Camus Hydronics ADVANTUS AVH 500 Installation, Operation And Service Manual
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Camus Hydronics ADVANTUS AVH 500 Installation, Operation And Service Manual

Camus Hydronics ADVANTUS AVH 500 Installation, Operation And Service Manual

Advantus series gas fired fire tube commercial condensing stainless steel boilers
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INSTALLATION OPERATION AND SERVICE MANUAL
ADVANTUS SERIES
GAS FIRED FIRE TUBE COMMERCIAL CONDENSING STAINLESS STEEL
Models; AVH 500, 600, 800, 1000, 1200, 1400, 1600, 1800, 2000, 2500, 3000, 3500, 4000
Models; AVW 500, 600, 800, 1000, 1200, 1400, 1600, 1800, 2000, 2500, 3000, 3500, 4000
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 vapors 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 neighbor'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 appliance.
To the End User: This booklet contains important information about this
appliance. Retain for future reference.
6226 Netherhart Road
HYDRONIC HEATING
HOT WATER HEATER
Mississauga, Ontario
L5T 1B7
Canada
™
BOILERS
H
HLW
P: 905.696.7800
F: 905.696.8801
www.camus-hydronics.com
99-0210 REV.00

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Summary of Contents for Camus Hydronics ADVANTUS AVH 500

  • Page 1 INSTALLATION OPERATION AND SERVICE MANUAL ADVANTUS SERIES ™ GAS FIRED FIRE TUBE COMMERCIAL CONDENSING STAINLESS STEEL BOILERS HYDRONIC HEATING Models; AVH 500, 600, 800, 1000, 1200, 1400, 1600, 1800, 2000, 2500, 3000, 3500, 4000 HOT WATER HEATER Models; AVW 500, 600, 800, 1000, 1200, 1400, 1600, 1800, 2000, 2500, 3000, 3500, 4000 WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death.

  • Page 3: Table Of Contents

    Table of Contents PART 1 GENERAL INFORMATION........................... 1 INTRODUCTION ..............................1 SPECIAL INSTRUCTIONS TO OWNER........................1 CHECKING EQUIPMENT ............................1 HOW IT OPERATES (SEQUENCE OF OPERATION) ....................2 1.4.1 HEAT TRANSFER PROCESS..........................3 1.4.2 END OF SEQUENCE............................3 CODES ..................................4 WARRANTY ................................
  • Page 4 GAS CONNECTION ............................... 16 GAS PIPING ................................16 INSTALL PIPING ..............................17 AIR/GAS RATIO VALVE ............................17 OPERATION OF NEGATIVE PRESSURE AND DIFFERENTIAL PRESSURE VALVES ........... 18 GAS MANIFOLD DIFFERENTIAL PRESSURE ADJUSTMENT (AV800-AV4000)............18 CHECKING GAS SUPPLY PRESSURE ........................18 3.7.1 REGULATED GAS SUPPLY PRESSURES FOR ADVANTUS BOILERS &...
  • Page 5 Advantus CONTROLLER ............................ 30 ERROR TABLE ............................... 31 PART 6 CONTROL PANEL.............................. 33 APPLIANCE TEMPERATURE CONTROLLER ......................33 CONFIGURE MENU .............................. 43 6.2.1 SYSTEM IDENTIFICATION & ACCESS......................43 6.2.2 PUMP CONFIGURATION..........................43 6.2.3 STATISTICS CONFIGURATION........................44 6.2.4 BURNER CONTROL TIMING AND RATES ..................... 44 6.2.5 BURNER CONTROL IGNITION ........................
  • Page 6 10.5.1 BURNER REMOVAL............................64 10.5.2 BURNER CLEANING PROCEDURE........................65 10.6 CHANGING THE HOT SURFACE IGNITER ......................65 10.6.1 RE-INSTALLING THE IGNITER........................65 10.7 HEAT EXCHANGER INSPECTION........................... 65 10.8 RE-INSTALL HEAT EXCHANGER ..........................66 10.9 COMBUSTION AIR FAN ............................66 10.10 COMBUSTION AND VENTILATION AIR ......................

  • Page 7: Part 1 General Information

    CAUTION It is important that all gas appliances are installed by a qualified installer/technician that is trained by Camus Hydronics Limited. It is in your own interest and that of safety to ensure that all local codes, and all the following “NOTES” and “WARNINGS” are complied with.

  • Page 8: How It Operates (Sequence Of Operation)

    Figure 2: Checking the Advantus Do not attempt to pry any panel off. To begin disassembly, you must first remove the two top panels (which can be lifted off without the use of tools). Only then will you be able to remove the front and two side panels. Once you have removed the two top panels, carefully check and confirm that all ¼”...

  • Page 9: Heat Transfer Process

    Figure 3: Advantus Ignition Cycle NOTE: If a flame signal is detected at the end of the pre-purge period, an error will occur. If at the end of the safety period (4 sec) no flame is detected, the control will go to post-purge to remove the unburned gas. After this, a re-ignition attempt is started following the same cycle.

  • Page 10: Codes

    Installation and service must be performed by Camus Hydronics Limited qualified factory trained service technicians. WARNING Should overheating occur or the gas supply fails to shut off, DO NOT turn off or disconnect the electrical supply to the pump. Shut off the gas supply at a location external to the appliance.

  • Page 11: Boiler Room Operating Condition

     If provided, test for spillage at the draft control device relief opening after 5 minutes of main burner operation. Use a co ld mirror, the flame of a match, or candle or smoke from a cigarette.  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.

  • Page 12: Installation Procedure And Location Of Unit

    Figure 4: Clearance from Combustibles When placing the appliance, be aware that a minimum clearance of 24” (60cm) must be provided at the front to allow easy acces s to the heat exchanger. When installed directly on carpeting, the appliance shall be installed on a metal or wood panel extending beyond the full width and depth of the appliance by at least 3 inches (76.2mm) in any direction, or if the appliance is installed in an alcove or close t, the entire floor shall be covered by the panel.
  • Page 13 Table 3: Appliance Dimensions and Specifications "W" “A” “B” “C” “D” “E” “F” “G” “H” “I” “J” “K” "L" "M" “N” “P” “R” "X" [Ø Weight Model [Øin.] [in.] [in.] [in.] [in.) [in.] [in.] [in.] [in.] [in.] [in.] [in.] [in.] [in.] [in.] [in.]...

  • Page 14: Part 2 Venting & Air Supply

    PART 2 VENTING & AIR SUPPLY DANGER It is extremely important to follow these venting instructions carefully. Failure to do so can cause severe personal injury, death or substantial property damage. DANGER Use of cellular core PVC (ASTM F891), cellular core CPVC or Radel® (polyphenosulfone) in venting systems is prohibited GENERAL VENTING GUIDE Figure 5: Venting Configurations OUTDOOR VENTING...

  • Page 15: Venting Guidelines For Category Ii And/Or Iv Venting

     The Category IV flue appliance must have all vent joints and seams sealed gas tight.  The flue products in the vent system will be cooled below their dew point and will form condensate in the flue. Flue construction must be of AL29-4C, 316L Stainless, S636 CPVC, S636 PPE. ...

  • Page 16: Vent Termination Clearances

    2.1.4 VENT TERMINATION CLEARANCES  Do not terminate the vent in a window well, stairwell, alcove, courtyard or other recessed area. The vent cannot terminate below grade. The bottom of the vent terminal shall be located at least 12 inches (30cm) above grade and above normal snow levels.

  • Page 17: Air Inlet Damper

    2.1.7 AIR INLET DAMPER In cold climates, it is essential to provide a motorized air inlet damper to control the supply of combustion air and prevent nuisance condensation. Each air inlet damper is designed to serve only one appliance and it must be electrically wired to the Air Inlet Damper Connection inside the junction box.

  • Page 18: Drain Tee

    2.1.11 DRAIN TEE Figure 8: Drain “T” and Neutralizer Cartridge Installation A drain line must be connected to the boiler condensate drain and to a tee installed in the vent pipe to collect and dispose of any condensate that may occur in the boiler and vent system. The drain tee should be installed at the point where the flue turns vertical for a roof top termination or as one of the first fittings in a horizontal flue that will terminate on a SIDEWALL.

  • Page 19: Air Required For Combustion And Ventilation

    (93.0298), it will be self-venting and suitable for outdoor installation. Outdoor models must be installed outdoors and must use the air intake and vent cap supplied by Camus Hydronics. Periodically check to ensure that air intake and vent cap are not obstructed.

  • Page 20: Location Of A Sidewall Vent Termination

    2.4.2 LOCATION OF A SIDEWALL VENT TERMINATION  The vent terminal shall terminate at least 3 feet (1m) above any forced air inlet within 10 feet (3m) horizontally.  The vent terminal MUST NOT terminate below a forced air intake at any distance. ...

  • Page 21: Location Of A Sidewall Air Inlet Terminal

    Room Air, Vent Terminal Clearances Canadian Installations US Installations Clearance above grade, veranda, porch, deck, or 12” (30 cm) 12 in (30 cm) balcony Clearance to window or door that may be opened 36” (91 cm) 4’ (1.2 m) below or to side of opening;...

  • Page 22: Part 3 Gas Connections

    PART 3 GAS CONNECTIONS Verify that the appliance is supplied with the type of gas specified on the rating plate. Consult factory for installations at high altitude. GAS CONNECTION  Safe operation of unit requires properly sized gas supply piping. See gas line sizing data. ...

  • Page 23: Install Piping

    INSTALL PIPING  The gas line should be sufficient to handle the total installed capacity. Verify pipe size with gas supplier.  Use new, properly threaded black iron pipe free from burrs. Avoid flexible gas connections. Internal diameter of flexible g as lines may not provide appliance with proper volume of gas.

  • Page 24: Operation Of Negative Pressure And Differential Pressure Valves

    Figure 10: AV800 – 4000: 1:1 Air/Gas Ratio Control Valve OPERATION OF NEGATIVE PRESSURE AND DIFFERENTIAL PRESSURE VALVES  The Advantus Models 500 & 600 both operate on the principle of negative pressure. As the fan varies in speed it generates a varying negative pressure at the fan suction which draws in a corresponding amount of gas.

  • Page 25: Regulated Gas Supply Pressures For Advantus Tm Boilers & Water Heaters

     Ensure inlet pressure is within specified range. Minimum and maximum gas supply pressures are specified in Table 7.  If gas pressure is out of range, contact the gas utility, gas supplier, qualified installer or service agency to determine necessary steps to provide proper gas pressure to the control.

  • Page 26: Gas Train And Controls

    The 1:1 air/gas ratio control actuator has embossed markings identifying + air, - air, + gas & - gas connections. Using a test hose assembly fitted with tees, connections can be made from the manometer to the appropriate ports on the actuator. ...

  • Page 27: Venting Of Gas Valves And Pressure Switches

    Figure 14: Typical Gas Train (Models AV2500-3000) Low End Gas Valve High Gas Switch Solenoid Valve Low Gas Switch A-valve Firing Valve Metering Valve High End Gas Valve Differential Gas Switch Figure 15: Typical Gas Train (Models AV3500-4000) Low End Gas Valve High Gas Switch Low Gas Switch A-valve...

  • Page 28: Burner

    3.11 BURNER Figure 16: Burner Metal Fiber This appliance uses a single cylindrical burner installed vertically into the cavity located in the center of the heat exchanger. The burner consists of a round mounting flange welded to a mixing tube. The top side of the mixing tube provides the transition which mounts the discharge from the combustion air fan into the burner.

  • Page 29: Part 4 Water Connection

    PART 4 WATER CONNECTION  Check all applicable local heating, plumbing and building safety codes before proceeding.  If the appliance is installed above radiation level, it must be provided with a low water cut-off device at the time of appliance installation (available from factory).

  • Page 30: Warning Regarding Chilled Water And Heating Coil Systems

    For outdoor installations in colder climates a snow screen should be installed to prevent snow and ice accumulation on and around the appliance. Regular inspections should be made to ensure that air intake and vent are free of snow and ice. Always consider th e use of a shelter such as a garden shed in lieu of direct exposure of the appliance to the elements.

  • Page 31: Instantaneous Water Heater

    INSTANTANEOUS WATER HEATER An instantaneous water heater is designed to deliver hot water without the use of a storage tank. It is suitable for applicat ions with variable load such as restaurants, condominiums, apartments and motels and typically used in conjunction with tempering valves to achieve temperature control.

  • Page 32: Low Water Cutoff (If Equipped)

    4.10 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.

  • Page 33: Circulating Pump Operation Of Heat Exchanger

    4.12.1 CIRCULATING PUMP OPERATION OF HEAT EXCHANGER MOST IMPORTANT This appliance is designed for continuous pump operation when the burner is firing. The pump control option allows the appliance circulating pump to be cycled “ON” prior to the burner firing and cycled “OFF” sometime after the set point is satisfied. The operation of the circulating pump is controlled by the Advantus temperature control (SOLA).

  • Page 34: Part 5 Electrical & Controls

    PART 5 ELECTRICAL & CONTROLS DANGER IT IS EXTREMELY IMPORTANT THAT THIS UNIT BE PROPERLY GROUNDED! ELECTRICAL CONNECTIONS Table 9: Minimum Power Requirements Maximum Over Current Full Load Amps Protection Model Voltage Requirement [Amperes] [Amperes] 500 – 1600 115VAC, 60Hz Δ...

  • Page 35: Variable Frequency Drive (Av800-4000)

    VARIABLE FREQUENCY DRIVE (AV800-4000) This appliance uses a VFD which provides power to the combustion fan. The fan motor operates on 230VAC 3 phase power. This three phase voltage is generated by the VFD and supplied directly to the fan motor. The VFD receives a 4-20mA modulating signal from the SOLA to vary the frequency of the voltage supplied to the fan motor.

  • Page 36: High Limit

    HIGH LIMIT A high limit aquastat control is located at the back of the appliance and the control bulb is installed in a dry well in the heat exchanger header outlet. The setting of this control limits maximum discharge water temperature. A manual reset high limit will have a red reset button which must be pushed whenever water temperature has exceeded the set point of the manual reset limit.

  • Page 37: Error Table

    ERROR TABLE The following tables provide a description of all the possible errors with the Advantus appliance. Errors can be divided into two groups. Alert errors (will disappear when error is gone) and lockout errors (can only be reset by the RESET button). When the control is in error, the pump will be running.
  • Page 38 Figure 26: Lockout History Press [Clear Lockout] Table 12: Alert Codes Description Burner switch turned OFF Burner switch turned ON Invalid subsystem reset request occurred Modulation Fault (DR300 – 1000 ONLY) Anti-short Cycle Fan speed not proved LCI off, safety circuit is open Setpoint was overridden due to sensor fault Modulation was overridden due to sensor fault Modulation rate was limited due to outlet limit...

  • Page 39: Part 6 Control Panel

    PART 6 CONTROL PANEL APPLIANCE TEMPERATURE CONTROLLER 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 (2) slotted screws and swinging the door open. The diagnostic information center as well as the on/off switch and the appliance temperature controls reside on the control box door.
  • Page 40 Figure 28: Home Screen Parameter Description Central Heating (AVH) Demand Domestic Hot Water (AVW) Lead Lag Burner State Current Status of Advantus Firing Rate Target Firing Rate (AV800-4000) Fan Speed Actual Firing Rate (AV500-600) Inlet Inlet Water Temperature [°F] Outlet Outlet Water Temperature [°F] Stack Stack Temperature [°F]...
  • Page 41 Hydronic Heating Modulation: Boiler Inlet, Boiler Fixed Setpoint Operation (Standalone) Description Electrical Connection(s) Programming Instructions Place toggle switch to LOCAL  Boiler operates at a fixed CH setpoint Press  Modulates on boiler Press [CH – Central Heat Configuration] inlet sensor (default) Press the to arrive at Setpoint ...
  • Page 42 13) Press [Show Line] to confirm reset curve 14) Press Sensor Configuration 15) Selet S5 (J8-11) sensor: 10K NTC single non-safety 16) Select Outdoor temperature source = EnviraCOM outdoor sensor Place toggle switch to REMOTE for remote enable operation (if required) System Sensor Enable (Standalone) Description Electrical Connection(s)
  • Page 43 4-20mA/ 0-10Vdc Setpoint Operation (Standalone) Description Electrical Connection(s) Programming Instructions Place both toggle switches in LOCAL  Boiler operates with variable setpoint Press determined by 4-20mA Press [CH – Central Heat Configuration] incoming signal Press the to arrive at Setpoint ...
  • Page 44 Modulation: Boiler Inlet, Fixed Setpoint Operation (Standalone) Description Electrical Connection(s) Programming Instructions Place both toggle switches to LOCAL  Boiler operates at a fixed DHW setpoint Press  Modulates on boiler Inlet Sensor operation inlet sensor (default) Press [DHW – Domestic Hot Water Configuration] ...
  • Page 45 AV(H,W) Lead lag Operation Master Boiler Description Electrical Connection(s) Programming Instructions Place both toggle switches to LOCAL  Master boiler lead lag setup Press  Modulates on system Select System Identification & Access sensor connected to Verify MB1 Modbus address = 1 master boiler Verify MB2 Modbus address = 1 ...
  • Page 46 Slave Boiler Description Electrical Connection(s) Programming Instructions Place both toggle switches to LOCAL  Slave boiler lead lag setup Press  System temperature Select System Identification & Access sensor must be Verify Modbus address. To be in sequential order connected to boiler #1. ...
  • Page 47 Master Boiler, System Sensor (Connected to Master Boiler #1) Description Electrical Connection(s) Programming Instructions  Master boiler system Press sensor configuration Press [Sensor Configuration]  System temperature Select S5 (J8-11) Sensor sensor must be Connector Type: 10K NTC Single Non-Safety connected to boiler #1.
  • Page 48 Rotation schedule adjustment Description Electrical Connection(s) Programming Instructions  Standard rotation Press schedule is based on Press [Lead Lag Master Configuration] equalizing run time on Press [Advanced Settings >] a 1-hour schedule Press the to arrive at Algorithms  To vary the rotation to a Select Lead selection method: Sequence order fixed schedule based Select Lag selection method: Sequence order...

  • Page 49: Configure Menu

    CONFIGURE MENU Figure 29: Configure Menu 6.2.1 SYSTEM IDENTIFICATION & ACCESS Menu Group Selection Parameter Description Product Type Commercial Hydronic Boiler OS number Part Number of SOLA Controller Software Version Software version System Identification & Access Date Code: Release date of software Boiler Name Advantus Model Number...

  • Page 50: Statistics Configuration

    6.2.3 STATISTICS CONFIGURATION Menu Group Sub-Menu Parameter Selection Description Selection Group Selection Displays the number of cycles the boiler pump has Boiler pump cycles been activated Displays the number of cycles the burner has been Burner cycles activated Burner run time Displays burner run time in hours Statistics Displays the number of cycles the CH pump has been...

  • Page 51: Sensor Configuration

    6.2.6 SENSOR CONFIGURATION Sub- Menu Group Menu Parameter Selection Description Selection Group Selection S1 (J8-4) sensor 10K NTC single non-safety Inlet Sensor S2 (J8-6) sensor 4-20mA 4-20mA Input Signal S3S4 (J8-8, 10) sensor 10K NTC dual safety Outlet Sensor Sensor Outdoor Sensor: Standalone boiler or Slave Configuration S5 (J8-11) sensor...

  • Page 52: Local/Remote Switch

    Wiring the Lead Lag Setup Use Cascade terminals in the juntion box to wire lead lag appliances Master Slave 2 Slave 7 J3, MB2 Figure 31: Lead Lag Wiring Setup (Left: Master, Right: Slave) NOTE Recycle power on all boilers after programming is complete if lag boilers are not discovered automatically NOTE CH Setpoint or DHW Setpoint must match Setpoint located in Lead Lag Master Configuration in order for the system to operate correctly.

  • Page 53: Variable Frequency Drive (Av800-4000)

    VARIABLE FREQUENCY DRIVE (AV800-4000) The VFD has 50 parameters, which can be adjusted. At present, only the following are pertinent: Table 13: Variable Frequency Drive Parameters Parameter # Function Settings Sets terminal strip as start/stop control Sets 4-20mA as standard reference source Min Freq.

  • Page 54: Part 7 Components

    PART 7 COMPONENTS HOT SURFACE IGNITER (GLOW BAR) The silicon carbide igniter is inserted directly through the fan flange and held in place by two screws. A hold down bracket as well as sealing gasket above and below the igniter assures a good seal. Care must be taken when removing and/or installing the ignit er since the silicon carbide element is brittle.

  • Page 55: Outer Jacket

    AV800-4000 Figure 34: Fan, Burner, Hot Surface Igniter and UV Scanner Arrangement (AV800 – 4000) Uses a sealed air fan to provide combustible air/gas mix to the burner and push the products of combustion through the heat e xchanger and venting system. The fan assembly consists of a sealed housing and fan wheel constructed from spark resistant cast aluminum. The fan is operated by a fully enclosed 230 VAC, 3-phase electric motor.

  • Page 56: Part 8 Field Startup Procedures

    PART 8 FIELD STARTUP PROCEDURES CHECKING THE INSTALLATION  Inspect the connections for water, gas and electricity.  Confirm that water is being pumped toward the heat exchanger inlet. Never pump away from the exchanger since this will result in a low-pressure zone, which will allow localized boiling and result in heat exchanger damage. ...
  • Page 57 The boiler must continue to run with stable combustion without making any howling noise which usually happens from an overly rich mixture. Once settings are complete at low fire, continue to run the machine for at least 5 more minutes and record the final low fire input and the combustion data.
  • Page 58 Increase CO2 Decrease CO2 High Fire Adjustment Counter-Clock Wise Clockwise 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. To adjust the low fire setting of the low end valve (AV800 – 4000) Use the Advantus Control Panel Press [DIAGNOSTICS] button...
  • Page 59 Use the Advantus Control Panel Press [DIAGNOSTICS] button Press [Diagnostic Tests] button Move the firing rate slider to 30.0% Press [Start Test] to operate the boiler at max fire for 5 minutes. Increase CO2 Decrease CO2 Low Fire Adjustment Clockwise Counter-Clock Wise When the correct combustion values are achieved replace the screw cap back on to the gas valve.
  • Page 60 Figure 39: Typical Gas Train (Models AV2500-3000) Low End Gas Valve High Gas Switch Solenoid Valve Low Gas Switch A-valve Firing Valve Metering Valve High End Gas Valve Differential Gas Switch Figure 40: Typical Gas Train (Models AV3500-4000) Low End Gas Valve High Gas Switch Low Gas Switch A-valve...

  • Page 61: Comissioning Appliance

    Table 15: Inline metering valve setting* LP Gas (Propane) Natural Gas Model # of Turns Clockwise # of Turns Clockwise 1 ½ 1000 1 ½ 1200 1 ½ 1400 1600 1800 2000 3 ¾ 2 ½ 2500 3 5/8 2 7/8 3000 3500 5 ¾...

  • Page 62: Part 9 Troubleshooting

    PART 9 TROUBLESHOOTING COMPONENT FAILURE MODE ANALYSIS • No effect on safety Incoming Power • Two wires interchanged • Live and Neutral wires are interchanged. • The 24Volts and 120 Volts wired Transformer are interchanged • Breaker on transformer trips Tripped •...
  • Page 63 COMPONENT FAILURE MODE ANALYSIS • Refer to Part 3 Gas Connection in this manual. • Supply Gas Issue • Natural Gas Pressure reads between 4” w.c. and 14” w.c. • L.P. Gas Pressure should be at 11” w.c. • Refer to Section 8.3 Gas Valve Adjustment Procedure for proper •...
  • Page 64 SYMPTOM FAILURE MODE ANALYSIS • Verify that the system is full of water and that all air has been • Manual Reset Safety High Limit properly purged from the system. tripped, outlet temperature in • Verify that the boiler is piped properly. Manual Reset High excess of 210 •...
  • Page 65 Table 16: Lockout Codes Description Unconfigured safety data Waiting for safety data verification 3-46 Internal Fault. Replace SOLA Controller Flame rod to ground leakage Static Flame 24VAC low/high Modulation Fault Fan speed not proved, ignition failure Interlock Off, safety circuit is open Heater Outlet high limit tripped Delta T Limit Stack limit tripped (PVC: 149...
  • Page 66 Alert 291: Abnormal Recycle: Flame was not on at end of ignition Alert 294: Abnormal Recycle: Flame was lost during Run Alert 324: Abnormal Recycle: Hardware flame bias Alert 377: Abnormal Recycle: Hardware flame bias delta This error occurs when a flame signal is not detected by the UV Scanner. A minimum signal of 0.8Vdc must be detected by the UV Scanner to prove the flame.
  • Page 67 Hold 63: LCI OFF (Load Control Input) Hold 67: ILK OFF (High Limit, Gas Pressure Switch, and Interrupted Air Switch) Alert 303-310: Abnormal Recycle: ILK off Alert 460: LCI lost in run This error occurs when one of more of the boiler safety switches are in an open condition when it is to be in a closed condition before the ignition sequence is allowed to proceed.
  • Page 68 Alert 354: Abnormal Recycle Delta-T limit This safety was breached as the inlet and outlet temperature difference exceeded 60°F. This is done to prevent damage to the heat exchanger. Before this error appears, the combustion air blower would have slowed down in an effort to prevent such an error from occurring.

  • Page 69: Part 10 Maintenance

    Camus trained service technician utilize a combustion analyzer to read CO CO and flue pressure according to Camus Hydronics recommendation. CAUTION Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation, verify proper operation after servicing.

  • Page 70: Condensation Treatment

    10.4 CONDENSATION TREATMENT This high efficiency appliance may operate as a condensing appliance for extended periods of time based on return water temperatures. Condensate occurs when the products of combustion are cooled below their dew point in the heat transfer proces s. The liquid condensate formed from this high efficiency heat transfer process is mildly acidic.

  • Page 71: Burner Cleaning Procedure

    NOTE When the combustion air fan is removed for any reason, the inlet to the burner must be covered to prevent further foreign obj ects from falling into the burner. Always look inside the burner to check for dents. Do not place a burner back into operation if the inner distribution screen has been dented during the service operation, call the factory for recommendations.

  • Page 72: Re-Install Heat Exchanger

    10.8 RE-INSTALL HEAT EXCHANGER  Carefully reinstall the heat exchanger if removed from the appliance  Cycle unit and check for proper operation  Replace the top cover 10.9 COMBUSTION AIR FAN Combustion air fan should be checked every 6 months. Clean the inlet screen and damper plate as required when installed in a dust or dirt contaminated location.

  • Page 73: Part 11 Installations

    PART 11 INSTALLATIONS WARNING Before starting the boiler smell near the floor, the interior of the boiler and around the boiler for any gas odors or any unusual odor. If there is any sign of a gas leak, do not proceed with startup. Repair all the leaks before attempting to start the boiler WARNING Propane boilers ONLY –...

  • Page 74: Water Connections

    11.5 WATER CONNECTIONS All models have groove locked inlet and outlet stainless steel connections. Pipe size must be in accordance with Table 3 and, between supply and return lines, must not exceed 80 feet of equivalent length. Any reduction in recommended pipe size may decrease flow resulting in high water temperatures, boiler noise, flashing to steam and non-warrantable heat exchanger damage.
  • Page 75 Boiler Operational Checks Turn the boiler main power switch to the “ON” position. Program the adjustable points. Turn the switch to the “ON” position to start boiler operation. Push the resets for low water level, high water temperature and alarm. Install a manometer on the gas supply to the boiler and verify minimum gas supply pressure as the burner fires at 100% of rated input.

  • Page 76: Domestic Hot Water Heater

    AV3000 – AV4000 11.9 DOMESTIC HOT WATER HEATER Hot water heaters are designed for installation with a storage tank. The operation of the properly sized circulating pump, the piping between the tank and heater and the control of water velocity, as explained below, are important for correct operation of your hot water heater.

  • Page 77: Temperature Rise At Full Firing Rate

    11.12 TEMPERATURE RISE AT FULL FIRING RATE The pump must run continuously when the burner is firing. With the pump running and the burner in the appliance in the off cycle, the inlet temperature and outlet temperature readings on the display should read approximately the same temperatures. Turn the hot water heater on and allow time for the temperature to stabilize.

  • Page 78: Part 12 Exploded View

    PART 12 EXPLODED VIEW...
  • Page 80 Blower Red Silicone Gasket Burner White Ceramic Gasket Graphite Gasket White Ceramic Gasket (only required if heat exchanger surface is rough or uneven)
  • Page 81 Advantus Models Ref# Part Description Part Number 109105 Base Stiffener 109301 109099 Condensate Tray Assembly 109350 109295 DR-14-1030 Electrical Box Assembly DR-14-1005 109114 Heat Exchanger Riser 109360 109306 Junction Box Assembly DF-14-5240A Mixing Chamber Assembly (Transition Arm) 109266 109102 109339 109353 Outer Jacket Back Panel 109368...
  • Page 82 Advantus Models Ref# Part Description Part Number 109743 Outer Jacket Left Panel (Top) 109745 109748 109103 109344 109354 Outer Jacket Right Panel (Bottom) 109369 109299 109315 109696 109733 Outer Jacket Right Panel (Top) 109744 109747 109749 Sight Glass Holder 13-5334 109108 Top Cover 109358...
  • Page 83 Advantus Models Ref# Part Description Part Number Sola Display S7999D1006 Terminal Block - 4 Pole TB200-4 Terminal Block - 6 Pole TB200-6 Terminal Block - 8 Pole TB200-8 Transformer (75VA) HCT-01J2BB07 Wiring Harness 77-0038 Advantus Kit Harness 77-0048 110008 Air Inlet Damper Assembly (Includes Siemens Electronic Damper Actuator) 110014 AF09 FAN KIT...
  • Page 84 Advantus Models Ref# Part Description Part Number 10-614-09 Relief Valve 10-615-15 10-616-15 VIC107-2 Victaulic Coupling VIC107-3 2” x ... Victaulic Stainless Steel Nipple (Inlet) 3” x ... 2” x ... Victaulic Stainless Steel Nipple (Outlet) 3” x ... 13-0026/16-0033 Air/Gas Mixing Tube 13-0027/16-0036 66-5005 50-GB5-01A...
  • Page 85 Advantus Models Ref# Part Description Part Number Gas Valve Regulator SKP25 45900450-030B Venturi VMU300A1046 109064 109730 Graphite Gasket 109542 109600 109691 109728 Red Silicone Gasket 109544 109599 109692 109729 White Ceramic Gasket with Graphite Facing 109543 109601 Air Vent (inlet) FV-4M1 Air Vent (Outlet) 590173...

  • Page 86: Part 13 Electrical Diagrams

    PART 13 ELECTRICAL DIAGRAMS...

  • Page 92: Condensing Boiler Limited 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.
  • Page 93 CAMUS Hydronics is a manufacturer of replacement parts for most copper finned and stainless steel water heaters and heating boilers as well as a supplier of specialty HVAC products. Our service line is open 24 hours, 7 days a week! The CAMUS CERTIFIED! Seal assures you that Reliability, Efficiency &...

This manual is also suitable for:

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