Camus Hydronics DMC153 Service manual

Camus Hydronics DMC153 Service manual
INSTALLATION OPERATION
AND SERVICE MANUAL
GAS FIRED COMMERCIAL COPPER TUBE BOILERS
SURE-FLAME SERIES
FOR HYDRONIC HEATING
Models; SFH420, 520, 600
HOT WATER SUPPLY
Models; SFW420, 520, 600
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
instruction,
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
99-0001
Rev. 03
Table of Contents
INTRODUCTION ............................................................................................................ 1
1.
GENERAL INSTRUCTIONS ................................................................................. 1
2.
BOILER LOCATION.............................................................................................. 2
3.
PROVIDE AIR FOR COMBUSTION AND VENTILATION............................... 2
4.
ELECTRICAL WIRING ......................................................................................... 3
5.
GAS SUPPLY AND PIPING .................................................................................. 3
6.
VENTING............................................................................................................... 4
7.
RELIEF VALVE ..................................................................................................... 7
8.
FREEZE PROTECTION ......................................................................................... 7
9. WARNING REGARDING CHILLED WATER SYSTEMS .................................. 7
10.
PIPING OF SYSTEM TO BOILER (FIG.3)......................................................... 8
11.
PLACING BOILER IN OPERATION.................................................................. 9
12. CHECK OUT OF IGNITION SYSTEM SAFETY SHUT-OFF DEVICE .......... 11
13.
LOW WATER TEMPERATURE SYSTEMS .................................................... 11
14. INSTANTANEOUS WATER HEATER ............................................................. 13
15. PILOT AND MAIN BURNER FLAMES............................................................ 13
15.1. MAIN BURNER................................................................................................ 14
15.2. PILOT BURNER ............................................................................................... 15
16.
OPERATION AND SERVICE............................................................................ 16
17. LIGHTING INSTRUCTIONS.............................................................................. 17
18. TROUBLE SHOOTING GUIDE ......................................................................... 18
19. TYPICAL GAS TRAIN ....................................................................................... 19
20. ELECTRICAL DIAGRAMS................................................................................ 19
21. EXPLODED VIEW .............................................................................................. 22
22. SURE FLAME REPLACEMENT PARTS LIST................................................. 23
WARRANTY ................................................................................................................. 24
INTRODUCTION
Camus Hydronics proudly introduces its Sure-Flame series of water heaters / hydronic
boilers. These machines are thoughtfully designed for easy operation and maintenance. We
are confident that you will come to appreciate the benefits of our product.
1.
GENERAL INSTRUCTIONS
The installation of this heater must conform to the requirements of the authority having
jurisdiction or, in the absence of such requirements, to the National Fuel Gas Code, ANSI
Z223.1 or 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 National
Fuel Gas Code, ANSI Z223.1, or Section 7, Venting Systems and Air Supply for Appliances,
of the CAN/CGA B149.1, 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 CSD1.
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.
WARRANTY:
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 build-up in the copper coils or tubes
is not a fault of the boiler and is not covered by warranty. Consult the factory
for recommendations for use in hard water areas.
Using or storing corrosive chemicals in the vicinity of this boiler can rapidly
attack the copper tubes and coils and voids warranty.
This boiler is intended to operate under non-condensing conditions. Inlet
temperatures must be maintained at 110°°F or higher. Warranty is void if heater
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.
1
2.
BOILER LOCATION
Install this boiler in a clean, dry location with adequate air supply and close to a good vent
connection.
Do not locate this boiler in an area where it will be subject to freezing.
The boiler must not be installed on carpeting and should be located close to a floor drain in
an area where leakage from the boiler or connections will not result in damage to the
adjacent area or to lower floors in the structure.
If necessary a suitable drain pan should be installed under the boiler.
If the boiler is installed above the level of the building’s radiation system, a low water cutoff
device must be installed in the boiler outlet at the time of installation. Some local codes
require the installation of a low water cutoff on all systems.
Locate the boiler so as to provide adequate clearance for inspection and service all around
the unit. It is recommended that 24” be provided for the top and sides and 48” for the front.
This boiler is suitable for alcove installation with minimum clearances to combustibles as
follows:
TOP :
SIDES :
REAR :
VENT :
3.
12”
12”
12”
6”
PROVIDE AIR 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 National Fuel Gas Code, ANSI Z223.1, or Sections 7.2,
7.3 or 7.4 of CAN/CGA B149.1 Installation Codes, and applicable provisions of the local
building codes.
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.
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
All electrical wiring to the boiler 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.
Provide disconnecting means of sufficient rating within sight of the boiler. These heaters
require an 115-V 60-hz supply. Depending on the pump used, a 15-amp breaker is usually
sufficient.
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.
Use minimum 18-gauge conductor for 24-volt field wiring to boiler. Splicing of wires is not
recommended.
Use sealed tight conduit suitable for outdoor use for outdoor installations.
For low water cutoff and remote controller, use terminal strip provided inside control panel.
Refer to wiring diagram provided with boiler.
5.
GAS SUPPLY AND PIPING
This boiler is intended to operate at inlet gas pressures not exceeding ½ psi (14” water
column). If higher pressures are present, consult the gas company for correction.
When pressure testing the gas supply piping at pressures above ½ psi, the boiler and its
individual gas shut-off valve must be disconnected from the supply piping.
Provide a trap (drip leg) as close to the heater as possible.
Install a good joint union and manual shut-off valve in the gas line near the heater to allow
easy removal of the gas control assembly.
Provide gas pressures at inlet to boiler manifold as follows:
Minimum (inches water column)
Maximum ( inches water column)
PROPANE
11
11
NATURAL GAS
5
7
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. Sizing based on Table 1 is
recommended.
Before operating the boiler, the complete gas train and all connections must be tested using
soap solution.
3
TABLE 1
DISTANCE FROM NATURAL GAS METER OR PROPANE SECOND STAGE REGULATOR
Input
Btu/hr
420,000
520,000
600,000
6.
0-100 FT.
NAT.
L.P.
1¼”
1”
1½”
1½”
1¼”
1¼”
100-200 FT.
NAT.
L.P.
1½”
1¼”
2”
1½”
2”
1½”
200-300 FT.
NAT.
L.P.
2”
1½”
2”
1½”
2”
1½”
VENTING
Boilers for outdoor installation are intended to vent using a listed vent cap.
For indoor installations the draft hood provided with this boiler must be installed without
alteration. Vent installations must be in accordance with Part 7, Venting of Equipment, of the
National Fuel Gas Code, ANSI Z223.1, or Section 7, Venting of Equipment and Air Supply
for Appliances, of the CAN/CGA B149.1, 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 boiler to the
vent terminal.
When an existing boiler 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 boiler, 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 the 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, 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.
4
e) Test for spillage at the draft hood 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 National Fuel Gas Code, ANSI Z223.1 or 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 National Fuel Gas Code,
ANSI Z223.1 or CAN/CGA B149, Installation Codes.
Heat exchanger surfaces and vent piping should be checked every six months for
deterioration and carbon deposits. 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.
A qualified service technician should follow this procedure when inspecting and cleaning the
heat exchanger and vent pipe.
1. Turn off electrical power and close main manual gas shut-off and allow boiler to cool
down
2. Remove the boiler draft diverter and vent pipe running to chimney.
• Check heat exchanger, vent and chimney for obstruction and clean as
necessary.
3. Remove burner from boiler and vacuum top heat exchanger and coils.
4. Reinstall parts removed in steps 2 and 3.
• Be sure that vent pipe has proper pitch and is properly sealed.
5. Restore electrical power and gas supply to boiler.
• Place boiler in operation using lighting instructions provided.
• Check for gas leaks and proper vent operation.
5
Three venting options are available for this boiler. See Figure 1 for details.
6
7.
RELIEF VALVE
A pressure relief valve is supplied as standard equipment. The relief valve protects against
damage that could be caused by malfunctioning controls or excessive water pressure. If a
relief valve is not used, warranty is void.
8.
FREEZE PROTECTION
Boiler installations are not recommended in areas where the danger of freezing exists
unless precautions are taken. Maintaining a mixture of 50% water and 50% propylene glycol
is the preferred methods of freeze protection in hydronic systems. This mixture will protect
the boiler to approximately -35 °F (-37 °C). To mai ntain the same temperature rise across
the boiler increase the G.P.M. flow by 15% and the head loss by 20%.
A snow screen should be installed to prevent snow and ice accumulation around the boiler.
Regular inspections should be made to ensure that air intake and vent are free of snow and
ice.
9.
WARNING REGARDING CHILLED WATER SYSTEMS
When a boiler 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 boiler. Appropriate flow
control valves; manual or motorized must be provided to prevent the chilled water from
entering the boiler. (See figure 2)
When a boiler is connected to heating coils located in air handling units (where they may be
exposed to refrigerated air circulation), the boiler piping system shall be equipped with a
flow control valve or other automatic means to prevent gravity circulation of chilled water
through the boiler. Chilled water in the boiler will create condensate on the boiler tubes,
which will collect in the combustion chamber causing corrosion.
7
10.
PIPING OF BOILER TO SYSTEM (FIG.3)
Check all applicable local heating, plumbing and building safety codes before proceeding.
Be sure to provide unions and gate valves at inlet and outlet to boiler so that it can be easily
isolated for service.
This boiler 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 20 °F . The
following table 2 is provided as a guide.
For application in areas known to have hard water conditions, contact factory for
recommendations.
TABLE 2
Model
SF 420
SF 520
SF 600
U.S G.P.M.
35
70
70
TEMP RISE
20.0
12.3
13.8
8
HEAT EX. ∆P FT
1.5
4.0
4.0
Figure 3
If the boiler is installed above radiation level, it must be provided with a low water cutoff
device at the time of boiler installation. (Available from factory)
A pressure relief valve is supplied with each Sure-Flame boiler. The relief valve must be
piped to the floor in a manner acceptable to the enforcing authority.
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 boiler.
Suitable pipe hangers must support the weight of all water and gas piping or floor stands.
Do not allow the boiler to run with inlet water temperature below 110ºF.
The boiler 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.)
10.1
WATER FLOW SWITCH (shipped loose)
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.
9
10.2
LOW WATER CUTOFF (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 (See figure 1A). 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 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 when connecting to 24 VAC circuit.
Figure 1A – Low Water Cut off Electrical Connections
10.3
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.
CAUTION
Avoid contact with hot discharge water
11.
PLACING BOILER IN OPERATION
The Sure-Flame boiler should be installed and started up by qualified personnel.
With the boiler off, open makeup water valve and allow system to fill slowly. Adjust the
pressure regulator to provide at least 15 psig at the highest point in the system.
With all air vents open, run system circulating-pump for a minimum of 30 minutes with the
boiler off.
Open all strainers in the circulating system and check for debris.
10
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 1/4 of the total 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.
Check water level in expansion tank. If level exceeds ½ of tank volume, air is still trapped in
system. Shut down boiler and continue to run pumps.
Within 3 days of start up, recheck all air vents and expansion tank as described above.
12.
CHECK OUT OF 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.
13.
LOW WATER TEMPERATURE SYSTEMS
In applications where the heating system requires supply water temperatures below 110ºF,
a bypass line must be installed upstream of the boiler pump so that outlet water can be recirculated to raise the inlet temp to a minimum of 110ºF. Balancing valves, preferably globe
valves are used to adjust flow. (See figure 4)
11
Figure 4
•
Adjustment procedure.
a) Fully open bypass and outlet valves.
b) With boiler running, read the inlet temperature after 15 minutes.
c) If the inlet temperature is less than 110 ºF slowly close outlet valve until the
inlet temperature climbs to 110 ºF
d) If the inlet temperature is greater than 110ºF but not greater than 140 ºF no
further adjustment is required.
e) Check the inlet temperature after 5 minutes and make final adjustments.
12
14.
INSTANTANEOUS WATER HEATER
An instantaneous water heater 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 5) Call factory for further recommendations.
Figure 5
15.
PILOT AND MAIN BURNER FLAMES
To maintain safe operation and the greatest efficiency of the boiler, check the main burner
and pilot burner every six months for proper flame characteristics.
13
15.1. MAIN BURNER
The main burner, figure 6 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 6
If burner characteristics do not match the above, check for accumulation of lint and other
foreign material at burner air inlets.
A qualified service technician should follow this procedure when burner needs cleaning.
1. Shut off power and close main manual gas valve.
• Allow burner to cool before removal.
2. Loosen union and remove main burner manifold assembly from boiler.
3. Thoroughly clean burner. Check all ports and air channels for blockage.
4. Reinstall the burner.
5. Restore electrical power and gas supply to the boiler.
• Following the lighting instructions put the boiler back into operation
• Check for gas leaks and proper boiler and vent operation.
14
15.2. PILOT BURNER
Turn the gas valve control knob counterclockwise to off position and allow the boiler to try
for ignition. Observe the spark making sure that it is strong and continuous.
If the spark is not acceptable the igniter will have to be removed. This can be readily
accomplished by disconnecting the pilot gas line and loosening the thumbscrew holding the
pilot bracket.
The spark gap should be 1/8” to 3/16”. Make sure that the pilot shield is in place and that the
electrode does not appear overheated or fouled with carbon. It may be necessary to clean
the ignition electrode using sandpaper. Once the pilot appears to be properly set, reinstall it
into the boiler making sure to properly tighten the pilot line connection.
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 ignition sensor and ground plate. (See figure 7)
Figure 7
Turn the gas control to “ON” and allow the main burner to light. The pilot must not
extinguish. After running for 15 minutes, cycle the boiler to ensure that the pilot remains
stable.
15
16.
OPERATION AND SERVICE
OPERATION:
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.
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 turn manual main gas on after pilot is established.
Set primary system controller to desired temperature.
To turn off boiler close main manual gas valve, close pilot manual valve and turn off electric
power to system.
SERVICE:
Disconnect main power and turn off gas supply before servicing unit.
To remove and clean the burner follows the detailed procedure in section 15 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 and coils checked for damage. If the exchanger is
damaged from scaling, it is not covered by warranty.
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.
16
17.
LIGHTING INSTRUCTIONS
1.
2.
3.
4.
5.
Turn off electric power to boiler.
Close main manual valve and main firing valve and wait 5 minutes.
Set primary system controller to desired temperature.
Set main manual valve to pilot position.
Turn on electric power to boiler. The electrode at the pilot should begin to spark. This
can be observed with a mirror. 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 strap. The pilot
can be adjusted by removing the pilot regulator cover and turning the adjustment
screw counterclockwise to increase it or clockwise to decrease it..
8. Open the main firing valve to allow gas to reach the main burner. If the main burner
fails to ignite, turn the main firing valve off to see if the pilot is burning. If not, repeat
lighting procedure steps 1 thru 7.
TO TURN OFF BOILER: Close main manual valve and main firing valve and turn off electric
power to system.
17
18.
TROUBLE SHOOTING GUIDE
SYMPTOM
1. Power light is not lit when switch is
flipped to “ON”
SOLUTION
•
Check wiring to switch.
•
Check circuit breaker
•
Check fuse
2. Water flow light remains off.
•
Ensure that pump is running
•
Check wiring to flow switch
3. Pilot sparks but does not light
•
Make sure 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.
4. Pilot lights momentarily, goes out and
•
Observe pilot for proper flame. Adjust
then sparks again repeatedly
if necessary
•
Remove pilot and ensure that shield is
in place and is properly located. Shield
should surround pilot on three sides
and be no more than ⅛” away from
frame of pilot.
5. Pilot lights but main burner does not fire. •
Ensure that main firing valve is in
“OPEN” position
•
Check wiring to valve from ignition
control.
6. Main burner lights but cycles off after a
•
Make sure that high limit is set high
few minutes
enough to prevent short cycling.
•
Adjust pilot pressure for steady flame
•
Remove pilot. Adjust shield and clean
ignition sensor.
7. Boiler starts to whine as the temperature •
Make sure that all air is bled from
rise increases.
system.
•
Make sure that the static pressure in
cold system is at least 15 psig.
•
Check temperature rise across boiler
to ensure adequate water flow.
•
If necessary, increase static water
pressure and decrease gas pressure.
18
19.
TYPICAL GAS TRAIN
20.
ELECTRICAL DIAGRAMS
Each Sure-Flame boiler will be provided with its own wiring diagram to guarantee that any
options ordered with the unit are properly detailed.
The following diagrams 99-5003 and 99-5004 are provided as typical samples only.
19
20
21
21.
EXPLODED VIEW
22
22.
SURE FLAME REPLACEMENT PARTS LIST
KEY ITEM #
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
DESCRIPTION
MODEL
420
520
600
SURE FLAME BASE PANEL ASSEMBLY
SURE FLAME BURNER SKIRT – FRONT
SURE FLAME BURNER – REAR
SURE FLAME BURNER ASSEMBLY
natural gas
0 – 2000 ft. @ 3.5” W.C.
natural gas
2000 – 4500 ft. @ 3.5” W.C.
L.P 0 – 2000 ft. @ 10.0” W.C.
L.P 2000 – 4500 ft. @ 10.0” W.C.
14-0010
14-0016
14-0017
14-0010
14-0016
14-0017
14-0010
14-0016
14-0017
66-0001
66-0004
66-0006
66-0009
66-0002
66-0005
66-0007
66-0010
66-0003
66-0002
66-0008
66-0011
IGNITER ASSEMBLY
spark ignition
standing pilot
SURE FLAME COIL SUPPORT BASE
COIL SLEEVE ASSEMBLY RETAING RODS (4)
CENTER OUTER JACKET - REAR PANEL
OUTER JACKET - FRONT PANEL
SPACER RING / HEAT EX. LOCATER FRAME
UPPER REAR PANEL
TOP PANEL
FLUE COLLECTOR
INDOOR DRAFT HOOD
OUTDOOR VENT CAP (approved type)
HEAT EXCHANGER CORE ASSEMBLY
COPPER COIL AND SLEEVE ASSEMBLY
66-0038
66-0039
14-0021
12-0001
14-0034
14-0028
14-0020
14-0018
14-0026
14-0060
14-0063
14-0066
15-0020
15-0040
66-0038
66-0039
14-0021
12-0002
14-0035
14-0029
14-0020
14-0018
14-0026
14-0060
14-0063
14-0066
15-0020
15-0050
66-0038
66-0039
14-0021
12-0002
14-0035
14-0029
14-0020
14-0018
14-0027
14-0061
14-0064
14-0067
15-0020
15-0050
14-0014
14-0015
14-0005
14-0070
17-0002
50-0011
14-0049
50-0012
14-0051
14-0014
14-0015
14-0005
14-0070
17-0002
50-0011
14-0049
50-0012
14-0051
14-0014
14-0015
14-0005
14-0070
17-0002
50-0011
14-0049
50-0012
14-0051
78-0002
78-0003
14-0037
78-0002
78-0003
14-0037
78-0002
78-0003
14-0037
OUTDOOR SKIRT – REAR
OUTDOOR SKIRT – FRONT
OUTDOOR STAND
ELECTRICAL ENCLOSURE
RADIATION SHIELD
VIEWPORT GLASS – INNER
VIEWPORT FRAME – INNER
PILOT VIEWER – OUTER
PILOT VIEWPORT – OUTER FRAME
MANUAL RESET HI - LIMIT
hydronic heating
domestic hot water
GAS MANIFOLD SUPPORT BRACKET
NOTE: All replacement parts available through CAMUS HYDRONICS LTD.
23
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.
24
CAMUS Hydronics is a
manufacture
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: 905·696·880
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