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

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3.9

GAS TRAIN AND CONTROLS

NOTE: Illustrations below do not reflect actual gas train assemblies on these models.

Figure 12: Typical Gas Train (models AV500 & AV600)

Figure 13: Typical Gas Train (Model AV800)

Summary of Contents for ADVANTUS AVH 500

Page 1: ...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 dep...

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Page 4: ...VENTING MATERIALS 10 2 1 4 VENT TERMINATION CLEARANCES 11 2 1 5 INLET CAP FOR ROOFTOP TERMINATION 11 2 1 6 LOCATION OF A ROOFTOP AIR INLET AND VENT CAPS 11 2 1 7 AIR INLET DAMPER 12 2 1 8 MASONRY CHIM...

Page 5: ...MS 27 4 7 INSTANTANEOUS WATER HEATER 28 4 8 WATER HEATER THERMOSTAT SETTING 28 4 9 WATER FLOW SWITCH shipped loose 28 4 10 LOW WATER CUTOFF If Equipped 29 4 11 RELIEF VALVE 29 4 12 CIRCULATING PUMP SE...

Page 6: ...ONSTRUCTION 57 8 3 GAS VALVE ADJUSTMENT PROCEDURE 57 8 4 COMISSIONING APPLIANCE 64 PART 9 TROUBLESHOOTING 65 PART 10 MAINTENANCE 72 10 1 EXAMINE THE VENTING SYSTEM 72 10 2 VISUALLY CHECK MAIN BURNER F...

Page 7: ...4 HEATING BOILER INSTALLATIONS 76 11 5 WATER CONNECTIONS 77 11 6 PIPING LENGTHS 77 11 7 INTERMITTENT PUMP OPERATION 77 11 8 SUMMARY 77 11 9 DOMESTIC HOT WATER HEATER 79 11 10 WATER THERMOSTAT SETTING...

Page 8: ...air pressure which the air gas ratio control gas valve matches on the gas side The steady state efficiency is maintained across the entire range of modulation Air and gas are metered in precise propor...

Page 9: ...the Combustion Fan after internal safety checks are satisfied b AV800 AV4000 The Advantus controller closes the pump contacts to start the pump which then causes the Flow Switch to close once minimum...

Page 10: ...he Post Purge timer is satisfied 13 The pump continues to circulate until the Post Purge time is satisfied 14 The boiler will then go into Standby as it waits for the next heat demand or remote enable...

Page 11: ...er operation for proper gas combustion and proper venting 1 5 CODES The equipment shall be installed in accordance with those installation regulations enforced in the local area where the installation...

Page 12: ...mum size as determined using the appropriate tables in Chapter 13 of the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or the Natural Gas and Propane Installation Code CAN CGA B149 1 Installation Cod...

Page 13: ...el must be strong enough to carry the weight of the heater when full of water Note Clearances from combustible construction are noted on the appliance rating plate Maintain minimum specified clearance...

Page 14: ...e must be installed so that the ignition system components are protected from water dripping spraying etc during appliance operation and service circulator replacement control replacement etc Applianc...

Page 15: ...22 37 3 1 1700 2000 30 42 93 63 80 60 72 4 22 16 6 23 7 22 37 3 1 1900 2500 30 42 93 63 80 60 72 4 22 16 6 23 7 22 37 3 1 2200 3000 35 47 101 66 90 62 78 5 26 5 24 23 17 27 50 3 1 2500 3500 35 47 101...

Page 16: ...pplicable provisions of the local building codes The distance of the vent terminal from adjacent building windows that open and building openings MUST comply with the latest edition of the National Fu...

Page 17: ...tion location for recommended location and clearances For direct vent applications the maximum wall thickness must be between 0 5 12 1 2 cm to 30 cm 2 1 3 APPROVED VENTING MATERIALS Exhaust Vent for U...

Page 18: ...condensate on the vent cap can result in a blocked flue condition Some discoloration to exterior building surfaces can be expected Adjacent brick or masonry surfaces should be protected with a rust r...

Page 19: ...ry chimney must be capped and sealed to provide a dead air space around the sealed corrosion resistant liner Consult with local code officials to determine code requirements or the advisability of usi...

Page 20: ...all be provided as a drain line from the tee and from the boiler condensate line The drain tubing from the tee must have a trap provided by a 4 10 cm diameter circular trap loop in the drain tubing an...

Page 21: ...two permanent openings a Net free area for combustion air opening shall be in accordance with all applicable codes In the absence of such codes provide combustion air opening with a minimum free area...

Page 22: ...any forced air inlet within 10 feet 3 m horizontally The vent terminal MUST NOT terminate below a forced air intake at any distance Do not terminate the vent in a window well stairwell alcove courtyar...

Page 23: ...y 12 30 cm 12 in 30 cm B Clearance to window or door that may be opened 36 91 cm 4 1 2 m below or to side of opening 1 30 cm above opening C Clearance to window or door that may be opened D Clearance...

Page 24: ...R INLET PIPE The maximum total length of the sidewall or vertical roof top combustion air inlet pipe as installed from the appliance to the air inlet terminal must not exceed 100 equivalent feet 30 5...

Page 25: ...pressure through the valve to a safe location in accordance with local codes Follow table 5 for sizing the vent line Table 5 Gas Pressure Relief Valve Vent Manifold Sizing Chart Size of Combined Vent...

Page 26: ...control valve Operation of the gas valve in combination with the combustion air fan allows the burner input rate to vary from 10 to 100 based on temperature demand Model 800 utilizes a low end and a...

Page 27: ...ratio gas valve Adjustment of manifold pressure is not normally required for proper operation It may be necessary to adjust the low fire adjustment screw located on the ratio control valve actuator i...

Page 28: ...pressure to the control If gas supply pressure is within normal range proceed to remove gas manometer and replace pressure tap fittings in the gas piping to the appliance Turn on gas supply at the ma...

Page 29: ...ignal by up to 15 This will occur once the actuator has driven downwards as far as it can go The amount that the actuator has opened is registered by an indicator arm which is visible through the view...

Page 30: ...23 3 9 GAS TRAIN AND CONTROLS NOTE Illustrations below do not reflect actual gas train assemblies on these models Figure 12 Typical Gas Train models AV500 AV600 Figure 13 Typical Gas Train Model AV800...

Page 31: ...ot require installation of a vent line The optional gas pressure switches are installed in the upper chamber of the appliance Threaded vent line connections from components requiring an external vent...

Page 32: ...arth metals This alloy is designed to operate stress free as a burner port surface The burner port surface can sustain operation from a blue flame down to infrared conditions as the burner input varie...

Page 33: ...ump toward the heat exchanger inlet Never pump away from the exchanger since this will result in a low pressure zone which will allow localized boiling and result in heat exchanger damage The Advantus...

Page 34: ...nce The connection to the appliance marked Inlet on the header should be used for return from the system The connection on the header marked Outlet is to be connected to the supply side of the system...

Page 35: ...6 0 5 15 7 0 2 600 n a n a 56 6 2 6 28 3 0 6 18 9 0 3 800 6 6 0 03 74 8 4 5 37 4 1 1 24 9 0 5 1000 8 2 0 05 93 4 7 0 46 7 1 8 31 2 0 8 1200 9 9 0 02 112 2 2 0 56 1 0 5 37 4 0 2 1400 11 5 0 02 130 8 2...

Page 36: ...oilers The relief valve is to be installed in the vertical position and mounted in the hot water outlet No valve is to be placed between the relief valve and the appliance To prevent water damage the...

Page 37: ...r 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 heatin...

Page 38: ...31 Figure 23 Recommended Piping with Reverse Return and Variable Primary Flow...

Page 39: ...below 500VA transformer DC0500UH VFD Model Range n a AV500 AV600 ESV371N04TXB AV800 0 5hp ESV751N04TXB AV1000 AV1600 1hp ESV112N04TXB AV1800 AV2000 1 5hp ESV222N02YXB AV2500 AV3500 3hp ESV402N02TXB AV...

Page 40: ...ed at the fan outlet housing for models 500 600 and they are installed at the fan intake for models 800 4000 One point measures total pressure air and is connected to a pitot tube facing the flow The...

Page 41: ...below the minimum setting of the pressure switch the appliance will shut down and an open gas pressure switch will be shown on the display 5 6 HIGH LIMIT A high limit Aquastat control is located at th...

Page 42: ...n is located on the ignition module Turning the main power OFF and the ON or cycling the thermostat will not reset a hard lockout condition Wait until the display shows the temperatures on screen befo...

Page 43: ...ed OFF 30 Burner switch turned ON 50 Modulation Fault AV500 600 ONLY 61 Anti short Cycle 62 Fan speed not proved 63 LCI off safety circuit is open 68 Setpoint was overridden due to sensor fault 69 Mod...

Page 44: ...ault 357 DHW sensor fault 359 Inlet sensor fault 460 LCI lost in run 550 Delta T inlet outlet limit was exceeded 614 Lead boiler was rotated due to measured run time If an internal hardware fault is d...

Page 45: ...d outlet water temperatures as well as flame signal Operation as an auto reset limit Operation as a control for inlet water temperature outlet temperature system temperature 70 F T heat exchanger prot...

Page 46: ...Temperature F DHW DHW Temperature F if equipped Header Header Temperature F if equipped Outdoor Outdoor Temperature F if equipped Button Description Configure Access Advantus parameters CH Parameters...

Page 47: ...r Reset Configuration 5 Select Enable Enable 6 Select Maximum outdoor temperature WWSD 7 Select Minimum outdoor temperature Outdoor Design 8 Select Low Water Temperature Min Water Temp 9 Select Outdoo...

Page 48: ...ote enable operation if required System Sensor Enable Standalone Description Electrical Connection s Programming Instructions Method to enable system sensor for Standalone applications 1 Press and 2 P...

Page 49: ...A water temperature 7 Select 20mA water temperature 8 Place toggle switch to REMOTE for remote operation if required 4 20mA 0 10Vdc Firing Rate Operation Standalone Description Electrical Connection s...

Page 50: ...figuration 4 Select Demand Switch Modulation sensor only 5 Select Modulation sensor Inlet Sensor Proceed to Step 17 DHW Sensor Stat operation 6 Press Sensor Configuration 7 Select S6S7 J9 1 3 Sensor D...

Page 51: ...d 3 Select System Identification Access 4 Verify MB1 Modbus address 1 5 Verify MB2 Modbus address 1 6 Select Lead Lag Master Configuration 7 Select Master Enabled Enabled Fixed Setpoint operation 8 En...

Page 52: ...mit Master Boiler System Sensor Connected to Master Boiler 1 Description Electrical Connection s Programming Instructions Master boiler system sensor configuration System temperature sensor must be co...

Page 53: ...elect Outdoor boost maximum off point Design max 17 Press Show Line to confirm reset curve 18 Press the to arrive at Warm Weather Shutdown 19 Select Enable Shutdown after demand ends Rotation schedule...

Page 54: ...Instructions Upon a call for heat the lead boiler will fire up to the specified base load rate 80 If the temperature is not within Error threshold 5o F of setpoint after Interstage delay 2 minutes a l...

Page 55: ...pt 9 Lead boiler fires up to base load rate and both boilers modulate in unison up to 100 or as low as 4 based on heating demand 10 Lag boiler shuts down first when Lead lag temp Lead lag setpoint Dro...

Page 56: ...SOLA to control a Central Heating pump Default Auto Pump is activated whenever a call for heat is present ON ON Pump is constantly powered Pump Output Pump B Specify pump contact Over run time 1 5 mi...

Page 57: ...RATES Figure 33 Burner Control Timing and Rates Menu Group Selection Sub Menu Group Selection Parameter Selection Description Burner Control Timing and Rates Prepurge rate 3000 RPM Prepurge fan speed...

Page 58: ...modulation After a period of Interstage delay the master boiler compares the lead lag temperature with the lead lag set point and will check if 1 An additional boiler is needed Lead lag temperature L...

Page 59: ...g boilers 112 4 LOCAL REMOTE SWITCH The local remote switch mounted inside the control box is designed to deliver an enable signal either relying on an external contact closure Remote or enabling the...

Page 60: ...minimum signal Refer to factory test sticker report 161 Speed at maximum signal Refer to factory test sticker report 181 Skip Frequency 1 Refer to factory test report 184 Skip Frequency Bandwidth Refe...

Page 61: ...quired for reliable ignition It is recommended that the Hot Surface Igniter be replaced every 4 000 hours of appliance operation to maintain peak ignition efficiency 7 2 UV SCANNER The UV Scanner is s...

Page 62: ...outlet pipe Depending on the appliance category an increaser will be required for the proper vent configuration Please refer to Table 3 dimensions and specifications 7 6 CONDENSATION COLLECTION Depend...

Page 63: ...aw of the motor is proportional to the modulated gas input rate of the appliance AV800 4000 Figure 38 Fan Burner Hot Surface Igniter and UV Scanner Arrangement AV800 4000 Uses a sealed air fan to prov...

Page 64: ...itch icon becomes green Once all lights past the STAT are green the SOLA will try for ignition When the igniter is hot enough the gas valve actuator is energized and if ignition is accomplished the Bu...

Page 65: ...e to run with stable combustion without making any howling noise which usually happens from an overly rich mixture Once settings are complete at low fire continue to run the machine for at least 5 mor...

Page 66: ...t To adjust the high fire setting AV500 600 After the low fire settings are stable ramp the boiler firing rate to 100 using the boiler control and bring the system temperatures up to 130 F or to highe...

Page 67: ...adjustments Continue this procedure until combustion levels are satisfied When the correct combustion values are achieved replace the screw cap back on to the gas valve To adjust the high fire setting...

Page 68: ...4000 Two manometers should be connected to the Advantus before proceeding to the next step to simultaneously monitor the air and gas signal Refer to Section 3 8 of this manual for details on connecti...

Page 69: ...62 NOTE Illustrations below do not reflect actual gas train assemblies on these models Figure 42 Typical Gas Train Models AV500 600 Figure 43 Typical Gas Train Models AV800...

Page 70: ...63 Figure 44 Typical Gas Train Models AV1000 3000 Figure 45 Typical Gas Train Models AV3500 4000...

Page 71: ...t high fire first followed by low fire adjustment Allow the water temperature to rise so that the heater cycles on the operator Check the temperature rise across the heat exchanger This will be indica...

Page 72: ...t the vent air inlet piping if equipped are correctly installed and obstructions are not present Verify 24 VAC is being supplied to the Low End Gas Valve relay from the Advantus Controller during igni...

Page 73: ...impeller may be stuck Use a flat head screwdriver on face of pump to turn impeller manually If 120 VAC is present during a call for heat but the pump still does not circulate replace pump Delta T Lim...

Page 74: ...connections Check the UV Scanner and verify that viewing window is clean and scanner is not flashing Replace scanner Blank Display Screen Blank display screen Check wire connections from Advantus Cont...

Page 75: ...229 Lead lag slave communication timeout 275 281 LCI off safety circuit is open 283 Demand off during measured purge time 291 Abnormal Recycle Flame was not on at end of Ignition period 292 Abnormal R...

Page 76: ...Scanner A minimum signal of 0 8Vdc must be detected by the UV Scanner to prove the flame Models 800 4000 For High End Valve Staging relay switch over is factory set and normally does not require fiel...

Page 77: ...h Check flow switch paddle Check Low Water Cutoff if equipped Check system water level LWCO location High Limit Check high limit Reset high limit Gas pressure switch Low gas switch Check inlet gas pre...

Page 78: ...anger Before this error appears the combustion air blower would have slowed down in an effort to prevent such an error from occurring Verify pump motor load to pump rated load Purge air from water lin...

Page 79: ...ner view port is hot and direct contact could result in burns Figure 46 Normal Burner Flame Profile short dense and blue at full fire infrared at low fire Normal Flame A normal flame at 100 of burner...

Page 80: ...eutralized condensate may then be discharged into a suitable drain system without fear of damage to the drain system Always check with local codes for specific pH requirements Neutralizers may be used...

Page 81: ...nd remove the two screws that hold the igniter Lift the igniter vertically out of the burner mounting flange Use care do not hit or break the silicon carbide igniter DO NOT pull out by leads 10 6 1 RE...

Page 82: ...alarm is recommended for the mechanical room Damage to the appliance by freezing is non warrantable Location Heating boilers hot water supply boilers or water heaters must be located in a room having...

Page 83: ...vely to neutralize condensate to required level 6 Check pH level of condensate WARNING The neutralizer condensate collection box must be filled with water to prevent flue gas emissions from escaping d...

Page 84: ...iler and on the suction side of the system pump 6 Support all water piping b Placing the Boiler in Operation Pre Start Check List 1 Review the location of the boiler clearances from combustible surfac...

Page 85: ...attempt the boiler will proceed to an Ignition Error fault After this has been verified recycle power on the boiler and open the firing valve 8 Once the boiler is running and the flame has stabilized...

Page 86: ...ller as detailed in Section 6 2 The maximum setting for this water heater is 140 F 3 There is a hot water scald potential if the temperature controller is set too high 11 11 WATER FLOW CONTROL To ensu...

Page 87: ...tank to achieve the proper temperature rise The required temperature rise and the recommended pump size are based on the heating of potable water with normal hardness Consult the factory when heating...

Page 88: ...81 PART 12 EXPLODED VIEW Figure A...

Page 89: ...82 Figure B FAN BURNER ASSEMBLY AV500 600 some items may not be as shown...

Page 90: ...83 Figure C FAN BURNER ASSEMBLY AV800 4000 some items may not be as shown...

Page 91: ...84 Figure D Figure E...

Page 92: ...85 Figure F Figure G...

Page 93: ...86 Figure H CONTROL BOARD ASSEMBLY...

Page 94: ...001464 005 B x 8 Not Shown Blocked Flue Switch 8021205256 x 9 Not Shown Differential Pressure Switch NS2 1427 x x 93 7050 x x x x x x x x x x x 10 Not Shown Stack Sensor NTC SENSOR 003 x 11 B C Graphi...

Page 95: ...ket Base Stiffener 109324 x x x x x x x x x x 109327 x x x 22 A Outer Jacket Base Support Left 109106 x x x x 109356 x x x x x x 109302 x x x 23 A Outer Jacket Base Support Right 109107 x x x x 109357...

Page 96: ...x DR 90 10006 x x x x x x DR 90 10007 x x x x x 34 A Bezel Top DR 90 10004 x 35 A Top Cover Front Plastic 109279 x x x x x x x x x x 109326 x x x 36 A Condensate Box Assembly 109687 x COMBUSTION CHAM...

Page 97: ...B Venturi 45900450 030B x VMU300A1046 x 48 D G A Valve 50 GB5 01A x x x x x 50 GB6 01A x x x x 50 GB7 01A x x 50 GB8 01A x x 49 D G Firing Valve Ball Valve USA0759101 x x L L L L USA1009101 L L L L L...

Page 98: ...t 33 0037 x ELECTRICAL ELECTRONIC COMPONENTS 66 Not Shown 2 10Vdc Converter ETISO V x 67 H Pump Delay Relay up to 1hp 1649341 8 x 68 Not Shown Snap Action Thermostat EKA 114 58 x 69 A Sola Display S79...

Page 99: ...iler x L6008A1242 DHW x 83 H Contactor Relay T92P7A22 24 x x x x 84 H Gas Valve Staging Control RIBMN24Q4C PX x x x x x x x x x x x 85 Not Shown Indoor Flow Switch F61KB 11C x 86 Not Shown Water Press...

Page 100: ...93 PART 13 ELECTRICAL DIAGRAMS...

Page 101: ...94...

Page 102: ...95...

Page 103: ...repaired heat exchanger will be returned to the customer and a credit will not be issued Heat Exchanger shall be warranted for 20 years of the appliance having declared FOB from Camus against Thermal...

Page 104: ...ng 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 Serviceability are built in...

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