Camus Hydronics Avenger Series Installation, Operation And Service Manual
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Camus Hydronics Avenger Series Installation, Operation And Service Manual

Gas fired commercial condensing stainless steel boilers
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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 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.
•
A Qualified installer, service agency or the gas supplier must perform installation and service.
Do not store or use gasoline or other flammable vapours and liquids in the vicinity of this or any other appliance.
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.
Installation, Operation and Service Manual
Gas Fired Commercial Condensing Stainless Steel Boilers
H
HLW
WARNING
WHAT TO DO IF YOU SMELL GAS
WARNING
Avenger® Series
Hydronic Heating Models ARH1000 thru ARH4000
Hot Water Heater Models ARW1000 thru ARW4000
99-0600 Rev.03

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  • Page 1 Avenger® Series Installation, Operation and Service Manual Gas Fired Commercial Condensing Stainless Steel Boilers Hydronic Heating Models ARH1000 thru ARH4000 Hot Water Heater Models ARW1000 thru ARW4000 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 .................................... 2 SEQUENCE OF OPERATION..................................2 1.4.1 HEAT TRANSFER PROCESS ................................3 1.4.2 END OF SEQUENCE ..................................4 CODES ........................................4 WARRANTY .........................................
  • Page 4 3.11 BURNER ........................................24 PART 4 WATER CONNECTION ..................................25 FREEZE PROTECTION ..................................... 25 WARNING REGARDING CHILLED WATER AND HEATING COIL SYSTEMS ..................26 INLET AND OUTLET CONNECTIONS ............................... 26 MINIMUM PIPE SIZE REQUIREMENTS ..............................26 HEAT EXCHANGER ....................................26 LOW WATER TEMPERATURE SYSTEMS ..............................
  • Page 5 PART 8 FIELD STARTUP PROCEDURES ................................ 55 CHECKING THE INSTALLATION ................................55 CHECKING THE CONSTRUCTION ................................55 GAS VALVE ADJUSTMENT PROCEDURE ............................... 55 COMISSIONING APPLIANCE ..................................59 PART 9 TROUBLESHOOTING ..................................60 PART 10 MAINTENANCE ....................................66 10.1 EXAMINE THE VENTING SYSTEM ................................66 10.2 VISUALLY CHECK MAIN BURNER FLAMES ............................

  • Page 6: 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 7: Checking Equipment

    CHECKING EQUIPMENT Check for signs of shipping damage upon receiving equipment. Pay attention to parts accompanying the boiler, which may show signs of mishandling. Verify total number of pieces shown on packing slip with those received. In case there is damage or a shortage, immediately notify carrier.

  • Page 8: Heat Transfer Process

    increases the modulation signal causes the Low-End Gas Valve to draw more gas. If the Low-End Gas Valve cannot satisfy demand, at a preset point the staging relay activates the Hot Surface Igniter to provide seamless transition to the High-End Gas Valve.

  • Page 9: End Of Sequence

    Consult and follow local Building and Fire Regulations and other Safety Codes that apply to this installation. Contact the local gas utility company to authorize and inspect all gas and flue connections. 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.

  • Page 10: Removal Of Existing Appliance

    Excessive water hardness causing a lime build-up on the stainless steel tubes is not a fault of the appliance and is not covered • by warranty. Consult the factory for recommendations for use in hard water areas (See Water Treatment and Water Chemistry). •...

  • Page 11: Boiler Room Operating Condition

    BOILER ROOM OPERATING CONDITION • Due to low jacket losses from the appliance, temperatures in a typical boiler room may drop significantly; supplemental heat is required to maintain ambient temperature at acceptable levels. Camus Avenger boilers are required to be vented as a Category II or IV condensing appliance. •...

  • Page 12: Installation Procedure And Location Of Unit

    1.10 INSTALLATION PROCEDURE AND LOCATION OF UNIT Install this appliance in a clean, dry location with adequate air supply. Do not locate this appliance in an area where it will be subject to freezing unless precautions are taken. Radiant losses from the •...

  • Page 13: Specifications And Dimensional Data

    1.11 SPECIFICATIONS AND DIMENSIONAL DATA Table 3: Appliance Dimensions and Specifications Model B (in.) C (in.) D (in.) E (in.) F (in.) G (in.) H (in.) I (in.) J (in.) K (in.) *L (in) (in.) 1000 29 1/2 51 1/2 14 7/8 53 7/8 67 1/8...
  • Page 14 Table 3A: Input / Output Model Input MBH Gross Output Turn-Down ARN-1000 1000 21:1 ARP-1000 1000 10:1 ARN-1500 1500 1,416 25:1 ARP-1500 1500 1,416 10:1 ARN-2000 2000 1,886 25:1 ARP-2000 2000 1,886 10:1 ARN-2500 2500 2,355 25:1 ARP-2500 2500 2,355 10:1 ARN-3000 3000...

  • Page 15: 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 16: Category Ii And Category Iv Venting

    2.1.1 CATEGORY II AND CATEGORY IV VENTING A Category II venting system operates with a negative pressure in the vent. A Category IV venting system operates with positive pressure generated by the internal combustion air fan which operates the combustion process and exhausts the flue products from the building. The Category II flues from multiple appliances can be combined into a common vent.

  • Page 17: Vent Termination Clearances

    NOTE Air Intake material must be of a type listed by a nationally recognized testing agency PVC Non-Foam Core Pipe. CPVC Non-Foam Core Pipe. Polypropylene ABS (Acrylonitrile-Butadiene-Styrene) Single Wall air intake pipes are to be insulated 5 feet from wall toward the interior of the building to minimize external sweating. 2.1.4 VENT TERMINATION CLEARANCES •...

  • Page 18: 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 19: 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 20: Conventional Venting (Indoor) Installations

    (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 21: Sidewall Venting

    SIDEWALL VENTING When fitted with vent terminals, the Avenger can vent up to 100 equivalent feet. Elbows can range from 7 to 19 feet in equivalent length depending on centerline radius. Refer to Table 3 for vent sizes. Appliances may be installed with either a horizontal sidewall vent or vertical roof top vent. Use approved single wall or double wall vent.
  • Page 22 Direct Vent Terminal Clearances Canadian Installations US Installations Clearance above grade, veranda, porch, deck, or 12” (30 cm) 12” (30 cm) balcony Clearance to window or door that may be opened 36” (91 cm) 12” (30 cm) Clearance to window or door that may be opened Clearance to permanently closed window Clearance to unventilated soffit Clearance to outside corner...

  • Page 23: 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 24: 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 25: Air/Gas Ratio Valve

    Table 7: Gas Pressures at Inlet to Appliance PROPANE NATURAL GAS Minimum (inches W.C.) Maximum (inches W.C.) *12.0 IN.W.C. for ARP-4000 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 appliance.

  • Page 26: Operation Of Negative Pressure And Differential Pressure Valves

    OPERATION OF NEGATIVE PRESSURE AND DIFFERENTIAL PRESSURE VALVES • Avenger models utilize both a negative pressure gas valve and a 1:1 air/gas ratio control valve. At the low end, these models operate on the principle of negative pressure and at the high end they operate on the principle of differential pressure. The differential air pressure measurement is made between the high and low pressure taps across the fan discharge and the •...

  • Page 27: Regulated Gas Supply Pressures For Avenger Boilers & Water Heaters

    3.7.1 REGULATED GAS SUPPLY PRESSURES FOR AVENGER BOILERS & WATER HEATERS A stable gas supply pressure is important to avoid rough starts with gas appliances such as Avenger boilers and water heaters, which use a 1:1 ratio control valve for internal gas pressure regulation. Camus requires that all Avenger models be supplied with no more than 14”...

  • Page 28: Gas Train And Controls

    GAS TRAIN AND CONTROLS NOTE: Illustrations below do not reflect actual gas train assemblies on these models. Figure 12: Typical Gas Train (Models AR1000-3000) Figure 13: Typical Gas Train (Models AR3500-4000)

  • Page 29: Venting Of Gas Valves And Pressure Switches

    3.10 VENTING OF GAS VALVES AND PRESSURE SWITCHES The optional gas pressure switches may be provided with threaded termination points to be vented to the atmosphere, outside the building. The gas pressure regulation function is provided by the ratio gas valve which does not require installation of a vent line. The optional gas pressure switches are installed in the upper chamber of the appliance.

  • Page 30: 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 (LWCO) device at the time of appliance installation (available from factory).

  • Page 31: Warning Regarding Chilled Water And Heating Coil Systems

    The requirement for the heat exchanger with water / glycol mixture will now be 115 gpm @ 15.6 feet. (ie. 1.2 x 13 ft. = 15.6 ft.) • • A similar procedure must be followed to calculate the additional head loss in pipe and fittings in order to select the proper pump. For outdoor installations in colder climates a snow screen should be installed to prevent snow and ice accumulation on and around the appliance.

  • Page 32: 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 applications with variable load such as restaurants, condominiums, apartments and motels and typically used in conjunction with tempering valves to achieve temperature control.

  • Page 33: Relief Valve

    Caution Remove jumper when connecting to 24 VAC circuit. Figure 18: Low Water Cut Off Electrical Connections (Safgard) Connection detail for placing L.W.C.O in 24V circuit WARNING: Be sure to remove the jumper between H and P1 Figure 19: Low Water Cut Off Electrical Connections (ITT) 4.11 RELIEF VALVE This appliance is supplied with a relief valve sized in accordance with ASME Boiler and Pressure Vessel Code, Section IV (“Heating...

  • Page 34: T Heat Exchanger Algorithm

    To select the proper pump, it is strongly recommended to consider the following: • Need to know the required flow (GPM) and pressure drop for your appliance (see Table 8). • Type of application: Hydronic Heating or Domestic Hot Water (DHW). For Hydronic Heating and DHW applications with normal water hardness choose a pump which will result in a temperature rise •...
  • Page 35 Figure 21: Recommended Piping with Reverse/Return and Variable Primary Flow...

  • Page 36: 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 Model Voltage Requirement Protection [Amperes] [Amperes] 1000 – 2000 115VAC, 60Hz 1000 –...

  • Page 37: Variable Frequency Drive

    To avoid serious damage, DO NOT ENERGIZE the appliance until the system is full of water. Ensure that all air is removed from • the heat exchanger pump housing and piping before beginning initial operation. Serious damage may result if the appliance is operated prior to purging of all air.

  • Page 38: Blocked Flue Switch

    Figure 122: Electronic Low Air Switch Large red numbers indicate actual real-time differential air pressure reading Small green numbers indicate differential air pressure setting “1” indicates air switch is open BLOCKED FLUE SWITCH All models use a normally closed automatic reset blocked flue switch to shut down the appliance under the following conditions: Air intake 50% blocked Vent outlet 80% blocked When the blocked flue switch has tripped, check the venting and/or air intake piping for obstructions before placing the unit into operation.

  • Page 39: Service Parts

    Figure 24: Ignition Module 5.7.1 SERVICE PARTS The electronic ignition module is not repairable. Any modification or repairs will invalidate the warranty and may create hazardous conditions that result in property damage, personal injury, fire, explosion and/or toxic gases. A faulty Hot Surface Igniter or ignition module MUST BE replaced with a new factory approved unit only.
  • Page 40 Table 11: Lockout Codes Description Unconfigured safety data Waiting for safety data verification 3-46, 58-60, 97-99, 143-148, 172-178 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 Stack limit tripped (PVC: 149...
  • Page 41 Table 12: Alert Codes Description Burner switch turned OFF Burner switch turned ON 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 Delta-T limit exceeded (70 °...

  • Page 42: 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 43 Figure 28: Home Screen Parameter Description Central Heating (ARH) Demand Domestic Hot Water (ARW) Lead Lag Burner State Current Status of Avenger Firing Rate Target Firing Rate Inlet Inlet Water Temperature [°F] Outlet Outlet Water Temperature [°F] Stack Stack Temperature [°F] DHW Temperature [°F], if equipped Header Header Temperature [°F], if equipped...
  • Page 44 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 45 Modulation: System Sensor, Outdoor Reset Operation (Standalone) NOTE: Outdoor Reset Module required (PN: W8735S1000) Description Electrical Connection(s) Programming Instructions Connect Remote Operator • Boiler operates with Connect System sensor to System/Outdoor contacts variable setpoint Connect Outdoor Sensor to J3 ECOM connector determined by outdoor Place toggle switch in LOCAL reset curve...
  • Page 46 4-20mA/ 0-10Vdc Setpoint Operation (Standalone) Description Electrical Connection(s) Programming Instructions Place toggle switch to LOCAL Boiler operates with • variable setpoint Press determined by 4-20mA Press [CH – Central Heat Configuration] incoming signal Press the to arrive at Setpoint Modulates on boiler •...
  • Page 47 DHW (Domestic Hot Water) Modulation: Boiler Inlet or DHW Sensor, Fixed Setpoint Operation (Standalone) Description Electrical Connection(s) Programming Instructions Place toggle switch to LOCAL Boiler operates at a • fixed DHW setpoint Press Modulates on boiler • Inlet Sensor operation inlet sensor (default) Press [DHW –...
  • Page 48 AR(H,W) Lead lag Operation Master Boiler Description Electrical Connection(s) Programming Instructions Place toggle switch 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 49 Slave Boiler Description Electrical Connection(s) Programming Instructions Place toggle switch 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. Outdoor temperature •...
  • Page 50 The control will proceed into a Lockout 2 condition Press [Verify] > [Begin] > [Yes] Press the reset button on the ignition control within the alotted time Master Boiler Press Press [Lead Lag Master Configuration] 10) Press [Advanced Settings >] to arrive at Outdoor Reset 11) Press the 12) Select Enable: Enabled...
  • Page 51 Base Load Rate Adjustment Description Electrical Connection(s) Programming Instructions Upon a call for heat the • Press lead boiler will fire up to Press [Lead Lag Master Configuration] the specified base load Press [Advanced Settings >] rate (80%). If the Press the to arrive at Rate Allocation temperature is not...
  • Page 52 Isolation Valve Operation (ALL Boilers) Description Electrical Connection(s) Programming Instructions Building pump varies flow through • boiler based on demand Press Sequence of operation where two or Select Pump Configuration more boilers or programmed to Scroll to Central Heat Pump operate in lead lag Select Pump start delay.

  • Page 53: 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 Avenger Model Number 6.2.2...

  • Page 54: 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 Statistics Burner run time Displays burner run time in hours Configuration Displays the number of cycles the CH pump has been...

  • Page 55: Sensor Configuration

    6.2.6 SENSOR CONFIGURATION Menu Group Sub-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 Configuration S5 (J8-11) sensor 10K NTC single non-safety...

  • Page 56: Local/Remote Switch

    When Local is selected via the DPDT switch, a constant enable signal is present. When troubleshooting the Avenger, it is recommended to switch to Local mode. MODBUS, BACNET IP, BACNET MSTP, LONWORKS, METASYSN2 INTEGRATION For detailed instructions on interfacing with Modbus/Bacnet/LonWorks/Metasys N2 Network, refer to Camus Hydronics website.

  • Page 57: Variable Frequency Drive

    VARIABLE FREQUENCY DRIVE 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 4-20 mA as standard reference source Min Freq.

  • Page 58: Part 7 Components

    PART 7 COMPONENTS HOT SURFACE IGNITOR 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 igniter since the silicon carbide element is brittle.

  • Page 59: Outer Jacket

    Avenger models feature a staging relay card which provides additional logic to open and close relays at factory set pre-determined points based on a Vdc signal provided by the VFD. These relays provide a means to activate/deactivate at various points in the boiler operation: Low-End and High-End Gas Valves (R1) Re-light Hot Surface Igniter (R2 &...

  • Page 60: 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 (return). Never pump away from the heat exchanger since this will result in a low-pressure zone, which will allow localized boiling and result in heat exchanger damage. Power to the boiler and pump must be from the same circuit to prevent the boiler firing in case the pump is accidentally shut off.
  • Page 61 Once the interface relay has switched to the High-End Valve, while maintaining the lowest possible water temperature, observe the differential gas pressure when running with the High-End Valve. The differential gas pressure must not drop below a minimum of 0.25” W.C.
  • Page 62 Move the firing rate slider to firing rate (%) indicated on test reports. Press [Start Test] to operate the boiler at this firing rate for 5 minutes. Increase CO Decrease CO High Fire Adjustment Counter- Clockwise 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.
  • Page 63 Turn the metering valve 1/8 turn in either way for each adjustment to keep track of the adjustments. After adjusting the valve wait a moment for the combustion levels to stabilize before attempting to make any further adjustments. Continue this procedure until combustion levels are satisfied.

  • Page 64: Comissioning Appliance

    • This boiler is designed for low fire soft start. At the start of trial for ignition the fan will decelerate to minimum fire and will light off at soft start speed before ramping up towards full input through the 4-20mA from the controller. •...

  • Page 65: 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 24 Volts and 120 Volts wired Transformer are interchanged • Breaker on transformer trips Tripped •...
  • Page 66 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 reads between 8” w.c. and 14” w.c. •...
  • Page 67 COMPONENT FAILURE MODE ANALYSIS • Fan does not rotate • Check fan power wires Fan Not Turning • Alert 122, 123, 128, 129, 130, 131, • Fan signal wires are interchanged • Minimum fan speed must be greater than 800 RPM •...
  • Page 68 Table 17: Alert Codes Description Burner switch turned OFF Burner switch turned ON Modulation Fault 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 Delta-T limit exceeded (70ºF) Ignition failure occurred Modulation rate was Limited due to outlet limit...
  • Page 69 Hold 63: LCI OFF (Load Control Input, Flow Switch, Interrupted Air Switch Blocked Flue Switch) Hold 67: ILK OFF (High Limit, Gas Pressure Switch) Alert 303-310: Abnormal Recycle: ILK off Alert 460: LCI lost in run These errors occur when one or 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 70 Alert 354: Abnormal Recycle Delta-T limit This safety was breached as the inlet and outlet temperature difference exceeded 70°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 71: Part 10 Maintenance

    Camus trained service technician utilizes 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 72: 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 process. The liquid condensate formed from this high efficiency heat transfer process is mildly acidic.

  • Page 73: 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 objects 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 74: 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. Re-install any panels, which were previously removed. • 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 75: 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 76: Water Connections

    11.4 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 77 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 78: Domestic Hot Water Heater

    Proven Pilot: AR3000 – AR4000 11.8 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 79: Temperature Rise At Full Firing Rate

    11.11 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 80: Part 12 Exploded View

    PART 12 EXPLODED VIEW Note: Some items may not be as shown. AVENGER PARTS LIST Figure A JACKET ASSMEBLY...
  • Page 81 JACKET ASSMEBLY Avenger Models ITEM Part Description Part Number FIGURE (S) 651-00390-000 651-00100-000 Primary Heat Exchanger 651-00115-000 651-00394-000 651-00391-000 EMKA Latch With Insert RH 043-00061-000 003-00249-000 HX Base 003-00251-000 003-00250-000 Electrical Box Assembly 848-02021-000 446-01750-000 446-01777-000 Jacket Frame 446-01783-000 446-01776-000 Junction Box Assembly 125-00555-000 136-00301-000...
  • Page 82 136-00106-000 136-00109-000 Outer Jacket Left Panel (Top) 136-00111-000 136-00107-000 136-00105-000 136-00110-000 Outer Jacket Side Panel (Bottom) 136-00112-000 136-00108-000 136-00106-000 136-00109-000 Outer Jacket Right Panel (Top) 136-00111-000 136-00107-000 019-00088-000 Top Cover 019-00091-000 019-00090-000 Literature Pocket 125-00458-000 019-00200-000 Bezel (Bottom) 019-00201-000 Bezel (Top) 832-18241-000 125-90027-000 Top Cover Front...
  • Page 83 Compression Latch >1” 043-00028-000 Compression Latch <1” 043-00028-000 Latch Frame Catch 043-00063-000 Honeywell Touch Screen 833-25171-000 12” Air Filter Assy. 125-00623-000...
  • Page 84 Figure B BLOWER & BURNER ASSEMBLY...
  • Page 85 BLOWER & BURNER ASSEMBLY Avenger Models ITEM Part Description Part Number FIGURE (S) Hot Surface Igniter 873-01045-000 UV Scanner 817-00654-000 853-09540-000 Graphite Gasket 853-09541-000 853-09554-000 853-09544-000 Red Silicone Gasket 853-09543-000 853-09552-000 853-09545-000 White Ceramic Gasket with 853-09542-000 Graphite Facing 853-09553-000 125-00518-000, (4”) 125-00507-000,...
  • Page 86 813-02817-000 813-02818-000 813-02819-000 813-02820-000 AF Fan Kit 833-25219-000 833-25208-000 833-25211-000 833-25215-000 090-05000-000 Air/Gas Mixing Tube 090-10301-000...
  • Page 87 Figure C TYPICAL GAS TRAIN AR1000-AR3000 Figure D TYPICAL GAS TRAIN AR3500-AR4000...
  • Page 88 GAS TRAIN ASSEMBLY Avenger Models ITEM Part Description Part Number FIGURE (S) 223-01371-000 223-01373-000 C, D A-Valve 223-01374-000 223-01375-000 223-01363-000 223-01367-000 C, D Firing Valve (Ball Valve) 223-01368-000 223-01369-000 223-01370-000 225-00883-000 225-00884-000 Metering Valve (Brass Gate C, D Valve) 225-00885-000 225-00925-000 C, D High End Gas Valve...
  • Page 89 Figure E CONTROL BOARD ASSEMBLY...
  • Page 90 CONTROL BOARD Avenger Models ITEM Part Description Part Number FIGURE (S) Sola Controller 833-25166-000 Control Box Mounting Plate 125-00566-000 Pump Delay Relay (up to 1hp) 959-05241-000 Transformer (75VA) 834-03852-000 Contactor Relay 175-00362-000 Gas Valve Staging Control 832-18259-000 Interface Relay 832-18299-000 833-25220-000 833-25209-000 VFD (460 Vac)
  • Page 91 ADDITIONAL PARTS Avenger Models ITEM Part Description Part Number FIGURE (S) On/Off Switch (with rainproof 817-11058-000 Not Shown cover) Inlet Sensor 817-04468-000 Not Shown Outlet Dual Sensor 817-04403-000 Not Shown Blocked Flue Switch 817-11046-000 Not Shown 817-11073-000 Differential Pressure Switch Not Shown 880-04535-000 Stack Sensor...

  • Page 92: Part 13 Electrical Diagrams

    PART 13 ELECTRICAL DIAGRAMS...

  • Page 107: 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 108 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 &...

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