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Camus Hydronics MICOFLAME GRANDE Series, Installation, Operation And Service Manual

The Camus Hydronics MICOFLAME GRANDE Series guarantees seamless heating with its innovative technology and unmatched efficiency. Enhance your understanding of its installation, operation, and maintenance by accessing the comprehensive, user-friendly "Installation, Operation, and Service Manual" available for free download at manualshive.com.

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49 

Ref 

# 

Part Name 

Model Number 

2010 

2500 

3000 

3500 

4000 

22 

Outer Jacket Side 
Panel - Left 

14-4232 

14-4232 

14-4232 

14-4232 

14-4232 

23 

Fan Mounting 
Support - Right 

14-4233 

14-4233 

14-4233 

14-4233 

14-4233 

24 

Burner Door Stop 

14-4234 

14-4234 

14-4234 

14-4234 

14-4234 

25 

Heat Exchanger 
Header Stop Bar 

14-4238 

14-4238 

14-4238 

14-4238 

14-4238 

26 

Fan Mounting 
Support - Left 

14-4239 

14-4239 

14-4239 

14-4239 

14-4239 

27 

Burner Door 

14-4240 

14-4240 

14-4240 

14-4240 

14-4240 

28 

V Baffles 

14-4241-20 

14-4241-30 

14-4241-30 

14-4241-40 

14-4241-40 

29 

HX Front and 
Back Baffles 

14-4242-20 

14-4242-30 

14-4242-30 

14-4242-40 

14-4242-40 

30 

Sight Glass 
Assembly 

MF Sightglass 

31 

Outer Jacket Door 
Jam 

N/A 

N/A 

N/A 

14-4252 

14-4252 

32 

Heat Exchanger 
Support Weldment 

14-4253 

14-4253 

14-4253 

14-4253 

14-4253 

34 

Outer Jacket Top 
Panel Support 

14-4255 

14-4255 

14-4255 

14-4255 

14-4255 

35 

Control Panel 
Assembly 

14-4160 

14-4160 

14-4160 

14-4160 

14-4160 

37 

Three Tiles Burner 
Box Assembly 

14-4225 

14-4225 

14-4225 

14-4225 

14-4225 

38 

Economizer 
Cover* 

14-4146 

14-4265-01 

14-4265-01 

14-4265-01 

14-4265-01 

39 

Economizer 
Assembly* 

14-4148-03 

14-4266-01 

14-4266-01 

14-4266-01 

14-4266-01 

40 

Front Refractory 

17-0084-01 

17-0084-02 

17-0084-02 

17-0084-03 

17-0084-03 

41 

Rear Refractory 

17-0085-01 

17-0085-02 

17-0085-02 

17-0085-03 

17-0085-03 

42 

Inlet Outlet 
Header 

13-0040 

13-0040 

13-0040 

13-0040 

13-0040 

43 

Gas Train 

- 

- 

- 

- 

- 

44 

Common End 
Refractory 

17-0083 

17-0083 

17-0083 

17-0083 

17-0083 

45 

Gas Train 

- 

- 

- 

- 

- 

46 

Fan 

55-0001 

47 

Return Header 

13-0041 

13-0041 

13-0041 

13-0041 

13-0041 

48 

Primary Heat 
Exchanger 

15-0195-01 

15-0195-02 

15-0195-02 

15-0195-03 

15-0195-03 

49 

Economizer 

CAM-2000  

 CAM-4000  

CAM-4000   

CAM-4000   

CAM-4000   

50 

Control Panel 
Outdoor Cover** 

14-4245 

14-4245 

14-4245 

14-4245 

14-4245 

51 

Control Panel 
Outdoor Cover 
Door** 

14-4246 

14-4246 

14-4246 

14-4246 

14-4246 

Summary of Contents for MICOFLAME GRANDE Series

Page 1: ...ny 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 installa...

Page 2: ......

Page 3: ... DISPLAY 22 8 5 MODE 1 2 SETPOINT OPERATION ADJUST DISPLAY 23 8 6 MODE 3 SETPOINT OPERATION VIEW DISPLAY 24 8 7 MODE 3 SETPOINT OPERATION ADJUST DISPLAY 25 8 8 MODE 4 5 OUTDOOR RESET OPERATION VIEW DISPLAY 26 8 9 MODE 4 5 OUTDOOR RESET OPERATION ADJUST DISPLAY 27 8 10 MODE 6 OUTDOOR RESET OPERATION VIEW DISPLAY 29 8 11 MODE 6 OUTDOOR RESET OPERATION ADJUST DISPLAY 30 8 12 MODE 7 8 EXTERNAL TEMPERA...

Page 4: ......

Page 5: ... in the copper coils or tubes is not a fault of the boiler and is not covered by warranty Consult the factory for recommendations for use in hard water areas Excessive pitting and erosion on the inside of the copper tube may be caused by high water velocity or the use of an undersized boiler for a DHW application and is not covered by warranty Using or storing corrosive chemicals in the vicinity o...

Page 6: ...r Sections 7 2 7 3 or 7 4 of the current CAN CGA B149 Installation Codes and Applicable provisions of the local building codes The operation of exhaust fans compressors air handling units etc can rob air from the room creating a negative pressure condition leading to reversal of the natural draft action of the venting system Under these circumstances an engineered air supply is necessary If the he...

Page 7: ...PPLY This appliance is intended to operate at inlet gas pressures not exceeding PSI 14 W C The appliance and its individual gas shut off valve must be disconnected from the supply piping when pressure testing the gas supply piping at pressures above PSI Provide a trap drip leg as close to the heater as possible Install a good joint union and manual shut off valve in the gas line near the heater to...

Page 8: ...ny exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed do not operate a summer exhaust fan Close fireplace dampers 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 control device relief opening after 5 minutes of main burner operatio...

Page 9: ... in operation using lighting instructions provided 8 While the appliance is operating check for flue gas leaks and proper vent operation Seal any flue gas leaks using appropriate gasket or sealing material Carefully examine the flue collector access panel and heat exchanger ends The MicoFlame Grande is category 1 85 efficient when supplied as a non condensing appliance When supplied with the optio...

Page 10: ... 100 73 Standard When venting through unheated spaces with single wall vent insulation must be properly wrapped around the vent pipe to prevent flue gas condensation inside the vent Periodically check to ensure that the vent terminal is unobstructed The following vent materials are suitable for MicoFlame Non Condensing Category III installations 1 Corrosion resistant stainless steel single wall 2 ...

Page 11: ...ack 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 The CHRM must be supplied with adequate water flow at all times during operation Do not operate the appliance with the CHRM piped ...

Page 12: ... that pipe and fittings are clean by swabbing with alcohol Use Dow Corning 736 or 732 RTV Polybar 500 RTV or Sil bond 4500 or 6500 to seal vent pipe Do not use other sealants or adhesives except as expressly permitted by vent manufacturer s instructions Consult vent pipe manufacturer s instructions for vent system assembly Follow vent pipe manufacturer s instructions if those instructions differ f...

Page 13: ...erminal shall not be installed closer than 3 feet 1m from an inside corner of an L shaped structure The vent terminal should have a minimum clearance of 4 feet 1 25m horizontally from and in no case above or below unless a 4 foot 1 25m horizontal distance is maintained from electric meters gas meters regulators and relief equipment In all cases local codes take precedence Flue gas condensate can f...

Page 14: ... building or the combustion air inlet to any other appliance 36 91cm 12 30 cm K Clearance to a mechanical air supply inlet 6 1 83 m 3 91 cm above if within 10 3 m horizontally L Clearance above paved sidewalk or paved driveway located on public property 7 2 13 m α M Clearance under veranda porch deck or balcony 12 30 cm β 1 In accordance with the current CSA B149 1 Natural Gas and Propane Installa...

Page 15: ...of opening 1 ft 300 mm above opening J Clearance to nonmechanical air supply inlet to building or the combustion air inlet to any other appliance 36 91cm 4 ft 1 2 m below or to side of opening 1ft 30 cm above opening K Clearance to a mechanical air supply inlet 6 ft 1 83 m 3 ft 91 cm above if within 10 ft 3 m horizontally L Clearance above paved sidewalk or paved driveway located on public propert...

Page 16: ... the discharge of the appliance Suitable pipe hangers or floor stands must support the weight of all water and gas piping The appliance must be installed so that the gas ignition system components are protected from water dripping spraying rain etc during appliance operation and service circulator replacement control replacement etc Shut off valves must be installed at the inlet and outlet connect...

Page 17: ...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 A diagnostic light will be indicated on the control display on a low flow condition CAUTION Remove jumper between H P1 when connecting to 2...

Page 18: ...6 Figure 6 Typical Chilled Water System 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 ...

Page 19: ...red flow through the appliance is based on normal water hardness Water hardness above normal levels will require higher flow rates to prevent scaling and Copper Nickel heat exchanger tubes to prevent erosion Choose a pump for the local water hardness conditions Alternatively soften the water to normal hardness level The appliance could be fitted with an economizer secondary heat exchanger to achie...

Page 20: ...16 Figure 7 Typical Heating System ...

Page 21: ...17 Figure 8 Typical Low Water Temperature System Figure 9 Typical Instantaneous Water System ...

Page 22: ...the air and gas mixes The LED indicator for air flow will not illuminate should the pressure switch detect a sustained low air condition The appliance is provided with one air switch per burner module 8 2 CONTROL PANEL 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 thumb screw and opening the doo...

Page 23: ...ngs After checking the settings allow the control to return to normal operation on its own Mode 1 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 tu...

Page 24: ...based on the purge feature Mode 5 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 o...

Page 25: ...ctrical enclosure across the contacts to be used for connection to the remote operator Heat demand provided via external analog input signal from EMS or tN4 system control e g 420 The control turns on the boiler pump and operates the boiler to maintain the boiler target at the boiler inlet sensor whenever a heat demand is present Once the external heat demand is removed from the control the contro...

Page 26: ...rameters Display Parameter Name Parameter Description Parameter Range Boiler System Temperature Mode 2 ONLY Real time System Temperature to Boiler 14 to 266oF 10 to 130oC Boiler Outlet Temperature Real time Outlet Temperature to Boiler 14 to 266oF 10 to 130oC Boiler Inlet Temperature Real time Inlet Temperature to Boiler 14 to 266oF 10 to 130oC Boiler Delta T Real time temperature difference betwe...

Page 27: ...il Mass Mode 2 ONLY Thermal mass of boiler This determines interstage delay and minimum on and minimum off times 1 to 3 Default 1 Differential Temperature To start the boiler below the Boiler Target temperature For example if the value is 10oF and the Boiler Target is 160oF the boiler will begin to modulate at 150oF and shut off at 170oF Au 2 to 42oF Au 17 to 6oC Default 10oF Stage Differential Di...

Page 28: ...nge Boiler Outlet Temperature Real time Outlet Temperature to Boiler 14 to 266oF 10 to 130oC Boiler Inlet Temperature Real time Inlet Temperature to Boiler 14 to 266oF 10 to 130oC Boiler Delta T Real time temperature difference between the outlet sensor and the inlet sensor 99 to 252oF 72 to 140oC Tank Temperature Real time Tank Temperature to Boiler 14 to 266oF 10 to 130oC Total Run Time Since In...

Page 29: ... modulation rate above and below the Tank Target Temperature For example if the value is 10oF and the Tank Target Temperature is 160oF the boiler will begin to modulate at 150oF and shut off at 170oF 2 to 10oF 1 to 5oC Default 3oF 1oC Boil Max Maximum boiler target temperature 120 to 225oF 48 to 107oC Default 210oF 99oC Differential Temperature To start the boiler below the Boiler Target temperatu...

Page 30: ...ge Outdoor Temperature Real time Outdoor Temperature 60 to 190oF 51 to 88oC Boiler System Temperature Real time System Temperature to Boiler Mode 5 ONLY 14 to 266oF 10 to 130oC Boiler Outlet Temperature Real time Outlet Temperature to Boiler 14 to 266oF 10 to 130oC Boiler Inlet Temperature Real time Inlet Temperature to Boiler 14 to 266oF 10 to 130oC Boiler Delta T Real time temperature difference...

Page 31: ...t annual outdoor temperature in the local area 60 to 50oF 51 to 10oC Default 10oF 23oC Boiler Start Temperature Starting water temperature used in the reset ratio calculation for the heating system Typically set to the desired building temperature 35 to 150oF 2 to 66oC Default 70oF 21oC Boiler Design Temperature Boiler design water temperature used in the reset ratio calculation for the heating sy...

Page 32: ...e 6oF below setpoint Au 2 to 42oF Au 17 to 6oC Default 10oF On Delay Interstage delay to activate the next stage 0 10 to 8 00 minutes Default 1 00 minute Minimum On Time Minimum on time for each stage 0 10 to 5 00 minutes Default 0 30 minute Minimum Off Time Minimum off time for each stage 0 10 to 5 00 minutes Default 0 50 minutes Pump Delay Boiler post pump time after burner has shut off in secon...

Page 33: ...ler Inlet Temperature Real time Inlet Temperature to Boiler 14 to 266oF 10 to 130oC Boiler Delta T Real time temperature difference between the outlet sensor and the inlet sensor 99 to 252oF 72 to 140oC Total Run Time Since Installation Monitors the amount of operational time since the unit was installed The two digits are the thousands of hours and the three digit display shows the hundreds of ho...

Page 34: ...post pump time after burner has shut off in seconds OFF 0 20 to 9 55 min On Default 1 00 min Temperature Units Select the desired unit of measurement oF oC Default oF 8 12 MODE 7 8 EXTERNAL TEMPERATURE TARGET OPERATION VIEW DISPLAY From the Home display 1 Press ITEM to view the following parameters Display Parameter Name Parameter Description Parameter Range Boiler Outlet Temperature Real time Out...

Page 35: ...Parameter Range Mode Operating mode for the boiler 1 to 8 Default 1 Boil Max Maximum boiler target temperature 120 to 225oF 48 to 107oC Default 210oF 99oC Boil Min Minimum boiler target temperature 80 to 180oF 26 to 82oC Default 130oF 54oC Differential Temperature To start the boiler below the Boiler Target temperature For example if the value is 10oF and the Boiler Target is 160oF the boiler will...

Page 36: ...shut off in seconds OFF 0 20 to 9 55 min On Default 1 00 min External Input Signal Mode 8 ONLY Select the range for the external input signal that adjusts the boiler target 0 10 or 2 10 Default 0 10 Offset Mode 8 ONLY Select the amount of temperature offset to add to the boiler target calculated from the external input signal 10 to 10oF 5 to 5oC Default 0oF Temperature Units Select the desired uni...

Page 37: ...ect 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 Gas Pressure Setting The gas valve pressure regulator is preset at the factory The following description is for the benefi...

Page 38: ...diation for at least 1 hour Check water level in expansion tank If level exceeds of tank volume air is still trapped in system Shut down appliance and continue to run pumps Within 3 days of start up recheck all air vents and expansion tank as described above 9 2 STAGING OPERATION All MicoFlame Grande models are available as on off 2 stage 3 stage and 4 stage Model 2000 is provided with two burners...

Page 39: ... High Fire Low Fire Low Fire Stage 3 High Fire High Fire High Fire Four Stages Stage 1 Low Fire Low Fire Low Fire Stage 2 High Fire Low Fire Low Fire Stage 3 High Fire High Fire Low Fire Stage 4 High Fire High Fire High Fire Table 10 Firing Modes Model 3500 and 4000 Four Burners Burner 1 Burner 2 Burner 3 Burner 4 Two Stages Stage 1 Low Fire Low Fire Low Fire Low Fire Stage 2 High Fire High Fire H...

Page 40: ...ation circuit is completed between the sensor and the burner ground The flame sensing circuit in the ignition module detects the flame current shuts off the spark generator and energizes the combination valve operator The combination valve opens and gas flows to the main burner where it is ignited by the pilot burner On the lock out ignition module the flame current also holds the safety lockout t...

Page 41: ... 1 9 4000 1 9 2 2 1 9 2 2 1 9 2 2 1 9 2 2 MODEL FLUE SWITCH RECYCLE POINT W C Burner 1 Burner 2 Burner 3 Burner 4 2000 1 5 1 9 1 5 1 9 2500 1 1 1 5 1 1 1 5 1 1 1 5 3000 1 5 1 9 1 5 1 9 1 5 1 9 3500 1 2 1 6 1 2 1 6 1 2 1 6 1 2 1 6 4000 1 5 1 9 1 5 1 9 1 5 1 9 1 5 1 9 Depending on field conditions air box pressures will have to be adjusted accordingly Always set the appliance for a CO2 level in the ...

Page 42: ...the electrode does not appear overheated or fouled with carbon It may be necessary to clean the ignition electrode using steel wool Once the pilot appears to be properly set reinstall it into the appliance making sure to properly tighten the pilot line connection If the pilot is removed from the main burner in the course of servicing the appliance it is important to reinstall it so that there is n...

Page 43: ... is established Set primary system controller to desired temperature To turn off appliance close main manual gas valve close pilot manual valve and turn off electric power to system SERVICE To maintain safe operation and the greatest efficiency of the appliance check the main burner and pilot burner for proper flame characteristics For hydronic heating applications the burner should be checked at ...

Page 44: ...ne If pilot fails to light and you suspect air in the 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 counter clockwise to increase it or clockwise to decrease it 8 Open the main manual and main firing ...

Page 45: ...ure that igniter and ground electrodes are positioned properly Clean with steel wool if necessary Verify that back of burner box is fully engaged into the retaining slot in the combustion chamber base 5 Pilot lights but main burner does not fire Verify that main manual valve is in ON position Check wiring to valve from ignition control 6 Main burner lights but cycles off after a few minutes Verify...

Page 46: ...ECTRICAL 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 ...

Page 47: ...43 ...

Page 48: ...44 ...

Page 49: ...45 16 EXPLODED VIEW MicoFlame Grande ...

Page 50: ...46 EXPLODED VIEW MicoFlame Grande Outdoor and or Condensing ...

Page 51: ...47 MicoFlame Grande Control Box ...

Page 52: ...14 4208 14 4208 14 4208 14 4208 14 4208 10 Base Panel 14 4209 20 14 4209 30 14 4209 30 14 4209 40 14 4209 40 11 Outer Jacket Top Cover 14 4210 20 14 4210 30 14 4210 30 14 4210 40 14 4210 40 12 Outer Jacket Back Panel 14 4211 20 14 4211 30 14 4211 30 14 4211 40 14 4211 40 13 Outer Jacket Front Lower Panel 14 4212 20 14 4212 30 14 4212 30 14 4212 40 14 4212 40 14 Outer Jacket Front Upper Panel 14 42...

Page 53: ...Support 14 4255 14 4255 14 4255 14 4255 14 4255 35 Control Panel Assembly 14 4160 14 4160 14 4160 14 4160 14 4160 37 Three Tiles Burner Box Assembly 14 4225 14 4225 14 4225 14 4225 14 4225 38 Economizer Cover 14 4146 14 4265 01 14 4265 01 14 4265 01 14 4265 01 39 Economizer Assembly 14 4148 03 14 4266 01 14 4266 01 14 4266 01 14 4266 01 40 Front Refractory 17 0084 01 17 0084 02 17 0084 02 17 0084 ...

Page 54: ... Ignition Module Continuous Retry S8610M3017 57 Ignition Module Single Try S8600H3010 58 Pilot Valve Combination Valve CV100B6N 22 0001 59 Pump Delay Relay LY1F24VAC 60 Tekmar Controller STG BTC4PA 61 On Off Switch ESWRB141D1121 ACC F 62 Camus MF Boiler Board 99 5082 68 Transformer HCT 01J2BB07 71 White Indicator LED LXR5010UW42149 72 Red Indicator LED LXR5010UB28230 73 Blue Indicator LED LXR5010S...

Page 55: ...MicoFlame DHW Years In Service MicoFlame Heating MicoFlame DHW 1 100 100 6 40 N A 2 100 100 7 35 N A 3 100 100 8 30 N A 4 100 100 9 25 N A 5 100 100 10 20 N A The exchanged or repaired heat exchanger will carry the balance of the remaining original warranty provided with the appliance based on the FOB date In the event a replacement heat exchanger is delivered and if the defective heat exchanger i...

Page 56: ...built water heaters and heating boilers as well as a 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 6226 Netherhart Road Mississauga Ontario L5T 1B7 TEL 905 696 7800 FAX 905 696 8801 ...

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