Installation Operation and Service Manual

INSTALLATION OPERATION

AND SERVICE MANUAL

MICOFLAME® SERIES

GAS FIRED RESIDENTIAL AND COMMERCIAL COPPER TUBE

BOILERS

FOR HYDRONIC HEATING

Non-Condensing Models; MFH060, 100, 150, 200, 250, 300, 400, 500, 600

Condensing Models; MFH062, 102, 152, 202, 252, 302, 402, 502, 602

HOT WATER SUPPLY

Non-Condensing Models; MFW060, 100, 150, 200, 250, 300, 400, 500, 600

Condensing Models; MFW062, 102, 152, 202, 252, 302, 402, 502, 602

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

99-0052

Rev. 7.3

Table of Contents

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

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

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

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

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

5. NORMAL GAS SUPPLY AND PIPING ...................................................................................................................... 4

6. VENTING ............................................................................................................................................................. 5

6.1 OUTDOOR VENTING ........................................................................................................................................... 8

6.2 SIDEWALL VENTING .......................................................................................................................................... 8

6.3 OUTDOOR AIR KIT ............................................................................................................................................. 8

6.4 FILTER KIT ......................................................................................................................................................... 9

6.5 STANDARD VENTING ......................................................................................................................................... 9

6.6 VENTING FOR CONDENSING APPLICATION ........................................................................................................ 9

7. ACCESSORIES ..................................................................................................................................................... 11

8. FREEZE PROTECTION ......................................................................................................................................... 12

9. WARNING REGARDING CHILLED WATER SYSTEMS ............................................................................................. 12

10. PIPING OF BOILER TO SYSTEM (FIG.4) ............................................................................................................... 13

11. PLACING BOILER IN OPERATION ....................................................................................................................... 14

12. MICOFLAME® CONTROL PANEL ........................................................................................................................ 15

12.1

12.2

12.3

12.4

12.5

12.6

12.7

12.8

12.9

12.10

GENERAL SYMBOL DESCRIPTION .............................................................................................................. 16

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

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

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

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

MODE 4 & 5: OUTDOOR RESET OPERATION: VIEW DISPLAY...................................................................... 21

MODE 4 & 5: OUTDOOR RESET OPERATION: ADJUST DISPLAY .................................................................. 22

MODE 6: EXTERNAL SEQUENCER OPERATION: VIEW DISPLAY ................................................................... 24

MODE 6: EXTERNAL SEQUENCER OPERATION: ADJUST DISPLAY ............................................................... 25

MODE 7 & 8: EXTERNAL TEMPERATURE TARGET OPERATION: VIEW DISPLAY ........................................... 25

12.11 MODE 7 & 8: EXTERNAL TEMPERATURE TARGET OPERATION: ADJUST DISPLAY ....................................... 26

13. IGNITION SYSTEM SAFETY SHUT-OFF DEVICE .................................................................................................... 28

14. LOW WATER TEMPERATURE SYSTEMS ............................................................................................................. 28

15. INSTANTANEOUS WATER HEATER .................................................................................................................... 29

16. CONDENSING HEAT RECOVERY MODULE .......................................................................................................... 30

17. PILOT AND MAIN BURNER FLAMES ................................................................................................................... 31

17.1. MAIN BURNER ................................................................................................................................................. 31

17.2 REMOVAL OF COMBUSTION CHAMBER LINING ................................................................................................ 33

17.3 PILOT BURNER ................................................................................................................................................. 33

18. OPERATION AND SERVICE ................................................................................................................................ 34

19. LIGHTING INSTRUCTIONS ................................................................................................................................. 35

20. TROUBLE SHOOTING GUIDE ............................................................................................................................. 36

21. TYPICAL GAS TRAIN .......................................................................................................................................... 37

22. ELECTRICAL DIAGRAMS .................................................................................................................................... 37

23. EXPLODED VIEW .............................................................................................................................................. 40

24. MICOFLAME® REPLACEMENT PARTS LIST ......................................................................................................... 42

WARRANTY ............................................................................................................................................................... 46

INTRODUCTION

Camus® Hydronics proudly introduces its MicoFlame® series of 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. Consult the factory for recommendations for use in hard water areas.

Damage to the heat exchanger as a result of scaling or corrosive water conditions in non-warrantable.

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:

TOP: 12”

SIDES: 12”

REAR: 12”

VENT: 6”

FLOOR: 0”

For boiler’s dimensions see Figure 1 and table 1

Model 60 - 300

Model 400 - 600

Side View (Left) Front View Side View (Right) Side View (Right) Condensing

Figure 1

2

Table 1

B' Dia.

Venting* E' Dia.

Model 'W'

MFNH060 18 3/4 1 1/2 1/2 3 3 3

MFNH100 18 3/4 1 1/2 1/2 3 3 4

MFNH150 18 3/4 1 1/2 1/2 3 3 4

MFNH200 18 3/4 1 1/2 1/2 4 4 5

MFNH250 25 1 1/2 3/4 4 4 5

MFNH300 25 1 1/2 3/4 5 5 6

MFNH400 31 1/2 2 1 5 5 6

MFNH500 31 1/2 2 1 6 6 7

MFNH600 36 1/2 2 1 6 6 7

3

3

3

4

4

5

5

6

6

* 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 are to be in accordance with the section “Air for Combustion and Installation”, Of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or clause 8.2, 8.3, 8.4 of “Natural

Gas and Propane Installation Code”, CAN/CSA B149.1.2, or appliance 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.

3

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 remote controller

Refer to wiring diagram provided with boiler.

5. NORMAL GAS SUPPLY AND PIPING

This boiler is intended to operate at inlet gas pressures not exceeding 1/4 PSI (7“W.C.) when firing with natural gas. If higher pressures are present, consult the gas company for correction.

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 ground 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 appliance in accordance with the limits in the table below:

PROPANE NATURAL GAS

Minimum Running (inches W.C.)

Maximum Lockup (inches W.C.)

10

11

4

14

4

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 2 is recommended.

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

Table 2

DISTANCE FROM NATURAL GAS METER OR PROPANE SECOND STAGE REGULATOR

Input

Btu/Hr

0-100 FT

NAT. L.P.

100-200 FT.

NAT. L.P.

200-300 FT.

NAT. L.P.

60,000

100,000

150,000

200,000

250,000

300,000

400,000

500,000

600,000

¾”

¾”

1“

1“

1 ¼”

1 ¼”

1 ¼”

1 ½“

1 ½“

½“

½“

¾”

¾”

1“

1“

1“

1 ¼”

1 ¼”

¾”

1“

1 ¼”

1 ¼”

1 ¼”

1 ½“

1 ½“

2”

2”

½“

¾”

1“

1“

1“

1 ¼”

1 ¼”

1 ½“

1 ½“

1“

1“

1 ¼”

1 ¼”

1 ½“

1 ½“

2”

2”

2”

¾”

¾”

1“

1“

1 ¼”

1 ¼”

1 ½”

1 ½“

1 ½“

6. 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 National Fuel Gas Code, ANSI Z223.1, or Section 7, Venting of Equipment and Air

Supply for Appliances, of the 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.

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,

5

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 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 latest or current as amended 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 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.

6

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.

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® is a category 1, 85% efficient when supplied as a non-condensing appliance. When supplied with the optional condensing cartridge, the MicoFlame® is 95% efficient and is considered to be a category II or IV appliance. Three venting options are available for this boiler. See Figure 2 for details.

(Please refer to Table 1 for vent dimensions)

Figure 2

7

6.1 OUTDOOR VENTING

When fitted with the factory supplied rain shield and UL approved vent cap, the MicoFlame® is selfventing. 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.

6.2 SIDEWALL VENTING

When fitted with the factory supplied vent terminal, the MicoFlame® can vent up to 50 equivalent feet.

Elbows can range from 5 to 9 feet in equivalent length depending on centerline 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. Aluminum 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.

6.3 OUTDOOR AIR KIT

When fitted with the factory supplied air inlet ring and air intake terminal, the MicoFlame® can draw outdoor air over an equivalent length of 50 feet. 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.

8

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.

6.4 FILTER KIT

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

6.5 STANDARD VENTING

The MicoFlame® 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.

6.6 VENTING FOR CONDENSING APPLICATION

When supplied with the optional condensing cartridge, the MicoFlame® is 95% efficient (category II or IV appliance) which requires the use of a special venting system fabricated from AL29-4C or equivalent material. Only venting components listed by a nationally recognized testing agency may be used.

This appliance may be installed with conventional, sidewall or vertical venting. Conventional vented appliances operate with negative pressure in the vent pipe and require a special vent adapter to increase the flue outlet diameter. Sidewall and vertically vented appliances operate with positive pressure in the vent pipe and may be directly connected to the flue outlet without the use of an increaser.

Consult the vent pipe manufacturer’s instructions for minimum clearances to combustible material for vent components. In the absence of instructions, the minimum clearance to combustible material is six inches.

Consult vent pipe manufacturer’s instructions for proper method of sealing vent pipe sections and fittings.

In the absence of instructions, make sure that pipe and fittings are clean by swabbing with alcohol. Use

Dow Corning 736 or 732 RTV, Polybar # 500 RTV or Sil-bond 4500 or 6500 to seal vent pipe. Do not use other sealants or adhesives except as expressly permitted by vent manufacturer’s instructions.

Consult vent pipe manufacturer’s instructions for vent system assembly. Follow vent pipe manufacturer’s instructions if those instructions differ from this section.

9

Conventional Venting

Multiple appliances may be vented into a conventional chimney. The chimney must be lined with AL29-4C and a single acting barometric damper must be provided for each appliance. Vent diameters are to be increased by one size over the recommended size

A qualified professional using a proven vent-sizing program with input of accurate operating parameters must properly calculate sizing of the venting system. In applications where flue gas temperatures are lower than can support a Category II with conventional negative draft, it will be determined at the venting design stage that a positive pressure will be developed in the vent. It will then be necessary to either provide separate vents as for Category IV, or to provide an extractor at the chimney outlet in order to maintain a negative draft in the chimney and allow common venting.

Approval of the installation will be at the discretion of authorities having jurisdiction.

The chimney must be protected from down drafts, rain and debris by using a listed chimney cap.

Sidewall and Vertical Venting

The maximum vent length is 50 equivalent feet. Vent pipe may be run through a vertical or horizontal chase provided that minimum clearances to combustible materials are maintained.

The vent termination location is restricted as follows:

Minimum 12 inches above grade plus normally expected snow accumulation. Or 7 feet above grade if located adjacent to public walkways. Do not install over public walkway where local experience indicates condensation or vapor from the boiler creates a nuisance or hazard. Minimum 3 feet above any forced air inlet located within 10 feet of vent termination. Minimum 4 feet below, 4 feet horizontally or above any door window or gravity air inlet. Minimum 4 feet horizontally from electric meters, gas meters, regulators and relief valves. Use appropriately designed thimbles when passing through combustible walls or roofs. Install fire stops where vent passes through floors, ceilings or framed walls. The fire stop must close the opening between the vent pipe and the structure. Locate vent terminal above combustion air intake terminal (if used) and no closer than 2 feet vertically or horizontally. Vertical venting requires flashing and a storm collar to prevent moisture from entering the structure. Vertical vent termination must be at least 2 feet plus the expected snow accumulation above the roof penetration height.

10

7. 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.

Low Water Cutoff Electrical Connections (Watts) Low Water Cutoff Electrical Connections (ITT)

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 the Primary Heat

Exchanger.

11

BOILER APPLICATION (HYDRONIC HEATING)

In case of boiler (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

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

8. 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.

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 3)

12

Figure 3

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.

10. PIPING OF BOILER TO SYSTEM (FIG.4)

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 3 is provided as a guide.

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

Table 3

60

100

150

200

250

300

400

500

600

Head Loss and Flow Vs Temperature Rise

Model

10 °F 20 °F 30 °F

USGPM

∆

P ft. USGPM

∆

P ft. USGPM

∆

P ft.

10.2 0.03 5.1 0.01 3.4 0.005

17.0 0.07 8.5 0.02 5.7 0.010

25.5

34.0

42.5

51.0

68.0

85.0

0.20

0.40

0.65

1.50

2.00

3.00

12.8

17.0

21.3

25.5

34.0

42.5

0.04

0.08

0.16

0.49

0.55

0.76

8.5

11.3

14.2

17.0

22.7

28.3

0.030

0.050

0.100

0.190

0.260

0.390

102.0 4.30 51.0 1.15 34.0 0.550

13

Figure 4

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.)

11. PLACING BOILER IN OPERATION

The MicoFlame® 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.

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.

14

Within 3 days of start up, recheck all air vents and expansion tank as described above.

12. MICOFLAME® CONTROL PANEL

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, and 4 and alarm.

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

KEY

Item

Table 4: BTC 1 Key Functions

KEY DESCRIPTION

The abbreviated name of the selected item will be displayed in the item field of the display. To view the next item, press the Item button.

Increase a parameter value.

Decrease a parameter value.

15

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.

12.1 GENERAL SYMBOL DESCRIPTION

SYMBOL

SYMBOL

NAME

Boiler

Pump

DHW

Pump

Heat

Demand

Flame

Proof

Burner

Warning

Pointers

WWSD

SYMBOL

DESCRIPTION

Shown when boiler pump is in operation

Shown when

DHW pump is in operation

Shown when heat demand is present

Shown when flame signal is proven

Shown when burner is on

Shown when an error is present

Shows the operation as indicated by the text (Proof

Dem)

Displays when the control is in

Warm Weather

Shutdown

16

12.2 MODE 1 & 2: SETPOINT OPERATION: VIEW DISPLAY

Mode 1 intended for hydronic heating. The set-point for inlet water control is pre-set to 180 o

F and the auto re-set limit is set to 230°F. The inlet 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 250°F. The control turns on the appliance 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

Mode 2 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-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 250°F. The control turns on the appliance 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.

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

(-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 counter

simultaneously to reset

the

-99 to 252 o

(-72 to 140 o

F

C)

Alternates between 00 and

999

17

12.3 MODE 1 & 2: SETPOINT OPERATION: ADJUST DISPLAY


1) Press simultaneously to view the following parameters:

Display

Parameter

Name


Mode

Operating mode for the boiler.

NOTE: A complete description of each mode can be found in section 8.4 Modes of Operation in this manual.

Parameter

Range

1 to 6

Default = 1

70 to 220 o

(21 to 104

F o

C)

Default = 120 o

(49 o

C)

F

Boiler Target

Temperature

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

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

F

(Au, -17 to 6 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

12.4 MODE 3: SETPOINT OPERATION: VIEW DISPLAY

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 inlet 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.



Display

Parameter

Name


Parameter

Range

Boiler Outlet

Temperature


14 to 266

(-10 o to 130

F o

C)

Boiler Inlet

Temperature


14 to 266 o

F

(-10 to 130 o

C)

Boiler Delta

T


-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



999

19

12.5 MODE 3: SETPOINT OPERATION: ADJUST DISPLAY



Display

Parameter

Name

Parameter Description Parameter Range

Mode

Boiler Target

Temperature


NOTE: A complete description of each mode can be found in section 8.4 Modes of Operation in this manual.

1 to 6

Default = 1


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

(OFF, 21 to 88 o

F

C)

Default = 130 o

(54 o

C)

F

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.

To provide a modulation rate above and below the Boiler


F and the Boiler

Target is 160 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


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

12.6 MODE 4 & 5: OUTDOOR RESET OPERATION: VIEW DISPLAY

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-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 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-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 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



Display

Parameter

Name


Parameter

Range

Outdoor

Temperature

Real-time Outdoor Temperature

-60 to 190 o

(-51

F to 88 o

C)

Boiler

System

Temperature

(Mode 5

ONLY)

Real-time System Temperature to

Boiler

14 to 266

(-10 o to 130

F o

C)

Boiler Outlet

Temperature


14 to 266

(-10 o to 130

F o

C)

Boiler Inlet

Temperature


14 to 266

(-10 o to 130

F o

C)

Boiler Delta

T

Total Run

Time Since

Installation



Press counter

simultaneously to reset the

-99 to 252 o

(-72 to 140 o

F

C)


999

21

12.7 MODE 4 & 5: OUTDOOR RESET OPERATION: ADJUST DISPLAY



Display

Parameter

Name


Mode


NOTE: A complete description of each mode can be found in section 8.4

Modes of Operation in this manual.

Parameter Range

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 Max

Boil Min

Maximum boiler target temperature

Minimum boiler target temperature

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)

120 to 225 o

(48 to 107 o

F

C)

Default = 210 o

F

(99 o

C)

80 to 180 o

(26 to 82 o

F

C)

Default = 130

(54 o

C) o

F

22

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

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.

Au, 2 to 42 o

(Au, -16 to 5

F o

C)

Default = 10 o

F

Stage

Differential

Dictates the staging of the boiler and each stage is iterative. For example, if the value is 3 o

F. Stage 1 will be active

3 o

F below setpoint, Stage 1 & 2 will be active 6 o

F below setpoint.

Au, 2 to 42 o

(Au, -17 to 6

F o

C)

Default = 10 o

F

On Delay

Interstage delay to activate the next stage

0:10 to 8:00 minutes

Default = 1:00 minute

Minimum On

Time

Minimum on time for each stage



Minimum Off

Time

Minimum off time for each stage


Default = 0:50 minutes

Pump Delay



Default = 1:00 min

23

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


F, o

C

Default = o

F

12.8 MODE 6: EXTERNAL SEQUENCER OPERATION: VIEW DISPLAY

Mode 6 is intended for multiple appliance application and all stages are closed at all times. In essence there is no operator at the appliance. A removable jumper is provided in the electrical enclosure across the contacts to be used for connection to the remote operator. The fixed auto re-set limit is set to 230°F. In addition to the auto reset limit the factory installs a manual re-set limit set to 250°F. The control provides pump operation. Staging operation is provided by an external sequencing control. Heat demand is provided to the external sequencing control. External sequencing control then provides heat demand to the control. Each control turns on its respective appliance pump and stage 1 contact whenever an external heat demand is present. Once the external heat demand is removed from the control, the control turns off the stage 1 contact and operates the pump to provide purging. Once the purge period is complete, the control turns off the appliance pump.



Display

Parameter

Name


Parameter

Range

Boiler Outlet

Temperature


14 to 266

(-10 o to 130

F o

C)

Boiler Inlet

Temperature


14 to 266

(-10 o to 130

F o

C)

Boiler Delta

T

Total Run

Time Since

Installation


-99 to 252 o

(-72 to 140 o

F

C)


Press the counter


24


999

12.9 MODE 6: EXTERNAL SEQUENCER OPERATION: ADJUST DISPLAY



Display

Parameter

Name


Mode


NOTE: A complete description of each mode can be found in section 8.4

Modes of Operation in this manual.

Parameter Range

1 to 6

Default = 1

Pump Delay



Default = 1:00 min

Temperature

Units


F, o

C

Default = o

F

12.10 MODE 7 & 8: EXTERNAL TEMPERATURE TARGET OPERATION: VIEW DISPLAY

Mode 7 A removable jumper is provided in the electrical enclosure across the contacts to be used for connection to the remote operator. Heat demand provided via external analog input signal from EMS or tN4 system control (e.g. 420). The control turns on the boiler pump and operates the boiler to maintain the boiler target at the boiler inlet sensor whenever a heat demand is present. Once the external heat demand is removed from the control, the control turns off the stage 1 contact and operates the pump to provide purging. Once the purge period is complete, the control turns off the appliance pump.

Mode 8 A removable jumper is provided in the electrical enclosure across the contacts to be used for connection to the remote operator. Heat demand provided via external analog input signal from EMS or tN4 system control (e.g. 420). The control turns on the boiler pump and operates the boiler to maintain the boiler target at the system sensor whenever a heat demand is present. Once the external heat demand is removed from the control, the control turns off the stage 1 contact and operates the pump to provide purging. Once the purge period is complete, the control turns off the appliance pump.

25



Display

Parameter

Name


Parameter

Range

Boiler Outlet

Temperature


14 to 266

(-10 o to 130

F o

C)

Boiler Inlet

Temperature


14 to 266

(-10 o to 130

F o

C)

Boiler Delta

T

Total Run

Time Since

Installation


Monitors the amount of operational time since the unit was installed. The two digits are the thousands of hours and the three digit display shows the hundreds of hours.

Press the counter


-99 to 252 o

(-72 to 140 o

F

C)


999

Boiler Target

Temperature


OFF, 70 to

220 o

F

(OFF,21 to

104 o

C)

12.11 MODE 7 & 8: EXTERNAL TEMPERATURE TARGET OPERATION: ADJUST DISPLAY



Display

Parameter

Name


Parameter

Range

Mode Operating mode for the boiler.

1 to 8

Default = 1

Boil Max Maximum boiler target temperature

120 to 225 o

F

(48 to 107 o

C)

Default = 210 o

F

(99 o

C)

26

Boil Min

Differential

Temperature

Stage

Differential

On Delay

Minimum On

Time

Minimum Off

Time

Minimum boiler target temperature

Interstage delay to activate the next stage

Minimum on time for each stage

Minimum off time for each stage

80 to 180 o

F

(26 to 82 o

C)

Default = 130 o

F

(54 o

C)

To start the boiler below the Boiler


F and the Boiler

Target is 160 o


F and shut off at

170 o

F.

Dictates the staging of the boiler and each stage is iterative. For example, if the value is 3 o

F. Stage

1 will be active 3 o

F below setpoint,

Stage 1 & 2 will be active 6 o

F below setpoint.

Au, 2 to 42 o

(Au, -17 to 5

F o

C)

Default = 10 o

F

Au, 2 to 42 o

(Au, -17 to 6

F o

C)

Default = 10 o

F






Default = 0:50 minutes

Pump Delay



Default = 1:00 min

External

Input Signal

(Mode 8

ONLY)

Select the range for the external input signal that adjusts the boiler target.

0:10 or 2:10

Default = 0:10

Offset

Select the amount of temperature offset to add to the boiler target calculated from the external input signal.

-10 to 10 o

F

(-5 to 5 o

C)

Default = 0 o

F

27

Temperature

Units


F, o

C

Default = o

F

13. 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.

14. LOW WATER TEMPERATURE SYSTEMS

In applications where the heating system requires supply water temperatures below 110°F, a bypass line 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, preferably globe valves are used to adjust flow. (See

Figure 5)

Figure 5

•

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 115°F (46 o

C) slowly close outlet valve until the inlet temperature climbs to 115°F (46 o

C) d. If the inlet temperature is greater than 115°F (46 o

C) but not greater than 140 °F no further adjustment is required. e. Check the inlet temperature after 5 minutes and make final adjustments.

28

15. 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 6) Call factory for recommendations.

Figure 6

29

16. 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 below:

30

17. 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.

17.1. MAIN BURNER

The main burner, Figure 7 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

31

Figure 7

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:

MODEL AIR BOX “ W.C.

(with burner firing)

FLUE SWITCH RECYCLE POINT

“ W.C

060

100

150

200

250

300

0.20

0.25

0.30

0.35

0.38

0.40

0.15

0.20

0.25

0.30

0.33

0.35

400

500

0.52

0.60

0.42

0.48

600 0.70 0.58

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 8.0 % for non-condensing appliances and 8.5% to 9.0% for condensing appliances. For propane fired appliances the setting will be approximately 1.5% higher.

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. 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.

32

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.

17.2 REMOVAL OF COMBUSTION CHAMBER LINING

The combustion chamber insulation in this appliance contains ceramic fiber material. Ceramic fibers can be converted to cristobalite in very high temperature applications. The International Agency for Research on Cancer (IARC) has concluded, “Crystalline silica in this form of quartz of cristobalite from occupational sources is carcinogenic to humans (Group 1)”. Normal operating temperatures in this appliance are below the level to convert ceramic fibers to cristobalite. Abnormal operating conditions would have to be created to convert the ceramic fibers in this appliance to cristobalite.

The ceramic fiber material used in this appliance is an irritant; when handling or replacing the ceramic materials it is advisable that the installer follow these safety guidelines.

•

Avoid breathing dust and contact with skin and eyes. o

Use NIOSH certified dust respirator (N95). This type of respirator is based on the OSHA requirements for cristobalite at the time this documentation was written. Other types of respirators may be needed depending on the job site conditions. Current NIOSH recommendations can be found on the NIOSH website at http://www.cdc.gov/niosh/homepage.html

. NIOSH approved respirators, manufacturers, and phone numbers are also listed on this website. o

Wear long-sleeved, loose fitting clothing, gloves, and eye protection

•

Apply enough water to the combustion chamber lining to prevent airborne dust.

•

Remove the combustion chamber lining from the water heater and place it in a plastic bag for disposal.

•

Wash potentially contaminated clothes separately from other clothing. Rinse clothes washer thoroughly.

NIOSH stated First Aid

•

Eye: Irrigate immediately

•

Breathing: Fresh air

17.3 PILOT BURNER

Turn the pilot firing valve to off position and allow the appliance to try for ignition. Observe the spark making sure that it is strong and continuous.

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”. Make sure that the electrodes do 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 8 shows the burner box assembly with the metal filter cover removed to expose pilot tube.

33

Figure 8

Once the spark is satisfactory, open the pilot gas and allow the pilot burner to light. Once air has been purged from the pilot line, the pilot flame should appear almost instantly at the initiation of spark. Cycle the pilot several times to confirm reliability. A properly set pilot will appear blue and will engulf the igniter and ground electrode.

Open the firing valve and allow the main burner to light. The pilot must not extinguish. After running for 15 minutes, cycle the appliance to ensure that the pilot remains stable.

18. 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.

34

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.

19. 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 counterclockwise to decrease it or clockwise to increase it.

8. Open the main manual and main firing valves to allow gas to reach the main burner. If the main burner fails to ignite, turn the firing valve off and check to see that the pilot is burning. If not, repeat lighting procedure steps 1 thru 7.

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

35

20. 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

6. Main burner lights but cycles off after a cycling.

•

Check pilot flame signal (µA).

•

Adjust pilot pressure for steady flame

•

Remove main burner. Check position of igniter and ground electrode. Clean with steel wool if necessary.

•

Verify that high limit is set high enough to prevent short few minutes

7. Boiler starts to whine as the temperature rise increases. 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

21. TYPICAL GAS TRAIN

Figure 9

22. ELECTRICAL DIAGRAMS

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

The following diagram 99-5060 is provided as a typical sample only.

37

38

Tekmar BTC-4PA Electrical Connections

17

18

19

20

21

22

23

24

9

10

11

12

13

14

15

16

3

4

5

Tekmar BTC-4PA

Description Terminal # Label

1

2

CD

HtD

Unused

Call for heat signal

Pr D Proof Demand to signal pilot is active

Com Common terminal for Outdoor, System and/or DHW sensors

Outdr 10kΩ outdoor sensor

6

7

8

Sys/D

Boil O

Boil in

10kΩ system or DHW sensor

10kΩ boiler outlet sensor

10kΩ boiler inlet sensor

Com Common terminal for boiler outlet and inlet sensor

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

--

C

Pmp

Unused

24Vac return for Tekmar BTC

Normally open pump contacts, closes on a call for heat

Pmp

Stg 1

Stg 1

Stage 1 burner contacts

Stg 2

Stg 2


Stg 3


Stg 3

Stg 4


Stg 4

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

R 24vac supply for Tekmar BTC

39

23. EXPLODED VIEW

40

41

24.

MICOFLAME® REPLACEMENT PARTS LIST

Item

#

Part Description

1

Combustion Chamber Base Panel

2

3

Combustion Chamber Common

End Panel-Right

Combustion Chamber Common

End Panel-Left

4

Control Box Assembly

5

Base Panel

*6

Flue Collector Outlet-Condensing

(2 Required Per Unit)

Flue Collector Outlet-Non

*7

8

Condensing (2 Required Per Unit)

Outer Jacket Back Panel-Non

Condensing

Outer Jacket Back Panel-

Condensing

Header Bar Seal (4 Required Per

Unit)

9

Support Leg (2 Required Per Unit)

10

Outer Jacket Left Panel

11

Outer Jacket Right Panel

12

Outer Jacket Front Lower Panel

13

Outer Jacket Front Upper Panel

14

Top Cover

15

Return Side Access Panel

16

Inlet-Outlet Access Panel

17

Stiffeners

60 100

14-4075

150

14-4059-01

14-4061-01-51

14-4062-01

14-4063-01

14-4060-01

14-4051

14-4050

MicoFlame® I Model Size

200 250 300

14-4055

14-4070 (STG)

14-4061-01 (STG)

14-4022-01

14-4082

14-4081

14-4067

14-4066

NOT REQUIRED

14-4028

14-4059-05

14-4061-05

14-4061-05-51

14-4014

14-4062-05

14-4063-05

14-4060-05

42

400 500

14-4005-02

14-4001

14-4000

600

14-4005-03

14-4009-02

14-4020-11

14-4009-03

14-4020

14-4011-02

14-4011-52

14-4022-02

14-4011-03

14-4011-53

14-4032

14-4031

14-4012-02

14-4013-02

14-4010-02

14-4017

14-4016

14-4015-02

14-4012-03

14-4013-03

14-4010-03

14-4015-03

Item

#

Part Description

18

19

Combustion Chamber Right

Support

Combustion Chamber Left

Support

20

*21

22

23

Flue Collector Top

Combustion Chamber Back Panel-

Non Condensing

Combustion Chamber Back Panel-

Condensing

Flue Collector End Bracket (2

Required Per Unit)

Combustion Chamber Upper Front

Panel

24

25

26

27

28

Burner Drawer Door

Heat Exchanger Header Bar Stop


Heat Exchanger Support Bracket



Stop (2 Required Per Unit)


#2 (2 Required Per Unit)

29

Left Heat Exchanger Support

30

Burner Box Assembly

31

Fan Mounting Support

32

33

Heat Exchanger "V" Baffles

(7 Required MF60-300, 9

Required MF400-600 Per Unit)

Heat Exchanger Front and Back

"V" Baffles (2 Required Per Unit, 1

60 100

14-4057-03

14-4072

150

14-4076

14-4080-01

14-4053


200 250 300

14-4054

14-4057-04 14-4057-05 14-4057-06

14-4058

14-4038-01

14-4037-11

14-4037-12

14-4037-13

14-4071

14-4079-012

NOT REQUIRED

14-4052

14-4056

14-4080-05

NONE

400 500

14-4003

14-4004

14-4007-02

14-4002-02

14-4002-52

14-4008

14-4006-02

14-4040-02

14-4038

14-4037-21

14-4037-22

600

14-4007-03

14-4002-03

14-4002-53

14-4006-03

14-4040-03

14-4037-23

14-4023

14-4125-02

14-4039-01

NONE

14-4039-03

14-4041-03 14-4041-03 14-4041-03 14-4041-04 14-4041-05 14-4041-06 14-4041-07 14-4041-08 14-4041-09

14-4042-03 14-4042-03 14-4042-03 14-4042-04 14-4042-05 14-4042-06 14-4042-07 14-4042-08 14-4042-09

43

Front & 1 Back)

Item

#

Part Description

34

37

Blower Assembly

35

Inlet/Outlet Header

36

Return Header

Header Bar

38

39

40

Refractory Set

Economizer Enclosure/Cover -

Condensing ONLY

Economizer Shell-Condensing

ONLY

41

Control Panel Outdoor Cover

42

Control Panel Outdoor Cover Door

43

O-Ring (Header Gasket)

44

Flue Collar-Non Condensing ONLY

45

Pre-Purge Card

46

30 Second Delay on Make

47

Pump Delay Relay

48

Pilot Solenoid

49

Red Strip Gasket

50

On/Off Switch

51

Breaker (4 amp)

*52

Flame Sensor

53

Igniter

*54

Ceramic Pilot Assembly (NG)

Ceramic Pilot Assembly (LP)

60 100

60-150-RFRS

150

55-0005

13-0110


200 250 300

55-0008

13-0111

14-4156

200-RFRS 250-RFRS 300-RFRS

14-4090

14-4086-01

14-4087-01

400

400-RFRS

500

55-0007

13-0004A

13-0003A

15-4157

500-RFRS

14-4046

14-4048

14-4086-05

14-4087-05

600

600-RFRS

BLK-O-Ring

14-4018-01 14-4018-02

TTMOR24A1X7

24-IMS24AaX30

LY1F24VAC

CV100B6N-22-0001

Red Silicone Sponge Gasket

C6000ALBB/G74/W46

W28-XQ1A-4

PSE-CH7

PSE-CH8

66-0107

66-0108

44

Mesh Pilot Assembly (NG)

Mesh Pilot Assembly (LP)

Item

#

Part Description

Ignition Module Continuous

*55

Ignition Module Single Try

56

Tekmar Controller (STG)

57

Air Switch

58

Transformer

59

Fan Manager

60

White LED (5 Required Per Unit)

61

Blue LED

62

Red LED

*63

Mesh 1 Tile Burner (2 Required

per Unit)

Mesh 2 Tile Burner (2 Required

per Unit)

*64

Gas Valve

Gas Valve-ON/Off

*65

Gas Valve- 2 Stage

3" Mixing Tube

4" Mixing Tube

60 100

66-5013

66-5014

150


200 250 300

S8610M3017

S8600H43010

BTC4PA

NS2-1427-00

HCT-01J2BB07

ST82D1004

LXR5010UW42149

LXR5010UB28230

LXR5010S128230

MF-Burner 1 Tile

N/A

VR8304M4002

VR8304Q4420

GMTM-03-TH

N/A

*Indicates variations of part based on model and/or serial number

N/A

400 500 600

IS20105-5762A

N/A

MF- Burner 2 Tile

V8944B1092

N/A

N/A

N/A

GMTM-04-TH

45

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

Within 10 years of the appliance having declared FOB from Camus®, 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. Percentage shown is the amount that would be covered by Camus® Hydronics Limited if deemed warranty based on the number of years the boiler has been in service.

Years In

Service

MicoFlame®

Heating

MicoFlame®

DHW

Years In

Service

MicoFlame®

Heating

MicoFlame®

DHW

1

2

100%

100%

100%

100%

6

7

40%

35%

N/A

N/A

3

4

100%

100%

100%

100%

8

9

10

30%

25%

20%

N/A

N/A

5

100% 100% N/A

The exchanged or repaired heat exchanger will carry the balance of the remaining original warranty provided with the appliance based on the FOB date. In the event a replacement heat exchanger is delivered and if the defective heat exchanger is deemed to be repairable by Camus® the repaired heat exchanger will be returned to the customer and a credit will not be issued. Heat Exchanger shall be warranted for (20) years of the appliance having declared FOB from Camus® against “Thermal Shock” (excluded, however, if caused by appliance operation at large changes exceeding 150ºF between the water temperature at inlet and appliance temperature or operating at temperatures exceeding 230 o

F.

BURNER HOW TO MAKE A CLAIM

If within FIVE years of the appliance having declared

FOB from 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 of the appliance having declared

FOB from Camus® whichever comes first Camus® will furnish a replacement or repair that part. Replacement

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. parts will be shipped FOB our factory. 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

46

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.

6226 Netherhart Road, Mississauga, Ontario L5T 1B7

TEL: 905·696·7800 FAX: 905·696·8801

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