ClearFire - Hydronic Startup Report

Transcription

1 ClearFire - Hydronic Startup Report Date Serial No. THIS FORM IS FOR MODEL CFC / CFW CLEARFIRE BOILERS Customer s Name Location Model Design Pressure Working Pressure Rated Input (nameplate rating) BTU/hr 28. Type of fuel Natural Gas LP Gas both [CFC only] Gas BTU Value Gas Company Burner Voltage Control Circuit Voltage Software version: Falcon control Falcon display How many boilers are tied into the same system? Boiler water treatment discussed with (name): Has the boiler been hydro tested in the field? Yes No If yes, at what pressure? Was the water level control explained and the procedure for testing demonstrated? Yes No Was setting and adjusting the temperature controls demonstrated and explained? Yes No Has the operator been instructed on troubleshooting and maintenance? Yes No BOILER ROOM & INSTALLATION CONDITIONS 1. What is the general condition of the boiler room at startup? New construction Damp Dusty Clean Other 2. What is the approximate altitude of the boiler installation? 3. Was the boiler used for heat during construction (before actual startup)? Yes No If yes, how long? And who operated this unit? Was a combustion air filter used during construction (recommended)? Yes No 4. Are electrical supply wires, fuse, circuit breakers, or disconnects supplied and sized per the boiler drawings and specifications? Yes No If no, please explain 5. Are all external limits and controls connected (flow switch, alarms, circuits, outdoor resets)? Yes No 6. Has any wiring been modified or changed before or during startup? Yes No If yes, provide a marked-up wiring diagram of the changes. 7. Is the boiler level? Yes No 8. [CFC only] Have the casing panels been installed properly and without damage? Yes No If no, explain

2 9. Is the safety relief valve mounted to the boiler outlet pipe connection and piping properly supported to prevent distortion? Yes No 10. Relief valve manufacturer Serial No. 11. Relief valve set point Valve discharge size 12. Relief valve capacity BTU/hr 13. Is the bottom drain line piped to a safe point of discharge? Yes No 14. [CFC only] Is the optional condensate collection pan installed? Yes No If no, has the condensate line been trapped and piped to drain? Yes No 15. [CFW only] Has the condensate drain been plugged? Yes No If no, has the drain been trapped and piped to drain? Yes No 16. Is the air vent line piped to an expansion tank, air separator, or auto air vent? Yes No If no, explain 17. What is the source for water make-up? Is a makeup water meter installed? Yes No 18. Is a water softener employed? Yes No Other methods employed for water conditioning 19. What type of hot water system is employed? Three-way valve Primary-secondary Reverse return Other: 20. What is the size of the system pump(s)? gpm Boiler pump (primary-secondary) gpm 21.Design temperature: Inlet [return] o F Outlet [supply o F 22. System operating pressure PSI 23. System design operating temperature o F 24. Is there a stack thermometer? Yes No 25. Is the unit tied into a lead lag system? Yes No If yes: How many boilers are on the lead lag system? Does the system include condensing and non-condensing boilers (hybrid system) Yes No Lead lag control manufacturer What is the system maximum design set point? 26. Does this unit communicate with an Energy Management System? Yes No If yes: Protocol used (e.g. Modbus, BACnet, LonWorks) Is a protocol translator in use? Yes Manufacturer No

3 27. Does the unit utilize any of these control functions: Outdoor reset Falcon Building EMS Remote enable Remote firing rate Remote set point NATURAL GAS PROPANE 28. Gas Piping: a) Gas supply pressure to boiler room b) If gas supply pressure to the boiler room is greater than 1 psig, is there a relief valve upstream of the gas train? c) The equivalent length of pipe from regulator to gas train is and the pipe size is d) The size of the Cleaver-Brooks supplied gas train is e) Has the gas line been tested for leaks? If no, explain f) Has a gas line filter been provided? g) Has a gas line drip leg been installed upstream of the regulator (required in any vertical piping) h) Has the gas line been cleaned or purged prior to starting? i) Has the Cleaver-Brooks supplied gas train been checked for internal cleanliness? 29. Main gas regulator manufacturer Capacity Size 30. What is the inlet gas pressure to the regulator? 31. Does the gas regulator feed gas to any other equipment? If yes, explain 32. If multiple boilers, does each have its own regulator? If no, explain

4 NOTE: Maximum supply gas pressure to ClearFire boilers is 1 psig. ASME CSD-1 requires a gas line drip leg with cleanout access in any vertical gas supply piping. Overpressure protection required if boiler room gas supply is greater than boiler gas train pressure rating. The gas lines must be cleaned/purged prior to initial startup for safe, reliable operation. 33. Gas booster manufacturer Capacity Size 34. Booster inlet pressure and outlet pressure 35. Does the booster run continuously? Or simultaneously with burner? Is it interlocked with burner? Yes No 36. Is the unit set up for direct vent combustion? Yes No If yes, explain hookup and size and type piping If no, was an air filter kit provided? Yes No 37. Are adequate openings provided for combustion air if direct venting is not used? Yes No How many? Size? 38. What controls the combustion air supply Outside air damper Fan Open ventilation (if not direct vent)? Other: 33. What type of stack is used? Overall equivalent length* of stack and breeching *Each 90 degree elbow or vent termination = 5 ft of ductwork. 40. If multiple boilers, is a stack draft control employed? Yes No If yes, is it interlocked with burner control? Yes No 41. Is the boiler controlling an isolation valve or a boiler pump? Yes No If yes, what is the overrun time/off delay? If no, is the valve/pump interlocked with burner control? Yes No PROCEDURES 1. Was the burner door insulation/refractory and burner inspected? Yes No 2. What is the setting of the High Gas Pressure Switch? WC (nat. gas) WC (propane) 3. What is the setting of the Low Gas Pressure Switch? WC (nat. gas) WC (propane) 4. What is the pressure at the gas train inlet, downstream of the regulator, at low fire WC (nat. gas) WC (propane) at high fire WC (nat. gas) WC (propane) 5. What is the setting of the Combustion Air Proving Switch? WC 6. [CFC only] What is the setting of the High Air Pressure Switch? WC

5 7. FALCON PARAMETERS - PLEASE FILL OUT THE TABLE BELOW Falcon parameter settings Parameter Group Parameter Name Setting Burner Control Ignition Burner Control Timings & Rates Modulation Configuration Modulation Configuration Modulation Configuration CH setpoint CH TOD setpoint CH on hysteresis CH off hysteresis CH P gain CH I gain CH D gain DHW enable DHW setpoint DHW TOD setpoint DHW P gain DHW I gain DHW D gain Lightoff rate Prepurge time CH max. mod. rate DHW max. mod. rate Minimum mod. rate

6 8. USE THIS TABLE TO RECORD COMBUSTION ANALYSIS DATA Natural Gas Propane Firing Rate Low High Low High % O2 %CO2 CO PPM NOx PPM Ambient Temperature Stack Temperature o F Stack Draft Water Temperature (outlet) Operating Pressure Flame Signal Gas pressure at gas valve inlet Gas pressure at regulator inlet 9. Electrical characteristics at high fire: Blower motor voltage Blower motor actual voltage Control circuit voltage Control circuit fuse size Blower rated amps Blower actual amps Control circuit amps Blower fuse size COMMENTS This report was completed by: CB authorized service company: This report was reviewed with: Were all questions answered? Yes No PLEASE RETURN ONE COPY TO C-B SERVICE DEPARTMENT FOR WARRANTY REGISTRATION finished forms to: mschroeder@cleaverbrooks.com CB /2011