Camus Hydronics MFH060 Installation, Operation And Service Manual
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Camus Hydronics MFH060 Installation, Operation And Service Manual

Modulating micoflame series gas fired residential and commercial copper tube boilers
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INSTALLATION OPERATION
AND SERVICE MANUAL
MODULATING MICOFLAME SERIES
GAS FIRED RESIDENTIAL AND COMMERCIAL COPPER TUBE
Non-Condensing Models; MFH060, 100, 150, 200, 250, 300, 400, 500, 600
Condensing Models; MFH062, 102, 152, 202, 252, 302, 402, 502, 602
Non-Condensing Models; MFW060, 100, 150, 200, 250, 300, 400, 500, 600
Condensing Models; MFW062, 102, 152, 202, 252, 302, 402, 502, 602
CAMUS
6226 Netherhart Road, Mississauga, Ontario, L5T 1B7
BOILERS
FOR HYDRONIC HEATING
HOT WATER SUPPLY
WARNING: If the information in these instructions is not
followed exactly, a fire or explosion may result causing
property damage, personal injury or death
•
Do not store or use gasoline or other flammable
vapours and liquids in the vicinity of this or any other
appliance.
•
WHAT TO DO IF YOU SMELL GAS
o Do not try to light any appliance,
o Do not touch any electrical switch; do not use any
phone in your building,
o Immediately call your gas supplier from a
neighbour's phone. Follow the gas supplier's
instructions,
o If you cannot reach your gas supplier, call the fire
department.
•
Qualified installer, service agency or the gas supplier
must perform installation and service.
To the installer: After installation, these instructions must be
given to the end user or left on or near the heater.
To the End User: This booklet contains important information
about this heater. Retain for future reference.
HYDRONICS
LTD.
99-0073
Rev. 00

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Summary of Contents for Camus Hydronics MFH060

  • Page 1 GAS FIRED RESIDENTIAL AND COMMERCIAL COPPER TUBE BOILERS FOR HYDRONIC HEATING Non-Condensing Models; MFH060, 100, 150, 200, 250, 300, 400, 500, 600 Condensing Models; MFH062, 102, 152, 202, 252, 302, 402, 502, 602 HOT WATER SUPPLY Non-Condensing Models; MFW060, 100, 150, 200, 250, 300, 400, 500, 600 Condensing Models;...

  • Page 3: Table Of Contents

    Table of Contents GENERAL INFORMATION ......................1 BOILER LOCATION........................2 PROVIDE AIR FOR COMBUSTION AND VENTILATION .............. 3 ELECTRICAL WIRING........................4 MODULATION SEQUENCE ......................4 GAS SUPPLY AND PIPING......................5 VENTING............................6 OUTDOOR VENTING ........................8 SIDEWALL VENTING........................9 OUTDOOR AIR KIT........................9 FILTER KIT ...........................
  • Page 4 20.3 SERVICE............................. 50 LIGHTING INSTRUCTIONS ......................50 TROUBLESHOOTING GUIDE ..................... 51 TYPICAL GAS TRAIN........................52 ELECTRICAL DIAGRAMS ......................53 24.1 MF 60 - 300 INTERNAL WIRING CONNECTION DIAGRAM ............54 24.2 MF 400 - 600 INTERNAL WIRING CONNECTION DIAGRAM ............ 55 24.3 MF 60 –...

  • Page 5: General Information

    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.

  • Page 6: Boiler Location

    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.

  • Page 7: Provide Air For Combustion And Ventilation

    Table 2: Appliance Dimensions, (inches) B' Dia. Venting E' Dia. Model MFNH060 18 3/4 1 1/2 MFNH100 18 3/4 1 1/2 MFNH150 18 3/4 1 1/2 MFNH200 18 3/4 1 1/2 MFNH250 1 1/2 MFNH300 1 1/2 MFNH400 31 1/2 MFNH500 31 1/2 MFNH600...

  • Page 8: Electrical Wiring

    ELECTRICAL WIRING All electrical wiring to the boiler must be electrically bonded to ground in accordance with the requirements of the authority having jurisdiction or, in the absence of such requirements, with the National Electrical Code, ANSI/NFPA 70 or the Canadian Electrical Code Part I, CSA C22.1, Electrical Code. Provide disconnecting means of sufficient rating within sight of the boiler.

  • Page 9: Gas Supply And Piping

    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.

  • Page 10: Venting

    Table 4: 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 NAT. L.P. NAT. L.P. NAT. L.P. 60,000 ¾”...
  • Page 11 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.

  • Page 12: Outdoor Venting

    Figure 2: Venting Arrangement 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. 2. Periodically check to ensure that air intake and vent cap are not obstructed. 3.

  • Page 13: Sidewall Venting

    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 centreline radius. See Table 2 for vent sizes. Boilers may be installed with either a horizontal sidewall vent or vertical roof top terminal.

  • Page 14: Venting For Condensing Application

    VENTING FOR CONDENSING APPLICATION When supplied with the optional condensing cartridge, the MicoFlame is 95% efficient (category II or IV appliance) which requires the use of a special venting system fabricated from AL29-4C 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.

  • Page 15: Accessories

    ACCESSORIES WATER FLOW SWITCH (shipped loose) A water flow switch is shipped loose and is to be installed in the outlet piping on all heating boilers and hot water supply boilers. The flow switch is wired in series with the 24VAC safety control circuit. A diagnostic light will be indicated on the control display on a low flow condition.

  • Page 16: Freeze Protection

    FREEZE PROTECTION • Appliance installations are not recommended outdoors in areas where danger of freezing exists unless precautions are taken. Maintaining a mixture of 50% water and 50% propylene glycol is the preferred method of freeze protection in hydronic systems. This mixture will protect the appliance to approximately -35ºF (-37ºC).

  • Page 17: Piping Of Boiler To System

    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.

  • Page 18: Placing Boiler In Operation

    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.

  • Page 19: Low Water Temperature Systems

    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).

  • Page 20: 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. (See Figure 7) Call factory for recommendations. Figure 7: Instantaneous Water Heater Suggested Piping CONDENSING HEAT RECOVERY MODULE (CHRM) The MicoFlame All Stainless Steel CHRM is mounted in a stainless steel chamber at the rear of the...
  • Page 21 Figure 8: Typical Condensing System 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.
  • Page 22 Table 6: CHRM Head Loss & Flow Model US GPM ∆P - Ft. 62 – 152 0.05 202 – 302 402 – 602 10.0 A neutralizer cartridge is provided and must be installed in the line from the condensate collection pot to the drain.
  • Page 23 Figure 10: Hydronic Heating Suggested Piping with CHRM Figure 11: Domestic Hot Water Suggested Piping with CHRM...

  • Page 24: Instrumentation And Controls

    INSTRUMENTATION AND CONTROLS 17.1 SAFETY CONTROLS High Temperature Limit The high temperature limit is located behind the appliance’s access doors. A remote capillary bulb runs to a thermo-well on the outlet side of the inlet/outlet header. The appliance high limit is set at the factory to 210ºF for hot water and 230ºF for heating.

  • Page 25: Setting The Appliance Temperature Controller

    • Error message display. • Test override feature to test pump operation and alarm. • 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.
  • Page 26 Figure 14: Mode 1 Piping & Electrical Layout 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 demand is generated when 24VAC is applied across CD (common demand) and Ht D (heat demand).
  • Page 27 Mode 3: Dedicated Domestic Hot Water Operation This mode is designed for domestic hot water. A DHW sensor must be 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.
  • Page 28 Figure 17: Mode 4 Piping & 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.
  • Page 29 Mode 6: External Target Temperature using Boiler Inlet Sensor The external input signal can be provided from a BMS, EMS or a tekmar tN4 System Control. The external input signal creates an internal demand and changes the boiler target according to a linear scale. The BTC 1 modulates the boiler to maintain the boiler target at the inlet sensor.
  • Page 30 Mode 7: External Target Temperature using System Temperature Sensor The external input signal can be provided from a BMS, EMS or a tekmar tN4 System Control. The external input signal creates an internal demand and changes the boiler target according to a linear scale. The control modulates the boiler to maintain the boiler target at the outlet sensor.
  • Page 31 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.

  • Page 32: Micoflame Control Panel

    MICOFLAME CONTROL PANEL Figure 22: BTC 1 Display Panel Figure 23: BTC Key Functions Table 8: BTC Key Functions KEY DESCRIPTION The abbreviated name of the selected item will be displayed in the item field of Item the display. To view the next item, press the Item button.

  • Page 33: General Symbol Description

    18.1 GENERAL SYMBOL DESCRIPTION SYMBOL SYMBOL SYMBOL NAME DESCRIPTION Shown when Boiler boiler pump is Pump in operation Shown when DHW pump is Pump in operation Shown when Heat heat demand is Demand present Shown when Flame flame signal is Proof proven Shown when...

  • Page 34: Mode 1 & 2: Setpoint Operation: View Display

    18.2 MODE 1 & 2: SETPOINT OPERATION: VIEW DISPLAY From the Home display; 1) Press [ITEM] to view the following parameters: Parameter Parameter Display Parameter Description Name Range To provide a target setpoint for the Boiler Target ---, 35 to 266 heating system.

  • Page 35: Mode 1 & 2: Setpoint Operation: Adjust Display

    18.3 MODE 1 & 2: SETPOINT OPERATION: ADJUST DISPLAY From the Home display; 1) Press simultaneously to view the following parameters: Parameter Parameter Display Parameter Description Name Range Operating mode for the boiler. 1 to 8 NOTE: A complete description of Mode each mode can be found in Default = 1...

  • Page 36: Mode 3: Dedicated Domestic Hot Water Operation: View Display

    18.4 MODE 3: DEDICATED DOMESTIC HOT WATER OPERATION: VIEW DISPLAY From the Home display; 1) Press [ITEM] to view the following parameters: Parameter Parameter Display Parameter Description Name Range To provide a target setpoint for the Boiler Target ---, 35 to 266 heating system.

  • Page 37: Mode 3: Dedicated Domestic Hot Water Operation: Adjust Display

    18.5 MODE 3: DEDICATED DOMESTIC HOT WATER OPERATION: ADJUST DISPLAY From the Home display; 1) Press simultaneously to view the following parameters: Parameter Display Parameter Description Parameter Range Name Operating mode for the boiler. 1 to 8 NOTE: A complete description of Mode each mode can be found in Default = 1...

  • Page 38: Mode 4 & 5: Outdoor Reset Operation: View Display

    18.6 MODE 4 & 5: OUTDOOR RESET OPERATION: VIEW DISPLAY From the Home display; 1) Press [ITEM] to view the following parameters: Parameter Parameter Display Parameter Description Name Range Outdoor -60 to 190 Real-time Outdoor Temperature Temperature (-51 to 88 To provide a target setpoint for the Boiler Target ---, 35 to 266...

  • Page 39: Mode 4 & 5: Outdoor Reset Operation: Adjust Display

    18.7 MODE 4 & 5: OUTDOOR RESET OPERATION: ADJUST DISPLAY From the Home display; 1) Press simultaneously to view the following parameters: Parameter Display Parameter Description Parameter Range Name Operating mode for the boiler. 1 to 8 NOTE: A complete description of Mode each mode can be found in Default = 1...

  • Page 40: Mode 6 & 7: External Target Temperature Input Operation: View Display

    Parameter Display Parameter Description Parameter Range Name Warm 35 to 105 F, OFF Weather Warm weather shutdown (2 to 41 C, OFF) Shutdown temperature using outdoor reset. Temperature Default = 0:20 min Temperature Select the desired unit of Units measurement Default = 18.8 MODE 6 &...

  • Page 41: Mode 6 & 7: External Target Temperature Input Operation: Adjust Display

    Parameter Display Parameter Description Parameter Range Name Real-time modulating output Modulation 0 to 100% percentage Monitors the amount of operational time since the MicoFlame was installed. The first two digits are the number of Total Run Alternates between thousands of hours and the three Time Since 00 and 999 Installation...

  • Page 42: Mode 8: External Drive Opeation: View Display

    18.10 MODE 8: EXTERNAL DRIVE OPEATION: VIEW DISPLAY From the Home display; 1) Press [ITEM] to view the following parameters: Parameter Display Parameter Description Parameter Range Name Boiler Outlet Real-time Outlet Temperature to 14 to 266 Temperature Boiler (-10 to 130 Boiler Inlet Real-time Inlet Temperature to 14 to 266...

  • Page 43: Mode 8: External Drive Opeation: Adjust Display

    18.11 MODE 8: EXTERNAL DRIVE OPEATION: ADJUST DISPLAY From the Home display; 1) Press simultaneously to view the following parameters: Parameter Parameter Display Parameter Description Name Range Operating mode for the boiler. 1 to 8 NOTE: A complete description of Mode each mode can be found in section Default = 1...
  • Page 44 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 Open The boiler will continue operation Test the inlet sensor and related wiring.

  • Page 45: Pilot And Main Burner Flames

    Error Message Description DHW Sensor Open The control will not operate the burner. Test the DHW sensor and related wiring. The error message will clear once the error condition is corrected and a button is pressed. Flame Proof Error Flame was not proved within 120 seconds of Demand 1 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.
  • Page 46 Figure 24: MicoFlame 60 – 300 Burner Assembly Figure 25: MicoFlame 400 – 600 Burner Assembly 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:...
  • Page 47 Table 9: Air Box Settings MODEL AIR BOX “ W.C. FLUE SWITCH RECYCLE POINT (with burner firing) “ W.C 0.20 0.15 0.25 0.20 0.30 0.25 0.35 0.30 0.38 0.33 0.40 0.35 0.80 0.70 0.90 0.80 1.00 0.90 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 10.

  • Page 48: Pilot Burner

    19.2 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.

  • Page 49: Start-Up

    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.
  • Page 50 MF 60 – 150 To adjust the high fire setting Set the Target Temperature to 190 F using the BTC 1 Controller. Figure 27: Venturi & Gas Valve Assembly Once the appliance is at maximum fan speed locate the input adjustment screw on the side of the venturi. Using a flat head screwdriver turn the screw clockwise to decrease CO levels and counter-clockwise to increase CO...
  • Page 51 MF 200 – 300 Figure 28: MF 200 – 300 Gas Valve To adjust the high fire setting Set the Target Temperature to 190 F using the BTC 1 Controller. Once the appliance is at maximum fan speed locate the high-fire adjustment screw on the top side of the gas valve.
  • Page 52 MF 400 – 600 Figure 29: MF 400 – 600 Gas Valve To adjust the high fire setting 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.
  • Page 53 Blocked Flue Switch The normally-closed blocked flue switch has been preset at the factory according to Table 9. 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.

  • Page 54: Service

    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.

  • Page 55: Troubleshooting Guide

    TROUBLESHOOTING GUIDE SYMPTOM SOLUTION • 1. Power light is not lit when switch is Check wiring to switch. • flipped to “ON” Check circuit breaker. • Check fuse. • 2. Water flow light remains off. Verify that pump is running. •...

  • Page 56: Typical Gas Train

    TYPICAL GAS TRAIN Figure 30: MicoFlame Modulation 60 – 300 Gas Train Figure 31: MicoFlame Modulation 400 – 600 Gas Train...

  • Page 57: Electrical Diagrams

    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.

  • Page 58: Mf 60 - 300 Internal Wiring Connection Diagram

    24.1 MF 60 - 300 INTERNAL WIRING CONNECTION DIAGRAM...

  • Page 59: Mf 400 - 600 Internal Wiring Connection Diagram

    24.2 MF 400 - 600 INTERNAL WIRING CONNECTION DIAGRAM...

  • Page 60: Mf 60 - 1000 Internal Wiring Ladder Diagram

    24.3 MF 60 – 1000 INTERNAL WIRING LADDER DIAGRAM...

  • Page 61: Exploded View

    EXPLODED VIEW...

  • Page 62: Micoflame Replacement Parts List

    MICOFLAME REPLACEMENT PARTS LIST MicoFlame Series Model Part Name Combustion Chamber 14-4075 14-4075 14-4075 14-4075 14-4055 14-4055 4005-01 4005-01 4005-03 Base Panel Combustion Chamber 14-4050 14-4050 14-4050 14-4050 14-4050 14-4050 14-4000 14-4000 14-4000 Common End Panel, Left Combustion Chamber 14-4051 14-4051 14-4051 14-4051...
  • Page 63 MicoFlame Series Model Part Name Combustion Chamber 14-4072 14-4072 14-4072 14-4072 14-4052 14-4052 4002-01 4002-01 4002-01 Rear Panel Flue Collector End 14-4058 2 Req'd Per Unit 14-4008 14-4008 14-4008 Bracket Combustion Chamber 14-4076 14-4076 14-4076 14-4076 14-4056 14-4056 Upper Front 4006-01 4006-01 4006-03...
  • Page 64 MicoFlame Series Model Part Name MicoFlame Modulating 77-0018 77-0018 77-0018 77-0018 77-0018 77-0018 77-0018 77-0018 77-0018 harness-1 burner Mico Modulating 77-0019 77-0019 77-0019 77-0019 77-0019 77-0019 77-0019 77-0019 77-0019 harness- Panel main (110V) Air Inlet Hole 14-4083 14-4083 14-4083 14-4083 14-4083 14-4083 14-4083...

  • Page 65: Warranty

    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.
  • Page 66 CAMUS Hydronics is a The CAMUS CERTIFIED! manufacturer Seal assures you that replacement parts for Reliability, Efficiency & most copper finned serviceability are built water heaters into every heating single unit! boilers as well more as a information supplier specialty...

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