Camus Hydronics TH082 Installation, Operation And Service Manual
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Camus Hydronics TH082 Installation, Operation And Service Manual

Gas fired residential and commercial stainless steel tank heaters
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INSTALLATION OPERATION
AND SERVICE MANUAL
GAS FIRED RESIDENTIAL AND COMMERCIAL STAINLESS
WARNING:
If the information in these instructions is not followed
exactly, a fire or explosion may result causing property
damage, personal injury or death
Do not store or use gasoline or other flammable
vapours and liquids in the vicinity of this or any
other appliance.
WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliance,
o
Do not touch any electrical switch; do not
o
use any phone in your building,
Immediately call your gas supplier from a
o
neighbour's phone. Follow the gas
supplier's instructions,
If you cannot reach your gas supplier, call
o
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.
CAMUS
6226 Netherhart Road, Mississauga, Ontario, L5T 1B7
STEEL TANK HEATERS
TH SERIES
HOT WATER SUPPLY
Models; TH082 ,102, 152, 202, 252,
292, 392, 502
HYDRONICS
LTD.
H
HLW
99-0079
Rev. 0.3

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Summary of Contents for Camus Hydronics TH082

  • Page 1 GAS FIRED RESIDENTIAL AND COMMERCIAL STAINLESS STEEL TANK HEATERS TH SERIES HOT WATER SUPPLY Models; TH082 ,102, 152, 202, 252, 292, 392, 502 WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS PART 1 GENERAL INFORMATION ....................... 1 INTRODUCTION ........................1 SPECIAL INSTRUCTIONS TO OWNER ................... 1 CHECKING EQUIPMENT ......................1 DISPLAY UNIT .......................... 1 SEQUENCE OF OPERATION ....................1 1.5.2 Heat Transfer Process ......................2 1.5.3 End of Sequence ........................2 INSTALLATION CODES ......................
  • Page 4 5.4.2 Alert Codes ..........................17 PART 6 CONTROL PANEL ........................18 TH CONTROLLER ........................18 SETTING THE TH CONTROLLER ..................18 DOMESTIC HOT WATER OPERATION ................. 18 PART 7 COMPONENTS ........................18 DIRECT SPARK IGNITER ...................... 18 FLAME SENSOR ........................18 COMBUSTION AIR FAN ......................

  • Page 5: Part 1 General Information

    Camus Hydronics. The serviceman must utilize a 15) When the heat demand is satisfied or is removed the combustion analyzer with CO...

  • Page 6: Heat Transfer Process

    • Note: Boilers and water heaters are heat producing If a flame signal is detected at the end of the pre-purge appliances. To avoid damage or injury, do not store period a lockout will occur. materials against the appliance or the vent-air inlet If at the end of the safety period (6 sec) no flame is system.

  • Page 7: Removal Of Existing Appliance

    • Damage caused by freezing or dry firing voids Turn off electrical power and main manual gas shut-off and allow appliance to cool down. warranty. • Remove the vent pipe at connection to heat exchanger This appliance is not to be used for temporary and check heat exchanger and vent for obstruction and heating of buildings under construction.

  • Page 8: Clearance From Combustible Material

    • 1.11 CLEARANCE FROM COMBUSTIBLE The appliance must be installed so that the ignition system components protected from water MATERIAL (dripping, spraying, etc.) during appliance operation This appliance is suitable for alcove (a closet without a service (circulator replacement, control door) installation with minimum clearances to combustibles replacement, etc.) as follows:...
  • Page 9 Table 3: TH Service Clearances Service Clearance, Inches (cm) Input [BTU/hr] Front Right Side Left Side Rear 80,000 24” (61cm) 18” (46cm) 0” (0cm) 24” (61cm) 12” (31 cm) 100,000 24” (61cm) 18” (46cm) 0” (0cm) 24” (61cm) 12” (31 cm) 150,000 24”...
  • Page 10 Maintain minimum specified clearances for adequate operation. All installations must allow sufficient space for servicing the vent connections, water pipe connections, circulating pump, bypass piping and other auxiliary equipment, as well as the appliance Figure 3: TH Service Clearances...

  • Page 11: Part 2 Air Inlet And Venting

    • Vent connectors serving appliances vented by PART 2 AIR INLET AND natural draft shall not be connected into any portion VENTING of a mechanical draft system operating under positive pressure. • A UL listed concentric vent/air intake kit may be used It is extremely important to follow these venting with the TH.

  • Page 12: Approved Venting Materials Category Iv

    Table 6: Required Vent and Air Inlet Diameters NOTE Vent Option 3 not recommended for R-2000 homes or Equivalent Length of Vent & Air Intake equivalent air tight construction. Pipes at Recommended Diameter* Category IV 2.2.1 Approved Venting Materials Category IV Over PVC and CPVC (Chlorinated Polyvinyl Chloride) Input...

  • Page 13: Combined Combustion Air Inlet

    Figure 6: Sidewall Horizontal Configuration NOTE Sealed combustion is required when the TH is placed in a space with other fan-assisted appliances. COMBINED COMBUSTION AIR INLET The TH may be installed with a combined combustion air inlet. The combined combustion air inlet pipe sizing can be calculated using the method shown below: Equivalent pipe diameter = Sq Root [(d + (d...

  • Page 14: Sidewall Air Inlet

    2.5.2 Sidewall Air Inlet The termination shall not be installed closer than 3 feet (1m) from an inside corner of an L-shaped structure, Figure 7: Sidewall Vent and Air Inlet Configuration window well, stairwell, alcove, courtyard or other recessed area as wind eddies could affect boiler performance or cause recirculation.
  • Page 15 The vertical termination must be a minimum of 3 The termination MUST NOT terminate below a forced feet (1m) above the point of exit. air inlet at any distance A vertical termination less than 10 feet (3.05m) The termination cannot terminate below grade. Position from a parapet wall must be a minimum of 2 feet the termination where vapours will not damage walls or (0.61m) higher than the parapet wall.

  • Page 16: Part 3 Gas Connection

    • IN GENERAL PART 3 GAS CONNECTION • The operation of exhaust fans, compressors, air Verify that the appliance is supplied with the type of gas handling units etc. can rob air from the room, creating specified on the rating plate. Consult factory for installations a negative pressure condition leading to reversal of the at high altitude.

  • Page 17: Checking Gas Supply Pressure

    The appliance and its individual gas shut-off valve must be IMPORTANT disconnected from the supply piping when pressure testing Upon completion of initial installation or following any repair the gas supply piping at pressures above ½ PSI work on the gas system, leak test all gas connections with a soap solution while the main burner is firing.

  • Page 18: Burner

    Figure 14: TH 502 1:1 Air/Gas Ratio Control Valve Regulated Gas Supply Pressures for Tank Heater Lift top cover to access high fire A stable gas supply pressure is important to avoid rough air/gas ratio adjustment (use 3mm starts with machines like the Tank Heater which use a 1 to 1 allen key for adjustment, counter- ratio control valve for internal gas pressure regulation.

  • Page 19: Part 4 Water Connection

    Table 9: Minimal System Pipe Size PART 4 WATER CONNECTION Water Size, • Check all applicable local heating, plumbing and Input, building safety codes before proceeding. • Btu/Hr [in.] If the appliance is installed above radiation level it must be provided with a low water cut-off device at the time 80,000 of appliance installation (available from Camus).

  • Page 20: Flow Proving Device

    Table 10: Flow and Pressure Drop at a Given PART 5 ELECTRICAL & Temperature Rise (DHW) CONTROLS 20 °F (11.1 °C) Temp Rise Input, IT IS EXTREMELY IMPORTANT THAT THIS UNIT BE Btu/Hr PROPERLY GROUNDED! USGPM ∆ ∆ ∆ ∆ P Ft. (min.

  • Page 21: Service Parts

    5.4.1 Lockout Codes Table 11: Connector Description Table 12: Lockout Codes Connector Connector Description Description Flame Sensor, Ground Rod None Fan Modulation 1-31 Internal hardware error Display Flame rod to ground leakage 24VAC Power Static Flame 24VAC low/high Gas Valve, Safety Interlock String Fan speed not proved, ignition failure Safety Annunciation, Remote Operator Blocked flue condition...

  • Page 22: Part 6 Control Panel

    PART 6 CONTROL PANEL PART 7 COMPONENTS TH CONTROLLER 7.1 DIRECT SPARK IGNITER The appliance is provided with an operator interface panel The direct spark igniter is inserted directly through the at the front. The TH Controller can be accessed by combustion chamber front door and held in place by two torx removing the black-coloured top cover steel jacket which is screws.

  • Page 23: 7.3 Combustion Air Fan

    7.3 COMBUSTION AIR FAN TH uses a modulating air fan to provide combustible air/gas mix to the burner and push the products of combustion through the heat exchanger and venting system. The fan assembly consists of a sealed housing and fan wheel constructed from spark resistant cast aluminum.

  • Page 24: Part 8 Th Control Panel

    Figure 21: TH Home Screen PART 8 TH CONTROL PANEL INTRODUCTION TO THE TH CONTROL PANEL The menu structure for the TH Control Panel was designed to be intuitive and easy to use for a first time user. To maintain the TH boiler at its correct settings three levels of security is provided.

  • Page 25: User Mode

    USER MODE To access the User menu press the ‘Next’ button to scroll through the parameters. Display Display Readout Description Display current heater Supply/ Outlet Outlet Water Temperature Water Temperature. Display current heater Return/Inlet Inlet water Temperature Water Temperature Display delta T temperature [(Outlet Delta Temperature Temperature) –...

  • Page 26: Setup Mode

    SETUP MODE From User Mode: Press and hold the [UP]/[DOWN] buttons for 3 seconds. The ‘Setup’ icon will be displayed in the Operating Mode portion of the display. The user can change screens by pressing the ‘Next’ button NOTE: Accessing the Setup Mode will put the TH Control Board into Standby. If the heater is firing, the TH Control Board will post-purge and go to Standby.

  • Page 27: Diagnostic Mode

    Preset time must be satisfied before heater is allowed to start the ignition Anti-short cycle sequence. Range: 0 to 10 minutes Default: 0.3 A 3-digit code “225” is required to Password restore the controller to its default settings. A Plug-in Module (PIM) is (not used) required to perform a backup.
  • Page 28 Display Display Readout Description When stack temperature approaches this value the boiler will automatically reduce firing rate. If temperature continues to climb this will result in the boiler shutting down while displaying an alert code. Maximum Stack Temperature PVC: 149 F (65 CPVC: 194 F (90...

  • Page 29: Setting The Tank Heater Hs Controller

    SETTING THE TANK HEATER HS The screenshot below displays the default homescreen. Figure 22: Home Screen CONTROLLER Button Description Back button to return to previous menu The first five parameters can be user customizable to Information button reflect the most vital information required on the boiler. The list of available parameters is outlined in the table below.
  • Page 30 Figure 23: Diagnostic Screen Pressing provides additional temperature information. Figure 24: Temperature screen PARAMETER DESCRIPTION Boiler pump Pump A Auxilary Pump B. 3-way valve diverter operation Pump DHW Pump Pump C. Additional contact rated for 1/6hp. Sequence of Operation Pump A is energized on DHW Interlock: Flow switch, LWCO (if equipped), Blocked flue switch (N/C), Low gas switch (4.5”...
  • Page 31 Domestic Hot Water Programming Instructions Modulation: Fixed Setpoint Operation (Standalone) Description Electrical Connection(s) Programming Instructions • 1) Place both toggle switches in LOCAL Boiler operates at a fixed DHW setpoint 2) Press and select Login • Modulates on boiler inlet Select Advanced Setup sensor (default) •...
  • Page 32 Domestic Hot Water Setup Programming Instructions Adjust lightoff rate Description Programming Instructions • 1) Place both toggle switches in LOCAL Adjust ignition speed on lightoff 2) Press and select Login • This may need to be adjusted Select Advanced Setup to achieve smooth lightoffs cannot be achieved through combustion settings...
  • Page 33 View burner run time, pump cycles Description Programming Instructions • 1) Place both toggle switches in LOCAL To view burner run time, pump cycles for maintenance 2) Press and select Login and service purposes Select Advanced Setup 4) Select System Config 5) Select Statistics Config...

  • Page 34: Part 9 Troubleshooting

    PART 9 TROUBLESHOOTING COMPONENT FAILURE MODE ANALYSIS • Two wires interchanged • No effect on safety Incoming Power • Live and Neutral wires are interchanged. Transformer • The 24Volts and 120 Volts wired • Transformer immediately burns out, replace transformer Tripped are interchanged •...
  • Page 35 SYMPTOM FAILURE MODE ANALYSIS • The TH boiler was running and • Verify that minimum fan speed is greater than 2500 RPM • Verify that all air has been purged from gas line flame signal suddenly • Inspect spark electrode and related wiring for damage and disappeared.
  • Page 36 SYMPTOM FAILURE MODE ANALYSIS • Manual Reset Safety High Limit • Verify that the capillary tube is broken. If this is the case, tripped, supply/outlet temperature replace Manual Reset High Limit in excess of 210 • Verify that the system is full of water and that all air has Manual Reset High •...
  • Page 37 Ignition Failed displayed on screen Hold 109: Ignition failed An ignition error occurs when 3 consecutive attempts at lighting the burner have failed. This is a manual reset error where the technician must press OK to clear the error. Check ignition speed is between Adjust ignition speed 2500 to 3000 RPM using to 3000 RPM...
  • Page 38 Hold 67: ILK OFF (Flow Switch, LWCO, Gas Pressure Switch, Blocked Flue Switch) Alert 303: Abnormal Recycle: ILK off during drive to Purge Alert 304: Abnormal Recycle: ILK off during Measured purge time Alert 305: Abnormal Recycle: ILK off during Drive to Pre-igntion Alert 306, 307: Abnormal Recycle: ILK off during Pre-ignition Alert 308: Abnormal Recycle: ILK off during Main Flame Alert 309: Abnormal Recycle: ILK off during Ignition Period...
  • Page 39 Hold 67: ILK OFF (Flow Switch, LWCO, Gas Pressure Switch, Blocked Flue Switch) Alert 303: Abnormal Recycle: ILK off during drive to Purge Alert 304: Abnormal Recycle: ILK off during Measured purge time Alert 305: Abnormal Recycle: ILK off during Drive to Pre-igntion Alert 306, 307: Abnormal Recycle: ILK off during Pre-ignition Alert 308: Abnormal Recycle: ILK off during Main Flame Alert 309: Abnormal Recycle: ILK off during Ignition Period...
  • Page 40 Stack limit exceeded displayed on screen Alert 125: Modulation was limited due to stack limit Alert 353: Abnormal recycle: stack limit A flue gas error occurs when the stack temperature has exceeded the maximum limit allowed by the vent material. This is an automatic reset error, when the stack temperature drops 20 F below the limit allowed the boiler is allowed to restart and an ignition attempt is made if the call for heat is not yet satisfied.
  • Page 41 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 type of failure indicates a flame rectification signal issue through the flame rod. Fasten flame sensor plug securely Is Flame sensor plug to flame sensor wire and check for...

  • Page 42: Setting The Correct Combustion

    SETTING THE CORRECT COMBUSTION To adjust the high-fire setting on standard display Press and hold the ‘Next’ button for 3 seconds to enter the Switch the main power off to the boiler by placing the diagnostic menu on the TH Control Panel. Press ‘Next’ until toggle switch in the ‘OFF’...
  • Page 43 Figure 30: Low Fire Adjustment Screen Increase CO2 Decrease CO2 Low Fire Counter- Adjustment Clockwise Clock Wise To return to normal operation press ‘Done’. TH 292 – 392 To adjust the low fire setting on the upgraded display Figure 28: TH 292 – 392 Gas Valve Press the button Low-fire air gas ratio adjustment...

  • Page 44: Part 10 Maintenance

    It is important that all gas appliances be serviced by a adjustment to keep track of the adjustments. After adjusting qualified technician trained by Camus Hydronics. It is in your the screw wait a moment for the combustion levels to own interest and that of safety to ensure that all local codes, stabilize before attempting to make any further adjustments.

  • Page 45: Cleaning Boiler Heat Exchanger

    10.3 CLEANING BOILER HEAT EXCHANGER exchanger and slowly working your way towards the front of the heat exchanger. Figure 35: Heat Exchanger & Burner Assembly 15) Remove the water proof material after cleaning is complete. 16) Re-install the heat exchanger door by evenly torquing down the (6) nuts to 3 ft-lbs, burner, igniter and flame sensor, and fan/ mixing tube assembly.

  • Page 46: Igniter And Flame Sensor Electrodes

    • As the condensate migrates through the reservoir in typical Disconnect the gas supply connection to the fan applications the pH is controlled to a range of 5.5 to 6.0 inlet. before exiting the system. Always check with local codes for •...

  • Page 47: Combustion And Ventilation Air

    depending on the job site conditions. to be shut off in a space where danger of freezing Current NIOSH recommendations can be exists, the following precautionary measures must be found NIOSH website taken: http://www.cdc.gov/niosh/homepage.html. o Shut off gas supply. NIOSH approved respirators, o Shut off water supply.

  • Page 48: Part 11 Installations

    WARNING PART 11 INSTALLATIONS The condensate collection box must be filled with water to prevent flue gas emissions from escaping during boiler WARNING operation. Before starting the boiler, smell near the floor and around the CAUTION boiler for any gas odours or any unusual odour. Remove the A leak in a boiler “System”...

  • Page 49: Temperature Rise At Full Firing Rate

    10) Review the installed gas piping from the meter The TH uses stainless steel heat exchanger tubes to the boiler. Ensure that the gas pipe, meter which are not sensitive to higher water velocity. If and any regulators are adequately sized. temperature rise is lower than anticipated it is not 11) Review the field wiring and electrical service necessary to reduce flow.

  • Page 50: Ignition Cycle

    11.9 IGNITION CYCLE The ignition cycle is shown in the table below. The values are the default factory settings. Figure 36: TH Ignition Cycle...

  • Page 51: Part 12 Suggested Piping Diagrams

    PART 12 SUGGESTED PIPING DIAGRAMS Figure 37: Dedicated DHW Suggested Piping Arrangement Figure 38: Combination Application Suggested Piping Arrangement Note: Cold water piping should be below hot water connections to prevent heat migration during times of low heat demand...

  • Page 52: Part 13 Exploded View & Parts List

    PART 13 EXPLODED VIEW & PARTS LIST...
  • Page 53 Name of Part Part ID 14-5625 Outer Jacket - Left 14-5605 14-5629 Outer Jacket – Top Cover 14-5609 44-0008 Air Intake Adapter 300704 44-0010 Blocked Flue 8021205256 Switch Outer Jacket - 14-5604 Back Pump (Armstrong) E12B E33B VK8115V1341 Gas Valve VR8615B1044 V8730C1015 14-0379...
  • Page 54 Name of Part Part ID Outer Jacket – 14-5607 Front Bottom Bezel Support 14-5615 Inner Jacket – 14-5610 Front 15-0021 SS Tank 15-0014 Bracket for 14-5525 Neutralizer Box 90-15100 Condensate Neutralizer Box 90-10030 14-5631 HX Base Support 14-5611 14-5621 Support Leg 14-5601 14-5622 Stiffner under...
  • Page 55 Name of Part Part ID 221.042.001-A 221.039.001-A Burner 221.041.001-A 221.037.001-A 221.038.001-A Burner Gasket GM10-25-074-09 45900400-132/B Gas Valve Elbow 45900400-144/B 45900441-015B Gas Valve Wire Harness 45900400-144/B ½” Fire Valve USA0509101T 2” Diameter Flex Pipe 3” Diameter Metal Latch 6521-00-0551-YT Strike 7800-02 On/Off Switch C6000ALBBCHLI Standard Display...

  • Page 56: Part 14 Electrical Diagrams

    PART 14 ELECTRICAL DIAGRAMS 14.1 TH 82- 502 INTERNALWIRING DIAGRAM...

  • Page 57: Detailed Connector Description

    14.2 DETAILED CONNECTOR DESCRIPTION Pin # Connector Connector Description Pin # Connector Connector Description 24VAC Power, Outlet Sensor Flame Sensor and Ground 24VAC Not Used 24 VAC Return Flame Sensor Remote Operator Ground Not Used Not Used Outlet Sensor & High Limit Fan PWM Modulation Not Used 11-12...
  • Page 58 CONDENSING BOILER LIMITED WARRANTY Camus Hydronics Limited (“Camus”) extends the following LIMITED WARRANTY to the owner of this appliance, provided ANY OTHER PART that the product has been installed and operated in accordance with the Installation Manual provided with the equipment. Camus...
  • Page 59 CAMUS Hydronics is a The CAMUS CERTIFIED! manufacturer Seal assures that replacement parts Reliability, Efficiency & most copper finned serviceability are built water heaters into every heating single unit! boilers as well as more information supplier of specialty HVAC on our innovative products products.

This manual is also suitable for:

Th202Th152Th292Th392Th102Th502 ... Show all

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