INSTALLATION OPERATION AND SERVICE MANUAL MICOFLAME GRANDE GAS FIRED COMMERCIAL COPPER TUBE BOILERS FOR HYDRONIC HEATING Models; MFH2010, 2500, 3000, 3500, 4000 HOT WATER SUPPLY Models; MFW2010, 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 vapours and liquids in the vicinity of this or any other appliance.
Table of Contents 1 GENERAL INSTRUCTIONS ........................................................................................................... 1 2. LOCATION ....................................................................................................................................... 1 3. AIR REQUIRED FOR COMBUSTION AND VENTILATION ...................................................... 2 4. ELECTRICAL WIRING.......................................................................................
DHW application and is not covered by warranty. Camus Hydronics proudly introduces MicoFlame Grande commercial water heaters / hydronic boilers. The MicoFlame Grande boiler is a fan assisted boiler based on a push through design which offers several venting options. These gasburning appliances are thoughtfully designed for easy operation and maintenance. We are confident that you will come to appreciate the benefits of our product.
Figure 1 – Appliance Dimensions Table 2 – Appliance Dimensions B' Dia. Venting* Standard Air Inlet (Optional) ‘W' ‘S’ 54 ⅝” 33 3/8” 78 7/8” 58” 78 7/8” 58” 103” 81 ¾” 103” 81 ¾” Condensing or Sidewall ‘L’ 34 ⅝” 34 ⅝” 34 ⅝” 34 ⅝” 34 ⅝” Outdoor ‘K’ 68” 72” 72” 72” 72” Gas Connection ‘I’ 6” 6” 6” 6” 6” Water Connection Model MF2000 MF2500 MF3000 MF3500 MF4000 E' Dia.
4. Table 3 – Gas Pressures at Inlet to Appliance PROPANE NATURAL GAS Minimum (inches W.C.) 11 4 Maximum (inches W.C.) 11 7 ELECTRICAL WIRING All electrical wiring to the appliance 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.
6. d) Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so that appliance operates continuously. e) Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle or smoke from a cigarette.
Figure 2 – Venting Arrangement 3. Remove burner from appliance and vacuum the burner, and the heat exchanger. If heat exchanger is excessively dirty it may be necessary to remove it from the appliance and wash it down with proper detergent cleaner. Be aware that the combustion chamber base is insulated with ½” thick ceramic blanket. If this material is damaged or displaced it must be replaced before starting up the appliance. 4. Reinstall parts removed in steps 2 and 3.
6.2 STANDARD VENTING 6.4 The MicoFlame Grande is a category I appliance and is approved for venting into a common chimney provided it is in good condition and meeting the local Codes. Typically, the chimney will be ‘B’ vent or brick with clay or metal liner. If the chimney height is much greater than 30 feet or if drafts are in excess of negative 0.05” W.C., it may be beneficial to provide a single acting barometric damper directly above the vent collar.
6.6 Figure 3 – Typical Condensing System CONDENSER HEAT RECOVERY MODULE (CHRM) The MicoFlame Grande All Stainless Steel CHRM is mounted in a stainless steel inner jacket chamber at the back of the appliance. The CHRM is constructed from all stainless steel headers and special multiple horizontal stainless tubes. This CHRM is designed to maximize heat transfer efficiency by fully condensing flue products and is suitable to resist the low PH of condensate.
Minimum 3 feet above any forced air inlet located within 10 feet of vent termination. Minimum 4 feet below, 4 feet horizontally or above any door window or gravity air inlet. Minimum 4 feet horizontally from electric meters, gas meters, regulators and relief valves. Use appropriately designed thimbles when passing through combustible walls or roofs. Install fire stops where vent passes through floors, ceilings or framed walls. The fire stop must close the opening between the vent pipe and the structure.
7 The following Table 6 is provided as a guide. For application in areas known to have hard water conditions, or for soft water contact factory for recommendations. WATER PIPING CAUTION The MicoFlame Grande Series should be installed by qualified personnel. Table 6 – Flow vs. Head Loss for Various Temperature Rise 20 °F Model USGPM ∆P ft. 2000 170 5.1 2500 200* 8.2 3000 200* 8.2 3500 200* 10.2 4000 200* 10.2 30 °F Model USGPM ∆P ft. 2000 113 2.4 2500 141 4.3 3000 170 6.2 3500 198 10.2 4000 200* 10.
LOW WATER CUT-OFF (if equipped) If this boiler is installed above radiation level, a low water cut-off device must be installed at the time of boiler installation. Some local codes require the installation of a low water cut-off on all systems. Electronic low water cut-offs are available as a factory supplied option on all models. Low water cut-offs should be tested at least yearly. The normally open switch contact of the low water cutoff is to be wired in series with the flow switch.
When an appliance is connected to heating coils located in air handling units (where they may be exposed to refrigerated air circulation), the appliance piping system shall be equipped with a flow control valve or other automatic means to prevent gravity circulation of chilled water through the appliance. Chilled water in the appliance will create condensate on the appliance tubes, which will collect in the combustion chamber causing corrosion. 7.4 d.
Figure 7 – Typical Heating System Figure 8 – Typical Low Water Temperature System 12
Figure 9 – Typical Instantaneous Water System Figure 10 – Typical Water Heating System 13
Figure 11 – Typical Water Heating System 14
8 1. Readings of inlet and outlet water temperatures as well as ∆T temperature rise. 2. Six pre-set modes of operation; mode 1, 2, 4, and 5 for heating, mode 3 for DHW and mode 6 for operation by a remote controller. 3. Operation as an auto reset limit. 4. Operation as a control for inlet water temperature. 5. Optional tank mounted sensor used in conjunction with inlet sensor. 6. Adjustable pump delay feature based on ∆T temperature difference between inlet and outlet temperatures. Accepts 1/6 hp.
feature. In this case, it is imperative that the system pump operates continuously in order to provide constant circulation past the system sensor. The appliance pump then turns back on with the first stage of the appliance. If the heat demand is removed, the appliance is turned off and the control operates the appliance pump P1 based on the purge feature. settings allow the control to return to normal operation on its own. 2. Mode 1 is intended for hydronic heating.
5. Mode 4 is intended for hydronic heating. The set-point for inlet water control is pre-set to 180°F and the auto re-set limit is set to 230°F. The inlet set-point can be adjusted, however the limit is fixed. In addition to the auto reset limit the factory installs a manual re-set limit set to 250°F. The control turns on the appliance pump and stages the appliance to maintain outdoor reset target temperature at the appliance inlet temperature whenever an external heat demand is present.
Figure 13 – Components and Auxiliary Control Connections 8.3 CONTROL DEVICES Ignition Module There is one ignition module provided per burner. The ignition module is mounted on a rail just behind the outer jacket front access door. The ignition module provide ignition sequence, flame monitoring and safety shutoff for the pilot. Fan Manager There is one fan manager provided in the control box per fan. The fan manager provides start and stop time delay for pre-purge and post-purge duties.
9 not being tested; Set meter to µA DC: Connect one of the meter’s terminals to the burner ground terminal on the S8600 and the other terminal to the burner ground wire; Pilot running without main burner will generate 1.5 µA average for best operation. With main burner running, the signal will be in a range of 4.0 to 7.0µA. OPERATION The MicoFlame Grande appliance should be installed and started up by factory qualified personnel. 9.
Pressure Switch Settings The switches have been preset at the factory as per Table 11. The following description is for the benefit of the start-up technician should minor adjustment be required. Differential air pressure switches are provided to shut down the gas supply line under block flue condition. One pressure switch is provided per burner.
Table 8 – Firing Modes Model 2000 (Two Burners) Burner 1 Burner 2 Stage 1 Low Fire Low Fire Two Stages Stage 2 High Fire High Fire Stage 1 Low Fire Low Fire Three Stage 2 High Fire Low Fire Stages Stage 3 High Fire High Fire Stage 1 Low Fire Low Fire Stage 2 Low Fire Low Fire Four Stages Stage 3 High Fire Low Fire Stage 4 High Fire High Fire Table 9 – Firing Modes Model 2500 and 3000 (Three Burners) Burner 1 Burner 2 Burner 3 Stage 1 Low Fire Low Fire Low Fire Two Stages Stage 2 High Fire High Fire High Fir
9.3 OPERATION SQUENCE Demand Satisfied Boiler Temperature Controller senses that the boiler target temperature was reached and deenergizes the stage 1 contact. POWER ON Demand for heat BTC Staging control 30 seconds count down before energizing the first stage. Next the stage switch closes. Staging Control Alarms High limit or low water flow will de-energize all gas valves, and the blower. Condition indicators are visible on the control panel.
Table 11 – Typical air box settings 10 PILOT AND MAIN BURNER FLAMES MODEL 10.1. MAIN BURNER 2000 The main burner, figure 14 should display the following characteristics; 2500 • • • • • 3000 Acceptable CO and CO2 levels for complete combustion. Light off smoothly. Reasonably quiet while running. Stable flame with minimum of lifting.
• Figure 15 – Pilot and Burner Box Remove burner being careful to not damage the igniter or ground electrodes. 3. Thoroughly clean burner using water or air. Check all ports and air channels for blockage. 4. Reinstall the burner being careful to fully engage the back of the burner box into the retaining slot in the combustion chamber base. Failure to properly locate the burner will result in erratic flame operation with the possibility of delayed ignition on light off. 5.
11 To turn off appliance close main manual gas valve, close pilot manual valve and turn off electric power to system. SERVICE: OPERATION AND SERVICE OPERATION: Before operating the appliance, the entire system must be filled with water, purged of air and checked for leaks. Do not use Stop leak or other appliance compounds. The gas piping must also be leak tested.
12 line, close the main manual valve and repeat lighting steps 1 thru 5. 7. Once the pilot lights, it should envelope the ignition rod and ground electrode. The pilot can be adjusted by removing the pilot regulator cover and turning the adjustment screw counterclockwise to increase it or clockwise to decrease it. 8. Open the main manual and main firing valves to allow gas to reach the main burner. If the main burner fails to ignite, turn the firing valve off and check to see that the pilot is burning.
13 TROUBLE SHOOTING GUIDE SYMPTOM 1. Power light is not lit when switch is flipped to “ON” 2. Water flow light remains off. 3. Pilot sparks but does not light 4. Pilot lights momentarily, goes out and then sparks again repeatedly 5. Pilot lights but main burner does not fire. 6. Main burner lights but cycles off after a few minutes 7. Appliance starts to whine as the temperature rise increases. SOLUTION • Check wiring to switch. • Activate push button for latch relay if provided.
14 TYPICAL GAS TRAIN Figure 16 – Gas Train 15 ELECTRICAL DIAGRAMS Each MicoFlame Grande appliance will be provided with its own wiring diagram to guarantee that any options ordered with the unit are properly detailed. The following diagrams 99-5082-1 and 99-5082 are provided as typical samples only.
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16 EXPLODED VIEW MicoFlame Grande 31
17 EXPLODED VIEW MicoFlame Grande Outdoor and/or Condensing 32
18 MICOFLAME GRANDE REPLACEMENT PARTS LIST Part Number 1 Model Number Part Name 2000 Combustion Chamber End Panel - Left 14-4200 2500 14-4200 3000 14-4200 3500 14-4200 4000 14-4200 2 Combustion Chamber End Panel - Right 14-4201 14-4201 14-4201 14-4201 14-4201 3 Combustion Chamber Rear Panel 14-4202-20 14-4202-30 14-4202-30 14-4202-40 14-4202-40 4 Combustion Chamber Support - Left 14-4203 14-4203 14-4203 14-4203 14-4203 5 Combustion Chamber Support - Right 14-4204 14-4204 1
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.
CAMUS Hydronics is a manufacturer of replacement parts for most copper finned water heaters and heating boilers as well as a The CAMUS CERTIFIED! Seal assures you that Reliability, Efficiency & serviceability are built into every single unit! For more information supplier of specialty HVAC products. Our service line is open 24 hours, 7 days a week! on our innovative products from CAMUS Hydronics Limited, call 905-696-7800 today. CAMUS HYDRONICS LTD.
