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Installation Operation and Service Manual

1. 10 Jeu 5 5 5 The operation of exhaust fans compressors air handling units etc can rob air from the room creating negative pressure condition leading to reversal of the natural draft action of the venting system Under these circumstances engineered air supply Is necessary If the heater is to be installed near 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 appliance must be electrically bonded to ground in accordance with the requirements of the authority having jurisdiction or in the absence of such requirements with the National Electrical Code ANSI NFPA 70 or the Canadian Electrical Code Part I CSA C22 1 Electrical Code Provide disconnecting means of sufficient rating within sight of the appliance These heaters require an 115V 60 Hz supply 15 amp breaker is sufficient for appliances
2. He o oil YN avos aos NONE heqe eat V N N Tin IMS S3Hd SV9 EA 0209 66 HI Ka aq jou Gulmeup SIU 131 SolUoJpAH Snue7 10 Auedoud ay s 5141 2 ji Sal sal c FP S600 LG 131 ON s SOINONGAH SNINYI 7 soote 4 9 45 Z 011 0 06 66 0 00 35 8 Q3LNIid SV SSINYVH NOILdO 34 NV4 la i la EE ntb mu en swo sv AR ome wn 90 M On pow L z SoNL s ZzOM lt 4 5 04 1 eles 2 04 1 0 akr ond m ra AV es oe NI z ouh 2100 24 M3TIOMINOO L 44 EXPLODED VIEW amp PARTS LIST 17 MODULATING MICOFLAME GRANDE en MODULATING MICOFLAME GRANDE OUTDOOR AND OR CONDENSING 46 MICOFLAME GRANDE REPLACEMENT PARTS LIST Model Number Part Name 2000 2500 300 350 4000 Combustion Chamber End Panel Left Combustion Chamber End Panel Right Combustion Chamber 14 4202 20 14 4202 30 14 4202 30 14 4202 40 14 4202 40 Rear Panel Combustion Chamber Support Left Combustion Chamber Support Right
3. 77 0028 77 0029 Modulating Power 77 0031 Harness Air Inlet Filter Air Switch 1520105 5762 Igntion Module Continuous Retr 58610 3017 Ignition Module m single Try Pilot Valve Combination Valve CV100B6N 22 0001 Burner Box Donut Condensing Models Only Outdoor Models Only Not Shown in Exploded View 49 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 U
4. 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 41 13 LIGHTING INSTRUCTIONS 1 Turn off electric power to appliance 2 Close main manual valve and main firing valve and wait 5 minutes 3 Set primary system controller to desired temperature 4 Open pilot valve 5 Turn on electric power to appliance The electrode at the pilot should begin to spark after pre purge is complete The pilot valve will open
5. 247 FLOW SWITCH C AIR SWITCH Figure 4 Low Water Cutoff Electrical Connections ITT HOT NEUTRAL SAFETY SIGNAL OUT SAFETY SIGNAL IN wired in Series as part of Burner Control Circuit 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 7 2 FREEZE PROTECTION e Appliance installations are not recommended outdoors or in areas where danger of freezing exists unless precautions are taken Maintaining a mixture of 50 water and 50 propylene glycol is the preferred method of freeze protection in hydronic systems This mixture will protect the appliance to approximately 35 F 37 C 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 e Given for example that Camus is showing a heat exchanger flow and head loss of 100 gom 10 feet e Increasing the flow by 15 now results in a head loss of 13 feet at 115 gpm from B amp G system syzer At this increased flow Camus now recommends to increase the head los
6. 5 5 1 9 9 Depending on field conditions air box pressures will have to be adjusted accordingly Always set the appliance for a CO level in the range listed Table 14 Table 14 Combustion Values Propane Natural Gas 7 5 9 0 8 5 PPM 10 0 PPM 8 5 9 0 PPM 10 0 lt 50 lt 50 1 9 8 5 9 0 7 59 8 0 PPM PPM PPM 10 5 9 0 9 5 37 A qualified service technician should follow this procedure when burner needs cleaning 1 Shut off power and close main manual gas valve e Allow burner to cool before removal Remove access cover screws e Disconnect pilot gas at bulkhead fitting e Disconnect ground wire and ignition wire e Remove nuts holding down burner e Gently pull down and forward to disengage burner e Remove burner being careful to not damage the igniter or ground electrodes e Inspect burner box donut gasket located between the mixing tube and the inlet to the burner If damaged replace burner box donut gasket with part number 109889 Thoroughly clean burner using low pressure water or air Never wipe or brush the surface of the burner nor use high pressure water or air Check all ports and air channels for blockage Reinstall the burner being careful to fully engage the back of the burner box into the retaining slot in the combustion chamber base Check to ensure that burner box is properly sealed against the donut gasket Failure to pro
7. Grande 2010 4000 Gas Valve To adjust the high fire setting Set the Target Temperature to 190 F using the BTC 1 Controller Locate screw 1 labeled as lt lt gt gt and make adjustments as necessary to satisfy the combustion values in Table 14 The markings on the setting screws are labeled as and for more and less gas respectively Turn the screw 1 4 turn in either way for each adjustment to keep track of the adjustments After adjusting the screw wait a moment for the combustion levels to stabilize before attempting to make any further adjustments Continue this procedure until combustion levels are satisfied Reset the Target Temperature to normal operating conditions on the BTC 1 Controller To adjust the low fire setting Observe the Boiler Inlet Temperature Set the Boiler Target temperature so that it is 10 F above the Boiler Inlet Temperature The boiler will begin to modulate to low fire as setpoint is being reached The actual modulation rate can be shown on the screen as Modulation this will be shown as a percentage Condensing Wa Locate screw 2 labeled as ET adjustments as necessary to satisfy the combustion values in Table 16 The markings on the setting screws are labeled as and for more and less gas respectively Turn the screw 1 4 turn in either way for each adjustment to keep track of the adjustments After adjusting the s
8. Boiler Target the burner shuts off Once the external heat demand is removed the BIC 1 19 turns off the appliance and operates the boiler pump based on the PUMP DELAY setting The auto re set limit is set to 210 F and is fixed In addition to the auto reset limit the factory installs a manual re set limit set to 250 F Figure 22 Mode 6 Piping Schematic 0 10 V dc external input signal 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 8 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 5000 resistor on the external input signal device s terminal If the system sensor is gt half of the differential below the Boiler Target the 1 then changes the proportional modulation output to the START modulation setting then closes the otage contact pins 15 amp 16 to proceed to trial for ignition The burner remains at minimum modulation until
9. NOTE This parameter is only available in Mode 7 Real time Outlet Temperature to Boiler Real time Inlet Temperature to Boiler Real time temperature difference between the outlet sensor and the inlet Sensor 85 to 266 F 2 to 130 C 14 to 266 F 10 to 130 C 14 to 266 F 10 to 130 C 14 to 266 F 10 to 130 C 99 to 252 F 72 to 122 C Display Parameter Description im Real time modulating output Modulation percentage Monitors the amount of operational time since the Micoflame was Modulation Total Run Time Since Installation 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 4 Y simultaneously to reset the counter 0 to 100 Alternates between 00 and 999 9 9 MODE 6 amp 7 EXTERNAL TARGET TEMPERATURE INPUT OPERATION ADJUST DISPLAY From the Home display 1 Press ltem Y simultaneously to view the following parameters Display Parameter Description imd ADJUST Differential Temperature Pump Delay Temperature Units 30 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 To provide a modulation rate above and below the Boiler Target temperature For example if the value is 10 F and the Boiler Target is 160 F the boiler will begin to modulate at 1
10. spraying rain etc during appliance operation and service circulator replacement control replacement etc Shut off valves must be installed at the inlet and outlet connections of the appliance to provide for isolation of the heat exchanger for servicing the appliance is installed above radiation level it must be provided with a low water cutoff device at the time of appliance installation This appliance is of a low mass design which provides for instant heat transfer Special attention to water flow rates will ensure that temperature rise does not exceed 35 F 19 4 C Table 6 is provided as a guide For application in areas known to have hard water conditions or for soft water contact factory _ for recommendations Table 6 Flow vs Head Loss for Various Temperature Rise 20 F Model USGPM APft 2010 170 5 1 2500 200 8 2 3000 200 8 2 3500 200 10 2 4000 200 10 2 30 F Model USGPM APtt 2010 113 2500 141 3000 170 3500 198 4000 200 35 F Model USGPM AP ft 2010 97 0 1 8 2500 121 0 3 3 3000 146 0 4 5 3500 170 0 7 7 4000 194 0 9 8 Maximum flow recommended Temperature rise will be exceeded CuNi heat exchanger should be considered for flow rates exceeding maximum recommended flows 7 1 PROTECTION DEVICES PRESSURE RELIEF VALVE shipped loose This appliance is supplied with a relief valve sized in accordance with ASME Boiler and Pressure Vessel Code Section IV Heating Boile
11. the pilot valve Rotate the regulator adjustment screw clockwise to increase the manifold pressure or counterclockwise to decrease it Once satisfied replace the regulator adjustment screw cap and the elbow pressure tap plug Table 11 Gas pressures at inlet to pilot PROPANE NATURAL GAS Minimum inches W C Maximum inches W C 34 Pilot Flame Rectification Setting The pilot flame rectification was preset at the factory The following description is for the benefit of the start up technician should minor adjustment be required Set pilot to obtain best reading from flame rectification Minimum average signal of 1 5 uA is required If required test the signal using DC uA meter following this procedure for Honeywell 58600 ignition module Disconnect ground wire at appliance transformer Disconnect the 24V power and ground wires from all 58600 ignition modules not being tested Set meter to uA DC Connect of the meters terminals to the burner ground terminal on the S8600 and the other terminal to the burner ground wire Pilot running without main burner will generate 1 5 UA average for best operation With main burner running the signal will be in a range of 4 0 to 7 0 Gas Pressure Setting The adjustable ratio gas valve pressure regulator was preset at the factory The following description is for the benefit of the start up technician should minor adjustment be required Optimum results are
12. Hes each mode can be found in section 8 4 Modes of Operation in this manual Default 1 OFF 0 20 to 9 55 Boiler post pump time after burner On Pump Delay has shut off in seconds Default 1 00 min OF ue Temperature Select the desired unit of i Units measurement Default F 9 12 ERROR MESSAGES Description The control was unable to read a piece of information its EEPROM memory The control will stop operation until all settings in the Adjust menu have been checked by the installer Outlet Sensor Short Circuit If the inlet sensor is operational the control will operate using the inlet sensor Otherwise the control will not operate the burner Test the outlet sensor and related wiring The error message will clear once the error condition is corrected and a button is pressed Outlet Sensor Open If the inlet sensor is operational the control will operate using the inlet sensor Otherwise the control will not operate the burner Test the outlet sensor and related wiring The error message will clear once the error condition is corrected and a button is pressed 32 m Inlet Sensor Short Circuit The boiler will continue operation Test the inlet sensor and related wiring The error message will clear once the error condition is corrected and a button is pressed Inlet Sensor Open The boiler will continue operation Test the inlet sensor and related wiring The error message will cl
13. adequate size to prevent undue pressure drop and must never be smaller than the size of the connection on the heater Table 5 lists recommendation for gas pipe sizes Before operating the appliance the complete gas train and all connections must be tested using non corrosive soap solution wiring diagram provided with appliance Table 5 Gas pipe size for distance from natural gas meter or propane second stage regulator Input 0 100 Btu Hr 2 Vg r P N 2 Ve 2 Ve 2 12 2 Ve Z AJRIQ I gt Input 100 200 FT NAT LP 2 16 2 Ve Input 200 300 i 6 VENTING Appliances for outdoor installation are intended to vent using a listed vent cap For indoor installations venting must be in accordance with Part 7 Venting of Equipment of the latest or current as amended National Fuel Gas Code ANSI 2223 1 or Section 7 Venting of Equipment and Air Supply for Appliances of the latest or current as amended CAN CGA B149 Installation Codes 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 minimum upward slope of 7 per foot from the appliance to the vent terminal When an existing appliance i
14. heater must conform to the requirements of the authority having jurisdiction in the absence of such requirements to the latest or current as amended National Fuel Gas Code ANSI 2223 1 or current CAN CGA B149 Installation Codes All electrical wiring must be done in accordance with the requirements of the authority having jurisdiction or in the absence of such requirements with the National Electrical Code ANSI NFPA 70 or the Canadian Electrical Code Part I CSA C22 1 Electrical Code Provisions for combustion and ventilation air must be in accordance with the section Air for Combustion and Ventilation of the National Fuel Gas Code ANSI Z223 1 NFPA 65 or clause 8 2 8 3 8 4 of Natural Gas and Propane Installation Code CAN CSA 149 1 2 or 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 causi
15. intended to prevent the bypass of air around the pilot Figure 27 Pilot and Burner Box 2 PILOT TUBE N GROUND ELECTRODE BURNER i 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 12 OPERATION AND SERVICE 12 1 CHECKLIST 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 i
16. prevent flue gas condensation inside the vent Periodically check to ensure that the vent terminal is unobstructed 6 6 OUTDOOR AIR KIT When fitted with the factory supplied air inlet ring and air intake terminal the Micoflame Grande can draw outdoor air over an equivalent length of 60 feet See Table 3 for vent sizes Appliances may be installed with either a horizontal sidewall vent or vertical roof top terminal Terminals differ with each application The following applies to outdoor air installations 1 Use only factory supplied air intake terminal 2 Periodically check to ensure that air intake is not obstructed Refer to local codes for proper installation and location of vent terminals Vertical vent terminal must be at least 3 feet above the highest point where it is located above the roof of a building 4 Locate the air intake at least five feet away from the vent discharge For sidewall venting locate the air intake below the vent outlet if possible 6 5 FILTER KIT A slot at the bottom of the rear panel is the standard air inlet configuration for the Micoflame Grande As an option outside air could be introduced directly through the back or top panels A filter kit is available The filter is washable and accounts for an_ additional pressure loss of less than 0 05 W C Highly recommended for dusty environments The filter kit can also be provided when using the outdoor air kit Conventional V
17. 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 1 of the volume with the balance filled with air Start up boiler following instructions provided Operate entire system including pumps and radiation for at least 1 hour Improper piping of this appliance will void the manufacturers warranty Improper piping arrangement may cause heat exchanger tube failure resulting in flooding and extensive property damage Excessive water hardness causing scaling in the copper heat exchanger tubes is not covered under the manufacturer s warranty Excessive pitting and erosion of the internal surface of the copper heat exchanger tubes due to high water velocity or chemicals is not covered under the manufacturer s warranty Improper operation of this appliance by permitting return water temperature below 130 F 55 C will result in flue gas condensation leading to corrosion deposits on the heat exchanger tubes and will void the warranty To eliminate trapped air install venting devices at high points in the system as well as in the piping on the suction of the pump and in the piping on the discharge of the appliance Suitable pipe hangers or floor stands must support the weight of all water and gas piping The appliance must be installed so that the gas ignition system components are protected from water dripping
18. 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 12 half of the differential above Boiler Target the burner shuts off Once the external heat demand is removed the BTC 1 turns off the appliance and operates the boiler pump based on the PUMP DELAY setting The auto reset limit is set to 210 F and is fixed In addition to the auto reset limit Camus installs a manual reset limit set to 250 F Figure 23 Mode 7 Piping amp Electrical Layout 0 10 V dc external input signal 20 Mode 8 External Direct Drive Operation This mode is designed only for hydronic heating operation This mode allows for an external control to operate the boiler through an analog direct drive input signal provided by a boiler sequencing control such as the S12 Sequencer When operating in this mode the external heat demand and DHW demand are disabled An external boiler sequencer provides a positive 0 10 VDC input signal to the control at V in and the negative signal is applied to the Com input The boiler remains off while the direct drive input signal range is between 0 to 0 5VDC Once the direct drive input signal reaches 0 5VDC the control turns on the appliance pump changes the modulating output to Start Modulation level until the flame is proved and then the modulating output is adjusted t
19. to permit gas flow to the pilot 6 There is a 15 second trial for ignition which is enough time to light the pilot if air is not present in the pilot line If pilot fails to light and you suspect air in the line close the main manual valve and repeat lighting steps 1 thru 5 7 Once the pilot lights it should envelope the ignition rod and ground electrode The pilot can be adjusted by removing the pilot regulator cover and turning the adjustment screw counter clockwise to increase it or clockwise to decrease it 8 Open the main manual and main firing valves to allow gas to reach the main burner If the main burner fails to ignite turn the firing valve off and check to see that the pilot is burning If not repeat lighting procedure steps 1 thru 7 TO TURN OFF APPLIANCE Close main manual valve and main firing valve and turn off electric power to system 14 TROUBLE SHOOTING GUIDE 1 Power light is not lit when switch is flipped to Check wiring to switch ON Activate push button for latch relay if provided Check circuit breaker Check fuse 3 Pilot sparks but does not light 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 4 Pilot lights momentarily goes out and then Observe pilot for proper flame A
20. will be shut off within 4 seconds of the pilot gas being shut off If shut down takes longer ignition control or gas valve may be defective If shutdown does not occur it is possible that the main gas flow is generating a signal at the pilot in which case the pilot shall not recycle with the pilot gas off Appliances Start Up With the appliance off open makeup water valve and allow system to fill slowly With all air vents open run system circulating pump for a minimum of 30 minutes with the appliance off Open all strainers in the circulating system and check for debris Check liquid level in expansion tank With system full of water at 15 PSIG cold the level of water in the expansion tank should not exceed W of the total volume with the balance filled with air Start up appliance following instructions provided Operate entire system including pumps and radiation for at least 1 hour Check water level in expansion tank If level exceeds 12 of tank volume air is still trapped in system Shut down appliance and continue to run pumps Within 3 days of start up recheck all air vents and expansion tank as described above 12 3 SERVICE Disconnect main power and turn off gas supply before servicing unit To remove and clean the burner follow the detailed procedure in section 16 of this manual After the first season of operation inspect the heat exchanger and venting Follow the detailed instructions in section 6 of this manual
21. with input up to 3 000 MBTUH For appliances with input over 3 000 MBTUH use 20 amp breaker The pump requires separate power supply 5 NORMAL GAS SUPPLY This appliance is intended to operate at inlet gas pressures not exceeding 1 4 PSI 7 W C when firing with natural gas If higher pressures are present consult the gas company for correction The appliance and its individual gas shut off valve must be disconnected from the supply piping when pressure testing the gas supply piping at pressures above 2 PSI Provide trap drip leg as close to the heater as possible Install a ground joint union and manual shut off valve in the gas line near the heater to allow easy removal of the gas control assembly The gas pressure at the appliance s inlet must be set in accordance with Table 4 Table 4 Gas Pressure Limits at Inlet to Appliance PROPANE Min Running inches W C Max Lockup inches W C 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 appliance Splicing of wires is not recommended Use sealed tight conduit suitable for outdoor use for outdoor installations Use terminal strip provided inside control panel for low water cut off and remote controller Refer to The gas supply line must be of
22. 4 4154 Glass Frame 34 Outer Jacket Top 14 4255 Panel Support Control Panel 35 Assembly 14 4160 Three Tiles Burner Box Assembly 38 14 4146 14 4265 01 14 4265 01 14 4265 01 14 4265 01 gg Economizer 14 4148 03 14 4266 01 14 4266 01 14 4266 01 14 4266 01 Assembl 40 Front Refractory 17 0084 01 17 0084 02 17 0084 02 17 0084 03 17 0084 03 1 Rear Refractory 17 0085 01 17 0085 02 17 0085 02 17 0085 03 17 0085 03 Inlet Outlet Header 13 0040 _ eee Gas Valve Body VGG10 504U 150232 07 Return Header 13 0041 4g Primary Heat 15 0195 01 15 0195 02 15 0195 02 15 0195 03 15 0195 03 Exchanger 9 2000 4000 4000 4000 4000 Control Panel Outdoor Cover 14 4245 Control Panel Outdoor Cover Inlet Outlet Header Outdoor Cover 14 4246 C1 OT A N SIG Co N 14 4247 48 SKP75 013U1 Gas Valve Actuator MicoGrande Modulating harness 2 77 0024 N A burner MicoGrande Modulating harness 3 N A 77 0025 N A burner i MicoGrande Modulating harness N A 77 0026 4 burner MicoGrande Modulating harness Water end harness right MicoGrande Modulating harness Water end harness 2 burner left MicoGrande Modulating harness Water end harness 3 4 burner left MicoGrande Modulating harness 77 0030 Panel main 110V MicoGrande 77 0027
23. 55 C slowly close outlet valve until the inlet temperature climbs to 130 F 55 C d If the inlet temperature is greater than 130 F 55 C but not greater than 140 F 55 C no further adjustment is required Check the inlet temperature after 5 minutes and make final adjustments 10 7 6 INSTANTANEOUS WATER HEATER An instantaneous appliance is designed to deliver hot water without the use of storage tank It is suitable for applications with variable load such as restaurants condominiums apartments and motels See Figure 11 Call manufacturer for recommendations 7 7 HOT WATER SYSTEM PIPING Piping and components connected to the appliance must be suitable for use with potable water The appliance should not be connected to any heating system piping or components previously used with non potable water Hot water storage tanks used in potable water system must be equipped with temperature and pressure relief valve Figures 12 and 13 illustrate typical water heating piping arrangement for single appliance and multiple appliances The storage tanks must be located as close as possible to the appliance to prevent excessive pressure drop The required flow through the appliance is based on normal water having hardness between 7 5 and 17 grains per gallon Water hardness above this range will require higher flow rates to prevent scaling and to prevent erosion of copper nickel heat exchanger tubes The manufacture
24. 55 F and shut off at 165 F Boiler post pump time after burner has shut off in seconds Select the desired unit of measurement 1to8 Default 1 Au 2 to 42 F Au 17 to 6 C Default 10 F OFF 0 20 to 9 55 min On Default 1 00 min F Default F 9 10 MODE 8 EXTERNAL DRIVE OPEATION VIEW DISPLAY From the Home display 2 Press ITEM to view the following parameters Boiler Outlet 14 to 266 F Temperature Real time Outlet Temperature to Boiler 10 to 130 C Boiler Inlet 14 to 266 F Temperature Real time Inlet Temperature to Boiler 10 to 130 C Real time temperature difference between the outlet sensor and the inlet 3919 252 E Boiler Delta T 72 to 122 C Sensor Real time modulating output Beli lue 0 to 100 Modulation Monitors the amount of operational time since the Micoflame was installed The first two digits are the number of thousands of hours and the three digit display shows the number of hundreds of hours Press 4 Y simultaneously to reset the counter Alternates between 00 and 999 Total Run Time Since Installation Table 10 Input Voltage vs Modulation Rate 31 9 11 MODE 8 EXTERNAL DRIVE ADJUST DISPLAY From the Home display 1 Press ltem A Y simultaneously to view the following parameters Display Parameter Description i ed Operating mode for the boiler NOTE A complete description of
25. 9 2 1 4 2 SETPOINT OPERATION VIEW DISPLAY From the Home display 1 Press ITEM to view the following parameters Display Parameter Description ird BOIL To provide a target setpoint for the 0 heating system Setpoint is controlled 99 lo 266 T 2 to 130 C Boiler Target TARGET Temperature BOILSUP System Temperature Boiler Outlet Temperature Boiler Inlet Temperature Boiler Delta T Modulation Total Run Time Since Installation to the inlet sensor System Temperature of Primary Loop NOTE This parameter is only available in Mode 2 Real time Outlet Temperature to Boiler Real time Inlet Temperature to Boiler Real time temperature difference between the outlet sensor and the inlet sensor Real time modulating output percentage Monitors the amount of operational time since the Micoflame was installed The first two digits are the number of thousands of hours and the three digit display shows the number of hundreds of hours Press 4 Y simultaneously to reset the counter 23 14 to 266 F 10 to 130 C 14 to 266 F 10 to 130 C 14 to 266 F 10 to 130 C 99 to 252 F 72 to 140 C 0 to 100 Alternates between 00 and 999 9 3 1 amp 2 SETPOINT OPERATION ADJUST DISPLAY From the Home display 1 Press V simultaneously to view the following parameters Display Parameter Description E Operating m
26. ARGET setting the burner shuts off Once the external heat demand is removed the BTC 1 turns off the appliance and operates the boiler pump based on the PUMP DELAY setting The water temperature is controlled based on a fixed setpoint BOIL TARGET The setpoint for inlet water is pre set to 120 F and the auto re set limit is set to 2109 and is fixed In addition to the auto reset limit the factory installs a manual re set limit set to 250 F Figure 17 Mode 1 Piping amp Electrical Layout Heat Demand mm Mode 2 Constant Temperature Control at System Sensor This mode is designed for hydronic heating Once a heat demand is present the BIC 1 modulates the boiler burner to maintain the boiler target at the system sensor heat demand is generated when 24VAC is applied across CD common demand and Ht D heat demand Dem 1 on the LCD display is lit If the system sensor is gt half of the differential below the BOIL TARGET the BTC 1 then changes the proportional modulation output to the START modulation setting the Stage contact pins 15 amp 16 closes to proceed to trial for ignition The burner remains at minimum modulation until the flame is proved and then the modulating output changes the boiler burner output to maintain the programmed boiler target temperature at the system sensor If the system sensor reaches 12 half of the differential above BOIL TARGET setting the burner shu
27. DULATION SEQUENC E ix Avi aaa dvd Sait WE C Vere al ke toldos EU Clg uten uei 35 PILCOT AND BURNER FLAME S 36 VAIN BUR NIE R eee E NEU 36 REMOVAL OF COMBUSTION CHAMBER LINING 38 38 12 OPERA HON SERVICE KE deus Be KO 39 PRE STARILGHEGRAS Tu 39 122 IP AREE 39 41 13 EIGATING INSTRUC TIONS Lr 41 14 TROUBLE SHOOTING GUIDE DN ll 42 15 AAS 43 16 ELECTRICAL DIAGRAMS sun 44 16 1 3500 4000 INTERNAL WIRING DIAGRAM 44 17 EXPLODED VIEW Le KAK e Se 45 MICOFLAME GRANDE REPLACEMENT PARTS LIST KMMK KK KK KK KK KK 47 50 1 GENERAL INFORMATION Camus Hydronics proudly introduces the Modulating Micoflame Grande series of water heaters hydronic boilers The Modulating Micoflame Grande is a fan assisted appliance based on a push through design which offers several venting options Heat output is controlled by an adjustable ratio air gas control valve The Modulating Micoflame Grande models are capable of modulating from 100 down to 40 of rated input These gas burning appliances are thoughtfully designed for easy operation and maintenance We are confident that you will come to appreciate the benefits of our product The installation of this
28. E 2 Chamber 1 1205 20 14 4205 30 14 4205 30 14 4205 40 14 4205 40 7 Combustion Chamber 4206 20 14 4206 30 14 4206 30 14 4206 40 14 4206 40 Upper Front 8 Flue Collector Top 14 4207 20 14 4207 30 14 4207 30 14 4207 40 14 4207 40 Flue Collector End 14 4209 20 14 4209 30 14 4209 30 14 4209 40 14 4209 40 oe top 14 4210 20 14 4210 30 14 4210 30 14 4210 40 14 4210 40 Sk Back 14 4211 20 14 4211 14 421 30 14 4211 30 14 4211 40 14 4211 40 Outer Jacket Front 14 4212 20 14 4212 30 14 4212 30 14 4212 40 14 4212 40 Outer Jacket Front re 14 4213 20 14 4213 30 14 4213 30 14 4213 40 14 4213 40 15 Base Support 16 4214 20 16 4214 30 16 4214 30 16 4214 40 16 4214 40 Weldment Base Panel Lips 14 4215 20 14 4215 30 14 4215 30 14 4215 40 14 4215 40 17 Inlet Outlet Side 14 4216 Access Panel 18 Return Side Access 14 4217 14 4218 14 4218 Centre Divider Flue Collector Outlet 14 4219 20 14 4219 30 14 4219 30 14 4219 40 14 4219 40 Outer Jacket Side Panel Right an Outer Jacket Side Panel Left ome Fan Mounting Ref Model Number Burner Door Stop 14 4234 Heat Exchanger Header Stop Bar 14 4238 Fan Mounting Support Left ie Burner Door 14 4240 V Baffles 14 4241 20 14 4241 30 14 4241 30 14 4241 40 14 4241 40 14 4242 20 14 4242 30 14 4242 30 14 4242 40 14 4242 40 Outer Jacket Sight Heat Exchanger Support Weldment KEJ 33 Inner Jacket Sight 1
29. INSTALLATION OPERATION AND SERVICE MANUAL MODULATING MICOPRAME GRANDE CAMUS Hydronics Ltd GAS FIRED COMMERCIAL COPPER TUBE BOILERS FOR HYDRONIC HEATING Non Condensing Models MFH2010 2500 3000 3500 4000 Condensing Models MFH2012 2502 3002 3502 4002 HOT WATER SUPPLY Non Condensing Models MFW2010 2500 3000 3500 4000 Condensing Models MFW2012 2502 3002 3502 4002 CERTIFIED WARNING If the information in these instructions is not followed exacily 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 Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbour s phone Follow the gas supplier s instructions 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 6226 Netherhart Road Mississauga Ontario L5T 1 7 99 0075 Rev 02 Table of Contents GENERALINFORMA FION Ic 1 LOCATION UR EE 1 A
30. IR REQUIRED FOR COMBUSTION AND 2 ELECTRICAEWIRING motionen LET EN 3 NORMAL GAS SUPPL Y Sise y ede vri edes Pur a 3 EN 4 OUT DOOR V EIN EB 5 STANDARD yyy mm Gen 6 SIDEWALE AND VENTINGEN 6 OUTDOOR Al Rae NN 6 KIT E 6 WATE ula ki cw 2n2x 7 PROTEGTION DEVICES 8 FREEZE PROTECTION SS 9 CHEIEEEDMVATER TEMS a 9 ee 10 LOW WATER TEMPERATURE SYS IEMS duod fe ren uk ee e a ey n QA eat 10 INSTANTANEOUS WATER HEATER rt ubt hel usu ite dure Fs K l X R r k k aab netos 10 HOT WATER SYSTEM PPING itii tur ssa ute vro etus vit er 10 CONDENSER HEAT RECOVERY MODULE CHRMD eese 10 CC ERE IT I M M 12 oslo 12 Primary secondary PIDIDO ere 12 INSTRUMENTATION AND CONTROLS Ne 15 SAFETY CONTROLS 15 CODNPROLTAAINEI KIN co 15 SETTING THE APPLIANCE TEMPERATURE 16 MODE
31. NIOSH recommendations can be found on the NIOSH website http www cdc gov niosh homep age html NIOSH approved respirators manufacturers and phone numbers are also listed on this website o Wear long sleeved loose fitting clothing gloves eye protection e Apply enough water to the combustion chamber lining to prevent airborne dust e Remove the combustion chamber lining from the water heater and place it in a plastic bag for disposal e Wash potentially contaminated clothes separately from other clothing Rinse clothes washer thoroughly NIOSH stated First Aid e Eye Irrigate immediately e Breathing Fresh air 38 113 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 readily accomplished after removing the main burner The spark gap should measure between 1 8 to 3 16 Make sure that the electrode does not appear overheated or fouled with carbon It may be necessary to clean the ignition electrode using steel wool Once the pilot appears to be properly set reinstall it into the appliance making sure to properly tighten the pilot line connection If the pilot is removed from the main burner in the course of servicing the appliance it is important to replace all gaskets and seals These seals are
32. S OF OPERATION a KAR Hu K y ORA UE a 16 Typical Factory Settings of Parameters for Micoflame Grande BTC 1 78 0017 21 MICOFLAME GRANDE CONTROL PANEL b Ro e ea 22 GENERAL SYMBOL DESGRIPTION unc tea EU Da a 22 MODE 1 amp 2 SETPOINI OPERATION VIEW DISPLAY used 23 MODE 1 amp 2 SETPOINT OPERATION ADJUST 24 MODE 3 DEDICATED DOMESTIC HOT WATER OPERATION VIEW DISPLAY 25 MODE 3 DEDICATED DOMESTIC HOT WATER OPERATION ADJUST DISPLAY 26 MODE 4 amp 5 OUTDOOR RESET OPERATION VIEW DISPLAY 27 MODE 4 amp 5 OUTDOOR RESET OPERATION ADJUST 28 MODE 6 amp 7 EXTERNAL TARGET TEMPERATURE INPUT OPERATION VIEW DISPLAY 29 MODE 6 amp 7 EXTERNAL TARGET TEMPERATURE INPUT OPERATION ADJUST DISPLAY 30 MODE 8 EXTERNAL DRIVE OPEATION VIEW DISPLAY 31 MODE 8 EXTERNAL DRIVE OPEATION 32 ERROR MESSAGES al desan oe ke k n dab 32 OPERATION etie ai mper ted 34 START UP Tr 34 MO
33. by undoing the thumb screw and opening the door The diagnostic information centre as well as the on off switch 24V fuse and the appliance temperature controls reside on the control panel door Figure 15 Display Appliance Temperature Controller and Indicating LED Va LI POWER ON HERGAS D OPERATOR OOO aw O Q WATER FLOW FLAME FAILURE O Q Q ow2 ARFLOW1 ea E20 GE 1 O O 15 The Boiler Temperature Controller BTC 1 for this appliance is Camus 78 0017 SmartFlame control The BTC 1 uses a Liquid Crystal Display LCD as a method of displaying boiler information The BTC 1 is used to setup and monitor the operation of the system The BTC 1 uses three push buttons for selecting and adjusting settings Boiler Temperature Controller Features It initiates the local call for heat and sets the target inlet appliance inlet water temperature This controller accommodates heating and domestic hot water control with multiple modes of operation which provide set point as well as reset control It provides the following e Readings of inlet and outlet temperatures and AT temperature rise e Operation as an auto reset limit Operation as a control for inlet water temperature e Optional tank mounted sensor used in conjunction with inlet sensor e Adjustable pump delay feature based on AT temperature difference between inlet and outlet temperatures Accepts 1 6 hp pump direct
34. crew wait a moment for the combustion levels to stabilize before attempting to make any further adjustments Continue this procedure until combustion levels are satisfied Reset the Target Temperature to normal operating conditions on the BTC 1 Controller Table 16 Combustion Values CO lt 50 lt 50 lt 50 lt 50 7 5 8 5 7 0 7 5 8 5 9 0 7 5 8 0 9 0 10 0 8 5 9 0 10 0 10 5 9 0 9 5 Pilot Flame Rectification Setting The pilot flame rectification was preset at the factory The following description is for the benefit of the start up technician should minor adjustment be required Set pilot to obtain best UA reading from flame rectification Minimum average signal of 1 5 uA is required If required test the signal using DC uA meter following this procedure for Honeywell 58600 ignition module Disconnect ground wire at appliance transformer Disconnect the 24V power and ground wires from all S8600 ignition modules not being tested Set meter to HA DC Connect one of the meters terminals to the burner ground terminal on the S8600 and the other terminal to the burner ground wire Pilot running without main burner will generate 1 5 UA average for best operation With main burner running the signal will be in a range of 4 0 to 7 0 normally closed blocked flue switch has been preset at the factory In cases where the heater loses the fla
35. djacent area or to lower floors in the structure If necessary a suitable drain pan must be installed under the appliance If the appliance is installed above the level of the buildings radiation system a low water cutoff device must be installed in the appliance outlet at the time of installation Some local codes require the installation of a low water cutoff on all systems Table 1 Service Clearances REAR SIDES FRONT This appliance is suitable for alcove installation with minimum clearances to combustibles as follows Table 2 Clearance to Combustibles SIDES 12 VENT 6 FLOOR 0 Figure 1 Appliance Dimensions Air Inlet Rear View Non Condensing Option 1 15 Front View Side View Left Non Condensing Option Side View Left Condensing Option Table 3 Appliance Dimensions 34 5434 33 3 8 34 34 34 34 2010 2500 MF3000 MF3500 MF4000 AIR REQUIRED FOR COMBUSTION AND VENTILATION Provisions for combustion and ventilation air must be in accordance with the section Air for Combustion and Ventilation of the National Fuel Gas Code ANSI Z223 1 NFPA 65 clause 8 2 8 3 8 4 of Natural Gas and Propane Installation Code CAN CSA B149 1 2 or applicable provisions of the local building codes 3 Dia Venting Dia uonoouuo ser
36. djust if Sparks again repeatedly necessary Check pilot flame signal Properly set pilot to generate 1 5 LA 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 main manual valve is in ON position Check wiring to valve from ignition control 6 Main burner lights but cycles off after a few Verify that high limit is set high enough to minutes prevent short cycling Check pilot flame signal UA Adjust pilot pressure for steady flame Remove main burner Check position of igniter and ground electrode Clean with steel wool if necessary 7 Appliance starts to whine as the temperature Verify that all air is bled from system rise increases Verify that the static pressure in cold system Is at least 15 psig at the highest point in the system Check temperature rise across appliance to ensure adequate water flow If necessary increase static water pressure and decrease oressure 42 15 TYPICAL GAS TRAIN Figure 29 Gas Train Solenoid Valve _ 7 Gas Valve Actuator Gas Valve Body j Metal Fiber Burner Firing Valve Mixing Tube Pilot Tube 43 3500 4000 INTERNAL WIRING DIAGRAM ELECTRICAL DIAGRAMS 16 16 1 L o
37. down 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 Remove burner from appliance and vacuum the heat exchanger If heat exchanger is excessively dirty it may be necessary to remove it from the appliance and wash it down with proper detergent cleaner Be aware that the combustion chamber base is insulated with 2 thick ceramic blanket If this material is damaged or displaced it must be replaced before starting up the appliance 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 CAUTION When replacing the burner be careful to fully engage the back of the burner box into the retaining slot in the combustion chamber base Failure to properly locate the burner will result in erratic flame operation with the possibility of delayed ignition on light off Once in place make sure that the burner box is sealed against the seal gasket provided at the mixing tube Restore electrical power and gas supply to the appliance Place appliance in operation using lighting instructions provided While the appliance is operating check for flue gas leaks and proper vent operation Seal any flue gas leaks using appropriate gasket or sealing material Carefully examine the flue collecto
38. e outlet sensor and the inlet 99 to 252 F T sensor 72 to 122 C DHW 14 to 266 F Temperature Real time DHW Temperature 10 to 130 C Real time modulating output percentage 1907 Modulation Modulation Monitors the amount of operational time since the Micoflame was installed The first two digits are the number of thousands of hours and the three digit display shows the number of hundreds of hours Press 4 Y simultaneously to reset the counter Alternates between 00 and 999 Total Run Time Since Installation 25 9 5 3 DEDICATED DOMESTIC HOT WATER OPERATION ADJUST DISPLAY From the Home display 1 Press ltem Y simultaneously to view the following parameters Display Parameter Description Bd Operating mode for the boiler NOTE A complete description of 1108 each mode can be found in section 8 4 Modes of Operation in this manual Default 1 OFF 70 to 220 F To provide a target setpoint for OFF 21 to the heating system Setpoint is 104 C controlled to the inlet sensor Boiler Target Temperature Default 120 F 82 C OFF 70 to 190 F To provide a target setpoint for OFF 21 to the DHW system Setpoint is 88 C controlled to the DHW sensor DHW Target Temperature Default 140 F 54 C To provide a modulation rate above and below the DHW Target Temperature For DHW example if the value is 10 F and Differential the DHW Target Temperatu
39. ear once the error condition is corrected and a button is pressed System Sensor Short Circuit If the outlet sensor is operational the boiler will operate using the outlet sensor If the outlet sensor is not available and the inlet sensor is operational the boiler will operate using the inlet sensor Otherwise the control will not operate the burner Test the supply sensor and related wiring The error message will clear once the error condition is corrected and a button is pressed System Sensor Open If the outlet sensor is operational the boiler will operate using the outlet sensor If the outlet sensor is not available and the inlet sensor is operational the boiler will operate using the inlet sensor Otherwise the control will not operate the burner Test the supply sensor and related wiring The error message will clear once the error condition is corrected and a button is pressed Outdoor Sensor Short Circuit The BTC 1 assumes an outdoor temperature of 32 F 0 C and continues operation Test the outdoor sensor and related wiring The error message will clear once the error condition is corrected and a button is pressed Outdoor Sensor Open The BTC 1 assumes an outdoor temperature of 32 F 0 C and continues operation Test the outdoor sensor and related wiring The error message will clear once the error condition is corrected and a button is pressed DHW Sensor Short Circuit The control will not operate the burne
40. enting Multiple condensing appliances may be vented into a common chimney The chimney must be lined with AL29 4C or equivalent and a single acting barometric damper must be provided for each appliance A qualified professional using 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 Il 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 The chimney must be protected from down drafts rain and debris by using a listed chimney cap Approval of the installation will be at the discretion of authorities having jurisdiction Sidewall and Vertical Venting The maximum vent length is 60 equivalent feet Vent pipe may be run through a vertical or horizontal chase provided that minimum clearances to combustible materials are maintained The vent should terminate a minimum 12 inches above grade plus normally expected snow accumulation or 7 feet above grade if located adjacent to public walkways Do not install over public walkway where local experience indicates condensation or vapour from the ap
41. ertically vented appliances operate with positive pressure in the vent pipe and may be directly connected to the flue outlet without the use of 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 736 732 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 Figure 7 Secondary Heat Exchanger Table 7 CHRM Head Loss amp Flow 7 9 PIPING The boiler can be piped in parallel or in primary secondary to the system The type of piping chosen affects the location of the control s operating temperature sensor The control can either use the boiler outlet sensor or the boiler system sensor 7 9 1 Parallel Piping In parallel piping applications the boiler outlet temperature is typically the same as the system temperature Therefo
42. ges the modulation output to the START modulation setting and closes the Stage contacts pins 15 amp 16 to proceed to trial for ignition The burner remains at minimum modulation until the flame is proved and then modulating output changes the boiler output to maintain the calculated boiler target temperature at the inlet sensor If the inlet sensor reaches 12 half of the differential above the BOIL TARGET the appliance is shut off The boiler pump continues to circulate until the PUMP DELAY timer expires The water temperature is controlled based on a calculated boiler target temperature The boiler start BOIL START temperature is pre set to 70 F and the auto re set limit is set to 210 F and is fixed In addition to the auto reset limit the factory installs a manual re set limit set to 250 F Figure 20 Mode 4 Piping amp Electrical Layout 18 Mode 5 Outdoor Reset using System Sensor This mode is designed for hydronic heating Once a heat demand is present the BTC 1 turns on the appliance pump and modulates the boiler to maintain the calculated outdoor reset target at the system sensor Outdoor reset calculates the boiler target temperature based on the outdoor air temperature and reset ratio A heat demand is generated when a voltage between 24VAC and 120VAC is applied across CD common demand and Ht D heat demand Once voltage is applied the BTC 1 turns on the Dem 1 segment in the display If warm weather sh
43. gize all gas valves and the blower Condition indicators are visible on the control panel Each burner blower set is provided with its own air pressure switch If a low air pressure condition is present power will not be supplied to the ignition module The blower will remain on and the air indicator will remain on for as long as there is a call for heat 36 11 PILOT AND MAIN BURNER FLAMES MAIN BURNER The main burner Figure 25 should display the following characteristics 11 1 e Acceptable CO and 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 26 Burner Metal Fiber Air Switch Sensing Tube Air Gas Mix If burner characteristics do not match the above check for proper air box pressure Look for accumulation of lint and other foreign material at fan air inlets Table 13 Air Box Settings at Full Fire MODEL AIR BOX W C with burner firing Burner Burner Burner Burner 1 2 3 4 seh PN MODEL 2 6 Burner Burner Burner Burner 1 2 3 4 1 1 1 1 5 5 1 8 1 8 8 2 2 2 2 2 2 1 6 9 9 1 1 9 1 9 1 9 1 9 1 22 E FLUE SWITCH RECYCLE POINT W C HERNEN LEE 1 1 9 1 5 5 5 9 1 2 1 6 5 9 r r 1 r lt 5 5 5 E 9 9 NS 2 1 2 6 1 6 1 6
44. h 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 1 of Owner Name of Dealer Address Address Model No Serial No Date of Installation Date of Initial Operation 6226 Netherhart Road Mississauga Ontario L5T 187 CANADA 50 51 CAMUS Hydronics is The CAMUS a manufacturer of CERTIFIED Seal replacement parts for assures you that most copper finned Reliability Efficiency amp serviceability are built water heaters wan into every heating CAMUS single unit as a information supplier of specialty on our innovative HVAC products Our products from CAMUS service line is open 24 Hydronics Limited call hours 7 days a week 905 696 7800 today CAMUS HYDRONICS LTD 6226 Netherhart Road Mississauga Ontario L5T 1B7 TEL 905 696 7800 FAX 905 696 8801
45. ilot flame current is not at least on average 1 5 HA and steady the module will not energize the combination valve and the main burner will not light The ignition module provides 100 gas shutoff followed by retry for ignition If required e g CSD 1 a module with lockout feature can be provided Main Burner When all pilot flames are established a flame rectification circuit is completed between the sensor and the burner ground The flame sensing circuit in the ignition module detects the flame current shuts off the spark generator and energizes the combination valve operator Once all pilots are lit the main gas valve opens and matches gas input to the available air As the fans ramp up gas input is adjusted accordingly On the lock out ignition module the flame current also holds the safety lockout timer in the reset operating condition When the call for heat ends both valve operators are de energized and both valves in the gas control close Normal Operation Modulation is controlled from the Boiler Temperature Controller The modulating fans are equipped with electrically commutated DC motors which respond to a PWM signal The control provided with the Modulating Micoflame allows remote control with an analog signal of 4 20mA or 2 10VDC Demand Satisfied The BIC 1 senses that the boiler target temperature was reached and de energizes the stage contact Control Alarms High limit or low water flow will de ener
46. ly across terminals 13 amp 14 e Adjustable target temp e Display of run hours for maintenance purposes Counter displays to 999 999 hours Flame failure signal 24 V Molex connector for ease of service Error message display Test override feature to test pump operation and alarm e Pump exercising feature runs pump 10 seconds every three days of no pump operation The menu structure for the Appliance Temperature Control was designed to be intuitive and easy to use for a first time user To maintain the Micoflame Modulating boiler at its correct settings two levels of access is provided User and Installer with an increasing amount of parameters that can be adjusted by the Installer This is done to provide an easy means of communication for the end user and a more indepth approach for factory installers when installing and troubleshooting Figure 16 Boiler Temperature Control BTC 1 Throttling Range External iii Modulation Offset Signal CAMUS hydronics Ltd SMART FLAME 78 0017 Y SETTING THE APPLIANCE TEMPERATURE CONTROLLER Press and hold all three buttons ltem V simultaneously for 1 second Pressing the ITEM key again will cause the last setting to be accepted Once all settings have been made wait for 30 seconds for the BTC 1 to return to normal operating mode To re enter the Installer menu press and hold all three buttons Item V si
47. me signal as it approaches high fire adjustment to the blocked flue switch may be necessary Condensing E 40 The following description is for the benefit of the start up technician should minor adjustment be required a Remove the lower front jacket panel b Reduce sensitivity of blocked flue switch by turning the flat screw 1 4 turn clockwise C Observe the operation of the burner as it approaches high fire if the heater continues to operate at high fire the switch has been correctly set If not repeat steps 2 and 3 d Re install lower front jacket panel Differential Air Proving Switch A differential low fire air proving switch is provided on every burner to prevent burner light off under block flue or blocked inlet condition The normally open differential air switches have been preset at the factory The following description is for the benefit of the start up technician should minor adjustment be required 1 Remove the lower front jacket panel 2 Insert allen key into the switch located on the combustion chamber door 3 Reduce sensitivity of differential air switch by turning the hex screw turn counter clockwise 4 Re install lower front jacket panel Ignition System Safety Shut Off Device After initial fill while the main burner is firing shut off gas to the pilot and clock the time taken for the main gas valve to shut down If the safety control is functioning properly power to the gas valve
48. multaneously for 1 second In normal operating mode the inlet temperature outlet temperature AT temperature and ON hours can be viewed by repeatedly pressing the ITEM key If you wish to check the setting you will have to start again by pressing and holding the V buttons simultaneously for 1 second and then use the ITEM key to scroll through the settings After checking the settings allow the BTC 1 to return to normal operation on its own 8 3 16 8 4 MODES OF OPERATION Mode 1 Constant Temperature Control This mode is designed for hydronic heating or domestic hot water DHW Once heat demand is present the BIC 1 turns on the appliance pump and modulates the boiler burner to maintain the boiler target at the boiler inlet sensor A heat demand is generated when a 24VAC is applied across CD common demand and Ht D heat demand Once voltage is applied the BTC 1 turns on the Dem 1 segment in the display If the inlet sensor is 2 half of the differential below the BOIL TARGET the BTC 1 then changes the proportional modulation output to the START modulation setting the Stage contact pins 15 amp 16 close to proceed to trial for ignition The burner remains at minimum modulation until the flame is proved and then the modulating output changes the boiler burner output to maintain the programmed boiler target temperature at the inlet sensor If the inlet sensor reaches 12 half of the differential above BOIL T
49. ndle or smoke from 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 0 improper operation of the common venting system must be corrected so that the installation conforms to the latest or current as amended National Fuel Gas Code ANSI Z223 1 or the current CAN CGA B149 Installation Codes When resizing any portion of the common venting system the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 11 of the latest or current as amended National Fuel Gas Code ANSI 7223 1 or the current CAN CGA B149 Installation Codes Hydronic heating heat exchanger surfaces and vent piping should be checked at least yearly for deterioration and carbon deposits Domestic hot water heat exchanger surfaces and vent piping should be checked every 6 six months Remove all soot or other obstructions from the chimney and flue which might impede draft action Replace any damaged or deteriorated parts of the venting system 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 appliance to cool
50. ng Intermittent pumping povided Mode 3 For DHW control with tank sensor Controls to boiler inlet sensor Intermittent pumping provided Mode 4 hydronic heating with outdoor reset constant Temperature control at boiler inlet sensor with proportional modulating logic Mode 5 hydronic heating with outdoor reset Temperature control at system sensor with selectable P I D or proportional modulating logic Intermittent pumping provided Mode 6 External analogue 0 10VDC signal generates temperature target Setpoint temperature control at heater inlet sensor using proportional modulating logic Intermittent pumping provided Mode 7 External analogue 0 10VDC signal generates temperature target Setpoint temperature control at system sensor with selectable PID or modulating logic Intermittent pumping provided 21 Mode 8 External analogue 0 10VDC signal closes the stage contacts to initiate heater Modulating output of the control follows the analog external input signal Temperature is controlled remotely independently of local settings Boiler max setting remains functional Intermittent pumping provided Factory Settings of Modulating Control 1 Access to the setup menu is achieved by pressing the ITEM UP and DOWN buttons simultaneously for 1 second Factory Settings Mode 231 gt 1 175 F Heati Target ducc 140 F DHW 230 F Heati High Limit Heati
51. ng 210 F DHW Throttling Range 10 F Dly Mod Differential Pump Delay WARNING DO NOT ATTEMPT TO ADJUST START MIN OR MAX MODULATION LEVELS IN THE FIELD 9 MICOFLAME GRANDE CONTROL PANEL VIEW pn rir LI E gt Throttling Range External Inout Modulation Offset Signal CAMUS hydronics Ltd SMART FLAME 78 0017 Y BOIL TARGET Figure 25 BTC 1 E Functions Table 9 BTC 1 Key Functions ESCRIPTION The abbreviated name of the selected item will be displayed in the item field of the display To view the next item press the button A Increase a parameter value Decrease a parameter value Levels of Access NE I View Access to general boiler and display settings and will allow adjustments to the central heating and domestic hot water setpoint Adjust Access to all user parameters and allows for changes to additional boiler parameters to allow for ease of startup and serviceability 22 9 1 Boiler Pump Sow gt DHW 1 Demand Proof Burner a GENERAL 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 Displays when the control is in Warm Weather Shutdown
52. ng 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 warrantable Excessive pitting and erosion on the inside of the copper tube may be caused by high water velocity or the use of an undersized boiler for a DHW application and is not covered by warranty Using or storing corrosive chemicals in the vicinity of this boiler can rapidly attack the copper tubes and voids warranty The primary heat exchanger of this boiler is intended to operate under non condensing conditions Inlet temperatures must be maintained at 1300 55 C for non condensing condensing appliances Warranty is void if the primary heat exchanger is allowed to operate in condensing mode Damage caused by freezing or dry firing voids warranty This boiler is not to be used for temporary heating of buildings under construction 2 LOCATION Install this appliance in a clean dry location with adequate air supply and close to a good vent connection Do not locate this appliance in an area where it will be subject to freezing unless precautions are taken The appliance is approved for installation directly on combustible flooring and should be located close to a floor drain in an area where leakage from the appliance or connections will not result in damage to the a
53. o track the direct drive input signal up to the maximum of 10VDC which is equivalent to maximum input rate When the direct drive signal modulates down to 0 5VDC the boiler operates at minimum fire When the signal drops below 0 5VDC the burner is shut off and the pump continues to circulate until the PUMP DELAY timer expires whereupon the pump shuts off The external boiler sequencer can specify the boiler inlet temperature However the BOIL MAX setting limits the highest temperature at the outlet sensor If the outlet temperature exceeds 210 F the modulating output immediately changes to 0 and the burner is shut off The burner is to remain off until the minimum off timer is satisfied and the boiler outlet temperature falls by 2 F 1 C below the BOIL MAX setting Figure 24 Mode 8 Piping amp Electrical Layout Modulating Modulating Smart Smart Flame Flame Camus 12 Sequencer m D mm system sensor MS 8 5 Typical Factory Settings of Parameters for Micoflame Grande BTC 1 78 0017 This modulating Micoflame is equipped with the CamusQ version of the Tekmar MPA control Summary of 8 Modes of Operation Mode 1 For setpoint control at heater inlet sensor Use for hydronic constant setpoint heating or domestic hot water applications External heat demand or pumping required Mode 2 For setpoint control at system sensor deal for monitoring constant hot loop or for pool heati
54. obtained when the levels shown in Table 10 are obtained After light off allow the burner to reach full fire and then adjust combustion using the high fire adjustment screw Bring the appliance to low fire and set the using the low fire adjustment If adjustment is necessary the following steps must be followed please refer to Figure 27 Remove the lower front jacket panel Remove the plug from the elbow pressure tap and connect a manometer Condensing Air Flow Setting The fan inlet air shutter has been preset at the factory The following description is for the benefit of the start up technician should minor adjustment be required Optimum results are obtained when the appliance is operated with air box pressure as set in Table 12 If adjustment is necessary the following steps must be followed Remove the lower front jacket panel connect a manometer to the air pressure tap provided on the combustion chamber door with the operating the air pressure should be set per Table 12 by adjusting the air inlet shutter on the fan inlet To adjust the air shutter first undo the securing nut and rotate the bolt so the shutter will open or close as required Table 12 Combustion Values Natural Gas Propane BRIDE 7 5 9 0 8 5 PPM 10 0 7 0 8 5 1 5 PPM 9 0 lt 50 lt 50 8 5 10 0 9 0 10 5 Once satisfied tighten the nut on the fan s shutter bolt making su
55. ode for the boiler NE 1 to 8 NOTE A complete description of each mode can be found in section 8 4 Modes of Operation in this manual 70 to 220 F To provide a target setpoint for 21 to 104 C the heating system Setpoint is controlled to the inlet sensor Default 120 F 49 C Boiler Target Temperature To provide a modulation rate ADJUST above and below the Boiler Au 2 to 42 F Target temperature For example Au 17 to 6 C if the value is 10 F and the Boiler Target is 160 F the boiler will begin to modulate at 155 F and shut off at 165 F OFF 0 20 to Boil f 9 55 min On Pump Delay post pump time after burner has shut off in seconds Default 1 00 min OF ue Differential Temperature Default 10 F Temperature Select the desired unit of Units measurement Default F 24 9 4 3 DEDICATED DOMESTIC HOT WATER OPERATION VIEW DISPLAY From the Home display 1 Press ITEM to view the following parameters Display Parameter Description Bi BOIL To provide target setpoint for the TARGET Su heating system Setpoint is controlled Temperature to the inlet sensor 35 to 266 F 2 to 130 C 14 to 266 F 10 to 130 C Boiler Outlet Temperature Real time Outlet Temperature to Boiler 14 to 266 F 10 to 130 C Boiler Inlet Real time Inlet Temperature to Boiler Temperature Real time temperature difference Boiler Delta between th
56. on the appliance piping system shall be equipped with a flow control valve or other automatic means to prevent gravity circulation of chilled water through the appliance Chilled water in the appliance will create condensate the appliance tubes which will collect in the combustion chamber causing corrosion 7 4 HEATING SYSTEM PIPING In larger systems It is advisable to connect the appliance to the piping employing the primary secondary pumping system This system is used to provide system advantages that would not be available with single pumping system Primary secondary pumping is illustrated in Figure 9 The following are some advantages of the primary secondary pumping system e Greatly reduce the stand by losses through the appliance e Minimize heat exchanger wear e Reduce power consumption 7 5 LOW WATER TEMPERATURE SYSTEMS In applications where the heating system requires supply water temperatures below 130 F 55 C a recirculation line or thermostatic mixing valve must be installed upstream of the appliance pump so that outlet water can be re circulated to raise the inlet temp to a minimum of 130 F 55 C for a recirculation line Balancing valves preferably globe valves are used to adjust flow See Figure 10 e Adjustment procedure a Fully open bypass and outlet valves b With appliance running read inlet temperature after 15 minutes c the inlet temperature is less than 130 F
57. perly locate the burner will result in erratic flame operation with the possibility of delayed ignition on light off Restore electrical power and gas supply to the appliance e Following the lighting instructions put the appliance back into operation e Check for gas leaks and proper appliance and vent operation 11 2 REMOVAL OF COMBUSTION CHAMBER LINING The combustion chamber insulation 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 e 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 00 site conditions Current
58. pliance 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 7 WATER PIPING Check all applicable local heating plumbing and building safety codes before proceeding With the boiler off open makeup water valve and allow system to fill slowly Adjust the pressure regulator to provide at least 15 PSIG in the system when cold The circulating pump must be installed at the appliance inlet Always pump toward the heat exchanger Minimum operating system pressure must not drop below 30 PSIG when hot With all vents open run system circulating pump for a minimum of 30 minutes with the boiler off Open all strainers in
59. r Test the DHW sensor and related wiring The error message will clear once the error condition is corrected and a button is pressed 33 Error Message Description DHW Sensor Open The control will not operate the burner Test the DHW sensor and related wiring The error message will clear once the error condition is corrected and a button is pressed Flame Proof Error Flame was not proved within 120 seconds of Demand 1 10 OPERATION The Micoflame Grande appliance should be installed and started up by factory qualified personnel 10 1 START UP Gas appliances are rated based on sea level operation with no adjustment required at elevations up to 2000 ft At elevations above 2000 ft the input rating must be reduced by 4 for each additional 1000 ft elevation Never increase the input of the appliance above that for which it is rated Pilot Pressure Setting The pilot was preset at the factory The following description is for the benefit of the start up technician should minor adjustment be required The pilot burner is controlled by a separate pilot valve Pilot pressure setting is as shown in Table 9 A view port is provided on the appliance s return end to view the pilot and the main burners If adjustment is necessary the following steps must be followed Remove the lower front jacket panel Remove the plug from the elbow pressure tap and connect a manometer Remove regulator adjustment screw cap from
60. r access panel and heat exchanger ends The Micoflame Grande is category 1 85 efficient when supplied as a non condensing appliance When supplied with the optional condensing cartridge the Micoflame Grande is 95 efficient and is considered to be a category or IV appliance Three venting options are available for this appliance in both condensing and non condensing configurations See Figure 2 for details Please refer to Table 3 for vent dimensions Non Condensing Condensing 6 1 OUTDOOR VENTING OUTDOOR VENTING Figure 2 Venting Arrangement SINGLE ACTING BAROMETRIC DAMPER STANDARD VENTING SINGLE ACTING BAROMETRIC DAMPER STANDARD VENTING OUTDOOR VENTING When fitted with the factory supplied rain shields and UL approved vent cap the Micoflame Grande is self venting The following applies to outdoor installations 1 2 3 Use only factory supplied rain shields Periodically check to ensure that air intake and vent cap are not obstructed Locate appliance at least 3 feet away from any overhang Locate appliance at least ten feet from building air intake Avoid installation in areas where runoff from adjacent building can spill onto appliance 6 2 STANDARD VENTING The non condensing 85 efficient Micoflame Grande is a category appliance and is approved for venting into a common chimney provided it is in good condition and meeting the local Codes Typically the chimne
61. r Heating System J 1921300099 1 L p Cold Water Supply Hot Water Storage Figure 14 Typical Water Heating System TG Hot Water Supply Storage Storage Tank Tank EG ETS p B N W T EV A TN i lt P3 4 NND Cold Water 7 Supply 8 3 3 N 3 L N B Boiler Boiler 14 8 INSTRUMENTATION AND CONTROLS 8 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 210 F for hot water and 230 F for heating Air Proving Switch An air proving switch is provided on each burner to prove the operation of the fan and adequate air flow to the burner The pressure switch sensing point is at the air box below the combustion chamber The LED indicator for air flow will not illuminate should the pressure switch detect a sustained low air condition Blocked Flue Switch A normally closed blocked flue switch is provided for the boiler It senses a blocked flue condition or a blocked fan inlet and shuts down the boiler 8 2 CONTROL PANEL The appliance is provided with a control panel at the front Operating controls are installed inside the control box and are accessible
62. r should be consulted when water conditions outside the aforementioned range are encountered The appliance could be fitted with an economizer secondary heat exchanger to achieve nominal efficiency of 95 This heat exchanger is fabricated from stainless steel and can accept inlet water temperature as low as 40 F 78 CONDENSER HEAT RECOVERY MODULE CHRM The Micoflame Grande All Stainless Steel CHRM is mounted in a stainless steel inner jacket chamber at the rear of the appliance The CHRM is constructed from all stainless steel headers and special multiple horizontal stainless tubes This CHRM is designed to maximize heat transfer efficiency by fully condensing flue products and is suitable to resist the low pH of condensate The CHRM must be supplied with adequate water flow at all times during operation Do not operate the appliance with the CHRM piped out or isolated The CHRM is mounted the discharge of the flue products from the primary heat exchanger This allows additional heat to be absorbed from the flue products exhausted from the combustion process If isolation valves are provided on the CHRM the provision of a relief valve at the outlet of the CHRM 15 recommended This valve is to be sized at minimum for 10 of the input of the appliance and is to be piped to drain When cold water supply with temperatures less than 130 F 55 C passes through the CHRM it will cool the flue products below dew points re
63. rcentage Monitors the amount of operational time since the Micoflame was installed The first two digits are the number of thousands of hours and the three digit display shows the number of hundreds of hours Press 4 Y simultaneously to reset the counter 27 60 to 190 F 51 to 88 C 35 to 266 F 2 to 130 C 14 to 266 F 10 to 130 C 14 to 266 F 10 to 130 C 14 to 266 F 10 to 130 C 99 to 252 F 72 to 122 C 0 to 100 Alternates between 00 and 999 9 7 MODE 4 4 5 OUTDOOR RESET OPERATION ADJUST DISPLAY From the Home display 1 Press ltem A Y simultaneously to view the following parameters Display Parameter Description id ADJUST Outdoor Start Temperature Outdoor Design Temperature Boiler Start Temperature Boiler Design Temperature Differential Temperature Pump Delay 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 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 Starting water temperature used in the reset ratio calculation for the heating system Typically set to the desired building temperature Boiler design wa
64. re is 160 F the boiler will begin to modulate at 155 F and shut off at 165 F provide a modulation rate above and below the Boiler Target temperature For example if the value is 10 F and the Boiler Target is 160 F the boiler will begin to modulate at 155 F and shut off at 165 F 2 to 10 F 1 to 5 C Default 3 F 1 C Au 2 to 42 F Differential Au 17 to 5 C Temperature Default 10 F OFF 0 20 to Boiler post pump time after 9 55 min On Pump Delay burner has shut off in seconds Default 1 00 min Temperature Select the desired unit of EG Units measurement Default F 26 9 6 MODE 4 amp 5 OUTDOOR RESET OPERATION VIEW DISPLAY From the Home display 1 Press ITEM to view the following parameters Display Parameter Description ird BOIL TARGET BOILSUP Madulation Outdoor Temperature Boiler Target Temperature oystem Temperature Boiler Outlet Temperature Boiler Inlet Temperature Boiler Delta T Modulation Total Run Time Since Installation Real time Outdoor Temperature To provide a target setpoint for the heating system Setpoint is controlled to the inlet sensor System Temperature of Primary Loop NOTE This parameter is only available in Mode 5 Real time Outlet Temperature Real time Inlet Temperature Real time temperature difference between the outlet sensor and the inlet sensor Real time modulating output pe
65. re it is secured CO lt 50 PPM lt 50 PPM lt 50 PPM 7 5 9 0 8 0 9 5 Condensing Pressure Switch Settings The air flow proving switches have been preset at the factory as per Table 12 The following description is for the benefit of the start up technician should minor adjustment be required One pressure switch is provided per burner If adjustment is necessary the following steps must be followed Remove the lower front jacket panel insert allen key into the switch located on the combustion chamber door with the fan running the switch should be set per Table 11 by rotating the allen key counter clockwise to make contact Ignition 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 lt 50 PPM 35 If shutdown does not occur it is possible that the main flow is generating a signal at the pilot in which case the pilot shall not recycle with the pilot gas off Appliances Start Up With the appliance off open makeup water valve and allow system to fill slowly With all air vents open run system circulating pump for a minimum of 30 minutes with the appliance off Open all s
66. re the operating temperature sensor is the boiler outlet sensor Figure 8 Parallel Piping Boiler Outlet Sensor Boiler Inlet Sensor 7 9 2 Primary Secondary Piping In primary secondary applications the boiler outlet temperature is typically hotter than the system supply temperature This occurs as the system supply pipe has a higher flow rate than the boiler outlet pipe Therefore the control requires a boiler outlet temperature sensor and a system temperature sensor Figure 9 Primary Secondary Piping Boiler Boiler Figure 10 Typical Heating System Temperature Temperature Gauge Gauge Return Air me Removal Building Expansion Tank Flow Switch Pump RV Pressure Xe Reducing Valve IN Check Valve Make Up Boiler A Figure 11 Typical Low Water Temperature System Temperature Temperature Gauge Gauge m Return Air Supply Removal Building 4 Circ Pump X Expansion Tank HH Boiler Flow Gare Switch Pump ta RV Pressure Boiler Xa Reducing Valve Check Valve v Make Up Figure 12 Typical Instantaneous Water System vV A Cold Water V Supply 1 e Boiler To Building Service Connection 13 Figure 13 Typical Wate
67. rs 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 the discharge line The discharge line shall allow complete drainage of the valve and line Relief valves should be manually operated at least once a year CAUTION Avoid contact with hot discharge water LOW WATER CUT OFF if equipped If this boiler is installed above radiation level a low water cut off device must be installed at the time of boiler installation Some local codes require the installation of a low water cut off on all systems Electronic low water cut offs are available as a factory supplied option on all models Low water cut offs should be tested every six 6 months The normally open switch contact of the low water cutoff is to be wired in series with the flow switch A diagnostic light will be indicated on the control display on a low flow condition CAUTION Remove jumper between H amp P1 when connecting to 24 VAC circuit Figure 3 Low Water Cutoff Electrical Connections Watts WARNING Be sure to remove the jumper between H and P1 Connection detail for placing L W C O in 24V circuit in series with flow switch
68. s by 20 e The requirement for the heat exchanger with water glycol mixture will now be 115 gom 15 6 feet ie 1 2 x 13ft 15 6 ft e 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 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 7 3 CHILLED WATER SYSTEMS When an appliance is connected to an air conditioning system where the same water is used for heating and cooling the chiller must be piped in parallel with the appliance Appropriate flow control valves manual or motorized must be provided to prevent the chilled water from entering the appliance See Figure 6 Figure 5 Typical Chilled Water System 1 Supply Return 1 Chiller Boiler WI I When an appliance is connected to heating coils located in air handling units where they may be exposed to refrigerated air circulati
69. s established Set primary system controller temperature to desired To turn off boiler close main manual gas valve close pilot manual valve and turn off electric power to system 122 START UP Gas appliances are rated based on sea level operation with no adjustment required at elevations up to 2000 ft At elevations above 2000 ft the input rating must be reduced by 4 for each additional 1000 ft elevation Never increase the input of the appliance above that for which it is rated Pilot Pressure Setting The pilot was preset at the factory The following description is for the benefit of the start up technician should minor adjustment be required The pilot burner is controlled by a separate pilot valve Pilot pressure setting is as shown in Table 15 A view port is provided on the appliance s return end to view the pilot and the main burners If adjustment is necessary the following steps must be followed Remove the lower front jacket panel Remove the plug from the elbow pressure tap and connect a manometer Remove regulator adjustment screw cap from the pilot valve Rotate the regulator adjustment screw clockwise to increase the manifold pressure or counterclockwise to decrease it 39 Minimum inches W C Maximum inches W C Once satisfied replace the regulator adjustment screw cap and the elbow pressure tap plug Table 15 Gas pressures at inlet to pilot NATURAL Figure 28 Micoflame
70. s removed from a common venting system the common venting system is likely to be too large for proper venting of the appliances remaining connected to it At the time of removal of an existing appliance the following steps must be followed with each appliance remaining connected to the common venting system placed in operation while the other appliances remaining connected to the common venting system are not in operation a Seal any unused openings in the common venting system b Visually inspect the venting system for proper size and horizontal pitch and determine that there is no blockage restriction leakage corrosion or other deficiency which could cause an unsafe condition c Insofar as is practical close all building doors and windows and all doors between the space which the appliances remaining connected to the common venting system are located and other spaces of the building Turn on clothes dryers and any appliances not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed 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 match or ca
71. se 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 Service Heating DHW Secondary HTX Service Heating DHW Secondary HTX 1 aa 20 20 e TT an ma MNA 0 4 4 0 10 40 9 2 Heat Exchanger shall be warranted for 20 years appliance having declared FOB from Camus against Thermal Shock excluded however if caused by appliance operation at large changes exceeding 150 F between the water temperature at intake and appliance temperature or operating at appliance temperatures exceeding 230 F BURNER If within FIVE years of the appliance having declared FOB from Camus 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 of the appliance having declared FOB from Camus whichever comes first Camus will furnis
72. sulting in the formation of condensation Furthermore the volumetric flow rate of the flue gases will be reduced The appliance CHRM loop may be used in condensing mode for a variety of application including domestic hot water and hydronic space heating Recommended piping arrangement is shown in Figure 5 Maximum capacity through the CHRM is summarized in Table 6 flows in excess of 60 GPM must be bypassed Figure 6 Typical Condensing System per NEUTRALIZER COLD WATER SUPPLY Condensate from the Micoflame Grande must be treated before being discharged to drain pH level of the condensate is to be checked regularly and the neutralizing medium is to be replaced as required A neutralizing cartridge is available from the factory The condensing Micoflame Grande must be vented using only special venting type AL29 4C stainless steel or equivalent please follow instructions detailed below 11 When supplied with the CHRM the Micoflame Grande is 95 efficient category Il 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 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 v
73. t according to a linear scale The BTC 1 modulates the boiler to maintain the boiler target at the inlet sensor An internal heat demand is generated when an analog positive 2 10VDC signal is applied to the V input and a negative DC signal is applied to the Com input The following table shows the various signals required to generate various Target temperatures Table 8 External Signal Cross Reference Chart mA Target dc Target 0 re o 0 4 50 F 10 C 1 2 _6 zo r 21 3 4 5 OFF OFF 68 F 20 C 43 C 139 F 5 C 77 C 79 C 88 C 89 C 99 90 F 32 C 110 F 43 C 130 F 54 C 190 F 88 C 192 F 89 C 210 F 99 C 210 F 99 C requires 5000 resistor A 4 20mA signal can be converted to a 2 10VDC signal by installing a 500Q resistor on the external input signal device s terminal 9 9 170 F 77 C 174 F 79 C 9 9 If the inlet sensor is 7 half of the differential below the Boiler Target the BIC 1 then changes the proportional modulation output to the START modulation setting the Stage contact pins 15 amp 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 12 half of the differential above
74. t to maintain the programmed boiler target temperature at the boiler inlet sensor Once the DHW tank reaches 2 of the tank differential above the TANK TARGET setting the internal demand is removed and the boiler burner is shut off The pump circulates until the PUMP DELAY timer expires The TANK TARGET setting is used to set the desired DHW tank setpoint The set point for inlet water is pre set to 130 and can be adjusted the auto re set limit is set to 210 F and is fixed In addition to the auto reset limit the factory installs a manual re set limit set to 210 Figure 19 Mode 3 Piping amp Electrical Layout Heat Demand Mode 4 Outdoor Reset using Boiler Inlet Sensor This mode is designed for hydronic heating Once a heat demand is present the BTC 1 turns on the appliance pump and modulates the boiler to maintain the calculated outdoor reset target at the boiler inlet sensor Outdoor reset calculates the boiler target temperature based on the outdoor air temperature and reset ratio A heat demand is generated when a voltage between 24VAC and 120VAC is applied across CD common demand and Ht D heat demand Once voltage is applied the BTC 1 turns on the Dem 1 segment in the display If warm weather shut down WWSD is activated the WWSD segment is lit If WWSD is not activated and the inlet sensor is Va half of the differential below the calculated BOIL TARGET the BTC 1 then chan
75. ter temperature used in the reset ratio calculation for the heating system Set to the boiler water temperature required to heat the building on the coldest annual outdoor temperature To provide a modulation rate above and below the Boiler Target temperature For example if the value is 10 F and the Boiler Target is 160 F the boiler will begin to modulate at 155 F and shut off at 165 F Boiler post pump time after burner has shut off in seconds 1to8 Default 1 35 to 85 F 2 to 29 C Default 60 F 21 C 60 to 50 F 51 to 10 C Default 10 F 23 C 35 to 150 F 2 to 66 C Default 70 F 21 C 70 to 230 F 21 to 110 C Default 180 F 82 C Au 2 to 42 F Au 16 to 5 C Default 10 F OFF 0 20 to 9 55 min On Default 1 00 min 35 to 105 F OFF 2 to 41 C OFF Warm Weather Shutdown Temperature Warm weather shutdown temperature using outdoor reset Default 0 20 min F C Select the desired unit of Temperature Units 9 8 MODE 6 amp 7 EXTERNAL TARGET TEMPERATURE INPUT OPERATION VIEW DISPLAY From the Home display 1 Press ITEM to view the following parameters Boiler Target Temperature System Temperature Boiler Outlet Temperature Boiler Inlet Temperature Boiler Delta T To provide a target setpoint for the heating system Setpoint is controlled to the inlet sensor Real time System Temperature
76. trainers in the circulating system and check for debris Check liquid level in expansion tank With system full of water at 15 PSIG cold the level of water in the expansion tank should not exceed W of the total volume with the balance filled with air Start up appliance following instructions provided Operate entire system including pumps and radiation for at least 1 hour Check water level in expansion tank If level exceeds 2 of tank volume air is still trapped in system Shut down appliance and continue to run pumps Within 3 days of start up recheck all air vents and expansion tank as described above 10 2 MODULATION SEQUENCE The Modulating Micoflame Grande is designed with intermittent pilots on each burner Before the appliance can light off all pilots must be lit Pre purge BTC 1 Staging control activates the pre purge cycle for 20 seconds before trial for ignition Ignition Trial On proof of air flow the air proving switch closes and energizes the ignition module The module first initiates a self check and then starts the pilot ignition sequence The modulating sequence begins with the modulating fan ramping down to ignition speed The safety shutoff valve opens which allows gas to flow to the pilot burner At the same time the electronic spark generator in the module produces 10 000 Volt spark pulse output The voltage generates a spark at the igniter that ignites the pilot If the pilot does not light or the p
77. ts off Once the external heat demand is removed the BTC 1 turns off the appliance and operates the boiler pump based on the PUMP DELAY setting In this case it is imperative that the system pump operates continuously in order to provide constant circulation past the system sensor The water temperature is controlled based on a fixed setpoint BOIL TARGET The setpoint for inlet water is pre set to 120 F and the auto re set limit is set to 210 F and is fixed In addition to the auto reset limit the factory installs a manual re set limit set to 250 F Figure 18 Mode 2 Piping amp Electrical Layout Heat Demand kN N J 1 17 Mode 3 Dedicated Domestic Hot Water Operation This mode is designed for domestic hot water A DHW sensor must be inserted into temperature immersion well within the DHW tank to function properly The BTC 1 modulates the boiler based on the boiler inlet sensor to maintain a tank temperature at the DHW sensor An internal heat demand is generated when the DHW sensor drops gt half of the tank differential setting below the desired DHW tank temperature Dem 1 is lit on the LCD screen The BTC 1 then changes the modulation output to the START modulation setting and closes the Stage contact pins 15 amp 16 to proceed to trial for ignition The burner remains at minimum modulation until the flame is proved and then modulating output changes the boiler outpu
78. ut down WWSD is activated the WWSD segment is lit If WWSD is not activated and the system sensor is gt half of the differential below the calculated BOIL TARGET the control then changes the modulation output to the START modulation setting and closes the Stage contacts pins 15 amp 16 to proceed to trial for ignition The burner remains at minimum modulation until the flame is proved and then the modulating output changes the boiler output to maintain the calculated boiler target temperature at the system sensor If the system sensor reaches Va half of the differential above the BOIL TARGET the appliance is shut off The appliance pump continues to circulate until the PUMP DELAY timer expires In this case it is imperative that the system pump operates continuously in order to provide constant circulation past the system sensor The water temperature is controlled based on a calculated boiler target temperature The boiler start BOIL START temperature is pre set to 70 F and the auto re set limit is set to 210 F and is fixed In addition to the auto reset limit the factory installs a manual re set limit set to 250 F Figure 21 Mode 5 Piping amp Electrical Layout Heat Demand 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 targe
79. y will be B vent or brick with clay or metal liner If the chimney height is much greater than 30 feet or if drafts are in excess of negative 0 05 W C it will be necessary to provide single acting barometric damper directly above the vent collar This damper will ensure smooth light off and minimize standby loss through the appliance Be sure to position the damper at least 6 away from the wall of the vent connector 6 3 SIDEWALL AND VERTICAL VENTING When fitted with the factory supplied vent terminal the Micoflame Grande can vent up to 60 equivalent feet Elbows can range from 8 to 15 feet in equivalent length depending on centreline radius See Table 3 for vent sizes Appliances may be installed with either 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 must be properly wrapped around the vent pipe to

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