Camus Hydronics | DMC103 | Service manual | Camus Hydronics DMC103 Service manual

Camus Hydronics DMC103 Service manual
INSTALLATION OPERATION
AND SERVICE MANUAL
MODULATING MICOFLAME GRANDE
GAS FIRED COMMERCIAL COPPER TUBE BOILERS
FOR HYDRONIC HEATING
Non-Condensing Models; MFH2010, 2500, 3000, 3500, 4000
Condensing Models; MFH2012, 2502, 3002, 3502, 4002
HOT WATER SUPPLY
Non-Condensing Models; MFW2010, 2500, 3000, 3500, 4000
Condensing Models; MFW2012, 2502, 3002, 3502, 4002
WARNING:
If the information in these instructions is not followed
exactly, a fire or explosion may result causing property
damage, personal injury or death
Do not store or use gasoline or other flammable
vapours and liquids in the vicinity of this or any other
appliance.
WHAT TO DO IF YOU SMELL GAS
o Do not try to light any appliance,
o Do not touch any electrical switch; do not use
any phone in your building,
o Immediately call your gas supplier from a
neighbour’s phone. Follow the gas supplier’s
instructions,
o If you cannot reach your gas supplier, call the
fire department.
Qualified installer, service agency or the gas
supplier must perform installation and service.
To the installer: After installation, these instructions must
be given to the end user or left on or near the heater.
To the End User: This booklet contains important
information about this heater. Retain for future reference.
CAMUS
HYDRONICS
LTD.
6226 Netherhart Road, Mississauga, Ontario, L5T 1B7
99-0075
Rev. 01
Table of Contents
1
2
3
4
5
6
6.1
6.2
6.3
6.6
6.5
7
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
7.9.1
7.9.2
8
8.1
8.2
8.3
8.4
8.5
9
9.1
9.2
9.3
9.4
9.5
9.6
9.7
9.8
9.9
9.10
9.11
9.12
10
10.1
10.2
11
GENERAL INFORMATION ................................................................................................................................. 1
LOCATION ....................................................................................................................................................... 1
AIR REQUIRED FOR COMBUSTION AND VENTILATION ..................................................................................... 2
ELECTRICAL WIRING ........................................................................................................................................ 3
NORMAL GAS SUPPLY ..................................................................................................................................... 3
VENTING ........................................................................................................................................................ 4
OUTDOOR VENTING ........................................................................................................................................ 5
STANDARD VENTING ....................................................................................................................................... 6
SIDEWALL AND VERTICAL VENTING ................................................................................................................. 6
OUTDOOR AIR KIT ........................................................................................................................................... 6
FILTER KIT ....................................................................................................................................................... 6
WATER PIPING ................................................................................................................................................ 7
PROTECTION DEVICES ..................................................................................................................................... 8
FREEZE PROTECTION ...................................................................................................................................... 9
CHILLED WATER SYSTEMS .............................................................................................................................. 9
HEATING SYSTEM PIPING ............................................................................................................................... 9
LOW WATER TEMPERATURE SYSTEMS ......................................................................................................... 10
INSTANTANEOUS WATER HEATER ................................................................................................................. 10
HOT WATER SYSTEM PIPING......................................................................................................................... 10
CONDENSER HEAT RECOVERY MODULE (CHRM) ........................................................................................... 10
PIPING........................................................................................................................................................... 11
Parallel Piping ............................................................................................................................................... 12
Primary / Secondary Piping ........................................................................................................................... 12
INSTRUMENTATION AND CONTROLS............................................................................................................. 15
SAFETY CONTROLS ........................................................................................................................................ 15
CONTROL PANEL ........................................................................................................................................... 15
SETTING THE APPLIANCE TEMPERATURE CONTROLLER ................................................................................. 16
MODES OF OPERATION ................................................................................................................................. 16
Typical Factory Settings of Parameters for MicoFlame Grande BTC 1 (78-0017)............................................. 21
MICOFLAME GRANDE CONTROL PANEL......................................................................................................... 22
GENERAL SYMBOL DESCRIPTION ................................................................................................................... 22
MODE 1 & 2: SETPOINT OPERATION: VIEW DISPLAY ...................................................................................... 23
MODE 1 & 2: SETPOINT OPERATION: ADJUST DISPLAY .................................................................................. 24
MODE 3: DEDICATED DOMESTIC HOT WATER OPERATION: VIEW DISPLAY .................................................... 25
MODE 3: DEDICATED DOMESTIC HOT WATER OPERATION: ADJUST DISPLAY ................................................. 26
MODE 4 & 5: OUTDOOR RESET OPERATION: VIEW DISPLAY .......................................................................... 27
MODE 4 & 5: OUTDOOR RESET OPERATION: ADJUST DISPLAY ....................................................................... 28
MODE 6 & 7: EXTERNAL TARGET TEMPERATURE INPUT OPERATION: VIEW DISPLAY ..................................... 29
MODE 6 & 7: EXTERNAL TARGET TEMPERATURE INPUT OPERATION: ADJUST DISPLAY .................................. 30
MODE 8: EXTERNAL DRIVE OPEATION: VIEW DISPLAY ................................................................................... 31
MODE 8: EXTERNAL DRIVE OPEATION: ADJUST DISPLAY ................................................................................ 32
ERROR MESSAGES ......................................................................................................................................... 32
OPERATION ................................................................................................................................................... 34
START-UP ..................................................................................................................................................... 34
MODULATION SEQUENCE ............................................................................................................................. 35
PILOT AND MAIN BURNER FLAMES ............................................................................................................... 36
11.1
11.2
11.3
12
12.1
12.2
12.3
13
14
15
16
16.1
17
MAIN BURNER .............................................................................................................................................. 36
REMOVAL OF COMBUSTION CHAMBER LINING ............................................................................................. 38
PILOT BURNER .............................................................................................................................................. 38
OPERATION AND SERVICE ............................................................................................................................. 39
PRE-START CHECKLIST ................................................................................................................................... 39
START-UP ...................................................................................................................................................... 39
SERVICE......................................................................................................................................................... 41
LIGHTING INSTRUCTIONS .............................................................................................................................. 41
TROUBLE SHOOTING GUIDE .......................................................................................................................... 42
TYPICAL GAS TRAIN ....................................................................................................................................... 43
ELECTRICAL DIAGRAMS ................................................................................................................................. 44
MF 3500 – 4000 INTERNAL WIRING DIAGRAM .............................................................................................. 44
EXPLODED VIEW & PARTS LIST ...................................................................................................................... 45
MICOFLAME GRANDE REPLACEMENT PARTS LIST .......................................................................................... 47
WARRANTY.................................................................................................................................................... 51
1
warrantable
Excessive pitting and erosion on the inside of the
copper tube may be caused by high water velocity
or the use of an undersized boiler for a DHW
application and is not covered by warranty.
Using or storing corrosive chemicals in the vicinity
of this boiler can rapidly attack the copper tubes
and voids warranty.
The primary heat exchanger of this boiler is
intended to operate under non-condensing
conditions. Inlet temperatures must be maintained
o
o
at 130 F (55 C) for non-condensing and
condensing appliances. Warranty is void if the
primary heat exchanger is allowed to operate in
condensing mode.
Damage caused by freezing or dry firing voids
warranty.
This boiler is not to be used for temporary heating
of buildings under construction.
GENERAL INFORMATION
Camus Hydronics proudly introduces the
Modulating MicoFlame Grande series of water
heaters / hydronic boilers. The Modulating
MicoFlame Grande is a fan assisted appliance
based on a push through design which offers
several venting options. Heat output is controlled
by an adjustable ratio air/gas control valve. The
Modulating MicoFlame Grande models are
capable of modulating from 100% down to 40%
of rated input. These gas-burning appliances are
thoughtfully designed for easy operation and
maintenance. We are confident that you will
come to appreciate the benefits of our product.
The installation of this heater must conform to
the requirements of the authority having
jurisdiction or, in the absence of such
requirements, to the latest or current as
amended National Fuel Gas Code, ANSI Z223.1
or current CAN/CGA B149 Installation Codes.
All electrical wiring must be done in accordance
with the requirements of the authority having
jurisdiction or, in the absence of such
requirements, with the National Electrical Code,
ANSI/NFPA 70 or the Canadian Electrical Code
Part I, CSA C22.1 Electrical Code.
Vent installations must be in accordance with
Part 7, Venting of Equipment, of the latest or
current as amended National Fuel Gas Code,
ANSI Z223.1, or Section 7, Venting Systems
and Air Supply for Appliances, of the current
CAN/CGA B149, Installation Codes and
applicable provisions of the local building codes.
When required by the authority having
jurisdiction, the installation must conform to the
Standard for Controls and Safety Devices for
Automatically Fired Boilers, ANSI/ASME CSD-1.
The qualified installer shall instruct the end user
in the safe and correct operation of this
appliance and shall ensure that the heater is in
safe working order prior to leaving the job site.
2
LOCATION
Install this appliance in a clean, dry location with
adequate air supply and close to a good vent
connection.
Do not locate this appliance in an area where it will
be subject to freezing unless precautions are
taken.
The appliance is approved for installation directly
on combustible flooring and should be located
close to a floor drain in an area where leakage
from the appliance or connections will not result in
damage to the adjacent area or to lower floors in
the structure.
If necessary a suitable drain pan must be installed
under the appliance.
If the appliance is installed above the level of the
building’s radiation system, a low water cutoff
device must be installed in the appliance outlet at
the time of installation. Some local codes require
the installation of a low water cutoff on all systems.
Table 1: Service Clearances
WARRANTY
TOP:
SIDES:
Factory warranty shall apply only when the
boiler is installed in accordance with local
plumbing and building codes, ordinances and
regulations, the printed instructions provided
with it and good industry practices.
Excessive water hardness causing a lime buildup in the copper coils or tubes is not a fault of
the
boiler.
Consult
the
factory
for
recommendations for use in hard water areas.
Damage to the heat exchanger as a result of
scaling or corrosive water conditions in non-
24”
24”
REAR:
FRONT:
24”
48”
This appliance is suitable for alcove installation
with minimum clearances to combustibles as
follows:
Table 2: Clearance to Combustibles
TOP:
SIDES:
REAR:
VENT:
FLOOR:
1
12”
12”
12”
6”
0”
Figure 1: Appliance Dimensions
Table 3: Appliance Dimensions
B' Dia. Venting
Condensing
or Sidewall
Standard
Air Inlet
(Optional)
“L”
W'
‘S’
34 ⅝” 54 ¾” 33 3/8”
34 ⅝” 79”
58”
34 ⅝” 79”
58”
34 ⅝” 103” 81 ¾”
34 ⅝” 103” 81 ¾”
Outdoor
“K”
68”
72”
72”
72”
72”
Gas
Connection
3
“I”
6”
6”
6”
6”
6”
Water
Connection
Model
MF2010
MF2500
MF3000
MF3500
MF4000
E' Dia.
3”
3”
3”
4”
4”
1 ½”
2”
2”
2 ½”
2 ½”
12”
14”
14”
16”
16”
12”
14”
14”
16”
16”
14”
16”
16”
18”
18”
12”
14”
14”
16”
16”
The operation of exhaust fans, compressors, air
handling units etc. can rob air from the room,
creating a negative pressure condition leading to
reversal of the natural draft action of the venting
system. Under these circumstances an
engineered air supply is necessary.
AIR REQUIRED FOR
COMBUSTION AND
VENTILATION
Provisions for combustion and ventilation air
must be in accordance with:
• Section 5.3. Air for combustion and
Ventilation, of the latest or current as
amended National Fuel Gas Code,
ANSI Z223.1, or;
• Sections 7.2, 7.3 or 7.4 of the latest or
current as amended CAN/CGA B149
Installation Codes, and;
• Applicable provisions of the local
building codes.
If the heater is to be installed near a corrosive or
potentially corrosive air supply, the heater must
be isolated from it and outside air should be
supplied as per code.
Potentially corrosive atmospheres will result
from exposure to permanent wave solution,
chlorinated waxes and cleaners, chlorine, water
softening chemicals, carbon tetrachloride,
halogen based refrigerants, Freon cleaning
solvents, hydrochloric acid, cements and glues,
masonry washing materials, antistatic fabric
softeners, dry cleaning solvents, degreasing
liquids, printing inks, paint removers, etc.
2
4
ELECTRICAL WIRING
5
NORMAL GAS SUPPLY
This appliance is intended to operate at inlet gas
pressures not exceeding 1/4 PSI (7“W.C.) when
firing with natural gas. If higher pressures are
present, consult the gas company for correction.
All electrical wiring to the appliance must be
electrically bonded to ground in accordance with
the requirements of the authority having
jurisdiction or, in the absence of such
requirements, with the National Electrical Code,
ANSI/NFPA 70 or the Canadian Electrical Code
Part I, CSA C22.1, Electrical Code.
The appliance and its individual gas shut-off
valve must be disconnected from the supply
piping, when pressure testing the gas supply
piping at pressures above ½ PSI. Provide a trap
(drip leg) as close to the heater as possible.
Install a ground joint union and manual shut-off
valve in the gas line near the heater to allow
easy removal of the gas control assembly. The
gas pressure at the appliance’s inlet must be set
in accordance with Table 4.
Table 4: Gas Pressure Limits at Inlet to Appliance
Provide disconnecting means of sufficient rating
within sight of the appliance. These heaters
require an 115V 60 Hz supply. A 15-amp
breaker is sufficient for appliances with input up
to 3,000 MBTUH. For appliances with input over
3,000 MBTUH, use a 20-amp breaker. The
pump requires a separate power supply.
Electrical connections must be made so that the
circulator will operate before the gas valve can
open. At no time may the control system allow
the burner to fire without water flowing in the
system.
Min. Running (inches W.C.)
Max. Lockup (inches W.C.)
PROPANE
10
11
NATURAL GAS
4
14
The gas supply line must be of adequate size to
prevent undue pressure drop and must never be
smaller than the size of the connection on the
heater. Table 5 lists recommendation for gas
pipe sizes. Before operating the appliance, the
complete gas train and all connections must be
tested using non-corrosive soap solution.
Table 5: Gas pipe size for distance from natural
gas meter or propane second stage regulator
Use minimum 18-gauge conductor for 24-volt
field wiring to appliance. Splicing of wires is not
recommended. Use sealed tight conduit suitable
for outdoor use for outdoor installations. Use
terminal strip provided inside control panel for
low water cut-off and remote controller. Refer to
wiring diagram provided with appliance.
Input
Btu/Hr
2,000,000
2,500,000
3,000,000
3,500,000
4,000,000
Input
Btu/Hr
2,000,000
2,500,000
3,000,000
3,500,000
4,000,000
Input
Btu/Hr
2,000,000
2,500,000
3,000,000
3,500,000
4,000,000
3
0-100 FT*
NAT.
L.P.
2 ½”
2”
3”
2 ½”
3”
2 ½”
3”
2 ½”
4”
2 ½”
100-200 FT*
NAT.
L.P.
3”
2 ½”
3”
2 ½”
4”
3”
4”
3”
4”
3”
200-300 FT*
NAT.
L.P.
3”
2 ½”
4”
3”
4”
3”
4”
3”
4”
3”
6
do not operate a summer exhaust fan.
Close fireplace dampers.
d) Place in operation the appliance being
inspected.
Follow
the
lighting
instructions. Adjust thermostat so that
appliance operates continuously.
e) Test for spillage at the draft control
device relief opening after 5 minutes of
main burner operation. Use the flame of
a match or candle or smoke from a
cigarette.
f) After it has been determined that each
appliance remaining connected to the
common venting system properly vents
when tested as outlined above, return
doors, windows, exhaust fans, fireplace
dampers and any other gas-burning
appliance to their previous condition of
use.
g) Any improper operation of the common
venting system must be corrected so
that the installation conforms to the
latest or current as amended National
Fuel Gas Code, ANSI Z223.1 or the
current CAN/CGA B149, Installation
Codes. When resizing any portion of the
common venting system, the common
venting system should be resized to
approach the minimum size as
determined using the appropriate tables
in Part 11 of the latest or current as
amended National Fuel Gas Code,
ANSI Z223, 1 or the current CAN/CGA
B149, Installation Codes.
VENTING
Appliances for outdoor installation are intended
to vent using a listed vent cap.
For indoor installations venting must be in
accordance with Part 7, Venting of Equipment,
of the latest or current as amended National
Fuel Gas Code, ANSI Z223.1, or Section 7,
Venting of Equipment and Air Supply for
Appliances, of the latest or current as amended
CAN/CGA B149, Installation Codes, and
applicable provisions of the local building codes.
Vent connectors serving appliances vented by
natural draft shall not be connected into any
portion of mechanical draft systems operating
under positive pressure.
Horizontal runs of vent pipe shall be securely
supported (approximately every 4 feet) to
prevent sagging and maintain a minimum
upward slope of ¼” per foot from the appliance
to the vent terminal.
When an existing appliance is removed from a
common venting system, the common venting
system is likely to be too large for proper venting
of the appliances remaining connected to it. At
the time of removal of an existing appliance, the
following steps must be followed with each
appliance remaining connected to the common
venting system placed in operation, while the
other appliances remaining connected to the
common venting system are not in operation.
a) Seal any unused openings in the
common venting system.
b) Visually inspect the venting system for
proper size and horizontal pitch and
determine that there is no blockage,
restriction, leakage, corrosion or other
deficiency, which could cause an unsafe
condition.
c) Insofar as is practical, close all building
doors and windows and all doors
between the space in which the
appliances remaining connected to the
common venting system are located and
other spaces of the building. Turn on
clothes dryers and any appliances not
connected to the common venting
system. Turn on any exhaust fans, such
as range hoods and bathroom exhausts,
so they will operate at maximum speed,
Hydronic heating heat exchanger surfaces and
vent piping should be checked at least yearly for
deterioration and carbon deposits. Domestic hot
water heat exchanger surfaces and vent piping
should be checked every 6 (six) months.
Remove all soot or other obstructions from the
chimney and flue, which might impede draft
action. Replace any damaged or deteriorated
parts of the venting system.
4
A qualified service technician should follow this
procedure when inspecting and cleaning the
heat exchanger and vent pipe.
The MicoFlame Grande is category 1, 85%
efficient when supplied as a non-condensing
appliance. When supplied with the optional
condensing cartridge, the MicoFlame Grande is
95% efficient and is considered to be a category
II or IV appliance. Three venting options are
available for this appliance in both condensing
and non-condensing configurations. See Figure
2 for details. (Please refer to Table 3 for vent
dimensions)
1. Turn off electrical power and close main
manual gas shut-off and allow appliance
to cool down
2. Remove the vent pipe running to
chimney. Remove top outer panel and
flue collector access panel. Check heat
exchanger, vent and chimney for
obstruction and clean as necessary.
Figure 2: Venting Arrangement
3. Remove burner from appliance and
vacuum the heat exchanger. If heat
exchanger is excessively dirty it may be
necessary to remove it from the
appliance and wash it down with proper
detergent cleaner. Be aware that the
combustion chamber base is insulated
with ½” thick ceramic blanket. If this
material is damaged or displaced it must
be replaced before starting up the
appliance.
4. Reinstall parts removed in steps 2 and
3. Be sure that vent pipe has proper
pitch and is properly sealed. Repair or
replace any gaskets, which may have
been damaged in steps 2 and 3.
5. CAUTION: When replacing the burner
be careful to fully engage the back of
the burner box into the retaining slot in
the combustion chamber base. Failure
to properly locate the burner will result in
erratic flame operation with the
possibility of delayed ignition on light off.
Once in place make sure that the burner
box is sealed against the seal gasket
provided at the mixing tube.
6.1
OUTDOOR VENTING
When fitted with the factory supplied rain shields
and UL approved vent cap, the MicoFlame
Grande is self-venting. The following applies to
outdoor installations:
1. Use only factory supplied rain shields.
2. Periodically check to ensure that air
intake and vent cap are not obstructed.
3. Locate appliance at least 3 feet away
from any overhang.
4. Locate appliance at least ten feet from
building air intake.
5. Avoid installation in areas where runoff
from adjacent building can spill onto
appliance.
6. Restore electrical power and gas supply
to the appliance.
7. Place appliance in operation using
lighting instructions provided.
8. While the appliance is operating, check
for flue gas leaks and proper vent
operation. Seal any flue gas leaks using
appropriate gasket or sealing material.
Carefully examine the flue collector
access panel and heat exchanger ends.
5
6.2
STANDARD VENTING
6.6
The non-condensing 85% efficient MicoFlame
Grande is a category I appliance and is
approved for venting into a common chimney
provided it is in good condition and meeting the
local Codes. Typically, the chimney will be ‘B’
vent or brick with clay or metal liner. If the
chimney height is much greater than 30 feet or if
drafts are in excess of negative 0.05” W.C., it
will be necessary to provide a single acting
barometric damper directly above the vent
collar. This damper will ensure smooth light off
and minimize standby loss through the
appliance. Be sure to position the damper at
least 6” away from the wall of the vent
connector.
6.3
OUTDOOR AIR KIT
When fitted with the factory supplied air inlet ring
and air intake terminal, the MicoFlame Grande
can draw outdoor air over an equivalent length
of 60 feet. See Table 3 for vent sizes.
Appliances may be installed with either a
horizontal sidewall vent or vertical roof top
terminal. Terminals differ with each application.
The following applies to outdoor air installations:
1. Use only factory supplied air intake
terminal.
2. Periodically check to ensure that air
intake is not obstructed.
3. Refer to local codes for proper
installation and location of vent
terminals. Vertical vent terminal must be
at least 3 feet above the highest point
where it is located above the roof of a
building
4. Locate the air intake at least five feet
away from the vent discharge. For
sidewall venting locate the air intake
below the vent outlet if possible.
SIDEWALL AND VERTICAL VENTING
When fitted with the factory supplied vent
terminal, the MicoFlame Grande can vent up to
60 equivalent feet. Elbows can range from 8 to
15 feet in equivalent length depending on
centreline radius. See Table 3 for vent sizes.
Appliances may be installed with either a
horizontal sidewall vent or vertical roof top
terminal. Terminals differ with each application.
Horizontal lengths over 5 feet must be installed
using corrosion resistant stainless steel. Use
single wall vent and seal all joints or use
pressure rated double wall vent.
6.5
FILTER KIT
A slot at the bottom of the rear panel is the
standard air inlet configuration for the
MicoFlame Grande. As an option, outside air
could be introduced directly through the back or
top panels. A filter kit is available. The filter is
washable and accounts for an additional
pressure loss of less than 0.05” W.C. Highly
recommended for dusty environments. The filter
kit can also be provided when using the outdoor
air kit.
Refer to local codes for proper installation and
location of vent terminals.
When using sidewall vent, all vent connector
seams and joints must be sealed with pressure
sensitive aluminium tape or silicone sealant as
specified by the vent manufacturer. Aluminium
tape must meet the provisions of SMACNA
AFTS-100-73 Standard.
Conventional Venting
Multiple condensing appliances may be vented
into a common chimney. The chimney must be
lined with AL29-4C or equivalent and a single
acting barometric damper must be provided for
each appliance.
When venting through unheated spaces with
single wall vent, insulation must be properly
wrapped around the vent pipe to prevent flue
gas condensation inside the vent.
Periodically check to ensure that the vent
terminal is unobstructed.
6
A qualified professional using a proven ventsizing program with input of accurate operating
parameters must properly calculate sizing of the
venting system. In applications where flue gas
temperatures are lower than can support a
Category II with conventional negative draft, it
will be determined at the venting design stage
that a positive pressure will be developed in the
vent. It will then be necessary to either provide
separate vents as for Category IV, or to provide
an extractor at the chimney outlet in order to
maintain a negative draft in the chimney and
allow common venting.
7
The chimney must be protected from down
drafts, rain and debris by using a listed chimney
cap. Approval of the installation will be at the
discretion of authorities having jurisdiction.
With all vents open, run system circulating pump
for a minimum of 30 minutes with the boiler off.
WATER PIPING
Check all applicable local heating, plumbing and
building safety codes before proceeding.
With the boiler off, open makeup water valve
and allow system to fill slowly. Adjust the
pressure regulator to provide at least 15 PSIG in
the system when cold.
The circulating pump must be installed at the
appliance inlet. Always pump toward the heat
exchanger. Minimum operating system pressure
must not drop below 30 PSIG when hot.
Open all strainers in the circulating system and
check for debris.
Sidewall and Vertical Venting
Check liquid level in expansion tank. With
system full of water at 15 PSIG, the level of
water in the expansion tank should not exceed
¼ of the volume with the balance filled with air.
Start up boiler following instructions provided.
Operate entire system including pumps and
radiation for at least 1 hour.
The maximum vent length is 60 equivalent feet.
Vent pipe may be run through a vertical or
horizontal chase provided that minimum
clearances to combustible materials are
maintained. The vent should terminate a
minimum 12 inches above grade plus normally
expected snow accumulation, or 7 feet above
grade if located adjacent to public walkways. Do
not install over public walkway where local
experience indicates condensation or vapour
from the appliance creates a nuisance or
hazard.
Improper piping of this appliance will void the
manufacturer’s warranty. Improper piping
arrangement may cause heat exchanger tube
failure resulting in flooding and extensive
property damage. Excessive water hardness
causing scaling in the copper heat exchanger
tubes is not covered under the manufacturer’s
warranty. Excessive pitting and erosion of the
internal surface of the copper heat exchanger
tubes due to high water velocity or chemicals is
not covered under the manufacturer’s warranty.
Improper operation of this appliance by
o
permitting return water temperature below 130 F
o
(55 C) will result in flue gas condensation
leading to corrosion deposits on the heat
exchanger tubes and will void the warranty.
Minimum 3 feet above any forced air inlet
located within 10 feet of vent termination.
Minimum 4 feet below, 4 feet horizontally or
above any door window or gravity air inlet.
Minimum 4 feet horizontally from electric meters,
gas meters, regulators and relief valves. Use
appropriately designed thimbles when passing
through combustible walls or roofs. Install fire
stops where vent passes through floors, ceilings
or framed walls. The fire stop must close the
opening between the vent pipe and the
structure.
Locate
vent
terminal
above
combustion air intake terminal (if used) and no
closer than 2 feet vertically or horizontally.
Vertical venting requires flashing and a storm
collar to prevent moisture from entering the
structure. Vertical vent termination must be at
least 2 feet plus the expected snow
accumulation above the roof penetration height.
To eliminate trapped air, install venting devices
at high points in the system as well as in the
piping on the suction of the pump and in the
piping on the discharge of the appliance.
Suitable pipe hangers or floor stands must
support the weight of all water and gas piping.
7
7.1
The appliance must be installed so that the gas
ignition system components are protected from
water (dripping, spraying, rain, etc.) during
appliance operation and service (circulator
replacement, control replacement, etc.)
PROTECTION DEVICES
PRESSURE RELIEF VALVE (shipped loose)
This appliance is supplied with a relief valve
sized in accordance with ASME Boiler and
Pressure Vessel Code, Section IV (“Heating
Boilers”). The relief valve is to be installed in the
vertical position and mounted in the hot water
outlet. No valve is to be placed between the
relief valve, and the appliance. To prevent water
damage, the discharge from the relief valve shall
be piped to a suitable floor drain for disposal
when relief occurs. No reducing couplings or
other restrictions shall be installed in the
discharge line. The discharge line shall allow
complete drainage of the valve and line. Relief
valves should be manually operated at least
once a year.
Shut off valves must be installed at the inlet and
outlet connections of the appliance to provide for
isolation of the heat exchanger for servicing. If
the appliance is installed above radiation level, it
must be provided with a low water cutoff device
at the time of appliance installation.
This appliance is of a low mass design, which
provides for instant heat transfer. Special
attention to water flow rates will ensure that
temperature rise does not exceed 35°F (19.4°C).
Table 6 is provided as a guide. For application in
areas known to have hard water conditions, or
for
soft
water
contact
factory
for
recommendations.
CAUTION
Avoid contact with hot discharge water
Table 6: Flow vs. Head Loss for Various
Temperature Rise
20°F
Model
USGPM
∆P ft.
2010
170
5.1
2500
200*
8.2
3000
200*
8.2
3500
200*
10.2
4000
200*
10.2
30°F
Model
USGPM
∆P ft.
2010
113
2.4
2500
141
4.3
3000
170
6.2
3500
198
10.2
4000
200*
10.2
35°F
Model
USGPM
∆P ft.
2010
97.0
1.8
2500
121.0
3.3
3000
146.0
4.5
3500
170.0
7.7
4000
194.0
9.8
LOW WATER CUT-OFF (if equipped)
If this boiler is installed above radiation level, a
low water cut-off device must be installed at the
time of boiler installation. Some local codes
require the installation of a low water cut-off on
all systems. Electronic low water cut-offs are
available as a factory supplied option on all
models. Low water cut-offs should be tested
every six (6) months. The normally open switch
contact of the low water cutoff is to be wired in
series with the flow switch. A diagnostic light will
be indicated on the control display on a low flow
condition.
CAUTION
Remove jumper between H & P1 when connecting to
24 VAC circuit.
Figure 3: Low Water Cutoff Electrical
Connections
* Maximum flow recommended. Temperature rise
will be exceeded. CuNi heat exchanger should be
considered for flow rates exceeding maximum
recommended flows.
8
FLOW SWITCH (shipped loose)
and will allow easier servicing of the appliance
under severe weather conditions.
A water flow switch is shipped loose and is to be
installed in the outlet piping on all heating boilers
and hot water supply boilers. The flow switch is
wired in series with the 24VAC safety control
circuit. A diagnostic light will be indicated on the
control display on a low flow condition.
7.2
7.3
When an appliance is connected to an air
conditioning system where the same water is
used for heating and cooling, the chiller must be
piped in parallel with the appliance. Appropriate
flow control valves; manual or motorized must
be provided to prevent the chilled water from
entering the appliance. (See Figure 6)
FREEZE PROTECTION
•
Appliance
installations
are
not
recommended outdoors or in areas
where danger of freezing exists unless
precautions are taken. Maintaining a
mixture of 50% water and 50%
propylene glycol is the preferred method
of freeze protection in hydronic systems.
This mixture will protect the appliance to
approximately
-35ºF
(-37ºC).
To
maintain the same temperature rise
across the appliance increase the GPM
flow by 15% and the head loss by 20%.
Figure 4: Typical Chilled Water System
The following example demonstrates the
procedure to follow for calculating the revised
head for the heat exchanger when using a
water/glycol mixture.
•
•
•
•
CHILLED WATER SYSTEMS
When an appliance is connected to heating coils
located in air handling units (where they may be
exposed to refrigerated air circulation), the
appliance piping system shall be equipped with
a flow control valve or other automatic means to
prevent gravity circulation of chilled water
through the appliance. Chilled water in the
appliance will create condensate on the
appliance tubes, which will collect in the
combustion chamber causing corrosion.
Given for example that Camus is
showing a heat exchanger flow and
head loss of 100 gpm @ 10 feet
Increasing the flow by 15% now results in
a head loss of 13 feet at 115 gpm (from
B&G system syzer). At this increased flow
Camus now recommends to increase the
head loss by 20%.
The requirement for the heat exchanger
with water / glycol mixture will now be
115 gpm @ 15.6 feet. (ie. 1.2 x 13ft. =
15.6 ft.)
A similar procedure must be followed to
calculate the additional head loss in pipe
and fittings in order to arrive at the
proper pump selection.
7.4
HEATING SYSTEM PIPING
In larger systems, it is advisable to connect the
appliance to the piping employing the primarysecondary pumping system. This system is used
to provide system advantages that would not be
available with a single pumping system.
Primary-secondary pumping is illustrated in
Figure 9.
The following are some advantages of the
primary-secondary pumping system:
For Outdoor installations a snow screen should
be installed to prevent snow and ice
accumulation around the appliance. Regular
inspections should be made to ensure that air
intake and vent are free of snow and ice. Always
consider the use of a shelter such as a garden
shed in lieu of direct exposure of the appliance
to the elements. The additional protection
afforded by the shelter will help to minimize
nuisance problems with electrical connections
•
•
•
9
Greatly reduce the stand by losses
through the appliance
Minimize heat exchanger wear.
Reduce power consumption
7.5
LOW WATER TEMPERATURE
SYSTEMS
The storage tanks must be located as close as
possible to the appliance to prevent excessive
pressure drop. The required flow through the
appliance is based on normal water having
hardness between 7.5 and 17 grains per gallon.
Water hardness above this range will require
higher flow rates to prevent scaling and to
prevent erosion of copper-nickel heat exchanger
tubes. The manufacturer should be consulted
when
water
conditions
outside
the
aforementioned range are encountered.
In applications where the heating system
requires supply water temperatures below 130°F
o
(55 C), a recirculation line or thermostatic mixing
valve must be installed upstream of the
appliance pump so that outlet water can be recirculated to raise the inlet temp to a minimum of
o
130°F (55 C) for a recirculation line. Balancing
valves, preferably globe valves are used to
adjust flow. (See Figure 10)
•
7.6
The appliance could be fitted with an economizer
(secondary heat exchanger) to achieve nominal
efficiency of 95%. This heat exchanger is
fabricated from stainless steel and can accept inlet
water temperature as low as 40ºF.
Adjustment procedure.
a. Fully open bypass and outlet
valves.
b. With appliance running, read
inlet temperature after 15
minutes.
c. If the inlet temperature is less
o
than 130°F (55 C) slowly close
outlet valve until the inlet
temperature climbs to 130°F
(55oC)
d. If the inlet temperature is
o
greater than 130°F (55 C) but
o
not greater than 140°F (55 C)
no
further
adjustment
is
required.
e. Check the inlet temperature
after 5 minutes and make final
adjustments.
7.8
The MicoFlame Grande All Stainless Steel
CHRM is mounted in a stainless steel inner
jacket chamber at the rear of the appliance. The
CHRM is constructed from all stainless steel
headers and special multiple horizontal stainless
tubes. This CHRM is designed to maximize heat
transfer efficiency by fully condensing flue
products and is suitable to resist the low pH of
condensate.
The CHRM must be supplied with adequate
water flow at all times during operation. Do not
operate the appliance with the CHRM piped out
or isolated.
INSTANTANEOUS WATER HEATER
An instantaneous appliance is designed to
deliver hot water without the use of a storage
tank. It is suitable for applications with variable
load such as restaurants, condominiums,
apartments and motels. (See Figure 11). Call
manufacturer for recommendations.
7.7
CONDENSER HEAT RECOVERY
MODULE (CHRM)
The CHRM is mounted in the discharge of the
flue products from the primary heat exchanger.
This allows additional heat to be absorbed from
the flue products exhausted from the
combustion process. If isolation valves are
provided on the CHRM, the provision of a relief
valve at the outlet of the CHRM is
recommended. This valve is to be sized at
minimum for 10% of the input of the appliance
and is to be piped to drain.
HOT WATER SYSTEM PIPING
Piping and components connected to the
appliance must be suitable for use with potable
water. The appliance should not be connected to
any heating system piping or components
previously used with non potable water. Hot
water storage tanks used in potable water
system must be equipped with temperature and
pressure relief valve. Figures 12 and 13 illustrate
typical water heating piping arrangement for
single appliance and multiple appliances.
When cold water supply with temperatures less
than 130ºF (55ºC) passes through the CHRM it
will cool the flue products below dew points
resulting in the formation of condensation.
Furthermore, the volumetric flow rate of the flue
gases will be reduced.
10
The appliance CHRM loop may be used in
condensing mode for a variety of application
including domestic hot water and hydronic space
heating. Recommended piping arrangement is
shown in Figure 5. Maximum capacity through
the CHRM is summarized in Table 6; flows in
excess of 60 GPM must be bypassed.
combustible material for vent components. In the
absence of instructions, the minimum clearance
to combustible material is six inches.
Consult vent pipe manufacturer’s instructions for
proper method of sealing vent pipe sections and
fittings. In the absence of instructions, make
sure that pipe and fittings are clean by swabbing
with alcohol. Use Dow Corning 736 or 732 RTV,
Polybar # 500 RTV or Sil-bond 4500 or 6500 to
seal vent pipe. Do not use other sealants or
adhesives except as expressly permitted by vent
manufacturer’s instructions.
Figure 5: Typical Condensing System
Consult vent pipe manufacturer’s instructions for
vent system assembly. Follow vent pipe
manufacturer’s instructions if those instructions
differ from this section.
Figure 6: Secondary Heat Exchanger
Condensate from the MicoFlame Grande must
be treated before being discharged to drain. pH
level of the condensate is to be checked
regularly and the neutralizing medium is to be
replaced as required. A neutralizing cartridge is
available from the factory. The condensing
MicoFlame Grande must be vented using only
special venting type AL29-4C stainless steel or
equivalent, please follow instructions detailed
below.
Table 7 – CHRM Head Loss & Flow
When supplied with the CHRM, the MicoFlame
Grande is 95% efficient (category II or IV
appliance) which requires the use of a special
venting system fabricated from AL29-4C or
equivalent material. Only venting components
listed by a nationally recognized testing agency
may be used.
Model
US GPM
∆P - Ft.
2010
40.0
5.5
2500
50.0
8.0
3000
60.0
11.0
3500
40.0
5.5
4000
40.0
5.5
7.9
PIPING
The boiler can be piped in parallel or in
primary/secondary to the system. The type of
piping chosen affects the location of the control’s
operating temperature sensor. The control can
either use the boiler outlet sensor or the boiler
system sensor.
This appliance may be installed with
conventional, sidewall or vertical venting.
Conventional vented appliances operate with
negative pressure in the vent pipe and require a
special vent adapter to increase the flue outlet
diameter. Sidewall and vertically vented
appliances operate with positive pressure in the
vent pipe and may be directly connected to the
flue outlet without the use of an increaser.
Consult
the
vent
pipe
manufacturer’s
instructions for minimum clearances to
11
7.9.1
Parallel Piping
the boiler outlet pipe. Therefore, the control
requires a boiler outlet temperature sensor and
a system temperature sensor
In parallel piping applications, the boiler outlet
temperature is typically the same as the system
temperature.
Therefore
the
operating
temperature sensor is the boiler outlet sensor.
Figure 8: Primary / Secondary Piping
Figure 7: Parallel Piping
7.9.2
Primary / Secondary Piping
In primary / secondary applications, the boiler
outlet temperature is typically hotter than the
system supply temperature. This occurs as the
system supply pipe has a higher flow rate than
Figure 9: Typical Heating System
12
Figure 10: Typical Low Water Temperature System
Figure 11: Typical Instantaneous Water System
13
Figure 12: Typical Water Heating System
Figure 13: Typical Water Heating System
14
8
INSTRUMENTATION AND
CONTROLS
8.1
SAFETY CONTROLS
The Boiler Temperature Controller (BTC 1) for
this appliance is a Camus 78-0017 SmartFlame
control. The BTC 1 uses a Liquid Crystal Display
(LCD) as a method of displaying boiler
information. The BTC 1 is used to setup and
monitor the operation of the system. The BTC 1
uses three push buttons for selecting and
adjusting settings.
High Temperature Limit
The high temperature limit is located behind the
appliance’s access doors. A remote capillary
bulb runs to a thermo-well on the outlet side of
the inlet/outlet header. The appliance high limit
is set at the factory to 210ºF for hot water and
230ºF for heating.
Boiler Temperature Controller Features:
It initiates the local call for heat and sets the
target inlet (appliance inlet) water temperature.
This controller accommodates heating and
domestic hot water control with multiple modes
of operation which provide set point as well as
reset control. It provides the following:
• Readings of inlet and outlet temperatures
and ∆T temperature rise
• Operation as an auto reset limit.
• Operation as a control for inlet water
temperature.
• Optional tank mounted sensor used in
conjunction with inlet sensor.
• Adjustable pump delay feature based on
∆T temperature difference between inlet
and outlet temperatures. Accepts 1/6
hp. pump directly across terminals 13 &
14.
• Adjustable; target temp
• Display of run hours for maintenance
purposes. Counter displays up to
999,999 hours.
• Flame failure signal 24 V.
• Molex connector for ease of service.
• Error message display.
• Test override feature to test pump
operation and alarm.
• Pump exercising feature runs pump 10
seconds every three days of no pump
operation.
Air Proving Switch
An air proving switch is provided on each burner
to prove the operation of the fan and adequate
air flow to the burner. The pressure switch
sensing point is at the air box below the
combustion chamber. The LED indicator for air
flow will not illuminate should the pressure
switch detect a sustained low air condition.
Blocked Flue Switch
A normally-closed blocked flue switch is
provided for the boiler. It senses a blocked flue
condition or a blocked fan inlet and shuts down
the boiler.
8.2
CONTROL PANEL
The appliance is provided with a control panel at
the front. Operating controls are installed inside
the control box and are accessible by undoing
the thumb screw and opening the door. The
diagnostic information centre as well as the
on/off switch, 24V fuse, and the appliance
temperature controls reside on the control panel
door.
Figure 14: Display, Appliance Temperature
Controller and Indicating LED
The menu structure for the Appliance
Temperature Control was designed to be
intuitive and easy to use for a first time user. To
maintain the MicoFlame Modulating boiler at its
correct settings two levels of access is provided,
User and Installer with an increasing amount of
parameters that can be adjusted by the Installer.
This is done to provide an easy means of
communication for the end user and a more
indepth approach for factory installers when
installing and troubleshooting.
15
Figure 15: Boiler Temperature Control (BTC 1)
8.4
MODES OF OPERATION
Mode 1: Constant Temperature Control
This mode is designed for hydronic heating or
domestic hot water (DHW). Once a heat
demand is present, the BTC 1 turns on the
appliance pump and modulates the boiler burner
to maintain the boiler target at the boiler inlet
sensor. A heat demand is generated when a
24VAC is applied across CD (common demand)
and Ht D (heat demand). Once voltage is
applied, the BTC 1 turns on the Dem 1 segment
in the display.
8.3
If the inlet sensor is ½ (half) of the differential
below the BOIL TARGET, the BTC 1 then
changes the proportional modulation output to
the START modulation setting, the Stage
contact (pins 15 & 16) close to proceed to trial
for ignition. The burner remains at minimum
modulation until the flame is proved and then the
modulating output changes the boiler burner
output to maintain the programmed boiler target
temperature at the inlet sensor. If the inlet
sensor reaches ½ (half) of the differential above
BOIL TARGET setting, the burner shuts off.
Once the external heat demand is removed, the
BTC 1 turns off the appliance and operates the
boiler pump based on the PUMP DELAY setting.
SETTING THE APPLIANCE
TEMPERATURE CONTROLLER
Press and hold all three buttons
simultaneously for 1 second. Pressing the ITEM
key again will cause the last setting to be
accepted. Once all settings have been made
wait for 30 seconds for the BTC 1 to return to
normal operating mode. To re-enter the Installer
menu press and hold all three buttons
simultaneously for 1 second. In normal operating
mode the inlet temperature, outlet temperature,
∆T temperature and ON hours can be viewed by
repeatedly pressing the ITEM key. If you wish to
check the setting you will have to start again by
pressing and holding the
buttons
simultaneously for 1 second, and then use the
ITEM key to scroll through the settings. After
checking the settings allow the BTC 1 to return
to normal operation on its own.
The water temperature is controlled based on a
fixed setpoint (BOIL TARGET).The setpoint for
inlet water is pre-set to 120oF and the auto reset limit is set to 210°F and is fixed. In addition
to the auto reset limit the factory installs a
manual re-set limit set to 250°F.
Figure 16: Mode 1 Piping & Electrical Layout
16
Mode 2: Constant Temperature Control at
System Sensor
Mode 3: Dedicated Domestic Hot Water
Operation
This mode is designed for hydronic heating.
Once a heat demand is present, the BTC 1
modulates the boiler burner to maintain the
boiler target at the system sensor. A heat
demand is generated when 24VAC is applied
across CD (common demand) and Ht D (heat
demand). Dem 1 on the LCD display is lit.
This mode is designed for domestic hot water. A
DHW sensor must be inserted into a
temperature immersion well within the DHW
tank to function properly. The BTC 1 modulates
the boiler based on the boiler inlet sensor to
maintain a tank temperature at the DHW sensor.
An internal heat demand is generated when the
DHW sensor drops ½ (half) of the tank
differential setting below the desired DHW tank
temperature. Dem 1 is lit on the LCD screen.
If the system sensor is ½ (half) of the differential
below the BOIL TARGET, the BTC 1 then
changes the proportional modulation output to
the START modulation setting, the Stage
contact (pins 15 & 16) closes to proceed to trial
for ignition. The burner remains at minimum
modulation until the flame is proved and then the
modulating output changes the boiler burner
output to maintain the programmed boiler target
temperature at the system sensor. If the system
sensor reaches ½ (half) of the differential above
BOIL TARGET setting, the burner shuts off.
Once the external heat demand is removed, the
BTC 1 turns off the appliance and operates the
boiler pump based on the PUMP DELAY setting.
In this case, it is imperative that the system
pump operates continuously in order to provide
constant circulation past the system sensor.
The BTC 1 then changes the modulation output
to the START modulation setting and closes the
Stage contact (pins 15 & 16) to proceed to trial
for ignition. The burner remains at minimum
modulation until the flame is proved and then
modulating output changes the boiler output to
maintain the programmed boiler target
temperature at the boiler inlet sensor. Once the
DHW tank reaches ½ of the tank differential
above the TANK TARGET setting, the internal
demand is removed and the boiler burner is shut
off. The pump circulates until the PUMP DELAY
timer expires.
The TANK TARGET setting is used to set the
desired DHW tank setpoint. The set-point for
inlet water is pre-set to 130°F and can be
adjusted, the auto re-set limit is set to 210°F and
is fixed. In addition to the auto reset limit the
factory installs a manual re-set limit set to 210°F .
The water temperature is controlled based on a
fixed setpoint (BOIL TARGET).The setpoint for
o
inlet water is pre-set to 120 F and the auto reset limit is set to 210°F and is fixed. In addition
to the auto reset limit the factory installs a
manual re-set limit set to 250°F.
Figure 18: Mode 3 Piping & Electrical Layout
Figure 17: Mode 2 Piping & Electrical Layout
Mode 4: Outdoor Reset using Boiler Inlet Sensor
17
This mode is designed for hydronic heating.
Once a heat demand is present, the BTC 1 turns
on the appliance pump and modulates the boiler
to maintain the calculated outdoor reset target at
the boiler inlet sensor. Outdoor reset calculates
the boiler target temperature based on the
outdoor air temperature and reset ratio.
Mode 5: Outdoor Reset using System Sensor
This mode is designed for hydronic heating.
Once a heat demand is present, the BTC 1 turns
on the appliance pump and modulates the boiler
to maintain the calculated outdoor reset target at
the system sensor. Outdoor reset calculates the
boiler target temperature based on the outdoor
air temperature and reset ratio.
A heat demand is generated when a voltage
between 24VAC and 120VAC is applied across
CD (common demand) and Ht D (heat demand).
Once voltage is applied, the BTC 1 turns on the
Dem 1 segment in the display. If warm weather
shut down (WWSD) is activated, the WWSD
segment is lit.
A heat demand is generated when a voltage
between 24VAC and 120VAC is applied across
CD (common demand) and Ht D (heat demand).
Once voltage is applied, the BTC 1 turns on the
Dem 1 segment in the display. If warm weather
shut down (WWSD) is activated, the WWSD
segment is lit.
If WWSD is not activated and the inlet sensor is
½ (half) of the differential below the calculated
BOIL TARGET, the BTC 1 then changes the
modulation output to the START modulation
setting and closes the Stage contacts (pins 15 &
16) to proceed to trial for ignition. The burner
remains at minimum modulation until the flame
is proved and then modulating output changes
the boiler output to maintain the calculated boiler
target temperature at the inlet sensor. If the inlet
sensor reaches ½ (half) of the differential above
the BOIL TARGET, the appliance is shut off.
The boiler pump continues to circulate until the
PUMP DELAY timer expires.
If WWSD is not activated and the system sensor
is ½ (half) of the differential below the calculated
BOIL TARGET, the control then changes the
modulation output to the START modulation
setting and closes the Stage contacts (pins 15
&16) to proceed to trial for ignition. The burner
remains at minimum modulation until the flame
is proved and then the modulating output
changes the boiler output to maintain the
calculated boiler target temperature at the
system sensor. If the system sensor reaches ½
(half) of the differential above the BOIL
TARGET, the appliance is shut off. The
appliance pump continues to circulate until the
PUMP DELAY timer expires. In this case, it is
imperative that the system pump operates
continuously in order to provide constant
circulation past the system sensor.
The water temperature is controlled based on a
calculated boiler target temperature. The boiler
start (BOIL START) temperature is pre-set to
o
70 F and the auto re-set limit is set to 210°F and
is fixed. In addition to the auto reset limit the
factory installs a manual re-set limit set to 250°F .
The water temperature is controlled based on a
calculated boiler target temperature. The boiler
start (BOIL START) temperature is pre-set to
o
70 F and the auto re-set limit is set to 210°F and
is fixed. In addition to the auto reset limit the
factory installs a manual re-set limit set to 250°F .
Figure 19: Mode 4 Piping & Electrical Layout
Figure 20: Mode 5 Piping & Electrical Layout
18
Mode 6: External Target Temperature using
Boiler Inlet Sensor
turns off the appliance and operates the boiler
pump based on the PUMP DELAY setting.
The auto re-set limit is set to 210°F and is fixed.
In addition to the auto reset limit the factory
installs a manual re-set limit set to 250°F.
Figure 21: Mode 6 Piping Schematic
The external input signal can be provided from a
BMS, EMS or a tekmar tN4 System Control. The
external input signal creates an internal demand
and changes the boiler target according to a
linear scale. The BTC 1 modulates the boiler to
maintain the boiler target at the inlet sensor.
An internal heat demand is generated when an
analog positive 2-10VDC signal is applied to the
+V input and a negative DC signal is applied to
the Com/- input.
The following table shows the various signals
required
to
generate
various
Target
temperatures.
Table 8: External Signal Cross Reference
Chart
4-20
Boiler
0-10V
Boiler
mA
Target
(dc)*
Target
0
- - - (OFF)
0
- - - (OFF)
2
- - - (OFF)
4
50 F (10 C)
6
70 F (21 C)
8
90 F (32 C)
o
o
o
o
o
o
1
50 F (10 C)
o
o
2
68 F (20 C)
o
o
3
86 F (30 C)
o
o
4
103 F (39 C)
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
5
121 F (49 C)
o
o
6
139 F (59 C)
o
o
7
157 F (69 C)
o
o
8
174 F (79 C)
o
o
9
192 F (89 C)
o
o
10
110 F (43 C)
12
130 F (54 C)
14
150 F (66 C)
16
170 F (77 C)
18
190 F (88 C)
20
210 F (99 C)
10
210 F (99 C)
* requires 500Ω resistor
A 4-20mA signal can be converted to a 210VDC signal by installing a 500Ω resistor on
the external input signal device’s terminal.
If the inlet sensor is ½ (half) of the differential
below the Boiler Target, the BTC 1 then
changes the proportional modulation output to
the START modulation setting, the Stage
contact (pins 15 & 16) closes to proceed to trial
for ignition. The burner remains at minimum
modulation until the flame is proved and then the
modulating output changes the boiler burner
output to maintain the programmed boiler target
temperature at the inlet sensor. If the inlet
sensor reaches ½ (half) of the differential above
Boiler Target, the burner shuts off. Once the
external heat demand is removed, the BTC 1
19
Mode 7: External Target Temperature using
System Temperature Sensor
Mode 8: External Direct Drive Operation
This mode is designed only for hydronic heating
operation. This mode allows for an external control
to operate the boiler through an analog direct drive
input signal provided by a boiler sequencing
control, such as, the S12 Sequencer. When
operating in this mode the external heat demand
and DHW demand are disabled.
An external boiler sequencer provides a positive
0-10 VDC input signal to the control at +V(in),
and the negative signal is applied to the Com/input.
The boiler remains off while the direct drive input
signal range is between 0 to 0.5VDC. Once the
direct drive input signal reaches 0.5VDC the
control turns on the appliance pump and
changes the modulating output to Start
Modulation level until the flame is proved and
then the modulating output is adjusted to track
the direct drive input signal up to the maximum
of 10VDC which is equivalent to maximum input
rate. When the direct drive signal modulates
down to 0.5VDC, the boiler operates at minimum
fire. When the signal drops below 0.5VDC the
burner is shut off and the pump continues to
circulate until the PUMP DELAY timer expires,
whereupon the pump shuts off.
The external boiler sequencer can specify the
boiler inlet temperature. However, the BOIL
MAX setting limits the highest temperature at the
outlet sensor. If the outlet temperature exceeds
o
210 F, the modulating output immediately
changes to 0% and the burner is shut off. The
burner is to remain off until the minimum off
timer is satisfied and the boiler outlet
o
o
temperature falls by 2 F (1 C) below the BOIL
MAX setting.
The external input signal can be provided from a
BMS, EMS or a tekmar tN4 System Control. The
external input signal creates an internal demand
and changes the boiler target according to a
linear scale. The control modulates the boiler to
maintain the boiler target at the outlet sensor.
An internal heat demand is generated when an
analog positive 2-10VDC signal is applied to the
+V input and a negative DC signal is applied to
the Com/- input.
Table 8 shows the relationship between various
external signals to the boiler target temperature.
A 4-20mA signal can be converted to a 210VDC signal by installing a 500Ω resistor on
the external input signal device’s terminal.
If the system sensor is ½ (half) of the differential
below the Boiler Target, the BTC 1 then
changes the proportional modulation output to
the START modulation setting, then closes the
Stage contact (pins 15 & 16) to proceed to trial
for ignition. The burner remains at minimum
modulation until the flame is proved and then the
modulating output changes the boiler burner out
to maintain the programmed boiler target
temperature at the system sensor. If the inlet
sensor reaches ½ (half) of the differential above
Boiler Target, the burner shuts off. Once the
external heat demand is removed, the BTC 1
turns off the appliance and operates the boiler
pump based on the PUMP DELAY setting.
The auto reset limit is set to 210oF and is fixed.
In addition to the auto reset limit, Camus installs
o
a manual reset limit set to 250 F.
Figure 22: Mode 7 Piping & Electrical Layout
Figure 23: Mode 8 Piping & Electrical Layout
20
8.5
Mode 8
- External analogue 0-10VDC signal
closes the stage contacts to initiate
heater. Modulating output of the control
follows the analog external input signal.
Temperature is controlled remotely
independently of local settings. Boiler
max. setting remains functional.
- Intermittent pumping provided
Typical Factory Settings of Parameters
for MicoFlame Grande BTC 1 (78-0017)
This modulating MicoFlame is equipped with the
Camus version of the Tekmar MPA control.
Summary of 8 Modes of Operation
Mode 1
- For setpoint control at heater inlet
sensor. Use for hydronic constant
setpoint heating or domestic hot water
applications.
- External heat demand or constant
pumping required.
Mode 2
- For setpoint control at system sensor
- Ideal for monitoring constant hot loop or
for pool heating
- Intermittent pumping povided.
Mode 3
- For DHW control with tank sensor.
Controls to boiler inlet sensor.
- Intermittent pumping provided
Mode 4
- For hydronic heating with outdoor reset.
Temperature control at boiler inlet
sensor with proportional modulating
logic.
Mode 5
- For hydronic heating with outdoor reset.
Temperature control at system sensor
with selectable P.I.D. or proportional
modulating logic.
- Intermittent pumping provided
Mode 6
- External analogue 0-10VDC signal
generates temperature target. Setpoint
temperature control at heater inlet
sensor using proportional modulating
logic.
- Intermittent pumping provided
Mode 7
- External analogue 0-10VDC signal
generates temperature target. Setpoint
temperature control at system sensor
with selectable PID or modulating logic.
- Intermittent pumping provided.
Factory Settings of Modulating Control
1) Access to the setup menu is achieved
by pressing the ITEM, UP and DOWN
buttons simultaneously for 1 second.
Parameter
Mode
Target
High Limit
Factory Settings
1
175oF (Heating)
140oF (DHW)
230oF (Heating)
210oF (DHW)
Throttling
Range
Modulation
Dly Mod.
Start Mod.
Min. Mod.
Max. Mod.
10oF
4:20
50 sec
Factory Set
Factory Set
Factory Set
Differential
Pump Delay
5 oF
1:00 min
WARNING: DO NOT ATTEMPT TO ADJUST
START, MIN. OR MAX. MODULATION
LEVELS IN THE FIELD.
21
9
9.1
MICOFLAME GRANDE
CONTROL PANEL
GENERAL SYMBOL DESCRIPTION
SYMBOL
SYMBOL
NAME
Boiler
Pump
Shown when
boiler pump is
in operation
DHW
Pump
Shown when
DHW pump is
in operation
Heat
Demand
Shown when
heat demand is
present
Flame
Proof
Shown when
flame signal is
proven
Burner
Shown when
burner is on
Warning
Figure 24: BTC 1 Key Functions
Pointers
WWSD
Table 9: BTC 1 Key Functions
KEY
Item
KEY DESCRIPTION
The abbreviated name of the selected
item will be displayed in the item field of
the display. To view the next item, press
the Item button.
Increase a parameter value.
Decrease a parameter value.
Levels of Access
View – Access to general boiler and display
settings and will allow adjustments to the central
heating and domestic hot water setpoint.
Adjust – Access to all user parameters and
allows for changes to additional boiler
parameters to allow for ease of startup and
serviceability.
22
SYMBOL
DESCRIPTION
Shown when
an error is
present
Shows the
operation as
indicated by the
text
Displays when
the control is in
Warm Weather
Shutdown
9.2
MODE 1 & 2: SETPOINT OPERATION: VIEW DISPLAY
From the Home display;
1) Press [ITEM] to view the following parameters:
Display
Parameter
Name
Boiler Target
Temperature
Parameter Description
To provide a target setpoint for the
heating system. Setpoint is controlled
to the inlet sensor
System Temperature of Primary Loop
System
Temperature
NOTE: This parameter is only
available in Mode 2
Parameter
Range
o
---, 35 to 266 F
o
(---, 2 to 130 C)
o
14 to 266 F
o
(-10 to 130 C)
o
Boiler Outlet
Temperature
Real-time Outlet Temperature to Boiler
14 to 266 F
(-10 to 130oC)
Boiler Inlet
Temperature
Real-time Inlet Temperature to Boiler
14 to 266 F
o
(-10 to 130 C)
Boiler Delta
T
o
Real-time temperature difference
between the outlet sensor and the inlet
sensor.
o
-99 to 252 F
o
(-72 to 140 C)
Modulation
Real-time modulating output
percentage
0 to 100%
Total Run
Time Since
Installation
Monitors the amount of operational
time since the MicoFlame was
installed. The first two digits are the
number of thousands of hours and the
three digit display shows the number
of hundreds of hours.
Press
simultaneously to reset
the counter
Alternates
between 00 and
999
23
9.3
MODE 1 & 2: SETPOINT OPERATION: ADJUST DISPLAY
From the Home display;
1) Press
simultaneously to view the following parameters:
Parameter
Display
Parameter Description
Name
Operating mode for the boiler.
NOTE: A complete description of
each mode can be found in
section 8.4 Modes of Operation in
this manual.
Mode
Parameter
Range
1 to 8
Default = 1
o
Boiler Target
Temperature
To provide a target setpoint for
the heating system. Setpoint is
controlled to the inlet sensor
Differential
Temperature
To provide a modulation rate
above and below the Boiler
Target temperature. For example,
o
if the value is 10 F and the Boiler
o
Target is 160 F the boiler will
o
begin to modulate at 155 F and
o
shut off at 165 F.
Pump Delay
Boiler post pump time after
burner has shut off, in seconds.
70 to 220 F
o
(21 to 104 C)
o
Default = 120 F
(49oC)
o
Au, 2 to 42 F
o
(Au, -17 to 6 C)
Default = Au
OFF, 0:20 to
9:55 min, On
Default = 1:00
min
o
Temperature
Units
24
Select the desired unit of
measurement
o
F, C
Default = oF
9.4
MODE 3: DEDICATED DOMESTIC HOT WATER OPERATION: VIEW DISPLAY
From the Home display;
1) Press [ITEM] to view the following parameters:
Display
Parameter
Name
Parameter Description
Parameter
Range
Boiler Target
Temperature
To provide a target setpoint for the
heating system. Setpoint is controlled
to the inlet sensor
---, 35 to 266 F
o
(---, 2 to 130 C)
Boiler Outlet
Temperature
Real-time Outlet Temperature to Boiler
14 to 266 F
o
(-10 to 130 C)
Boiler Inlet
Temperature
Real-time Inlet Temperature to Boiler
14 to 266 F
o
(-10 to 130 C)
Real-time temperature difference
between the outlet sensor and the inlet
sensor.
-99 to 252oF
o
(-72 to 122 C)
DHW
Temperature
Real-time DHW Temperature
14 to 266 F
o
(-10 to 130 C)
Modulation
Real-time modulating output
percentage
0 to 100%
Total Run
Time Since
Installation
Monitors the amount of operational
time since the MicoFlame was
installed. The first two digits are the
number of thousands of hours and the
three digit display shows the number
of hundreds of hours.
Press
simultaneously to reset
the counter
Alternates
between 00 and
999
Boiler Delta
T
o
o
o
o
25
9.5
MODE 3: DEDICATED DOMESTIC HOT WATER OPERATION: ADJUST DISPLAY
From the Home display;
simultaneously to view the following parameters:
1) Press
Display
Parameter
Name
Parameter
Range
Parameter Description
Operating mode for the boiler.
NOTE: A complete description of
each mode can be found in
section 8.4 Modes of Operation in
this manual.
Mode
Boiler Target
Temperature
DHW Target
Temperature
DHW
Differential
Differential
Temperature
Pump Delay
Temperature
Units
To provide a target setpoint for
the heating system. Setpoint is
controlled to the inlet sensor
To provide a target setpoint for
the DHW system. Setpoint is
controlled to the DHW sensor
To provide a modulation rate
above and below the DHW
Target Temperature. For
o
example, if the value is 10 F and
the DHW Target Temperature is
160oF the boiler will begin to
o
modulate at 155 F and shut off at
o
165 F.
To provide a modulation rate
above and below the Boiler
Target temperature. For example,
o
if the value is 10 F and the Boiler
o
Target is 160 F the boiler will
o
begin to modulate at 155 F and
o
shut off at 165 F.
Boiler post pump time after
burner has shut off, in seconds.
Select the desired unit of
measurement
1 to 8
Default = 1
OFF, 70 to
o
220 F
(OFF,21 to
o
104 C)
o
Default = 120 F
o
(82 C)
OFF, 70 to
o
190 F
(OFF, 21 to
o
88 C)
Default = 140oF
o
(54 C)
o
2 to 10 F
o
(1 to 5 C)
o
Default = 3 F
o
(1 C)
o
Au, 2 to 42 F
o
(Au, -17 to 5 C)
Default = Au
OFF, 0:20 to
9:55 min, On
Default = 1:00
min
o
o
F, C
o
Default = F
26
9.6
MODE 4 & 5: OUTDOOR RESET OPERATION: VIEW DISPLAY
From the Home display;
1) Press [ITEM] to view the following parameters:
Display
Parameter
Name
Parameter Description
Outdoor
Temperature
Real-time Outdoor Temperature
Boiler Target
Temperature
To provide a target setpoint for the
heating system. Setpoint is controlled
to the inlet sensor
System Temperature of Primary Loop
System
Temperature
NOTE: This parameter is only
available in Mode 5
Parameter
Range
-60 to 190oF
o
(-51 to 88 C)
o
---, 35 to 266 F
o
(---, 2 to 130 C)
o
14 to 266 F
o
(-10 to 130 C)
o
Boiler Outlet
Temperature
Real-time Outlet Temperature
14 to 266 F
o
(-10 to 130 C)
Boiler Inlet
Temperature
Real-time Inlet Temperature
14 to 266 F
o
(-10 to 130 C)
Boiler Delta
T
o
Real-time temperature difference
between the outlet sensor and the inlet
sensor.
o
-99 to 252 F
o
(-72 to 122 C)
Modulation
Real-time modulating output
percentage
0 to 100%
Total Run
Time Since
Installation
Monitors the amount of operational
time since the MicoFlame was
installed. The first two digits are the
number of thousands of hours and the
three digit display shows the number
of hundreds of hours.
Press
simultaneously to reset
the counter
Alternates
between 00 and
999
27
9.7
MODE 4 & 5: OUTDOOR RESET OPERATION: ADJUST DISPLAY
From the Home display;
1) Press
simultaneously to view the following parameters:
Display
Parameter Name
Parameter Description
Parameter
Range
Operating mode for the boiler.
NOTE: A complete description of
each mode can be found in
section 8.4 Modes of Operation in
this manual.
Mode
1 to 8
Default = 1
o
Outdoor Start
Temperature
Outdoor starting temperature
used in the reset ratio for the
heating system. Typically set to
the desired building temperature.
Outdoor Design
Temperature
Outdoor design temperature used
in the reset ratio for the heating
system. Set to the coldest annual
outdoor temperature in the local
area.
Boiler Start
Temperature
Starting water temperature used
in the reset ratio calculation for
the heating system. Typically set
to the desired building
temperature.
Boiler design water temperature
used in the reset ratio calculation
for the heating system. Set to the
boiler water temperature required
to heat the building on the coldest
annual outdoor temperature.
To provide a modulation rate
above and below the Boiler
Target temperature. For example,
o
if the value is 10 F and the Boiler
o
Target is 160 F the boiler will
begin to modulate at 155oF and
o
shut off at 165 F.
Boiler Design
Temperature
Differential
Temperature
Boiler post pump time after
burner has shut off, in seconds.
Pump Delay
28
35 to 85 F
o
(2 to 29 C)
Default = 60oF
o
(21 C)
o
-60 to 50 F
o
(-51 to 10 C)
o
Default = -10 F
(-23oC)
o
35 to 150 F
o
(2 to 66 C)
o
Default = 70 F
(21oC)
70 to 230oF
o
(21 to 110 C)
o
Default = 180 F
o
(82 C)
Au, 2 to 42oF
o
(Au, -16 to 5 C)
Default = Au
OFF, 0:20 to
9:55 min, On
Default = 1:00
min
Display
Parameter Name
Parameter
Range
Parameter Description
o
Warm Weather
Shutdown
Temperature
Warm weather shutdown
temperature using outdoor reset.
Temperature Units
Select the desired unit of
measurement
35 to 105 F,
OFF
o
(2 to 41 C, OFF)
Default = 0:20
min
o
o
F, C
o
Default = F
9.8
MODE 6 & 7: EXTERNAL TARGET TEMPERATURE INPUT OPERATION: VIEW DISPLAY
From the Home display;
1) Press [ITEM] to view the following parameters:
Display
Parameter
Name
Boiler Target
Temperature
Parameter Description
To provide a target setpoint for the
heating system. Setpoint is controlled
to the inlet sensor.
Real-time System Temperature
System
Temperature
NOTE: This parameter is only
available in Mode 7
Parameter
Range
o
---, 35 to 266 F
o
(---, 2 to 130 C)
14 to 266oF
o
(-10 to 130 C)
Boiler Outlet
Temperature
Real-time Outlet Temperature to Boiler
14 to 266oF
o
(-10 to 130 C)
Boiler Inlet
Temperature
Real-time Inlet Temperature to Boiler
14 to 266oF
o
(-10 to 130 C)
Real-time temperature difference
between the outlet sensor and the inlet
sensor.
-99 to 252oF
o
(-72 to 122 C)
Boiler Delta
T
29
Display
9.9
Parameter
Name
Parameter
Range
Parameter Description
Modulation
Real-time modulating output
percentage
0 to 100%
Total Run
Time Since
Installation
Monitors the amount of operational
time since the MicoFlame was
installed. The first two digits are the
number of thousands of hours and the
three digit display shows the number
of hundreds of hours.
Press
simultaneously to reset
the counter
Alternates
between 00 and
999
MODE 6 & 7: EXTERNAL TARGET TEMPERATURE INPUT OPERATION: ADJUST DISPLAY
From the Home display;
1) Press
simultaneously to view the following parameters:
Display
Parameter
Name
Parameter
Range
Parameter Description
Operating mode for the boiler.
Mode
Differential
Temperature
Pump Delay
NOTE: A complete description of
each mode can be found in
section 8.4 Modes of Operation in
this manual.
To provide a modulation rate
above and below the Boiler
Target temperature. For example,
o
if the value is 10 F and the Boiler
o
Target is 160 F the boiler will
o
begin to modulate at 155 F and
o
shut off at 165 F.
Boiler post pump time after
burner has shut off, in seconds.
1 to 8
Default = 1
o
Au, 2 to 42 F
(Au, -17 to 6oC)
Default = Au
OFF, 0:20 to
9:55 min, On
Default = 1:00
min
o
Temperature
Units
30
Select the desired unit of
measurement
o
F, C
o
Default = F
9.10
MODE 8: EXTERNAL DRIVE OPEATION: VIEW DISPLAY
From the Home display;
2) Press [ITEM] to view the following parameters:
Parameter
Name
Parameter Description
Boiler Outlet
Temperature
Real-time Outlet Temperature to Boiler
14 to 266 F
o
(-10 to 130 C)
Boiler Inlet
Temperature
Real-time Inlet Temperature to Boiler
14 to 266 F
o
(-10 to 130 C)
Boiler Delta
T
Real-time temperature difference
between the outlet sensor and the inlet
sensor.
-99 to 252 F
o
(-72 to 122 C)
Modulation
Real-time modulating output
percentage
0 to 100%
Total Run
Time Since
Installation
Monitors the amount of operational
time since the MicoFlame was
installed. The first two digits are the
number of thousands of hours and the
three digit display shows the number
of hundreds of hours.
Press
simultaneously to reset
the counter
Alternates
between 00 and
999
Display
Parameter
Range
o
o
Table 10: Input Voltage vs. Modulation Rate
Input
Voltage
Modulation
Input
Voltage
[V]
[%]
[V]
[%]
0
0
4
36.8
0.5
0
5
47.4
1
5.3
6
57.9
1.5
10.5
7
68.4
Modulation
2
15.8
8
78.9
2.5
21.1
9
89.5
3
26.3
10
100
31
o
9.11
MODE 8: EXTERNAL DRIVE OPEATION: ADJUST DISPLAY
From the Home display;
simultaneously to view the following parameters:
1) Press
Display
Parameter
Name
Parameter
Range
Parameter Description
Operating mode for the boiler.
Mode
Pump Delay
NOTE: A complete description of
each mode can be found in section
8.4 Modes of Operation in this
manual.
Boiler post pump time after burner
has shut off, in seconds.
1 to 8
Default = 1
OFF, 0:20 to 9:55
min, On
Default = 1:00
min
o
Temperature
Units
9.12
Select the desired unit of
measurement
o
F, C
o
Default = F
ERROR MESSAGES
Error Message
Description
The control was unable to read a piece of information its EEPROM
memory. The control will stop operation until all settings in the Adjust
menu have been checked by the installer.
Outlet Sensor Short Circuit.
If the inlet sensor is operational, the control will operate using the inlet
sensor. Otherwise, the control will not operate the burner.
Test the outlet sensor and related wiring. The error message will clear
once the error condition is corrected and a button is pressed.
Outlet Sensor Open.
If the inlet sensor is operational, the control will operate using the inlet
sensor. Otherwise, the control will not operate the burner.
Test the outlet sensor and related wiring. The error message will clear
once the error condition is corrected and a button is pressed.
32
Error Message
Description
Inlet Sensor Short Circuit
The boiler will continue operation.
Test the inlet sensor and related wiring. The error message will clear
once the error condition is corrected and a button is pressed.
Inlet Sensor Open
The boiler will continue operation
Test the inlet sensor and related wiring. The error message will clear
once the error condition is corrected and a button is pressed.
System Sensor Short Circuit
If the outlet sensor is operational, the boiler will operate using the
outlet sensor. If the outlet sensor is not available and the inlet sensor
is operational, the boiler will operate using the inlet sensor.
Otherwise, the control will not operate the burner.
Test the supply sensor and related wiring. The error message will
clear once the error condition is corrected and a button is pressed.
System Sensor Open
If the outlet sensor is operational, the boiler will operate using the
outlet sensor. If the outlet sensor is not available and the inlet sensor
is operational, the boiler will operate using the inlet sensor.
Otherwise, the control will not operate the burner.
Test the supply sensor and related wiring. The error message will
clear once the error condition is corrected and a button is pressed.
Outdoor Sensor Short Circuit
The BTC 1 assumes an outdoor temperature of 32oF (0oC) and
continues operation.
Test the outdoor sensor and related wiring. The error message will
clear once the error condition is corrected and a button is pressed.
Outdoor Sensor Open
The BTC 1 assumes an outdoor temperature of 32oF (0oC) and
continues operation.
Test the outdoor sensor and related wiring. The error message will
clear once the error condition is corrected and a button is pressed.
DHW Sensor Short Circuit
The control will not operate the burner.
Test the DHW sensor and related wiring. The error message will clear
once the error condition is corrected and a button is pressed.
33
Error Message
Description
DHW Sensor Open
The control will not operate the burner.
Test the DHW sensor and related wiring. The error message will clear
once the error condition is corrected and a button is pressed.
Flame Proof Error
Flame was not proved within 120 seconds of Demand 1
10
Pilot Flame Rectification Setting
The pilot flame rectification was preset at the
factory. The following description is for the
benefit of the start-up technician should minor
adjustment be required. Set pilot to obtain best
µA reading from flame rectification. Minimum
average signal of 1.5 µA is required. If required,
test the signal using a DC µA meter following
this procedure for Honeywell S8600 ignition
module: Disconnect ground wire at appliance
transformer; Disconnect the 24V power and
ground wires from all S8600 ignition modules
not being tested; Set meter to µA DC: Connect
one of the meter’s terminals to the burner
ground terminal on the S8600 and the other
terminal to the burner ground wire; Pilot running
without main burner will generate 1.5 µA
average for best operation. With main burner
running, the signal will be in a range of 4.0 to 7.0
µA.
OPERATION
The MicoFlame Grande appliance should be
installed and started up by factory qualified
personnel.
10.1
START-UP
Gas appliances are rated based on sea level
operation with no adjustment required at
elevations up to 2000 ft. At elevations above
2000 ft the input rating must be reduced by 4%
for each additional 1000 ft elevation. Never
increase the input of the appliance above that
for which it is rated.
Pilot Pressure Setting
The pilot was preset at the factory. The following
description is for the benefit of the start-up
technician should minor adjustment be required.
The pilot burner is controlled by a separate pilot
valve. Pilot pressure setting is as shown in Table
9. A view port is provided on the appliance’s
return end to view the pilot and the main
burners. If adjustment is necessary the following
steps must be followed: Remove the lower front
jacket panel; Remove the ⅛” plug from the
elbow pressure tap and connect a manometer;
Remove regulator adjustment screw cap from
the pilot valve; Rotate the regulator adjustment
screw clockwise to increase the manifold
pressure or counterclockwise to decrease it;
Once satisfied replace the regulator adjustment
screw cap and the elbow pressure tap plug.
Gas Pressure Setting
The adjustable ratio gas valve pressure
regulator was preset at the factory. The following
description is for the benefit of the start-up
technician should minor adjustment be required.
Optimum results are obtained when the CO2
levels shown in Table 10 are obtained. After light
off allow the burner to reach full fire and then
adjust combustion using the high fire adjustment
screw. Bring the appliance to low fire and set the
CO2 using the low fire adjustment. If adjustment
is necessary the following steps must be
followed (please refer to Figure 27): Remove the
lower front jacket panel; Remove the ⅛” plug
from the elbow pressure tap and connect a
manometer.
Table 11 – Gas pressures at inlet to pilot
PROPANE
Minimum (inches W.C.)
Maximum (inches W.C.)
3.9
9.3
NATURAL
GAS
1.3
3.5
34
Air Flow Setting
The fan inlet air shutter has been preset at the
factory. The following description is for the
benefit of the start-up technician should minor
adjustment be required.
Optimum results are obtained when the
appliance is operated with air box pressure as
set in Table 12. If adjustment is necessary the
following steps must be followed: Remove the
lower front jacket panel; connect a manometer
to the air pressure tap provided on the
combustion chamber door; with the fan
operating the air pressure should be set per
Table 12 by adjusting the air inlet shutter on the
fan inlet; To adjust the air shutter, first undo the
securing nut and rotate the bolt so the shutter
will open or close as required
If shutdown does not occur it is possible that the
main flow is generating a signal at the pilot in
which case the pilot shall not recycle with the
pilot gas off.
Appliances Start Up
With the appliance off, open makeup water valve
and allow system to fill slowly. With all air vents
open, run system circulating pump for a
minimum of 30 minutes with the appliance off.
Open all strainers in the circulating system and
check for debris. Check liquid level in expansion
tank. With system full of water at 15 PSIG cold,
the level of water in the expansion tank should
not exceed ¼ of the total volume with the
balance filled with air. Start up appliance
following instructions provided. Operate entire
system including pumps and radiation for at
least 1 hour. Check water level in expansion
tank. If level exceeds ½ of tank volume, air is
still trapped in system. Shut down appliance and
continue to run pumps. Within 3 days of start up,
recheck all air vents and expansion tank as
described above.
Table 12 – Combustion Values
Natural Gas
Propane
NonCondensing
Condensing
Max.
Fire
Min.
Fire
Max.
Fire
Min.
Fire
CO2
CO
CO2
CO
7.5% 8.5%
7.0% 7.5%
8.5% 9.0%
7.5% 8.0%
< 50
PPM
< 50
PPM
< 50
PPM
< 50
PPM
9.0% 10.0%
8.5% 9.0%
10.0% 10.5%
9.0% 9.5%
< 50
PPM
< 50
PPM
< 50
PPM
< 50
PPM
10.2
MODULATION SEQUENCE
The Modulating MicoFlame Grande is designed
with intermittent pilots on each burner. Before
the appliance can light off, all pilots must be lit.
Pre-purge
Once satisfied tighten the nut on the fan’s
shutter bolt making sure it is secured.
BTC 1 Staging control activates the pre-purge
cycle for 20 seconds before trial for ignition.
Pressure Switch Settings
The air flow proving switches have been preset
at the factory as per Table 12. The following
description is for the benefit of the start-up
technician should minor adjustment be required.
One pressure switch is provided per burner. If
adjustment is necessary the following steps
must be followed: Remove the lower front jacket
panel; insert allen key into the switch located on
the combustion chamber door; with the fan
running the switch should be set per Table 11 by
rotating the allen key counter-clockwise to make
contact.
Ignition Trial
On proof of air flow, the air proving switch closes
and energizes the ignition module. The module
first initiates a self check and then starts the pilot
ignition sequence. The modulating sequence
begins with the modulating fan ramping down to
ignition speed. The safety shutoff valve opens,
which allows gas to flow to the pilot burner. At
the same time, the electronic spark generator in
the module produces 10,000 Volt spark pulse
output. The voltage generates a spark at the
igniter that ignites the pilot. If the pilot does not
light, or the pilot flame current is not at least, on
average, 1.5 µA and steady, the module will not
energize the combination valve and the main
burner will not light. The ignition module
provides 100% gas shutoff, followed by retry for
ignition. If required (e.g. CSD-1) a module with
lockout feature can be provided.
Ignition System Safety Shut-Off Device
After initial fill while the main burner is firing,
shut off gas to the pilot and clock the time taken
for the main gas valve to shut down. If the safety
control is functioning properly, power to the gas
valve will be shut off within 4 seconds of the pilot
gas being shut off. If shut down takes longer,
ignition control or gas valve may be defective.
35
Main Burner
When all pilot flames are established, a flame
rectification circuit is completed between the
sensor and the burner ground. The flame
sensing circuit in the ignition module detects the
flame current, shuts off the spark generator and
energizes the combination valve operator. Once
all pilots are lit the main gas valve opens and
matches gas input to the available air. As the
fans ramp up gas input is adjusted accordingly.
On the lock out ignition module, the flame
current also holds the safety lockout timer in the
reset operating condition. When the call for heat
ends, both valve operators are de-energized,
and both valves in the gas control close.
11
PILOT AND MAIN BURNER
FLAMES
11.1
MAIN BURNER
The main burner, Figure 25 should display the
following characteristics;
•
•
•
•
•
Acceptable CO and CO2 levels for
complete combustion
Light off smoothly
Reasonably quiet while running
Stable flame with minimum of lifting
Blue flame with natural gas, yellow tips
with propane gas
Figure 25 - Burner
Normal Operation
Modulation is controlled from the Boiler
Temperature Controller. The modulating fans
are equipped with electrically commutated DC
motors which respond to a PWM signal.
The control provided with the Modulating
MicoFlame allows remote control with an analog
signal of 4-20mA or 2-10VDC.
Demand Satisfied
The BTC 1 senses that the boiler target
temperature was reached and de-energizes the
stage contact.
If burner characteristics do not match the above,
check for proper air box pressure. Look for
accumulation of lint and other foreign material at
fan air inlets.
Control Alarms
High limit or low water flow will de-energize all
gas valves, and the blower. Condition indicators
are visible on the control panel. Each
burner/blower set is provided with its own air
pressure switch. If a low air pressure condition is
present, power will not be supplied to the ignition
module. The blower will remain on and the air
indicator will remain on for as long as there is a
call for heat.
36
Table 13 –Air Box Settings at Full Fire
MODEL
2000
2500
3000
3500
4000
MODEL
2000
2500
3000
3500
4000
A qualified service technician should follow this
procedure when burner needs cleaning.
AIR BOX “ W.C. (with burner firing)
Burner Burner Burner Burner
#1
#2
#3
#4
1.9
1.9
(2.2)
(2.2)
1.5
1.5
1.5
(1.8)
(1.8)
(1.8)
1.9
1.9
1.9
(2.2)
(2.2)
(2.2)
1.6
1.6
1.6
1.6
(1.9)
(1.9)
(1.9)
(1.9)
1.9
1.9
1.9
1.9
(2.2)
(2.2)
(2.2)
(2.2)
FLUE SWITCH RECYCLE POINT “
W.C
Burner Burner Burner Burner
#1
#2
#3
#4
1.5
1.5
(1.9)
(1.9)
1.1
1.1
1.1
(1.5)
(1.5)
(1.5)
1.5
1.5
1.5
(1.9)
(1.9)
(1.9)
1.2
1.2
1.2
1.2
(1.6)
(1.6)
(1.6)
(1.6)
1.5
1.5
1.5
1.5
(1.9)
(1.9)
(1.9)
(1.9)
1. Shut off power and close main manual
gas valve.
• Allow burner to cool before removal.
2. Remove access cover screws.
• Disconnect pilot gas at bulkhead
fitting.
• Disconnect ground wire and ignition
wire.
• Remove nuts holding down burner.
• Gently pull down and forward to
disengage burner.
• Remove burner being careful to not
damage the igniter or ground
electrodes.
3. Thoroughly clean burner using low
pressure water or air. Never wipe or
brush the surface of the burner nor use
high pressure water or air. Check all
ports and air channels for blockage.
4. Reinstall the burner being careful to fully
engage the back of the burner box into
the retaining slot in the combustion
chamber base. Failure to properly locate
the burner will result in erratic flame
operation with the possibility of delayed
ignition on light off.
5. Restore electrical power and gas supply
to the appliance.
• Following the lighting instructions
put the appliance back into
operation
• Check for gas leaks and proper
appliance and vent operation.
Depending on field conditions air box pressures
will have to be adjusted accordingly. Always set
the appliance for a CO2 level in the range listed
in Table 14.
Table 14: Combustion Values
Natural Gas
Propane
NonCondensing
Condensing
Max.
Fire
Min.
Fire
Max.
Fire
Min.
Fire
CO2
CO
CO2
CO
7.5% 8.5%
7.0% 7.5%
8.5% 9.0%
7.5% 8.0%
< 50
PPM
< 50
PPM
< 50
PPM
< 50
PPM
9.0% 10.0%
8.5% 9.0%
10.0% 10.5%
9.0% 9.5%
< 50
PPM
< 50
PPM
< 50
PPM
< 50
PPM
37
11.2 REMOVAL OF COMBUSTION
CHAMBER LINING
11.3
PILOT BURNER
Turn the pilot firing valve to off position and
allow the appliance to try for ignition. Observe
the spark making sure that it is strong and
continuous.
The combustion chamber insulation in this
appliance contains ceramic fiber material.
Ceramic fibers can be converted to cristobalite
in very high temperature applications. The
International Agency for Research on Cancer
(IARC) has concluded, “Crystalline silica in this
form of quartz of cristobalite from occupational
sources is carcinogenic to humans (Group 1)”.
Normal operating temperatures in this appliance
are below the level to convert ceramic fibers to
cristobalite. Abnormal operating conditions
would have to be created to convert the ceramic
fibers in this appliance to cristobalite.
The ceramic fiber material used in this appliance
is an irritant; when handling or replacing the
ceramic materials it is advisable that the installer
follow these safety guidelines.
• Avoid breathing dust and contact with
skin and eyes.
o Use NIOSH certified dust
respirator (N95). This type of
respirator is based on the OSHA
requirements for cristobalite at
the time this documentation was
written.
Other
types
of
respirators may be needed
depending on the job site
conditions.
Current
NIOSH
recommendations can be found
on the NIOSH website at
http://www.cdc.gov/niosh/homep
age.html. NIOSH approved
respirators, manufacturers, and
phone numbers are also listed
on this website.
o Wear long-sleeved, loose fitting
clothing, gloves, and eye
protection
• Apply enough water to the combustion
chamber lining to prevent airborne dust.
• Remove the combustion chamber lining
from the water heater and place it in a
plastic bag for disposal.
• Wash potentially contaminated clothes
separately from other clothing. Rinse
clothes washer thoroughly.
NIOSH stated First Aid
• Eye: Irrigate immediately
• Breathing: Fresh air
If the spark is not acceptable the igniter will have
to be adjusted. This can be readily
accomplished after removing the main burner.
The spark gap should measure between 1/8” to
3/16”. Make sure that the electrode does not
appear overheated or fouled with carbon. It may
be necessary to clean the ignition electrode
using steel wool. Once the pilot appears to be
properly set, reinstall it into the appliance
making sure to properly tighten the pilot line
connection.
If the pilot is removed from the main burner in
the course of servicing the appliance, it is
important to replace all gaskets and seals.
These seals are intended to prevent the bypass
of air around the pilot.
Figure 26 – Pilot and Burner Box
Once the spark is satisfactory, open the pilot gas
and allow the pilot burner to light. Once air has
been purged from the pilot line, the pilot flame
should appear almost instantly at the initiation of
spark. Cycle the pilot several times to confirm
reliability. A properly set pilot will appear blue
and will engulf the igniter and ground electrode.
Open the firing valve and allow the main burner
to light. The pilot must not extinguish. After
running for 15 minutes, cycle the appliance to
ensure that the pilot remains stable.
38
12
OPERATION AND
SERVICE
12.1
PRE-START CHECKLIST
Once satisfied replace the regulator adjustment
screw cap and the elbow pressure tap plug.
Table 15 – Gas pressures at inlet to pilot
PROPANE
Before operating the boiler, the entire system
must be filled with water, purged of air and
checked for leaks. Do not use Stop leak or other
boiler compounds. The gas piping must also be
leak tested.
Minimum (inches W.C.)
Maximum (inches W.C.)
3.9
9.3
NATURAL
GAS
1.3
3.5
Figure 27: MicoFlame Grande 2010 – 4000
Gas Valve
Any safety devices including low water cutoff,
flow switch and high limit used in with this boiler
must receive periodic inspection (every six
months) to assure proper operation. A low water
cutoff of the float type should be flushed every
six months. All relief valves should be inspected
and manually operated every six months.
For your safety follow the lighting and operating
instructions below and on the boiler.
To turn on main burner, slowly open firing valve
after pilot is established.
Set primary
temperature.
system
controller
to
desired
To turn off boiler close main manual gas valve,
close pilot manual valve and turn off electric
power to system.
To adjust the high fire setting
12.2
Set the Target Temperature to 190 F using the
BTC 1 Controller.
o
START-UP
Gas appliances are rated based on sea level
operation with no adjustment required at
elevations up to 2000 ft. At elevations above
2000 ft the input rating must be reduced by 4%
for each additional 1000 ft elevation. Never
increase the input of the appliance above that
for which it is rated.
Locate screw (1) labeled as <<PGAS/PAIR>> and
make adjustments as necessary to satisfy the
combustion values in Table 14. The markings on
the setting screws are labeled as “+” and “-“, for
more and less gas, respectively. Turn the screw
1/4 turn in either way for each adjustment to
keep track of the adjustments. After adjusting
the screw wait a moment for the combustion
levels to stabilize before attempting to make any
further adjustments. Continue this procedure
until combustion levels are satisfied.
Pilot Pressure Setting
The pilot was preset at the factory. The following
description is for the benefit of the start-up
technician should minor adjustment be required.
The pilot burner is controlled by a separate pilot
valve. Pilot pressure setting is as shown in Table
15. A view port is provided on the appliance’s
return end to view the pilot and the main
burners. If adjustment is necessary the following
steps must be followed: Remove the lower front
jacket panel; Remove the ⅛” plug from the
elbow pressure tap and connect a manometer;
Remove regulator adjustment screw cap from
the pilot valve; Rotate the regulator adjustment
screw clockwise to increase the manifold
pressure or counterclockwise to decrease it;
Reset the Target Temperature to normal
operating conditions on the BTC 1 Controller.
To adjust the low fire setting
Observe the Boiler Inlet Temperature. Set the
o
Boiler Target temperature so that it is 10 F
above the Boiler Inlet Temperature. The boiler
will begin to modulate to low-fire as setpoint is
being reached. The actual modulation rate can
be shown on the screen as Modulation, this will
be shown as a percentage.
39
The following description is for the benefit of the
start-up technician should minor adjustment be
required.
Locate screw (2) labeled as
and make
adjustments as necessary to satisfy the
combustion values in Table 16. The markings on
the setting screws are labeled as “+” and “-“, for
more and less gas, respectively. Turn the screw
1/4 turn in either way for each adjustment to
keep track of the adjustments. After adjusting
the screw wait a moment for the combustion
levels to stabilize before attempting to make any
further adjustments. Continue this procedure
until combustion levels are satisfied.
a. Remove the lower front jacket panel
b. Reduce sensitivity of blocked flue switch
by turning the flat screw ¼ turn
clockwise
c.
Reset the Target Temperature to normal
operating conditions on the BTC 1 Controller.
d. Re-install lower front jacket panel
Table 16 – Combustion Values
Natural Gas
NonCondensing
Condensing
Max.
Fire
Min.
Fire
Max.
Fire
Min.
Fire
CO2
7.5% 8.5%
7.0% 7.5%
8.5% 9.0%
7.5% 8.0%
CO
< 50
PPM
< 50
PPM
< 50
PPM
< 50
PPM
Differential Air Proving Switch
A differential low fire air proving switch is
provided on every burner to prevent burner light
off under block flue or blocked inlet condition.
The normally-open differential air switches have
been preset at the factory. The following
description is for the benefit of the start-up
technician should minor adjustment be required.
Propane
CO2
9.0% 10.0%
8.5% 9.0%
10.0% 10.5%
9.0% 9.5%
Observe the operation of the burner as it
approaches high fire, if the heater
continues to operate at high fire the
switch has been correctly set. If not,
repeat steps 2 and 3.
CO
< 50
PPM
< 50
PPM
< 50
PPM
< 50
PPM
1) Remove the lower front jacket panel
2) Insert allen key into the switch located
on the combustion chamber door
Pilot Flame Rectification Setting
The pilot flame rectification was preset at the
factory. The following description is for the
benefit of the start-up technician should minor
adjustment be required. Set pilot to obtain best
µA reading from flame rectification. Minimum
average signal of 1.5 µA is required. If required,
test the signal using a DC µA meter following
this procedure for Honeywell S8600 ignition
module: Disconnect ground wire at appliance
transformer; Disconnect the 24V power and
ground wires from all S8600 ignition modules
not being tested; Set meter to µA DC: Connect
one of the meter’s terminals to the burner
ground terminal on the S8600 and the other
terminal to the burner ground wire; Pilot running
without main burner will generate 1.5 µA
average for best operation. With main burner
running, the signal will be in a range of 4.0 to 7.0
µA.
The normally-closed blocked flue switch has
been preset at the factory. In cases where the
heater loses the flame signal as it approaches
high fire adjustment to the blocked flue switch
may be necessary.
3) Reduce sensitivity of differential air
switch by turning the hex screw ¼ turn
counter-clockwise.
4) Re-install lower front jacket panel
Ignition System Safety Shut-Off Device
After initial fill while the main burner is firing,
shut off gas to the pilot and clock the time taken
for the main gas valve to shut down. If the safety
control is functioning properly, power to the gas
valve will be shut off within 4 seconds of the pilot
gas being shut off. If shut down takes longer,
ignition control or gas valve may be defective. If
shutdown does not occur it is possible that the
main gas flow is generating a signal at the pilot
in which case the pilot shall not recycle with the
pilot gas off.
Appliances Start Up
With the appliance off, open makeup water valve
and allow system to fill slowly. With all air vents
open, run system circulating pump for a
minimum of 30 minutes with the appliance off.
Open all strainers in the circulating system and
check for debris. Check liquid level in expansion
tank. With system full of water at 15 PSIG cold,
40
the level of water in the expansion tank should
not exceed ¼ of the total volume with the
balance filled with air. Start up appliance
following instructions provided. Operate entire
system including pumps and radiation for at
least 1 hour. Check water level in expansion
tank. If level exceeds ½ of tank volume, air is
still trapped in system. Shut down appliance and
continue to run pumps. Within 3 days of start up,
recheck all air vents and expansion tank as
described above.
12.3
13
LIGHTING INSTRUCTIONS
1. Turn off electric power to appliance.
2. Close main manual valve and main
firing valve and wait 5 minutes.
3. Set primary system controller to desired
temperature.
4. Open pilot valve.
5. Turn on electric power to appliance. The
electrode at the pilot should begin to
spark after pre-purge is complete. The
pilot valve will open to permit gas flow to
the pilot.
6. There is a 15 second trial for ignition,
which is enough time to light the pilot if
air is not present in the pilot line. If pilot
fails to light and you suspect air in the
line, close the main manual valve and
repeat lighting steps 1 thru 5.
7. Once the pilot lights, it should envelope
the ignition rod and ground electrode.
The pilot can be adjusted by removing
the pilot regulator cover and turning the
adjustment screw counter-clockwise to
increase it or clockwise to decrease it.
8. Open the main manual and main firing
valves to allow gas to reach the main
burner. If the main burner fails to ignite,
turn the firing valve off and check to see
that the pilot is burning. If not, repeat
lighting procedure steps 1 thru 7.
SERVICE
Disconnect main power and turn off gas supply
before servicing unit.
To remove and clean the burner, follow the
detailed procedure in section 16 of this manual
After the first season of operation inspect the
heat exchanger and venting. Follow the detailed
instructions in section 6 of this manual.
CAUTION: Label all wires prior to disconnection
when servicing controls. Wiring errors can cause
improper and dangerous operation. Verify
proper operation after servicing.
Any audible sounds in the equipment, like
pinging, crackling or hissing are indications of
scaling or lack of sufficient water flow. Under
these conditions the boiler must be shut down
immediately and the heat exchanger checked for
damage. If the exchanger is damaged from
scaling, it is not covered by warranty.
TO TURN OFF APPLIANCE: Close main
manual valve and main firing valve and turn off
electric power to system.
Should your equipment be subjected to fire,
flood or some other unusual condition, turn off
all gas and electrical supply. If you are unable to
turn off the gas , call your gas company or gas
supplier at once. Do not put the unit back in
operation until it has been checked by a
qualified agency to ensure that all controls are
functioning properly.
Units that are not operated for a period of 60
days or more are considered seasonal
operations. It is recommended that before
returning one of these units to service, the
proper operation of all controls be checked by a
qualified service technician.
41
14
TROUBLE SHOOTING GUIDE
SYMPTOM
1. Power light is not lit when switch is flipped to
“ON”
2. Water flow light remains off.
3. Pilot sparks but does not light
4. Pilot lights momentarily, goes out and then
sparks again repeatedly
5. Pilot lights but main burner does not fire.
6. Main burner lights but cycles off after a few
minutes
7. Appliance starts to whine as the temperature
rise increases.
SOLUTION
•
Check wiring to switch.
•
Activate push button for latch relay if
provided.
•
Check circuit breaker.
•
Check fuse.
•
Verify that pump is running.
•
Check wiring to flow switch.
•
Verify that main manual valve is open.
•
Follow lighting instructions to bleed air out
of pilot line.
•
Remove main burner and inspect for
moisture or dirt in pilot or in pilot line.
•
Verify that pilot is sealed to main burner
base.
•
Verify that gas connections are tight.
•
Observe pilot for proper flame. Adjust if
necessary.
•
Check pilot flame signal. Properly set pilot
to generate 1.5 µA. D.C. on average.
•
Remove main burner and ensure that
igniter and ground electrodes are
positioned properly. Clean with steel wool
if necessary.
•
Verify that back of burner box is fully
engaged into the retaining slot in the
combustion chamber base.
•
Verify that main manual valve is in “ON”
position.
•
Check wiring to valve from ignition control.
•
Verify that high limit is set high enough to
prevent short cycling.
•
Check pilot flame signal (µA).
•
Adjust pilot pressure for steady flame
•
Remove main burner. Check position of
igniter and ground electrode. Clean with
steel wool if necessary.
•
Verify that all air is bled from system.
•
Verify that the static pressure in cold
system is at least 15 psig at the highest
point in the system.
•
Check temperature rise across appliance
to ensure adequate water flow.
•
If necessary, increase static water
pressure and decrease gas pressure.
42
15
TYPICAL GAS TRAIN
Figure 28 – Gas Train
43
16
ELECTRICAL DIAGRAMS
16.1
MF 3500 – 4000 INTERNAL WIRING DIAGRAM
44
17
EXPLODED VIEW & PARTS LIST
MODULATING MICOFLAME GRANDE
45
MODULATING MICOFLAME GRANDE OUTDOOR AND/OR CONDENSING
46
MICOFLAME GRANDE REPLACEMENT PARTS LIST
Ref
#
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Part Name
Combustion
Chamber End
Panel - Left
Combustion
Chamber End
Panel - Right
Combustion
Chamber Rear
Panel
Combustion
Chamber Support
- Left
Combustion
Chamber Support
- Right
Combustion
Chamber Base
Combustion
Chamber Upper
Front
Flue Collector Top
Flue Collector End
Bracket
Base Panel
Outer Jacket Top
Cover
Outer Jacket Back
Panel
Outer Jacket Front
Lower Panel
Outer Jacket Front
Upper Panel
Base Support
Weldment
Base Panel Lips
Inlet Outlet Side
Access Panel
Return Side
Access Panel
19
Combustion
Chamber Centre
Divider
20
Flue Collector
Outlet
21
Outer Jacket Side
Panel - Right
2010
Model Number
3000
2500
3500
4000
14-4202-40
14-4202-40
14-4200
14-4201
14-4202-20
14-4202-30
14-4202-30
14-4203
14-4204
14-4205-20
14-4205-30
14-4205-30
14-4205-40
14-4205-40
14-4206-20
14-4206-30
14-4206-30
14-4206-40
14-4206-40
14-4207-20
14-4207-30
14-4207-30
14-4207-40
14-4207-40
14-4208
14-4209-20
14-4209-30
14-4209-30
14-4209-40
14-4209-40
14-4210-20
14-4210-30
14-4210-30
14-4210-40
14-4210-40
14-4211-20
14-4211-30
14-4211-30
14-4211-40
14-4211-40
14-4212-20
14-4212-30
14-4212-30
14-4212-40
14-4212-40
14-4213-20
14-4213-30
14-4213-30
14-4213-40
14-4213-40
16-4214-20
16-4214-30
16-4214-30
16-4214-40
16-4214-40
14-4215-20
14-4215-30
14-4215-30
14-4215-40
14-4215-40
14-4216
14-4217
N/A
N/A
N/A
14-4218
14-4218
14-4219-20
14-4219-30
14-4219-30
14-4219-40
14-4219-40
14-4231
47
Ref
#
22
23
24
25
26
27
28
29
30
31
32
33
34
35
37
38
39
40
41
42
43
44
45
46
47
Part Name
Outer Jacket Side
Panel - Left
Fan Mounting
Support - Right
Burner Door Stop
Heat Exchanger
Header Stop Bar
Fan Mounting
Support - Left
Burner Door
V Baffles
HX Front and
Back Baffles
Outer Jacket Sight
Glass Frame
Outer Jacket Door
Jam
Heat Exchanger
Support Weldment
Inner Jacket Sight
Glass Frame
Outer Jacket Top
Panel Support
Control Panel
Assembly
Three Tiles Burner
Box Assembly
Economizer
Cover*
Economizer
Assembly*
Front Refractory
Rear Refractory
Inlet Outlet
Header
Gas Train
Common End
Refractory
Gas Valve Body
Fan
Return Header
2010
Model Number
3000
2500
3500
4000
14-4241-40
14-4241-40
14-4242-40
14-4242-40
14-4252
14-4252
14-4232
14-4233
14-4234
14-4238
14-4239
14-4241-20
14-4241-30
14-4240
14-4241-30
14-4242-20
14-4242-30
14-4242-30
14-4151
N/A
N/A
N/A
14-4253
14-4154
14-4255
14-4160
14-4225
14-4146
14-4265-01
14-4265-01
14-4265-01
14-4265-01
14-4148-03
14-4266-01
14-4266-01
14-4266-01
14-4266-01
17-0084-01
17-0085-01
17-0084-02
17-0085-02
17-0084-02
17-0085-02
17-0084-03
17-0085-03
17-0084-03
17-0085-03
-
-
13-0040
-
-
17-0083
VGG10.504U
G1G170
13-0041
48
Primary Heat
Exchanger
15-0195-01
15-0195-02
15-0195-02
15-0195-03
15-0195-03
49
Economizer
CAM-2000
CAM-4000
CAM-4000
CAM-4000
CAM-4000
50
Control Panel
Outdoor Cover**
14-4245
48
Ref
#
51
52
53
54
55
56
Part Name
Control Panel
Outdoor Cover
Door**
Inlet Outlet
Header Outdoor
Cover**
Gas Valve
Actuator
MicoGrande
Modulating
harness-2 burner
main
MicoGrande
Modulating
harness-3 burner
MicoGrande
Modulating-4
burner main
MicoGrande
Modulating
harness-Water
end harness, right
MicoGrande
Modulating
harness-Water
end harness 2burner, left
MicoGrande
Modulating
harness-Water
end harness 3-4
burner, left
MicoGrande
Modulating
harness-Panel
main (110V)
MicoGrande
Modulating
harness-Panel
main (220V)
57
Air Inlet Filter
58
Air Switch
Igntion Module –
Continuous Retry
Ignition Module –
Single Try
Pilot Valve/
Combination
59
60
61
2010
Model Number
3000
2500
3500
4000
14-4246
14-4247
SKP75.013U1
77-0024
N/A
N/A
77-0025
N/A
N/A
77-0026
77-0027
77-0028
N/A
N/A
77-0029
77-0030
77-0031
12”
14”
16”
IS20105-5762A
S8610M3017
S8600H3010
CV100B6N-22-0001
49
Valve
* Condensing Models
Only
** Outdoor Models Only
Not Shown in Exploded View
50
WARRANTY
GENERAL
Camus Hydronics Limited (“Camus”), extends the following LIMITED WARRANTY to the owner of this appliance,
provided that the product has been installed and operated in accordance with the Installation Manual provided with
the equipment. Camus will furnish a replacement for, or at Camus option repair, any part that within the period
specified below, shall fail in normal use and service at its original installation location due to any defect in
workmanship, material or design. The repaired or replacement part will be warranted for only the unexpired portion of
the original warranty. This warranty does not cover failures or malfunctions resulting from: (1) Failure to properly
install, operate or maintain the equipment in accordance with Camus’ manual; (2) Abuse, alteration, accident, fire,
flood, foundation problems and the like; (3) Sediment or lime buildup, freezing, or other conditions causing
inadequate water circulation; (4) Pitting and erosion caused by high water velocity; (5) Failure of connected systems
devices, such as pump or controller; (6) Use of non-factory authorized accessories or other components in
conjunction with the system; (7) failing to eliminate air from, or replenish water in, the connected water system; (8)
Chemical contamination of combustion air or use of chemical additives to water.
HEAT EXCHANGER
If within TEN years after initial installation of the appliance, a heat exchanger, shall prove upon examination by
Camus to be defective in material or workmanship, Camus will exchange or repair such part or portion on the
following pro rated limited warranty. (1) Years one through five - standard warranty (2) Years six through ten replacement purchase price pro rated at the following schedule: Year six - 60%, Year seven - 65%, Year eight -70%,
Year nine -75% Year ten -80% of the current list price of the current list price This term is reduced to FIVE years if the
appliance is used for other than hydronic space heating.
Heat Exchanger shall be warranted for (20) years from date of installation against “Thermal Shock” (excluded,
however, if caused by appliance operation at large changes exceeding 150 ºF between the water temperature at
intake and appliance temperature, or operating at appliance temperatures exceeding 230 ºF).
BURNER
If within FIVE years after initial installation of the appliance a burner shall prove upon examination by Camus to be
defective in material or workmanship, Camus will exchange or repair such part or portion.
ANY OTHER PART
If any other part fails within one (1) year after installation, or eighteen (18) months from date of factory shipment
based on Camus' records, whichever comes first. Camus will furnish a replacement or repair that part. Replacement
parts will be shipped f.o.b. our factory.
HOW TO MAKE A CLAIM
Any claim under this warranty shall be made directly to Camus Hydronics Limited Canadian Head Office
SERVICE LABOR RESPONSIBILITY
Camus shall not be responsible for any labour expenses to service, repair or replace the components supplied. Such
costs are the responsibility of the owner.
DISCLAIMERS
Camus shall not be responsible for any water damage. Provisions should be made that in the event of a
water/appliance or fitting leak, the resulting flow of water will not cause damage to its surroundings.
Name of Owner
Name of Dealer
Address
Address
Model No.
Serial No.
Date of Installation:
Date of Initial Operation:
6226 Netherhart Road, Mississauga, Ontario, L5T 1B7, CANADA
51
52
CAMUS Hydronics is a
manufacturer
of
replacement parts for
most copper finned
water heaters
and
heating
boilers as well
as a
The CAMUS CERTIFIED!
Seal assures you that
Reliability, Efficiency &
serviceability are built
into
every
single unit!
For
more
information
supplier of specialty
HVAC products. Our
service line is open 24
hours, 7 days a week!
on
our
innovative
products from CAMUS
Hydronics Limited, call
905-696-7800 today.
CAMUS HYDRONICS LTD.
6226 Netherhart Road, Mississauga, Ontario L5T 1B7
TEL: 905·696·7800 FAX: 905·696·8801
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