INSTALLATION OPERATION

AND SERVICE MANUAL

MICOFLAME SERIES 2

GAS FIRED COMMERCIAL COPPER TUBE BOILERS

FOR HYDRONIC HEATING

Models; MFH800, 1000, 1200, 1400, 1600, 1800, 2000

HOT WATER SUPPLY

Models; MFW800, 1000, 1200, 1400, 1600, 1800, 2000

H

HLW

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

99-0053

Rev. 04

Table of Contents

INTRODUCTION ................................................................................................................................................... 1

1 GENERAL INSTRUCTIONS ............................................................................................................................ 1

2 BOILER LOCATION ....................................................................................................................................... 2

3 PROVIDE AIR FOR COMBUSTION AND VENTILATION ................................................................................. 3

4 ELECTRICAL WIRING .................................................................................................................................... 3

5 STAGING OPERATION .................................................................................................................................. 4

6 GAS SUPPLY AND PIPING ............................................................................................................................. 5

7 VENTING ...................................................................................................................................................... 5

7.1 OUTDOOR VENTING ................................................................................................................................... 7

7.2 SIDEWALL VENTING ................................................................................................................................... 8

7.3 OUTDOOR AIR KIT ...................................................................................................................................... 8

7.4 FILTER KIT ................................................................................................................................................... 9

7.5 STANDARD VENTING .................................................................................................................................. 9

7.6 VENTING FOR CONDENSING APPLICATION ............................................................................................... 9

8 ACCESSORIES ............................................................................................................................................... 9

9 FREEZE PROTECTION ................................................................................................................................. 11

10 WARNING REGARDING CHILLED WATER SYSTEMS ................................................................................... 11

11 PIPING OF BOILER TO SYSTEM (FIG.5) ....................................................................................................... 12

12 PLACING BOILER IN OPERATION ............................................................................................................... 13

13 INSTRUMENTATION AND CONTROLS ....................................................................................................... 13

13.1 SAFETY CONTROLS.................................................................................................................................... 13

13.2 CONTROL PANEL ....................................................................................................................................... 13

13.2.1 MODE 1 & 2: SETPOINT OPERATION ................................................................................................ 16

13.2.2 MODE 1 & 2: SETPOINT OPERATION: VIEW DISPLAY ....................................................................... 17

13.2.3 MODE 1 & 2: SETPOINT OPERATION: ADJUST DISPLAY .................................................................... 18

13.2.4 MODE 3: DHW SETPOINT OPERATION ............................................................................................. 19

13.2.5 MODE 3: SETPOINT OPERATION: VIEW DISPLAY .............................................................................. 19

13.2.6 MODE 3: DHW SETPOINT OPERATION: ADJUST DISPLAY ................................................................. 20

13.2.7 MODE 4 & 5: OUTDOOR RESET OPERATION .................................................................................... 21

13.2.8 MODE 4 & 5: OUTDOOR RESET OPERATION: VIEW DISPLAY ........................................................... 22

13.2.9 MODE 4 & 5: OUTDOOR RESET OPERATION: ADJUST DISPLAY ........................................................ 23

13.2.10 MODE 6: EXTERNAL TARGET TEMPERATURE USING BOILER INLET SENSOR ................................... 24

13.2.12 MODE 6 & 7: EXTERNAL TARGET TEMPERATURE INPUT OPERATION: VIEW DISPLAY .................... 26

13.2.13 MODE 6 & 7: EXTERNAL TARGET TEMPERATURE INPUT OPERATION: ADJUST DISPLAY ................. 27

14 IGNITION SYSTEM SAFETY SHUT-OFF DEVICE ........................................................................................... 29

15 LOW WATER TEMPERATURE SYSTEMS ..................................................................................................... 29

16 INSTANTANEOUS WATER HEATER ............................................................................................................ 30

17 CONDENSING HEAT RECOVERY MODULE ................................................................................................. 30

18 PILOT AND MAIN BURNER FLAMES........................................................................................................... 32

18.1 MAIN BURNER .......................................................................................................................................... 32

18.2 PILOT BURNER .......................................................................................................................................... 34

19 OPERATION AND SERVICE ......................................................................................................................... 35

20 LIGHTING INSTRUCTIONS .......................................................................................................................... 35

21 TROUBLE SHOOTING GUIDE ...................................................................................................................... 36

22 TYPICAL GAS TRAIN ................................................................................................................................... 37

23 ELECTRICAL DIAGRAMS ............................................................................................................................. 37

24 EXPLODED VIEW ........................................................................................................................................ 41

25 MICO FLAME REPLACEMENT PARTS LIST .................................................................................................. 44

WARRANTY ....................................................................................................................................................... 48

INTRODUCTION

Camus Hydronics proudly introduces its MicoFlame series 2 of commercial water heaters / hydronic boilers. 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.

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 latest or current as amended 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 latest edition or the current as amended National Fuel Gas Code, ANSI Z223.1, or Section 7, Venting Systems and Air

Supply for Appliances, of the 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.

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.

The primary heat exchanger of this boiler is intended to operate under non-condensing conditions. Inlet temperatures must be maintained at 110

°°°°

F or higher. 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.

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 is suitable for installation on combustible flooring 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:

Table 1: Clearance to Combustibles

TOP: 12”

SIDES: 12”

REAR: 12”

VENT: 6”

FLOOR: 0”

Figure 1: MicoFlame II Dimensions

Side View (Left)

Condensing Option

Front View Side View (Right)

Non-Condensing Option

Rear View

Non-Condensing Option

2

Table 2: Various Connection Sizes

B' Dia. Venting* E' Dia.

Model W'

MF800 45 3/4 2 1/2 1 8 8 10 8

MF1000 52 3/4 2 1/2 1 1/4 8 8 10 8

MF1200 62 2 1/2 1 1/4 10 10 12 10

MF1400 71 1/4 2 1/2 1 1/4 10 10 12 10

MF1600 80 3/4 2 1/2 1 1/2 12 12 14 12

MF1800 89 3/4 2 1/2 1 1/2 12 12 14 12

MF2000 99 2 1/2 1 1/2 12 12 14 12

*Non-Condensing models are shipped with standard vent opening size unless sidewall vent is specified

3 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 latest or the current as amended National

Fuel Gas Code, ANSI Z223.1, or;

•

Sections 7.2, 7.3 or 7.4 of the latest of the current as amended CAN/CGA B149 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.

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 115V,

60Hz 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.

Use terminal strip provided inside control panel for low water cut-off and remote controller

Refer to wiring diagram provided with boiler.

3

5 STAGING OPERATION

Staging of the MicoFlame series 2 is dependent on the number of burners supplied. Models 800 and

1000 are supplied with a single burner and are available as on/off and two stages. Models 1200 through

2000 are supplied with two burners and are available as on/off, 2-stage, 3-stage and 4-stage.

Each burner is supplied with a dedicated airflow proving signal and separate proved pilot ignition system.

All fans must be running in order for the appliance to proceed to trial for ignition.

MicoFlame series 2 supplied with more than one burner may use burners that are not of identical size in order to accommodate fans within the space allocated. In case where burners are not identical, the right side burner will be the one with the higher input.

Each MicoFlame series 2 is supplied with the appropriate wiring diagram showing the actual staging sequence provided as well as any special controls or options requested.

When converting multiple MicoFlame series 2 appliances to an external sequencing control it is absolutely necessary to program the sequencer properly by entering the number of stages provided on the appliance. In this way the sequencer will lead/lag or rotate the boilers properly.

A full diagnostics panel is provided on the MicoFlame series 2. On a call for heat, status lights will light up if the particular safety is working properly. Once all safeties have been proved, the boiler will proceed to trial for ignition and will then sequentially bring on the burner stages (and the corresponding lights). If the safety proving sequence does not proceed to completion, the first safety light to remain off will indicate the cause of the problem. All other lights below the problem indicator light will also remain off.

Burner staging is arranged to allow a minimum firing rate of no less than 50% in order to minimize possibility of condensation in the venting. Staging of burners for models 1200 through 2000 is as follows:

Table 3: Burner Firing Rates

Two

Stage

Stage 1

Stage 2

Left Burner

Low Fire

High Fire

Right Burner

Low Fire

High Fire

Three

Stage *

Stage 1

Left Burner Right Burner

Low Fire Low Fire

Stage 2 Low Fire High Fire

Stage 3 High Fire High Fire

* Recommended for Models 1400 and 1600

Four

Stage

Stage 1

Stage 2

Stage 3

Stage 4

Left Burner

Low Fire

Low Fire

Low Fire

High Fire

Right Burner

Low Fire

Low Fire

High Fire

High Fire

4

6 GAS SUPPLY AND PIPING

This boiler is intended to operate at inlet gas pressures not exceeding ½ PSI (14“ W.C.). 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 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:

Table 4: Gas Pressures at Inlet to Appliance

Minimum (inches W.C.)

Maximum (inches W.C.)

PROPANE

11

11

NATURAL GAS

4

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 4 is recommended.

Before operating the boiler, the complete gas train and all connections must be tested using soap solution.

Table 5: Recommended Gas Pipe Size

Single Appliance Installation

(For distance from natural gas meter or propane second stage regulator)

DISTANCE FROM NATURAL GAS METER OR PROPANE SECOND STAGE REGULATOR

Input

Btu/Hr

800,000

1,000,000

1,200,000

1,400,000

1,600,000

1,800,000

2,000,000

0-100 FT

NAT.

2”

2”

2 ½“

2 ½“

2 ½“

2 ½“

2 ½“

L.P.

1 ½“

1 ½“

2“

2“

2“

2“

2”

100-200 FT.

NAT.

2 ½“

2 ½“

2 ½“

2 ½“

3”

3”

3”

L.P.

2“

2“

2“

2“

2 ½“

2 ½“

2 ½“

200-300 FT.

NAT.

2 ½“

2 ½“

3”

3”

3”

3”

3”

L.P.

2“

2“

2 ½“

2 ½“

2 ½“

2 ½“

2 ½“

7 VENTING

Boilers 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 of the 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 boiler to the vent terminal.

5

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. 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 latest or current as amended 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 of the National Fuel Gas Code, ANSI Z223, 1 or the latest or current as amended of the

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 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.

3. Remove burner from boiler and vacuum the burner, and the heat exchanger. If heat exchanger is excessively dirty it may be necessary to remove it from the boiler and wash it down with proper detergent cleaner. Be aware that the combustion chamber base is insulated with ¼” thick ceramic paper. If this material is damaged or displaced it must be replaced before starting up the boiler.

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.

6. Restore electrical power and gas supply to boiler.

7. Place boiler in operation using lighting instructions provided.

6

8. While the boiler 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.

The MicoFlame series 2 is category 1, 85% efficient when supplied as a non-condensing appliance.

When supplied with the optional condensing cartridge, the MicoFlame series 2 is 95% efficient and is considered to be a category II or IV appliance. Three venting options are available for this boiler in both condensing and non-condensing configurations. See Figure 2 for details. (Please refer to Table 2 for vent dimensions)

Figure 2: Venting Configuration

7.1 OUTDOOR VENTING

When fitted with the factory supplied rain shield and UL approved vent cap, the MicoFlame series 2 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 boiler at least 3 feet away from any overhang.

4. Locate boiler at least ten feet from building air intake.

5. Avoid installation in areas where runoff from adjacent building can spill onto boiler.

7

7.2 SIDEWALL VENTING

When fitted with the factory supplied vent terminal, the MicoFlame series 2 can vent up to 60 equivalent feet. Elbows can range from 8 to 15 feet in equivalent length depending on centreline radius. See Table 1 for vent sizes.

Boilers 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.

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.

When venting through unheated spaces with single wall vent, insulation should be wrapped around the vent pipe to prevent flue gas condensation inside the vent.

Periodically check to ensure that the vent terminal is unobstructed.

7.3 OUTDOOR AIR KIT

When fitted with the factory supplied air inlet ring and air intake terminal, the MicoFlame series 2 can draw outdoor air over an equivalent length of 60 feet. See Table 2 for vent sizes.

Boilers 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 and at least two feet higher than any part of the building within a horizontal distance of ten feet

4. Locate the air intake five feet away from the vent discharge. For sidewall venting locate the air intake below the vent outlet if possible.

8

7.4 FILTER KIT

A louvered rear panel is the standard air inlet configuration for the MicoFlame series 2. 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.

7.5 STANDARD VENTING

The MicoFlame series 2 is a category 1 appliance and is approved for venting into a common standard chimney. If chimney height is much greater than 30 feet or if drafts are excessive, it may be preferable 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 boiler. Be sure to position the damper at least 6 “ away from the wall of the vent connector.

7.6 VENTING FOR CONDENSING APPLICATION

When supplied with the optional condensing cartridge, the MicoFlame series 2 is 95% efficient (category

II or IV appliance) which requires the use of special venting system. Refer to installation instruction No.

93-0152-1. Only venting components listed by a nationally recognized testing agency may be used.

8 ACCESSORIES

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.

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. 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 3: Low Water Cut Off Electrical Connections, Watts (left) & ITT

9

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.

CONDENSING HEAT RECOVERY MODULE PIPING CONFIGURATIONS

Caution: If isolation valves are provided on the CHRM, the provision of a relief valve at the outlet of the secondary 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 in a manner similar to the appliance relief valve.

CHRM IN SERIES WITH PRIMARY HEAT EXCHANGER (INTEGRATED LOOP)

The supply water (Cold water) is pre-heated by CHRM and fed into the outlet of the primary Heat

Exchanger. Provisions must be made to prevent cold water below 115ºF (46ºC) entering to the Primary

Heat Exchanger.

BOILER APPLICATION (HYDRONIC HEATING)

In case of boilers (Hydronic heating boiler) application, the return water (supply water) may be more than

115ºF (46ºC), therefore there is no need for a recirculation loop and the primary heat exchanger and

CHRM can be piped in parallel. Since the inlet water temperature to CHRM exceeds 115ºF (46ºC) it will not condense fully and therefore the CHRM will not perform to its maximum efficiency capacity. If water colder than 115ºF (46ºC) is available it can be fed to the CHRM.

WATER HEATER APPLICATION (HOT WATER SUPPLY)

In case of domestic water supply (Water Heating), the fresh inlet water temperature will be less than

115ºF (46 ºC), in this case the CHRM may be fed directly with part of the supply water using a secondary pump.

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.

The relief valve is to be located as near as practical to the outlet of the boiler. To maintain capacity do not reduce the inlet connection of the relief valve. Connect the outlet of the relief valve to a suitable drain. The drainpipe must point down from the valve and must not be smaller than the outlet of the valve. The end of the drain line should not be concealed or threaded and should be protected against freezing. No valve of any kind should be installed between the relief valve and the unit or in the drain line. Extensive runs, traps or bends could reduce the capacity of the valve. This valve should be checked for proper operation at least once a year by a qualified service technician.

10

9 FREEZE PROTECTION

•

Appliance installations are not recommended outdoors 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%.

The following example demonstrates the procedure to follow for calculating the revised head for the heat exchanger when using a water / glycol mixture.

•

Given 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.

•

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 and will allow easier servicing of the appliance under severe weather conditions.

10 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 4)

Figure 4: Chilled Water System

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.

11

11 PIPING OF BOILER TO SYSTEM (FIG.5)

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 35°F (19.4°C). The following table is provided as a guide.

For application in areas known to have hard water conditions, contact factory for recommendations.

Table 6: Flow and Pressure Drop at a Given Temperature Rise

Head Loss and Flow vs. Temperature Rise

20 °F 30 °F 35 °F

Model

800

1000

1200

1400

1600

1800

USGPM ∆ P ft. USGPM ∆ P ft. USGPM ∆ P ft.

66.6 2.8 44.4 1.1 38.0 0.8

83.3 4.9 55.5 2.0 47.6 1.5

100.0

*

*

*

6.9

*

*

*

66.7

77.8

88.9

100.0

3.1

4.3

5.4

6.9

57.1

66.7

76.2

85.7

2.4

3.4

4.0

5.1

6.2 2000 * * * *

* Contact factory for recommendations

Figure 5: Typical Boiler Piping System

95.2

12

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)

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 115°F (46 o

C).

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.)

12 PLACING BOILER IN OPERATION

The MicoFlame series 2 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 in the system when cold.

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.

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 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. Minimum operating system pressure when hot must not drop below 30 PSIG.

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.

13 INSTRUMENTATION AND CONTROLS

The appliance is equipped with safety controls as well as operational controls.

13.1 SAFETY CONTROLS

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.

Air Flow Switch

A differential air pressure switch is provided to prove the operation of the fan and adequate air flow to the burner. The pressure switch sensing point is at the inlet to the mixing tube where the air and gas mixes.

The LED indicator for air flow will not illuminate should the pressure switch detect a sustained low air condition. The appliance is provided with one air switch per burner module.

13.2 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 box door.

13

Figure 6 – Display, Appliance Temperature Controller and Indicating LED

The Boiler Temperature Controller (BTC) for this appliance is a Camus 780014 SmartFlame control. This controller accommodates up to four-stage control with six modes of operation which provides setpoint as well as rest control. It provides the following:

1. Readings of inlet and outlet water temperatures as well as ∆ T temperature rise.

2. Six pre-set modes of operation; mode 1, 2, 4, and 5 for heating, mode 3 for DHW and mode 6 for operation by a remote controller.

3. Operation as an auto reset limit.

4. Operation as a control for inlet water temperature.

5. Optional tank mounted sensor used in conjunction with inlet sensor.

6. Adjustable pump delay feature based on ∆ T temperature difference between inlet and outlet temperatures. Accepts 1/6 hp. pump directly across terminals 13 & 14.

7. Adjustable; target temp, inter-stage differential, on delay between stages, minimum on time per stage, minimum off time per stage.

8. Display of run hours for maintenance purposes. Counter wraps around at 1000 hours.

9. Flame failure signal 24 V.

10. Molex connector for ease of service.

11. Error message display.

12. Test override feature to test pump operation, stages 1, 2, 3, 4, and 5 and alarm.

13. Pump exercising feature runs pump 10 seconds every three days of no pump operation.

Setting the Appliance Temperature Control

Press and hold the ITEM, UP and DOWN buttons simultaneously for 1 second. The appliance will shut down and pressing the ITEM key and then selecting the desired setting using the UP, DOWN buttons, can now make the settings. Pressing the ITEM key again will cause the last setting to be accepted. After settings have been made wait 30 seconds for the control to return to normal operating mode. In normal operating mode the inlet temperature, outlet temperature, ∆ T temperature and ON hours can be viewed by repeatedly pressing the ITEM key only. If you wish to check the setting you will have to start again by pressing and holding the ITEM, UP and DOWN buttons simultaneously for 1 second, and then use only the ITEM key to scroll through the settings. After checking the settings allow the control to return to normal operation on its own.

14

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.

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.

General Symbol Description

SYMBOL

SYMBOL

NAME

Increase a parameter value.

SYMBOL DESCRIPTION

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 Shown when an error is present

Pointers

WWSD

Shows the operation as indicated by the text (Proof Dem)

Displays when the control is in

Warm Weather Shutdown

15

13.2.1 MODE 1 & 2: SETPOINT OPERATION

Mode 1

Intended for hydronic heating. The set-point for inlet water control is pre-set to 180°F and the auto re-set limit is set to 230°F. The inlet set-point can be a djusted, however the limit is fixed. In addition to the auto reset limit the factory installs a manual re-set limit set to 250°F. The control turns on the applianc e pump and stages the appliance to maintain set-point target temperature at the appliance inlet temperature whenever an external heat demand is present. Once the external heat demand is removed, the control turns off the appliance and operates the appliance pump based on the purge feature

Mode 2

Intended for hydronic heating. The set-point for inlet water control is pre-set to 180°F and the auto re-set limit is set to 230°F. The inlet set-point can be a djusted, however the limit is fixed. In addition to the auto reset limit the factory installs a manual re-set limit set to 250°F. The control turns on the applianc e pump and stages the appliance to maintain set-point target temperature at the appliance inlet temperature whenever an external heat demand is present. Once the external heat demand is removed, the control turns off the appliance and operates the appliance pump based on the purge feature. The control turns on the appliance pump and stages the appliance to the set-point target temperature at the system temperature whenever an external heat demand is present. Once the last appliance stage turns off and the heat demand is still present, the control then operates the appliance pump based on the purge feature. In this case, it is imperative that the system pump operates continuously in order to provide constant circulation past the system sensor. The appliance pump then turns back on with the first stage of the appliance. If the heat demand is removed, the appliance is turned off and the control operates the appliance pump P1 based on the purge feature.

16

13.2.2 MODE 1 & 2: SETPOINT OPERATION: VIEW DISPLAY

From the Home display;

1) Press [ITEM] to view the following parameters:

Display

Parameter

Name

Boiler

System

Temperature

(Mode 2

ONLY)

Parameter Description

Real-time System Temperature to

Boiler

Parameter

Range

14 to 266

(-10 o to 130

F o

C)

Boiler Outlet

Temperature

Real-time Outlet Temperature to Boiler

14 to 266 o

F

(-10 to 130 o

C)

Boiler Inlet

Temperature

Real-time Inlet Temperature to Boiler

14 to 266

(-10 o to 130

F o

C)

Boiler Delta

T

Total Run

Time Since

Installation

Real-time temperature difference between the outlet sensor and the inlet sensor.

-99 to 252 o

(-72 to 140

F o

C)

Monitors the amount of operational time since the Unit 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 the counter

simultaneously to reset

Alternates between 00 and

999

17

13.2.3 MODE 1 & 2: SETPOINT OPERATION: ADJUST DISPLAY

From the Home display;

1) Press simultaneously to view the following parameters:

Display

Parameter

Name

Parameter Description

Mode Operating mode for the boiler.

Parameter

Range

1 to 6

Default = 1

Boiler Target

Temperature

To provide a target setpoint for the heating system. Setpoint is controlled to the inlet sensor

70 to 220 o

(21 to 104

F o

C)

Default = 120 o

F

(49 o

C)

Boil Mass

(Mode 2

ONLY)

Thermal mass of boiler. This determines interstage delay and minimum on and minimum off times.

1 to 3

Default = 1

Differential

Temperature

To provide a modulation rate above and below the Boiler

Target temperature. For example, if the value is 10 o

F and the Boiler

Target is 160 o

F the boiler will begin to modulate at 150 o

F and shut off at 170 o

F.

Au, 2 to 42 o

(Au, -17 to 6

F o

C)

Default = 10 o

F

Pump Delay

Boiler post pump time after burner has shut off, in seconds.

OFF, 0:20 to

9:55 min, On

Default = 1:00 min

Temperature

Units

Select the desired unit of measurement o

F, o

C

Default = o

F

18

13.2.4 MODE 3: DHW SETPOINT OPERATION

Mode 3 is intended for domestic water heating. The set-point for inlet water control is pre-set to 140°F and the auto re-set limit is set to 200°F. The inle t set-point can be adjusted, however the limit is fixed. In addition to the auto reset limit the factory installs a manual re-set limit set to 210°F. The control turns on the appliance pump and stages the appliance to maintain set-point target temperature at the appliance inlet temperature. An internal demand is generated from the DHW sensor which could be placed in the storage tank while the external heat demand is permanently wired or through a timer. Once the DHW tank is satisfied (internal demand is removed), the control turns off the appliance and operates the appliance pump based on the purge feature.

13.2.5 MODE 3: SETPOINT OPERATION: VIEW DISPLAY

From the Home display;

1) Press [ITEM] to view the following parameters:

Display

Parameter

Name

Parameter Description

Parameter

Range

Boiler Outlet

Temperature

Real-time Outlet Temperature to Boiler

14 to 266

(-10 o to 130

F o

C)

Boiler Inlet

Temperature

Real-time Inlet Temperature to Boiler

14 to 266

(-10 o to 130

F o

C)

Boiler Delta

T

Real-time temperature difference between the outlet sensor and the inlet sensor.

-99 to 252 o

(-72 to 140 o

F

C)

Tank

Temperature

Real-time Tank Temperature to Boiler

14 to 266

(-10 o to 130

F o

C)

Total Run

Time Since

Installation

Monitors the amount of operational time since the unit 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 the counter

simultaneously to reset

19

Alternates between 00 and

999

13.2.6 MODE 3: DHW SETPOINT OPERATION: ADJUST DISPLAY

From the Home display;

1) Press simultaneously to view the following parameters:

Display

Parameter

Name

Parameter Description

Mode

Parameter Range

Operating mode for the boiler.

1 to 6

Default = 1

Boiler Target

Temperature

To provide a target setpoint for the heating system. Setpoint is controlled to the inlet sensor

OFF, 70 to 220

(OFF,21 to 104 o o

F

C)

Default = 140 o

F

(82 o

C)

Tank Target

Temperature

To provide a target setpoint for the Tank. Setpoint is controlled to the Tank sensor

OFF, 70 to 190 o

F

(OFF, 21 to 88 o

C)

Default = 130 o

F

(54 o

C)

Tank

Differential

Differential

Temperature

To provide a modulation rate above and below the Tank Target

Temperature. For example, if the value is 10 o

F and the Tank

Target Temperature is 160 o

F the boiler will begin to modulate at

150 o

F and shut off at 170 o

F.

To provide a modulation rate above and below the Boiler

Target temperature. For example, if the value is 10 o

F and the Boiler

Target is 160 o

F the boiler will begin to modulate at 150 o

F and shut off at 170 o

F.

2 to 10 o

F

(1 to 5 o

C)

Default = 3 o

F (1 o

C)

Au, 2 to 42 o

(Au, -17 to 5

F o

C)

Default = 10 o

F

Pump Delay

Temperature

Units

Boiler post pump time after burner has shut off, in seconds.

Select the desired unit of measurement

OFF, 0:20 to 9:55 min, On

Default = 1:00 min o

F, o

C

Default = o

F

20

13.2.7 MODE 4 & 5: OUTDOOR RESET OPERATION

Mode 4 is intended for hydronic heating. The set-point for inlet water control is pre-set to 180°F and the auto re-set limit is set to 230°F. The inlet set-po int can be adjusted, however the limit is fixed. In addition to the auto reset limit the factory installs a manual re-set limit set to 250°F. The control turns on the appliance pump and stages the appliance to maintain outdoor reset target temperature at the appliance inlet temperature whenever an external heat demand is present. Once the external heat demand is removed, the control turns off the appliance and operates the appliance pump based on the purge feature.

Mode 5 is intended for hydronic heating. The set-point for inlet water control is pre-set to 180°F and the auto re-set limit is set to 230°F. The inlet set-po int can be adjusted, however the limit is fixed. In addition to the auto reset limit the factory installs a manual re-set limit set to 250°F. The control turns on the appliance pump and stages the appliance to maintain outdoor reset target temperature at the system temperature whenever an external heat demand is present. Once the last appliance stage turns off and the heat demand is still present, the control then operates the appliance pump based on the purge feature. In this case, it is imperative that the system pump operates continuously in order to provide constant circulation past the system sensor. The appliance pump then turns back on with the first stage of the appliance. If the heat demand is removed, the appliance is turned off and the control operates the appliance pump based on the purge feature.

21

13.2.8 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

Parameter

Range

-60 to 190

(-51 to 88 o o

F

C)

Boiler

Supply

Temperature

(Mode 5

ONLY)

Real-time System Temperature to

Boiler

14 to 266

(-10 o to 130

F o

C)

Boiler Outlet

Temperature

Real-time Outlet Temperature to Boiler

14 to 266

(-10 o to 130

F o

C)

Boiler Inlet

Temperature

Real-time Inlet Temperature to Boiler

14 to 266

(-10 o to 130

F o

C)

Boiler Delta

T

Total Run

Time Since

Installation

Real-time temperature difference between the outlet sensor and the inlet sensor.

Monitors the amount of operational time since the unit 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 the counter

simultaneously to reset

-99 to 252 o

(-72 to 140

F o

C)

Alternates between 00 and

999

22

13.2.9 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

Mode Operating mode for the boiler.

1 to 6

Default = 1

Outdoor

Start

Temperature

Outdoor

Design

Temperature

Outdoor starting temperature used in the reset ratio for the heating system.

Typically set to the desired building 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

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.

Boil Mass

(Mode 2

ONLY)

Thermal mass of boiler. This determines interstage delay and minimum on and minimum off times.

1 to 3

Default = 1

35 to 85 o

F

(2 to 29 o

C)

Default = 60 o

F

(21 o

C)

-60 to 50 o

F

(-51 to 10 o

C)

Default = -10 o

F

(-23 o

C)

35 to 150 o

F

(2 to 66 o

C)

Default = 70 o

F

(21 o

C)

70 to 230 o

F

(21 to 110 o

C)

Default = 180 o

F

(82 o

C)

Differential

Temperature

To provide a modulation rate above and below the Boiler Target temperature. For example, if the value is 10 o

F and the Boiler Target is 160 o

F the boiler will begin to modulate at

150 o

F and shut off at 170 o

F.

Au, 2 to 42 o

(Au, -16 to 5

F o

C)

Default = 10 o

F

23

Pump Delay

Boiler post pump time after burner has shut off, in seconds.

OFF, 0:20 to 9:55 min, On

Default = 1:00 min

Warm

Weather

Shutdown

Temperature

Warm weather shutdown temperature using outdoor reset.

35 to 105 o

(2 to 41 o

F, OFF

C, OFF)

Default = 0:20 min

Temperature

Units

Select the desired unit of measurement o

F, o

C

Default = o

F

13.2.10 MODE 6: EXTERNAL TARGET TEMPERATURE USING BOILER INLET SENSOR

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.

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 goes to minimum fire. 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 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.

24

13.2.11 MODE 7: EXTERNAL TARGET TEMPERATURE USING SYSTEM TEMPERATURE

SENSOR

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 13 shows the relationship between various external signals to the boiler target temperature. A 4-20mA signal can be converted to a 2-10VDC signal by installing a 500 Ω 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 goes to minimum fire. 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 210 o

F and is fixed. In addition to the auto reset limit, Camus installs a manual reset limit set to 250 o

F.

The following table shows the various signals required to generate various Target temperatures.

Table 7: External Signal Cross Reference Chart

4-20 mA Boiler Target

0 - - - (OFF)

2

4

6

8

10

12

14

16

- - - (OFF)

50 o

F (10 o

C)

70 o

F (21 o

C)

90 o

F (32 o

C)

110 o

F (43 o

C)

130 o

F (54 o

C)

150 o

F (66 o

C)

170 o

F (77 o

C)

190 o

F (88 o

C) 18

20 210 o

F (99 o

C)

* requires 500 Ω resistor

0-10V

(dc)* Boiler Target

0

1

2

3

4

5

6

7

8

9

10

- - - (OFF)

50 o

F (10 o

C)

68 o

F (20 o

C)

86 o

F (30 o

C)

103 o

F (39 o

C)

121 o

F (49 o

C)

139 o

F (59 o

C)

157 o

F (69 o

C)

174 o

F (79 o

C)

192 o

F (89 o

C)

210 o

F (99 o

C)

A 4-20mA signal can be converted to a 2-10VDC signal by installing a 500 Ω resistor on the external input signal device’s terminal.

25

13.2.12 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

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 o

F

(---, 2 to 130 o

C)

System

Temperature

(Mode 7

ONLY)

Real-time System Temperature

14 to 266

(-10 to 130 o o

F

C)

Boiler Outlet

Temperature

Real-time Outlet Temperature to

Boiler

14 to 266

(-10 to 130 o o

F

C)

Boiler Inlet

Temperature

Real-time Inlet Temperature to

Boiler

14 to 266

(-10 to 130 o o

F

C)

Boiler Delta

T

Real-time temperature difference between the outlet sensor and the inlet sensor.

-99 to 252 o

F

(-72 to 122 o

C)

Modulation

Real-time modulating output percentage

0 to 100%

Total Run

Time Since

Installation

26

Monitors the amount of operational time since the

DynaFlame 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

13.2.13 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

Mode

Parameter Description

Operating mode for the boiler.

NOTE: A complete description of each mode can be found in section 6.1 Modes of Operation in this manual.

Parameter Range

1 to 8

Default = 1

Modulation

Mode

(Mode 7

ONLY)

Modulation mode.

Automatic: PId

Manual: P

PId or P

Default: P

Boil Max

Boil Min

Maximum outlet temperature

Minimum inlet temperature

120 to 230 o

F

(49 to 110 o

C)

Default = 210 o

(99 o

C)

F

80 to 180 o

F

(26 to 82 o

C)

Default = 130 o

(54 o

C)

F

Boil Mass

(Mode 5

ONLY)

Thermal mass of boiler. This determines interstage delay and minimum on and minimum off times.

1 to 3

Default = 1

Modulation

Selects the output modulating signal to the variable frequency drive

Default: 4:20

Modulation

Delay

Selects the time (in seconds) after a flame signal is established before modulation is allowed to proceed.

10 to 230 seconds

Default = 30 seconds

Start

Modulation

Selects the start modulation rate

0% to 50%

Default = 0%

27

Display

Parameter

Name

Parameter Description Parameter Range

Minimum

Modulation

Selects the minimum modulation rate

0% to 50%

Default = 0%

Maximum

Modulation

Selects the maximum modulation rate

50% to 100%

Default = 100%

Differential

Temperature

To provide a modulation rate above and below the Boiler

Target temperature. For example, if the value is 10 o

F and the Boiler

Target is 160 o

F the boiler will begin to modulate at 155 o

F and shut off at 165 o

F.

Au, 2 to 42 o

(Au, -17 to 6 o

F

C)

Default = 10 o

F

Pump Delay

Boiler post pump time after burner has shut off, in seconds.

OFF, 0:20 to 9:55 min, On

Default = 1:00 min

External

Input

Select the range of external input signal (Vdc)

0:10 or 2:10

Default: 0:10

Offset

Temperature

Units

Select the temperature offset of the boiler target temperature. The boiler target is determined from the external input signal.

-10 to 10 o

(-5 to 5

F o

C)

Default = 0 o

F

Select the desired unit of measurement o

F, o

C

Default = o

F

28

4-20 mA Boiler Target

0 - - - (OFF)

2

4

6

8

10

12

14

16

18

20

- - - (OFF)

50 o

F (10 o

C)

70 o

F (21 o

C)

90 o

F (32 o

C)

110 o

F (43 o

C)

130 o

F (54 o

C)

150 o

F (66 o

C)

170 o

F (77 o

C)

190 o

F (88 o

C)

210 o

F (99 o

C)

0-10V

(dc)* Boiler Target

0

1

2

3

4

5

6

7

8

9

10

- - - (OFF)

50 o

F (10 o

C)

68 o

F (20 o

C)

86 o

F (30 o

C)

103 o

F (39 o

C)

121 o

F (49 o

C)

139 o

F (59 o

C)

157 o

F (69 o

C)

174 o

F (79 o

C)

192 o

F (89 o

C)

210 o

F (99 o

C)

14 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.

15 LOW WATER TEMPERATURE SYSTEMS

In applications where the heating system requires supply water temperatures below 110 °F, a bypass lin e must be installed upstream of the boiler pump so that outlet water can be re-circulated to raise the inlet temp to a minimum of 110 °F. Balancing valves, pre ferably globe valves are used to adjust flow. (See

Figure 7)

Figure 7: Low Water Temperature System

29

•

Adjustment procedure. a. Fully open bypass and outlet valves. b. With boiler running, read inlet temperature after 15 minutes. c. If the inlet temperature is less than 110°F slow ly close outlet valve until the inlet temperature climbs to 110°F d. If the inlet temperature is greater than 110°F b ut not greater than 140°F no further adjustment is required. e. Check the inlet temperature after 5 minutes and make final adjustments.

16 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 8) Call factory for recommendations.

Figure 8: Instantaneous Water Piping Suggested System

17 CONDENSING HEAT RECOVERY MODULE

The MicoFlame could be provided in condensing mode for a variety of application including domestic hot water and hydronic space heating.

The CHRM is intended to extract total (sensible and latent) heat from the flue gases downstream of the primary heat exchanger. As a result, condensation of moisture in the flue gas will take place on the

CHRM surfaces and in the exhaust vent. This condensation is a natural outcome when efficiencies exceed 90%.

A neutralizer cartridge is provided and must be installed in the line from the condensate collection pot to the drain. PH level of the condensate is to be checked regularly and neutralizing medium is to be replaced as required to maintain effectiveness. A neutralizer cartridge is available from the factory.

Recommended installation methods of the condensing MicoFlame will vary depending on the application and the expected water temperature variation of the system.

Examples of recommended installation for typical applications are shown on the next page:

30

31

18 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.

18.1 MAIN BURNER

The main burner, Figure 9 should display the following characteristics;

•

Acceptable CO and CO

2

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 9: Burner

If burner characteristics do not match the above, check for proper air box pressure. Also look for accumulation of lint and other foreign material at fan air inlets. Typical air box settings are as follows (a setting in brackets denotes condensing application):

Table 8: Typical Air Box Settings

MODEL

800

1000

1200

1400

1600

1800

2000

AIR BOX “ W.C. (with burner firing) FLUE SWITCH RECYCLE POINT “ W.C

Left Burner Right Burner Left Burner Right Burner

-

-

0.9 (1.1)

0.9 (1.1)

0.9 (1.1)

1.6 (1.9)

1.9 (2.2)

1.4 (1.7)

1.9 (2.2)

0.9 (1.1)

1.4 (1.7)

1.9 (2.2)

1.6 (1.9)

1.9 (2.2)

-

-

0.8 (0.9)

0.7 (0.9)

0.7 (0.9)

1.2 (1.6)

1.5 (1.9)

1.0 (1.4)

1.5 (1.9)

0.7 (0.9)

1.1 (1.3)

1.5 (1.8)

1.2 (1.6)

1.5 (1.9)

Depending on field conditions air box pressures will have to be adjusted accordingly. Always set the appliance for a CO

2

level in the range of 7.5% to 8.5 % for non-condensing appliances and 8.5% to 9.0% for condensing appliances. For propane fired appliances the settings will be approximately 1.5% higher.

A qualified service technician should follow this procedure when burner needs cleaning.

32

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 two wing 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. 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 boiler.

•

Following the lighting instructions put the boiler back into operation

•

Check for gas leaks and proper boiler and vent operation.

33

18.2 PILOT BURNER

Turn the pilot firing valve 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 adjusted. This can be readily accomplished after removing the main burner.

The spark gap should be 1/8” to 3/16” between igniter and ground rod and 3/8” between igniter and surface of metal fiber. 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 reinstall it so that there is no gap between the top surface of the pilot tube and the underside of the metal filter support screen. When properly set it will not be possible to slip a business card between the pilot burner and the support screen. Figure 10 shows the burner box assembly with the metal filter cover removed to expose pilot tube.

Figure 10: 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. (See Figure 10)

Open the firing valve 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.

34

19 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 open firing valve 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, follow the detailed procedure in section 17 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.

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.

20 LIGHTING INSTRUCTIONS

1. Turn off electric power to boiler.

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 boiler. 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 decrease it or clockwise to increase it.

35

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.

TO TURN OFF BOILER: Close main manual valve and main firing valve and turn off electric power to system.

21 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

SOLUTION

•

Check wiring to switch.

•

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.

5. Pilot lights but main burner does not fire. •

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

6. Main burner lights but cycles off after a few minutes

7. Boiler starts to whine as the temperature rise increases. ground electrode. Clean with steel wool if necessary.

•

Verify that high limit is set high enough to prevent short cycling.

•

Adjust pilot pressure for steady flame

•

Remove main burner. Adjust pilot shield and clean ignition sensor.

•

Verify that all air is bled from system.

•

Verify 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.

36

22 TYPICAL GAS TRAIN

Figure 11: Gas Train

23 ELECTRICAL DIAGRAMS

Each MicoFlame series 2 boiler will be provided with its own wiring diagram to guarantee that any options ordered with the unit are properly detailed.

The following diagrams 99-5072 and 99-5082 are provided as typical samples only.

37

38

39

Tekmar BTC-4PA Electrical Connections

10

11

12

13

14

15

16

17

Terminal # Label

1 CD

2

3

4

HtD

Pr D

Com

Unused

Tekmar BTC-4PA

Call for heat signal

Description

Proof Demand to signal pilot is active

Common terminal for Outdoor, System and/or DHW sensors

5

6

7

8

9

Outdr

Sys/D

Boil O

Boil in

Com

10kΩ outdoor sensor

10kΩ system or DHW sensor

10kΩ boiler outlet sensor

10kΩ boiler inlet sensor

Common terminal for boiler outlet and inlet sensor

18

19

20

21

22

23

24

+Vdc +Vdc for Modes 6, 7 for setpoint input

-- Unused

C

Pmp

Pmp

Stg 1

Stg 1

Stg 2

Stg 2

Stg 3

Stg 3

Stg 4

Stg 4

24Vac return for Tekmar BTC

Normally open pump contacts, closes on a call for heat

Stage 1 burner contacts

Stage 2 burner contacts

Stage 3 burner contacts

Stage 4 burner contacts

Alarm Alarm signal, closes in the event of a fault (24Vac)

R 24vac supply for Tekmar BTC

40

24

EXPLODED VIEW

41

MicoFlame II Gas Train

42

MicoFlame II 800 – 1000 Control Box

43

25 MICO FLAME REPLACEMENT PARTS LIST

13

14

15

16

17

18

4

5

6

7

8

9

10

11

Item

#

1

2

3

Part Description

Combustion Chamber End Panel - Left

Combustion Chamber End Panel - Right

Combustion Chamber Rear Panel-Non

Condensing

Combustion Chamber Rear Panel-Condensing

Combustion Chamber Support - Left

Combustion Chamber Support - Right

Combustion Chamber Base Panel

Combustion Chamber Upper Front Panel

Flue Collector Top

Flue Collector End Bracket

Base Panel

Outer Jacket Top Cover

*12

Outer Jacket Back Panel-Condensing

Outer Jacket Back Panel-Non

Condensing/Outdoor

Outer Jacket Lower Front Panel (2 Required Per

Unit)

Outer Jacket Upper Front Panel

Leg

Stiffener

Inlet Outlet Side Access Panel

Return Side Access Panel

MicoFlame II Model Size

800 1000 1200 1400

14-4100

1600 1800 2000

14-4101-08-10

14-4102-08 14-4102-10

14-4101-12-20

14-4102-16

14-4102-08-51 14-4102-10-51 14-4102-12-51 14-4102-14-51 14-4102-16-51 14-4102-18-51 14-4102-20-51

14-4103

14-4104-08-10

14-4105-08 14-4105-10

14-4106-08

14-4107-08

14-4106-10

14-4107-10

14-4105-12

14-4106-12

14-4107-12

14-4105-14

14-4106-14

14-4104-12-20

14-4105-16

14-4106-16

14-4107-16

14-4105-18

14-4106-18

14-4107-18

14-4105-20

14-4106-20

14-4107-20

14-4109-08

14-4110-08

14-4111-08-51

14-4111-08-61

14-4109-10

14-4110-10

14-4111-10-51

14-4111-10-61

14-4109-12

14-4110-12

14-4111-12-51

14-4111-12-61

14-4107-14

14-4108

14-4109-14

14-4110-14

14-4111-14-

51

14-4111-14-

61

14-4109-16

14-4110-16

14-4111-16-51

14-4111-16-61

14-4109-18

14-4110-18

14-4111-18-51

14-4111-18-61

14-4109-20

14-4110-20

14-4111-20-51

14-4111-20-61

14-4112-08 14-4112-10 14-4112-12 14-4112-14 14-4112-16 14-4112-18 14-4112-20

14-4113-08

14-4115-08

14-4113-10

14-4115-10

14-4102-12

14-4113-12

14-4115-12

14-4102-14

14-4113-14

14-4114

14-4115-14

14-4116

14-4117

14-4113-16

14-4115-16

14-4102-18

14-4113-18

14-4115-18

14-4102-20

14-4113-20

14-4115-20

44

Item

#

19

*20

21

22

23

24

25

26

27

28

29

30

31

36

37

38

32

33

34

35

Part Description

Combustion Chamber Support - Centre

Flue Collector Outlet-Non Condensing

Flue Collector Outlet-Condensing

Outer Jacket Side Panel - Right

Outer Jacket Side Panel - Left

Fan Mounting Support - Right

Fan Mounting Support - Left

Burner Door Stop

Burner Door

V Baffles (800-1200 9 Required per Unit, 1400-

2000 18 Required per Unit)

HX Front and Back Baffles (2 Required per Unit,

1 front and 1 back)

Outer Jacket Sight Glass Frame

Outer Jacket Door Jam

Heat Exchanger Support Weldment (2 Required

Per Unit)

Inner Jacket Sight Glass Frame

Outer Jacket Top Panel Support

Control Panel Assembly

Two Tile Burner Box Assembly

Three Tile Burner Box Assembly

Economizer Cover

Economizer Assembly

Inlet/Outlet Header

800

N/A

14-4119-08-10

14-4134-08

14-4140-08

14-4141-08

14-4142-08

N/A

N/A

14-4146-08-10

14-4148-03

1000

14-4120-08-10-51

14-4134-10

14-4140-10

14-4141-10

14-4142-10

MicoFlame II Model Size

1200 1400 1600

14-4118-12-20

14-4119-12-16

14-4120-12-20-51

14-4131

14-4132

14-4133

14-4134-12

14-4140-12

14-4141-12

14-4142-12

14-4139

14-4134-14

14-4140-14

14-4141-14

14-4142-14

14-4151

14-4152

14-4153

14-4154

14-4155

14-4160

14-4125-02

14-4125-03

14-4146-18-20

14-4134-16

14-4140-16

14-4141-16

14-4142-16

14-4166-01

15-5004

1800

N/A

14-4134-20

14-4140-20

14-4141-20

14-4142-20

14-4165-01

2000

14-4119-18-20

14-4134-18

14-4140-18

14-4141-18

14-4142-18

45

Item

#

39

44

45

46

40

41

42

43

47

48

49

50

51

52

53

54

55

56

*57

Part Description

Return Header

Header Bar

Header Bar Stop (2 Required Per Unit)

Control Panel Outer Cover

Control Panel Outer Cover Door

Blower Assembly

Ignition Module Continous

Ignition Module Single Try

Refractory Set

Donut Gasket

Pre-Purge Card

30 Second Delay on Make

Pump Delay Relay

Pilot Solenoid

Red Strip Gasket

On/Off Switch

Igniter

Flame Sensor

Ceramic Pilot Assembly (NG)

Mesh Pilot Assembly (NG)

Ceramic Pilot Assembly (LP)

*58

Mesh Pilot Assembly (LP)

800

800-RFRS

1000

1000-RFRS

MicoFlame II Model Size

1200 1400

15-5005

1600

15-4157

14-4138

14-4171

14-4172

55-0001

S8610M3017

S8610043010

1200-RFRS 1400-RFRS

CH010

TTMOR24A1X7

24-IMS24AaX30

LY1F24VAC

CV100B6N-22-0001

Red Silicone Sponge Gasket

C6000ALBB/G74/W46

1600-RFRS

PSE-CH8

PSE-CH7

66-0107

66-5013

66-0108

66-5014

46

1800 2000

1800-RFRS 2000-RFRS

67

68

69

70

71

72

73

Item

#

59

60

61

62

63

64

65

66

Part Description

Ignitor Module (Continuous)

Ignitor Module (Single Try)

Tekmar Controller (STG)

Air Switch

Low Gas Switch (Not Shown in Exploded View,

in Boiler Price Book)

High Gas Switch (Not Shown in Exploded View,

in Boiler Price Book)

115/24V AC Transformer

Mixing Tube (2 Required per Unit)

Gas Valve (left)

Gas Valve (right)

Solenoid Valve (left)

Transformer

Fan Manager

Breaker (4 AMP)

White Indicator LED

Red Indicator LED

Blue Indicator LED

800

V8944B1092

N/A

K3A462U

MicoFlame II Model Size

1000

V8944B1100

N/A

1200 1400

S8610M3017

S8600112010

BTC4PA

IS3010106-5769A

C6097A1012

1600

C6097B1028

HCT-01J28807

MF1-GMTM-04-CH

V8944B1092 V8944B1092

V8944B1092 V8944B1092

V4295A1049

HCT-01J2BB07

ST82D1004

W28-XQ1A-4

LXR5010UW42149

LXR5010UB28230

LXR5010S128230

V8944B1092

V8944B1100

1800 2000

V8944B1092 V8944B1100

V8944B1092 V8944B1100

V4295A1056

47

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

Address

Model No.

Date of Installation:

Name of Dealer

Address

Serial No.

Date of Initial Operation:

6226 Netherhart Road, Mississauga, Ontario, L5T 1B7, CANADA

48

CAMUS Hydronics is a manufacturer of replacement parts for most copper finned water heaters and heating boilers as well

as a supplier of specialty

HVAC products. Our service line is open 24

hours, 7 days a week!

The CAMUS CERTIFIED!

Seal assures you that

Reliability, Efficiency &

serviceability are built into every single unit!

For more

information on our innovative products from CAMUS

Hydronics Limited, call

905-696-7800 today.

CAMUS HYDRONICS LTD.

6226 Netherhart Road Drive, Mississauga, Ontario L5T 1B7

TEL: 905·696 7800 FAX: 905·696 8801