Model CFV ClearFire Commercial Boilers

CLEARFIRE - MODEL CFV

9.5 - 60 HP
Steam Vertical Boiler

CONTENTS
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-3
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-6
DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-13
PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-18
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-20
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-36

LIST OF FIGURES

Tube Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-3

AluFer© Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-3
Premix Burner Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-4
Burner maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-4
CFV connections and controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-5
CB Falcon Display/Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-9
CB Falcon pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-10
CFV Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-11
Gas Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-12
CFV electrical panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-12

B7-1
Model CFV ClearFire Commercial Boilers

Model CFV Steam Boiler Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-14

Inside Air - Two Opening Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-23
Two Opening Ducted Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-24
One Opening Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-24
Engineered Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-25
Direct Vent Combustion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-27
Direct Vent Combustion kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-27
Typical gas header piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-30
Example gas piping <1 psig supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-30

LIST OF TABLES

Operating Conditions - CB Falcon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-7

CB Falcon burner sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-8
Model CFV Steam Boiler Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-15
Model CFV Steam Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-16
Model CFV Recommended Steam Nozzle Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-16
Model CFV Gas Pressure Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-16
Model CFV Steam Boiler Safety Valve Outlet Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-17
Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-17
Predicted Fuel-to-Steam Efficiencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-18
Radiation and Convection Losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-19
Model CFV Boilers: Natural Gas, Estimated Emission Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-20
Predicted sound levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-20
Feedwater flow rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-21
Model CFV Water Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-21
Model CFV Blowdown Tank Sizing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-22
Gas line capacity - Schedule 40 metallic pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-31
Pipe sizing for multiple unit manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7-35

B7-2 Rev 3 15
Model CFV ClearFire Commercial Boilers

FEATURES AND BENEFITS

General The ClearFire Model CFV is a single pass, vertical down-fired durable firetube steam boiler.
Extended heating surface tubes provide a very high level of performance in a compact
package. An integral premix burner is provided for natural gas operation. As standard, the
Model CFV burner provides low emissions of <20 PPM NOx. Propane fuel is also available.

Advanced Technology Heat is transferred through 3” OD carbon steel tubes with patented AluFer© extended heating
surfaces. The AluFer© tube design provides for optimum heat transfer and eliminates laminar
gas flow during minimum firing, providing optimized efficiency throughout the firing range
(see Figure B7-1 and Figure B7-2).

Figure B7-2. Tube Cross Section

Figure B7-1. AluFer© Tubes

High Efficiency With the AluFer© extended heating surface tubes, the Model CFV steam boiler will provide
fuel-to-steam efficiency of up to 81% operating at 125 psig (up to 87% with optional
economizer).

Quality Construction ISO 9001-2001 certification ensures the highest manufacturing standards.
ASME code construction ensures high quality design, safety, and reliability. Units are third-
party inspected and are stamped to assure compliance.

Certification Each unit is tested and certified in accordance with UL/cUL standards and the UL/cUL label is
affixed attesting to equipment meeting the latest UL requirements for packaged steam boilers.

Premix Technology The ClearFire CFV burner utilizes Premix technology to mix both gas fuel and combustion air
prior to entering the burner canister, with fuel flow governed by the air flow during firing
transitions. Combined with a variable speed fan, this technology provides very low emission
levels, exceptionally safe operation, and nearly 100% combustion efficiency. An inlet air filter
is provided as standard to prevent airborne dust from entering the combustion canister.

Full Modulation The variable speed fan modulates to provide only the amount of heat required to the boiler.
Full modulation reduces on/off cycling and provides excellent load tracking with reduced
operating costs. The burner does not require mechanical linkage connections between the fuel
input valve and air control. Instead, the microprocessor control adjusts the fan speed in
accordance with system demand, determining fuel input without mechanical device

B7-3
Model CFV ClearFire Commercial Boilers

positioning. This method of controlling the fuel-air ratio eliminates slippage due to linkages,
minimizes burner maintenance, and provides control repeatability. See Figure B7-3.

Figure B7-3. Premix Burner Technology

Ease of Maintenance The blower is easily removed to allow inspection or service of the burner canister, tubes, and
tube sheets (see Figure B7-4). A union connection provides easy disconnect from the fuel
train. All burner components are easily accessed for inspection and maintenance.

Figure B7-4. Burner maintenance

B7-4
Model CFV ClearFire Commercial Boilers

Designed for commercial The CFV packaged boiler is designed for 150 psig MAWP (Maximum Allowable Working
steam applications Pressure) and is constructed of durable ASTM grade steel materials. Figure B7-5 shows the
component and connection locations.

Figure B7-5. CFV connections and controls

B7-5
Model CFV ClearFire Commercial Boilers

PRODUCT OFFERING
Information in this section applies to steam boiler sizes ranging from 9.5 horsepower
through 60 horsepower for operation on natural gas or LP gas only. Fuel oil operation
is not available for the model CFV. Standard installation is for indoor use with an
optional engineering design for outdoor applications.
The complete package has been tested and certified in accordance with UL/cUL.
Package is approved and listed and bears the appropriate UL/cUL package boiler
label.
Dimensions, ratings, and product information may change due to market
requirements or product enhancements. The information contained herein is a guide
for general purposes only.

Standard Equipment The equipment listed below applies to the standard boiler package offering. Optional
items are available to meet specific projects when required.

1. The Boiler
A.Each boiler (pressure vessel) size is designed and built for a Maximum Allowable
Working Pressure (MAWP) of 150 psig in accordance with ASME Section I
(bearing the “S” stamp).
B.The vessel is insulated with a 2” thick blanket and mounted on a base frame. A
304 stainless steel casing covers the insulation.
C.Vessel connections are furnished for:
Steam outlet
Bottom drain or blowoff
Surface blowoff
Chemical feed
Feedwater makeup
High water level overflow
D.For waterside inspection, handholes are provided.
E. The combustion exhaust is located at the top rear.

2. Boiler trim and controls

• Water column with primary low water cutoff and pump control (probe type).
• Water column gauge glass and gauge glass drain valve.
• Water column drain valve.
• Auxiliary low water cutoff (probe type), manual reset.
• Operating limit pressure control, auto reset.
• Excess steam pressure control, manual reset.
• Pressure transmitter for burner on/off and modulation.
• Steam pressure gauge.
• ASME safety relief valve.

B7-6
Model CFV ClearFire Commercial Boilers

3. CB Falcon Control System

A.Control Description - The Falcon control is an integrated burner management
and modulation control with a touch-screen display/operator interface.
B.Functionality - The controller incorporates the following functions:
• PID load control.
• Burner sequencing with safe start check, pre-purge, direct spark ignition, and
post purge.
• Electronic ignition.
• Flame Supervision.
• Safety shutdown with time-stamped display of lockout condition - last 15
lockouts stored in memory.
• Variable speed control of the combustion air fan.
• Supervision of low and high gas pressure, air proving, stack back pressure,
and low water.
• Alarm output
• Remote enable & remote modulation or set point.
• First-out annunciator.
• Diagnostics.
• Real-time data trending (w/System Display).
• (3) pump/auxiliary relay outputs.
• Modbus communication.
• Outdoor temperature reset.
• Anti-short-cycling mode
• Time-of-day (night setback) operation
• Three levels of access to control configuration:
•End-user
•Installer/Service Engineer (password protected)
•OEM Manufacturer (password protected)
• Lead Lag for up to 8 boilers with optional kit

Table B7-1. Operating Conditions - Falcon

Operating 32 F to 122 F (0 C to 50 C)
Temperature Range
Storage -40 F to 140 F (-40 C to 60 C)
Humidity 85% max. relative humidity

B7-7
Model CFV ClearFire Commercial Boilers

Table B7-2. Falcon burner sequence

1. Heat request detected (Setpoint minus On Hysteresis); LCI limits and steam
demand detected (terminals J6 3 and J8 3).
2. The CH pump is switched on (relay contact closes).
3. After a system Safe Start Check, the Blower (combustion air fan) is started
4. After the ILK input is energized - 10 sec. allowed for IAS input (combustion air
proving) to energize - and the purge rate proving fan RPM is achieved, prepurge
time is started.
5. When 30 sec. purge time is complete, the fan RPM is changed to the lightoff
speed.
6. Trial for Ignition (4 sec).
7. The ignitor and the gas valve are energized.
8. The ignitor is turned off at the end of the direct burner ignition period.
9. The fan is kept at the lightoff rate during the stabilization time.
10.Release to modulation (Run).
11.At the end of the CH-heat request the burner is switched off and the fan stays on
until post purge is complete (15 sec.). Boiler enters standby mode.

C.Main Electrical Connection - 115V/single phase/60Hz (50Hz available)

D.Demand switch - Local/Remote/Off.
E. Combustion Air Proving Switch
F. 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. Monitored in Interlock (ILK) Circuit.
G.System Configuration - Falcon configuration is grouped into the following
functional groups:

• System Identification and Access • Anti-condensation Configuration

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

H.Falcon Control Access - There are three levels of access to the CB 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 CB Falcon for a
particular installation, and is password-protected.
• OEM Level - read/change all parameters; for factory configuration of boiler-

B7-8
Model CFV ClearFire Commercial Boilers

specific parameters. Password-protected and restricted to CB or factory

authorized service personnel.
For additional information regarding service and setup of the burner controller, refer to
CB manual part no. 750-269.

Figure B7-6. Falcon Display/Operator Interface

B7-9
Model CFV ClearFire Commercial Boilers

FALCON STEAM CONTROL

PLUG CONNECTORS

BLUE
UV
FAN POWER (25 VDC)
FAN GND
WHITE PWM OUT
TACHOMETER

1 4
4 3
EGND 12 1 24 VAC
2 5 2 1
2 24 VAC RTNS
11
J1 3 6
J2
L2 FOR 120VAC OR 10 3 STAT
24VAC RETURN (OPTOS) 9 4 +
STEAM PRESSURE
5 – 1
L1 8 SENSOR
+
P PUMP A { 7
6 J4 J8
6
7 – 4-20 mA

{
P 5 8
PUMP B
4 9

PUMP C {
3 10
P
2 STEAM 11
1 CONTROL 12

{ 7 1
BLOWER/HSI 2
6
5 3
EX. IGNITION 4 J5 J9 4 STACK TEMP A
MAIN VALVE 3 5 STACK TEMP RTN
PILOT VALVE 2 6 STACK TEMP B
INTERLOCK 1 7

8 1 REMOTE RESET
ALARM
7 PIM 2 TOD
6 3
PRE IGN INTLK 5
POWER 4 + 4 TO 20 MA I
J10 +
4 J6 5 0 - 10 VDC V
3 FLAME 6 – MA /VDC RTN
LCI
ANNUN 1/IAS 2 7
ANNUN 2 1 8
ALARM
7 1 FUTURE
ANNUN 3 6 RESET 2
STRENGTH
FLAME

ANNUN 4 5 3
J7 J11 4
ANNUN 5 4
ANNUN 6 3 5
ANNUN 7 HFS 2 6 FUTURE System Display
ANNUN 8 LFS 1 7
J3
LOCAL GLOBAL
MODBUS MODBUS ECOM
A B C A B C D R C

Local Display
MULTIPLE BUILDING
APPLIANCE AUTOMATION
CONTROLLER SYSTEM

GLOBALMODBUS
LOCALMODBUS

1 EXTERNALLY POWERED PRESSURE SENSOR (0-15 PSI OR 0-150 PSI).

Figure B7-7. CB Falcon pinout

4. Forced draft burner

A.The burner is a "Pre-mix" design consisting of a unitized venturi, single body dual
safety gas valve, blower, and burner head (canister).

B7-10
Model CFV ClearFire Commercial Boilers

B.Full modulation is accomplished with a variable speed fan for up to 5:1

turndown ratio on 40 horsepower boilers and larger (4:1 turndown on 30
horsepower and less).
C.For near flameless combustion, the burner utilizes a Fecralloy metal fiber head
(canister).
D.Noise level at maximum firing is less than 70 dBA regardless of boiler size.
E. When boiler is operating on natural gas, NOx emissions will be less than 20
PPM regardless of boiler size; certified for California and Texas low emissions
requirements.
F. As an option, the burner can utilize direct vent combustion air.
G.Ignition of the main flame is via direct spark, utilizing high voltage electrodes
and a UV scanner for flame supervision.
H.To ensure adequate combustion air is present prior to ignition, and to ensure the
fan is operating, a combustion air proving switch is provided.
I. For ease of inspection and maintenance, the blower is hinged for easy swing
away from the boiler permitting full inspection of the burner components, front
tube sheet and furnace.
J. A flame observation port is located at the top of the boiler.

Figure B7-8. CFV Burner

5. Burner Gas Train
The standard gas train is equipped in accordance with UL 795, ASME, CSD-1, XL-
GAP (formerly GE-GAP/IRI), and FM. Each burner gas train includes:
• Low gas pressure interlock, manual reset
• High gas pressure interlock, manual reset
• ASME CSD-1 test cocks
• Downstream manual ball type shutoff cock
• Single body dual safety shutoff gas valve
• Gas pressure regulator for maximum of 1 psig inlet pressure

B7-11
Model CFV ClearFire Commercial Boilers

Manual SOV
Test Cocks

Gas Valve: dual safety shutoff

w/internal regulation

Manual SOV

Regulator

LGPS HGPS

Figure B7-9. Gas Train

6. Boiler control panel

A standard NEMA 1 type panel enclosure is mounted on the side of the boiler. This
panel encloses the Falcon control, water level circuit boards, terminals, fuse blocks,
and ignition transformer. 115/1/60 terminals are provided for contractor connections.

IGNITION
PUMP CONTACTOR TRANSFORMER
TERMINAL BLOCK

HIGH LIMIT
CONTROL
ALARM HORN (OPT.) UV SCANNER
CABLE
LIGHT PACKAGE (OPT.)

TRANSFORMER
FALCON CB FALCON
DISPLAY/INTERFACE OP. LIMIT CONTROLLER
CONTROL

CHEM.
FEED
PUMP

PRESSURE XMTR

ALWCO CONTROLLER POWER SUPPLY,

DEMAND SWITCH
NIGHT SETBACK (OPT.) FALCON DISPLAY
LWCO CONTROLLER/PUMP CONTROL

Figure B7-10. CFV electrical panel

Optional Equipment For option details, contact the local authorized Cleaver-Brooks representative. In
summary, here are some of the options that can be provided with the boiler package:
• Bottom blowdown valves, shipped loose or mounted and piped
• Surface blowoff valve, shipped loose or mounted and piped

B7-12
Model CFV ClearFire Commercial Boilers
• Feedwater stop and check valves, shipped loose or mounted and piped
• Surface blowoff skimmer tube
• Steam stop valve, shipped loose or mounted and piped
• ASME hydro test of boiler piping
• Modbus communications
• Alarm light package
• Direct vent combustion air provision

DIMENSIONS AND RATINGS

For layout purposes, the overall dimensions for the Model CFV are shown in Figure
B7-11 and Table B7-3. Connection sizes are given in Table B7-3 and ratings of each
boiler size are noted in Table B7-4. Additional information is shown in the following
tables and illustrations:
Table B7-5 Recommended steam nozzle sizes
Table B7-6 Minimum required gas pressure
Table B7-7 Safety valve outlet sizes
Table B7-8 Boiler room width

B7-13
Model CFV ClearFire Commercial Boilers

Figure B7-11. Model CFV Steam Boiler Dimensions

BB
X

CC (4) 58"Ø HOLES

DD

3" TYP.

K E

GG
N

L F
P Q
AA
M

EE FF

S
T

H B C

G D

B7-14
Model CFV ClearFire Commercial Boilers

Table B7-3. Model CFV Steam Boiler Dimensions

Boiler Horsepower
Dimension 9.5 10 15 20 25 30 40 50 60
LENGTHS
Overall A 45 45 45 53 53 61 61 70 70
Centerline to Base Front B 16 16 16 19.5 19.5 23.5 23.5 28 28
Centerline to Base Rear C 16 16 16 19.5 19.5 23.5 23.5 28 28
Centerline to Stack Outlet D 22.5 22.5 22.5 24.5 24.5 30.5 30.5 34.5 34.5
Centerline to Combustion Air Inlet E 4 4 4 4 4 4 7 7 7
Boiler I.D. F 27 27 27 34 34 42 42 51 51
WIDTHS
Base, Overall G 32.5 32.5 32.5 39.5 39.5 47.5 47.5 57 57
Base, c/l to c/l Holes H 30.75 30.75 30.75 37.75 37.75 45.75 45.75 55 55
Centerline to Gas Inlet K 26 26 26 26 26 26 33 33 33
HEIGHTS
Overall L 85 85 85 84 91 86 95.5 100 106
Vessel M 74 74 74 73 79 76 81 82 88
Top of Boiler Clearance N 24 24 24 24 24 24 36 36 36
Floor to Gas Inlet P 78 78 78 77 83 80 87.5 90 96
Floor to Air Inlet Q 78 78 78 76 83 80 87.5 89 95
Floor to Feedwater Inlet R 30 30 30 27 27 29.5 29.5 34.5 34.5
Floor to Drain/Blowdown S 12 12 12 11 11 14 14 16 16
Floor to Stack Outlet T 9 9 9 8.5 8.5 10 10 11.5 11.5
BOILER CONNECTIONS
Horizontal Centerline to Gas Inlet V 5 5 5 5 5 5 5 5.5 5.5
Horizontal Centerline to Steam Outlet W 2 2 2 5 5 6.5 6.5 7.25 7.25
Vertical Centerline to Steam Outlet X 11.5 11.5 11.5 14 14 17.5 17.5 19.75 19.75
Feedwater AA 1 1 1 1 1 1 1 1-1/4 1-1/4
Steam Outlet BB 1-1/2 1-1/2 1-1/2 1-1/2 2 2 2 3 3
Gas Inlet CC 1 1 1 1 1 1-1/4 1-1/4 1-1/2 1-1/2
Surface Blowoff DD 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4
Drain / Blowdown EE 1 1 1 1 1 1 1 1-1/4 1-1/4
Stack O.D. FF 6 6 6 6 6 8 8 10 10
Combustion Air Inlet GG 4 4 4 4 4 6 6 8 8
WEIGHTS - LBS
Water Weight (Normal) 730 730 710 1195 1365 1840 2050 2715 3090
Approx. Dry Weight 1950 1950 2000 2540 2780 3540 4030 5280 5740

B7-15
Model CFV ClearFire Commercial Boilers

Table B7-4. Model CFV Steam Ratings

Boiler H.P. 9.5 10 15 20 25 30 40 50 60
Ratings
Rated Capacity - Steam (lbs/hr from & at 212ºF) 328 345 518 690 863 1,035 1,380 1,725 2,070
Output (1000 Btu/hr) 318 335 502 669 837 1,004 1,339 1,674 2,008
Fireside Heating Surface (sq.ft.) 65 65 84 128 159 165 258 312 388
Approximate Fuel Consumption At Rated Capacity
Natural Gas Input (cfh) - 150# SteamA 393 413 620 826 1,033 1,240 1,653 2,066 2,479
Power Requirements - 60Hz (Single Phase, 115 VAC)
Blower Motor Size (Watts)B 335 335 335 335 335 335 750 1,200 1,200
Notes:
A. Input calculated at nominal 81% efficiency for 1000 Btu gas content
B. For altitudes above 700 ft, contact your local Cleaver Brooks authorized representative for verification of blower motor size.

Table B7-5. Model CFV Recommended Steam Nozzle Size

OPERATING BOILER HP
PRESSURE
PSIG 9.5 10 15 20 25 30 40 50 60
60 1.5 1.5 1.5 1.5 2 2 2 3 3
75 1.5 1.5 1.5 1.5 2 2 2 3 3
100 1.5 1.5 1.5 1.5 2 2 2 3 3
125 1.5 1.5 1.5 1.5 2 2 2 3 3
Notes:
A. Steam nozzle sizes given in inches.
B. Sizes based on 4000-5000 fpm steam velocity.

B7-16
Model CFV ClearFire Commercial Boilers

Table B7-6. Model CFV Gas Pressure Requirements Table B7-7. Model CFV Steam Boiler
Safety Valve Outlet Size
Minimum VALVE SETTING
Boiler HP Inlet pipe size Gas valve size pressure required Max. pressure 150 PSIG STEAM
(inches) (inches) at gas train inches w.c. NO. OF OUTLET
connection
BOILER HP VALVES SIZE (IN.)
9.5 1 0.5 7.2" w.c.
10 1 0.5 7.2" w.c. REQ'D
15 1 0.75 7.3" w.c. 9.5 1 3/4
28 10 1 3/4
20 1 0.75 7.5" w.c.
25 1 1 7.7" w.c. 15 1 3/4
30 1.25 1 8.5" w.c. 20 1 3/4
40 1.25 1.25 11.0" w.c. 25 1 1
50 1.5 1.25 10.0" w.c. 30 1 1
60 1.5 1.25 10.0" w.c. 40 1 1
50 1 1-1/4
60 1 1-1/4
NOTE: Valve manufacturers are Kunkle,
Consolidated or Conbraco, depending on
availability.
Table B7-8. Clearances

BOILER HP 9.5-15 20-25 30-40 50-60

DIM. "A" 40 44 48 52
DIM. "B" 62 63 71 80
NOTES:
1. Recommended Minimum Distance Between Boiler and Wall. Dimension "A" allows for a clear 24" aisle between the
water column on the boiler and the wall. If space permits, this aisle should be widened.
2. Recommended Minimum Distance Between Boilers. Dimension "B" between boilers allows for a clear aisle of 24". If
space permits, this aisle should be widened.
3. Clearance above boiler 36”.

B7-17
Model CFV ClearFire Commercial Boilers

PERFORMANCE DATA
Table B7-9 shows predicted fuel-to-steam efficiencies for the Model CFV.
The specified boiler efficiency is based on the following conditions:

• Natural Gas
Carbon, % by weight = 69.98
Hydrogen, % by weight = 22.31
Sulfur, % by weight = 0.0
Heating Value, Btu/lb = 21,830
• Efficiencies are based on ambient air temperature of 80o F (27 C), relative
humidity of 30%, and 15% excess air in the exhaust gas stream.
• Efficiencies are based on the manufacturer's published radiation and convection
losses; see Table B7-10.
• Any efficiency verification testing will be based on the stack loss method.
• Nominal feedwater temperature of 1900 F (88 C) or greater.

Table B7-9. Predicted Fuel-to-Steam Efficiencies

OPERATING PRESSURE = 125 psig

BHP % OF LOAD

25% 50% 75% 100%

9.5 81.7 82.0 81.8 81.4

10 81.7 82.0 81.8 81.4

15 81.4 81.4 80.9 80.2

20 81.5 81.6 81.2 80.7

25 81.6 81.9 81.6 81.2

30 81.4 81.4 80.9 80.2

40 81.8 82.4 82.3 82.2

50 81.4 81.6 81.1 80.6

60 81.6 81.9 81.6 81.3

B7-18
Model CFV ClearFire Commercial Boilers

Table B7-10. Model CFV Radiation and Convection Losses

125# Operating Pressure
BHP
25% 50% 75% 100%
9.5-10 1.9 1.0 0.7 0.5
15 1.9 1.0 0.7 0.5
20 1.9 1.0 0.7 0.5
25 1.9 1.0 0.7 0.5
30 1.9 1.0 0.7 0.5
40 1.9 1.0 0.7 0.5
50 1.9 1.0 0.7 0.5
60 1.9 1.0 0.7 0.5

The emission data included in Table B7-11 consists of typical controlled emission
levels of the Model CFV boiler. Because of the premix burner technology, the standard
burner provided with the CFV package provides low emissions as standard without
the need for external or special devices.
Table B7-12 shows predicted sound levels at high fire.

Table B7-11. Model CFV Boilers: Natural Gas, Estimated Emission Levels
POLLUTANT UNITS
ppmA 10
CO
lb/MMBtu 0.007
ppmA 20
NOx
lb/MMBtu 0.024
ppmA 1
SOx
lb/MMBtu 0.001
HC/VOC5 ppmA 10
lb/MMBtu 0.004
ppmA -
PM
lb/MMBtu 0.01

A. ppm levels are given on a dry volume

basis and corrected to 3% oxygen (15%
excess air)

B7-19
Model CFV ClearFire Commercial Boilers

Table B7-12. Predicted sound levels

BHP Sound Level-dbA
9.5-10 60
15 65
20 60
25 66
30 62
40 68
50 67
60 69
Sound levels are measured 3 feet from the front of the panel at an elevation of 5 feet
from the floor.

ENGINEERING DATA
The following engineering information is provided for the Model CFV steam boiler.
Additional information may be obtained from your local Cleaver-Brooks
representative.
Feedwater Steam boilers require make-up water for steam production. This make-up can be a
combination of condensate return and raw make-up or in some instances, 100% raw
make-up. Proper treatment of make-up water is essential to the longevity and
performance of the boiler. Table B7-13 shows the rate of make-up required and Table
B7-14 shows the water quality guidelines.
Table B7-13. Feedwater flow rates
BHP Gallons/Hour
9.5 39
10 41
15 62
20 83
25 103
30 124
40 165
50 207
60 248
Feedwater flow is at maximum firing rate, 212°F steaming capacity

Table B7-14. Model CFV Water Quality

Constituent Level
Hardness 1.0 ppm max.
Iron 0.1 ppm max.
pH 8.3 - 10.5
Suspended Solids 300 ppm max.

B7-20
Model CFV ClearFire Commercial Boilers

Blowdown As steam is produced, unwanted solids are left behind in the water and become
concentrated within the vessel. If these constituents are allowed to adhere to the heat
transfer surfaces they will impede the flow of energy. Their removal requires proper
blowdown - either bottom, surface, or both. Table B7-15 shows the recommended
blowdown tank requirements for bottom blowdown. The surface blowdown
requirement is relative to the water quality and to the level of TDS control desired by
the water treatment specialist. Local codes will dictate the manner of treating
blowdown affluent.
Some local codes require blowdown tanks to be constructed in accordance with
recommendations of the National Board of Boiler and Pressure Vessel Inspectors. The
National Board's recommendations base the size of the blowdown tank on the
removal of at least 4 inches of water from the boiler.

Table B7-15. Model CFV Blowdown Tank Sizing Information

BOILER HP WATER (GAL)
9.5-10 3
15 3
20 6
25 6
30 8
40 8
50 12
60 12
NOTE: Quantity of water removed from boiler
by lowering normal water line 2".

Stack/Breeching General - Under ANSI Z21.13 the ClearFire Model CFV can operate as a Category II,
Criteria III or IV boiler as deemed appropriate for the application.
Proper design and installation of the flue gas venting is critical to efficient and safe
operation of the boiler. The vent should be designed with proper supports and
clearances from combustible materials. Use insulated vent pipe spacers where the
vent passes through combustible roofs and walls.
The design of the stack and breeching must provide the required draft at each boiler
stack connection as proper draft is critical to safe and efficient burner performance.
Although constant pressure at the flue gas outlet is not required, it is necessary to
size the breeching and stack to limit flue gas pressure variations. Consideration of the
draft must be given whenever direct combustion air ducting is utilized and lengthy
runs of breeching are employed. Please note: The allowable pressure range for design
of the stack and breeching is negative 0.25" w.c. (-62 Pa) to a positive 0.25" w.c.
(+62 Pa) for proper lightoff and combustion. NOTE: This pressure range does not
pertain to the boiler room; that is, the boiler room must be neutral or slightly positive,
never negative when using air from the boiler room for combustion.
Whenever two or more CFV boilers are connected to a common breeching/stack, a
mechanical draft control system may be required to ensure proper draft at all times.

B7-21
Model CFV ClearFire Commercial Boilers

Cleaver-Brooks recommends individual stacks for multiple boiler installations.

Combustion Air - The burner must be supplied with adequate volume of

uncontaminated air to support proper combustion and equipment ventilation. Air
shall be free of chlorides, halogens, fluorocarbons, construction dust or other
contaminants that are detrimental to the burner or boiler heating surfaces.
Combustion air can be supplied by means of conventional venting, that is, with
combustion air drawn from the area immediately surrounding the boiler (boiler room
is neutral or slightly positive pressure), or with a direct vent to outside the boiler room
where air is drawn directly from the exterior of the building. Regardless of the
method, all installations must comply with NFPA54 (the National Fuel Gas Code -
NFGC) for U.S. installations and CAN/CSA B149.1 and B149.2 for Canadian
installations.
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 conventional air intake.
In accordance with NFPA 54, the required volume of indoor air shall be determined
in accordance with the "Standard Method" or "Known Air Infiltration Rate Method".
Where 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 the NFPA Handbook for
additional information).

Unconfined Spaces
All Air From Inside the Building - If combustion air is drawn from inside the building
(the mechanical equipment room does not receive air from outside via louvers or vent
openings and the boiler is not equipped with direct vent) and the boiler is located in
an unconfined space, use the following guidelines:
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 meets 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.
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.
One opening must terminate within twelve inches of the top, and one opening must
terminate within twelve inches from the bottom of the room.
See Figure B7-12; refer to the NFGC for additional information.

B7-22
Model CFV ClearFire Commercial Boilers

Figure B7-12. Inside Air - Two Opening Method

GAS
VENT

12" MINIMUM

FRESH AIR OPENING

INTERIOR WALL

FRESH AIR OPENING

12" MINIMUM

All Air From Outdoors - If all combustion air will be received from outside the
building (the mechanical room is linked with the outdoors), the following methods
can be used:
Two Opening Method (Figure B7-13) - 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 from the bottom of the
room.
A. The opening must be linked directly or by ducts with the outdoors.
B. 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.
C. 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.

B7-23
Model CFV ClearFire Commercial Boilers

Figure B7-13. Two Opening Ducted Method

GAS
VENT

12" MINIMUM

OUTLET AIR DUCT

INTERIOR WALL

EXTERIOR WALL

FRESH AIR
INLET DUCT

12" MINIMUM

One Opening Method (Figure B7-14) - One permanent opening, commencing within
12 inches of the top of the room shall be provided.
A. The equipment shall have clearances of at least 1 inch from the sides and back
and 6 inches from the front of the appliance.
B. 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 unconfined space.
C. Refer to the NFGC for additional information.
Figure B7-14. One Opening Method

GAS
VENT

12" MINIMUM

FRESH AIR OPENING

EXTERIOR WALL

B7-24
Model CFV ClearFire Commercial Boilers

Unconfined Spaces
Engineered Design - When determining boiler room air requirements for an
unconfined space the "Engineered Design" method may be used. Following this
method, consideration must be given to the size of the room, airflow and velocity of
air as follows:
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 below a height
of 7 feet. This allows air to sweep the length of the boiler (see Figure B7-15).
Figure B7-15. Engineered Method

GAS
VENT

FRESH AIR OPENING

FRESH AIR OPENING

EXTERIOR WALL
EXTERIOR WALL

B. Air supply openings can be louvered for weather protection, but they should not be
covered with fine mesh wire, as this type of covering has poor air flow qualities 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 slight
vacuum under certain conditions and cause variations in the quantity of combustion
air. This can result in unsafe burner performance.
D. It is forbidden to have the total area of the air supply openings at less than one
square foot.
E. Size the openings by using the formula (Area in ft2 = cfma/fpma), where cfma =
cubic feet per minute of air; fpma = feet per minute of air.
F. Amount of air required (cfm):
1. Combustion Air = Maximum boiler horsepower (bhp) times 8 cfm.
2. Ventilation Air = Maximum boiler horsepower (bhp) times 2 cfm.
3. Total Air = 10 cfm per bhp (up to 1000 feet elevation, add 3% more per 1000
feet of added elevation).
G. Acceptable air velocity in the boiler room (fpm):
1. From floor to 7 feet high = 250 fpm.
2. Above 7 feet from boiler room floor = 500 fpm.

B7-25
Model CFV ClearFire Commercial Boilers

Example of required air openings (Engineered Method):

Determine the area of the boiler room air supply openings for (2) 60 horsepower
Model CFV boilers at 750 feet elevation. The air openings will be 5 feet above the
floor level.
Total boiler horsepower (bhp): 60 x 2 = 120 bhp
From F.3 above, total air required = 120 bhp x 10 = 1200 cfm.
Air Velocity: From G.1 above = 250 fpm.
Area required: From the formula in E above, 1200cfm/250fpm = 4.8 square feet
total.
Area/Opening: 4.8 divided by 2 = 2.4 ft2 per opening (2 required).

Notice
Consult local codes, which may supersede these requirements.

Direct Combustion Air - If combustion air will be drawn directly from the outside
(direct vent combustion, sometimes called "sealed combustion") by means of a duct
connected directly to the burner air intake, use the following guidelines:
1. Install combustion air duct in accordance with local codes and the boiler
operating and maintenance manual.
2. Provide for adequate ventilation of the boiler room or mechanical equipment
room.
3. Duct material can be PVC or metallic vent material. It should be air tight to
prevent in leakage of air during operation.
4. Maximum pressure drop for the duct shall not exceed 0.25" w.c. negative. If this
pressure drop is exceeded a larger size duct is recommended.
5. Multiple boilers may be connected to a single duct with take-offs to each boiler.
6. If the duct will run horizontally to an outside wall, it is recommended that the
duct have a slight downward slope away from the burner intake to prevent
collected moisture from draining into the burner connection.
7. If the outside air is dust-laden or the installation is near a heavily traveled
roadway, it is recommended that an air filter be installed to prevent intake of
contaminants that could accumulate on the burner canister.

B7-26
Model CFV ClearFire Commercial Boilers

Figure B7-16. Direct Vent Combustion

Casing Support Fan/Blower

Attachment
Venturi
Gasket

Adapter Flange
Flexible Connection
Direct Vent Connection

Figure B7-17. Direct Vent Combustion kit

Gas Piping General - The ClearFire Model CFV gas fired steam boilers are full modulating input
units that require appropriate gas supply pressure and volume for proper operation
and long burner life. The gas requirements specified in this section must be satisfied
to ensure efficient and stable combustion. Installation must follow these guidelines
and of the local authorities that have installation jurisdiction.
Gas Train Components - CFV boilers are equipped with a gas train that meets the
requirements of UL/cUL and ASME CSD-1, and also the requirements of FM and GE-
GAP (formerly IRI). The gas train and its components have been designed and tested
to operate for the highest combustion efficiency for the CFV units. Major components
are as noted in the current product specifications and O & M manual.
Gas Pressure Requirements - For proper and safe operation, each Model CFV boiler
requires a stable gas pressure input. The pressure requirements are listed in the O&M

B7-27
Model CFV ClearFire Commercial Boilers

manual and current specifications and are added here (Table B7-6) for reference
purposes.
The minimum inlet supply pressure must be as noted in Table B7-6 when firing the
boiler at low fire and high fire. Actual gas pressure should be measured when the
burner is firing using a manometer at the upstream test port connection on the main
gas valve. For a multiple unit installation, gas pressure should be set for a single unit
first, then the remaining units should be staged on to ensure that gas pressure droop
is not more than 1" w.c. and never below the required pressure. Fluctuating gas
pressure readings could be indicative of a faulty supply regulator or improper gas train
size to the boiler.

Gas Piping - CFV units are standardly equipped with a gas pressure regulator. If
upstream pressure exceeds 1 psig, an additional upstream regulator must be installed
along with a pressure relief valve. Note: Gas connection is at the left side of the boiler,
left hand side as you face the front of the boiler.
For buildings or boiler rooms with gas supply pressure exceeding 28" w.c. a "full lock-
up" type regulator is recommended along with proper overpressure protection (e.g.
relief valve). In addition to the regulator, a plug type or "butterball type" gas shutoff
cock should be installed upstream of the regulator for use as a service valve. This is
also required to provide positive shutoff and isolate the unit during gas piping tests.
Drip legs are required on any vertical piping at the gas supply to each boiler so that
any dirt, weld slag, or debris can deposit in the drip leg rather than into the boiler gas
train. The bottom of the drip leg should be removable without disassembling any gas
piping. The connected piping to the boiler should be supported from pipe supports
and not supported by the boiler gas train or the bottom of the drip leg.
All gas piping and components to the boiler gas train connection must comply with
NFPA 54, local codes, and utility requirements as a minimum. Only gas approved
fittings, valves, or pipe should be used. Standard industry practice for gas piping is
normally Schedule 40 black iron pipe and fittings.
Before starting the unit(s) all piping must be cleaned of all debris to prevent its'
entrance into the boiler gas train. Piping should be tested as noted in NFPA 54 and
the boiler must be isolated during any tests.
After initial startup, the inlet screen to the gas valve should be checked and cleaned
for any debris buildup
Gas Supply Pipe Sizing - For proper operation of a single unit or a multiple unit
installation, we recommend that the gas pipe sizing be sized to allow no more than
0.3" w.c. pressure drop from the source (gas header or utility meter) to the final unit
location. The gas supplier (utility) should be consulted to confirm that sufficient
volume and normal pressure are provided to the building at the discharge side of the
gas meter or supply pipe.
For installations of new boilers into an existing building, gas pressure should be
measured with a manometer to ensure sufficient pressure is available. A survey of all
connected "gas using devices" should be made. If appliances other than the boiler or
boilers are connected to the gas supply line, then a determination must be made of
how much flow volume (CFV = cubic feet per hour) will be demanded at one time
and the pressure drop requirement when all appliances are firing.

B7-28
Model CFV ClearFire Commercial Boilers

The total length of gas piping and all fittings must be considered when sizing the gas
piping. Total equivalent length should be calculated from the utility meter or source to
the final unit connection. As a minimum guideline, gas piping Tables B7-16 through
B7-21 should be used. The data in these tables is from the NFPA 54 source book,
2006 edition.
To verify the input of each device that is connected to the gas piping, obtain the btu/
hr input and divide this input by the calorific value of the gas that will be utilized. For
instance, a 40 HP unit with 1,613,253 btu/hr input divided by a gas calorific value
of 1060 will result in a CFV flow of 1,522. The single boiler is approximately 20 feet
from the gas supply header source. And with a measured gas supply pressure of 10"
w.c. we find from Table 16 that a supply pipe size of 2" should be used as a
minimum.

B7-29
Model CFV ClearFire Commercial Boilers

Figure B7-22. Typical gas header piping

MODEL CFV MODEL CFV MODEL CFV MODEL CFV

Figure B7-23. Example gas piping <1 psig supply

B7-30
Model CFV ClearFire Commercial Boilers

Table B7-16. Gas line capacity - Schedule 40 metallic pipe

Pipe Size
Nominal 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4"
Actual I.D. 1.049 1.380" 1.610" 2.067" 2.469" 3.068" 4.026"
Length in feet **Maximum Capacity in Cubic Feet of Gas per Hour (CFV)
10 514 1,060 1,580 3,050 4,860 8,580 17,500
20 363 726 1,090 2,090 3,340 5,900 12,000
30 284 583 873 1,680 2,680 4,740 9,660
40 243 499 747 1,440 2,290 4,050 8,290
50 215 442 662 1,280 2,030 3,590 7,330
60 195 400 600 1,160 1,840 3,260 6,640
70 179 368 552 1,060 1,690 3,000 6,110
80 167 343 514 989 1,580 2,790 5,680
90 157 322 482 928 1,480 2,610 5,330
100 148 304 455 877 1,400 2,470 5,040
125 131 269 403 777 1,240 2,190 4,460
150 119 244 366 704 1,120 1,980 4,050
175 109 209 336 648 1,030 1,820 3,720
200 102 185 313 602 960 1,700 3,460
**Fuel: Natural Gas
**Inlet Pressure: Less than 2.0 psi
**Pressure Drop: 0.30" w.c.
**Specific Gravity: 0.60

Table B7-17. Gas line capacity - Schedule 40 metallic pipe

Pipe Size
Nominal 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4"
Actual I.D. 1.049" 1.380" 1.610" 2.067" 2.469" 3.068" 4.026"
Length in feet **Maximum Capacity in Cubic Feet of Gas per Hour (CFV)
10 678 1,390 2,090 4,020 6,400 11,300 23,100
20 466 957 1,430 2,760 4,400 7,780 15,900
30 374 768 1,150 2,220 3,530 6,250 12,700
40 320 657 985 1,900 3,020 5,350 10,900
50 284 583 873 1,680 2,680 4,740 9,600
60 257 528 791 1,520 2,430 4,290 8,760
70 237 486 728 1,400 2,230 3,950 8,050
80 220 452 677 1,300 2,080 3,670 7,490
90 207 424 635 1,220 1,950 3,450 7,030
100 195 400 600 1,160 1,840 3,260 6,640
125 173 355 532 1,020 1,630 2,890 5,890
150 157 322 482 928 1,480 2,610 5,330
175 144 296 443 854 1,360 2,410 4,910
200 134 275 412 794 1,270 2,240 4,560
**Fuel: Natural Gas
**Inlet Pressure: Less than 2.0 psi
**Pressure Drop: 0.50" w.c.
**Specific Gravity: 0.60

B7-31
Model CFV ClearFire Commercial Boilers

Table B7-19. Gas line capacity - Schedule 40 metallic pipe

Pipe Size

Nominal 1/2" 3/4" 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4"
Actual I.D. 0.622 0.824 1.049" 1.380" 1.610" 2.067" 2.469" 3.068" 4.026"
Length in
**Maximum Capacity in Cubic Feet of Gas per Hour (CFV)
feet
10 1,510 3,040 5,560 11,400 17,100 32,900 52,500 92,800 189,000

20 1,070 2,150 3,930 8,070 12,100 23,300 57,100 65,600 134,000

30 869 1,760 3,210 6,590 9,880 19,000 30,300 53,600 109,000

40 753 1,520 2,780 5,710 8,550 16,500 26,300 46,400 94,700

50 673 1,360 2,490 5,110 7,650 14,700 23,500 41,500 84,700

60 615 1,240 2,270 4,660 6,980 13,500 21,400 37,900 77,300

70 569 1,150 2,100 4,320 6,470 12,500 19,900 35,100 71,600

80 532 1,080 1,970 4,040 6,050 11,700 18,600 32,800 67,000

90 502 1,010 1,850 3,810 5,700 11,000 17,500 30,900 63,100

100 462 954 1,710 3,510 5,260 10,100 16,100 28,500 58,200

125 414 836 1,530 3,140 4,700 9,060 14,400 25,500 52,100

150 372 751 1,370 2,820 4,220 8,130 13,000 22,900 46,700

175 344 695 1,270 2,601 3,910 7,530 12,000 21,200 43,300

200 318 642 1,170 2,410 3,610 6,960 11,100 19,600 40,000

500 192 401 717 1,470 2,210 4,250 6,770 12,000 24,400

1000 132 275 493 1,010 1,520 2,920 4,650 8,220 16,800

1500 106 221 396 812 1,220 2,340 3,740 6,600 13,500

**Fuel: Natural Gas

**Inlet Pressure: 2.0 psi

**Pressure Drop: 1.0 psi

**Specific Gravity: 0.60

B7-32
Model CFV ClearFire Commercial Boilers

Table B7-20. Gas line capacity - Schedule 40 metallic pipe

Pipe Size

Nominal 1/2" 3/4" 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4"
Actual I.D. 0.622 0.824 1.049" 1.380" 1.610" 2.067" 2.469" 3.068" 4.026"
Length in
**Maximum Capacity in Cubic Feet of Gas per Hour (CFV)
feet
10 2,350 4,920 9,270 19,000 28,500 54,900 87,500 155,000 316,000

20 1,620 3,380 6,370 13,100 19,600 37,700 60,100 106,000 217,000

30 1,300 2,720 5,110 10,500 15,700 30,300 48,300 85,400 174,000

40 1,110 2,320 4,380 8,990 13,500 25,900 41,300 75,100 149,000

50 985 2,060 3,880 7,970 11,900 23,000 36,600 64,800 132,000

60 892 1,870 3,520 7,220 10,300 20,300 33,200 58,700 120,000

70 821 1,720 3,230 6,640 9,950 19,200 30,500 54,000 110,000

80 764 1,600 3,010 6,180 9,260 17,800 28,400 50,200 102,000

90 717 1,500 2,820 5,800 8,680 16,700 26,700 47,100 96,100

100 677 1,420 2,670 5,470 8,200 15,800 25,200 44,500 90,300

125 600 1,250 2,360 4,850 7,270 14,000 22,300 39,500 80,500

150 544 1,140 2,140 4,400 6,590 12,700 20,200 35,700 72,900

175 500 1,050 1,970 4,040 6,060 11,700 18,600 32,900 67,100

200 465 973 1,830 3,760 5,640 10,900 17,300 30,600 62,400

500 283 593 1,120 2,290 3,430 6,610 10,300 18,600 38,000

1000 195 407 897 1,380 2,360 4,550 7,240 12,000 26,100

1500 156 327 616 1,270 1,900 3,650 5,820 10,300 21,000

**Fuel: Natural Gas

**Inlet Pressure: 3.0 psi

**Pressure Drop: 2.0 psi

**Specific Gravity: 0.60

B7-33
Model CFV ClearFire Commercial Boilers

Table B7-21. Gas line capacity - Schedule 40 metallic pipe

Pipe Size

Nominal 1/2" 3/4" 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4"
Actual
0.622 0.824 1.049" 1.380" 1.610" 2.067" 2.469" 3.068" 4.026"
I.D.
Length
**Maximum Capacity in Cubic Feet of Gas per Hour (CFV)
in feet
10 3,190 6,430 11,800 24,200 36,200 69,700 111,000 196,000 401,000

20 2,250 4,550 8,320 17,100 25,600 49,300 78,600 139,000 283,000

30 1,840 3,720 6,790 14,000 20,900 40,300 64,200 113,000 231,000

40 1,590 3,220 5,880 12,100 18,100 34,900 55,600 98,200 200,000

50 1,430 2,880 5,260 10,800 16,200 31,200 49,700 87,900 179,000

60 1,300 2,630 4,800 9,860 14,800 28,500 45,400 80,200 164,000

70 1,200 2,430 4,450 9,130 13,700 26,400 42,000 74,300 151,000

80 1,150 2,330 4,260 8,540 12,800 24,700 39,300 69,500 142,000

90 1,060 2,150 3,920 8,050 12,100 23,200 37,000 65,500 134,000

100 979 1,980 3,620 7,430 11,100 21,400 34,200 60,400 123,000

125 876 1,770 3,240 6,640 9,950 19,200 30,600 54,000 110,000

150 786 1,590 2,910 5,960 8,940 17,200 27,400 48,500 98,900

175 728 1,470 2,690 5,520 8,270 15,900 25,400 44,900 91,600

200 673 1,360 2,490 5,100 7,650 14,700 23,500 41,500 84,700

500 384 802 1,510 3,100 4,650 8,950 14,300 25,200 51,500

1000 264 551 1,040 2,130 3,200 6,150 9,810 17,300 35,400

1500 212 443 834 1,710 2,570 4,940 7,880 13,900 28,400

**Fuel: Natural Gas

**Inlet Pressure: 5.0 psi

**Pressure Drop: 3.5 psi

**Specific Gravity: 0.60

B7-34
Model CFV ClearFire Commercial Boilers

Gas Header - For multiple unit installations, a single common gas header is
recommended with individual takeoffs for each boiler (See Figure B7-22). Boiler gas
manifold piping should be sized based on volume requirements and lengths between
each boiler and the fuel main header. Tables B7-22 through B7-29 indicate the
proper sizing for multiple units of equal size, placed on the factory standard center
with the indicated take off size. For installations with a mixed sized use, determine
the flow of each unit and total the input. With the total input, determine length of run
from the source and determine what size header will be needed for the flow of all
units firing. Pipe sizes are based on Table B7-16 with boiler gas line take-off at 20
feet from the header. If pipe runs are greater or if gas pressure is different, refer to the
Tables for pipe sizing.

Pipe sizing for multiple unit manifolds

Table B7-22. CFV 9.5 & 10 HP Boilers Table B7-23. CFV 15 HP Boilers
# of # of
1 2 3 4 1 2 3 4
Units Units
Pipe Size Pipe Size
1-1/4" 1-1/4" 1-1/4" 1-1/4" 1-1/4" 1-1/4" 1-1/4" 1-1/4"
To Boiler To Boiler
Header Header
1-1/4" 1-1/4" 2" 2" 1-1/4" 2" 2" 2-1/2"
Pipe Size Pipe Size

Table B7-24. CFV 20 HP Boilers Table B7-25. CFV 26 HP Boilers

# of # of
1 2 3 4 1 2 3 4
Units Units
Pipe Size Pipe Size
1-1/2" 1-1/2" 1-1/2" 1-1/2" 1-1/2" 1-1/2" 1-1/2" 1-1/2"
To Boiler To Boiler
Header Header
1-1/2" 2" 2-1/2" 2-1/2" 1-1/2" 2" 2-1/2" 3"
Pipe Size Pipe Size

Table B7-26. CFV 30 HP Boilers Table B7-27. CFV 40 HP Boilers

# of # of
1 2 3 4 1 2 3 4
Units Units
Pipe Size Pipe Size
2" 2" 2" 2" 2" 2" 2" 2"
To Boiler To Boiler
Header Header
2" 2-1/2" 3" 3" 2" 2-1/2" 3" 4"
Pipe Size Pipe Size

Table B7-28. CFV 50 HP Boilers Table B7-29. CFV 60 HP Boilers

# of # of
1 2 3 4 1 2 3 4
Units Units
Pipe Size Pipe Size
2" 2" 2" 2" 2-1/2" 2-1/2" 2-1/2" 2-1/2"
To Boiler To Boiler
Header Header
2" 3" 3" 4" 2-1/2" 3" 4" 4"
Pipe Size Pipe Size

B7-35
Model CFV ClearFire Commercial Boilers

SPECIFICATIONS
MODEL CFV PRODUCT SPECIFICATIONS
1.0 GENERAL BOILER DESIGN
A. The boiler shall be a Cleaver-Brooks Model CFV 700, single pass vertical commercial
Firetube design or approved equal. It shall be mounted on a heavy-duty steel frame with
premix forced draft burner and burner controls as a complete package from one
manufacturer.
B. Approvals - The complete package including the burner shall be Underwriters Laboratories,
Inc. listed and the official UL/cUL label shall be affixed to the package attesting to its
certification.
C. As a preassembled package, the standard boiler shall be factory fire tested.
D. The complete package as shipped, shall be ready for connections to water, fuel, blowdown,
and exhaust venting. Certain items may be shipped loose to prevent their damage such
as the safety valves and gauges.
E. The specified boiler shall have an output rating of _____ horsepower when fired with
Natural Gas [LP Gas] with a gas supply pressure of ____" w.c. Power supply to the boiler
shall be 115/1/60 or 50Hz. Design pressure shall be 150# steam. Operating
characteristics shall be [___] psig steam. Steam boilers shall be supplied with ____
degrees F make-up water @ ____%.

F. Performance: shall be as specified in Paragraph 5 below.

1.1 BOILER SHELL

A. The boiler shell must be constructed in accordance with the ASME Code, either Section I
for high-pressure steam or Section IV for low-pressure steam. The vessel must be
subjected to the required inspections of the Code conducted by an independent third party
inspector. A signed inspection sheet shall be provided to the purchaser and the appropriate
ASME symbol shall be affixed or stamped onto the boiler.
1. Boiler shall be mounted on base rails suitable for transporting by fork lift.
2. Burner housing shall be removable or hinge-mounted (50-60 HP) to allow tube
inspection.
3. Each carbon steel boiler tube shall utilize the AluFer heat transfer design technology for
high efficiency and reduction in overall size of the vessel and shall be a minimum of
0.105 tube wall thickness.
4. To facilitate waterside inspection, 3 hand holes shall be provided.
5. An observation port for flame inspection shall be provided.
6. Boiler insulation shall consist of 2-inch fiberglass blanket, which shall be covered with
a 304 SS sheet metal jacket. This jacket and insulation design shall permit field
removal and reattachment if necessary for inspection, etc.
7. The entire boiler and base frame shall be factory painted.
8. Exhaust vent shall be located at the rear of the boiler and shall be a slip connection.
Stack support shall be by means other than the boiler connection.

1.2 BOILER SHELL TAPPINGS/OPENINGS

A. The following boiler vessel tappings/openings shall be furnished:

B7-36
Model CFV ClearFire Commercial Boilers

1. Steam supply by NPT connection for high-pressure steam.

2. Bottom blowdown.
3. Feedwater Make-up.
4. Surface blowoff.
5. Chemical Feed.
6. High Water Level Overflow Drain to discharge water in the boiler if water level reaches
an unacceptable level.

2.0 STEAM BOILER TRIM (All piping and devices per ASME CSD-1)
A. Water Column
1. A water column shall be furnished complete with gauge glass and water column
blowdown valve.
a. Feedwater Pump control - shall be integral with the water column via probe control
device and electronics for on/off pump operation.
b. Low Water cutoff - shall be integral with the water column via probe control device
and solid state electronics mounted and wired in the control panel.
B. An Auxiliary Low Water Cutoff shall be provided. It shall be located on the top centerline
of the boiler using an internal probe and of the manual reset design.
C. For safety steam pressure lockout a high limit pressure control, manual reset shall be
provided. The device shall be mercury free.
D. To provide steam demand tracking a steam pressure transmitter shall be provided that
provides an input signal for burner positioning in accordance to steam demand.
E. A 3" Steam Pressure Gauge shall be piped onto the trim piping, including an inspectors
test cock.
F. In accordance with the A.S.M.E. Code an approved A.S.M.E. rated and stamped safety
valve shall be provided and set at 150#.

3.0 BURNER AND BURNER CONTROLS

A. Mode of Operation - to minimize short cycling and provide highest efficiency the burner for
the specified boiler shall be of the electronic modulation with a turndown ratio of 5:1 for
Natural Gas for sizes of 40 horsepower and greater, and 4:1 for sizes below 40 horsepower.
On/off or low/high burner operation shall not be accepted.
B. The burner shall be enclosed in a NEMA 1 type enclosure. A lift off top cover shall be
provided to gain access to the burner and controls.
C. Design - The burner design shall be of the linkage-less premix technology wherein the fuel
and air are mixed in the fan housing assembly prior to entering the burner canister.
Separately driven linkage or servo motor driven fuel and air valves shall not be permitted.
1. Fan housing shall utilize non-sparking material and shall be approved for premix
operation.
2. The fan shall be driven by a variable speed motor which shall react to output demand
requirements via the demand control Motor shall be a high efficiency DC Brushless
type. Continuous speed synchronous motors will not be acceptable.
D. Ignition of the fuel shall be of the direct spark design; separate pilot gas train is not
required. Dual ignition electrodes shall used for the spark generated from the panel
mounted ignition transformer.

B7-37
Model CFV ClearFire Commercial Boilers

E. Combustion shall take place on the surface of the burner canister. The canister shall be
constructed of Fecralloy material and stainless steel and shall be warranted for five years
against failure from defects or poor workmanship.
F. Air Filter - shall be fitted to the intake air venturi to filter the incoming air supply when
using boiler room air. The air filter shall be designed to be easily cleaned and re-used.
G. Fuel - The burner shall be designed for operation with natural gas or LP gas. Gas Train,
shall be located at the front of the burner and along the left side of the boiler. In accordance
with UL/cUL and ASME CSD-1, the following components shall be furnished:
1. Single body dual solenoid safety shutoff valve incorporating the following:
a. The valve shall be a 1:1 ratio valve with an integral trim regulator and shall operate
in relation to the fan speed. An air sensing line shall be connected from the air inlet
venturi (mounted to the fan motor) and to the gas valve for control of gas input.
b. As fan speed increases a negative pressure will be applied to the valve, allowing the
valve to open further, permitting more fuel to flow into the venturi for mixing. As fan
speed is reduced, fuel input shall be reduced accordingly. Air shall always lead fuel from
low to high or high to low.
2. Manual fuel shutoff valve - shall be located downstream of the gas valve and used for
CSD-1 leak testing.
3. Gas Pressure Interlocks - one shall be provided for sensing high gas pressure and one
provided to sense low gas pressure. Each control shall be of the manual reset type.
4. Gas Pressure Regulator - shall be provided upstream of the gas valve to provide
regulated pressure to the gas train from the gas supply. This regulator shall be suitable
for a maximum of 1 psig gas pressure. If gas pressure exceeds 1 psig, a gas pressure
relief valve shall be furnished and upstream pressure regulator that is of the full lockup
type.
5. Manual Shutoff Valves - shall be provided upstream of the gas regulator to manually
close off the gas supply when servicing the gas train or isolating the boiler. A shutoff
valve shall be provided at the burner for tightness checking of the gas valve.
6. Combustion Air Proving Switch shall be provided to prove, prior to modulation that the
fan is operating properly.
H. Flame Safety
1. Flame sensing shall be accomplished with a UV scanner mounted in the burner
mounting plate, designed for easy removal for inspection or replacement.
4.0 CONTROL PANEL - A NEMA 1 type enclosure is furnished and located at the front of the
boiler above the burner to house the following components:
A. Falcon controller combining flame supervision, burner sequencing, modulating control, and
operating limit control.
B. Falcon touchscreen display/operator interface
C. Boiler Control Circuit On/Off switch.
D. Demand switch.
E. Terminals for control interface wiring, customer connections, and connections for incoming
power.
F. Solid state circuit boards for water level controls.
G. Selectable Options:
Alarm Light Package to provide indication of Low Water, Flame Failure, Load
Demand, Fuel Valve On, including a horn with silence switch for alarm conditions.

B7-38
Model CFV ClearFire Commercial Boilers

H. When multiple boilers are to be installed together, a system integration control shall be
provided to stage up to 8 boilers. The control shall include automatic selection of needed
boilers based on demand. The control shall force each boiler to a lower fire before allowing
any boiler to operate at high fire, thus allowing ‘inverse efficiency’ (higher efficiency at
lower firing rates). The control shall monitor supply header pressure and shall
communicate with boilers via RS-485 wiring.
5.0 PERFORMANCE
The proposed Boiler shall provide the following operating performance targets for Natural Gas:
A. Efficiency - For 150# steam operating at 125#, the guaranteed Fuel to Steam Efficiency
shall be 81%. Efficiency rating shall account for radiation and convection losses.
B. Emissions - NOx emissions shall be less than 20 PPM corrected to 3% O2 and less than
10 PPM CO over the operating range of the burner turndown. If emissions exceed this
level, the boiler manufacturer shall correct at their expense until this level is achieved on
a repeatable basis.
C. Radiation losses shall be less than 0.5% of the rated input at maximum firing.
D. Steam quality shall be 99.5% at maximum firing regardless of operating pressure.
6.0 WARRANTY
The package boiler shall be warranted for a period of one year from date of start-up or 18
months from shipment whichever shall occur first.

B7-39