 y sued H ell4Je9 9 4939 47 129 CCC OGL ON Hed Attach Using Spray Adhesive or Pins Clips 7 Lf LTH kif y y SECTION B B SECTION A A 19 Bumer Assembly 25 HP DETAIL D Locate Grounding Tab Here Sensing Line CB P N 380 01069 C W Item 9
25. 507C08115 Surface Blowoff Piping Optional 157C02295 Surface Blowoff Dip Tube Optional 868 00450 Capscrew Hex Hd 3 8 16 UNC x4 Lg 914 00093 Retainer Ring TruArc 5 Shaft 952 00392 Washer Fender 3 8 Bolt 952 00111 Washer Plated 056C00297 Pin Hinge Front Door 19 6 860 00596 Setscrew Flat Pnt 3 8 16 UNC x 5 Lg 008803606 Bracket Train Piping 008B03643 Bracket Blowdown Piping 841 01122 U Bolt With Nuts 18 02568 118400296 Name Plate 858 0091 118403666 Name Plate 090 02027 Operating Limit Control Tubing 090 02028 High Limit Control Tubing 090 02026 Pressure Transmitter Tubing SAFETY VALVE 50 HP 940 4993 60 HP 940 5297 Not Ensure door is centered over furnace Adjust item 19 as required to align door Apply grease to pin prior to installation Front Burner Housing Removed For Clarity NLY DRAWING DIMENSI IST BE FOLLOWED TOLERANCE UNLESS OTHERWISE SPECIFIED CHECKED BY FRACTIONAL DECIMAL C CTIONAL P wer of commitme HOLE LOCATIONS ANGLES DATE DRILLED PUNCHED OR SLOTTED HOLES 11 20 2007 20 2007 HIGH LEVEL ASSEMBLY 50 60HP 15 ST ts 146 00554 T Part No 750 222 6 7 Chapter 6 ClearFire H Parts 7 High Level Assembly 50 60 HP 150 St 5 i oms sey s i e i 18805638 ____ Label CFH Boiler Pane 2_ 118A0363 ____ Data Plate CFH Bolles
26. 6 Electrical C Oe BIOS 2 7 Chapter 3 Stack and Intake Vent Sizing and Installation Venting Connections General 0 3 2 dee HMM 3 2 Vent Terminal Location 2 1 0 2 24 3 3 Horizontal Thru Wall Venting Inside 3 5 Horizontal Thru wall Direct Venting 3 6 Horizontal Thru wall Stack Vent Termination 3 7 Vertical Venting Inside Combustion Air 3 8 Vertical Venting Direct Sealed Combustion Air 3 9 Chapter 4 Commissioning Operating Conditions 2 4 2 4 2 CONTO SEDO a a 4 2 ClearFire H Boiler Burner Controls 4 3 A Modulating Control Configuration and Operation 4 3 B Flame Safety Control Operation 4 6 C Variable Speed Blower Interface 4 9 D Water Level Controls 2 2 2 4 11 E Operating and High Limit Controls 4 12 Initial start up procedure e bre t 4 12 Gas Train and Piping 35 4 12 4 13 C Operation Check Gas Valve Gas Pre
27. C HGPS Low and High Gas Pressure Switches Chapter 4 Commissioning CAPS low pressure connection HGPS 1 Open the upstream manual shutoff valve and wait a few moments for gas pressure to rise 2 Lower the switch setting to minimum 3 Initiate light off sequence 4 The CB90 should lock out on an interlock failure 5 Reset CB90 6 Dial the HGPS back to its maximum setting and reset the lock out condition should clear CAPS 1 Initiate burner sequence 2 During purge cycle set Combustion Air Proving Switch to its maximum setting 3 The CB90 Flame Safety control should lock out on an airflow failure CB90 display will show LOCKOUT PURGE INTERLOCK OPEN Note If the CAPS fails to open even when set to maximum test by dis connecting the low pressure line to the switch and initiating burner sequence The switch should now break during the purge cycle Recon nect low pressure side after a successful CAPS check 4 Following a successful CAPS check dial the CAPS back to its minimum setting and reset the CB90 GAS VALVE 1 Initiate burner sequence At PTFI Trial for Ignition verify gas valve LEDs energize indicating both safety shutoff valves open 2 Aflame fail test
28. CTRL LE PTFI FLAME ALARM DEC HEX p 5565 o p emee To 9 p p jw __ 18 s 39 9 w wswWewe wow __ m s eo m pw 9 m pw wwe e 9 7 s peen ____ 9 5 m wswdwesmwome __ 9 9 4 1 wem o 3 9 o 39 9 5 s losartan 3 9 9 a wwmWmaeder __ 9 9 9 m jwswsemomns ___ 9 jwememe ee NOT LIGHTED e LIGHTED FLASHING x x x x Figure 5 13 CB90 LEDs 5 10 Part No 750 222 Chapter 5 Service And Periodic Maintenance RWF40 Faults Alarm lockout conditions are indicated the RWF40 display by flashing numbers The table below shows the controller error codes Cause Controller B ehavior Display Remedy Actual value display red shows Overrange or underrange on ana log input 1 lt 1999 gt flashing Actual value is not measured Setpoint display shows the set Controller initiates lockout point The limit comparator responds to analog input 1 according to con figuration C113 Check electrical connections for open circuit of sensor Overrange or underrange on ana lo
29. Fecralloy metal fiber burner canister Full modulation is provided using the integral variable speed combustion air fan up to 5 1 turndown 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 Provision is made for optional direct venting Combustion Air Proving Switch standard Air filter for combustion air intake standard Burner Canister Gas Valve Venturi Figure 1 6 Burner Components 1 4 BURNER GAS TRAIN The gas train assembly is provided in accordance with UL cUL Val certification and ASME CSD 1 The gas train assembly is factory p assembled and wired consisting of the following components Low Figure 1 7 Gas Train 1 4 03 0 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 Part No 750 222 Chapter 1 Introduction 1 5 CONTROLS The Model CFH incorporates the following primary controllers A The RWF40 modulating pressure controller PID control drives the variable speed blower for optimum firing rate Controller display shows Setpoint and Actu
30. HYS1 Switch on threshold HY Steresis 1 HYS3 Switch off threshold HY Steresis 3 Items at the Parameter level that Auto tune will adjust Pb 1 Proportional band 1 dt derivative time Factory setting 10 Factory setting 80 rt Integral action time Factory setting 350 Item at the configuration level that Auto tune will adjust dF1 Time constant for digital Filter analog 1 Values for Pb 1 dt rt and dF1 can always be changed Auto tune uses two different methods to force oscillations and will automatically select and use a method based on at the start of Auto tune what the difference is between the setpoint w and the process value When Auto tune is started with a large difference typically before the process control loop has stabilized Auto tune performs a forced oscillation around a switching level When Auto tune is started with a small difference typically after the process control loop has stabilized Auto tune performs a forced oscillation around the setpoint w output Auto tune start off point HY S3 process value set point VV Auto tune switching level on point HY S1 time If for any reason the controller exceeds the switch off threshold HYS3 Auto tune will be cancelled 10 Conditions The controller must be in the modulating output mode D1 is open and the step icon lis off burner is released green LED above is on relay 1 is activated contact between term
31. It is important to run through a test operation with fuel shut off following the tripping of a circuit breaker a blown fuse or any instance of chattering of any external current consuming devices 2 CB 8080 Rev 1 CLEAVER BROOKS MOUNTING BASE KNOCKOUTS 12 FOR 1 2 CONDUIT 2 101 6 Cleaver Brooks S Y 3 16 MOUNTING ES 1 2 112 7 HOLES 7 5 3 16 131 7 All dimensions in inches millimeters in parentheses WARNING This equipment is a Class B digital apparatus which complies with the Radio Interference Regulations CRC c 1374 Table 5 AMBIENT TEMPERATURE LIMITS Wr APPROVALS Underwriters Laboratories Inc Factory Mutual System FM Approved Listed Guide MCCZ File MP1537 Underwriters Laboratories Inc Recognized Components Guide MCCZ2 File MP1537 WARNING Selection of programmer and amplifier type for a particular application should be made by a competent professional such as a Boiler Burner technician licensed by a state or government agency engineering personnel of the burner boiler or furnace manufacturer or in the performance of duties based the informat
32. Item Description Value Sec C111 0000 Analog input 1 9 Std Signal 0 1VDC 8 1 Analog input 2 0 none 8 1 Analog input 3 0 none 8 1 D2 function 0 none 8 1 C112 8200 8 1 Limit comparator 8 input 1 8 1 Controller type 2 modulating 4 20mA 8 1 Setpoint SP1 0 via buttons 8 2 Locking 0 none 8 2 C113 0220 Unit address 02 Modbus address 8 2 Decimal Units 2 decimals 8 2 Out of range Signal 0 limit comparator OFF 8 2 SCL SCaleLow 0 A Analog input 1 8 3 1 SCH SCale High 150 Analog input 1 8 3 2 SCL2 SCaleLow 0 A Analog input 2 8 3 3 SCH2 SCale High 100 Analog input 2 8 3 4 SPL SetPoint Low 150 limits low setpoint to 160 F 8 3 5 SPH SetPoint High 15 limits high setpoint to 205 F 8 3 6 OFF1 Actual value correction 0 Analog input 1 8 3 7 OFF2 Actual value correction 0 input 2 8 3 8 OFF2 Actual value correction 0 Analog input 3 8 3 9 Df1 Digital filter time constant 0 Analog input 1 8 3 10 12 Set parameters See Hint section 2 3 How to adjust parameters The actual value display 0 shows the current parameter value The setpoint display AL shows the parameter item you are adjusting Increase ry or decrease 14 the value accept it by waiting 2 seconds Once it flashes proceed to the next parameter HYSt by pressing and releasing Adjust all of the parameters as shown below Parameter level values Value Description Sec 160 AL Limit value for comparator 9 2 5 HYSt
33. Low Fire Offset Figure 4 12 Main Gas Choke High Fire Adjustment Chapter 4 Commissioning Figure 4 13 Combustion air proving switch modulating the burner via the RWF40 from low fire to high fire two or more times to ensure a consistent air fuel ratio 1 Check inlet gas pressure and reset low gas pressure switch 2 Review burner sequence before proceeding see above Section 4 4 3 Initiate burner firing sequence 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 the low fire offset screw may also be tried Check that gas pressure to gas valve inlet is sufficient to fire burner see Table 4 3 for gas pressure requirements 4 After burner lights maintain in low fire position At low fire using main choke on gas valve and a combustion analyzer set O2 level within 3 896 O2 5 Manually modulate the burner to high fire Adjust the gas choke if necessary to obtain desired 02 5 0 6 0 6 Modulate to low fire and fine tune offset screw to obtain desired O2 5 0 6 0 7 Verify adjustments by modulating back and forth between low and high fire 8 The Combustion Air Proving Switch CAPS see Figure 4 13 should be set at this time After the burner is set up dial the CAPS setting upward and restart the burner Set just below the point the switch breaks at low fire speed G Limit Contr
34. Sec 8 1 8 2 Sec 8 1 Sec 8 3 1 Sec 8 3 2 Sec 8 3 3 Sec 8 3 4 Sec 8 3 5 Sec 8 3 6 Sec 8 3 7 Sec 8 3 8 Sec 8 3 9 Sec 8 3 10 Sec 8 3 11 Sec 8 3 12 Sec 8 3 13 Sec 8 3 14 Sec 7 8 2 Sec 7 8 2 Sec 7 8 2 7 8 2 7 8 2 7 8 2 7 8 2 7 5 51 7 5 2 7 5 2 7 5 6 Sec 7 5 51 7 5 5 6 2 1 6 2 1 6 2 1 11 1 3 11 1 2 14 Setpoint Your Display Setting Configuration level items sec 6 4 Aou 2 and 802 changeover shit Limit comparator controler pe idi NA Ui address decimal place uisgnafrowoume SCale Low analog input 1 measured value range 1999 to 9999 SCale Low analog input 2 measured value range 1999 to 9999 SCale High analog input 2 measured value range 1999 to 9999 Set Point Low limit 1999 to 9999 0 Set Point High limit 1999 to 9999 orFF1 __ OFFset analog input 1 Actual value correction 1999 to 9999 EE ONE orF2 OFFset analog input 2 Actual value correction 1999 to 9999 EE NE OFFset analog input 3 Actual value correction 1999 to 9999 dF1 digital Filter analog input 1 274 order in seconds 0 to 100 Setpoint Display Setting Configuration level items Modbus option only RWF40 0X2B97 Sec 6 4 _ O Filter time constant digital Filter
35. Stack Vent Termination 3 7 Vertical Venting Inside Combustion Air 3 8 Vertical Venting Direct Sealed Combustion Air 3 9 Milwaukee Wisconsin www cleaver brooks com Chapter 3 Stack and Intake Vent Sizing and Installation Notice For additional information on boiler categorization see latest edition standard of National Fuel Gas Code or in Canada the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment or applicable provisions of local building codes 3 2 3 1 Venting Connections General Proper installation of flue gas exhaust venting is critical for the efficient and safe operation of the ClearFire boiler Definition of Appliance Categories Boilers are divided into four categories based on the pressure and temperature produced in the exhaust stack and the likelihood of condensate production in the vent Category A boiler which operates with a non positive vent static pressure and with a vent gas temperature that avoids excessive condensate production in the vent e Category 11 A boiler which operates with a non positive vent static pressure and with a vent gas temperature that may cause excessive condensate production in the vent Category A boiler which operates with a positive vent pressure and with a vent gas temperature that avoids excessive condensate production in the ven
36. To mount the C6097 Pressure Switch refer to instructions in form number 65 0237 furnished with the switch The pressure switch can be mounted to 2 or 3 on either side of the valve Second Valve Fast Opening Flow rate is adjusted from O76 to 100 of full rated flow To adjust the flow rate 1 Remove the flat round blue plastic cap from the cover Using a 3 mm 7 64 in hex wrench turn the adjustment screw counterclockwise to increase or clockwise to decrease the flow rate 2 Snap the flat round blue plastic cap back onto the cover Final Checkout of the Installation oet the system in operation after any adjustment is completed and observe several complete cycles to ensure that all burner components function correctly OPERATION The V4730C V8730C are normally closed valves The valves open when energized and close when power Is removed WARNING Explosion and Electrical Shock Hazard Can cause severe injury death or property damage 1 Do not put the system into service until you have satisfactorily completed the Valve Leak Test all applicable tests described in the Checkout section of the instructions for the flame safeguard control and any other tests required by the burner manufacturer 2 All tests must be performed by a trained experienced flame safeguard technician 3 Close all manual fuel shutoff valves immediately if trouble occurs After the installation is complete cycle the valve several times wit
37. VERTES 6 11 Gas man Lo 6 12 Gas 11 11 7413 HP 6 13 oas DARIN 6 14 Das TANI 6 15 Gas 40 HP 6 16 Gas Train 50 60 6 17 Burner Assembly 10 HP 6 18 Burner Assembly 15 HP 6 19 Burner Assembly 20 HP 6 20 Burner Assembly 25 HP 6 21 Burner Assembly 30 HP 6 22 Burner Assembly 40 HP 6 23 Burner Assembly 50 60 6 24 Boller 6 25 Recommended Spare Parts 1156 6 26 Milwaukee Wisconsin www cleaver brooks com 104 14014 Part No 750 222 Chapter 6 ClearFire H Parts T 00V8TT Y31109 SVD 1N ALVIdAWYN 000 12200 811 6c JoA0 91 8 8 000 72110 626 9 8c UOIJE JEISUT 92101024 104 29509800 DNIdId 000
38. and Flame Rod 5 7 Waterside Inspection Cleaning 5 8 5 8 Troubleshooting 22222 2 5 9 EU d 5 12 Milwaukee Wisconsin www cleaver brooks com Chapter 5 Service And Periodic Maintenance 9 1 GENERAL A well planned maintenance program will help avoid unnecessary downtime or costly repairs and will promote safety and aid boiler inspectors It is recommended that a boiler room log or record be maintained Recording of daily weekly monthly and yearly maintenance activities will help to obtain economical and lengthy service from the equipment Only trained and authorized personnel should be permitted to operate adjust or repair the boiler and related equipment The boiler room should be kept free of all material and equipment not necessary to the operation of the boiler or heating system Be alert to unusual noises improper gauge readings leaks etc Any leaks fuel water steam exhaust gas should be repaired promptly and with attention to safety Preventive measures such as regularly checking the tightness of connections should be included in regular maintenance activities Insurance regulations and local laws normally require periodic inspection of the pressure vessel by an authorized inspector NOTE To insure proper Inspections are usually though not
39. and venturi mixing unit See Figures 4 9 4 10 The gas valve consists of a single body with dual solenoid shut off valves filter screen and a built in constant pressure gas air servo controller The blower is controlled by the RWF40 with airflow relative to the speed of the fan The airflow creates a drop in pressure due to the venturi effect The servo controller of the valve actuator senses air pressure change and accordingly brings about a change in the gas flow proportional to the air pressure The gas follows the airflow in a given ratio so that fuel always follows the air as the burner firing rate increases or decreases 1 Check the gas delivery system to be sure it is properly piped and wired 2 Review available gas pressure to assure it is compatible with the main gas regulators upstream of the ClearFire H gas train Note The maximum rated inlet pressure to the CFH gas train is 1 psig 27 7 WC An upstream regulator and overpressure protection are required if building supply gas pressure is greater than 1 psig 3 To bleed air from the supply pipe open the manual gas shut off valve upstream of the burner gas train and bleed air from the piping by loosening the union in the upstream piping 4 The burner and its gas connection must be leak tested before placing the boiler into operation 5 Gas Pressure Regulator Using the adjusting screw on the main gas regulator adjust the inlet pressure to the recommended levels in T
40. burner HYS3 Switch off threshold Hysteresis 3 upper q Response threshold H Heating curve slope P Parallel displacement Items are only displayed when controller is configured for a 3 position output The display is steady nothing is flashing V and the value for AL can now be adjusted PGM EXIT You can decrease the value by pressing and releasing it EXIT You can accept the change by waiting 2 seconds The red LED s will blink once and become the new value Your options at this point are You can increase the value by _ pressing and releasing it Or you can advance to the Next parameter by pressing once and releasing it HYSt can be adjusted the same way you just did AL Press and release to immediately return to the basic display Press d and release it to advance down to Pb 1 the next parameter after the last parameter item P press and release it to advance down to SP1 the 15 user item after the last user item the menu cycles back to the 1 user item Or simply wait 30 seconds and the controller will automatically return to the basic display 2 Hints 2 4 How to change a setpoint SP1 SP2 dSP RWF40 Basic display gt RWFAO0 user manual Section 6 2 Actual value Shown at the right is the basic display display Satpoint The current configuration of your specific display controller will
41. determine which levels you will be allowed to access C112 must 2 1 or xxx0 to access the parameter level PGM EXIT AN The C112 locking code can only be adjusted by the manufacturer From the basic display you may skip the user level to reach the parameter level Press and hold for 3 seconds and release The actual value display 0 shows the current parameter value The setpoint display AL shows the parameter item you are adjusting Parameter level items summary AL Alarm Limit value for comparator HYSt Switching differential Hysteresis for limit comparator Pb 1 Proportional band 1 dt derivative time rt Integral action time db dead band contact spacing tt Actuator running time HYS1 Switch on threshold HYSteresis 1 2 stage burner HYS2 Switch off threshold HYSteresis 2 2 stage burner HYS3 Switch off threshold HY Steresis 3 upper q Response threshold H Heating curve slope P Parallel displacement items are only displayed when controller is configured for 3 pos output Example Adjust the value for parameter AL If no keys are pressed for 30 seconds at anytime the controller will automatically return to the basic display The current value of AL 0 is shown in the actual value display The current parameter item AL is shown in the setpoint display The display is steady nothing is flashing and the value for AL can now be adjusted Yo
42. flame detector or its application Contacts There are no accessible contacts in the CB90 Where contacts are used their design assures long trouble free life when the load circuits are maintained within the published load ratings Humidity In areas of high humidity the control chassis should be removed and placed in a dry atmosphere when the system is expected to be out of service for an extended period Periodic Safety Check It is recommended that a procedure be established to test the complete flame safeguard system at least once a month This test should verify the proper operation of all limit switches and safety inter locks as well as flame failure protection and fuel safety shutoff valve tightness Rotation It is recommended that control and scanner units purchased as spares be installed periodically to ensure proper operation CLEAVER BROOKS BROOKS The power of commitment CB 8080 Rev 1
43. installed on combustible flooring 2 3 Chapter 2 Installation Figure 2 2 Clearances Steam Outlet Stack Outlet Feedwater Combustion Air Gas Train Opt Direct Vent Chem Feed Blowdown Figure 2 3 CFH Steam Boiler Connections 2 4 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 Chap
44. keeping the air vent valve open Close valve before to proper boiler operation placing boiler back into operation Always ensure that probes remain free of debris and 5 7 SAFETY VALVE buildup The safety valve is an important safety device and deserves attention accordingly Follow the recommendations of your boiler inspector regarding valve inspection and testing The frequency of testing either by use of the lifting lever or by raising the steam pressure should be based on the recommendation of your boiler inspector and or the valve manufacturer and should be in accordance with sections VI and VII of the ASME Boiler and Pressure Vessel Code Avoid excessive operation of the safety valve a valve that is opened too frequently can develop leaks Safety valves should be operated only often enough to assure that they are in good working order When a pop test is required raise the operating pressure to the set pressure of the valve allowing it to open and reseat as it would in normal service Do not hand operate the valve with less than 75 of the stamped set pressure on the underside of the disc When hand operating be sure to hold the valve in an open position long enough to purge accumulated foreign material from the seat area and then allow the valve to snap shut Figure 5 12 Safety Valve 5 8 Part No 750 222 Chapter 5 Service And Periodic Maintenance 9 8 TROUBLESHOOTING CB90 Flame Safety Lockout Codes The CB90 f
45. level From the parameter level you may now advance to the configuration level by pressing Pem again holding for 3 seconds and then releasing it The actual value display 9030 shows the current configuration value The setpoint display C111 shows the configuration item you are adjusting Configuration level items summary C111 Analog input 1 Analog input 2 Analog input 3 D2 function sensors 14 types standard signal none external SP analog SP Shift none outdoor sensors none SP chg over SP binary shift C112 Limit comparator Controller type none input 1 2 3 3 position modulating 0 20mA Setpoint SP1 via buttons with outside sensor Locking none configuration parameters buttons C113 address 0 9 Unit address 0 9 Decimal Units Cor F and decimals Signal out of range limit comparator OFF ON SCL SCale Low Analog input 1 SCH SCale High Analog input 1 SCL2 5 Low Analog input 2 SCH SCale High Analog input 2 SPL Set Point Lower SPH Set Point Higher OFF1 Actual value correction OFFset Analog input 1 OFF2 Actual value correction OFFset Analog input 2 OFF2 Actual value correction OFFset Analog input 3 Df1 Digital filter time constant for Analog input 1 Example Re configure adjust the value for C111 If no keys are pressed for 30 seconds at anytime the controller will automatically return to the basic display The current value of C11
46. necessarily scheduled for periods operation use only Cleaver of normal boiler downtime such as an off season This period can be parts for used to accomplish maintenance replacement or repairs that cannot easily be done at other times While the inspection pertains primarily to the waterside and fireside surfaces of the pressure vessel the inspection period provides operators with an opportunity for a detailed check of all boiler components including piping valves gaskets refractory etc Comprehensive cleaning spot painting and replacement of expendable items should be planned for and taken care of during this time Cleaver Brooks recommends common replacement parts be on hand during inspection and maintenance Please refer to the Recommended Spare Parts List In the Parts section of this manual 9 2 BLOWDOWN Water treatment alone can never completely eliminate unwanted solids from boiler feedwater In order to keep these substances to a minimum blowdown should be performed at regular intervals Bottom blowdown fittings include a quick opening valve nearest the boiler and a slow opening valve The quick opening valve is opened first and closed last with blowdown controlled using the slow opening or downstream valve siow Onpaning Valve 4 Figure 5 1 Bottom blowdown piping 5 2 Part No 750 222 Chapter 5 Service And Periodic Maintenance Manual Blowdown Procedure Blowdown is most effective when the
47. period 15 second post purge run check switch 033 3164 Amplifier flame rod photocell amplifier 3 second FFRT 033 3165 Open wiring base cabinet mounting Accessories 033 2714 Two line by 16 character back lit LCD display with keypad 033 2974 Remote display cable with RJ45 connection in 2 or 4 foot long lengths To be used with the appropriate daughter 033 3491 board 033 3492 RS232 RS485 converter with power supply and RJ12 jack 033 2715 933 2714 remote display mounting kit with 4 or 2 cable respectively Provides NEMA 4 protection 033 3133 933 3493 Monitoring device using cellular networks Provides various reporting methods For a complete system choose one of each of the following Chassis Flame Detector Programmer Module Wiring Base Amplifier Module WARNING Installer must be trained and qualified Follow the burner manufacturers instructions if supplied Otherwise proceed as follows 4 CB 8080 Rev 1 CLEAVER BROOKS INSTALLATION OF CONTROL SCANNERS AND FLAME DETECTORS A Wiring Base Mount the wiring base on the burner or on a panel The location should be free from excessive vibra tion and within the specified ambient temperature rating The base may be mounted in any angular position All wiring must comply with NEC Class 1 Line Voltage wiring and applicable electrical codes regulations and local ordinances Use moisture resistant wire suitable for at least 90
48. removed installed pins 283 see below 2 D removed instaled pins 283 see below 1 9 removed installed pins 283 1 9 removed installed pins 283 seebelow 2 B removed installed pins 28 40 Hi Alt pins 28 seebelow 2 D removed installed pins 28 60 894 4075 GGG250 GN3901 115 28 wj CO CO CO HH O CO Shunt pins Description SW1 JP1 Remove shunt for burner sequencing with CB90 SW1 DIP switch settings JP2 Blower specific Soft start 182 50 2 amp 3 30 TFor high altitude gt 1500 ASL applications SW2 SW4 should be increased to compensate for reduced combustion air density Part No 750 222 4 9 Chapter 4 Commissioning Figure 4 6 UGB switch and jumper locations Important Changes to SW1 DIP switches jumper positions must be made with power disconnected from the control panel N Caution Setting SW2 too low or SW4 too high can lead to under or over firing of the CFH boiler Both conditions can be hazar dous and are likely to shorten the life of the burner and or boiler Jumper should always be removed umper P2 remains or is removed depending on the specific premix blower on your boiler Jumper P6 should be connected to pins 2 amp 3 for 30 rate ignition speed SW1 actually consists of four DIP switches These need to be set to the positions shown in Table 4 2 for pro
49. software version and units of your controller at any time by pressing the d WW at the same time and holding them 59 The current configuration of your specific controller will determine which levels you will You will see one of the three displays shown below be allowed to access A C112 of xxx3 will prevent use of the keys SN CS Y A I K6 Manual operation can only be performed when the thermostat function is active and burner is released to modulation The software version of your controller Version 102 in this example is shown in the actual value display The green burner LED must be on relay 1 is energized and the contact The current units configuration F or 90 is shown in the setpoint Q13 N O Q14 Com is closed display If at any time the burner LED turns off the controller will exit the manual operation function The display will return to the where it was if you release the keys at the same time if not you will return back to the basic display Configure Codes 1 Units summary C will be displayed if your controller is configured with C111 Analog input 1 Sensor Pt100 Ni100 C113 No decimals C C113 One decimal C F will be displayed if your controller is configured with C111 Analog input 1 Sensor Pt100 Ni100 C113 No decimals 113 One
50. the current configuration item value The setpoint display C111 shows the configuration item you are adjusting The display is steady not flashing and by default the 4 rightmost digit may now be adjusted You can select which digit you wish to adjust by pressing once and releasing it The 3 digit is now flashing indicating that it is now the adjustable digit Cycle thru each digit of C111 and configure as charted below then accept by pressing and releasing All four upper digits will flash once and the new configuration value is displayed in 4 steady digits Press E ana release to configure C112 C113 thru Df1 Configuration level values Item Description Value Sec C111 9000 Analog input 1 9 Landis amp Staefa Ni 1000 8 1 Analog input 2 0 None 8 1 Analog input 3 0 None 8 1 D2 function 0 None 8 1 C112 8200 8 1 Limit comparator 8 input 1 8 1 Controller type 2 modulating 4 20mA 8 1 Setpoint SP1 0 via buttons 8 2 Locking 0 None 8 2 C113 0220 Unit address 02 Modbus address 8 2 Decimal Units 2 decimals 8 2 Out of range Signal 0 limit comparator OFF 8 2 SCL SCaleLow 0 A Analog input 1 8 3 1 SCH SCale High 100 Analog input 1 8 3 2 SCL2 SCale Low 0 Analog input 2 8 3 3 SCH2 SCale High 100 Analog input 2 8 3 4 SPL SetPoint Low 160 limits low setpoint to 160 F 8 39 SPH SetPoint High 205 limits high setpoint to 205 F 8 3 6 OFF1 Actual value correction 0 Analog input 1 8
51. the new setting displayed value will flash to indicate it has been saved Allowable set point range is limited by Configuration parameters SPL amp SPH see Configuration settings Table 4 1 Return to the basic display by pressing the EXIT key Parameter level settings include PID settings Pb proportional band dt derivative time rt integral time differential on HYS1 and differential off HYS3 settings To access the Parameter level press and hold the lt PGM gt key for 3 seconds then release The current parameter value will be displayed in red The current parameter will be shown in green By pressing the lt PGM gt key one can advance through the parameters to reach the parameter that requires review or a change Settings are changed using the UP lt DOWN arrow keys and saved by pressing the lt PGM gt key Return to the basic display by pressing the EXIT key Configuration level settings should be factory set and rarely require adjustment Please note only qualified CB factory and service personnel should make changes to Configuration level settings If adjustment is necessary this level can be accessed by first accessing the Parameter level as described above Once at the Parameter level repeat press and hold of the lt PGM gt key for another 3 seconds then release One can advance through the Configuration settings by pressing the lt PGM gt key Changes to Configuration parameters C111
52. vertical center line of the regulator 5 Within 6 ft 1 8m if any gas service regulator vent outlet 6 Lessthan 1 ft 300mm above grade level 7 Within 3 ft 1m of a window or door which can be opened in any building any non mechanical air supply inlet to any building to the combustion air inlet of any other appliance 8 Underneath a verandah porch or deck unless A The verandah porch or deck is fully open on a minimum of two sides beneath the floor B the distance between the top of the vent termination and the underside of the verandah porch or deck is greater than 1 ft 30cm Note For sealed vent installations where the air is piped in from outside a protective screen on the air inlet termination elbow must be used to act as an inlet screen Examine the venting at least once a year Check all joints and vent pipe connections for tightness corrosion or deterioration Venting Installation Tips Support piping horizontal runs at least every five 5 feet vertical runs use braces e under or near elbows N Caution Observe the following to avoid personal injury or property damage To cut nonmetallic vent pipe use a fine toothed hacksaw 34 teeth per inch Do not use nonmetallic vent pipe or fittings that are cracked or damaged Do not use nonmetallic vent fittings if they are cut or altered Do not drill holes or use screws or rivets in nonmetallic vent pipe or fitt
53. way through each setting s range The low fire adjustment screw is accessed by removing the slotted cap on the gas regulator using a blade screwdriver see Figure 4 11 The high fire adjustment screw is accessed by removing the blue plastic cap from the valve cover see Figure 4 12 Turn the adjustment screw completely clockwise counting the turns until the screw will no longer turn Then turn the adjustment screw counterclockwise half the number of turns counted when turning clockwise NOTE When adjusting low fire offset clockwise adjustments increase gas flow and counterclockwise adjustments decrease gas flow When adjusting the main gas choke clockwise adjustments decrease gas flow and counterclockwise adjustments increase gas flow Refer to Appendix A for further information on gas valve setup operation and testing F Setting Combustion Note A Combustion Analyzer is mandatory to properly set up the ClearFire H burner No attempt to fire and adjust the burner is permitted without this equipment Note Ensure boiler is filled with water prior to burner startup The burner does not have need of linkages for fuel air adjustment nor is a separate manual auto switch provided for burner positioning All firing rate adjustments are accomplished via the RWF40 Control Setting combustion will require manually Part No 750 222 3 i m Chapter 4 Commissioning Figure 4 11 Regulating Adjusting Screw
54. with enough clean water to cover the tubes Add the cleaning solution then fill to the top The water used in the initial fill should be at ambient temperature 7 Fire the boiler intermittently at a low rate sufficient to hold solution just at the boiling point Boil for at least five hours Do not produce steam pressure 8 Allow a small amount of fresh water into the boiler This will create a slight overflow that will carry off surface impurities 9 Continue the boil and overflow process until the water clears Shut the burner down 10 Let the boiler cool to 120 F or less 11 Remove hand hole plates and wash the waterside surfaces thoroughly using a high pressure hose 12 Inspect the surfaces If they are not clean repeat boil out procedure 13 After closing the handholes and reinstalling safety or relief valves fill the boiler and fire it until the water is heated to at least 180 F to drive off any dissolved gases Table 4 4 CFH Boiler Water Capacity Boiler Horsepower ter Horsepower Normal water volume 4 7 Post start up checkout procedure 1 After verifying correct water level fire the boiler in manual low fire 2 Ensure the control valves will not shut off flow to the boiler 3 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 4 Verify the ability of the flame sys
55. xxx1 Locks the Configuration Level C112 code 2 Locks the Parameter Level C112 code Xxx3 Locks all levels and keys 2 1 2 User Level From the basic display you may advance to the user level by pressing and releasing it The actual value display 180 shows the setpoint you are adjusting or viewing The setpoint display SP 1 shows the parameter you are adjusting or viewing You can adjust the values within limits for SP1 SP2 dSP view tA SP E depending on your specific configuration PGM EXIT To adjust user level values please see the 4 How to change a setpoint RWF40 user manual Section 6 2 1 2 1 3 Parameter Level From the user level you may advance to the parameter level by pressing and holding for 3 seconds and then releasing it C112 must be xxx0 or xxx1 to access this level The actual value display 0 shows the parameter s actual value The setpoint display AL shows the parameter you are adjusting or viewing You can adjust the values for AL Hyst Pb 1 dt rt HYS 1 HYS 2 HYS 3 q H and P depending on your specific configuration To adjust parameter values please see 3 How to adjust parameters or amp RWF40 user manual Section 7 2 1 4 Configuration Level From the parameter level you may advance to the configuration level by pressing Pem and holding again for 3 seconds and then releasing it C112 must be
56. zero is provided Information appears on the screen in the following locations OPERATING STATUS TIMING during Purge or TFI OR Standby Purge TFI Auto etc FLAME SIGNAL STRENGTH PURGE 00 05 during TFI or Auto ADDITIONAL STATUS INFO flame signal strength cause of STARTING BURNER ARROW appears when MODE key current lockout etc OR 15 required to access sub menus BURNER HISTORY SCRL key lockout history program setup etc required burner cycles burner SCRL RESET MODE lockouts etc OR SUB MENU HEADINGS SCRL and MODE keys required lockout history program setup etc Any time the CB90 is powered on the SCRL key can be used to scroll through and display the total burner hours burner cycles burner lockouts and system hours on the bottom line of the display The top will continue to show the current run mode e g PURGE AUTO etc Following the historical information the SCRL key will display three sub menus providing the following information and or functions Lockout History with burner cycle and burner hour time stamp Program Setup to display programmer type purge timing switch configuration etc Part No 750 222 4 7 Chapter 4 Commissioning 4 8 System Information values of average pilot and main flame signal and reset burner history Please note normal indicated flame signal is between 26 and 42 The MODE key is used to access the system sub menus An arrow wi
57. 0 to access this level The actual value display 9030 shows the configuration item s actual value The setpoint display C111 shows the configuration item you are adjusting You can adjust the values within limits for C111 C112 C113 SCL SCH SCL2 SCH2 SPL SPH OFF1 OFF2 OFF3 and dF1 depending on your specific configuration To adjust configuration values please see the 2 How to configure our RWFAO RWF40 user manual Section 8 Return to the Basic Display You may exit any level and return to the basic display at any time in two ways First to exit immediately press and release it The second way is to simply wait 30 seconds and the controller will automatically return to the basic display 2 Hints 2 2 How to configure your RWF40 RWF40 Basic display Actual value Shown at the right is the basic display display Setpoint The current configuration of your specific display controller will determine which levels you will be allowed to access C112 must be to access the configuration level AN The C112 locking code can only be adjusted by the manufacturer To reach the configuration level you start from the basic display shown above skip past the user level and go first to the parameter level and then finally to the configuration level Press and hold for 3 seconds and then release it You are now at the parameter
58. 1 11 993 15760 EXTERNAL LOCK WASHER 10 32 1 872 00381 BOARD INSULATION 1 Th x 3 5 8 x 72 1 4 LG 33 1 817 02420 SWITCH HIGH AIR PRESSURE 34 1 859 00022 TEE 150 MI 25 35 2 857 00726 NIPPLE 25 SCH 80 X 1 5 LG 36 1 857 00679 NIPPLE 25 SCH 80 X 3 LG 37 1 848 00157 Terminal Ignition Straight Spring Snap 7mm Cable sued H aJl4Je9 9 4939 47 CO Ul NO NO NO Attach Using Spray Adhesive or Pins Clips 2 See Note 1 3 Lr 1 S SECTION B B SECTION A A SECTION C C o NO NO 20 Burner Assembly 30 HP Parts List ITEM PART NUMBER DESCRIPTION 1 1 132C02500 Insulated Front Door Assembly 2 1 853 00982 Gasket 1 1 4 Dia x 110 LG 3 2 380A01034 Gasket Adapter Plate to Door 4 1 380 01030 Burner Canister 5 1 380 01067 Adapter Plate Blower to Door 6 4 869 00030 Nut Hex 3 8 16 UNC 7 1 380A01037 Gasker Adapter Plate to Blower 8 1 894 04076 Blower Unit 115V 9 1 048 00660 Venturi Air Gas C W Sensing Line 10 2 380A01032 Gasket Electrode C W Items 11 and 12 11 1 380 01031 Electrode Double 12 1 380A01039 Electrode Single 13 1 065 00879 Retainer Sight Port 14 1 851 00026 Sight Glass Pyr
59. 1 9030 is shown in the actual value display The current configuration item C111 is shown in the setpoint display The display is steady not flashing and by default the 4 rightmost digit is the one you may now adjust You can select the digit you want to adjust by pressing once and releasing it The 3 digit is now flashing indicating that it is now the adjustable digit Each time you press and release kA you cycle thru each digit right to left and back again To TN the value of the flashing digit press and release it Each time you press F and release you cycle up thru the allowable values and back again EWT Once you have the desired value displayed and flashing you may accept it by pressing and releasing it All four upper digits will flash once The controller displays the new configuration values in 4 steady digits Your options at this point are Press and release to immediately return to the basic display or press and release it to advance to C112 press again and release it to advance to C113 press and release it to advance to SCL after the last configuration item Df1 press release it to advance to AL the 1 parameter after the last parameter item P press and release it to advance to SP1 the 15 user item after the last user item it cycles back to the 1 user item Or simply wai
60. 20 _ 0200 __ 143 Modbus address deg F K6 off _ 0130 _ 0130 54 7 ScaelAnmdoginptllow 0 SCH ScaleAnaloginput High 15 _ 150 _____ 5012 ScaeAndoginut2low 0 0 SCH2 ScaleAndoginpu2 High 135 _ 135 SP 1 SetPontlowlimt 0 __ Set PointHigh Limit 14335 _ 135 Offset correction An 0 20 Offset correction An2 0 Offset correction An 0 0 DigtalFiltes ani 1 1 4 20mA Part No 750 222 RWF40 Default 111 XX3X C111 x3xxor x4xx RWF40 Default 350 RWF40 Default 9030 0010 0110 I Chapter 4 Commissioning Basic display indicates the measured process variable steam pressure or hot water outlet temperature at the top in red with the current modulating set point below it in green A green LED above the burner symbol indicates operating status ON indicates the burner is released for modulation OFF indicates the boiler process variable has exceeded the off point SPx HYS3 and has yet to reach the on point SPx HYS1 The LED will turn ON and the burner will be released for modulation when the process variable falls below the ON point please note this LED does not necessarily indicate that the burner is operating it merely indicates that the modulating control has released the burner for operation To enter manual firing rate contr
61. 2714 Display Module is a backlit 2 line by 16 character LCD display with keypad to pro vide both current operation and historical information of the CB90 The 833 2714 contains a keypad consisting of three push keys SCRL RESET and MODE Remote reset is available through the 833 2714 Keypad The 833 2714 displays current burner status first out annunciation in the event of a lockout condi tion historical burner information detailed lockout information of the last six 6 lockout conditions and programmer configuration information Through the display the ability to program the unit address for communications as well as resetting the stored information cycles hours and lockouts to zero is provided Depending on the information being displayed data is displayed on the 833 2714 screen in the fol lowing locations OPERATING STATUS TIMING Standby Purge TFI During Purge or TFI OR Auto etc FLAME SIGNAL STRENGTH During MTFI or Auto PURGE 00 05 p cd STARTING BURNER ADDITIONAL INFORMATION ON OPERATING STATUS bi Flame Signal Strength Cause of current Lockout etc OR ARROW displayed when BURNER HISTORY SCRL key required MODE key is required to Burner Cycles Burner Lockouts etc OR access sub menus SUB MENU HEADINGS SCRL and MODE keys required Program Lockout History Program Setup etc At any time the 90 is powered the SCRL key is used to scroll through and display the tot
62. 94 1e pepuno46 yee je1neu 511 sey Ajddns Oy 021 941 1241 9 031 aw 2 pue maios y 1 4 1495910 ejqeJnseaeu ou 1 9191 WUD ON eds uoniu i dooJp 1 usaop 11 os si 3y 124 pue pepunoJ quee 06 1 S jeuruuJe 1241 Aj149A 5 16 5 04 9199 E U 01 si aseq 4 94 1041 980 eui 01 14011014 9 1 quee pijos e s 3134 ey JJ9A L NOILWNLIS JJS L NOILWNLIS 135 daldridiNVv 5411 9NILOOHS318fn0U L d3NNV92S 39V 1d3d 3A123430 S ISSVH2 90 NO d3lNINVd90uUd q313lNV 13 L NOILWNLIS 335 393H9 HOLIMS 393H9 300500 JequinN 9514 NO 22 9 031 3 74 1N3S3ud SNid OWA 021 SI 0219318 11318084 WN31SAS 391438 1934403 Y3M019 493H9 ONIHIM d3xv3ud 13538 dO 3503 39V 1948 d3NNV9S JAOWSY d3ldl TdINV 39V 1d3d iNO d3MO 18 ANY SI 13 SI SISSVHO JOWIddd 33H 38 LON 1 5 3 AVH S3ATVA T3nd ANY 9NIYIM 2 9 23H29 2 135444 9VAOcI 5 Nowuviv 8080 Rev 1 BROOKS 1 m CLEAVER NO 8 A ON NOILVNLIS ON NOILVNLIS A ON NOILVNLIS
63. ARRZ7572K17 SELF CLOSING 22 4 1860 00033 MACHINE SCREW 10 32 UNF X 375 LG 23 1 507C07955 GAS TRAIN PIPING 24 4 1869 00036 NUT HEX 5 16 18 UNC 25 1 1800 00098 VENTURI GASKET 26 1 008C03564 GAS VALVE BRACKET 27 1 1841 01122 U BOLT WITH NUTS 28 4 1868 00536 SOCKET HEAD CAP SCREW 10 24 UNC x 1 Lg 29 1 880 02005 AIR FILTER KIT 6 30 4 1952 00145 1 4 FLAT WASHER 31 1 1008C03620 BRACKET JUNCTION BOX 32 4 1869 00061 NUT HEX MACHINE SCREW 10 24 UNC 33 4 1993 16083 CAPSCREW 10 32 x 1 2 Lg 34 11 993 15760 EXTERNAL LOCK WASHER 10 35 1 1872 00381 BOARD INSULATION 1 TH X 3 5 8 X 91 LG 36 1 1859 00022 TEE 150 25 37 1 1859 00078 ELBOW 90 25 150 M I 38 3 1857 00726 NIPPLE 25 SCH 80 X 1 5 LG 39 1 1817 02420 HIGH AIR PRESSURE SWITCH 40 1 1848 00157 TERMINAL IGNITION SPRING SNAP sued H aJl4Je9 9 4939 47 CCC 0GL ON Hed 4 9 22 Bumer Assembly 50 60 HP Parts List ITEM QTY PART NUMBER DESCRIPTION A 1 1 132C02546 Insulated Front Door Assembly SEE NOTE 1 2 1 853 00982 Gasket Rope 1 3 2 380 01034 Gasket Adapter Plate to Vessel 4 1 380 01074 Burner Can Unit 5 1 380A01036 Adapter Plate Vessel to Blower 6 4 869 00030 Nut Hex Locate Grounding Tab Here 7 1 380401038 Gask
64. C112 amp C113 are performed by pressing the lt DOWN arrow key to select the digit that requires changing then press the UP arrow key to change the digit to the value desired Repeat until each digit is set to the proper value Once the specific C11x parameter is correct press the lt PGM gt key to save Other Configuration parameters such as set point limiting SPL amp SPH and remote set point scaling SCL2 amp SCH2 are changed and saved as described above in User and Parameter levels Part No 750 222 Table 4 1 RWF40 MODULATING BOILER CONTROL Factory default configuration User Level Functions 15 Steam 150 Steam Set Point 1 10 100 SP2 310 100 _ X digtalSetPointshift 0 tA Outdoor Air Temperature n3 current reading current reading SRE Remote External Set Point An2 current value current value Parameter Level Functions 15 Steam 150 Steam K6 relay alarm level BEN __ HYSt K6 relay alarm differential ____ ___ PID Proportional Band __ 2 258 1 dt Derivative time _____ PID Integral time LE 15 15 HYS Difeetialon 0 0 HYS3 Difeenialff 2 6 __ _ NA ____ 1 1 P NA 0 Configuration Level Functions 15 Steam 150 Steam C111 An Input 1 An2 An3 DualSP Fool 47 4 20mA 2 Modulating 4 20 output 0
65. Fittings To Be 150 M I Unless Otherwise Specified Plug All Unused Openings Use Pipe Joint Compoud On All Threaded Joints Use Gaskets O Rings Where Applicable All Joints Must Be Gas Tight LGPS Attached To Port 2 First Leak Test In Port P HGPS amp Second Leak Test Attached To Port 4 port P ITEM PART NO DESCRIPTION 9 1 85701626 125 Sch 80 x 1 5 Lg sued H ell4Je9 9 4939 47 CCC OGL ON Hed 9 10 Gas Train 15 HP Notes 940 07163 Gas Combo 120V 75 NPT C W 75 Adapter dins 2 2 80000092 peel d dius 941 02632 2 M I Unless Otherwise Specified 859 00108 Elbow Street 90 1 NPT 1508 M I Plug All Unused Openings Use Pipe Joint Compoud On All Threaded Joints 817 02420 High Gas Pressure Switch Use Gaskets O Rings Where Applicable 857 00719 Nipple 125 NPT Sch 80 x Closed All Joints Must Be Gas Tight 859 00077 Elbow 90 125 NPT 150 1 LGPS Attached To Port 2 First Leak Test In Port P 857 01626 Nipple 125 Sch 80 x 1 5 Lg HGPS amp Second Leak Test Attached To Port 4 858 00166 857 00642 Nipple 1 Sch 80 x 8 0 Lg 918 00032 Gas Pressure Regulator Maxitrol RV61 1 NPT o 847 01172 Bushing Hex 25 x 125 a NOOO CJ Nipple 1 NPT Sch 80 x 3 0 Lg Elbow Street 90 75 150 1 Reducer Coup
66. NDS MP230 PREPURGE DELAY TIME DID FLAME LED COME ON NO PROPER NO PILOT VOLTAGE YES Y 120V ACROS 3 2 CHECK FUSE IN CHECK OUTPUT CHASSIS WIRING PROPER NO IGNITION YES 2 VOLTAGE 120V ACROSS DID TFI LED GO OFF NO 1 WIRING AFTER SUITABLE gt 4 PROGRAMMER YES YES REPLACE CHASSIS m PROPER NO MAIN VALVE VOLTAGE 120V ACROSS Y 5 2 REPLACE CHECK OUTPUT NO CHASSIS WIRING IS NO THERE A GOOD FIRE MAKE PROPER YES BURNER ADJUSTMENT NO REPEAT RESET SUCCESSFUL POSITION SITUATION 1 ALIGN SCANNER YES NO TO RESET THE CONTROL THE CONTROL POWER MUST BE ON L1 L2 REPAIR WIRING AMPLIFIER OR CHASSIS REPLACE SCANNER DEFECTIVE 23 3A110343d SISSVHI H3lNINvH90Hd si 041009 4 aued 211129 9 94 01 4 966 101 y 9 e unu 01 JUeM wajqosd 94194 Aew 514 yury noA j Ajddns 19 00 3y ui sjuarsueJ e eq Aew 91941 510108 94 uga 219 95001 Ig 79502 18W10 sug1 941 Ajensn si 10 eu yee Ajpijos si 0295 s eunojsueJ 101101 eu 1241 uiuo NO asned ue 1 uonejosi Ajddns
67. ON 859 00108 Elbow Street 3 Plug Unused Openings M TA 2 L6 1 7044 jowGePesweSWth esros o fs 89007 CCC 0GL ON Hed Ls NN 918 00032 Gas Pressure Regulator Maxitrol RV61 1 857 02199 16 1 847 01172 Hex 11 39 17 1 859 00021 825 00239 Leakage Test Cock 10 4 port P a CX o port P sued H aJl4Je9 9 4939 47 13 Gas Train HP NO NO Notes r 1 All Piping To Be SA106 Gr B Sch 40 Or Better 2 All Fittings To Be 150 M I Unless Otherwise Specified 3 Plug Unused Openings LII 4 Use Pipe Joint Compoud On All Threaded Joints d 5 Use Gaskets O Rings Where Applicable 6 All Joints Must Gas Tight 34 3 4 REF 22 15 1 4 OW port P 12 ty 15 rr TI CY Q Lir amu T age T aO 71 15 7 port 4 port p o I ITEMQTY PARTNO DESCRIPTION 5 4 85700639 7 2 6 1 81702414 Low Gas Pressure Switch 8 3 8590077 Ebow 90 1 9 3 8570113 Nipple 2 13 2 85700644 14 2 85702199 16 1
68. OOKS EXTERNAL METER CONNECTIONS The test jacks are located on the amplifier card If external access is desired for a panel meter the fig ure shown below will assist you in locating the position to drill through on the front cover The hole sizes should be large enough to accommodate the body of the meter probes The tests accept meter probes up to 080 or 2mm diameter ADDING HOLES IN COVER TO ACCESS TEST JACKS RECOMMEND 9 16 TO 3 8 HOLES TO ACCOMODATE METER PROBES Cleaver Brooks INSTALLATION TESTING Use of Test Meter All Controls Testing the Cleaver Brooks CB90 Controls requires the use of a test AC DC multimeter with a min imum 1000 ohm volt AC scale and 20 000 ohm volt DC scale With the test meter on the DC scale and the test meter leads inserted into the test jacks on the ampli fier Red for positive polarity Black for minus polarity a DC voltage reading of 4 0 to 10 volts for all amplifier types should be obtained when the control is detecting flame and 0 volts when no flame is present Wildly fluctuating readings are an indication of an unstable flame or flame sen sor requiring maintenance Inadequate flame signal may be improved by 1 Assuring that the flame detector and wiring installations have followed the instructions begin ning on page 25 Assuring that the flame detector is clean and within the ambient temperature limits Assuring that the flame is sufficiently lar
69. Sight Glass Gasket 0625 x 1 438 I D x 1 719 O D 16 1 860 00097 Machine Screw 8 32 UNC x 75 LG 17 1 857 00728 Nipple 25 NPT SCH 80 x 2 5 LG 18 19 1 857 00726 Nipple 25 80 1 5 LG 20 1 859 00022 5 16 3 55 150 1 4 21 1 817 03468 Combustion Air Proving Switch 22 2 845 00468 Connector 125 NPT x 25 O D 23 1 939 00661 Tubing Aluminum 25 O D x 035 Wall x 25 LG 24 uu MC ccena ren 25 Zn MERERI 26 1 507 08213 Piping Gas Train 27 2 869 00198 Nut Hex 5 16 18 UNC 28 1 880 01858 Air Filter Kit 4 29 1 800 00098 Venturi Gasket 30 1 868 00536 Socket Head Capscrew 10 24 UNC x 1 LG 31 ae acer See eT 32 1 869 00061 Nut Hex Machine Screw 10 24 UNC 33 1 1993 16083 Capscrew Hex 10 32 x 1 2 LG 34 1 1993 15760 External Lock Washer 10 35 1 1872 00381 Board Insulation 36 1 817 02420 Switch High Air Pressure 37 1 848 00157 Terminal Ignition Spring Snap 7mm Cable Sensing Line CB P N 380 01069 C W Item 9 sued H ell4Je9 9 4939 47 CCC OGL ON Hed 61 9 Attach Using Spray Adhesive or Pins Clips SECTION A A SECTION C C 17 Burner Assembly 15 HP LISt ITEM QTY PART NUMBER DESCRIPTION 1 1 132C02497 Insul
70. Switching differential for limit comparator 8 2 10 Pb 1 SPE setpoint external 9 2 80 dt Derivative time 22 350 rt Integral action time 9 2 5 HYS1 5 F below setpoint 55 1 3 HYS2 Burner off 2 stage 5 24 5 HYS3 Burner off 5 F above setpoint 5 5 1 0 q Response threshold 5 6 1 Heating curve slope 5 5 1 0 P Parallel displacement 5 5 Set user level values See Hint section3 4 How to change a setpoint You may enter the user level directly from the basic display Press and release The actual value display 180 shows the current user level item value The setpoint display SP 1 shows the user level item you are adjusting Increase rN or decrease the value accept it by waiting 2 seconds Once it flashes press Pem and release Adjust SP1 as shown below User level values Value Item 100 SP 1 Description Sec Set point 1 0 9 1 Setup is complete Sec 5 Refers to the RWF40 user manual section 3 Notes 3 1 Logic summary SP 1 v 80 AL lirnit alarm 5 HY St hystersis 2 Window Function C112 input 1 as shown normal swtunction setpoint C112 input1 2xxx sw function ie all 6 amp K amp 5 OFF are reversed SP 1 80 AL limit alarm 5 HY St hystersis 2 Lower Limit setpoint C112 input 3xxx as shown normal swfunction C112
71. TFI and Auto Flame Signal Averages AVERAGES 26 35 41 47 53 59 65 1 9 Combined Status see Description Below Most Recent Lockout Data 2nd Most Recent Lockout Data Returns complete lockout description of stored 3rd Most Recent Lockout lockout history Includes lockout message 4th Most Recent Lockout burner cycles Data oth Most Recent Lockout Data 6th Most Recent Lockout Data Messages 00 05 08 10 15 21 and 26 are unique in that a limited number of successive registers can be combined with these requests For example a request to message 00 can contain up to 6 data words The response to this would contain STATUS MSGN GSTAT TIMER FLAME and LOGSTAT If the requested data word count DAT were to be 2 then the response would contain STATUS and MSGN only Message 15 last 6 lockouts can return data ranging from 1 to 6 with 1 referring to the most recent lockout Message 26 returns the current operating status as well as stored burner hours and burner cycles as a snapshot of the entire CB90 system When all 9 words are requested the data returned consists of STATUS MSGN FLAME INPUTS OUTPUTS BNRMINS and BNRCYCS The MSGN being transmitted is a numerical value and must be interpreted by the communicating device which actually is an advantage since this can be made to be whatever message text the end user wants In other words it allows for programming custom messages without actually changing the message in the progr
72. able 4 3 Part No 750 222 Figure 4 10 Power Up Ensure blower motor is properly wired for the available power supply 115 V 1Ph 60Hz Verify the voltage Control voltage is 115V 1Ph to ensure it is within specification for the application Set all limit and interlock switches to the appropriate setting for the application C Operation Check Gas Valve Gas Pressure Switches and Combustion Air Proving Switch Before initial firing of the burner the gas valve Low Gas Pressure Switch LGPS High Gas Pressure Switch HGPS and Combustion Air Proving Switch CAPS should be checked for proper operation e Before proceeding review Section 4 3 Control Setpoints for initial LGPS HGPS and CAPS settings Close the downstream manual shut off valve before checking pressure switches and CAPS LGPS 1 To check the Low Gas Pressure Switch first close the upstream manual shutoff valve both manual shutoff valves should now be closed 2 Start the burner and wait 10 seconds during purge for CAPS to be made 3 Turn the LGPS setting to maximum 4 Open the test cock to bleed the gas line 5 he CB90 should lock out indicating LOCKOUT PURGE INTERLOCK OPEN 6 Reset the 90 and change the LGPS setting back to minimum to proceed Part No 750 222 Gas Train Pressure Chapter 4 Commissioning Table 4 3 ClearFire H Gas Pressure Requirements 2g 2g 2g W C W
73. al Value Modulatin Controller can be configured for various options such as dual Controller set point remote set point and outdoor reset Optional Modbus communications version available B CB90 Flame Safety Control for burner sequencing and flame monitoring Safe start check pre purge ignition release to modulation and post purge steps are controlled by the CB90 Modbus communications available with ED510 display Additional control system features include Supervision of low and high gas pressure Combustion air proving e Operating limit control High limit control with manual reset Low water controls Primary LWCO pump control consisting of control board in the electrical panel and external water column probe Auxiliary LWCO consisting of control board manual reset test switch and vessel mounted probe Safety relief valve 1 Figure 1 9 Low Water and Limit Controls Part No 750 222 Flame Safe Display optional Figure 1 8 Model CFH Controls 1 5 Chapter 1 Introduction AluFer Furnace Tubes Flue Gas Outlet 24 Burner _ Canister ASME Code Pressure Vessel 1 6 COMPONENT CONNECTION LOCATIONS Figure 1 10 shows the Model CFH component orientation Refer to Chapter 3 for recommended vent sizes and lengths for the specific boiler installation Safety Relief Valve Low Water Cut Off Pressure N Gauge Steam isi bs Limit Controls Outlet Premix Burner
74. al num ber burner hours burner cycles burner lockouts and system hours on the bottom line of the 833 2714 display The top line will continue to show the current run mode of the control e g PURGE AUTO etc Following the historical information the SCRL key will display three 3 sub menus providing the following information and or functions Lockout History with burner cycle and burner hour time stamp Program Setup to display programmer type purge timing switch configuration etc System Information values of average pilot and main flame signal and reset burner his tory The system sub menus require the MODE key to gain access to the information associated with each sub menu An arrow is displayed in the lower right hand corner of the display to indicate a system sub menu is available Once within the sub menu pressing the SCRL key displays the next item within the sub menu and pressing the MODE key will exit the sub menu and return the display to the top of the main menu AUTO Number of burner operating hours Terminal 5 energized BNR HOURS AUTO Number of burner cycles BNR CYCLES CB 8080 Rev 1 11 CLEAVER 5 Number of burner lockouts AUTO BNR LOCKOUTS Number of hours the control has been powered AUTO SYS HOURS AUTO Sub menu to display the cause of the last 6 lockouts The MODE key is required to LOCKOUT HISTORY display the actual lockouts Sub menu to display vario
75. al surfaces at the same ground reference But this same system is unable to provide this at higher frequencies because of the increased impedance caused by the skin effect The purpose of the ferrite core is to provide a low impedance at these higher frequencies and absorb this unwanted energy Care must be taken not to route the ED580 cable in close proximity to any starter motor contactors located in the control panel or across any high voltage ignition wires COMMUNICATIONS SCANNERS When interfacing Cleaver Brooks controls to a communication system be it a PLC or other micro processor based device ferrite cores should also be utilized Proper twisted shielded pair cable must be utilized In a multi drop system the shields should be tied together within a cabinet and not to any ground point The shield at the source end of the cable of the multi drop connection can then be ter minated to ground Source end 15 defined as the originating end of the communication system Care must be taken not to route communication cables in close proximity to any starter motor con tactors located in the control panel or across any high voltage ignition wires Refer to Fireye bulletin E 8002 for proper installation The armored cable supplied with the Ultra Violet and Infrared scanners should be connected to equipment by means of a good mechanical connection such as a conduit fitting It may be necessary to utilize heat insulator P N 35 69 to isolate t
76. ammer The 90 stores its burner on time Terminal 5 powered and system on time L1 powered in min utes Internally the programmer converts this to hours for display purposes however the result is CB 8080 Rev 1 15 10 CLEAVER BROOKS rounded down The information being supplied by Modbus will be the actual time in minutes and it is up to the communicating device to do the conversion Since the maximum value stored in the CB90 is 9 999 999 minutes the maximum value in hex therefore is 98967FH and comprises of two data words The maximum cycle count is 999 999 decimal or OF423FH still two data words As example the System on Minutes data is transmitted from the CB90 to the interface as high word low word as shown below MESSAGE ADDRESS 8 MESSAGE ADDRESS 9 HIGH WORD LOW WORD HIGH BYTE LOW BYTE HIGH BYTE LOW BYTE Note Data from address 9 cannot be accessed directly values are represented in a HEX or base 16 format GSTAT determines the type of value TIMER represents TIMER can be a running timer such as is used in purge a flame signal or meaningless Only the lower nibble of GSTAT has any value If this value is 0 then the TIMER value has no meaning The value in TIMER is a background minute timer in the CB90 and should be ignored If GSTAT is between 4 and 7 the TIMER represents the current value flame signal If GSTAT is a 1 2 or 3 then TIMER represents a running timer value The bau
77. analog input 3 weather dependent setpoint shift SCale High analog input 1 measured value range 1999 to 9999 00 Your Range 0 to 1440 1278 oLLo Working range Limit Lower 1999 to 9999 1999 Working range Limit High 1999 to 9999 9999 Bus watchDog timer in seconds 0 to 7200 Setpoint Your Display Setting Parameter level items Sec 6 3 Air value for Limit comparator programmable ray 1999 to 9999 Hysteresis ewichingaiferenia tor K6 imcomparaor band affects Presponse fowls ore SS derivative time in seconds affects D response of controller Integral action time in seconds affects of controller 0 1 5 Switch on threshold HYSteress 5 Switch offtreshotd HYSteresis2 Zstage bummer _ 0088 _ Switch offtreshotd HYSteresis3 upe _ Responsethresnod 1 Heating curve slope owa Parallel displacement weather dependent setpoint shift 90 to 90 eem 90 20 00 9 _ L ssssemenswisgumpuzor i 9 mE nem E p _ 0 NEN BEEN NN 4 Actuator running time in seconds visible when C112 is 0 3 pos modulating 10 to 3000 p md NEN EN a 514 dd
78. and control It is recommended that the water column and gauge glass be blown down every shift to remove accumulated solids Regular blowdown of the water column will help maintain the integrity of the water level probes and will help to ensure trouble free operation of the boiler See Figure 5 2 for procedure Part No 750 222 5 3 Chapter 5 Service And Periodic Maintenance 1 Open Water Column blowdown valve 5 to 3 Close upper gauge glass isolation valve 10 sec to discharge water from WC 4 Open gauge glass blowdown valve to 2 Close WC blowdown valve discharge water from gauge glass 5 Close lower gauge glass isolation valve 8 Close gauge glass blowdown 6 Open upper gauge glass isolation valve valve 7 Open lower gauge glass isolation valve to discharge steam from gauge glass Figure 5 2 Water Column and Gauge Glass Blowdown 5 4 Part No 750 222 Chapter 5 Service And Periodic Maintenance Periodic replacement of the water gauge glass should be part of a regular maintenance program A broken or discolored glass should be replaced at once Use a proper size rubber packing Do not use loose packing which could be forced below the glass and possibly plug the valve opening Close the valves when replacing the glass Slip a packing nut packing washer and packing ring onto each end of the glass Insert one end of the glass into the upper gauge valve body far enough to allow the lower end to be dropped i
79. ary to open the operating control L1 7 to have the CB90 in the IDLE or STANDBY position Depressing the reset switch for greater than 10 seconds will cause the address of the CB90 to be displayed in a binary format on the LEDs located on the programmer board Because the default is address 0 and since address 0 would mean no LEDs would be lit the ALARM LED is made to flash when the address is 0 CTRL LED is the least significant bit while the ALARM relay is the most significant bit To increment the address counter depress and release the RESET push button and observe the LED pattern If the RESET switch is untouched for 30 seconds the current address displayed will be stored to memory and the CB90 will automatically exit the address mode CB 8080 Rev 1 19 CLEAVER BROOKS TEST JACK VOLTAGE For all amplifiers the CB90 provides a uniform 0 10 volt signal to represent the flame signal strength A signal reading greater than 4 volts 1s considered sufficient to provide reliable operation This same signal 15 also available in a numerical format on the 833 2714 display The chart below correlates the test jack voltage to the numerical value The signal clamps at 10 volts at a numerical value greater than 42 and the numerical value clamps at 80 LLI lt H 1 gt Q lt H H 6 16 20 24 28 32 36 40 60 AMPLIFIER TEST JACK VOLTAGE VS 833 2714 DISPLAY MODULE 20 CB 8080 Rev 1 CLEAVER BR
80. ated Front Door Assembly 2 1 853 00982 Gasket Rope 1 1 4 Dia x 78 LG 3 1 380 01053 Gasket Adapter Plate to Vessel 4 1 380 01045 Burner Canister 5 1 380 01052 Adapter Plate Vessel To Blower 6 4 869 00030 Nut Hex 3 8 16 UNC 7 1 380 01037 Gasket Adapter Plate to Blower 8 1 894 04076 Blower Unit 115V 9 1 048 00659 Venturi Air Gas Premix C W Sensing Line 10 2 380 01032 Gasket Electrode C W Items 11 and 12 11 1 380 01062 Electrode Single 12 1 380 01061 Electrode Double 13 1 065 00879 Retainer Sight Port 14 1 851 00026 Sight Glass Pyrex 1875 x 1 75 O D 15 1 853 00213 Sight Glass Gasket 0625 x 1 438 I D x 1 719 O D 16 1 860 00097 Machine Screw 8 32 UNC x 75 LG 17 2 857 00728 Nipple 25 NPT SCH 80 x 2 5 LG 19 1 857 00726 Nipple 25 NPT SCH 80 x 1 5 LG 20 1 859 00022 5 16 3 55 150 1 4 21 1 817 03468 Combustion Air Proving Switch 22 2 845 00468 Connector 125 x 25 O D 23 1 1939 00661 Tubing Aluminum 25 O D x 035 Wall x 25 LG 24 1 928 00228 Cable Ring Loop McMaster Carr 7572K17 Self Closing 25 1 860 00033 Machine Screw 10 32 UNF x 375 LG 26 1 507 07950 Piping Gas Train 27 4 869 00198 Nut Hex 5 16 18 UNC 28 1 880C01858 Air Filter Kit 4 29 1 800 00098 Venturi Gasket 30 1 868 00536 Socket Head Capscrew 10 24 UNC x 1 LG 31 1 008 03620 Bracket Junction Box 32 1 869 00061 Nut Hex Machine Screw 10 24 UNC 33 1 1993 16083 Capsc
81. boiler is under a light load and when the water level is at the Normal Operating Water Level Be sure the blowdown piping is in proper operating condition Waste should be piped to a point of safe discharge 1 Open the quick opening valve 2 Crackthe second or downstream valve slightly to allow the lines to warm then continue opening slowly to its fully open position The duration of each blowdown should be determined by water analysis A reduction of water level in the gauge glass by about 1 2 can often serve as a rough guide but should not replace water analysis procedures 3 When blowdown is complete close the downstream slow opening valve first as quickly as possible Then close the quick opening valve Finally crack the downstream valve slightly then close it tightly It is generally recommended that bottom blowdown be performed at least once in every eight hour period Actual frequency may vary depending on water conditions and boiler operating conditions Caution Consult the appropriate water treatment personnel regarding blowdown do not pump the lever blowdown scheduling action valve open and closed Equipment damage may result Under no circumstances should a blow down valve be left open Never leave the boiler unattended during blowdown 9 3 WATER COLUMN BLOWDOWN Free flow of water through the water column and gauge glass is essential to obtaining accurate boiler water level indication
82. can also be conducted at this time With the gas shutoff closed while the burner attempts ignition the CB90 Flame Safety should lock out indicating PTFI ignition failure Reset as needed After verifying proper operation of LGPS HGPS CAPS and Gas Valve re open the downstream manual shut off valve D LWCO and ALWCO Check e Before testing low water controls disconnect power to the feed pump LWCO 1 To verify proper LWCO operation conduct a blowdown of the water column refer to Chapter 5 Section 5 3 Water Column Blowdown 2 During WC blowdown the burner should shut off when low water level is reached 3 Upon shutdown check the LWCO control board in the CFH electrical panel The LED indicator should be off indicating that the LWCO has switched off the control circuit Part No 750 222 ALWCO 1 To check the ALWCO drain the boiler refer to Chapter 5 Sec tion 5 2 Blowdown 2 Observe the ALWCO control board in the CFH electrical panel When the ALWCO level is reached the LED indicator should go Out 3 Close the blowdown valves refill boiler and reset the ALWCO After testing the low water controls reconnect power to the feed pump E Low and High Fire Adjustments Before initial firing of the burner the integral gas regulator should be adjusted Adjustments are made using a TORX T40 low fire adjustment and 3 mm hex wrench main gas choke The adjustments should initially be set to half
83. ches and CAPS 4 13 D LWCO ALWCO Check 4 14 E Low and High Fire Adjustments 4 15 F Setting Combustion 4 15 G Limit Controls CHECK 456 uc dedo eo COR 4 4 16 Boil Out of anew unit 4 16 Post start up checkout procedure 4 17 A Warning The boiler and its gas connection must be leak tested before placing the boiler in operation Milwaukee Wisconsin www cleaver brooks com Chapter 4 Commissioning 4 2 NOTE If hydrostatic testing is required on site use water at 70 deg F and pressure not to exceed 90 of the safety valve rating 4 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 Boiler room ambient conditions Relative humidity 85 9096 Ambient temperature range 0 C to 50 9C 32 F to 1229F Storage temperature range 20 C to 60 C 4 F to 140 F 4 2 Filling Boiler Open the manual bleed valve before allowing water to enter into the boiler Make sure the drain valve is closed The boiler should be filled slowly to allow air to escape while water f
84. control e g average main flame signal strength status of the high fire and low fire end switches etc The MODE key is used to enter the SYSTEM INFO sub menu and the SCRL key is used to advance Screen Displays AUTO 45 SYSTEM INFO AUTO 45 AVG PILOT FLM 22 AUTO 45 AVG MAIN FLM 40 Description SCRL key advances through the historical information until System Info is displayed Pressing and releasing the MODE Key enters the sub menu The average flame signal strength of the pilot flame 22 The average flame signal strength of the main flame 40 13 CLEAVER 5 SCRL PRESS RESET TO Historical data will be cleared to 0 Must be done while CLEAR HISTORY terminal I 7 is open MODE AUTO 45 Mode key returns to run message FLAME SIGNAL COMMUNICATIONS The protocol to be used is Modbus RTU This is implemented by the master PC PLC etc issuing a poll to the slave CB90 and the slave responding with the appropriate message A typical format of a poll request is as follows DST FNC ADR ADR DAT DAT CRC CRC HI LO HI LO LO HI DST refers to the logical address of the slave set but using reset pushbutton or 833 2714 ENC is the function being requested FNC 03 is a read request ADR is the message number or register number of the data being requested In Modbus register addresses begin at 40001 but is interpreted as address 00 DAT 15 the number of words being requested word is an in
85. creasing and holds the current firing rate of the burner When the FN is released output value Stops decreasing and the output to terminals X1 and X1 also Stops decreasing and holds the current firing rate of the burner and the controller returns to the automatic mode On Modulating burners with modulating output the output to terminals X1 and X2 also returns to automatic operation On Modulating burners with 3 position output J K6 3 Position Output Modulating Output Figure 1 Connection diagrams the output to relay 2 and relay 3 also returns to automatic operation 2 Hints 2 7 Auto tune self setting function gt RWFA0 user manual section 6 2 4 and 9 1 RWF40 User manual refers to a self setting function that for the purposes of this manual will be refered to as Auto tune Technical Explanation Auto tune is a self setting software function that is integrated into the RW F40 controller and can be repeated as often as desired Auto tune tests the reaction in the modulating mode of operation of the process control loop to steps in the actuator position according to a special procedure The data during the forced oscillations is then recorded and used to calculate new values that are optimized for your specific controlled system Auto tune items summary Items at the user level that will affect Auto tune SP 1 Set Point 1
86. d main fuels Initiate a normal start up Observe the test meter which should read no more than 1 2 volt DC If higher levels are observed realign the UV scanner and or shield the spark from the scanner s view Move the Run Check switch to the Run position check pilot flame response time by manually shutting off the pilot fuel and initiate a normal start up With no pilot flame present the control will de energize the pilot assembly at the end of the trial for ignition interval selectable by dipswitch 4 and go into safety shutdown WARNING The minimum pilot test must be accomplished by a trained and qualified burner technician Minimum Pilot Test This test assures that the flame detector will not sense a pilot flame too small to light a the main flame reliably It must be made on every new installation as well as following the repositioning or replacement of the flame detector This procedure should not be used on a direct spark burner 1 2 3 Manually shut off the fuel to the main burner Place the Run Check switch in the Check position if supplied Connect a test meter to the test jacks on the Amplifier Module or observe the reading on the 833 2714 display Initiate a normal start up Reduce the fuel to the pilot until the DC voltmeter reads 4 0 volts This is the minimum pilot For flame rectification the flame signal for minimum pilot varies depending on the application See WARNING below Return the Run Check sw
87. d rate of the CB90 is fixed at 4800 bits per second The format of the data is 8 data bits no parity and 1 stop bit Due to the RS485 format the communication format is considered half duplex That is only one user is permitted on the communication lines at a time The information contained in INPUTS and OUTPUTS represents the status of the interlocks and relays respectively For the INPUTS a 1 in the interlock position defines the interlock as being on or energize where the 1 in any bit position in the OUTPUT register signifies the relay as being ener gized Term Temm _ VENE Rud Me ain Fuel mk Reset and Mode represent the keypad located on the 833 2714 display A O in any of these positions indicates the switch is depressed A 1 in the opto coupler position indicates the opto cou pler is on or interlock closed Modulation 16 A 417 in any terminal position indicates the relay is energized Term 4 indicates the state of relay located in the 500 series programmers It is suggested that repeated polling interval not be less than 200 mSec per request Requesting data such as burner minutes system minutes and burner cycles be kept at a minimum due to the amount of processing time required to gather that data CB 8080 Rev 1 CLEAVER 5 Table 1 77 45H MPOSTIDLE rence
88. decimal W ill be displayed if your controller is configured with C111 Exxx Hxxx Analog input 1 Standard input 4 20 C113 xxOx Doesn t matter gt RWFAO0 user manual Section 6 2 2 and 6 2 3 RWF40 Basic display Actual value display setpoint display PGM 2 Hints 2 6 Manual operation continued Modulating burner 3 Position output EXIT Press and hold for 5 seconds and release The red LED above the manual icon turns on to indicate that the controller is now in the manual mode Relay 2 and relay 3 will hold their current state energized or de energized that they were in until another key is pressed When the is pressed Relay 3 is energized Decrease icon turns on N O contact Q Y2 closes to drive the modulating device down which decreases the firing rate of the burner When the is pressed Relay 2 is energized Increase icon turns on N O contact Q Y1 closes to drive the modulating device up which increases the firing rate of the burner 1 1 Ch Release of burner d Output 5 4 20 mA 0 10 V Xi When the is released Relay 3 is de energized Decrease icon turns off N O contact Q Y2 opens to hold the modulating device V where it is which holds the ob sad firing rate of the burner When the FM is released Relay 2 is de energi
89. degrees C Good electrical wiring practice should be followed to ensure an adequate ground system Refer to General Grounding Rules later in this document for grounding methods A good ground system should be provided to minimize the effects of AC quality problems A prop erly designed ground system meeting all the safety requirements will ensure that any AC voltage quality problems such as spikes surges and impulses have a low impedance path to ground A low impedance path to ground is required to ensure that large currents involved with any surge voltages will follow the desired path in preference to alternative paths where extensive damage may occur to equipment WARNING Controls require safety limits utilizing isolated mechanical contacts Electronic limit switches may cause erratic operation and should be avoided Care must be taken to NOT route the high energy ignition wire in close proximity to the flame sensor wiring particularly when using 833 3164 amplifier CB 8080 Rev 1 CLEAVER BROOKS INSTALLING THE PROGRAMMER AND AMPLIFIER MODULES WARNING Remove power from the control before proceeding FIGURE 1 AMPLIFIER PROGRAMMER Remove the dust cover from the chassis Insert the amplifier module into the slot in the corner of the chassis and gently push the module into position Insert the programmer module into the slot at the right side of the chassis and gently push the module into position WARNING Turn o
90. drilled in the UV1 UV2 sight pipe will assist in keeping the pipe clean and free from smoke For positive pressure furnaces provide clean air to pressurize the sight pipe if necessary CB 8080 Rev 1 CLEAVER BROOKS IINSTALLATION 69NDI FLAME ROD The 69NDI flame rod proves a gas pilot flame and or main gas flame It is a spark plug type unit con sisting of 1 2 NPT mount a KANTHAL flame rod a glazed porcelain insulating rod holder and a spark plug connector for making electrical connections The 69301 is available in 12 18 or 24 lengths The flame rod may be located to monitor only the gas pilot flame or both the gas pilot and main gas flames It is mounted on a 1 2 NPT coupling The following instructions should be observed 1 Keep flame rod as short as possible 2 Keep flame rod at least 1 2 from any refractory 3 Flame rod should enter the pilot flame from the side so as to safely prove an adequate pilot flame under all draft conditions 4 Ifthe flame is nonluminous air and gas mixed before burning the electrode tip should extend at least 1 2 into the flame but not more than halfway through WRONG POSITION CORRECT POSITION PILOT BURNER CORRECT POSITION OF PILOT FLAME 5 If the flame is partly luminous the electrode tip should extend only to the edge of the flame It is not necessary to maintain absolutely uninterrupted contact with the flame 6 Itis preferable to angle the rod downward to m
91. e MODE AUTO 45 screen has returned to the normal run message FLAME SIGNAL 12 CB 8080 Rev 1 MODE SCRL SCRL SCRL SCRL SCRL SCRL SCRL SCRL MODE Press SCRL MODE SCRL CB 8080 Rev 1 PROGRAM SETUP CLEAVER 5 The sub menu PROGRAM SETUP allows the user to review the various operational settings of the programmer module e g programmer type purge timing etc The MODE key is used to enter the PROGRAM SETUP sub menu and the SCRL key is used to advance through the sub menu AUTO 45 PROGRAMR MEP345 AUTO 45 ENGR CODE NO 9 AUTO 45 AMP MERT AUTO 45 FLAME FAIL TIME 3s AUTO 45 PURGE TIME 30s AUTO 45 PTFI TIME 4s AUTO 45 POST PURGE 0s AUTO 45 TYPE NON RECYCLE AUTO UNIT ADDRESS 00 AUTO 45 SYSTEM INFO Programmer Type is a MEP345 Software Engineering code of the programmer module is code 9 Amplifier module identified Flame Failure Response Time FFRT is 3 seconds Purge timing selected by the dipswitches 1s 30 seconds Prove 7 6 open to start is disabled selected by dipswitches Trial for ignition time is 4 seconds Post purge time is 0 seconds selected by dipswitches Control recycles on flame fail Unit Address is 00 Refer to section on communications Mode key returns to normal run message The sub menu SYSTEM INFO allows the user to review information pertaining to the operation of the
92. e RS P Setpoint Your Display Setting User level items Sec 6 2 1 temperature Ambient outside analog input 3 visible when C111 is xx1x xx2x xx3x SPL to SPH Set Point External predefinition analog input 2 visible when C111 is xx1x xx2x xx3x APPENDIX C CB90 Flame Safety CLEAVER BROOKS The power of commitment OPR CTRL INTRLCK v CB90 FLAME SAFEGUARD CONTROLS for CLEARFIRE Boilers 0 LISTED APPROVED WARNING Selection of this control for a particular application should be made by a com petent professional licensed by a state or other government Inappropriate application of this product could result in an unsafe condition hazardous to life and property DESCRIPTION The CB90 Series Flame Safeguard Control is a compact microprocessor based modular burner management system designed to provide automatic ignition and continuous flame monitoring for commercial sizes of heating and process equipment firing any type of fuel The advantages of the CB90 are zero dependence on discrete components previously used for timing functions A complete CB90 system consists of relay module 833 3162 programmer module 833 3163 ampli fier module 833 3164 wiring subbase 833 3165 and a flame rod for flame detection An optional alphanumeric display 833 2714 is available that provides complete English language description of the current operating status as well as diagnostic history T
93. ed petroleum LP gas only on the pipe threads screw the flanges onto the pipes Do not thread the pipe too far into the flange Valve distortion or malfunction can result from excess pipe in the flange Make sure O ring sealing surfaces are clean Using general purpose lithium grease grease the O ring Install the O ring into the O ring groove provided on the valve body one O ring per groove 10 Mount the gas valve to the flanges using the screws removed earlier 11 Complete the electrical connections as instructed in the Electrical Connections section WARNING Fire or Explosion Hazard Can cause severe injury death or property damage Perform a soap and water solution gas leak test any time work is done on a gas system POI Electrical Connections SUME WARNING 1 Use 14 16 or 18 AWG copper conductor 600 volt insulation moisture resistant wire for line Electrical Shock Hazard Can cause voltage connections Recommended wire types are severe injury or death Disconnect the TTW60C THW75C or THHN9OC power supply before beginning wiring to 2 Follow the instructions below for wiring the gas prevent electrical shock More than one valve See Fig 2 and 3 for reference disconnect may be involved a T1 yellow will be L2 120 Vac 24 Vac b T2 black will be L1 120 Vac or 24 Vac to Valve 1 c T3 blue will be L1 120 Vac or 24 Vac to Valve 2 d Ground green will be earth ground
94. en the stack caps center to center dem Installations Refer to latest edition of the National Fuel Gas Code Vent termination requirements are as follows 1 Vent must terminate at least four 4 feet below four 4 feet horizontally or one 1 foot above any door window or gravity air inlet to the building 2 The vent must not be less than seven 7 feet above grade when located adjacent to public walkways 3 Terminate vent at least three 3 feet above any forced air inlet located within ten 10 feet 4 Vent must terminate at least four 4 feet horizontally and in no case above or below unless four 4 feet horizontal distance is maintained from electric meters gas meters regulators and relief equipment 5 Terminate vent at least six 6 feet away from adjacent walls 6 DO NOT terminate vent closer than five 5 feet below roof overhang Part No 750 222 3 3 Chapter 3 Stack and Intake Vent Sizing and Installation 3 4 Canada Installations Refer to the latest edition of CAN CGA 149 1 and B149 2 A vent shall not terminate 1 Directly above a paved sidewalk or driveway which is located between two single family dwellings and serves both dwellings 2 Less than 7 ft 2 13m above a paved sidewalk or paved driveway located on public property 3 Within 6 ft 1 8m of a mechanical air supply inlet to any building 4 Above a meter regulator assembly within 3 ft 900mm horizontally of the
95. er test jacks provide uniform 0 10 vdc for flame signal strength gt CB 8080 Rev 1 1 M CLEAVER BROOKS SPECIFICATIONS Supply 120 VAC min 102 max 132 50 60 Hz Power Consumption 12 VA Operating Shipping Weight Approx 3 lbs 1 4 kg Operating Temperature 40 F 40 C to 140 F 60 C Table 1 LOAD RATINGS All Ratings are 120V 60 Hz Fireye Terminal Typical Load Maximum Rating 120V 60 Hz 3 4 Pilot valve s 125 VA pilot duty solenoid valve plus Individual or combined solenoid valve Ignition Transformer 5 Release to modulation 125 VA pilot duty solenoid or 25 VA pilot duty solenoid and 400 opening motorized 250 VA hold 250 VA Transformer Motor or Contactor pu 8 rated to energize and de energize 9 8 FLA 8 9 LRA on safety lockout Minimum load requirement 100mA Table 2 ALTERNATIVE LOAD RATINGS COMBINATION NUMBER MAIN VALVE TERMINAL 3 IGNITION TERMINAL 4 RELEASE TO MODULATE TERMINAL 5 Za f 4 5A Ignition 50 VA Pilot Duty 180 VA Ignition plus 2A Pilot Duty 65 VA Pilot Duty plus 4 5A ignition motor values with plus Motor valves 600VA in rush with 3850 VA 360 VA open 250 in rush 700 VA VA hold open 250 VA hold CAUTION Published load ratings assume that no control be required to handle inrush current more often than once in 15 seconds The use of control switches solenoids relays etc which chatter will lead to premature failure
96. erienced personnel suit ably equipped for moving heavy equipment 2 1 Lifting and moving the boiler The ClearFire H boiler is equipped with two lifting lugs on top of the boiler shell 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 2 2 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 Important The ClearFire H boiler requires soft water Failure to observe this requirement can lead to dangerous operating conditions and may result in damage to the boiler If necessary your Cleaver B rooks representative can provide additional information regarding your water softening requirement
97. et Adapter Plate to Blower 8 1 894 04075 Blower Unit 9 1 See table Venturi C W Sensing Line 10 2 380A01032 Gasket Electrode C W Items 11 and 12 Sensing Line 11 1 380A01061 Electrode Dual Clearfire Ignition CB P N 380 01069 12 1 380401060 Electrode Single Clearfire Flame Rod 13 1 065C00879 Retainer Sight Port 14 1 851 00026 Sight Glass Pyrex or Pins Clips 15 2 1853 00213 Sight Glass Gasket 16 3 1860 00097 Machine Screw 17 2 1857 00727 Nipple 18 1 857 00679 Nipple 19 1 859 00022 TEE 1 20 1 1817 03468 Combustion Ait Proving Swith 21 2 845 00468 Connector 22 1 939 00661 Tubing Aluminum 23 1 507C08104 Piping Gas Train Weld Item 26 24 4 869 00198 Nut Hex In Assembly 25 1 880C02005 Air Filter Kit Venturi 26 1 008C03564 Gas Train Bracket 27 1 841 01122 U Bolt 28 1 872 00381 Board Insulation 32 8 952 00133 Washer 30 4 993 16083 Capscrew 31 11 993 15760 External Lock Washer 10 32 4 952 00145 1 4 Flat Washer 33 4 868 00536 Socket Head Cap Screws 34 1 008 03620 Bracket Junction Box 35 1 1869 00061 Nut Hex Machine Screw 36 1 817 02420 Switch High Air Pressure 37 1 800 00098 Venturi Gasket 38 1 848 00157 Terminal Ignition Spring Snap 7mm Cable Notes 1 When Installing Gasket Rope Compress Rope to Maximize Diameter Item 9 Venturi SOhp 048 00656 60hp 048 00662 LLL LL LL
98. evices for Automatically Fired Boilers ANSI ASME CSD 1 A WARNING Improper installation adjustment ser vice or maintenance can cause equip ment damage personal injury or death Refer to the Operation and Maintenance manual provided with the boiler Installa tion and service must be performed by a qualified Cleaver Brooks service provid A 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 A 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 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 Notice This manual must be maintained in legi ble condition and kept adjacent to the boiler or in a safe place for future refer ence Contact your local Cleaver Brooks representative if additional manuals are required WARNING 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 A WARNING The installation must conform to the re qui
99. ex 1875 x 1 75 LG 15 2 853 00213 Sight Glass Gasket 0625 x 1 438 ID x 1 719 OD 16 3 860 00097 Machine Screw 48 32 UNC x 75 LG 17 1 857 00679 Nipple 25 SCH 80 x 3 LG 18 2 857 00726 Nipple 25 SCH 80 x 1 5 LG 19 1 859 00022 TEE 150 MI 25 20 1 817 03468 Combustion Air Proving Switch 21 2 845 00468 Connector 125 NPT x 25 OD 22 1 1939 00661 Tubing Aluminum 25 OD x 035 Wall x 25 LG 23 4 928 00228 Cable Ring Loop McMaster Carr 7572K17 Self Closing DETAIL D 24 4 860 00033 Machine Screw 10 32 UNF x 375 LG 25 1 507 08078 Piping Gas Train 26 4 869 00036 Nut Hex 5 16 18 UNC 27 1 880C01858 Air Filter Kit 4 28 4 952 00145 1 4 Flat Washer 29 1 800 00098 Venturi Gasket 30 4 868 00536 Socket Head Cap Screws 10 24 UNC x 1 LG 31 4 869 00061 Nut Hex Machine Screw 10 24 UNC 32 10 11 28 26 13 6 5 12 Y 10 Y 32 Y 33 32 4 993 16083 Capscrew Hex 10 32 x 1 2 LG A 33 11 993 15760 External Lock Washer 10 1 T 34 1 872 00381 Board Insulation 1 TH x 3 5 8 x 91 LG 35 1 008 03620 Bracket Junction Box Q Q 36 1 817 02420 Switch High Air Pressure s 37 1 848 00157 Terminal Ignition Spring Snap 7mm Cable B 9 Q Grounding Tab Here D 27 9 7 Sensing Line CB PAN 380 01069 C W Item 9 o o Q 35 4 00 n C 23 24 25 33 31 30 29 sued H ell4Je9
100. f 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 Notice Corrosion and sludge deposits in old systems must be removed prior to installation of a new boiler 2 3 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 Part No 750 222 Chapter 2 Installation Ah Warning The boiler must not be
101. ff the power when installing or removing the control Replaceable Fuse The chassis modules are designed with a field replaceable fuse The fuse is located on the printed cir cuit board below the transformer In the event the fuse becomes OPEN the Operating Control TFI and Flame LED s will light However relays KL or KF will not be energized and the control will lock out and indicate Lockout Check Blown Fuse The fuse will blow as a result of an overload con dition on Terminals 3 4 or 5 To replace the fuse remove power from the system and using a small screwdriver or similar tool install a replacement fuse P N 833 2398 or equivalent 10 amp fuse e g Wickman 19373 071 K WARNING Disconnect power before servicing 6 CB 8080 Rev 1 CLEAVER BROOKS FIGURE 2 Replaceable Fuse Location LED INDICATOR LIGHTS The CB90 Programmer Module has 5 LED lights to indicate the operating status of the control and also to display the coded sequence under locked out conditions The function of the lights under a normal operating condition is Operating Control This LED 15 energized whenever the burner control switch and all other various limit switches are closed and power is applied to Terminal 7 Interlock or Air Flow This LED is illuminated whenever power is detected on Terminal 6 indi cating the air flow switch or other running interlock is closed If the operating control is closed and the runnin
102. g input 3 When analog input 3 is config ured for outside temperature C111 and the measured value is called up the actual value dis play red shows 1999 flash Outside temperature is not mea sured Weather dependent setpoint is Ing Inactive Check electrical connections for open circuit of sensors Overrange or underrange on ana log input 2 Setpoint shift is not measured Controller initiates lockout When analog input 2 is config ured C111 and the measured value is called up the actual value display red shows 1999 flashing 9 e Check electrical connections for open circuit of sensor Overrange or underrange on ana log input 2 Actual value display red shows XXXXXX Setpoint display green shows 1999 flashing Setpoint shift is not measured Controller initiates lockout Check electrical connections for open circuit of sensor Part No 750 222 Chapter 5 Service And Periodic Maintenance 5 9 If the boiler will be out of use for an extended period precautions must be taken to protect fireside and waterside surfaces from deterioration due to corrosion At the start of lay up thoroughly clean the fireside by removing any soot or other products of combustion from the tubes tube sheets and other fireside surfaces After brushing all surfaces clean sweep away or vacuum any residue The fireside may be flushed with water however
103. g interlock switch remains open this LED will flash at a 1 second rate TFI This LED is illuminated only during the pilot trial for ignition period and the stabilization period when so equipped Flame This LED 15 on whenever a flame signal is detected and the control is not in a locked out state Alarm This LED flashes when an alarm condition is detected and is used as an address indicator see communication During an alarm condition the Alarm LED is made to flash at approximately a 1 second rate The remaining four LEDs are illuminated as a coded sequence identifying the reason for the lockout While in the Idle or Off state the LEDs are made to flash sequentially to show the operational status of the control every minute The LEDs can be tested by pressing and releasing the Reset push button while in the Idle or Off state CB 8080 Rev 1 7 CLEAVER BROOKS LOCKOUT CODES _ Ana e TL e 5 e o wewwmmmim ______ ris o wan e e o tecoutanpttortin cama o 9 9 emn monaste o e 9 9 is wmm e umma o e elol a wss e e a omme o e o onres o u e _____ o o o Wwe
104. ge to detect Assuring that the flame quality fuel to air ratio combustion air velocity is satisfactory 08515 Trying a shorter sight pipe or increasing the sight pipe diameter The burner manufacturer should be consulted before mechanical changes are made When using a flame rectification amplifier a micro ammeter may be connected in series with the wire to Terminal 52 Normal flame will produce a meter reading between 4 and 10 micro amps With the test meter on the AC scale line and load voltages may be measured at the identified test points on the chassis WARNING Before making a pilot flame test manually shut off the fuel supply to the main burner Normal Pilot Flame Test Programmers with Run Check Switch 1 At pilot trial for ignition TFI place the Run Check switch in the Check position 2 During the pilot flame test and adjustment period if flame is not detected within 30 seconds the control will lock out and require manual reset to initiate another cycle CB 8080 Rev 1 21 3 CLEAVER BROOKS Observe the pilot flame signal on the test meter or the 833 2714 display If the flame signal is below 4 0 volts DC or a reading of 10 on a remote display re adjust the pilot flame or realign the flame detector When using UV detection a test is required to verify that UV radiation from the ignition spark is not being detected To accomplish this manually shut off both the pilot an
105. grammer type within the family The data represented by PROGTYP can be used to guard against the wrong programmer being installed in a system CB 8080 Rev 1 17 CLEAVER BROOKS Table 2 MESSAGE DESCRIPTION DEC 8 68 7 LOCKOUTLINEFREQUENCYNOISEDETECTED _______ e 8 UNTADDRES 0 e ___ _____ NEN 0 7 1 11 12 13 or 16 LOCKOUT AMPLIFIER HIGH COUNT FAIL 19 2 LOCKOUT FLAME FAIL MTFI OFF 0 7 CH DH OEH 10H 13H i 25H LOCKOUT FLAME FAIL AUTO LOCKOUT FLAME FAIL TFI i T 18 CB 8080 Rev 1 CLEAVER 5 Addressing Modes For communication in a multi burner or multi control environment each CB90 must have a unique address The range of address allowed within the CB90 is 0 to 31 allowing for a possible 32 units to be connected in a single multi drop node As shipped the default address is 0 The address of the 90 may be set using two methods Using the 833 2714 display it is necessary is SCRL to the PROGRAM SETUP menu and enter that submenu with the MODE key SCRL down until the dis play indicates UNIT ADDRESS with the actual address of the CB90 being displayed on the top line of the display Pressing and releasing the RESET key will cause the address to increment The address after 31 is 0 The second method is to use the local reset located on the plug in board It is first necess
106. h the manual fuel shutoff valve cock closed Make sure the valve functions properly Also perform the Valve Leak Test before putting the valve into service Valve Leak Test Fig 5 This is a test for checking the closure tightness of the gas shutoff valve It should be performed only by trained experienced flame safeguard technicians during the initial startup of the burner system or whenever the valve is replaced It is recommended that this test should also be included in the sched uled inspection and maintenance procedures For a periodic inspection test follow steps 1 3 4 5 8 9 10 12 13 16 17 D E DOWNSTREAM WARNING Electrical Shock Hazard C inj gt 2 ock Hazard Can cause severe injury os 4 S 4 S lt m 1 4 IN G8 MM Remove the power from the system before beginning FLEXIBLE the valve leak test to prevent electrical shock More test 2 than one disconnect may be involved ALUMINUM OR 21 22 eer 1 De energize the control system to make sure no WITH WATER power goes to the valves 2 Close the upstream manual gas cock A 3 Make sure the manual test petcock F is closed in the leak test tap assembly 4 To test the first SSOV remove the 1 8 in fis CAN ALSO BE A PERMANENT PETCOCK 3mm NPT plug from pressure tap point P FX PRESSURE REGULATING VALVE 5 Install the leak test tap into pressure tap point EX ssov sarerv SHUTOFF VALVE o
107. he 833 3162 chassis contains a daughter board having provisions for local reset remote display modbus communications and normally closed relay contacts The relay contacts are used to control the blower motor output speed Terminal 5 of the chassis is used to release the burner to full modula tion 5 seconds after the main burner establishing period Modular CB90 controls incorporate a safety checking circuit that is operative on each start If flame real or simulated is detected prior to a start or during purge the fuel valves will not be energized and unit will lock out Functions provided by the CB90 flame safeguard system 30 second high fire purge controlled by contacts on daughter board 10 second low fire purge controlled by contacts on daughter board Fixed 4 second flame establishing ignition period Ignition terminal off after flame establishing period 5 second flame stabilization period Pilot terminal 3 remains energized through the entire firing cycle 15 second Post Purge duration Release to modulate energized 5 seconds after AUTO Ignore state of air flow switch interlock for first 10 seconds of purge Retry three times if air flow opens during the pre purge period Lockout on air flow during the run period oo N Lockout on flame fail during the run period Modbus communications allowing for hookup to PLC system smart LED s that provide on board diagnostic lockout information Amplifi
108. he burner head and combustion chamber With the burner head assembly swung open the burner parts and combustion chamber can be inspected Part No 750 222 Figure 5 3 Water column gauge glass Figure 5 4 Front burner access panel removed leniter Figure 5 5 Electrode connections 5 5 Chapter 5 Service And Periodic Maintenance Figure 5 6 Burner assembly open Figure 5 8 Fastening burner door 5 6 A Check ignition and ionization electrodes for deposits and proper gap Clean or replace as required Refer to Fig 5 9 and Fig 5 10 B Check the burner canister for any damage burn marks or perforations Replace if damaged If the canister is in good condition clean out any dirt or dust with a vacuum cleaner or low pressure air hose C Inspect door refractory and patch any cracks D Inspect the pressure vessel and combustion chamber area for any damage or residue If dirt or contaminants are found it is recommended that the tube sheet and tubes be washed with a high pressure power washer E Replace the burner door gasket New gasket should be properly situated in door gasket seat If any adverse conditions are observed during operation or inspection contact your authorized Cleaver Brooks service representative When inspection and servicing are completed reassemble the burner in reverse order When re fastening burner door 1 Coat bolt threads with anti seize compound 2 Tighten bolt
109. he sensing end of the scanner from boiler ground Care must be taken not to route the scanner cable across the high voltage ignition cable The high energy ignition cable should be checked periodically for cracking connections and aging In applications using flame rod units it may be beneficial to route a separate return wire from the S1 terminal to the flame rod assembly This will minimize the effects of transient currents flowing into the 90 In all cases scanner wires should be routed in separate conduit and not joined with any high voltage AC or ignition cables MAINTENANCE 26 Periodically the spark electrode should be inspected for proper gapping and cracked ceramics At ignition time the high energy from the ignition transformer will attempt to conduct to the point of least resistance and with an improper spark gap where the conduction takes place will no longer be controlled The rating of the control transformer must be sized to handle the inrush currents of the pilot sole noid and ignition transformer at TFI and then the inrush currents of the main fuel valve assembly at MTFI time Inspect neatness of wiring in junction boxes and cabinets It is best to have connections short and direct and also not having wires bunched up and tied off Also connections should be periodically Smoke or unburned combustion gases absorb ultraviolet energy On installations with negative pres sure combustion chambers a small hole
110. iler must be installed in the mounting provided 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 Apply only a moderate amount of pipe compound to male threads and avoid overtightening which can distort the seats Use only flat jawed wrenches on the flats provided Connection to the main steam header is made at the nozzle projecting upward from the boiler shell ASME code requires a suitable stop valve to be installed between the boiler and main steam header if multiple boilers are tied to the header This valve should be located as close as possible to the boiler to facilitate venting and pressure testing A suitably rated gate valve is recommended for this purpose Feedwater is introduced through the piping assembly installed on the side of the boiler vessel A stop valve and check valve are optional equipment Figure 2 5 The feedwater supply should provide sufficient pressure to meet minimum flow requirements Cleaver Brooks offers blowdown piping and valves as an option for CFH boilers Whether supplied by Cleaver Brooks or others blowdown equipment is required for all steam boilers A qualified boiler a
111. ills the boiler Do not close the manual vent valve until the feed water pump shuts off When it does close the valve Check to ensure that no leaks appear at any pipe connections and correct if water leaks are noticed 4 3 Control Setpoints Preliminary settings of the burner boiler controls are necessary for the initial starting of the boiler After the burner has been properly set minor adjustments to these controls may be necessary for the particular installation For initial starting set the following controls accordingly 1 Operating and High Limit Controls Set the dial maximum 2 Combustion Air Proving Switch Set the dial minimum 4 Low Gas Pressure Switch Set the dial minimum 5 High Gas Pressure Switch Set the dial maximum Depress all manual reset buttons for all controls prior to starting Part No 750 222 Chapter 4 Commissioning 4 4 ClearFire H Boiler Burner Controls The ClearFire H primary boiler burner controls include the following RWF40 RWF40 modulating control Modulating Flame Safety Control Display e CB90 flame safety control e UGB variable speed blower interface e Low water cut off and pump control LWCO e Auxiliary low water cut off ALWCO e Operating and high limit controls OLC and HLC Please review the tables within this Commissioning section to familiarize yourself with the functions and parameters of the Controllers Warning The ClearFire H i
112. in the correct position see Fig 5 7 amp Fig 5 8 3 Assuring that the flame is sufficiently large to detect 4 Assuring that the flame quality fuel to air ratio combustion air velocity is satisfactory 5 Re positioning the flame detector for better flame sensing A Cleaver Brooks representative should be consulted before mechanical changes are made When using a flame rectification amplifier a micro ammeter may be connected in series with the wire to Terminal S2 Normal flame will produce a meter reading between 4 and 10 micro amps With the test meter on the AC scale line and load voltages may be measured at the identified test points on the chassis Part No 750 222 Chapter 4 Commissioning C Variable Speed Blower Interface The UGB variable speed blower interface is located in the control panel at the front of the boiler Figure 4 5 The UGB receives inputs from the 90 and RWFAO controls which control the premix blower through the burner safety sequence and modulation The settings of this interface are critical for proper operation of the CFH boiler Please check that these settings are correct prior to operation of the boiler UGB settings are found in Table 4 2 Please see Fig 4 6 for locations of each shunt jumper and switch Table 4 2 UGB Settings PREMIX BLOWER CONFIGURATION UGB Board Settings Shunt position swe 504 Ji 2 Pe __ __ _ _ __ __ 1 9
113. inals Q14 and Q13 is closed controller is not in manual mode red LED above S is off Procedure Start Auto tune by pressing KA and release The current temperature value 175 is shown in the actual value display The current function item tunE is flashing in the setpoint display You can cancel Auto tune while it is flashing pressing FY and releasing When tunE stops flashing on it s own Auto tune is complete You can save the new values for Pb 1 dt rt and dF1 by pressing and holding for at least 2 seconds Possible results and their correction A favorable value for dt is rt 4 x X Pb Pb too small too large Optimum adjustment rt dt rt dt too small too large Self setting start Identification of the controlled system PID controller settings Controlled f Controller a E X E A Block diagram of Auto tune 2 Hints 2 8 Setting up a standard temperature application Using a 1000 ohm Ni RTD L amp S 556 541 13 F to 203 F Configure If no keys are pressed for 20 seconds the controller will exit this mode and return to the basic display See Hint section 2 2 How to configuration your RWF40 From the basic display or user level press and hold for 3 seconds and then release and again press Pom and hold for 3 seconds and then release The actual value display 9030 shows
114. ings Part No 750 222 Chapter 3 Stack and Intake Vent Sizing and Installation 3 4 Horizontal Thru Wall Venting Inside Air Category For boilers connected to gas vents or chimneys vent installations shall be in accordance with Part 7 Venting of Equipment of the latest edition of National Fuel Gas Code or in Canada the latest edition of CAN CGA B 149 1 and 2 Installation Code for Gas Burning Appliances and Equipment or applicable provisions of local building codes These installations utilize the boiler mounted blower to vent the combustion products to the outside Combustion air is taken from inside the room and the vent is installed horizontally through the wall to the outside Adequate combustion and ventilation air must be supplied to the boiler room in accordance with the National Fuel Gas Code or in Canada the latest edition of CAN CGA B 149 1 and 2 Installation Code for Gas Burning Appliances and Equipment The direct vent cap is not considered in the overall length of the venting system The vent must be installed to prevent the flue gas leakage Care must be taken during assembly to insure that all joints are sealed properly and are airtight The vent must be installed to prevent the potential accumulation of condensate in the vent pipes It is recommended that 1 vent be installed with a slight downward slope of not more than 1 4 per foot of horizontal run to the vent terminal 2 The vent be
115. inimize the effect of sagging and to prevent it from coming in contact with any object 7 adequate grounding surface for the flame must be provided The grounding surface in actual contact with the flame must be at least four times greater than the area of the portion of the flame rod in contact with the flame It is essential to adjust the flame rod and ground area ratio to provide a maximum signal reading NOTE Interference from the ignition spark can alter the true signal reading by adding to or sub tracting from it This trend sometimes may be reversed by interchanging the primary wires line volt age to the ignition transformer This interference can also be reduced by the addition of grounded shielding between the flame rod and ignition spark 8 Proven types of flame grounding adapters as shown below may be used to provide adequate grounding surface High temperature stainless steel should be used to minimized the effect of metal oxidation This assembly may be welded directly over the pilot or main burner nozzle BOMB FIN GROUNDING ASSEMBLY THREADED ROD ASSEMBLY CB 8080 Rev 1 27 6 CLEAVER BROOKS MAINTENANCE 28 Type 69ND1 Flame Rod The flame rod and its insulator should be kept clean by washing routinely with soap and water Rods should be routinely replaced as they oxidize Flame Signal Strength Routine observation of the flame signal strength will forewarn any deterioration in the capability of the
116. inspected fre quently to check for the presence of any 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 by the owner and his or her operating personnel must comply with all requirements or regulations of his insurance company and or other authority having jurisdiction In the event of any conflict or inconsis tency between such requirements and the warnings or instructions contained herein please contact Cleaver Brooks be fore proceeding vi TABLE OF CONTENTS Chapter 1 Introduction Model Features And Benefits 1 2 TS BOWEN Rt e gs 1 3 BUNE aiu sacado d gore oi deside aee 1 4 Burner ucc 1 4 Cea e E RE EC EX alo ood de acie et 1 5 Component Connection Locations 1 6 Optional Equipment 1 7 Chapter 2 Installation Lifting and moving the boiler 2 2 Water Treatment 121 2 2 UM LSU DELI DES 2 3 Flue Gas Connection 1 212 menn 2 4 CONMECUONS cc ET 2 5 Boiler Water Side Connections 2
117. insulated through the length of the horizontal run For appliances installed in extreme cold climate it is recommended that 1 Theventbeinstalled with a slight upward slope of not more than 1 4 per foot of horizontal run to the vent terminal In this case an approved condensate trap must be installed per applicable codes 2 The vent be insulated through the length of the horizontal run Part No 750 222 Inside _ 7X Intake A i 8 Flue Gas Vent Figure 3 1 Horizontal Venting Thru Wall Using Inside Air For Combustion 3 5 Chapter 3 Stack and Intake Vent Sizing and Installation 3 6 Figure 3 2 Horizontal Thru wall Direct Venting System Category Installation Sealed Combustion Air Stack Venting 3 5 Horizontal Thru wall Direct Venting These installations utilize the boiler mounted blower to draw combustion air from outside and vent combustion gases to the outside The sealed combustion air vent cap is not considered in the overall length of the venting system Care must be taken during assembly that all joints are sealed properly and are airtight for both the combustion air intake and the exhaust stack piping system The stack vent must be installed to prevent the potential accumulation of condensate in the stack pipes It is recommended that 1 vent be installed with a slight downward slope of not more than 1 4 per foot of horizontal
118. ion from the OEM WARNING This equipment generates and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual may cause interference to radio communications It has been tested and found to comply with the limits for a Class A computing device pursuant to Subpart J of part 15 of FCC Rules which are designed to pro vide reasonable protection against such interference when operated in a commercial envi ronment Operation of this equipment in a residential area is likely to cause interference in which case the user at his own expense will be equipped to take whatever measures that may be required to correct the problem CB 8080 Rev 1 3 CLEAVER BROOKS In order for the CB90 to gather and retain statistical and historic data such as burner hours burner cycles system hours and average flame signal it is necessary that Terminal 1 be pow ered at all times Removing power from Terminal 1 at the end of the firing cycle causes all data gathered during the previous 16 hours or last 9 cycles to be lost ORDERING INFORMATION CB90 Components 933 3162 Chassis 120 VAC input with normally closed relay output terminals alpha numeric display interface to 833 2714 and Modbus capability 933 3163 Programmer non recycle on main flame 30 second purge 4 second fixed 5 second stabilization period early spark termination Non recycle on air flow failure during run
119. itch to the Run position if supplied Slowly turn on the main fuel and insure the main flame lights off promptly and normally WARNING If light off is delayed shut off the power to the installation Realign the flame detector so a larger pilot flame is required before flame is detected Repeat this test until the main flame lights reliably with minimum pilot Flame Failure Test gt DP Im Temporarily connect spark ignition and pilot to Terminal 43 Initiate a normal start up Manually shut off all fuel and observe the loss of flame signal on the test meter If flame signal does not reduce to zero within the flame failure response time of the control FERT determined by the selection of the amplifier verify the UV flame detector is not actu ated by the ignition spark If spark is detected a metallic shield or relocation of the UV detector is required 22 CB 8080 Rev 1 MAKE IT CALL FOR HEAT SEE SITUATION 2 SEE SITUATION 3 CB 8080 Rev 1 NO HEAT Y 0 0 ON ALARM BLINKING o INSTALL DC VOLTMETER IN TEST JACKS SHUT FUEL SUPPLY COCK RESET CONTROL DID OPERATE CONTROL LED COME ON AIR FLOW LED COME DID TFI LED COME ON AFTER SUITABLE DELAY PROGRAMMER OR CHASSIS DEFECTIVE CLEAVER 5 CB90 SERVICE GUIDE JACKS SITUATION 1 NORMAL LOCKOUT Ado VDC AMPLIFIER MODULE MP100 4 7 SECO
120. lame safety includes a diagnostic feature to alert operators to conditions causing a lockout When using the optional display the LOCKOUT HISTORY sub menu shows the last six lockouts along with the burner cycle and burner hour when each lockout occurred Pressing the MODE key shows the number and description of the most recent lockout see example below The SCRL key shows the burner hour followed by the burner cycle when the lockout occurred Pressing SCRL again advances through the lockout list repeating the above sequence The MODE key returns to the main menu Example while in the LOCKOUT HISTORY submenu use the SCRL and MODE buttons as follows Example Screen Description Display MODE LO 127 TFI The most recent lockout condition This is the FLAME FAIL 127th lockout of the system Lockout occurred during TFI SCRL LO 127 TFI Lockout 127 occurred after 136 hours of burner BNR HOURS 136 operation SCRL LO 127 TFI Lockout 127 occurred at burner cycle 744 BNR CYCLE 744 SCRL LO 126 PURGE The second latest lockout condition History AIR FLOW OPEN indicates the lockout occurred during purge MODE AUTO 45 Screen has returned to the normal run message FLAME SIGNAL Part No 750 222 5 9 Chapter 5 Service And Periodic Maintenance To view lockout codes when not using the optional display remove the electrical panel cover and note the LED configuration on the CB90 unit see table below DESCRIPTION OP
121. lectric controls and safety devices which vary considerably from one boiler to another This manual contains information designed to show how a basic burner operates Operating controls will normally function for long periods of time and we have found that some operators become lax in their daily or monthly testing assuming that normal operation will continue indefinitely Malfunctions of controls lead to uneconomical operation and damage and in most cases these conditions can be traced directly to carelessness and deficiencies in testing and maintenance 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 his 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 Float bowls of these controls must be inspected frequently to check for the presence of foreign substances that would impede float ball movement The waterside condition of the pressure vessel is of extreme importance Waterside surfaces should be
122. ling 150 M I 1 x 75 Nipple 1 NPT Sch 80 x 1 5 Lg Plug Pipe Square head 125 NPT Nipple 75 NPT Sch 80 x 1 5 Lg Union 75 150 M I Nipple 1 NPT Sch 80 2 5 Lg Nipple 75 NPT Sch 80 x 3 5 Lg Supplied With Item 1 port 2 sued H ell4Je9 9 4939 47 CCC OGL ON Hed 9 11 Gas 20 HP PART DESCRIPTION 800 00092 Adapter 1 Notes 941 02632 Valve Ball 1 All Piping To Be SA106 Gr B Sch 40 Or Better 859 00108 Elbow Street 90 2 All Fittings To Be 150 M I Unless Otherwise Specified 857 00751 Nipe 1 D 940 07163 Valve Gas 120V 75 4 Use Pipe Joint Compoud On All Threaded Joints 817 02414_ 5 Use Gaskets O Rings Where Applicable 9 H e 4 9870719 Npe O Ln 9 890077 Ebow90 O 10 2 85701626 Npe 2 2 112 1 870130 Npe Fi3 1 857 0080 Npe 116121 85702199 2 85 0042 Npe 23 375 Ref 11 27 800 00090 Adapter 75 85800088 jug T OOG 4 a keot P TH sued H ell4Je9 9 4939 47 vi9 12 Gas Train 25 HP 1 All Piping To Be SA106 Gr B Sch 40 Or Better 2 All Fittings To 150 M I Unless Otherwise Specified 2 2 0941 02632 VaveButerBall Notes ITEM PART NUMBER DESCRIPTI
123. ll appear in the lower right hand corner of the display when a sub menu is available Once within a sub menu the SCRL key will show the next item in the menu and the MODE key will exit the sub menu and return the display to the main menu Lockout History The LOCKOUT HISTORY sub menu shows the last six lockouts along with the burner cycle and burner hour when the lockout occurred Pressing the MODE key shows the number and description of the most recent lockout see example below The SCRL key shows the burner hour followed by the burner cycle when the lockout occurred Pressing SCRL again advances through the lockout list repeating the above sequence The MODE key returns to the main menu Use of Test Meter Testing the CB90 Control requires the use of a test AC DC multimeter with a minimum 1000 ohm volt AC scale and 20 000 ohm volt DC scale With the test meter on the DC scale and the test meter leads inserted into the test jacks on the amplifier Red for positive polarity Black for minus polarity DC voltage reading of 4 0 to 10 volts for all amplifier types should be obtained when the control is detecting flame and 0 volts when no flame is present Wildly fluctuating readings are an indication of an unstable flame or flame sensor requiring maintenance Inadequate flame signal may be improved by 1 Assuring that the flame detector and wiring installation is correct 2 Assuring that the flame detector is clean and
124. modulation relay separately This allows the control of the blower speed allowing for a complete purge and release to modulation control during AUTO FUNCTION TERMINAL STANDBY STABILIZATION CYCLE COMPLETE OPERATING CONTROL 1 AIR FLOW INTERLOCK s e AIRFLOW MUST CLOSE 10 SECONDS AFTER CYCLE gt MAIN MODULATE Rel Engergize elay gerg energize De energize Open De energize Open 10 SEC TO BRING BLOWER TO LOW SPEED Eb cm energize sm EIER E unis Recycle 3 times on air flow failure during purge 2 Non recycle on flame fail 3 on air flow flame failure while flame on PLUG IN DAUGHTER BOARDS Description A plug in board is pre installed in the 833 3162 chassis to provide local reset remote alpha numeric display serial communications and normally closed relay contacts FIGURE 3 PLUG IN BOARD LOCATION AND INSTALLATION PLUG IN BOARD STANDOFF RELEASE DIRECTION RELAY CONTACTS REMOTE DISPLAY RJ45 JACK B SERIAL COMMUNICATIONS A RS485 10 CB 8080 Rev 1 CLEAVER BROOKS REMOTE DISPLAY The CB90 provides an interface to the optional 833 2714 display module The 833 2714 connects to the CB90 through the plug in board using a 833 294 2 f t or 833 3491 4 ft cable Part numbers 833 2715 4 ft and 833 3133 2 ft are available for remote mounting to the 833 2714 Display Module and to provide NEMA 4 protection The 833
125. n Lifting and moving the 2 2 Water Treatment 2 2 Boiler Room 2 3 Flue Gas Connection 2 4 Gas Connections 2 5 Boiler Water Side Connections 2 6 Electrical Connections 2 7 Warning 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 A 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 N Caution 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 Milwaukee Wisconsin www cleaver brooks com Chapter 2 Installation 2 2 Figure 2 1 Lifting boiler N Caution In order to avoid damage to the unit lifting or moving the boiler should only be done by exp
126. n the valve body USE THE DOWNSTREAM ON THE 5504 MEAN 6 Open the upstream manual gas cock A to re Fig 5 Valve Leak Test pressurize the first SSOV 7 Immerse the 1 4 in 6 mm tube vertically 1 2 in 13 mm in a jar of water 8 Slowly open the manual test petcock F 9 When the rate of bubbles coming through the water stabilizes count the number of bubbles ap pearing during a ten second period Each bubble appearing represents a flow rate of 0 001 cfh 28 cch See Table 4 10 Close the upstream manual gas cock A 11 Remove the leak test tap from the valve body 12 Using a small amount of pipe sealant on the 1 8 in 3 mm plug reinstall the plug in pres sure tap point P 13 To test the second SSOV remove the 1 8 in 3 mm NPT plug from the flange pressure tap point 4 14 Install the leak test tap into pressure tap point 4 15 Close the downstream manual gas cock E 16 Immerse the 1 4 in 6 mm tube vertically 1 2 in 13 mm into a Jar of water Maximum Number Pipe Size Maximum Seat of Bubbles in ES Leakage UL 10 seconds p 0 Table 1 Maximum bubbles per pipe size 17 Slowly open the manual test petcock F 18 When the rate of bubbles coming through the water stabilizes count the number of bubbles ap pearing during a ten second period Each bubble appearing during a 10 second period represents a flow rate of 0 001 cfh 28 cch See Table 1 19 Remo
127. nd piping installer should make all boiler waterside connections Warning Only properly certified personnel such as the safety valve manufacturer s certified representative can adjust or repair the boiler safety valves Failure to follow this warning could result in serious personal injury or death Part No 750 222 Chapter 2 Installation 2 7 Electrical Connections Refer to Figure 2 6 for CFH wiring and cable connections A qualified electrician or service technician must make the electrical connections to the boiler all local electrical and building codes should be adhered to Main power and any remote wiring should be brought to the left side of the control panel and terminated at the appropriate terminals provided For specific information on your boiler electrical control system see Figure 2 7 or refer to the Cleaver Brooks wiring diagram provided with the boiler Figure 2 6 CFH wiring and cable connections LENS Sng E pc 3 Connect black ionization cable to single electrode and burner ground tab Connect white spark cable to dual electrode and ignition transformer Connect ground cable to dual electrode and ignition transformer ground Plug AC power harness plug into blower Plug DC blower control harness plug into blower incoming AC power per wiring diagram Connect optional heat request inputs per wiring diagram Connect pump contr
128. ne or more are open determine the cause s correct the trouble and proceed 4 If there is proper voltage at the valve but the valve still does not open check for normal gas pres sure 5 f the valve still does not open replace the valve If the valve does not close when one or more of the appropriate contacts in the thermostat controller limits or flame safeguard control is open 1 Make sure the valve is wired in the correct circuit 2 Open the master switch to remove power from the valve 3 If the valve closes now check the wiring for the valve and correct the wiring as necessary 4 Check for a short in the electrical circuit and repair it as necessary SERVICE INFORMATION WARNING Explosion Hazard and Electrical Shock Hazard Can cause severe injury death or property damage Turn off gas supply and disconnect all electrical power to the valve before servicing IMPORTANT Only trained experienced flame safeguard technicians should attempt to service or repair flame safeguard controls and burner assemblies Scheduled Inspection and Maintenance set up and follow a schedule for periodic inspection and maintenance including the burner all other controls and the valves It is recommended that the valve leak test in the Checkout section be included in this schedule Refer to the instructions for the primary safety control sO for more inspection and maintenance information Screen Strainer Replacement Make su
129. ng Feedwater equipment should be checked and ready for use Be sure that all valves piping boiler feed pumps and receivers are installed in accordance with prevailing codes and practices As with any firetube boiler waterside care and maintenance are of critical importance to the Model CFH Constant attention to water requirements will pay dividends in the form of longer life less down time and prevention of costly repairs Care taken in placing the pressure vessel into initial service is vital as the waterside of new boilers and new or remodeled systems 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 Part No 750 222 Chapter 1 Introduction Figure 1 4 Model CFH Boiler N 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 Failure to follow these instructions could result in equipment damage 1 3 Chapter 1 Introduction 1 3 THE BURNER Figure 1 5 Model Burner Incorporating premix technology the burner utilizes mixing venturi dual safety shutoff single body pressure regulating gas valve variable speed blower and
130. ng To Be SA106 Gr B Sch 40 Or Better 2 All Fittings To Be 1502 M I Unless Otherwise Specified 3 Plug All Unused Openings 4 Use Pipe Joint Compound On All Threaded Joints 5 Use Gaskets O Rings Where Applicable 6 All Joints Must Be Gas Tight DETAIL A Install Union With Nut Side Towards Regulator DETAIL B sued H ell4Je9 9 4939 47 CCC 0GL ON Hed or Pins Clips D 2 2 571 77777 na A SECTION A A 81 9 16 Bumer Assembly 10 HP f CA T 2271 17771 SECTION B B Parts List ITEM QTY PART NUMBER DESCRIPTION 1 1 132 02497 Insulated Front Door Assembly 2 1 853 00982 Gasket Rope 1 1 4 Dia x 78 LG 3 1 380 01053 Gasket Adapter Plate to Vessel 4 1 380 01055 Burner Can Unit 5 1 380 01094 Adapter Plate Vessel To Blower 6 4 869 00030 Nut Hex 3 8 16 UNC 7 1 380 01037 Gasket Adapter Plate to Blower 8 1 894 04076 Blower Unit 115V 9 1 048 00659 Venturi Air Gas Premix C W Sensing Line 10 2 380 01032 Gasket Electrode C W Items 11 and 12 11 1 380 01062 Electrode Single 12 1 380 01061 Electrode Double 13 1 065 00879 Retainer Sight Port 14 1 851 00026 Sight Glass Pyrex 1875 x 1 75 O D 15 1 853 00213
131. nt Connection Locations 1 6 Optional EQqUIDITIGDE s acu cac dra Y 1 7 Milwaukee Wisconsin www cleaver brooks com Chapter 1 Introduction Figure 1 2 AluFer Tube Cross 1 2 Section CB90 Flame Safety Control 1 1 MODEL CFH FEATURES AND BENEFITS Compact Firetube Design The Model CFH boiler is a compact horizontally fired firetube boiler Figure 1 1 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 High Efficiency With the extended heating surface provided by the patented AluFer tube design Figure 1 2 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 Low Water and Pump Controls Power and Control Wiring Figure 1 3 Model CFH Electrical Panel Pa
132. nto the lower body Slide the packing nuts onto each valve and tighten It is recommended that the boiler is off and cool when the glass is replaced However if the glass is replaced while the boiler is in service open the blowdown valve and slowly bring the glass up to temperature by opening the gauge valves slightly After the glass is warmed up close the blowdown valve and open the gauge valves completely 5 4 FIRESIDE CLEANING PROCEDURE DISASSEMBLY 1 Locate the manual shutoff gas valve for the gas supply to the burner and turn it to the closed or shut position 2 Disconnect all electrical power to the control panel at the primary switch box or breaker box supplying power to the boiler 3 Remove the front casing enclosure and set aside 4 Disconnect power and signal harnesses from blower 5 Disconnect the ignition cables and flame sensor cable from the electrodes 6 a If using room combustion air remove air filter Inspect and clean as necessary NOTE Do not discard the air filter It may be cleaned and re used Contact Cleaver Brooks for cleaning kits b Remove the air combustion piping at the inlet to the fan air intake if supplied with direct vent combustion 7 Disconnect the burner gas train from the gas supply piping 8 Unscrew the hold down bolts securing the burner door to the pressure vessel 9 The burner door burner head blower motor and assembly can now be swung open providing access to t
133. ol from the basic display press and hold the EXIT key for 5 seconds then release A red LED will turn ON to indicate the controller has switched to manual firing rate control The current control output 0 100906 will be displayed in green Please note the firing rate will always start at 0 when first entering manual operation Change the manual firing rate by pressing the UP and DOWN arrow keys until the desired rate is displayed Once the key is released the displayed control output will flash indicating the new firing rate has been saved The burner should modulate to this firing rate accordingly Return to automatic firing rate control by pressing and holding the EXIT key for 5 seconds then release For more information see the RWF40 User Hints Appendix B in this manual If additional help is needed contact your Cleaver Brooks representative B Flame Safety Control Operation The CB90 flame safety control is located in the control panel at the front of the boiler The CB90 control is factory configured for operation with all CFH boiler applications The control is mounted inside the control panel The LED s indicate operating status and alarm lockout conditions The manual reset button should be pressed to clear any lockout condition after the condition has been remedied Please refer to the CB90 manual in Appendix C of this manual for details on operation sequencing wiring etc The CFH boiler uses direct spa
134. ols Check The OLC and HLC can be tested while the boiler is producing steam by adjusting the switch setting downward A lockout should result when the switch setting is at or just below the current steam pressure Readjust each switch and reset HLC after testing Refer to Section 4 4 E Operating and High Limit Controls 4 6 Boil Out of a new unit The inside of a new boiler may contain oil grease or other contaminants which if not removed could adversely affect system performance New units should be cleaned by boil out before use Recommended boil out procedure is as follows 1 Determine boiler water capacity see Table 4 4 Have sufficient cleaning material on hand to complete the job 2 When dissolving dry chemicals slowly introduce the chemical into warm water in a suitable container Stir constantly until the chemical is completely dissolved Part No 750 222 Chapter 4 Commissioning 3 An over flow pipe should be attached to one of the top boiler openings and routed to a safe point of discharge A relief or safety valve tapping is normally used for this purpose 4 Water relief valves and steam safety valves must be removed before adding the boilout solution to avoid contaminating the valves Use caution when removing and reinstalling these devices 5 All valves in the piping leading to or from the system must be closed to prevent cleaning solution from getting into the system 6 Fill the boiler vessel
135. ols per wiring diagram N El E COD 2267 ay Notice The blower signal wiring must be isolated from the blower power wiring and the high voltage ignition cables Part No 750 222 2 7 WIRING SHOWN WITH OPTIONAL Chapter 2 Installation REMOTE FIRING RATE CONTROL Figure 2 7 Wiring Diagram ER SUPPLY W e NDEI NEUTRA DE 22 i JUNDED NEUTRAL paco JIVISION FUSIBLE DISC BMF LPCC o A ELECTRODE RECYCLE LIMITS 9 En 29 57 Jy SHEILDED CABLE OLC HLC o NO COM NO MR C NC A 36 ArT C A s M HE e 45 Vg n PND ONLY 0 7 e 11 MOM 6 LOAD DEMAND LICHT SILENCE RELAY GROUND ONE END ONLY M 77 ALARM 16 32 RN Jy 12 N 39 LOCKO INTER
136. on without affecting the fuel air metering at medium and high firing rates 3000 to 5000 rpm of the blower but at lower firing rates 1000 rpm the fuel might be reduced up to 1076 when the valve is not mounted upright To counter this the low fire gas flow may be carefully field adjusted for non upright mounting as follows 1 With the valve in the final mounting position adjust the venturi fan for the lowest burner firing rate 2 Remove the slotted cap on the gas regulator using a slotted screwdriver This will expose the off set adjustment screw see Fig 1 3 Using a TORX E T40 or a 5 mm hex wrench carefully adjust the low fire gas setting for proper combustion 4 After proper low fire offset adjustment has been made reinstall the slotted cap on the regulator 5 Before commissioning the burner check for proper lightoff and verify correct fuel air mix and combustion quality throughout the entire firing range from lowest to highest fan speeds used Fig 1 Regulating Adjusting Screw SLOTTED CAP ADJUSTMENT Pam REGULATOR Mounting Locations The distance between the gas valve and the wall ground must be a minimum of 11 5 16 in 30 cm Main Gas Connection 1 Take care that dirt does not enter the gas valve during handling 2 Remove the flanges from the valves 3 Use new properly reamed pipe free from chips 4 Apply a moderate amount of good quality pipe dope resistant to the action of liquefi
137. per operation of the CFH boiler SW2 SWA rotary switches limit the minimum and maximum blower speeds and corresponding minimum and maximum firing rate respectively It is important that these switches be set at the factory recommended settings especially at initial start up Some fine tuning of these switches is allowed to suit the installation if a gas meter is available to check actual fuel input at low and high fire rates SW2 and SW4 can be adjusted during burner operation Part No 750 222 D Water Level Controls The LWCO pump control and ALWCO control boards are located in the control panel at the front of the boiler The LWCO control is connected to conductance probes mounted within the external water column This column has 4 probes used for the following functions low water cut off pump on pump off and high water alarm optional The ALWCO control is connected to a conductance probe s in either a vessel mounted probe head or optional external column The ALWCO includes a panel mounted manual reset test switch 10 15 HP 15 Steam 1 1 16 1 16 0 9 1 16 3 1 4 E 1 16 Part No 750 222 10 15 HP 150 Steam 3 1 16 1 16 0 11 1 16 51 4 E 1 16 11 16 t 1 16 10 1 16 4 1 4 E 1 16 3 1 16 T 1 16 0 11 16 0 1 16 0 12 1 16 10 1 16 6 1 4 1116 4 1 4 E 1 16 CFH Probe and WC Levels Chapter 4 Commissioning
138. pulled into the combustion air intake installed above This type of installation can cause non warrantable problems with components and poor operation of the unit due to the recirculation of flue products 3 7 Chapter 3 Stack and Intake Vent Sizing and Installation 3 8 3 7 Vertical Venting Inside Combustion Air Category III Central Heating 7 Flue Gas Vent Sereen 24 Minimum Claarfira Bollar Figure 3 3 Vertical Stack with Inside Combustion Air These installations utilize the boiler mounted blower to vent the combustion products to the outside Combustion air is taken from inside the room and the vent is installed vertically through the roof to the outside Adequate combustion and ventilation air must be supplied to the boiler room in accordance with the National Fuel Gas Code or in Canada the latest edition of CAN CGA B 149 1 AND 2 Installation Code for Gas Burning Appliances and Equipment To prevent condensation accumulation in the vent it is required to install the horizontal portion of vent with a slight upward slope of not more than 1 4 per foot of horizontal run and an approved condensate trap must be installed per applicable codes Part No 750 222 Chapter 3 Stack and Intake Vent Sizing and Installation Ah Warning The Stainless Steel non restricted direct vent cap must be furnished in accordance with AGA CGA requirements 3 8 Vertical Venting Direct Sealed Combustion Air Categor
139. re the gas supply is turned off and all electrical power has been removed Remove bolts nuts from flange valve Remove flange from gas supply pipe Remove old screen strainer Clean the strainer by using compressed air or replace the strainer Install the cleaned strainer or new strainer Make sure O ring sealing surface is clean on the flange Using general purpose lithium grease grease the O ring Apply a moderate amount of good quality pipe dope resistant to the action of LP gas only on the pipe threads 10 Install the O ring in the O ring groove provided on the flange valve body one O ring per groove 11 Screw the flange onto the pipe 12 Mount the gas valve to the flange using the bolts and nuts for each flange 13 Apply power to the valve 14 Turn on the main gas supply 15 Complete the valve leak test 16 Return the valve to service CON GD APPENDIX B RWFAO Modulating Controller User Hints Contents 1 Introduction to hints manual cus CHOR eS 3 1 1 1 use TIS Manual ce cea care cert 3 1 1 2 Symbols used ile li il 3 2 3 01 4 2 1 Getting started with RWF40O menu nenne nenne nenne 4 2 1 1 Slant Baste 4 2 1 2 EE up E E E AE A E E E
140. rements of the authority having jurisdic tion or the absence of such requirements to UL 795 Commercial In dustrial Gas Heating Equipment and or the National Fuel Gas Code ANSI Z223 1 Notes CLEAVEH BROOKS Model CFH ClearFire Packaged Boiler Gas High Efficiency Boiler Operation Service and Parts Manual CLEAVER Cleaver Brooks 2007 Please direct purchase orders for replacement manuals to your local Cleaver Brooks authorized representative Manual Part No 750 222 11 08 Printed in U S A A WARNING 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 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 con tents carefully The unit will provide good service and continued operation if proper operating and maintenance instruc tions are followed 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 pe
141. rew Hex 10 32 x 1 2 LG 34 1 993 15760 External Lock Washer 10 35 1 1872 00381 Board Insulation 36 1 817 02420 Switch High Air Pressure 37 1 848 00157 Terminal Ignition Spring Snap 7mm Cable Sensing Line CB P N 380 01069 C W Item 9 sued H ell4Je9 9 4939 47 CCC OGL ON Hed 0c 9 Attach Using Spray Adhesive or Pins Clips SECTION A A SECTION C C 18 Bumer Assembly 20 HP DETAIL D 5 CARS 3 3 8 Parts List ITEM QTY PART NUMBER DESCRIPTION 1 1 132C02544 Insulated Front Door Assembly 2 1 853 00982 Gasket Rope 1 1 4 DIA x 85 LG 3 2 380A01053 Gasket Adapter Plate to Door 4 1 380 01045 Burner Canister 5 1 380 01052 Adapter Plate Blower to Door 6 4 869 00030 Nut Hex 3 8 16 UNC 7 1 380 01037 Gasket Adapter Plate to Blower 8 1 894 04076 Blower Unit 115V 9 1 048 00655 Venturi Air Gas Premix C W Sensing Line 10 1380A01032 Gasket Electrode Included With Items 11 and 12 11 1 380 01061 Electrode Double C W Gasket 12 1 380 01060 Electrode Single C W Gasket 13 1 065 00879 Retainer Sight Port 14 1 851 00026 Sight Glass Pyrex 1875 x 1 75 OD 15 2 853 00213 Sight Glass Gasket 0625 x 1 438 ID x 1 719 OD 16 3 860 00097 Machine Screw 48 32 UNC x 75 17 1 859 00022
142. rk ignition no gas pilot to light the main flame Flame sensing is accomplished with a flame rod or ionization electrode Please note PTFI indication actually refers to the main trial for ignition period Figure 4 4 CB90 Flame Safety Basic burner sequencing Control 1 Standby limits open 2 Limits closed 3 Blower enable blower starts and attains high fire speed 4 High fire purge 30 sec air flow interlock 10 sec delay air failure lockout after 374 purge attempt or during ignition trial 4 6 Part No 750 222 Chapter 4 Commissioning 5 Intermediate ignition speed allow 10 sec to stabilize 30 of HF 6 Main Trial For Ignition PTFI 4 sec a Ignition energized b Main Fuel Valve energized c Flame supervision lockout on flame failure 7 Flame proved then 5 sec stabilization period 8 Auto Release to Modulate 9 Main Fuel Valve de energized 10 Post purge 15 sec 11 Blower stop standby External Display optional The optional externally mounted CB90 display is mounted on the right side of the control panel The CB90 display indicates current burner status first out alarm in the event of a lockout condition historical burner information detailed lockout information of the last six 6 lockout conditions and programmer configuration information Through the display the ability to program the unit address for communications as well as resetting the stored information cycles hours and lockouts to
143. rn needs a low impedance to earth ground For a ground path to be low impedance at RF fre quencies the connection must be made with minimum length conductors having maximum sur face areas 5 All connections should be free of nonconductive coatings and protected against rust m Utilizing conduit as a means of providing a ground must be avoided 7 Installing ground rods at the burner control panel defeats the purpose of a single point ground as described above and could also present a safety hazard INSTALLATION Do not run high voltage ignition transformer wires in the same conduit with flame detection wiring Do not run scanner wires in a conduit with line voltage circuits Ensure the frame of the ignition transformer is securely connected to control panel frame or prefera bly the burner frame The CB90 chassis contains a transient suppressing device connected internally across hot and neutral and then to the internal bracket For this to be effective the chassis must be screwed securely into the wiring subbase CB 8080 Rev 1 25 10 CLEAVER BROOKS REMOTE DISPLAY When the 833 2714 is to be remotely mounted on the front of the control panel the ED580 cable must contain a ferrite core The cable end with the ferrite core must be mounted at the control end High frequency currents flow more to the surface of the conductor The 60 Hz ground system prop erly designed has sufficient low impedance at 60 Hz to maintain all met
144. rsonal injury or death It is the responsibility of the owner to train and advise not only his or her personnel but the contractors personnel who are servicing repairing or operating the equipment in all safety aspects Cleaver Brooks equipment is designed and engineered to give long life and excellent service on the job 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 af ford a high degree of protection and safety operation of equipment is not to be considered free from all dangers and hazards inherent in handling and firing of fuel Any automatic features included in the design do not relieve the attendant of any responsibility Such features merely free him of certain repetitive chores and give him more time to devote to the proper upkeep of equipment It is solely the operator s responsibility to properly operate and maintain the equipment No amount of written instructions can replace intelligent thinking and reasoning and this manual is not intended to relieve the operating personnel of the responsibility for proper operation On the other hand a thorough understanding of this manual is required before at tempting to operate maintain service or repair this equipment Because of state local or other applicable codes there are a variety of e
145. rt No 750 222 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 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 are limited to 15 psig design and are typically used for heating applications High pressure boilers are typically used for process loads and can have a design pressure of 75 to 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 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 setti
146. run to the stack terminal 2 The stack vent is to be insulated through the length of the horizontal run For appliances installed in extreme cold climate it is recommended that 1 The stack vent be installed with a slight upward slope of not more than 1 4 per foot of horizontal run to the vent terminal In Part No 750 222 Chapter 3 Stack and Intake Vent Sizing and Installation this case an approved condensate trap must be installed per applicable codes 2 The stack vent is to be insulated through the length of the horizontal run 3 6 Horizontal Thru wall Stack Vent Termination The stack vent cap MUST be mounted on the exterior of the building The stack vent cap cannot be installed in a well or below grade The stack vent cap must be installed at least one 1 foot above ground level and above normal snow levels Multiple stack vent caps should be installed in the same horizontal plane with a three 3 foot clearance from the side of one stack cap to the side of the adjacent stack vent cap s Combustion air supplied from outside must be free of particulate and chemical contaminants To avoid a blocked flue condition keep all the vent caps clear of snow ice leaves debris etc Part No 750 222 N Caution Multiple direct stack vent caps MUST NOT be installed with a combustion air inlet directly above a stack vent cap This vertical spacing would allow the flue products from the stack vent cap to be
147. s 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 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 Part No 750 222 A Warning Inadequate or improper water treatment will shorten the life of the boiler and could result in a hazardous condition 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 Mr to accurately determine the amount of raw water admitted to the oiler Surface blow of
148. s 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 A Modulating Control Configuration and Operation Figure 4 2 CB90 Unit The RWF40 modulating control is located externally at the right side of the control panel for convenient access to all operating controls A steam pressure transmitter mounted at the control trim piping provides the measured process variable signal to the RWF40 controller The RWF40 modulating controller should be factory configured for the specific CFH boiler application Prior to starting the boiler verify that these settings are correct for your application Please refer to CB default settings Table 4 1 for your specific application Make any changes at this time if needed The basic display indicates measured process variable and modulating set point The controller will always return to the basic display automatically if no key is pressed for 30 seconds Part No 750 222 4 3 Chapter 4 Commissioning DECREASE INCREASE Value 4 4 Value Figure 4 3 RWF40 User level settings consist of the modulating set points SP1 amp SP2 These set points can be accessed by pressing the lt PGM gt key Change the setting by pressing the and lt DOWN keys until the desired set point is displayed Press the key to save
149. s gradually in a diagonal pattern to ensure a secure fit see Figure 5 7 It may take several cycles of the pattern to reach uniform tightness 3 Torque bolts to 11 ft lbs 132 in lbs Ensure that all connections are tight and secure before reconnecting power or fuel supply After turning the gas supply on reset the gas pressure switches NOTE A gas valve leak test is recommended during fireside inspection See Appendix A for leak test procedure NOTE Re torque door bolts 7 10 days after replacing burner door gasket Part No 750 222 Chapter 5 Service And Periodic Maintenance 9 9 ELECTRODES AND FLAME ROD EN PP a 4 a Figure 5 9 Electrode Setup The ignition and ionization electrodes should be checked on an annual basis or as needed if ignition problems are encountered Replacement should be accomplished as shown in Figure 5 9 with Caution the electrode turned toward the burner mantle canister after it is dimensions on both the Ignition Electrodes inserted into the burner head and the Flame Rod are not easily adjustable Bending the rods can cause damage to the insulating material In addition a bent electrode will have a tendency to return to its original shape when heated If the electrodes are out of specification replacement is generally recommended Sight Glass Single Electrode Dual Electrode 1 8 E 1 3 2
150. s is required an explanation will be given This symbol is used to draw your attention to a particular remark This symbol indicates refererence to the RWF40 user manual 2 Hints 2 1 Getting started with the RWF40 menu RWF40 menu system has three Levels beyond the Basic Display the User Level the Parameter Level and the Configuration Level RWF40 Basic display gt RWF40 user manual Section 6 Operation Actual value display setpoint 2 1 1 Start with the Basic Display Shown at the right is the basic display upper larger 4 digit red LEDs 180 will be referred to as the Actual value display EXIT The lower smaller 4 digit green LEDs 180 will be referred to as the Setpoint display CS The current configuration of your specific controller will determine which levels you will be allowed to access C112 must be to access the configuration level AN The C112 locking code can only be adjusted by the manufacturer All controllers will return to the basic display automatically if no key is pressed for 30 seconds RWF40 configuration codes C111 C112 and C113 are all four digits The x s used in the explanations in this manual represent a don t care digit in the code SO xxx0 could mean 1000 2100 5430 etc and we are only concerned with the non x digits C112 code summary C112 code xxxO Locks nothing C112 code
151. ss WwAwWemOn e o e 9 wewowkmowns e o ac e e wwe 1 19 O NOT LIGHTED e LIGHTED FLASHING All LED s Flashing indicates defective programmer The CB90 chassis is shipped with a convenient peel off label that can be applied to any surface inside cover for future reference 8 CB 8080 Rev 1 10 CLEAVER 5 DIAGNOSTIC MESSAGES TROUBLESHOOTING GUIDE Check Programmer Inspect wiring to main fuel valve Replace programma Check Chassis Inspect wiring to pilot valve and igniter Chassis Opto Replace chassis Amplifier High Count Fail Replace Amplifier module Amplifier Auto Check Fail Use orifice in sight pipe Replace Amplifier module Check Scanner Inspect scanner wiring replace scanner Replace UV tube or scanner Check Blown Fuse Inspect defective pilot valve or igniter Line Frequency Noise Detected Check for SCR motors or DC drives ground syster Fuel Value State Change Terminal 5 main fuel detected on during TFI Check external wiring or replace chassis Check Amplifier Amplifier not passing diagnostic tests Replace Amplifier module system Error Noise transient Check high energy ignition noise location Be sure it is not arcing to chassis or wrapped with scanner wiring CB 8080 Rev 1 9 CLEAVER BROOKS 833 3163 PROGRAMMER SEQUENCE The 833 3163 programmer provides additional logic used to control the
152. ss Switches and CAPS 4 13 LWCO ALWCO Check secte ek p b 4 14 E Low and High Fire Adjustments 4 15 Fx Seting ComblustlOfi seo cios Po e o er 4 15 Gz imt Controls eoo ub 4 16 Boll Oubor a NEW EDEN CUR C E e E ron ita 4 16 Post start up checkout procedure 4 17 vii Chapter 5 Service and Periodic Maintenance Chapter 6 Parts 5 2 Sie Teo 5 2 Water Column Blowdown enm 5 3 Fireside Cleaning Procedure Disassembly 5 5 Electrodes and Flame Rod 5 7 Waterside Inspection Cleaning 5 8 21 12 85 5 8 11861110 18101218 112 MM TETTE 5 9 WAY 5 12 High Level Assembly 10 HP 15 6 2 High Level Assembly 15 HP 15 6 3 High Level Assembly 15 HP 150 Steam 6 4 High Level Assembly 20 25 HP 6 5 High Level Assembly 30 40 6 6 High Level Assembly 50 60 HP 15 Steam 6 7 High Level Assembly 50 60 HP 150 Steam 6 8 COMO Patel
153. t Category IV A boiler which operates with a positive vent pressure and with a vent gas temperature that may cause excessive condensate production in the vent The ClearFire H should be considered a Category III boiler Depending on the application the specifying engineer may dictate alternative category flue venting as deemed appropriate Warning Contact the manufacturer of the vent material if there is any question about the boiler categorization and suitability of a vent material for application on a Category 111 vent system Using improper venting materials can result in personal injury death or property damage Notice During winter months check the vent cap and make sure no blockage occurs from build up of snow Condensate can freeze on the vent cap Frozen condensate on the vent cap can result in a blocked flue condition 3 2 Vent Stack The vent should be supported to maintain proper clearances from combustible materials Use insulated vent pipe spacers where the vent passes through combustible roofs and walls Part No 750 222 Chapter 3 Stack and Intake Vent Sizing and Installation 3 3 Vent Terminal Location Give special attention to the location of the vent termination to avoid possibility of property damage or personal injury 1 Combustion gases can form a white vapor plume in the winter The plume could obstruct a window view if the termination is installed in close proximity to windows
154. t 30 seconds and the controller will automatically return to the basic display 2 Hints 2 3 How to adjust parameters gt RWFA0 user manual Section 6 3 Shown at the right is the basic display The current configuration of your specific controller will determine which levels you will be RWF40 Basic display Actual value display Example Adjust the value for parameter AL If no keys are pressed for 30 seconds at anytime the controller will automatically return to the basic display The current value of AL 0 is shown in the actual value display The current parameter item AL is shown in the setpoint display allowed to access C112 must be 1 or xxx0 to access the parameter level AN The C112 locking code can only be adjusted by the manufacturer From the basic display you may skip the user level to reach the parameter level Press PGM and hold for 3 seconds and release The actual value display 0 shows the current parameter value The setpoint display AL shows the parameter item you are adjusting Parameter level items summary AL Alarm Limit value for comparator HYSt Switching differential Hysteresis for limit comparator Pb 1 Proportional band 1 dt derivative time rt Integral action time db dead band contact spacing tt Actuator running time HYS1 Switch on threshold Hysteresis 1 2 stage burner HYS2 Switch off threshold Hysteresis 2 2 stage
155. teger consisting of 2 bytes The normal response from a slave is as follows DST FNC DBC DATA CRC CRC Hi Lo LO HI DBC 15 the data byte count being returned It must be two times the DAT number from the poll request DATA is the data returned and is always a series of 2 byte integers If 4 words were requested then DBC would be 8 and there would be 8 data bytes or 4 data words containing the requested data The format of the data is 4800 N 8 1 meaning 4800 baud no parity and 1 stop bit 14 CB 8080 Rev 1 CLEAVER BROOKS Below is a table of currently available messages provided by the CB90 programmers followed by a description where necessary MESSAGE WORDS VALUE ADDRESS REQUESTED 1 6 STATUS 83 053H RUN 202 OCAH LOCKOUT 01 1 MSGN Current message being displayed see Table 2 __ 02 1 GSTAT Defines Timer Type DAE TIMER Time Flame Address FLAME Flame Signal LOGSTAT Current logic module PURGE TFI AUTO see Table 1 1 1 1 1 3 INPUTS Input limits state OUTPUTS Output relays state SYSMINS System on minutes BNRWINS CYCLES Completed Burner Cycles 1 6 1 2 1 04 1 LOCKOUT COUNT otored Lockout Count LOCKOUT HISTORY Last 6 Lockouts first word is the most current lockout Bd Ww 03 05 10 12 1 6 21 12 DEVTYP Programmer device type 7 CB90 22 AMPTYP Amplifier Type 833 3164 0B0H PROGTYP Programmer Type N A 24 2 FLAME SIGNAL
156. tem to detect and respond to a loss of flame This can be done by removing the ionization Part No 750 222 4 17 Chapter 4 Commissioning electrode flame rod cable For a successful test the boiler should shut down and the gas safety shutoff valve close with the display indicating a lockout condition Reconnect the ionization cable to the electrode Adjust gas choke for high fire combustion to desired excess air level 5 6 02 recommended Using offset screw set low fire O2 same as high fire O2 Check the draft on the outlet stack on each boiler compare to acceptable limits 25 to 50 W C and record in start up form Switch to automatic operation and monitor flue gas to ensure consistent excess air Reassemble all panels and covers that were removed and replace any plugs that were removed to check gas pressure If boiler is equipped with a High Air Pressure Switch check switch operation 10 Verify with customer that softened water is being used and that 11 a proper water treatment program is in place Provide instructions to owner and operators on operation safety and maintenance of the equipment Part No 750 222 CLEAVER BROOKS Chapter 5 Service And Periodic Maintenance General 5 2 bri 5 2 Water Column Blowdown 5 3 Fireside Cleaning Procedure Disassembly 5 5 Electrodes
157. ter 3 in this manual for more information 2 4 Part No 750 222 2 5 Gas Connections Gas Shut Off Valve and Gas Filter A manually operated shut off valve and pressure regulator are provided as standard on the ClearFire H boiler Figure 2 4 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 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 A dedicated gas pressure regulator is required for each boiler to ensure consistent gas pressure at the boiler Part No 750 222 Chapter 2 Installation gt Shutoff Valve Figure 2 4 ClearFire Gas Piping Shut off Valve and Regulator Ah Warning A sediment trap must be provided upstream of the gas controls 2 5 Chapter 2 Installation Notice Before filling boiler check that all waterside openings fittings are plugged and all inspection Covers are secured Figure 2 5 Feedwater Inlet 2 6 2 6 Boiler Water Side Connections A pressure relief valve Safety Valve provided with the bo
158. ting 2 seconds Once it flashes press Pem and release Adjust SP1 as shown below User level values Value Item Description Sec 180 SP1 Setpoint 1 Setup is complete Sec 5 Refers to the RWF40 user manual section 2 Hints 2 9 Setting up a standard pressure application Using a QBE sensor Siemens part QBE620 P10 P10 is 150PSI Configure f no keys are pressed for 20 seconds the controller will exit this mode and return to the basic display See Hint section 2 2 How to configuration your RWF40 From the basic display or user level press and hold for 3 seconds and then release and again press Pom and hold for 3 seconds and then release The actual value display 9030 shows the current configuration item value The setpoint display C111 shows the configuration item you are adjusting The display is steady not flashing and by default the 4 rightmost digit may now be adjusted You can select which digit you wish to adjust by pressing once and releasing it The 3 digit is now flashing indicating that it is now the adjustable digit Cycle thru each digit of C111 and configure as charted below then accept by pressing and releasing All four upper digits will flash once and the new configuration value is displayed in 4 steady digits Press ana release to configure C112 C113 thru Configuration level values
159. u can decrease the value by pressing and releasing it PGM EXIT You can accept the change by waiting 2 seconds The red LED s will blink once and become EXIT the new value Your options at this point are You can increase the value by pressing and releasing it E PGM EXIT Or you can advance to the next parameter by pressing once and releasing it HYSt can be adjusted the same way you just did AL Press and release to immediately return to the basic display Press and release it to advance down to Pb 1 the next parameter after the last parameter item P press and release it to advance down to SP1 the 15 user item after the last user item the menu cycles back to the 1 user item Or simply wait 30 seconds and the controller will automatically return to the basic display 2 Hints 2 5 How to display the software version and units gt RWFAO0 user manual Section 6 2 5 RWF40 Basic display Actual value Shown at the right is the basic display display setpoint display The current configuration of your specific controller will determine which levels you will be allowed to access 1 2 6 A C112 of xxx3 will prevent use of the keys AN The C112 locking code can only be adjusted by the manufacturer Shown at the right is the basic display You can display the
160. us operating parameters of the programmer and ampli AUTO fier The MODE key is required to enter the sub menu PROGRAM SETUP Sub menu to display information pertaining to the operation of the control The AUTO MODE key is required to enter the sub menu SYSTEM INFO LOCKOUT HISTORY The sub menu LOCKOUT HISTORY will display the last six 6 lockouts along with the burner cycle and burner hour when the lockout occurred When the MODE key is pressed the screen will display the most recent lockout condition and the number of that lockout e g LO 127 represents the 127th lockout of that control The SCRL key will display the Burner Hour followed by the Burner Cycle when the lockout occurred The SCRL key will advance to the next lockout and repeat the sequence listed above The MODE key will exit the sub menu PRESS SCREEN DISPLAYS DESCRIPTION SCRL AUTO 45 scrolling through the historical information LOCKOUT HISTORY MODE LO 127 TFI The latest most recent lockout condition This is the 127th lockout of FLAME FAIL the control History indicates the lockout occurred during SCRL LO 127 TFI The last lockout occurred after 136 hours of burner operation BNR HOURS 136 SCRL LO 127 TFI The last lockout occurred at burner cycle 744 BNR CYCLE 744 SCRL LO 126 PURGE The second latest lockout condition This is the 126th lockout of the con AIR FLOW OPEN trol History indicates the lockout occurred during purg
161. used DIN 43551 Plug Connector wrth 36 in 914 mm leadwires included Flexible mounting positions of venturi manifold to fan Replaceable pipe flange adapters available Position indication lamp for each valve stage Read these instructions carefully Failure to follow them could damage the product or cause a hazardous condition Check the ratings given in the instructions and on the product to make sure the product is suit able for your The installer must be a trained experienced flame safeguard technician After installation is complete check out product operation as provided in these instructions WARNING Fire or Explosion Hazard Can cause severe injury death or property damage 1 2 3 4 Turn off the gas supply before beginning installation Disconnect power to the valve actuator before beginning installation to prevent electrical shock and damage to the equipment Do not remove the seal over the valve inlet and outlet until ready to connect piping The valve must be installed so that the arrow on the valve points in the direction of the gas flow so that gas pressure helps to close the valve Mounting Position The valve venturi is factory calibrated in the upright position for the most accurate metering of the gas flow This is with the air flow through the venturi in a horizontal direction and the gas flow into the valve in a horizontal direction The valve can be mounted up to 90 degrees from this positi
162. ve the leak test tap from the valve body 20 Using a small amount of pipe sealant on the 1 8 in 3 mm NPT plug reinstall the plug in pres Sure tap point 4 After the Test 1 Make sure the downstream manual gas cock E is closed 2 Open the upstream manual gas cock A and energize the valve through the safety system 3 Test with rich soap and water solution to make sure there is no leak at the test tap D or any pipe adapter valve mating surfaces 4 De energize the valve C 5 Open the downstream manual gas cock E 6 Restore the system to normal operation TROUBLESHOOTING WARNING Electrical Shock Hazard Can cause severe injury death or property damage Use extreme caution when troubleshooting line voltage is present IMPORTANT Do not replace the valve until all other sources of trouble are eliminated Troubleshooting Procedure If the valve does not open when the thermostat or controller calls for heat 1 Check for voltage at the valve leadwires or terminal block 2 f there is no voltage at the valve leadwires or terminal block make sure a voltage is connected to the master switch b master switch is closed and overload protection circuit breaker fuse or similar device has not opened the power line 3 If there is still no voltage at the valve leadwires or terminal block make sure all appropriate contacts in the thermostat or controller limits and flame safeguard control are closed o
163. wowen mermween pant numee _ a i 146600528 146C00528 146C00509 146600509 Front Door assemby 6 1 9460502 94005500 94094993 94005500 1 2830333 283003333 20303333 28303333 0 o f gt 118803637 118803637 118803637 118803637 Label CFH Boter Casno Notes Ensure door is centered over furnace Adjust item 21 as required to align door Apply grease to pin prior to installation Handhole Items QTY 15 150 25 3 4 317 00057 HANDHOLE COVER STUD AND WASHER ASSEMBLY 26 3 4 953 00048 HANDHOLE YOKE 2 PRONG FORGED 27 3 4 853 00934 HANDHOLE GASKET 2 3 4 x 1 2 PART NUMBER DESCRIPTION DETAIL B Add extra item 18 s CLEAVER BROOKS The power of commitment power of commi HIGH LEVEL ASSEMBLY 40HP 15 ST BOILER N T S wew 146 00529 6 6 Part No 750 222 Chapter 6 ClearFire H Parts 6 High Level Assembly 50 60 HP 15 St ITEM 50 60 HP 15 P N DESCRIPTION 270C03336 Pressure Vessel Assembly 429 01591 Burner Assembly 507C08183 Control Piping 4 1 Safety Valve 465C02606 Insulation And Lagging Assembly 6 1 283 03333 Control Panel 118B03637 Label CFH Boiler Casing 8 1 118803638 Label CFH Boiler Panel 118403634 Data Plate Boilers 507C08107 Mounted Feedwater Piping Optional 507C08105 Bottom Blowdown Piping Optional
164. y Ill No substitutions of flue pipe or vent cap material are allowed Such substitutions would jeopardize the safety and health of inhabitants Figure 3 4 Vertical Stack with Sealed Combustion Air These installations utilize the boiler mounted blower to draw combustion air from outside and vent combustion products to the outside A positive pressure venting system is required To prevent condensation accumulation in the vent it is required to install the horizontal portion of vent with a slight upward slope of not more than 1 4 per foot of horizontal run an approved condensate trap must be installed per applicable codes Part No 750 222 3 9 Chapter 4 Commissioning Operating Conditions 4 2 4 2 Control ue eee Co CR 4 2 ClearFire H Boiler Burner 5 4 3 A Modulating Control Configuration and Operation 4 3 B Flame Safety Control Operation 4 6 C Variable Speed Blower Interface 4 9 D Water Level Controls 4 11 E Operating and High Limit Controls 4 12 Initial start up procedure 4 12 Gas Train and Piping 4 12 ED 4 13 C Operation Check Gas Valve Gas Press Swit
165. z 9 08811 SNISVO 431108 38V1 000 6960 811 2 829208811 TANVd s31108 138 1 000 82920 811 STO00D9bT 3A1VA SATAY 134 5 000 209S0 0r6 1 02 91 9 X 8 YAddOO 000 96110 666 T 61 9116 ONN 91 8 2 LNIOd 1V14 25136 000 96500 098 9 81 14 5 5 1 S3NIVI3 000 66000 916 T ZT 462002980 400 1NO H NId 000 26200 950 1 91 po Lid H3HSVM 000 TTT00 7S6 2 ST X ONN 91 8 54 2 000 05500 898 8 1109 8 5 I3QN34 3HSVM 000 26200 256 8 ET T SLAN 1109 N 000 22110 198 z 08800 NNOQMOT8 L33OV38 000 2 920 800 T TT 009505800 ONIdId SVD 13 000 0090 800 OT jeuondo 66203261 3871 4 35v4ans 000 5600 261 1 6 jeuondo S1 1802409 ONIdId JJOMO 8 FOWIUNS 000 61180 208 1 8 reuondo 15609105 WO LLOS 000 56 0 706 T 4 jjeuondo 78080906 5NIdId 331VMQ334 000 8080 0 1 9 555509880 TANVd TONLNOD 000 66660 682 1 S ATAWASSV SNISSV1 8 NOLLVINSNI 000 80 59 1 656402408 9NIdId 1 000 6 620 205 T 98510062 NIVUL SVD ATAWASSV uaNsng 000 98510 6 1 c TZZE0D0ZZ A18I3SSV TASSAA AUNSSAYd 000 1 220 0 2 1 NOLLdIu2S3Q
166. zed Increase icon turns off N O contact Q Y1 opens to hold the V A modulating device where it is which PGM EXIT holds the firing rate of the burner i Output 2 Relay2 Increase 3 Relay 3 v Decrease Modulating burner Modulating output EXIT Press and hold for 5 seconds and release The red LED above the manual icon turns on to indicate that the controller is now in the manual mode Relay 2 and relay 3 will hold their current state energized or de energized that they were in until another key is pressed By design the 0 output starts driving the modulating device to low fire but if you promptly press the after the red LED above the hand icon turns on you can prevent the from going all the way When the is pressed the output value starts increasing and the output to terminals X1 and X1 starts increasing the same amount and increases the firing rate of the burner EXIT When the FW is pressed the output value Starts decreasing and the output lt to terminals X1 and X1 starts decreasing the same amount and decreases the firing rate of the burner To exit manual operation EXIT Press for 5 seconds and release The red LED above the hand symbol S turns off When the is released output value stops increasing and the output to terminals X1 and X1 also stops in

Model CFH w/ CB90-RWF40 – 750-222, 5/2007 or 11/2008 edition

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Model CFH w/ CB90-RWF40 &ndash; 750-222, 5/2007 or 11/2008 edition

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Model CFH w/ CB90-RWF40 – 750-222, 5/2007 or 11/2008 edition