Camus Hydronics MICOFLAME 2 Series Guida all'installazione

99-0053

Rev. 01

INSTALLATION OPERATION

AND SERVICE MANUAL

MICOFLAME SERIES 2

GAS FIRED COMMERCIAL COPPER TUBE BOILERS

FOR HYDRONIC HEATING

Models; MFH800, 1000, 1200, 1400, 1600, 1800, 2000

HOT WATER SUPPLY

Models; MFW800, 1000, 1200, 1400, 1600, 1800, 2000

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

oDo not try to light any appliance,

oDo not touch any electrical switch; do not use any

phone in your building,

oImmediately call your gas supplier from a

neighbour’s phone. Follow the gas supplier’s

instructions,

oIf 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.

CAMUS HYDRONICS LTD.

6226 Netherhart Road, Mississauga, Ontario, L5T 1B7

Table of Contents

INTRODUCTION..................................................................................................................................1

1. GENERAL INSTRUCTIONS............................................................................................................1

2. BOILER LOCATION ........................................................................................................................2

3. PROVIDE AIR FOR COMBUSTION AND VENTILATION .........................................................3

4. ELECTRICAL WIRING....................................................................................................................3

5. STAGING OPERATION...................................................................................................................4

6. GAS SUPPLY AND PIPING.............................................................................................................5

7. VENTING...........................................................................................................................................6

7.1 OUTDOOR VENTING..............................................................................................................8

7.2 SIDEWALL VENTING............................................................................................................9

7.3 OUTDOOR AIR KIT ................................................................................................................9

7.4 FILTER KIT............................................................................................................................10

7.5 STANDARD VENTING.........................................................................................................10

7.6 VENTING FOR CONDENSING APPLICATION.................................................................10

8. RELIEF VALVE ..............................................................................................................................10

9. FREEZE PROTECTION..................................................................................................................10

10. WARNING REGARDING CHILLED WATER SYSTEMS........................................................11

11. PIPING OF SYSTEM TO BOILER (FIG.4)..................................................................................11

12. PLACING BOILER IN OPERATION...........................................................................................13

13. IGNITION SYSTEM SAFETY SHUT-OFF DEVICE..................................................................13

14. LOW WATER TEMPERATURE SYSTEMS...............................................................................13

15. INSTANTANEOUS WATER HEATER.......................................................................................14

16. PILOT AND MAIN BURNER FLAMES......................................................................................15

16.1. MAIN BURNER ..................................................................................................................15

16.2. PILOT BURNER..................................................................................................................17

17. OPERATION AND SERVICE ......................................................................................................18

18. LIGHTING INSTRUCTIONS .......................................................................................................19

19. TROUBLE SHOOTING GUIDE...................................................................................................20

20. TYPICAL GAS TRAIN .................................................................................................................21

21. ELECTRICAL DIAGRAMS..........................................................................................................21

22. EXPLODED VIEW......................................................................................................................24

23. MICO FLAME REPLACEMENT PARTS LIST ..........................................................................25

WARRANTY ........................................................................................................................................... 26

INTRODUCTION

Camus Hydronics proudly introduces its MicoFlame series 2 of commercial water heaters /

hydronic boilers. These gas-burning appliances are thoughtfully designed for easy operation

and maintenance. We are confident that you will come to appreciate the benefits of our product.

1. GENERAL INSTRUCTIONS

The installation of this heater must conform to the requirements of the authority having

jurisdiction or, in the absence of such requirements, to the National Fuel Gas Code, ANSI

Z223.1 or CAN/CGA B149 Installation Codes. All electrical wiring must be done 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 .

Vent installations must be in accordance with Part 7, Venting of Equipment, of the National Fuel

Gas Code, ANSI Z223.1, or Section 7, Venting Systems and Air Supply for Appliances, of the

CAN. CGA B149, Installation Codes and applicable provisions of the local building codes.

When required by the authority having jurisdiction, the installation must conform to the Standard

for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1.

The qualified installer shall instruct the end user in the safe and correct operation of this

appliance and shall ensure that the heater is in safe working order prior to leaving the job site.

WARRANTY:

Factory warranty shall apply only when the boiler is installed in accordance with

local plumbing and building codes, ordinances and regulations, the printed

instructions provided with it and good industry practices.

Excessive water hardness causing a lime build-up 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.

Using or storing corrosive chemicals in the vicinity of this boiler can rapidly

attack the copper tubes and coils and voids warranty.

The primary heat exchanger of this boiler is intended to operate under non-

condensing conditions. Inlet temperatures must be maintained at 110 °F or

higher. Warranty is void if the primary heat exchanger is allowed to operate in

condensing mode.

Damage caused by freezing or dry firing voids warranty.

This boiler is not to be used for temporary heating of buildings under

construction.

2. 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 must not be installed on carpeting 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.

If necessary a suitable drain pan should be installed under the boiler.

If the boiler is installed above the level of the building’s radiation system, a low water cutoff

device must be installed in the boiler outlet at the time of installation. Some local codes require

the installation of a low water cutoff on all systems.

Locate the boiler so as to provide adequate clearance for inspection and service all around the

unit. It is recommended that 24” be provided for the top and sides and 48” for the front.

This boiler is suitable for alcove installation with minimum clearances to combustibles as

follows:

TOP: 12”

SIDES: 12”

REAR: 12”

VENT: 6”

For boiler’s dimensions see Figure 1 and table 1

Side View (Left)

Condensing Option Front View Side View (Right)

Non-Condensing Option Rear View

Non-Condensing Option

Figure 1

B' Dia. Venting E' Dia.

Model W'

Water

Connection

Gas

Connection

Outdoor

Condensing

or Sidewall

Standard

Air Inlet

MF800 45 3/4 2 1/2 1 8 8 10 8

MF1000 52 3/4 2 1/2 1 1/4 8 8 10 8

MF1200 62 2 1/2 1 1/4 10 10 12 10

MF1400 71 1/4 2 1/2 1 1/4 10 10 12 10

MF1600 80 3/4 2 1/2 1 1/2 12 12 14 12

MF1800 89 3/4 2 1/2 1 1/2 12 12 14 12

MF2000 99 2 1/2 1 1/2 12 12 14 12

Table 1

3. PROVIDE AIR FOR COMBUSTION AND VENTILATION

Provisions for combustion and ventilation air must be in accordance with:

•Section 5.3. Air for combustion and Ventilation, of the National Fuel Gas Code, ANSI

Z223.1, or;

•Sections 7.2, 7.3 or 7.4 of 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 heater is to be installed near a corrosive or potentially corrosive air supply, the heater

must be isolated from it and outside air should be supplied as per code.

Potentially corrosive atmospheres will result from exposure to permanent wave solution,

chlorinated waxes and cleaners, chlorine, water softening chemicals, carbon tetrachloride,

halogen based refrigerants, Freon cleaning solvents, hydrochloric acid, cements and glues,

masonry washing materials, antistatic fabric softeners, dry cleaning solvents, degreasing liquids,

printing inks, paint removers, etc.

4. 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. These heaters require

an 115V 60hz supply. Depending on the pump used, a 15-amp breaker is usually sufficient.

Electrical connections must be made so that the circulator will operate before the gas valve can

open. At no time may the control system allow the burner to fire without water flowing in the

system.

Use minimum 18-gauge conductor for 24-volt field wiring to boiler. Splicing of wires is not

recommended.

Use sealed tight conduit suitable for outdoor use for outdoor installations.

Use terminal strip provided inside control panel for low water cut-off and remote controller

Refer to wiring diagram provided with boiler.

5. STAGING OPERATION

Staging of the MicoFlame series 2 is dependent on the number of burners supplied. Models

800 and 1000 are supplied with a single burner and are available as on/off and two stages.

Models 1200 through 2000 are supplied with two burners and are available as on/off, 2-stage, 3-

stage and 4-stage.

Each burner is supplied with a dedicated airflow proving signal and separate proved pilot

ignition system. All fans must be running in order for the appliance to proceed to trial for ignition.

MicoFlame series 2 is supplied with more than one burner may use burners that are not of

identical size in order to accommodate fans within the space allocated. In case where burners

are not identical, the right side burner will be the one with the higher input.

Each MicoFlame series 2 is supplied with the appropriate wiring diagram showing the actual

staging sequence provided as well as any special controls or options requested.

When converting multiple MicoFlame series 2 appliances to an external sequencing control it is

absolutely necessary to program the sequencer properly by entering the number of stages

provided on the appliance. In this way the sequencer will lead/lag or rotate the boilers properly.

A full diagnostics panel is provided on the MicoFlame series 2. On a call for heat, status lights

will light up if the particular safety is working properly. Once all safeties have been proved, the

boiler will proceed to trial for ignition and will then sequentially bring on the burner stages (and

the corresponding lights). If the safety proving sequence does not proceed to completion, the

first safety light to remain off will indicate the cause of the problem. All other lights below the

problem indicator light will also remain off.

Burner staging is arranged to allow a minimum firing rate of no less than 50% in order to

minimize possibility of condensation in the venting. Staging of burners for models 1200 through

2000 is as follows:

Two

Stage Left Burner Right Burner

Stage 1 Off Full-Fire

Stage 2 Full Fire Full-Fire

Three

Stage * Left Burner Right Burner

Stage 1 Off Lo-Fire

Stage 2 Off Hi-Fire

Stage 3 Full-Fire Hi-Fire

*Recommended for Models 1400 and 1600

Four

Stage Left Burner Right Burner

Stage 1 Off Lo-Fire

Stage 2 Off Hi Fire

Stage 3 Lo-Fire Hi-Fire

Stage 4 Hi-Fire Hi-Fire

6. GAS SUPPLY AND PIPING

This boiler is intended to operate at inlet gas pressures not exceeding ½ PSI (14“ W.C.). If

higher pressures are present, consult the gas company for correction.

When pressure testing the gas supply piping at pressures above ½ PSI, the boiler and its

individual gas shut-off valve must be disconnected from the supply piping.

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 allow easy

removal of the gas control assembly.

Provide gas pressures at inlet to boiler manifold as follows:

PROPANE NATURAL GAS

Minimum (inches W.C.) 11 4

Maximum (inches W.C.) 11 7

The gas supply line must be of adequate size to prevent undue pressure drop and must never

be smaller than the size of the connection on the heater. Sizing based on Table 2 is

recommended.

Before operating the boiler, the complete gas train and all connections must be tested using

soap solution.

DISTANCE FROM NATURAL GAS METER OR PROPANE SECOND STAGE REGULATOR

0-100 FT 100-200 FT. 200-300 FT.Input

Btu/Hr NAT. L.P. NAT. L.P. NAT. L.P.

800,000 2” 1 ½“ 2 ½“ 2“ 2 ½“ 2“

1,000,000 2” 1 ½“ 2 ½“ 2“ 2 ½“ 2“

1,200,000 2 ½“ 2“ 2 ½“ 2“ 3” 2 ½“

1,400,000 2 ½“ 2“ 2 ½“ 2“ 3” 2 ½“

1,600,000 2 ½“ 2“ 3” 2 ½“ 3” 2 ½“

1,800,000 2 ½“ 2“ 3” 2 ½“ 3” 2 ½“

2,000,000 2 ½“ 2” 3” 2 ½“ 3” 2 ½“

Table 2

7. VENTING

Boilers for outdoor installation are intended to vent using a listed vent cap.

For indoor installations venting must be in accordance with Part 7, Venting of Equipment, of the

National Fuel Gas Code, ANSI Z223.1, or Section 7, Venting of Equipment and Air Supply for

Appliances, of the CAN/CGA B149, Installation Codes, and applicable provisions of the local

building codes.

Vent connectors serving appliances vented by natural draft shall not be connected into any

portion of mechanical draft systems operating under positive pressure.

Horizontal runs of vent pipe shall be securely supported (approximately every 4 feet) to prevent

sagging and maintain a minimum upward slope of ¼” per foot from the boiler to the vent

terminal.

When an existing boiler is removed from a common venting system, the common venting

system is likely to be too large for proper venting of the appliances remaining connected to it .At

the time of removal of an existing boiler, the following steps must be followed with each

appliance remaining connected to the common venting system placed in operation, while the

other appliances remaining connected to the common venting system are not in operation.

a) Seal any unused openings in the common venting system.

b) Visually inspect the venting system for proper size and horizontal pitch and determine

that there is no blockage, restriction, leakage, corrosion or other deficiency, which could

cause an unsafe condition.

c) Insofar as is practical, close all building doors and windows and all doors between the

space in which the appliances remaining connected to the common venting system are

located and other spaces of the building. Turn on the clothes dryers and any appliances

not connected to the common venting system. Turn on any 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 hood relief opening after 5 minutes of main burner operation.

Use the flame of a match or candle or smoke from a cigarette.

f) 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. When resizing any portion of the common venting system, the

common venting system should be resized to approach the minimum size as determined

using the appropriate tables in Part 11 of the National Fuel Gas Code, ANSI Z223, 1 or

CAN/CGA B149, Installation Codes.

Heat exchanger surfaces and vent piping should be checked every six months for deterioration

and carbon deposits. Remove all soot or other obstructions from the chimney and flue, which

might impede draft action. Replace any damaged or deteriorated parts of the venting system.

A qualified service technician should follow this procedure when inspecting and cleaning the

heat exchanger and vent pipe.

1. Turn off electrical power and close main manual gas shut-off and allow boiler to cool

down

2. Remove the vent pipe running to chimney. Remove top outer panel and flue collector

access panel. Check heat exchanger, vent and chimney for obstruction and clean as

necessary.

3. Remove burner from boiler and vacuum the burner, and the heat exchanger. If heat

exchanger is excessively dirty it may be necessary to remove it from the boiler and wash

it down with proper detergent cleaner. Be aware that the combustion chamber base is

insulated with ¼” thick ceramic paper. If this material is damaged or displaced it must be

replaced before starting up the boiler.

4. Reinstall parts removed in steps 2 and 3. Be sure that vent pipe has proper pitch and is

properly sealed. Repair or replace any gaskets, which may have been damaged in steps

2 and 3.

5. CAUTION: When replacing the burner be 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.

6. Restore electrical power and gas supply to boiler.

7. Place boiler in operation using lighting instructions provided.

8. While the boiler 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 series 2 is category 1, 85% efficient when supplied as a non-condensing

appliance. When supplied with the optional condensing cartridge, the MicoFlame series 2 is

95% efficient and is considered to be a category II or IV appliance. Three venting options are

available for this boiler in both condensing and non-condensing configurations. See Figure 2 for

details. (Please refer to Table 1 for vent dimensions)

Figure 2

7.1 OUTDOOR VENTING

When fitted with the factory supplied rain shield and UL approved vent cap, the MicoFlame

series 2 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. Locate boiler at least 3 feet away from any overhang.

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