Model CFLC ClearFire Condensing...

Model CFLC ClearFire Commercial Boilers

Model CFLC ClearFire Condensing Boiler

Table of ContentsMODEL CFLC FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3MODEL CFLC PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15STACK/BREECHING SIZE CRITERIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32CB FALCON CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

List of FiguresAluFer Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Burner service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Premix Burner Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Model CFLC Cutaway View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5CFLC Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Model CFLC Dimensional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9CFLC Efficiency Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Hydraulic Resistance CFLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Condensate Piping Direct To Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Condensate Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Gas Piping Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Gas Header Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Model CFLC Minimum Room Clearance Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Two Opening Outside Wall Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Two Opening Ducted Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29One Opening Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Two Opening Engineered Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Inside Air - Vertical Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Vertical Stack with Direct Vent Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Falcon pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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List of TablesU.S. Standard Dimensions Model CFLC Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Metric Dimensions Model CFLC Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Model CFLC Boiler Ratings (Sea Level to 2000 Feet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12CFLC Efficiencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Model CFLC Boilers: Natural Gas, Estimated Emission Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Noise Level (dBA) measured 3 feet in front of boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15CFLC Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16CFLC Flow Rates (Metric) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Model CFLC Minimum Over Pressure Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Model CFLC Boiler Safety Valve Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Model CFLC Water Chemistry Requirements in accordance with ABMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Glycol Application Guidelines - Model CFLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Model CFLC Maximum Condensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Model CFLC Minimum and Maximum Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Model CFLC Minimum Required Gas Pressure Altitude Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Altitude Correction for Input Capacity at Various Altitude Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Operating Conditions - Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Operating Conditions - Display/Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Operating Conditions - VFD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Falcon control sequence (Central Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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MODEL CFLC FEATURES AND BENEFITS

Compact Firetube Design

The Model CFLC boiler is a durablefiretube condensing hot water boiler.The internal extended-heating surfacetubes provide very high levels ofperformance in a compact space,offering over 6 square feet of heatingsurface per boiler horsepower, providingmany years of trouble free performance.

Advanced Technology

Tubes are constructed from UNS S32101 duplex stainless steel with AluFer tubeinserts (lower vessel) and carbon steel with rifled surface (upper vessel) for optimalheat transfer.

Advanced Construction

The extended heating surface design provides the ideal solution for the demands ofa condensing boiler and helps to recover virtually all the latent heat of the flue gas.Each tube consists of an outer stainless steel tube (waterside) and the AluFerextended surface profile on the flue gas side.

High Efficiency With the extended heating surface tubes the CFLC boiler will provide fuel to waterefficiency of up to 99% at low fire and 95% at high fire.

Ease of Maintenance The powder coated steel casing is designed for easy removal and re-assembly. Asshown in Figure 2, the burner is hinged for simple opening for inspection of theburner cylinder, tubes and tube sheets.

Figure 2. Burner service

Quality Construction ISO 9001:2001 certified manufacturing process ensures the highest degree ofmanufacturing standards are always followed.

ASME Code construction ensures high quality design, safety, third party inspection,and reliability, and is stamped accordingly.

Premix Technology The burner utilizes “Premix” technology to mix both gas fuel and combustion airprior to entering the burner canister, with air “leading” during burner firingtransitions. Combined with a variable speed fan, this technology provides very lowemission levels, exceptionally safe operation, and nearly 100% combustionefficiency.

Figure 1. AluFer Inserts

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Full Modulation The variable speed fan provides modulated firing for reduced on/off cycling,excellent load tracking, and reduced operating costs. The burner does not requiremechanical linkage connections between the fuel input valve and air control.Instead, the microprocessor control positions the fan speed in accordance withsystem demand, and this determines the fuel input without mechanical devicepositioning - that is, linkage-less fuel/air ratio control. This eliminates linkageslippage, minimizes burner maintenance, and provides control repeatability. This isshown schematically in Figure 3.

Figure 3. Premix Burner Technology

Designed For Heating Applications

The pressure vessel is designed for 160 psig MAWP (Max. Allowable WorkingPressure) and is constructed of durable ASTM Grade Steel and Stainless Steelmaterials. Figure 4 shows the counter flow heat exchanger design that gives optimalheat transfer. The design also prevents hot spots, does not require a minimum flowfor thermal shock protection, and does not require a minimum return watertemperature. In fact, the design carries a 20-year thermal shock warranty.

Because of its design characteristics, the Model CFLC is well suited for applicationsutilizing indoor/outdoor reset controls, radiant floor heating, snow melt systems,ground source heat pump systems and systems that utilize variable speedcirculating pumps. It may also be employed in standard hot water systems thatrequire higher heated water at colder outdoor temperatures but then requireminimum temperatures during warmer heating days, realizing fuel efficiency savingsover traditional hot water boilers.

While the design does not lend itself to the direct supply of potable water, a separatestorage tank with an internal heat exchanger can be employed, as themicroprocessor control permits domestic water programming. Therefore, the ModelCFLC can service both hydronic heating and domestic water source heating.

Dual Return Two return pipes - high and low temperature - allow condensing performance withas little as 10% return water at condensing temperature.

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Figure 4. Model CFLC Cutaway View

MODEL CFLC PRODUCT OFFERINGInformation in this section applies to condensing hot water boiler sizes ranging from4,000,000 BTU input through 12,000,000 BTU input for operation on Natural Gasor LP Gas only. Installation is for indoor use only.

Dimensions, ratings, and product information may change to meet current marketrequirements and product improvements. Therefore, use this information as a guide.

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Standard Equipment Equipment described below is for the standard boiler offering:

1. The BoilerA. Each boiler size is designed for a Maximum Allowable Working Pressure

(MAWP) of 160 psig (11 Bar), constructed in accordance with the ASMECode Section IV and bear the “H” stamp. Maximum Allowable WorkingTemperature (MAWT) is 250 deg F (121 C); Maximum OperatingTemperature 230 deg F (110 C). There is no minimum return temperature.

B. The insulated boiler is mounted on a base and enclosed in a powder coatedsteel casing.

C. One hot water outlet and dual return provided.2. Boiler Trim and Controls

A. The following items are furnished:B. Probe Type Low Water Cutoff control, manual reset.C. High Water Temperature Cutoff, manual reset.D. NTC (negative temp. coefficient) sensor for hot water supply temperature.E. NTC sensor for hot water return temperature.F. ASME Safety Relief Valve set @ 160 psig. (11 Bar)G. Temperature and pressure gauges.

3. Burner ControlA. Falcon burner control - an integrated burner management and modulation

control with a touch-screen display/operator interface. Its functions includethe following:1. Two (2) heating loops with PID load control.2. Burner sequencing with safe start check, pre-purge, pilot ignition, and post purge.3. Electronic ignition.4. Flame Supervision.5. Safety shutdown with time-stamped display of lockout condition.6. Variable speed control of the combustion fan; Variable Speed Drive provided.7. Supervision of low and high gas pressure, air proving, stack back pressure, high limit,

and low water.8. First-out annunciator.9. Real-time data trending.

10. (3) pump/auxiliary relay outputs.11. Modbus communication capability.12. Outdoor temperature reset.13. Remote firing rate or setpoint control14. Setback/time-of-day setpoint15. Lead/Lag for up to 8 boilers16. Control circuit transformer

B. Variable Speed Drive for combustion air fan1. Compact packaged unit2. Factory configured and wired for boiler application

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Figure 5. CFLC Control Panel

4. Forced Draft BurnerA. The burner is a “Pre-mix” design consisting of a unitized venturi, gas valve(s) with

safety shutoff and proof-of-closure, blower/motor, and burner head.B. Full modulation is accomplished with a supplied variable speed fan for 5:1

turndown ratio.C. For near flameless combustion, the burner utilizes a Fecralloy-metal fiber head.D. Operating on Natural Gas, NOx emissions will be less than 20 PPM regardless of

boiler size and the boiler is certified for California and Texas for Low NOx emissions.E. As an option, the burner is capable of direct vent combustion.F. Ignition of the main flame is by gas pilot, with UV scanner for flame supervision.G. To ensure adequate combustion air is present prior to ignition, and to ensure the fan

is operating, a combustion air proving switch is furnished.H. A High Air Pressure Switch is provided to ensure burner lockout in case of excessive

back pressure due to a blocked condensate drain or a blocked stack.I. For ease of maintenance and inspection, the blower/motor assembly is furnished

with a hinge which permits the assembly to swing away. This provides access to theburner and electrode as well as the tube sheet and tubes.

J. Air filter provided as standard. Additional filter media can be ordered.K. VSD-duty TEFC 3-phase tri-voltage motor.

5. Burner Gas Train

The standard gas train is equipped in accordance with cULus certification andcomplies with ASME CSD-1. Each burner gas train includes:

A. Low Gas Pressure Interlock, manual reset.B. High Gas Pressure Interlock, manual reset.C. ASME CSD-1 Test Cocks.D. Downstream manual ball type shutoff cock.

FALCON DISPLAY / OPERATOR INTERFACE

DEMAND SWITCH

IGNITION TRANSFORMER

FALCON CONTROLLER

LWCO CONTROLLER

TRANSFORMER, 115v/25v

TRANSFORMER, 460/230/208V PRI

TERMINAL TRACK

LWCO RESET

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E. Safety shutoff gas valve(s) with POC.

Optional Equipment For option details, contact the local authorized Cleaver-Brooks representative. Insummary, here are some of the options that can be provided with the boiler:

A. Condensate neutralization tank assembly - consists of neutralizing media, filter,and PVC condensate holding tank.

B. Direct vent kit for direct vent combustion.C. Outdoor temperature sensor for outdoor reset, frost protection, or warm weather

shutdown.D. Header temperature sensor for multiple boiler Lead/Lag operation.E. Auxiliary Low Water Control (shipped loose) for field piping by others into the

system piping.F. Alarm Horn for safety shutdown.G. Relays for output signal for burner on, fuel valve open.H. Stack thermometer (shipped loose - for field installation by others).I. Stack temperature limit-sensor.J. Auto air vent.K. Boiler drain valve.

DIMENSIONS AND RATINGSFor layout purposes, the overall dimensions for the Model CFLC are shown in Table1 (US Dimensions) and Table 2 (Metric Dimensions) including the various pipeconnection sizes for supply and return water, drain, and vent. The performanceratings for the boiler are shown in Table 3.

Altitude Relative to the ratings shown, installation of the boiler above 2000 feet elevationwill result in input capacity reduction. Please refer to Table 4 for input ratings of theboiler at various elevations.

PERFORMANCE DATA

Efficiency The Model CFLC is a “full condensing” boiler realizing efficiency gain at variableoperating conditions. It is designed to extract the latent heat of condensation over agreater range than other designs. The nominal point of condensation isapproximately 132 F (55.5 C). The ClearFire, due to its more efficient heat transferdesign and lower stack temperature, is able to capture the latent heat ofcondensation over a broader range.

Fuel-to-water efficiency is relative to specific operating conditions. Operatingefficiency will be greater in the “condensing” mode of operation as noted above, yetwith its inherently greater heat transfer surfaces and superior pre-mix burner, theClearFire’s efficiency under “traditional” hot water conditions is also outstanding.Table 4 shows the guaranteed efficiencies at various operating conditions and firingrates for Natural Gas. It should be noted that the efficiency is exceptional at high fireand low fire versus other designs where high efficiency is realized only with low fireor minimal firing rates and low temperature returns.

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Figure 6. Model CFLC Dimensional Views

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Table 1. U.S. Standard Dimensions Model CFLC Boiler

ITEM DIMENSIONS (inches) 4000 5000 6000 8000 10000 12000A Overall Height 96 96 106 106 126 126B Overall Width 48 48 57.5 57.5 69 69C Overall Depth 117 117 131 131 147 147D Casing Height 89 89 99 99 119 119F Casing Depth 111.5 111.5 125.5 125.5 141.5 141.5G Gas Connection to Floor 94 94 104 104 124 124H Gas Connection to Boiler Centerline 18 18 21 21 26 26J Gas Connection to Front of Boiler 56.5 56.5 58 58 60 60K Air Inlet Venturi to Floor 84 84 95 95 114 114L Air Inlet Centerline to Boiler Centerline 8 8 10.5 10.5 10 10M Air Inlet Centerline to Front of Boiler 18.5 18.5 21 21 30.5 30.5N Stack Connection to Floor 91 91 101 101 121 121P Stack Connection to Boiler Centerline 14.5 14.5 18 18 21 21Q Stack Connection to Front of Boiler 20.5 20.5 23 23 32 32R Control Panel Projection 3 3 3 3 3 3S Return Connections to Floor 11 11 14.5 14.5 16 16T Supply Connection to Floor 94 94 104 104 124 124U Supply Connection to Front of Boiler 36.5 36.5 40.5 40.5 50 50V Floor to Drain Connection 4.5 4.5 6 6 7.5 7.5

CONNECTIONSAA Water Return, 150# RF Flg 6” 6” 6” 6” 8” 8”BB Water Supply, 150# RF Flg 6” 6” 6” 6” 8” 8”CC Boiler Air Vent, NPT 2” 2” 2” 2” 2” 2”DD Boiler Drain, NPT 1-1/2” 1-1/2” 1-1/2” 1-1/2” 1-1/2” 1-1/2”EE Flue Gas, Nominal OD 14” 14” 16” 16” 20” 20”FF Combustion Air Option 8” 8” 10” 10” 12” 12”GG Gas Connection, NPT 2” 2” 2-1/2” 2-1/2” 2-1/2” 2-1/2”HH Condensate Drain, FPT 1-1/4” 1-1/4” 1-1/4” 1-1/4” 1-1/2” 1-1/2”JJ Relief Valve outlet @ 160# Setting 1-1/4” 1-1/4” 1-1/4” 1-1/2” 1-1/2” 2”

CLEARANCESMM Overhead 36 36 36 36 36 36NN Front 36 36 36 36 36 36PP Rear 36 36 36 36 36 36QQ Side 24 24 24 24 24 24

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Table 2. Metric Dimensions Model CFLC Boiler

ITEM DIMENSIONS (mm) 4000 5000 6000 8000 10000 12000A Overall Height 2438 2438 2692 2692 3200 3200B Overall Width 1219 1219 1461 1461 1753 1753C Overall Depth 2972 2972 3327 3327 3734 3734D Casing Height 2261 2261 2515 2515 3023 3023F Casing Depth 2832 2832 3188 3188 3594 3594G Gas Connection to Floor 2388 2388 2642 2642 3150 3150H Gas Connection to Boiler Centerline 457 457 533 533 660 660J Gas Connection to Front of Boiler 1435 1435 1473 1473 1524 1524K Air Inlet Venturi to Floor 2134 2134 2413 2413 2896 2896L Air Inlet Centerline to Boiler Centerline 203 203 267 267 254 254M Air Inlet Centerline to Front of Boiler 470 470 533 533 775 775N Stack Connection to Floor 2311 2311 2565 2565 3073 3073P Stack Connection to Boiler Centerline 368 368 457 457 533 533Q Stack Connection to Front of Boiler 521 521 584 584 813 813R Control Panel Projection 76 76 76 76 76 76S Return Connections to Floor 279 279 368 368 406 406T Supply Connection to Floor 2388 2388 2642 2642 3150 3150U Supply Connection to Front of Boiler 927 927 1029 1029 1270 1270V Floor to Drain Connection 114 114 152 152 191 191

CONNECTIONSAA Water Return, 150# RF Flg 6” 6” 6” 6” 8” 8”BB Water Supply, 150# RF Flg 6” 6” 6” 6” 8” 8”CC Boiler Air Vent, NPT 2” 2” 2” 2” 2” 2”DD Boiler Drain, NPT 1-1/2” 1-1/2” 1-1/2” 1-1/2” 1-1/2” 1-1/2”EE Flue Gas, Nominal OD 14” 14” 16” 16” 20” 20”FF Combustion Air Option 8” 8” 10” 10” 12” 12”GG Gas Connection, NPT 2” 2” 2-1/2” 2-1/2” 2-1/2” 2-1/2”HH Condensate Drain, FPT 1-1/4” 1-1/4” 1-1/4” 1-1/4” 1-1/2” 1-1/2”JJ Relief Valve outlet @ 160# Setting 1-1/4” 1-1/4” 1-1/4” 1-1/2” 1-1/2” 2”

CLEARANCESMM Overhead 914 914 914 914 914 914NN Front 914 914 914 914 914 914PP Rear 914 914 914 914 914 914QQ Side 610 610 610 610 610 610

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Table 3. Model CFLC Boiler Ratings (Sea Level to 2000 Feet)Description Units 4000 5000 6000 8000 10000 12000

Input Max. BTU/Hr. 4,000,000 5,000,000 6,000,000 8,000,000 10,000,000 12,000,000KCAL/Hr. 1,008,000 1,260,000 1,512,000 2,016,000 2,520,000 3,024,000

Natural Gas (1000 Btu/ft3) FT3/Hr 4000 5000 6000 8000 10000 12000Natural Gas M3/Hr 113 142 170 226 283 340Output at 130/80 F [54/27 C] 100%Firing

BTU/Hr. 3,760,000 4,700,000 5,640,000 7,520,000 9,400,000 11,280,000KCAL/Hr. 947,520 1,184,400 1,421,280 1,895,040 2,368,800 2,842,560BHP 112 140 168 225 281 337KW 1102 1377 1653 2204 2755 3305

Output at 180/140 F [82/60 C] 100%Firing

BTU/Hr. 3,520,000 4,400,000 5,280,000 7,040,000 8,800,000 10,560,000KCAL/Hr. 887,040 1,108,800 1,330,560 1,774,080 2,217,600 2,661,120BHP 105 131 158 210 263 315KW 1031 1289 1547 2063 2579 3094

MAWP PSI 160 160 160 160 160 160BAR 11 11 11 11 11 11

MAWT °F 250 250 250 250 250 250°C 121 121 121 121 121 121

Operating Temperature, Max. °F 230 230 230 230 230 230°C 110 110 110 110 110 110

Water Content Gallons 395 374 559 511 871 819Liters 1495 1416 2116 1934 3297 3100

Weight w/o Water (Shipping) Pounds 7,450 7,800 9,800 10,500 15,300 16,100Kg 3379 3538 4445 4763 6940 7303

Operating Weight Pounds 10,743 10,918 14,460 14,760 22,562 22,928Kg 4873 4952 6559 6695 10234 10400

Fireside Heating Surface ft2 756 915 1,123 1,454 1,885 2,223m2 70 85 104 135 175 207

Waterside Heating Surface ft2 298 344 441 546 750 862m2 28 32 41 51 70 80

Standby Heat Loss BTU/Hr 8,000 10,000 12,000 16,000 20,000 24,000Watts 2344 2930 3516 4689 5861 7033

Fan Motor Size HP 5 5 7.5 10 15 20Operating Voltage, Fan A Volts/Ph/Hz 460/3/60 460/3/60 460/3/60 460/3/60 460/3/60 460/3/60Control Circuit B Volts/Ph/Hz 115/1/60 115/1/60 115/1/60 115/1/60 115/1/60 115/1/60Incoming Power (Ampacity) Amps 10.5 10.5 14.8 18.5 27.3 34.8Flue Gas Mass Flow @ 100% Firing(Natural Gas)

lb/hr 4532 5665 6,798 9,064 11,330 13,596kg/h 2056 2570 3084 4111 5139 6167

Notes:A. Consult Cleaver Brooks for alternate voltage requirements.B. Single point 3-phase power requirement; control circuit transformer is provided as standard

12


ClearFire Efficiencies

The table below, and the series of graphs following it, show the operating efficiencies ofeach size Model CFLC boiler, including radiation losses. As the Model CFLC is a fullycondensing boiler, maximum efficiency is obtained when operating within the condensingmode, utilizing the latent heat of condensation.

Table 4. CFLC Efficiencies

Boiler Size

% Firing Rate

Return Water Temperature deg F (deg C)

68 80 100 120 130 140 160

(20) (27) (38) (49) (55) (60) (72)

20% 98.4 97.3 95.1 91.3 89.4 88.5 88.0

4000 50% 97.3 96.6 93.7 89.9 88.6 88.4 87.9

75% 95.9 94.8 92.4 89.3 88.2 88.2 87.6

100% 94.6 93.3 91.1 88.7 87.9 87.9 87.3

20% 97.8 97.2 94.7 91.5 89.9 88.6 88.0

5000 50% 97.4 95.9 92.8 90.0 89.0 88.4 87.9

75% 95.8 93.7 90.9 89.1 88.5 88.2 87.6

100% 94.5 93.2 90.6 88.5 88.0 87.9 87.3

20% 98.4 97.3 95.1 91.3 89.4 88.5 88.0

6000 50% 97.3 96.6 93.7 89.9 88.6 88.4 87.9

75% 95.9 94.8 92.4 89.3 88.2 88.2 87.6

100% 94.6 93.3 91.1 88.7 87.9 87.9 87.3

20% 97.8 97.2 94.7 91.5 89.9 88.6 88.0

8000 50% 97.4 95.9 92.8 90.0 89.0 88.4 87.9

75% 95.8 93.7 90.9 89.1 88.5 88.2 87.6

100% 94.5 93.2 90.6 88.5 88.0 87.9 87.3

20% 98.4 97.3 95.1 91.3 89.4 88.5 88.0

10000 50% 97.3 96.6 93.7 89.9 88.6 88.4 87.9

75% 95.9 94.8 92.4 89.3 88.2 88.2 87.6

100% 94.6 93.3 91.1 88.7 87.9 87.9 87.3

20% 97.8 97.2 94.7 91.5 89.9 88.6 88.0

12000 50% 97.4 95.9 92.8 90.0 89.0 88.4 87.9

75% 95.8 93.7 90.9 89.1 88.5 88.2 87.6

100% 94.5 93.2 90.6 88.5 88.0 87.9 87.3

Conditions:Natural gas firing35% excess airRelative Humidity = 50%Combustion air temperature = 80 0F∆T = 40 0FR & C Loss = 0.2% of rated capacity

13


Figure 7. CFLC Efficiency Curves

86

88

90

92

94

96

98

100

60 [15] 80 [27] 100 [38] 120 [49] 140 [60] 160 [72]

20

50

75

100

% Firing Rate

Effic

ienc

y %

Return water temperature deg F [C]

4000

86

88

90

92

94

96

98

100

60 [15] 80 [27] 100 [38] 120 [49] 140 [60] 160 [72]

20

50

75

100

% Firing Rate

Effic

ienc

y %


6000

86

88

90

92

94

96

98

100

60 [15] 80 [27] 100 [38] 120 [49] 140 [60] 160 [72]

20

50

75

100

% Firing RateEf

ficie

ncy

%


10000

86

88

90

92

94

96

98

100

60 [15] 80 [27] 100 [38] 120 [49] 140 [60] 160 [72]

20

50

75

100

% Firing Rate


5000

Effic

ienc

y %

86

88

90

92

94

96

98

100

60 [15] 80 [27] 100 [38] 120 [49] 140 [60] 160 [72]

20

50

75

100

% Firing Rate


8000

Effic

ienc

y %

86

88

90

92

94

96

98

100

60 [15] 80 [27] 100 [38] 120 [49] 140 [60] 160 [72]

20

50

75

100

% Firing Rate


12000

Effic

ienc

y %

14


Emissions Table 5. Model CFLC Boilers: Natural Gas, Estimated Emission Levels

A. ppm levels are given on a dry volume basis and corrected to 3% oxygen (15% excess air).

B. Optional 9 ppm NOx available.

Noise Level The Model CFLC is exceptionally quiet at all operating levels, does not require anysound level modifications to provide ultra low noise levels, and is virtually vibrationfree. Thus, it is very suitable in applications that demand low noise levels.

Table 6 shows the noise levels of the Clearfire at various firing rates.

Table 6. Noise Level (dBA) measured 3 feet in front of boiler

ENGINEERING DATA

Boiler Information The Model CFLC boiler is designed for service in any closed hydronic system andcan be used to augment any hot water system. It can be put into operation as asingle stand-alone unit with 5:1 turndown or in multiple units for larger turndownand capacity.

Clearfire boilers may be utilized in water heating systems with no minimum returntemperature and supply temperatures from 130 F (55 C) to 230 F (110 C).Because the Clearfire is a full condensing boiler, low water temperature (below thedewpoint) restrictions do not apply. In fact, the lower the return the better the fuelsavings.

Variable temperature differentials can be designed to make use of changing outdoorconditions and thus, the Clearfire is not restricted to a nominal 20 F (10 C)differential. The boiler is designed to withstand thermal stresses with supply andreturn temperature differences up to 100 F (55 C), without the use of a boiler-circulating pump, blend pump or minimum water flow.

POLLUTANT UNITS

COppmA <10

lb/MMBtu <0.007

NOxppmA <20B

lb/MMBtu <0.024

SOxppmA <1

lb/MMBtu <0.001

HC/VOCppmA <4

lb/MMBtu <0.0016

PMppmA -

lb/MMBtu <0.01

20% Firing Rate 50% Firing Rate 100% Firing Rate

CFLC 4000 67 69 76CFLC 5000 70 71 80CFLC 6000 65 69 79CFLC 8000 67 70 82CFLC 10000 64 70 81CFLC 12000 65 72 85

15


Flow Rates and Pressure Drops

To maintain rated capacity of the boiler, recommended flow rates should not beexceeded as the flow will remove the heat beyond the capacity of the boiler. Tables7 and 8 can be used to determine the full boiler output relative to systemtemperature drop and the maximum recommended system pump flow. Knowing theflow rate, the pressure drop through the boiler can be found in Figure 8.

System Operating Parameters

To prevent water flashing to steam within the boiler or system, hot water boilersmust operate with proper over-pressure. System over-pressure requirements areshown in Table 9.

Note: The ASME Code Section IV limits the maximum setting of the excess temperature control to 250 F (121 C) for boilers constructed with duplex stainless steel. This is to ensure that water temperature will not reach the boiling point (steaming) and therefore, so as not to exceed the maximum limit of this control and in compliance with the Code, the operating limit of 230 F (110 C) is set for normal boiler operation.

While proper overpressure is required, a means to relieve excess pressure at orbeyond the design pressure of the boiler must be provided. As boiler water isheated, expansion occurs. And this expansion must be accounted for either with anexpansion tank (air filled) or with a bladder type tank. These devices permit thewater pressure to expand outside of the boiler and not impact the pressure vessel orpressure relieving device. But, in accordance with Code, each boiler is equippedwith an ASME approved safety relieving device should pressure build-up occur (SeeTable 11 and Table 10).

Air Venting The elimination of entrained air is required. It is recommended that each unit bepiped to an expansion tank. If this is not possible, then an auto air vent should beprovided on the vent connection of the boiler. The caveat in using an auto vent isthat free oxygen can be introduced to the vessel as the boiler cools, or in someinstances the vent can become plugged.

The hydronic system, in addition to individual boilers, should be provided with amechanism for the elimination of air.

Hot Water Piping The CFLC can be used in primary flow or primary-secondary arrangements. Thelarge water volume firetube design makes the CFLC a low-flow tolerant boiler.Variable speed or on/off pumps may be employed in the piping scheme.

Example schematic diagrams of typical hydronic piping systems can be found on theCleaver-Brooks web site.

Table 7. CFLC Flow Rates*System Temperature Drop Deg F

Boiler Size

10 20 40 60 80 100

Flow Rate GPM

4000 752 376 188 125 94 75

5000 940 470 235 157 117 94

6000 1128 564 282 188 141 113

8000 1504 752 376 251 188 150

10000 1880 940 470 313 235 188

12000 2255 1128 564 376 282 226

Recommended Flow Rates relative to temperature drop so as not to exceedboiler output capacity

Table 8. CFLC Flow Rates* (Metric)System Temperature Drop Deg C

Boiler Size

6 11 22 33 44 56

Flow Rate m3/hr

4000 171 85 43 28 21 17

5000 213 107 53 36 27 21

6000 256 128 64 43 32 26

8000 341 171 85 57 43 34

10000 427 213 107 71 53 43

12000 512 256 128 85 64 51

Recommended Flow Rates relative to temperature drop so as not to exceed boiler output capacity

*Flow rates based on 94% nominal efficiency

16


Figure 8. Hydraulic Resistance CFLC

CFLC 4000 CFLC 5000

CFLC 6000 CFLC 8000

CFLC 10000 CFLC 12000

Pres

sure

PSI

Pres

sure

PSI

Pres

sure

PSI

Pres

sure

PSI

Pres

sure

PSI

Pres

sure

PSI

Flow rate GPM Flow rate GPM



17


Table 9. Model CFLC Minimum Over Pressure Requirements

Table 10. Model CFLC Boiler Safety Valve Information

Outlet Water Temperature Minimum System Pressure

(°F) (°C) PSIG Bar

80-180 27-82 12 0.83

181-185 83-85 15 1.03

186-205 86-96 18 1.24

206-215 97-101 24 1.66

216-225 102-107 30 2.07

226-240 108-116 42 2.90

Boiler SizeConnection

@ BoilerValve Set @ 160 psig Total Relief

Capacity (MBH)Number of Valves Outlet Size

4,000 (1) @ 2" 1 1-1/4" 6,587

5,000 (1) @ 2" 1 1-1/4" 6,587

6,000 (2) @ 2" 1 1-1/4" 6,587

8,000 (2) @ 2" 2 1" 8,430

10,000 (2) @ 2" 1 1" 10,802

1 1-1/4"

12,000 (2) @ 2" 1 2" 13,974




4,000 (1) @ 2" 1 1-1/4" 5,258

5,000 (1) @ 2" 1 1-1/4" 5,258

6,000 (2) @ 2" 2 1" 6,728

8,000 (2) @ 2" 1 1" 8,622

1 1-1/4"

10,000 (2) @ 2" 1 2" 11,152

12,000 (2) @ 2" 1 2-1/2" 19,830




4,000 (1) @ 2" 1 2" 5,919

5,000 (1) @ 2" 1 2" 5,919

6,000 (2) @ 2" 1 2-1/2" 10,515

8,000 (2) @ 2" 1 2-1/2" 10,515

10,000 (2) @ 2" 1 2-1/2" 10,515

12,000 (2) @ 2" 1 2-1/2" 13,304

1 1-1/4"




4,000 (1) @ 2" 1 2-1/2" 6,215

5,000 (1) @ 2" 1 2-1/2" 6,215

6,000 (2) @ 2" 1 2-1/2" 6,215

8,000 (2) @ 2" 1 2" 9,712

1 2-1/2"

10,000 (2) @ 2" 2 2-1/2" 12,250

12,000 (2) @ 2" 2 2-1/2" 12,250

18


Water Treatment Even though hot water systems are "closed", some amount of make-up water (up to10%) will be introduced. This more often than not happens from seal leaks ofpumps, or other minimal leaks from valves etc., that go unnoticed. Therefore,proper water chemistry of a hot water boiler is necessary for good operation andlongevity, particularly to ensure that free oxygen is removed to prevent watersidecorrosion (see Table 11).

Table 11. Model CFLC Water Chemistry Requirements in accordance with ABMA

Glycol The Model CFLC boiler may be operated with a solution of glycol and water. Whereglycols are added, the system must first be cleaned and flushed. Correct glycolselection and regular monitoring of the in-use concentration and its stability isessential to ensure adequate, long-term freeze protection, as well as protectionfrom the effects of glycol-derived corrosion resulting from glycol degradation.

Typically, ethylene glycol is used for freeze protection, but other alternatives exist,such as propylene glycol. Glycol reduces the water-side heat capacity (lowerspecific heat than 100% water) and can reduce the effective heat transfer to thesystem. Because of this, design flow rates and pump selections should be sizedwith this in mind.

Generally, corrosion inhibitors are added to glycol systems. However, all glycolstend to oxidize over time in the presence of oxygen, and when heated, formaldehydes, acids, and other oxidation products. Whenever inadequate levels ofwater treatment buffers and corrosion inhibitors are used, the resulting water glycolmixture pH may be reduced to below 7.0 (frequently reaching 5) and acid corrosionresults. Thus, when pH levels drop below 7.0 due to glycol degradation the onlyalternative is to drain, flush, repassivate, and refill with a new inhibited glycolsolution.

The following recommendations should be adhered to in applying ClearFire modelCFLC boilers to hydronic systems using glycol:

1) Maximum allowable antifreeze proportion (volume%): 50% antifreeze (glycol)50% water

2) Glycol minimum temperature rating 300 deg F (149 deg C).3) Maximum allowable boiler outlet/supply temperature: 200 deg F (93 deg C).

Parameter Limit

Glycol 50%

pH 8.3 - 9.5

Nitrates 50 ppm

Sulphates 50 ppm

Chloride 30 ppm

Oxygen 0.1 ppm

Specific Conductivity 3500 mmho/cm

Total Hardness <10 ppm

19


4) Minimum water circulation through the boiler:a) The minimum water circulation must be defined in such a way that the

temperature difference between the boiler outlet/supply and inlet/return is amaximum of 40 deg F (22 deg C), defined as DT (Delta T). A DT Limit

algorithm should be enabled in the boiler controller.b) Independent from the hydraulics of the heating system, constant water

circulation through each boiler is required. (Requires a dedicated boilerpump if in a primary/secondary loop arrangement.) Refer to table below forminimum boiler circulation rates.

6) Minimum over-pressure at the boiler:

For outlet temperatures up to the maximum of 200 deg F (93 deg C), a minimumoperating pressure of 30 psig (2.1 bar) is required.

7) pH level should be maintained between 8.3 and 9.5

Table 12. Glycol Application Guidelines - Model CFLC

Condensation As the Model CFLC boiler is a full condensing boiler, condensation will developduring startup of a cold boiler or at any time when the return water temperature isbelow the dew point or approximately 132 F (55.5 C).

The condensation collects in the flue gas collection chamber from the tube surfacesand from the stack. As prescribed by local codes, this condensate may bedischarged directly to the drain or treated using an optional treatment assembly.Figure 9 depicts piping without the treatment assembly and Figure 10 shows theoptional treatment assembly. Table 13 shows the amount of condensation that willform when the boiler operates in full condensing mode.

Minimum required boiler circulation rate (gpm) at maximum firing rate.

ClearFireModel-Size

System ∆T (˚F)

∆T = 10˚ ∆T = 20˚ ∆T = 30˚ ∆T = 40˚

CFLC-4000 813 407 271 203

CFLC-5000 1016 508 339 254

CFLC-6000 1220 610 374 281

CFLC-8000 1626 813 499 368

CFLC-10000 2033 1016 624 468

CFLC-12000 2439 1220 749 562

Notes/Limitations:

1. Glycol concentration limit of 25%-50%. Minimum required system operating pressure is 30 psig.

2. Maximum system operating temperature of 200 ˚F. Maximum ∆T of 40˚.

3. Circulation rates correlate with boiler output based on 92% nominal efficiency.

4. Standard altitude (<2000' ASL). Contact C-B for high altitude applications.

5. Pumps should be sized based on system design ∆T and minimum required flow rates.

6. At minimum firing rate, the minimum circulation rate should correspond to the boiler's turndown.

20


Table 13. Model CFLC Maximum Condensation

Figure 9. Condensate Piping Direct To Drain

Condensate Piping

The number of condensate treatment tanks required depends on the total amountof condensate produced by the system. As a general rule, CB recommends one tankper boiler (sizes 4,000 - 8,000) and two tanks (sizes 10,000 - 12,000).See Figure 10 for suggested piping.

NoticeIf a treatment kit is utilized, clearance must be provided for servicing the assembly and for periodically adding the neutralizing granules.

Boiler Size Gallons per Hour Liters per Hour

4000 27 102.2

5000 34 128.7

6000 41 155.2

8000 54 204.4

10000 68 257.4

12000 82 310.4

*Boiler operating @ maximum in full condensing mode

*Based on 68°F (20°C) return water temperature

* pH of 4.0 - 5.5

COLD WATER RETURN

CONDENSATE DRAIN

DRAIN

WARM WATER RETURN

BOILER REAR

A CONDENSATE TRAPIS PIPED WITHIN THEBOILER.

21


Figure 10. Condensate Piping

Gas Fuel Connections

The local Gas Company should be consulted for the requirements for installationand inspection of gas supply piping. Installation of gas supply piping and ventingmust be in accordance with all applicable engineering guidelines and regulatorycodes. All connections made to the boiler must be arranged so that all componentsare accessible for inspection, cleaning, and maintenance.

A drip leg should be installed in the supply line before the connection to the boiler.The drip leg should be at least as large as the gas piping connection on the boiler.See Figure 11 and Figure 12 for piping suggestions.

4000-8000 10000-12000

22


Figure 11. Gas Piping Schematic

Consideration of volume and pressure requirements must be given when selectinggas supply piping.

Connections to the burner gas train must include a union so that the burner may beopened for inspection and maintenance.

A. Gas supply connection is at top of the boiler.B. Table 14 shows the gas pressure required at the inlet of the gas line.C. Table 15 shows the correction factors for gas pressure at elevations at 2000

feet and higher above sea level.

23


Figure 12. Gas Header Piping

24


Table 14. Model CFLC Minimum and Maximum Gas Pressure

Table 15. Model CFLC Minimum Required Gas Pressure Altitude Correction

Table 16. Altitude Correction for Input Capacity at Various Altitude Levels

Ratings assume 35% excess air, 80°F combustion airBlower speed adjustments should be made to match performance and local conditions accordingly.For minimum gas pressure requirements, corrections for altitude should be made per Boiler Book Table 16.Natural gas heating value of 1000 BTU/SCF assumed.

Boiler Model Minimum pressure required at gas train connection

Maximum Pressure***

4000 14 "WC 1.2 PSI

5000 14 "WC 1.2 PSI

6000 28 "WC 2 PSI

8000 28 "WC 2 PSI

10000 31 'WC 2 PSI

12000 31 "WC 2 PSI

*** Higher gas pressure will require an upstream regulator

Altitude in Feet Correction Factor Altitude in Feet Correction Factor

1000 1.04 6000 1.25

2000 1.07 7000 1.3

3000 1.11 8000 1.35

4000 1.16 9000 1.4

5000 1.21

To obtain minimum required inlet pressure, select altitude of installation and multiply the pressureshown in Table 15 by the correction factor corresponding to the altitude listed above.

Natural Gas

700' ASL 2000’ 4000’ 6000’ 8000’ 10000’

CFLC 4000 4000 MBTU/hr 4000 3800 3610 3430 3258

CFLC 5000 5000 5000 4750 4513 4287 4073

CFLC 6000 6000 6000 5700 5415 5144 4887

CFLC 8000 8000 8000 7600 7220 6859 6516

CFLC 10000 10000 10000 9500 9025 8574 8145

CFLC 12000 12000 12000 11400 10830 10289 9774

25


Boiler Room Information

The boiler must be installed on a level non-combustible surface. If the surface is notlevel, piers or a raised pad, slightly larger than the length and width of the boilerbase dimensions, will make boiler leveling possible. Installing the boiler on a raisedpad or piers will make boiler drain connections more accessible and will keep waterfrom splashing onto the boiler whenever the boiler room floor is washed.

Note: The pad or piers must be of sufficient load bearing strength to safely support the operating weight of the boiler and any additional equipment installed with it. Approximate operating weights are shown in Dimensions and Ratings.

Leveling Once the boiler is placed, it must be leveled side to side and front to back using thesupply and return nozzles for horizontal and vertical positions. If shims are requiredto level the boiler, the weight of the boiler must be evenly distributed at all points ofsupport.

Clearances The boiler must be installed so that all components remain accessible. Clearanceheight above all CFLC boilers is 36”.

Figure 13. Model CFLC Minimum Room Clearance Dimensions

26


Boiler Room Combustion and Ventilation Air

The boiler(s) must be supplied with adequate quantities of uncontaminated air tosupport proper combustion and equipment ventilation. Air shall be free of chlorides,halogens, fluorocarbons, construction dust or other contaminants that aredetrimental to the burner/boiler. If these contaminants are present, we recommendthe use of direct vent combustion provided the outside air source isuncontaminated.

Combustion air can be supplied by means of conventional venting, wherecombustion air is drawn from the area immediately surrounding the boiler (boilerroom must be positive pressure), or with direct vent (direct vent combustion) whereair is drawn directly from the outside. All installations must comply with local Codesand with NFPA 54 (the National Fuel Gas Code - NFGC) for the U.S. and forCanada, CAN/CGA B 149.1 and B 149.2.

Note: A boiler room exhaust fan is not recommended as this type of device can cause a negative pressure in the boiler room if using a conventional air intake.

In accordance with NFPA54, the required volume of indoor air shall be determinedin accordance with the “Standard Method” or “Known Air Infiltration Rate Method”.Where the air infiltration rate is known to be less than 0.40 Air Changes per Hour,the Known Air Infiltration Rate Method shall be used. (See Section 8.3 in theNFPA54 Handbook for additional information.)

Combustion Air Supply - Unconfined Spaces (For U.S. Installations Only)

A. All Air From Inside the Building - If additional combustion air is drawn frominside the building (the mechanical equipment room does not receive airfrom outside via louvers or vent openings and the boiler is not equipped withdirect vent combustion) and the boiler is located in a unconfined space, usethe following guidelines:

1. The mechanical equipment room must be provided with two permanent openings linked directly with additional room (s) of sufficient volume so that the combined volume of all spaces meet the criteria for an unconfined space. Note: An “unconfined space” is defined as a space whose volume is more than 50 cubic feet per 1,000 Btu per hour of aggregate input rating of all appliances installed in that space.

2. Each opening must have a minimum free area of one square inch per 1,000 Btu per hour of the total input rating of all gas utilizing equipment in the mechanical room.

3. One opening must terminate within twelve inches of the top, and one opening must terminate within twelve inches of the bottom of the room.

4. Refer to the NFGC, Section 8.3 for additional information.

27


Figure 25. Two Opening Outside Wall Method

B. All Air From Outdoors - If all combustion air will be received from outside the building (the mechanicalroom equipment is linked with the outdoors), the following methods can be used:

1. Two Opening Method (Figure 25) - The mechanical equipment room must be provided with two permanent openings, one terminating within twelve inches from the top, and one opening terminating within twelve inches of the bottom of the room.

2. The openings must be linked directly or by ducts with the outdoors.3. Each opening must have a minimum free area of one square inch per

4,000 Btu per hour of total input rating of all equipment in the room, when the opening is directly linked to the outdoors or through vertical ducts.

4. The minimum free area required for horizontal ducts is one square inch per 2,000 Btu per hour of total input rating of all the equipment in the room.

GASVENT

WATERHEATER

GASVENT

INTERIOR WALL

FRESH AIR OPENING

FRESH AIR OPENING

12" MINIMUM

12" MINIMUM

CLEARFIREBOILER

28


Figure 26. Two Opening Ducted Method

C. One Opening Method (Figure 27) - One permanent opening, commencingwithin 12 inches of the top of the enclosure, shall be provided. 1. The equipment shall have clearances of at least 1 inch from the sides and

back and 6 inches from the front of the appliance.2. The opening shall directly communicate with the outdoors and shall have

a minimum free area of 1 square inch per 3000 BTU's per hour of the total input rating of all equipment located in the enclosure, and not less than the sum of the areas of all vent connectors in the confined space.

3. Refer to the NFGC, Section 8.3 for additional information.

GASVENT

CLEARFIREBOILER

WATERHEATER

GASVENT

EXTERIOR WALL

INTERIOR WALL

FRESH AIRINLET DUCT

OUTLET AIR DUCT

12" MINIMUM

12" MINIMUM

29


Figure 27. One Opening Method

Unconfined Space/Engineered Design

When determining boiler room air requirements for unconfined space, the size of theroom, airflow, and velocity of air must be reviewed as follows:

1. Size (area) and location of air supply openings in the boiler room.A. Two permanent air supply openings in the outer walls of the boiler room are

recommended. Locate one at each end of the boiler room, preferably belowa height of 7 feet. This allows air to sweep the length of the boiler. SeeFigure 28.

B. Air supply openings can be louvered for weather protection, but they shouldnot be covered with fine mesh wire, as this type of covering has poor air flowqualities and is subject to clogging with dirt and dust.

C. A vent fan in the boiler room is not recommended, as it could create a slightvacuum under certain conditions and cause variations in the quantity ofcombustion air. This can result in unsafe burner performance.

D. Under no condition should the total area of the air supply openings be lessthan one square foot.

GASVENT

WATERHEATER

GASVENT

EXTERIOR WALL

FRESH AIR OPENING

12" MINIMUM

30


Figure 28. Two Opening Engineered Method

E. Size the openings by using the formula:

Area in square feet = cfm/fpm

Where cfm = cubic feet per minute of air

Where fpm = feet per minute of air

2. Amount of Air Required (cfm).A. Combustion Air = 0.25 cfm per kBtuh.B. Ventilation Air = 0.05 cfm per kBtuh. C. Total air = 0.3 cfm per kBtuh (up to 1000 feet elevation. Add 3% more per

1000 feet of added elevation).3. Acceptable air velocity in the Boiler Room (fpm).

A. From floor to 7 feet high = 250 fpm.B. Above 7 feet above floor = 500 fpm.

Example: Determine the area of the boiler room air supply openings for (2) CFLC4000 boilers at 750 feet elevation. The air openings to be 5 feet above floor level.

• Air required: 4000 x 2 = 8000 kBtuh. From 2C above, 8000 x 0.3 = 2,400 cfm.

• Air Velocity: Up to 7 feet = 250 fpm from 3 above.

• Area required: Area = cfm/fpm = 2,400/250 = 9.6 square feet total.

• Area/Opening: 9.6/2 = 4.8 sq-ft/opening (2 required).

GASVENT

WATERHEATER

GASVENT

EXTERIOR WALL

FRESH AIR OPENING

EXTERIOR WALL

FRESH AIR OPENING

31


NoticeConsult local codes, which may supersede these requirements.

Direct Vent Combustion

If combustion air will be drawn directly from the outside by means of a ductconnected to the burner air intake, use the following as a guide:

1. Install combustion air vent (direct vent combustion) in accordance with the boiler's Operating and Maintenance manual.

2. Provide for adequate ventilation of the boiler room or mechanical equipment room.

3. In cold climates, and to mitigate potential freeze-up of the intake pipe, it is highly recommended that a motorized sealed damper be used to prevent the circulation of cold air through the boiler during non-operating hours.

STACK/BREECHING SIZE CRITERIA

General Boilers are divided into four categories based on the pressure and temperatureproduced in the exhaust stack and the likelihood of condensate production in thevent.

• Category I. 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.

• Category II. 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 III. A boiler which operates with a positive vent pressure and with a vent gas temperature that avoids excessive condensate production in the vent.

• 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.

Depending on the application, the Model CFLC may be considered Category II, III,or IV. The specifying engineer should dictate flue venting as appropriate to theinstallation.In some cases, PVC/CPVC material meeting ULC Type BH Class IIB specificationsmay be used. Use of PVC/CPVC depends on operating conditions, specific ventsuppliers, and any local codes having jurisdiction. Refer to vent manufacturer’sspecifications for applicability.

Proper installation of flue gas exhaust venting is critical to efficient and safeoperation of the Clearfire Boiler. The vent should be supported to maintain properclearances from combustible materials. Use insulated vent pipe spacers where thevent passes through combustible roofs and walls.

The design of the stack and breeching must provide the required draft at each boilerflue gas connection; proper draft is critical to burner performance.

Although constant pressure at the flue gas outlet is not required, it is necessary tosize the breeching and stack to limit flue gas pressure variation. Consideration of thedraft must be given whenever direct vent combustion is utilized and lengthy runs ofbreeching are employed. Please note: The system should be designed for a pressurerange of minus 1/10” to plus 1/10” W.C. for proper combustion and light offs.

Whenever two or more boilers are connected to a common breeching/stack, a draftcontrol system may be required to ensure proper draft.

32


Vent Termination To avoid the possibility of property damage or personal injury, special attention tothe location of the vent termination must be considered.

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.

2. Prevailing winds could cause freezing of Condensate and water/ice buildup on building, plants, or roof.

3. The bottom of the vent termination and the air intake shall be located at least 12 inches above grade, including the normal snow line.

4. Non-insulated single-wall metal vent pipe shall not be used outside in cold climates for venting combustion gases.

5. Through the wall vents for Category II and Category IV 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.

6. To prevent accidental contact by people or pets, the vent termination shall be guarded.

7. DO NOT terminate vent in window well, alcove, stairwell or other recessed area, unless approved by local authority.

8. DO NOT terminate above any door, window, or gravity air intake as Condensate can freeze causing ice formation.

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. Multiple direct stack installations require four feet clearance between the stack caps, center to center.

U.S. Installations Refer to the latest edition of the National Fuel Gas Code/NFPA 54. Vent termination requirements are:

1. Vent must terminate at least four feet below and four feet horizontally or one foot above any door, window or gravity air inlet to the building.

2. The vent must be at least seven feet above grade when located adjacent to public walkways.

3. Terminate vent at least three feet above any forced air inlet located within ten feet.

4. Vent must terminate at least four feet horizontally, and in no case above or below unless four feet horizontal distance is maintained, from electric meters, gas meters, regulators, and relief equipment.

5. Terminate vent at least six feet from adjacent walls.6. DO NOT terminate vent closer than five feet below roof overhang.

Canadian Installations

Refer to the latest edition of CAN/CSA-B149.1 and B149.2. 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 feet (2.31m) above a paved sidewalk or paved driveway located on public property.

33


3. Within 6 feet (1.8m) of a mechanical air supply inlet to any building.4. Above a meter/regulator assembly with 3 feet (900mm) horizontally of the

vertical centerline of the regulator.5. Within 6 feet (1.8m) of any gas service regulator vent outlet.6. Less than 1 foot (300mm) above grade level.7. Within 3 feet (1m) of a window or door which can be opened in any building,

any non-mechanical air supply inlet to any building or 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 one foot (300mm).

34


Vertical Venting Inside Combustion Air

Figure 29. Inside Air - Vertical Vent

As noted in Paragraph A above, these installations use air from within the boilerroom for combustion. The same recommendations apply as noted in Paragraph Aabove as well as the recommendations on flue vent sizing in Table 17.

Flue Gas Vent

24"Minimum

10'-0" or Less

48"Minimum

Termination

35


Vertical Venting -Direct Vent Combustion

Figure 30. Vertical Stack with Direct Vent Combustion Air

As noted in Paragraph B above, these installations use air from outside the buildingfor combustion. The same recommendations apply as noted in B and also, therecommendations on flue vent sizing according to Table 18.

ELECTRICAL Voltage requirements for the Fan Motor are 208/230/460. Control Circuit voltage is120/1/60 for all boiler sizes. A transformer is provide. Refer to Table 3 “Ratings” forampacity requirements.

Vent Termination

Air Intake (w/Screen)

48" Minimum

48" Minimum

12" Minimumabove roofor snow line

Vent Termination

Air Intake (w/Screen)

48" Minimum

12" Minimumabove parapetor snow line

36" Minimumabove intak

24" Minimum

With parapet wall

36


FALCON CONTROLLER1. Control Description - The Falcon hydronic control is an integrated burner

management and modulation control with a touch-screen display/operator interface.

2. Functionality - The controller is capable of the following functions:• Flame supervision• Burner sequencing• Heating/modulation control• Hot water system pump control• High Limit temperature control• Thermowell-mounted NTC temperature sensors to provide measured process variable

signals to the controller.• User-friendly touchscreen interface• Modbus communication capability• Alarm/lockout messaging with history (last 15 messages)• Annunciation• Outdoor reset• Central Heating and Domestic Hot Water loop control• Password protection of configurable parameters• High Stack Temperature limit• Remote reset• Lead/Lag sequencing• (3) configurable pump relays• Remote modulation/remote setpoint• Frost protection

• Time of Day (dual setpoint) control• Three levels of access to control configuration:

•End-user•Installer/Service Engineer (password protected)•OEM Manufacturer (password protected)

Table 17. Operating Conditions - Controller

Temperature RangeOperating -4 F to 150 F (-20 C to 66 C)

Storage -40 F to 150 F (-40 C to 66 C)

Humidity 85% max. relative humidity, non-condensing

Table 18. Operating Conditions - Display/Interface

Temperature RangeOperating 32 F to 122 F (0 C to 50 C)


Humidity 85% max. relative humidity

Table 19. Operating Conditions - VFD

Temperature RangeOperating 14 F to 122 F (-10 C to 50 C)


Humidity 95% max. relative humidity, non-condensing

37


3. Main Voltage Connection - 208/230/460V, 3phase, 60Hz4. Local/Remote demand switch5. Combustion Air Proving Switch - This input is used for proving airflow sufficient

for proper combustion throughout the burner run sequence.6. High Air Pressure Switch - prevents boiler operation in the event of high stack

back pressure (blocked flue or condensate drain).7. Gas Pressure Switch - Gas pressure switches for low gas pressure and high gas

pressure prevent the burner from being activated if either is open. Each switch is a physical manual reset device, requiring physical depression of the reset button if either switch is not closed prior to burner start or during burner operation.

8. NTC (Negative Temperature Coefficient) Thermistor Inputs (10k @ 25 oC)A.Flow Temperature (Outlet water temperature)B.Return Temperature (Inlet water temperature)C.Optional Domestic Water TemperatureD.Optional Outdoor TemperatureE.Optional Stack TemperatureF.Optional Header Temperature

9. System Configuration - Falcon configuration is arranged into the following functional groups:

Table 20. Falcon control sequence (Central Heat)

1. Heat request detected (CH demand)

2. Boiler pump enabled or isolation valve opened

3. Safe Start Check, dynamic ILK input test (if enabled), blower switched on

4. If ILK input and CAPS switch closed and high fire switch is made, begin 30 sec-ond prepurge

5. When purge complete, blower to lightoff speed; low fire switch closes

6. Pilot Trial for Ignition - 10 seconds; pilot gas valve energized for 10 sec., ignition transformer for 5 sec.

7. Main Trial for Ignition - 5 seconds

8. Main gas valve(s) switched on

9. Pilot turned off at the end of MTFI period; 10 sec. stabilization time

10. Release to modulation (Run)

11. At the end of CH heat demand, burner fuel valve(s) close and blower stays on for 15 sec. post purge period. Boiler enters standby mode.

•System Identification & Access •CH - Central Heat Configuration•Outdoor Reset Configuration •DHW - Domestic Hot Water Configuration•Modulation Configuration •Pump Configuration•Statistics Configuration •High Limits•Stack Limit •Other Limits•Anti-condensation Configuration •Frost Protection Configuration•Annunciation Configuration •Burner Control Interlocks•Burner Control Timings & Rates •Burner Control Ignition•Burner Control Flame Failure •System Configuration•Fan Configuration •Lead Lag Configuration

38


10. Falcon Access - There are three levels of access to the Falcon controller:

• End User Level - read or view parameters; change setpoints. No password required.

• Installer/Service Level - read all parameters; enables changing of most parameters. This access level is used to configure the Falcon for a particular installation, and is password-protected.

• OEM Level - read/change all parameters; for factory configuration of boiler-specific parameters. Password-protected and restricted to CB or factory authorized service personnel.

For additional information regarding service and setup of the burner controller, referto CFLC manual 750-363 or to the Falcon manual 750-265.

Figure 31. Falcon pinout

3

1

4

2

FLAMESTRENGTH

LOCALMODBUSA B C

GLOBALMODBUSA B C

POWER

FLAME

ALARM

RESET

PIM

1

2

3

4

5

6

HYDRONICCONTROL

J1 J2

J3ECOMD R C

L1

L2 FOR 120VAC OR 24VAC RETURN (OPTOS)

EGND

BLOWER/HSI

EX. IGNITION

ALARM

MAIN VALVEPILOT VALVE

ANNUN 1/IASANNUN 2

ANNUN 3ANNUN 4ANNUN 5ANNUN 6

PRE IGN INTLK

INTERLOCK

P

P

P

LCI

PUMP A

{{

{

{

PUMP B

PUMP C

ANNUN 7 HFSANNUN 8 LFS

24 VAC24 VAC RTN

INLET TEMPINLET TEMP RTN

4-20 mA REMOTE SOURCE

OUTLET TEMP AOUTLET TEMP RTN

OUTLET TEMP BOUTDOOR TEMP

OUTDOOR TEMP RTNOR HEADER TEMP

DHW TEMP ADHW TEMP RTN

DHW TEMP BSTACK TEMP A

STACK TEMP RTNSTACK TEMP B

TODREMOTE RESET

0 - 10 VDC MA /VDC RTN

4 TO 20 MAV

I

BUILDINGAUTOMATION

SYSTEM

System Display

LEAD LAG MODBUSLOCALMODBUS

++–

UVBLUE

WHITE

STAT

FALCON HYDRONIC CONTROLPLUG CONNECTORS

J4

J5

J6

J7

J8

J9

J10

121110 9 8 7 6 5 4 3 2 1

7654321

87654321

7654321

123456789

101112

1234567

12345678

+_

MODBUS GATEWAY

MOD.OUTPUT

39


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