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Installation Operation and Service Manual

1. 18 BK ON OFF appliance must be replaced it must be replaced with W 39 SWITCH wiring having a temperature rating of at least 105C N W 2 CONTROL 39 BK BK W 25 W x1 HARNESS FUSE U fA y y BIS 1 BK L FIELD SUPPLY 5 75 VA Y 2 DOM f R 13 d Q O O 115V 60Hz TRANS FAN BL w 3e W N 26 RH I RELAY T1 S 49 W TT i A T EE R NS N x2 Y Y 5C xd 6 RX 1 OS o 8B R a A 24VAC RO
2. L 115V ON OFF X i La 2 3 al Ka N 8 J 4 6 8 U P 5 5 ER 117 3 ri zva fd 12 Z TRANS PUMP FAN RELAY RELAY a R1 LY1F R2 LY1F BEES 24V POWER ON LIGHT fi REMOTE OPERATOR y FLAME BTC 1 H Ds 2 29M jra 12C R 24 1 T1 11 ALERT 23 RELAY 103V nj mA22 RE INLET 1 9 Com Gnd 21 gt AIR y FLOW E HIGH 7 Boil O Vdc 19 4 SWITCH XT SWITCH WO LIMIT 6 Sys D 18 us LIGHT LIGHT LIGHT OUTLET 1 5 Outdr 17 SENSOR 2 4 Com Stg 16 o or p ba E 3 PrD Su AIR FLOW HIGH 2 HtD mp14 FLUE SWITCH SWITCH LIMIT 1 CD Pmpl13 FLAME ROD i HONEYWELL S8600 123456 3 O IGNITION MODULE 1 Saa2z2239 2 2 z oo N L z IGNITER 4 PILOT 1 A S VALVE MAIN GAS B VALVE IGN 1 DRAWN a 0718 2008 CAMUS HYDRONICS LIMITED TITLE QA 60 1000 MODULATING MICOFLAME MFG TEKMAR BTC Camus Hydronics Limited This drawing may not be used copied without Camus s prior written consent This drawing is the property of SIZE DWG NO REV C 99 5086 S 00 BEBE SHEET 1 1 18 19 52 25 EXPLODED VIEW MicoFlame Exploded View a a e of a O 53
3. Name of Owner Name of Dealer Address Address Model No Serial No Date of Installation Date of Initial Operation 6226 Netherhart Road Mississauga Ontario L5T 1B7 CANADA 57 CAMUS Hydronics is a The CAMUS CERTIFIED manufacturer of Seal assures you that replacement parts for Reliability Efficiency amp most copper finned serviceability are built water heaters into every L m m l and heating CAMUS single unit boilers as well CERTIFIED For more 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
4. BURNER 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 20 OPERATION AND SERVICE 20 1 PRE START 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 is established Set primary system controller to desired temperature To turn off boiler close main manual gas valve close pilot manual valve and turn off electric power to system 20 2 ST
5. W C 09 ooo 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 in Table 12 Table 12 Combustion Values CO 50 9 0 50 PM 10 0 PPM 8 5 P Condensing LA 7 0 8 5 7 5 PPM 9 0 PPM PPM 10 0 50 ae 10 5 PPM 9 15 lt 50 90 lt 50 8 0 PPM 9 5 PPM 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 2 Remove access cover screws Disconnect pilot gas at bulkhead fitting Disconnect ground wire and ignition wire Remove two wing nuts holding down burner Gently pull down and forward to disengage burner e Remove burner being careful to not damage the igniter or ground electrodes 3 Thoroughly clean burner Check all ports and air channels for blockage 4 Reinstall the burner being careful to fully engage the back of the burner box into the retaining slot in the combustion chamber base Failure to properly locate the burner will result in erratic flame operation with the possibility of delayed ignition on light off 5 Restore electrical power and gas supply to the boiler e Following the lighting instructions put the boiler back into operation e Check for gas leaks and proper boiler and vent operation 42 19 2 REMOVAL OF COMBUSTION CHAMBER
6. 26 MICOFLAME REPLACEMENT PARTS LIST MicoFlame Series Model Part Name Combustion 1 Chamber 14 4055 14 4005 01 14 4005 03 Base Panel Combustion Chamber Common End 14 4050 14 4000 Panel Left Combustion Chamber Common cad 14 4051 14 4001 Right Panel Control Box Assembly 14 4028 14 4009 02 14 4009 03 Flue 14 4070 5 Collector 2 Req d 14 4020 2 Req d Per Unit Outlet Per Unit Outer Back Non us 14 4011 01 14 4011 03 Condensing Header Bar 14 4022 8 Leg 14 4014 2 Req d Per Unit ich LEE TT 14 4032 Left qg OU aio 14 4031 Right GG eee 14 4012 01 14 4011 03 Lower 05 Outer Front 14 4063 od 14 4010 01 14 4010 03 Return Side EL 44 4066 14 4016 Access Panel Stiffeners 14 4015 01 14 4015 02 Combustion Chamber 14 4053 14 4003 Support Right Combustion Chamber 14 4054 14 4004 02 Support Left Flue 14 4057 Collector Top 14 4007 01 14 4007 03 54 MicoFlame Series Model Part Name Co Combustion 20 Chamber 14 4052 14 4002 01 Rear Panel Flue 14 4058 2 21 Collector End Req d Per 14 4008 14 4008 14 4008 Bracket Unit Combustion Chamber Upper Front Panel Burner HX Header Bar Stop 14 4038 01 Heat Exchanger 14 4035 01 Support Brkt Heat Exchanger Support Brkt Stop HX Support Burner Box Assembly NS Fan Mounting Support N A 14 4039 01 Staging Fan Mounting Support N A 14 4179 Modulation HX V Baffles 14 4041 06 14 4041 07 14 4041 08 144941 14 4042 07 1
7. 14 to 266 F Real time Outlet Temperature 10 to 130 C 14 to 266 F Real time Inlet Temperature 10to 130 C Real time temperature difference between the outlet sensor and the inlet sensor 99 to 252 F 72 to 122 C Real time modulating output percentage 0 to 100 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 34 18 7 MODE 4 amp 5 OUTDOOR RESET OPERATION ADJUST DISPLAY From the Home display 1 Press ltem A Y simultaneously to view the following parameters Display Parameter Description Parameter Range 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 35 to 85 F Outdoor starting temperature 2 to 29 C used in the reset ratio for the heating system Typically set to the desired building temperature Outdoor Start Temperature Default 60 F 21 C OUTDR DSGN Outdoor design temperature used 60 to 50 F Outdoor in the reset ratio for the heating 51 to 10 C Design system Set to the coldest annual Temperature outdoor temperature in the local Default 10 F area 23 C Starting water temperature used 35 to 150 F in
8. 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 Y 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 1 2 half of the differential above BOIL TARGET setting the burner shuts off Once the external heat demand is removed the BTC 1 turns off the appliance and operates the boiler pump based on the PUMP DELAY setting 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 and is fixed In addition to the auto reset limit the factory installs a manual re set limit set to 250 F 21 Figure 14 Mode 1 Piping amp Electrical Layout Heat Demand lt SN Mode 2 Constant Temperature Control at System Sensor This mode is designed for hydronic heating Once a heat demand is present the BTC 1 modulates the boiler burner to maintain the boiler target at the system sensor A heat dema
9. ANSI NFPA 70 or the Canadian Electrical Code Part I CSA C22 1 Electrical Code Provide disconnecting means of sufficient rating within sight of the boiler These heaters require an 115V 60Hz supply Depending on the pump used a 15 amp breaker is usually sufficient Electrical connections must be made so that the circulator will operate before the gas valve can open At no time may the control system allow the burner to fire without water flowing in the system Use minimum 18 gauge conductor for 24 volt field wiring to boiler Splicing of wires is not recommended Use sealed tight conduit suitable for outdoor use for outdoor installations Use terminal strip provided inside control panel for low water cut off and remote controller Refer to wiring diagram provided with boiler 9 MODULATION SEQUENCE Models 300 through 600 are supplied with a modulating fan which pressurizes the space below the combustion chamber and feeds air to the venturi connected to the air gas mix tube Before the appliance can light off the air proving switch must be closed and the pilot must be lit The blocked flue switch is normally closed and opens only under blocked air or blocked flue conditions All models are supplied with a single burner Each MicoFlame is supplied with the appropriate wiring diagram showing the sequence provided as well as any special controls or options requested When converting multiple MicoFlame appliances to an external sequencing cont
10. Heat Exchanger shall be warranted for 20 years from date of installation against Thermal Shock excluded however if caused by appliance operation at large changes exceeding 150 F between the water temperature at intake and appliance temperature or operating at appliance temperatures exceeding 230 F BURNER If within FIVE years after initial installation of the appliance a burner shall prove upon examination by Camus to be defective in material or workmanship Camus will exchange or repair such part or portion ANY OTHER PART If any other part fails within one 1 year after installation or eighteen 18 months from date of factory shipment based on Camus records whichever comes first Camus will furnish a replacement or repair that part Replacement parts will be shipped f o b our factory HOW TO MAKE A CLAIM Any claim under this warranty shall be made directly to Camus Hydronics Limited Canadian Head Office SERVICE LABOR RESPONSIBILITY Camus shall not be responsible for any labour expenses to service repair or replace the components supplied Such costs are the responsibility of the owner DISCLAIMERS Camus shall not be responsible for any water damage Provisions should be made that in the event of a water appliance or fitting leak the resulting flow of water will not cause damage to its surroundings E BM A i O A 8 O A A
11. LINING The combustion chamber insulation in this appliance contains ceramic fiber material Ceramic fibers can be converted to cristobalite in very high temperature applications The International Agency for Research on Cancer IARC has concluded Crystalline silica in this form of quartz of cristobalite from occupational sources is carcinogenic to humans Group 1 Normal operating temperatures in this appliance are below the level to convert ceramic fibers to cristobalite Abnormal operating conditions would have to be created to convert the ceramic fibers in this appliance to cristobalite The ceramic fiber material used in this appliance is an irritant when handling or replacing the ceramic materials it is advisable that the installer follow these safety guidelines 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 job site conditions Current NIOSH recommendations can be found on the NIOSH website at http www cdc gov niosh homepage html NIOSH approved respirators manufacturers and phone numbers are also listed on this website o Wear long sleeved loose fitting clothing gloves and eye protection e Apply enough water to the combustion chamber lining to prevent airborne dust e Remove the combustion chamber
12. Supply for Appliances of the current CAN CGA B149 Installation Codes and applicable provisions of the local building codes When required by the authority having jurisdiction the installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 The qualified installer shall instruct the end user in the safe and correct operation of this appliance and shall ensure that the heater is in safe working order prior to leaving the job site WARRANTY Factory warranty shall apply only when the boiler is installed in accordance with local plumbing and building codes ordinances and regulations the printed instructions provided with it and good industry practices Excessive water hardness causing a lime build up in the copper coils or tubes is not a fault of the boiler Consult the factory for recommendations for use in hard water areas Damage to the heat exchanger as a result of scaling or corrosive water conditions in non warrantable Using or storing corrosive chemicals in the vicinity of this boiler can rapidly attack the copper tubes and coils and voids warranty The primary heat exchanger of this boiler is intended to operate under non condensing conditions Inlet temperatures must be maintained at 130 F or higher Warranty is void if the primary heat exchanger is allowed to operate in condensing mode Damage caused by freezing or dry firing voids warranty This boiler is not to be
13. control is in Warm Weather Shutdown 20 18 2 MODE 1 amp 2 SETPOINT OPERATION VIEW DISPLAY From the Home display 1 Press ITEM to view the following parameters Display Parameter Description Bir BOIL To provide a target setpoint for the O heating system Setpoint is controlled 35 to 266 F 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 30 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 18 3 MODE 1 amp 2 SETPOINT OPERATION ADJUST DISPLAY From the Home display 1 Press ltem A V simultaneously to view the following parameters Dis
14. corrected and a button is pressed DHW Sensor Short Circuit The control will not operate the burner Test the DHW sensor and related wiring The error message will clear once the error condition is corrected and a button is pressed 40 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 19 PILOT AND MAIN BURNER FLAMES To maintain safe operation and the greatest efficiency of the boiler check the main burner and pilot burner every six months for proper flame characteristics 19 1 MAIN BURNER The main burner Figure 24 for models 300 600 should display the following characteristics Acceptable CO and CO 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 24 MicoFlame 300 600 Burner Assembly Metal Fiber Igniter Ground Rod Pilot Tube If burner characteristics do not match the above check for proper air box pressure Also look for accumulation of lint and other foreign material at fan air inlets Typical air box settings are as follows 41 Table 11 Air Box Settings MODEL AIR BOX W C FLUE SWITCH RECYCLE POINT with burner firing
15. inserted into a temperature immersion well within the DHW tank to function properly The BTC 1 modulates the boiler based on the boiler inlet sensor to maintain a tank temperature at the DHW sensor An internal heat demand is generated when the DHW sensor drops 2 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 output to maintain the programmed boiler target temperature at the boiler inlet sensor Once the DHW tank reaches 1 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 F and can be adjusted the auto re set limit is set to 210 F and is fixed In addition to the auto reset limit the factory installs a manual re set limit set to 210 F Figure 16 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 pu
16. 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 19 3 PILOT BURNER Turn the pilot firing valve to off position and allow the appliance to try for ignition Observe the spark making sure that it is strong and continuous If the spark is not acceptable the igniter will have to be adjusted This can be readily accomplished after removing the main burner The spark gap should be 1 8 to 3 16 Make sure that the electrode does not appear overheated or fouled with carbon It may be necessary to clean the ignition electrode using steel wool Once the pilot appears to be properly set reinstall it into the appliance making sure to properly tighten the pilot line connection If the pilot is removed from the main burner in the course of servicing the appliance it is important to reinstall it so that there is no gap between the top surface of the pilot tube and the underside of the metal filter support screen When properly set it will not be possible to slip a business card between the pilot burner and the support screen Figure 25 shows the burner box assembly with the metal filter cover removed to expose pilot tube 43 Figure 25 Pilot and Burner Box SE I iu PILOT TUBE Y S LON E fi NS S IGNITER E SS GROUND ELECTRODE ho D
17. or above any door window or gravity air inlet Minimum 4 feet horizontally from electric meters gas meters regulators and relief valves Use appropriately designed thimbles when passing through combustible walls or roofs Install fire stops where vent passes through floors ceilings or framed walls The fire stop must close the opening between the vent pipe and the structure Locate vent terminal above combustion air intake terminal if used and no closer than 2 feet vertically or horizontally Vertical venting requires flashing and a storm collar to prevent moisture from entering the structure Vertical vent termination must be at least 2 feet plus the expected snow accumulation above the roof penetration height 10 8 ACCESSORIES 8 1 WATER FLOW SWITCH shipped loose A water flow switch is shipped loose and is to be installed in the outlet piping on all heating boilers and hot water supply boilers The flow switch is wired in series with the 24VAC safety control circuit A diagnostic light will be indicated on the control display on a low flow condition 82 LOW WATER CUTOFF If Equipped If this boiler is installed above radiation level a low water cut off device must be installed at the time of boiler installation Some local codes require the installation of a low water cut off on all systems Electronic low water cut offs are available as a factory supplied option on all models Low water cut offs should be tested every six months The n
18. replacement part will be warranted for only the unexpired portion of the original warranty This warranty does not cover failures or malfunctions resulting from 1 Failure to properly install operate or maintain the equipment in accordance with Camus manual 2 Abuse alteration accident fire flood foundation problems and the like 3 Sediment or lime buildup freezing or other conditions causing inadequate water circulation 4 Pitting and erosion caused by high water velocity 5 Failure of connected systems devices such as pump or controller 6 Use of non factory authorized accessories or other components in conjunction with the system 7 failing to eliminate air from or replenish water in the connected water system 8 Chemical contamination of combustion air or use of chemical additives to water HEAT EXCHANGER If within TEN years after initial installation of the appliance a heat exchanger shall prove upon examination by Camus to be defective in material or workmanship Camus will exchange or repair such part or portion on the following pro rated limited warranty 1 Years one through five standard warranty 2 Years six through ten replacement purchase price pro rated at the following schedule Year six 60 Year seven 65 Year eight 70 Year nine 75 Year ten 80 of the current list price of the current list price This term is reduced to FIVE years if the appliance is used for other than hydronic space heating
19. shuts off the spark generator and energizes the combination control which is a one to one air gas ratio control valve As the modulating fan ramps up gas input is adjusted accordingly to match the airflow When the call for heat ends the valve is de energized and the fan modulates off Normal Operation Modulation is controlled from the Boiler Temperature Controller The modulating fan is equipped with an electrically commutated DC motor which responds to a PWM signal The control provided with the Modulating MicoFlame allows remote control with an analog signal of 4 20mA or 2 10VDC Demand Satisfied The BTC 1 senses that the boiler target temperature was reached and de energizes the stage contact Control Alarms High limit or low water flow will de energize all gas valves and the blower Condition indicators are visible on the control panel Each burner blower set is provided with its own air pressure switch If a low air pressure condition is present power will not be supplied to the ignition module The blower will remain on and the air indicator will remain on for as long as there is a call for heat If the safety proving sequence does not proceed to completion the first safety light to remain off will indicate the cause of the problem All other lights below the problem indicator light will also remain off 6 NORMAL GAS SUPPLY AND PIPING This boiler is intended to operate at inlet gas pressures not exceeding 1 4 PSI 7 W C whe
20. the boiler will Default 1 Au 2 to 42 F Differential Au 17 to 6 C Temperature Default Au begin to modulate at 155 F and shut off at 165 F OFF 0 20 to 9 55 Boiler post pump time after min On RAND Dee burner has shut off in seconds Default 1 00 min O O Temperature Select the desired unit of Ps Units measurement Default F 37 18 10 MODE 8 EXTERNAL DRIVE OPEATION VIEW DISPLAY From the Home display 1 Press ITEM to view the following parameters Display Parameter Description Parameter Range VIEW Boiler Outlet Real time Outlet Temperature to 14 to 266 F Temperature Boiler 10 to 130 C Boiler Inlet Real time Inlet Temperature to 14 to 266 F Temperature Boiler 10 to 130 C Boiler Delta Real time temperature difference 99 to 2529F between the outlet sensor and the O H inlet sensor MED ER Real time modulating output percentage U to 100 Modulation Modulation Monitors the amount of operational time since the MicoFlame was installed The first Total Run two digits are the number of Alternates Time Since thousands of hours and the three between 00 and Installation digit display shows the number of 999 hundreds of hours Press Y simultaneously to reset the counter 38 18 11 MODE 8 EXTERNAL DRIVE OPEATION ADJUST DISPLAY From the Home display 1 Press ltem A Y simultaneously to view the following parameters Display Parameter Des
21. the pilot and clock the time taken for the main gas valve to shut down If the safety control is functioning properly power to the gas valve will be shut off within 4 seconds of the pilot gas being shut off If shut down takes longer ignition control or gas valve may be defective If shutdown does not occur it is possible that the main gas flow is generating a signal at the pilot in which case the pilot shall not recycle with the pilot gas off 47 20 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 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 pu
22. the reset ratio calculation for 2 to 66 C the heating system Typically set to the desired building Default 70 F temperature 21 C Boiler Start Temperature Boiler design water temperature used in the reset ratio calculation for the heating system Set to the boiler water temperature required to heat the building on the coldest annual outdoor temperature 70 to 230 F Boiler 21 to 110 C Design Temperature Default 180 F 82 C To provide a modulation rate SSC above and below the Boiler Target temperature For example de 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 Au 2 to 42 F Au 16 to 5 C Default Au OFF 0 20 to 9 55 Boiler post pump time after min On POP Dee burner has shut off in seconds Default 1 00 min 35 pr ILI WWSD ADJUST F Warm Weather Shutdown Temperature Temperature Units Warm weather shutdown temperature using outdoor reset Select the desired unit of measurement 35 to 105 F OFF 2 to 41 C OFF Default 0 20 min oF ue Default F 18 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
23. 0 600 INTERNAL WIRING LADDER DIAGRAM sunaunennnnnnevnnvnnannnennnnrnennennnennvnnnnnnnnnnnnennsnnnvnnennnnnennsnnn 52 SIE RRE SE NICOFLAME REPLACEMENT PARIS IL 54 WARN 57 1 GENERAL INFORMATION Camus Hydronics proudly introduces the Modulating MicoFlame series of water heaters hydronic boilers The Modulating MicoFlame 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 Models are capable of modulating from 100 down to 35 of rated input These gas burning appliances are thoughtfully designed for easy operation and maintenance We are confident that you will come to appreciate the benefits of our product The installation of this heater must conform to the requirements of the authority having jurisdiction or in the absence of such requirements to the latest or current as amended National Fuel Gas Code ANSI Z223 1 or current CAN CGA B149 Installation Codes All electrical wiring must be done in accordance with the requirements of the authority having jurisdiction or in the absence of such requirements with the National Electrical Code ANSI NFPA 70 or the Canadian Electrical Code Part CSA C22 1 Electrical Code Vent installations must be in accordance with Part 7 Venting of Equipment of the latest or current as amended National Fuel Gas Code ANSI Z223 1 or Section 7 Venting Systems and Air
24. 201 M BKA1 4 z 1013 Y R 28 204 E WR BIN p p Bl FIELD SUPPLIED m Q RJ OPTIONAL EQUIPMENT SR T iby db BK BLACK a 09 11 2008 CAMUS HYDRONICS LIMITED 2 R O S 2 R 205 BL BLUE O TITLE BURNER BOX BR BROWN GA 1 d SECHS AE GROUND G GREEN 400 1000 MODULATING MICOFLAME PRE L O ORANGE MEG TEKMAR BTC 208 P PURPLE seere BL R W WHITE is drawing is the property o CONNECTION Camus Hydronics Limited SIZE DWG NO REV d s BL 109 O BL 110 E R FEN DIAGRAM This drawing may not be C 99 5086 C 00 FLOW AIR BLOCKED R RED used copied without Camus s AE SWITCH prior written consent SHEET 1 OF SWITCH 9 FLUE n 6 d 8 17 18 19 20 21 27 51 MF 300 600 INTERNAL WIRING LADDER DIAGRAM 24 2
25. 4 4042 08 144042 HX Front amp Rear Baffles 14 4042 06 55 0008 Blower Assembl Inlet Outlet Return Modulating 55667 1 Fan 55667 21200 4002 55 14 4006 14 4056 14 4006 01 14 4040 23 24 14 4038 02 14 4035 02 14 4036 01 14 4036 02 14 4023 14 4023 N A 14 4029 O 27 8 2 NO co O O 30 3 32 33 34 EJES al 1 37 EREM 00 ale AN CO MicoFlame Modulating harness 1 burner Mico Modulating harness 77 0019 Panel main 110V 77 0018 a Air Inlet Hole 14 4083 Cover Flue Collar 14 4068 E Outer Jacket Economizer 14 4090 14 4046 Cover 75VA Transformer A HCT 01J2BB07 ES LY1F Ignition Module S8610M3017 Continuous Retry Ignition Module S8600H3010 Single Try Time Delay 24 IMS24A9X30 Rela Modulating d 78 0017 Pre Purge TMOR24A1X7 Card Post Purge ST82D1004 Card Condensing Models Only Not Shown in Exploded View 56 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
26. ART 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 44 The pilot burner is controlled by a separate pilot valve Pilot pressure setting is as shown in Table 13 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 7s plug from the elbow pressure tap and connect a manometer Remove regulator adjustment screw cap from the pilot valve Rotate the regulator adjustment screw clockwise to increase the manifold pressure or counterclockwise to decrease it Once satisfied replace the regulator adjustment screw cap and the elbow pressure tap plug Table 13 Gas pressures at inlet to pilot NATURAL Minimum inches W C Maximum inches W C 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 readin
27. C 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 e 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 directly across terminals 13 amp 14 e Adjustable target temp e Display of run hours for maintenance purposes Counter displays up to 999 999 hours e Flame failure signal 24 V e Molex connector for ease of service 20 e Error message display e 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 are provided User and Installer with an increasing amount of parameters that can be adjusted by the Installer
28. Electrical Layout Mode 5 Outdoor Reset using System Sensor This mode is designed for hydronic heating Once a heat demand is present the BTC 1 turns on the appliance pump and modulates the boiler to maintain the calculated outdoor reset target at the system sensor Outdoor reset calculates the boiler target temperature based on the outdoor air temperature and reset ratio A heat demand is generated when a voltage between 24VAC and 120VAC is applied across CD common demand and Ht D heat demand Once voltage is applied the BTC 1 turns on the Dem 1 segment in the display If warm weather shut down WWSD is activated the WWSD segment is lit If WWSD is not activated and the system sensor is Ya 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 15 816 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 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 temper
29. INSTALLATION OPERATION AND SERVICE MANUAL MODULATING MICOPLAME SERIES GAS FIRED RESIDENTIAL AND COMMERCIAL COPPER TUBE BOILERS CERTIFIED FOR HYDRONIC HEATING Non Condensing Models MFH400 500 600 Condensing Models MFH402 502 602 US HOT WATER SUPPLY Non Condensing Models MF W400 500 600 Condensing Models MF W402 502 602 ENERGY STAR HIGH EFFICIENCY HAUTE EFFICACITE H HLW WARNING If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury or death Do not store or use gasoline or other flammable vapours and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS 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 1B7 99 0073 Rev 01 Table of Contents 1 GENERALINFORMATION costas ita 1 2 BOILER LOCATIO
30. M the provision of a relief valve at the outlet of the CHRM is recommended This valve is to be sized at minimum for 10 of the input of the appliance and is to be piped to drain When cold water supply with temperatures less than 130 F 55 C passes through the CHRM it will cool the flue products below dew point resulting 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 8 Maximum capacity through the CHRM is summarized in Table 7 flows in excess of 60 GPM must be bypassed 16 Figure 8 Typical Condensing System ef F N M ro ei SI La OS JU DEN gt NEUTRALIZER ei Condensate from the MicoFlame 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 must be vented using only special venting type AL29 4C stainless steel or equivalent please follow instructions detailed below When supplied with the CHRM the MicoFlame is 95 efficient category ll or IV appliance which requires the use of a special venting system fabricated from AL29 4C or equivalent material Only venting compone
31. ME CONTROL PANEL Figure 22 BTC 1 Display Panel BOIL E re OU TARGET Boil E Dem pi Ga Throttling Range L External Input Modulation Offset Signal pi CAMUS hydronics Ltd SMART FLAME 78 0017 tem A Y Figure 23 BTC Key Functions ltem A Y a i Table 10 BTC Key Functions The abbreviated name of the selected item will be displayed in the item field of the display To view the next item press the Item button Increase a parameter value Decrease a parameter value Levels of Access View Access to general boiler and display settings and will allow adjustments to the central heating and domestic hot water setpoint Adjust Access to all user parameters and allows for changes to additional boiler parameters to allow for ease of startup and serviceability CAUTION DO NOT under any circumstance attempt to adjust the maximum modulation rate of the boiler as this can lead to serious injury and abnormal boiler behavior 28 18 1 GENERAL SYMBOL DESCRIPTION SYMBOL SYMBOL NAME Boiler Pump DHW Pump Heat Demand Flame Proof Burner Warning Pointers 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 oresent Shows the operation as indicated by the text Displays when the
32. MFNH600 3 PROVIDE AIR FOR COMBUSTION AND VENTILATION Provisions for combustion and ventilation air must be in accordance with e Section 5 3 Air for combustion and Ventilation of the latest or current as amended National Fuel Gas Code ANSI 2223 1 or e Sections 7 2 7 3 or 7 4 of CAN CGA B149 Installation Codes and e Applicable provisions of the local building codes The operation of exhaust fans compressors air handling units etc can rob air from the room creating a negative pressure condition leading to reversal of the natural draft action of the venting system Under these circumstances an engineered air supply is necessary If the heater is to be installed near a corrosive or potentially corrosive air supply the heater must be isolated from it and outside air should be supplied as per code Potentially corrosive atmospheres will result from exposure to permanent wave solution chlorinated waxes and cleaners chlorine water softening chemicals carbon tetrachloride halogen based refrigerants Freon cleaning solvents hydrochloric acid cements and glues masonry washing materials antistatic fabric softeners dry cleaning solvents degreasing liquids printing inks paint removers etc 4 ELECTRICAL WIRING All electrical wiring to the boiler must be electrically bonded to ground in accordance with the requirements of the authority having jurisdiction or in the absence of such requirements with the National Electrical Code
33. N op A AA AAA emi ne 2 3 PROVIDE AIR FOR COMBUSTION AND VENTILATION cccccseccsececseceessceeececenceeneeeeeceeeteuceeeeceaeeeseeeteneeees 3 4 ELECTRICAL WIRING EE 4 5 MODULEATIONSSEOUEN GE geet 4 6 NORMAL GAS SUPPLY AND PIPING ui it 5 7 VENTING sa 6 7 1 OUTDOOR VENTING ura daa 8 7 2 SIDEWALEVENTINO uns ida 9 7 3 OUTDOOR AIR KIT crane ar aa 9 7 4 PIETER e KEE 9 7 5 Spip pPipSiz Nc PC 9 7 6 VENTING F R CONDENSING APPLICATION sene 10 8 ACCESSORIES 11 8 1 WATER FLOW SWITCH shipped10065e has 11 8 2 LOW WATER CUITO FEN NN 11 8 3 RELIEF VALVE Eelere Ree EE 11 9 FREEZE PROTECT O Ns rias 12 10 WARNING REGARDING CHILLED WATER SVSTEMS eene enne enne rns snnt 12 11 PIPING OF BOILER TO SYTER 13 12 PLACING BOILER TN OPERATION Are 14 13 IGNITION SYSTEM SAFETY SHUT OFF DEVICE 5t seo vota CRI toe Eon Fee Cete as 14 14 LOW WATER TEMPERATURE YTES sisi CP ots piede eva OO Seen 15 15 INSTANTANEOUS WATER HENTER ae 16 16 CONDENSING HEAT RECOVERY MODULE CHRM esee enn e mener ennt sns 16 17 INSTRUMENTA TON AND CONTROLS atan art E 20 17 1 SEN CONTROLS NN 20 17 2 EENHEETEN 20 17 3 SETTING THE APPLIANCE TEMPERATURE CONTROLLER eese nennen enn enne s 21 17 4 MODESOFORENSTIO N Mor Pp HC EM 21 18 MICOFLAIVIE CONTROL PANEL EE 28 18 1 GENERAL SYMBOL DESCRIP TION on isos 29 18 2 MODE 1 amp 2 SETPOINT OPERATION VIEW DISPLAY ccccssccssccnssssesscccsscessss
34. OM R AS 35B R RO e THERMOSTAT N 1 24 N ali 4 PUMP LJ y MBL 3 3 TER RELAY 246 e BK ANALOG INPUT R1 LY1FS 4 3 5 LAR e E T 25 TO 140 R x3 104 23B BK BK E b SYSTEM 2 E i AT A ANALOG INPUT i Es SENSOR 1 STEEN a a f pa tes Oj id R2 DE 113757 RS 34 J ES OUTDOOR 2 l APTO 7 8 aii ee 33 SENSOR 204 ECH WM lh 140 AAA C3 S Y 20B 24 ANN BK 8 YR 2 oe PUMP R CA 32 R R 51 108 5C s 1 2 3 4 5 6 LE a 7A zr 225923 p ey S f3 6 9n215 9 9 z R BkT215 811114 W BK MM MEM pc aea n EE ol a d ba 114 71013 2 R BK SY 12 MT 36 258 L INL 17 R 30 Y 2 5 E 147 W BK BTC i N R 20D 20D KER id il HONEYWELL s8600 SNITER a 9 tynn 4gde SS PM EN IGNITION MODULE 1 29 18 o amp ALERT Pa pr BA 74 I POWER oo 10 V n mAp2 BL Y J1 9 Com Gnd21 Y RN Na BL APIS NAAA BL 448 Boil in PWM20 W BK ee OPERATOR sl 2 AAA R 177 Boil O VdeH9 R BK 7C Y 41417 HARNESS S W 5 Outdr 17 AA 114 D NN N oN Y 44 Com Stg 1 R A Y NSW e E R la 3 Q 350 R 3 PrD Stg5 tT P R XY FLOW SWITCH iro m 2 T 1811 OUTLET RH2 HD Pmpt4 5 74 Den Sp S n 4 2 SENSOR 8 52H 1 CD Pmp13 2 S Y NO S FLAME 0 AIR SWITCH F 3 6 e E SENSOR 1 R op ZK I 3 SWITC 2 W SS D INLET R R R Y Tg 2 SENSOR Rx MAIN FLAME BL lf dp BLOWER AL Sie ig e BA By NR Nes y t XY FLAME FAILURE 1 2 3 4 5 p N R Bk W BK y Y BK 203 NY BK13 6 91215 J2 A P 202 M BK 2 5 8 1114 6 R 29
35. S When a boiler is connected to an air conditioning system where the same water is used for heating and cooling the chiller must be piped in parallel with the boiler Appropriate flow control valves manual or motorized must be provided to prevent the chilled water from entering the boiler See Figure 4 Figure 4 Typical Chilled Water System 4 Supply i Return ES 71 Chiller Q sen Boiler Pump q When a boiler is connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation the boiler piping system shall be equipped with a flow control valve or other automatic means to prevent gravity circulation of chilled water through the boiler Chilled water in the boiler will create condensate on the boiler tubes which will collect in the combustion chamber causing corrosion 12 11 PIPING OF BOILER TO SYSTEM Check all applicable local heating plumbing and building safety codes before proceeding Be sure to provide unions and gate valves at inlet and outlet to boiler so that it can be easily isolated for service This boiler is of a low mass design which provides for instant heat transfer Special attention to water low rates will ensure that temperature rise does not exceed 35 F 19 4 C The following Table is provided as a guide For application in areas known to have hard water conditions contact factory for recommendations Tab
36. This is done to provide an easy means of communication for the end user and a more in depth approach for factory installers when installing and troubleshooting Figure 13 Boiler Temperature Control BTC 1 Throttling Range J ga External Input Modulatlon Offset Signal CAMUS hydronics Ltd SMART FLAME 78 0017 Item A Y 17 3 SETTING THE APPLIANCE TEMPERATURE CONTROLLER Press and hold all three buttons ltem A 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 Irem A V simultaneously 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 ltem A 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 17 4 MODES OF OPERATION Mode 1 Constant Temperature Control This mode is designed for hydronic heating or domestic hot water DHW Once a heat demand is present the BTC 1 turns on the appliance pump and modulates the boiler burner to maintain the boiler target at the boiler inlet sensor
37. 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 al 2 Turn off electrical power and close main manual gas shut off and allow boiler to cool 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 boiler and vacuum the heat exchanger If heat exchanger is excessively dirty it may be necessary to remove it from the boiler and wash it down with proper detergent cleaner Be aware that the combustion chamber base is insulated with 14 thick ceramic paper If this material is damaged or displaced it must be replaced before starting up the boiler 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 Restore electrical power and gas supply to boiler Place boiler in operation using lighting instructions provided While the b
38. arget 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 1 half of the differential below the Boiler Target the BTC 1 then changes the proportional modulation output to the START modulation setting then closes the Stage contact pins 15 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 burner out to maintain the programmed boiler target temperature at the system sensor If the inlet sensor reaches LG 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 20 Mode 7 Piping amp Electrical Layout 0 10 V dc external input signal 26 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
39. ature 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 18 Mode 5 Piping amp Electrical Layout Heat Demand boro eet A A A E Be 24 Mode 6 External Target Temperature using Boiler Inlet Sensor The external input signal can be provided from a BMS EMS or a tekmar NA System Control The external input signal creates an internal demand and changes the boiler target according to a linear scale The BTC 1 modulates the boiler to maintain the boiler target at the inlet sensor An internal heat demand is generated when an analog positive 2 10VDC signal is applied to the V input and a negative DC signal is applied to the Com input The following table shows the various signals required to generate various Target temperatures Table 8 External SE Cross Reference Chart nk Eg ECH OFP Lor OFF E 50 F 10 2 3 90 F 32 C 4 130 F 54 Pe SCH 59 170 zn T C 59 C F 69 C F 79 C ae aaa TA 20 210 Se 10 210 F 99 requires 5000 resistor 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 inlet sensor is 1 2 half of the
40. ce 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 Flow Switch An air proving switch is provided to prove the operation of the fan and adequate air flow to the burner The pressure switch sensing point is at the 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 to shut off the burner in case of a blockage to the fan inlet or vent outlet 17 2 CONTROL PANEL The appliance is provided with a control panel at the front Operating controls are installed inside the control box and are accessible by undoing the thumb screw and opening the door The diagnostic information centre as well as the on off switch 24V fuse and the appliance temperature controls reside on the control panel door Figure 12 Display Appliance Temperature Controller and Indicating LED r O 2 E B gt 9 00000 NG The Boiler Temperature Controller BTC 1 for this appliance is a Camus 78 0017 SmartFlame control The BTC 1 uses a Liquid Crystal Display LCD as a method of displaying boiler information The BTC 1 is used to setup and monitor the operation of the system The BT
41. cription i ed 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 0 20 to 9 55 Boiler post pump time after burner MIN On Pump Delay has shut off in seconds Default 1 00 min OF ve Temperature Select the desired unit of i Units measurement Default F 18 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 OUT 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 39 Error Message Description Inlet Sensor Short Circuit The boiler will continue operation Test the inlet sensor and related wiring The error message will clear once the error condition is corrected and a button is pressed Inlet Sensor O
42. differential below the Boiler 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 inlet sensor If the inlet sensor reaches 1 2 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 re set limit is set to 210 F and is fixed In addition to the auto reset limit the factory installs a manual re set limit set to 250 F Figure 19 Mode 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 NA 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 t
43. e 2 Pressure drop across the primary HX generates flow through secondary HX Zone Returns Flue Outlet MicoFlame AT of 30 F AT of 10 F Series Secondary AP ft 22m CAMUS HYDRONICS LIMITED lo Ime Hydronic Heating Natural Gas Firing MicoFlame 95 Efficiency This drawing is the property of Camus Hydronics Limited SIZE DWG NO REV This drawing may not be 186019230 0193 80 used copied without Camus s S E prior written consent Beer OF Euer 1 of 1 Notes Provide isolation valves and instrumentation where required Boiler to be provided with flow switch and relief valve on boiler s outlet Cold water supply line to be at least the same size as hot water supply line Inlet water temperature must be at all times MicoFlame not less than 110 F MicoFlame AT of 30 F AT of 10 F Series EAR een EN I 7 Hot Water Storage Grande Grande Grande Grande Grande Only heat exchanher AP Piping loss should be added 2222 CAMUS HYDRONICS LIMITED m l Proposed Hot Water Piping az Arrangment Natural Gas Firing This drawing is the property of MicoFlame 95 Efficient Camus Hydronics Limited c DWG NO REV This drawing may not be mb 0193 st r 00 used copied without Camus s V i prior written consent Beer OF Euer 1 of 1 17 INSTRUMENTATION AND CONTROLS 17 1 SAFETY CONTROLS High Temperature Limit The high temperature limit is located behind the applian
44. entreline radius See Table 3 for vent sizes Boilers may be installed with either a horizontal sidewall vent or vertical roof top terminal Terminals differ with each application Horizontal lengths over 5 feet must be installed using corrosion resistant stainless steel Use single wall vent and seal all joints or use pressure rated double wall vent Refer to local codes for proper installation and location of vent terminals When using sidewall vent all vent connector seams and joints must be sealed with pressure sensitive aluminium tape or silicone sealant as specified by the vent manufacturer Aluminium tape must meet the provisions of SMACNA AFTS 100 73 Standard When venting through unheated spaces with single wall vent insulation should be wrapped around the vent pipe to prevent flue gas condensation inside the vent Periodically check to ensure that the vent terminal is unobstructed 7 3 OUTDOOR AIR KIT When fitted with the factory supplied air inlet ring and air intake terminal the MicoFlame can draw outdoor air over an equivalent length of 50 feet See Table 3 for vent sizes Boilers may be installed with either a horizontal sidewall vent or vertical roof top terminal Terminals differ with each application The following applies to outdoor air installations 1 Use only factory supplied air intake terminal 2 Periodically check to ensure that air intake is not obstructed 3 Refer to local codes for proper installation and
45. ers and any appliances not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed do not operate a summer exhaust fan Close fireplace dampers d Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so that appliance operates continuously e Test for spillage at the draft control device relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette f After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous condition of use g Any improper operation of the common venting system must be corrected so that the installation conforms to the National Fuel Gas Code ANSI Z223 1 or CAN CGA B149 Installation Codes When resizing any portion of the common venting system the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 11 of the latest or current as amended National Fuel Gas Code ANSI Z223 1 or CAN CGA B149 Installation Codes Heat exchanger surfaces and vent piping should be checked every six months for deterioration and carbon deposits Remove all soot or other obstructions from the chimney
46. g from flame rectification Minimum average signal of 1 5 uA is required lf required test the signal using a 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 one of the meter s terminals to the burner ground terminal on the 58600 and the other terminal to the burner ground wire Pilot running without main burner will generate 1 5 yA average for best operation With main burner running the signal will be in a range of 4 0 to 7 0 pA High Fire Setting The gas valve high fire pressure regulator is 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 CO readings as indicated in Table 13 If adjustment is necessary the following steps must be followed please refer to Figure 26 In order to perform adjustments to the gas valve the MicoFlame must be firing before proceeding MF 300 600 45 Figure 26 MF 300 600 Gas Valve LIFT TOP COVER TO ACCESS HIGH FIRE AIR GAS RATIO ADJUSTMENT USE 3mm ALLEN KEY FOR ADJUSTMENT CLOCKWISE DECREASES CO LOW FIRE AIR GAS RATIO ADJUSTMENT put E Le USE FLAT HEAD SCREWDRIVER mala FOR ADJUSTMENT TP CLOCKWISE INCREASES CO GAS INLET To adjust the high fire setti
47. gh to prevent a few minutes short cycling Adjust pilot pressure for steady flame Remove main burner Adjust pilot shield and clean ignition sensor 7 Boiler starts to whine as the Verify that all air is bled from system temperature rise increases Verify that the static pressure in cold system is at least 15 psig Check temperature rise across boiler to ensure adequate water flow If necessary increase static water pressure and decrease pressure 49 23 TYPICAL GAS TRAIN Figure 27 MicoFlame Modulation 300 600 Gas Train Metal Fiber Burner Gas Valve I d Cas Rb 3 Pilot Tube Firing Valve Mixing Tube Venturi 24 ELECTRICAL DIAGRAMS Each MicoFlame boiler will be provided with its own wiring diagram to guarantee that any options ordered with the unit are properly detailed The following diagrams 99 5085 C 99 5086 C and 99 5086 S are provided as a typical sample only 50 MF 300 600 INTERNAL WIRING CONNECTION DIAGRAM 24 1 20 21 22 23 24 Note 1 If any of the original wire as supplied with the
48. he BTC 1 Controller Table 14 Combustion Values Natural Gas Propane 1 5 50 9 0 lt 50 8 5 PPM 10 0 PPM Condensing 7 0 8 5 7 5 PPM 9 0 PPM Condensin 9 0 PPM 10 5 PPM 8 0 PPM 9 5 PPM 46 Blocked Flue Switch The normally closed blocked flue switch has been preset at the factory according to Table 11 In cases where the heater loses the flame signal as it approaches high fire adjustment to the blocked flue switch may be necessary 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 Reduce sensitivity of blocked flue switch by turning the flat screw 1 4 turn clockwise 3 Observe the operation of the burner as it approaches high fire with the fan inlet 1 3 blocked if the heater continues to operate at high fire the switch has been correctly set If not repeat steps 2 and 3 4 Re install lower front jacket panel Differential Air Switch A differential air pressure switch is provided to prove air flow at minimum fire conditions 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 1 4 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
49. ion 7 Venting of Equipment and Air Supply for Appliances of the CAN CGA B149 Installation Codes and applicable provisions of the local building codes Vent connectors serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under positive pressure Horizontal runs of vent pipe shall be securely supported approximately every 4 feet to prevent sagging and maintain a minimum upward slope of 14 per foot from the boiler to the vent terminal When an existing boiler is removed from a common venting system the common venting system is likely to be too large for proper venting of the appliances remaining connected to it At the time of removal of an existing boiler the following steps must be followed with each appliance remaining connected to the common venting system placed in operation while the other appliances remaining connected to the common venting system are not in operation a Seal any unused openings in the common venting system b Visually inspect the venting system for proper size and horizontal pitch and determine that there is no blockage restriction leakage corrosion or other deficiency which could cause an unsafe condition c Insofar as is practical close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building Turn on the clothes dry
50. ion pot to the drain pH level of the condensate is to be checked regularly and neutralizing medium is to be replaced as required to maintain effectiveness A neutralizer cartridge is available from the factory CONDENSING HEAT RECOVERY MODULE PIPING CONFIGURATIONS Caution If isolation valves are provided on the CHRM the provision of a relief valve at the outlet of the secondary is recommended This valve is to be sized at minimum for 10 of the input of the appliance and is to be piped to drain in a manner similar to the appliance relief valve CHRM IN SERIES WITH PRIMARY HEAT EXCHANGER INTEGRATED LOOP The MicoFlame could be provided in condensing mode for a variety of application including domestic hot water and hydronic space heating The CHRM is intended to extract total sensible and latent heat from the flue gases downstream of the primary heat exchanger As a result condensation of moisture in the flue gas will take place on the CHRM surfaces and in the exhaust vent This condensation is a natural outcome when efficiencies exceed 90 Recommended installation methods of the condensing MicoFlame will vary depending on the application and the expected water temperature variation of the system Examples of recommended installation for typical applications are shown on the next page 18 Figure 10 Hydronic Heating Suggested Piping with CHRM Notes 1 Two way valve V1 set to maintain 110 F minimum inlet boiler temperatur
51. le 6 Flow and Pressure Drop at a Given Temperature Rise Head Loss and Flow Vs Temperature Rise Figure 5 Typical Boiler Piping to System If the boiler is installed above radiation level it must be provided with a low water cutoff device at the time of boiler installation Available from factory To eliminate trapped air install venting devices at high points in the system as well as in the piping on the suction of the pump and in the piping on the discharge of the boiler 13 Suitable pipe hangers must support the weight of all water and gas piping or floor stands Do not allow the boiler to run with inlet water temperature below 130F The boiler must be installed so that the gas ignition system components are protected from water dripping spraying rain etc During appliance operation and service circulator replacement control replacement etc 12 PLACING BOILER IN OPERATION The MicoFlame boiler should be installed and started up by qualified personnel With the boiler off open makeup water valve and allow system to fill slowly Adjust the pressure regulator to provide at least 15 PSIG in the system when cold With all air vents open run system circulating pump for a minimum of 30 minutes with the boiler off Open all strainers in the circulating system and check for debris Check liquid level in expansion tank With system full of water at 15 PSIG the level of water in the expansion tank should not exceed Lo of
52. location of vent terminals Vertical vent terminal must be at least 3 feet above the highest point where it is located above the roof of a building and at least two feet higher than any part of the building within a horizontal distance of ten feet 4 Locate the air intake five feet away from the vent discharge For sidewall venting locate the air intake below the vent outlet if possible 7 4 FILTER KIT A collar sized as per Table 3 is the standard air inlet configuration for the MicoFlame A filter kit is available The filter is washable and accounts for an additional pressure loss of less than 0 05 W C Highly recommended for dusty environments The filter kit can also be provided when using the outdoor air kit 7 5 STANDARD VENTING The non condensing 85 efficient MicoFlame is a category 1 appliance and is approved for venting into a common standard chimney If chimney height is much greater than 30 feet or if drafts are in excess of negative 0 05 W C it will be necessary to provide a single acting barometric damper directly above the vent collar This damper will ensure smooth light off and minimize standby loss through the boiler Be sure to position the damper at least 6 away from the wall of the vent connector 7 6 VENTING FOR CONDENSING APPLICATION When supplied with the optional condensing cartridge the MicoFlame is 95 efficient category II or IV appliance which requires the use of a special venting system fabricated fro
53. m AL29 4C material Only venting components listed by a nationally recognized testing agency may be used This appliance may be installed with conventional sidewall or vertical venting Conventional vented appliances operate with negative pressure in the vent pipe and require a special vent adapter to increase the flue outlet diameter Sidewall and vertically vented appliances operate with positive pressure in the vent pipe and may be directly connected to the flue outlet without the use of an increaser Consult the vent pipe manufacturer s instructions for minimum clearances to combustible material for vent components In the absence of instructions the minimum clearance to combustible material is six inches Consult vent pipe manufacturer s instructions for proper method of sealing vent pipe sections and fittings In the absence of instructions make sure that pipe and fittings are clean by swabbing with alcohol Use Dow Corning 736 or 732 RTV Polybar 500 RTV or Sil bond 4500 or 6500 to seal vent pipe Do not use other sealants or adhesives except as expressly permitted by vent manufacturer s instructions Consult vent pipe manufacturer s instructions for vent system assembly Follow vent pipe manufacturer s instructions if those instructions differ from this section Conventional Venting Multiple condensing appliances may be vented into a common chimney The chimney must be lined with AL29 4C and a single acting barometric damper must be pr
54. mp 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 1 half of the differential below the calculated BOIL TARGET the BTC 1 then changes the modulation output to the START modulation setting and closes the Stage contacts pins 15 16 to proceed to trial for ignition The burner remains at minimum modulation until the flame is proved and then modulating output changes the boiler output to maintain the calculated boiler target temperature at the inlet sensor If the inlet sensor reaches 1 2 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 23 Figure 17 Mode 4 Piping amp
55. n firing with natural gas If higher pressures are present consult the gas company for correction When pressure testing the gas supply piping at pressures above Y PSI the boiler and its individual gas shut off valve must be disconnected from the supply piping Provide a trap drip leg as close to the heater as possible Install a ground joint union and manual shut off valve in the gas line near the heater to allow easy removal of the gas control assembly Provide gas pressures at inlet to boiler gas train as follows Table 4 Gas Pressure limits at Inlet to Appliance De GAS inches W C inches W C 4 The gas supply line must be of adequate size to prevent undue pressure drop and must never be smaller than the size of the connection on the heater Sizing based on Table 5 is recommended Before operating the boiler the complete gas train and all connections must be tested using soap solution Table 5 Gas pipe size for distance from natural gas meter or propane second stage regulator DISTANCE FROM NATURAL GAS METER OR PROPANE SECOND STAGE REGULATOR Input 0 100 FT 100 200 FT 200 300 FT Btu Hr L P 300 000 D RS 400 000 500 000 1 we 600 000 2 7 VENTING Boilers for outdoor installation are intended to vent using a listed vent cap For indoor installations venting must be in accordance with Part 7 Venting of Equipment of the latest or current as amended National Fuel Gas Code ANSI Z223 1 or Sect
56. nd 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 Y 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 4 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 1 2 half of the differential above BOIL TARGET setting the burner shuts off Once the external heat demand is removed the BTC 1 turns off the appliance and operates the boiler pump based on the PUMP DELAY setting In this case it is imperative that the system pump operates continuously in order to provide constant circulation past the system sensor The 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 and is fixed In addition to the auto reset limit the factory installs a manual re set limit set to 250 F Figure 15 Mode 2 Piping amp Electrical Layout Heat Demand 24 O 4 33 SU P2 22 Mode 3 Dedicated Domestic Hot Water Operation This mode is designed for domestic hot water A DHW sensor must be
57. ng Set the Target Temperature to 190 F using the BTC 1 Controller Once the appliance is at maximum fan speed locate the input adjustment screw on the top side of the gas valve Using a flat head screwdriver turn the screw clockwise to decrease CO levels and counter clockwise to increase CO levels 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 Low fire is achieved at 25 The MicoFlame will respond immediately and operate at low fire When this is achieved locate the low fire adjustment screw as illustrated in Figure 29 Using a flat screwdriver rotate clockwise to increase CO levels and counter clockwise to decrease CO levels When the correct combustion values are achieved replace the screw cap back on to the gas valve Reset the Target Temperature to normal operating conditions on t
58. nts listed by a nationally recognized testing agency may be used This appliance may be installed with conventional sidewall or vertical venting Conventional vented appliances operate with negative pressure in the vent pipe and require a special vent adapter to increase the flue outlet diameter Sidewall and vertically vented appliances operate with positive pressure in the vent pipe and may be directly connected to the flue outlet without the use of an increaser Consult the vent pipe manufacturer s instructions for minimum clearances to combustible material for vent components In the absence of instructions the minimum clearance to combustible material is six inches Consult vent pipe manufacturer s instructions for proper method of sealing vent pipe sections and fittings In the absence of instructions make sure that pipe and fittings are clean by swabbing with alcohol Use Dow Corning 736 or 732 RTV Polybar 500 RTV or Sil bond 4500 or 6500 to seal vent pipe Do not use other sealants or adhesives except as expressly permitted by vent manufacturer s instructions Consult vent pipe manufacturer s instructions for vent system assembly Follow vent pipe manufacturer s instructions if those instructions differ from this section Figure 9 Secondary Heat Exchanger 17 Table 7 CHRM Head Loss Flow 3 402 602 A neutralizer cartridge is provided and must be installed in the line from the condensate collect
59. oiler is operating check for flue gas leaks and proper vent operation Seal any flue gas leaks using appropriate gasket or sealing material Carefully examine the flue collector access panel and heat exchanger ends The MicoFlame is a category 1 85 efficient when supplied as a non condensing appliance When supplied with the optional condensing cartridge the MicoFlame is 95 efficient and is considered to be a category Il or IV appliance Three venting options are available for this boiler See Figure 2 for details Please refer to Table 3 for vent dimensions Figure 2 Venting Arrangement Non Condensing SINGLE ACTING BAROMETRIC DAMPER STANDARD VENTING SINGLE ACTING BAROMETRIC DAMPER STANDARD VENTING SIDEWALL VENTING 7 1 OUTDOOR VENTING When fitted with the factory supplied rain shield and UL approved vent cap the MicoFlame is self venting The following applies to outdoor installations 1 Use only factory supplied rain shields Periodically check to ensure that air intake and vent cap are not obstructed Locate boiler at least 3 feet away from any overhang Locate boiler at least ten feet from building air intake St gt Se Im Avoid installation in areas where runoff from adjacent building can spill onto boiler 7 2 SIDEWALL VENTING When fitted with the factory supplied vent terminal the MicoFlame can vent up to 50 equivalent feet Elbows can range from 5 to 9 feet in equivalent length depending on c
60. ormally open switch contact of the low water cutoff is to be wired in series with the flow switch A diagnostic light will be indicated on the control display on a low flow condition Caution remove jumper when connecting to 24 VAC circuit Figure 3 Low Water Cutoff Electrical Connections 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 247 FLOW SWITCH TO AIR SWITCH 8 3 RELIEF VALVE shipped loose This appliance is supplied with a relief valve sized in accordance with ASME Boiler and Pressure Vessel Code Section IV Heating Boilers The relief valve is to be installed in the vertical position and mounted in the hot water outlet No valve is to be placed between the relief valve and the appliance To prevent water damage the discharge from the relief valve shall be piped to a suitable floor drain for disposal when relief occurs No reducing couplings or other restrictions shall be installed in the discharge line The discharge line shall allow complete drainage of the valve and line Relief valves should be manually operated at least once a year 11 9 FREEZE PROTECTION e Appliance installations are not recommended outdoors in areas where danger of freezing exists unless precautions are taken Maintaining a mixture of 50 water and 50 propylene glycol is the preferred method of freeze protection in hydronic systems This mixtu
61. ouscoussensessuseesseseuseossenenssss 30 18 3 MODE 1 amp 2 SETPOINT OPERATION ADJUST DISPLAY cssccsscsossssosseccuscesssscescouscesecusseususeuscousensessss 31 18 4 MODE 3 DEDICATED DOMESTIC HOT WATER OPERATION VIEW DISPLAY eee 32 18 5 MODE 3 DEDICATED DOMESTIC HOT WATER OPERATION ADJUST DISPLAY eee 33 18 6 MODE 4 amp 5 OUTDOOR RESET OPERATION VIEW DISPLAN mener 34 18 7 MODE 4 amp 5 OUTDOOR RESET OPERATION ADJUST DISPLAY oocccnccnnnccnnccncnccncncononononcnnnaconcnncncnnanononcnnos 35 18 8 MODE 6 7 EXTERNAL TARGET TEMPERATURE INPUT OPERATION VIEW DISPLAY eee 36 18 9 MODE 6 7 EXTERNAL TARGET TEMPERATURE INPUT OPERATION ADJUST DISPLAY eee 37 18 10 MODE 8 EXTERNAL DRIVE OPEATION VIEW DISPLAY esses nnne enn nnns 38 18 11 MODE 8 EXTERNAL DRIVE OPEATION ADJUST DISPLAY nemen nennen nennen 39 18 12 ERROR MESSAGES onsite difti a actos sealed Les MOOR o adds 39 19 PILOTANDMAIN BURNER FLAMES raid 41 19 1 MAIN BURNER spe 41 19 2 REMOVAL OF COMBUSTION CHAMBER LINING vvs AG 43 19 3 20 20 1 20 2 20 3 21 22 23 24 24 1 24 2 25 26 PILOT BURNER aar 43 OPERATION ANDOSERVMICE add iba 44 EE CHECKLIST PT 44 APR 44 SENGEN 48 HGRHTNG INS TRUCHON S ee 48 TROOBLESHOOTING GUIDE aia 49 TYPICAL GAS IRAN EE 50 ELECTRICAL RE RUM 50 MF 300 600 INTERNAL WIRING CONNECTION DIAGRAM uarunennnennnvnnrnnvnrennnnnnnvnnnnrennnennnnnnnnnennvnnennnenusnnnene 51 MF 30
62. ovided for each appliance A qualified professional using a proven vent sizing program with input of accurate operating parameters must properly calculate sizing of the venting system In applications where flue gas temperatures are lower than can support a Category II with conventional negative draft it will be determined at the venting design stage that a positive pressure will be developed in the vent It will then be necessary to either provide separate vents as for Category IV or to provide an extractor at the chimney outlet in order to maintain a negative draft in the chimney and allow common venting Approval of the installation will be at the discretion of authorities having jurisdiction The chimney must be protected from down drafts rain and debris by using a listed chimney cap Sidewall and Vertical Venting The maximum vent length is 50 equivalent feet Vent pipe may be run through a vertical or horizontal chase provided that minimum clearances to combustible materials are maintained The vent termination location is restricted as follows Minimum 12 inches above grade plus normally expected snow accumulation Or 7 feet above grade if located adjacent to public walkways Do not install over public walkway where local experience indicates condensation or vapor from the appliance 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
63. pen The boiler will continue operation Test the inlet sensor and related wiring The error message will clear once the error condition is corrected and a button is pressed System Sensor Short Circuit If the outlet sensor is operational the boiler will operate using the outlet sensor If the outlet sensor is not available and the inlet sensor is operational the boiler will operate using the inlet sensor Otherwise the control will not operate the burner Test the supply sensor and related wiring The error message will clear once the error condition is corrected and a button is pressed System Sensor Open If the outlet sensor is operational the boiler will operate using the outlet sensor If the outlet sensor is not available and the inlet sensor is operational the boiler will operate using the inlet sensor Otherwise the control will not operate the burner Test the supply sensor and related wiring The error message will clear once the error condition is corrected and a button is pressed Outdoor Sensor Short Circuit The BTC 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 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
64. play Parameter Description E Operating mode for the boiler NE 1 to8 NOTE A complete description of each mode can be found in section 8 4 Modes of Operation in Site 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 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 OFF 0 20 to f 9 55 min On Pump Delay Boiler post pump time after burner has shut off in seconds Default 1 00 min OF SC Au 2 to 42 F Differential Au 17 to 6 C Temperature Default Au Temperature Select the desired unit of Units measurement Default F 31 18 4 MODE 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 t To provide a target setpoint for the TARGET PONET Noel 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 temperat
65. provides a positive 0 10 VDC input signal to the control at V in and the negative signal is applied to the Com input The boiler remains off while the direct drive input signal range is between 0 to 0 5VDC Once the direct drive input signal reaches 0 5VDC the control turns on the appliance pump and changes the modulating output to Start Modulation level until the flame is proved and then the modulating output is adjusted to track the direct drive input signal up to the maximum of 10VDC which is equivalent to maximum input rate When the direct drive signal modulates down to 0 5VDC the boiler operates at minimum fire When the signal drops below 0 5VDC the burner is shut off and the pump continues to circulate until the PUMP DELAY timer expires whereupon the pump shuts off The external boiler sequencer can specify the boiler inlet temperature However the BOIL MAX setting limits the highest temperature at the outlet sensor H 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 21 Mode 8 Piping amp Electrical Layout Modulating Modulating Camus S12 8 Smart Smart Sequencer Flame Flame ee system sensor Table 9 Input Voltage vs Modulation Rate mnmniiT An l L a DOLI at DN d VIO aUuaton 18 MICOFLA
66. rature is less than 130 F 55 C slowly close outlet valve until the inlet temperature climbs to 130 F 55 C d Ifthe inlet temperature is greater than 130 F 55 C but not greater than 140 F 60 C no further adjustment is required e Check the inlet temperature after 5 minutes and make final adjustments o gt 15 15 INSTANTANEOUS WATER HEATER An instantaneous water heater is designed to deliver hot water without the use of a storage tank It is suitable for applications with variable load such as restaurants condominiums apartments and motels See Figure 7 Call factory for recommendations Figure 7 Instantaneous Water Heater Suggested Piping 16 CONDENSING HEAT RECOVERY MODULE CHRM The MicoFlame All Stainless Steel CHRM is mounted in a stainless steel 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 in the discharge of the flue products from the primary heat exchanger This allows additional heat to be absorbed from the flue products exhausted from the combustion process If isolation valves are provided on the CHR
67. re 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 gom from B amp G system syzer At this increased flow Camus now recommends to increase the head loss 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 e For Outdoor installations a snow screen should be installed to prevent snow and ice accumulation around the appliance Regular inspections should be made to ensure that air intake and vent are free of snow and ice Always consider the use of a shelter such as a garden shed in lieu of direct exposure of the appliance to the elements The additional protection afforded by the shelter will help to minimize nuisance problems with electrical connections and will allow easier servicing of the appliance under severe weather conditions 10 WARNING REGARDING CHILLED WATER SYSTEM
68. rol each modulating heater can be regarded as one stage In this way the sequencer will lead lag or rotate the boilers properly One option Mode 8 on the BTC 1 allows the remote controller to initiate and modulate the boiler with a single 0 10V analog signal Refer to Table 8 for details Pre purge BTC 1 Modulation 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 pilot flame current is not at least on average 1 5 pA 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 the pilot flame is 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
69. steps 1 thru 7 Iu pu IT 2 TO TURN OFF BOILER Close main manual valve and main firing valve and turn off electric power to system 48 22 TROUBLESHOOTING GUIDE SYMPTOM SOLUTION 1 Power light is not lit when switch is e Check wiring to switch flipped to ON e Check circuit breaker e Check fuse e Check wiring to flow switch 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 Observe pilot for proper flame Adjust if necessary and then sparks again repeatedly Check pilot flame signal Properly set pilot to generate 1 5 uA D C on average Remove main burner and ensure that the 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 Verify that high limit is set high enough to prevent fire short cycling Check pilot flame signal uA Adjust pilot pressure for steady flame Remove main burner Check position of the igniter and ground electrode Clean with steel wool if necessary 6 Main burner lights but cycles off after Verify that high limit is set high enou
70. t 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 21 LIGHTING INSTRUCTIONS Turn off electric power to boiler Close main manual valve and main firing valve and wait 5 minutes Set primary system controller to desired temperature Open pilot valve Turn on electric power to boiler The electrode at the pilot should begin to spark after pre purge is complete The pilot valve will open to permit gas flow to the pilot There is a 15 second trial for ignition which is enough time to light the pilot if air is not present in the pilot line If pilot fails to light and you suspect air in the line close the main manual valve and repeat lighting steps 1 thru 5 7 Once the pilot lights it should envelope the ignition rod and ground electrode The pilot can be adjusted by removing the pilot regulator cover and turning the adjustment screw counter clockwise to decrease it or clockwise to increase it 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
71. the boiler will begin to modulate at 155 F and shut off at 165 F 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 Select the desired unit of measurement Parameter Range 1 to 8 Default 1 OFF 70 to 220 F OFF 21 to 104 C Default 120 F 82 C OFF 70 to 190 F OFF 21 to 88 C Default 140 F 54 C 2 to 10 F 1 to 5 C Default 3 F 1 C Au 2 to 42 F Au 17 to 5 C Default Au OFF 0 20 to 9 55 min On Default 1 00 min OF EE Default F 18 6 From the Home display MODE 4 8 5 OUTDOOR RESET OPERATION VIEW DISPLAY 1 Press ITEM to view the following parameters Display Parameter Description ird Outdoor Temperature n Boiler Target TARGET Temperature BOILSUP oystem Temperature Boiler Outlet Temperature Boiler Inlet Temperature Boiler Delta T Modulation Total Run Time Since Installation 60 to 190 F Real time Outdoor Temperature LEI to 88 C To provide a target setpoint for the heating system Setpoint is controlled to the inlet sensor 35 to 266 F 2 to 130 C System Temperature of Primary Loop 14 to 266 F 10to 130 C NOTE This parameter is only available in Mode 5
72. the heating system Setpoint is controlled to the inlet sensor Real time System Temperature 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 36 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 Parameter Range Modulation Real time modulating output 0 to 100 percentage Modulation Monitors the amount of operational time since the MicoFlame was installed The Total Run first two digits are the number of Time Since thousands of hours and the three Installation digit display shows the number of hundreds of hours Press 4 Y simultaneously to reset the counter Alternates between 00 and 999 18 9 MODE 6 amp 7 EXTERNAL TARGET TEMPERATURE INPUT OPERATION ADJUST DISPLAY From the Home display 1 Press ltem A Y simultaneously to view the following parameters Display Parameter Description Parameter Range Operating mode for the boiler NOTE A complete description of Poo each mode can be found in section 8 4 Modes of Operation in this manual To provide a modulation rate ADJUST above and below the Boiler Target temperature For example if the value is 10 F and the Boiler Target is 160 F
73. the total volume with the balance filled with air Start up boiler following instructions provided Operate entire system including pumps and radiation for at least 1 hour Check water level in expansion tank If level exceeds 1 of tank volume air is still trapped in system Shut down boiler and continue to run pumps Within 3 days of start up recheck all air vents and expansion tank as described above 13 IGNITION SYSTEM SAFETY SHUT OFF DEVICE After initial fill while the main burner is firing shut off gas to the pilot and clock the time taken for the main gas valve to shut down If the safety control is functioning properly power to the gas valve will be shut off within 4 seconds of the pilot gas being shut off If shut down takes longer ignition control or gas valve may be defective 14 14 LOW WATER TEMPERATURE SYSTEMS In applications where the heating system requires supply water temperatures below 130 F 55 C a bypass line must be installed upstream of the boiler pump so that outlet water can be re circulated to raise the inlet temp to a minimum of 130 F 55 C Balancing valves preferably globe valves are used to adjust flow See Figure 6 Alternatively a thermostatic mixing valve may be supplied available as a factory option Figure 6 Low Water Temperature System e Adjustment procedure Fully open bypass and outlet valves With boiler running read inlet temperature after 15 minutes c If the inlet tempe
74. ure difference Boiler Delta between the 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 010 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 Y simultaneously to reset the counter Alternates between 00 and 999 Total Run Time Since Installation 22 18 5 MODE 3 DEDICATED DOMESTIC HOT WATER OPERATION ADJUST DISPLAY From the Home display 1 Press ltem A Y simultaneously to view the following parameters SC Parameter Display Mama ADJUST Boiler Target Temperature DHW Target Temperature DHW Differential Differential Temperature Pump Delay Temperature Units 33 Parameter Description Operating mode for the boiler NOTE A complete description of each mode can be found in section 8 4 Modes of Operation in this manual To provide a target setpoint for the heating system Setpoint is controlled to the inlet sensor To provide a target setpoint for the DHW system Setpoint is controlled to the DHW sensor To provide a modulation rate above and below the DHW Target Temperature For example if the value is 10 F and the DHW Target Temperature is 160 F
75. used for temporary heating of buildings under construction 2 BOILER LOCATION Install this boiler in a clean dry location with adequate air supply and close to a good vent connection Do not locate this boiler in an area where it will be subject to freezing The boiler is suitable for installation on combustible flooring and should be located close to a floor drain in an area where leakage from the boiler or connections will not result in damage to the adjacent area or to lower floors in the structure If necessary a suitable drain pan should be installed under the boiler If the boiler is installed above the level of the building s radiation system a low water cutoff device must be installed in the boiler outlet at the time of installation Some local codes require the installation of a low water cutoff on all systems Table 1 Service Clearances REAR SIDES FRONT Table 2 Clearance to Combustibles VENT 6 gt FLOOR 0 For boiler s dimensions see Figure 1 and Table 3 Figure 1 Appliance Dimensions Model 400 600 W Ment Mon Condensit 3 33 Economizer Inlet A 23 1 8 221 8 Air Inlet Non Condensing Air Inlet Condensing in 40 1 Side View Left Front View Side View Right Side View Right Condensing Table 3 Appliance Dimensions inches B Dia Venting 100p1NO Duisuopuo5 JO EM9pIS O O 3 O O O O 5 5 1 MFNH300 MFNH400 MFNH500

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