Camus Hydronics BLUE-FLAME Series Einrichtungshandbuch

INSTALLATION OPERATION

AND SERVICE MANUAL

GAS FIRED COMMERCIAL COPPER TUBE BOILERS

BLUE-FLAME SERIES

FOR HYDRONIC HEATING

Models; BFH 480, 660, 840, 1020, 1200, 1380, 1560, 1740,

1950

HOT WATER SUPPLY

Models; BFW 480, 660, 840, 1020, 1200, 1380, 1560, 1740,

1950

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

instruction,

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

99-0030

Rev. 03.00

Table of Contents

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

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

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

3. PROVIDE AIR FOR COMBUSTION AND VENTILATION ........................................................2

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

5. GAS SUPPLY AND PIPING............................................................................................................3

6. VENTING.........................................................................................................................................4

7. SAFETY DEVICES ..........................................................................................................................7

7.1 WATER FLOW SWITCH (shipped loose)..................................................................................7

7.2 LOW WATER CUTOFF (If Equipped).......................................................................................7

7.3 RELIEF VALVE (shipped loose)...............................................................................................7

8. FREEZE PROTECTION...................................................................................................................7

9. WARNING REGARDING CHILLED WATER SYSTEMS............................................................ 8

10. PIPING OF BOILER TO THE SYSTEM (FIG.3)..........................................................................8

11. PLACING BOILER IN OPERATION..........................................................................................10

12. CHECK OUT OF IGNITION SYSTEM SAFETY SHUT-OFF DEVICE....................................10

13. LOW WATER TEMPERATURE SYSTEMS..............................................................................10

14. INSTANTANEOUS WATER HEATER.......................................................................................12

15. PILOT AND MAIN BURNER FLAMES......................................................................................12

15.1. MAIN BURNER .........................................................................................................................12

15.2. PILOT BURNER.........................................................................................................................14

16. OPERATION AND SERVICE .....................................................................................................15

17. LIGHTING INSTRUCTIONS .......................................................................................................16

18. TROUBLE SHOOTING GUIDE...................................................................................................17

19. TYPICAL GAS TRAIN.................................................................................................................18

20. ELECTRICAL DIAGRAMS.......................................................................................................... 18

21. EXPLODED VIEW........................................................................................................................21

22. BLUE FLAME REPLACEMENT PARTS LIST ..........................................................................22

WARRANTY ........................................................................................................................................... 23

INTRODUCTION

Camus Hydronics proudly introduces its Blue-Flame Series of Water Heaters / Hydronic Boilers.

These machines 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 B149.1, 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 codes, standards, ordinances and regulations,

•The printed instructions provided with the boiler 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.

This boiler is intended to operate under non-condensing conditions. Inlet temperatures

must be maintained at 110°F or higher. Warranty is void if heater 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”

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 B149.1 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 115-V 60-hz 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.

For low water cutoff and remote controller, use terminal strip provided inside control panel.

Refer to wiring diagram provided with boiler.

5. GAS SUPPLY AND PIPING

This boiler is intended to operate at inlet gas pressures not exceeding ½ psi (14” water

column). 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 gas train as follows:

PROPANE NATURAL GAS

Minimum (inches water column) 11 5

Maximum ( inches water column) 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 1 is

recommended.

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

soap solution.

TABLE 1

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.

480,000 1¼” 1” 1½” 1¼” 2” 1½”

660,000 1½” 1¼” 2” 1½” 2” 1½”

840,000 2” 1½” 2½” 2” 2½” 2”

1,020,000 2” 1½” 2½” 2” 2½” 2”

1,200,000 2½” 2” 2½” 2” 3”

2½”

1,380,000 2½” 2” 2½” 2” 3”

2½”

1,560,000 2½” 2” 3”

2½” 3” 2½”

1,740,000 2½” 2” 3”

2½” 3” 2½”

1,950,000 2½” 2” 3”

2½” 3” 2½”

6. VENTING

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

The BlueFlame windproof cabinet protects the unit from weather, when fitted with the factory

supplied air intake and UL approved vent cap (93-0297), it will be self-venting and suitable for

outdoor installation.

1. Outdoor models must be installed outdoors and must use the Air Intake and Vent Cap

supplied by Camus Hydronics. Alternately, all listed vent cap may be used along with the

Camus supplied air intake

2. Periodically check to ensure that air intake and vent cap are not obstructed.

3. Locate appliance at least 3 feet away from any overhang.

4. Locate appliance at least ten feet from building air intake.

5. Avoid installation in areas where runoff from adjacent building can spill onto appliance.

For outdoor installations, always consider the use of a shelter such as a garden shed in lieu of

direct exposure of the appliance to the elements. The additional protection afforded by the

shelter will help to minimize nuisance problems with electrical connections and will allow easier

servicing of the appliance under severe weather conditions.

For indoor installations the draft hood provided with this boiler must be installed without

alteration. 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 of Equipment and Air Supply for

Appliances, of the CAN/CGA B149.1, 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 boiler draft diverter and vent pipe running to chimney.

•Check heat exchanger, vent and chimney for obstruction and clean as

necessary.

3. Remove burner tray from boiler and vacuum top heat exchanger and coils.

4. Reinstall parts removed in steps 2 and 3.

•Be sure that vent pipe has proper pitch and is properly sealed.

5. Restore electrical power and gas supply to boiler.

•Place boiler in operation using lighting instructions provided.

•Check for gas leaks and proper vent operation.

Three venting options are available for this boiler. See Figure 1 below for details.

Standard Venting

Outdoor Venting

Sidewall Venting

Side View

Figure 1

7. SAFETY DEVICES

7.1 WATER FLOW SWITCH (shipped loose)

A water flow switch is shipped loose and is to be installed in the outlet piping on all heating

boilers and hot water supply boilers. The flow switch is wired in series with the 24VAC safety

control circuit. A diagnostic light will be indicated on the control display on a low flow condition.

7.2 LOW WATER CUTOFF (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 every six months. 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 when connecting to 24

VAC circuit.

7.3 RELIEF VALVE (shipped loose)

This appliance is supplied with a relief valve sized in accordance with ASME Boiler and

Pressure Vessel Code, Section IV (“Heating Boilers”). 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 discharge from the relief valve shall be

piped to a suitable floor drain for disposal when relief occurs. No reducing couplings or other

restrictions shall be installed in the discharge line. The discharge line shall allow complete

drainage of the valve and line. Relief valves should be manually operated at least once a year.

8. FREEZE PROTECTION

Boiler installations are not recommended in areas where the danger of freezing exists unless

precautions are taken. Maintaining a mixture of 50% water and 50% propylene glycol is the

preferred methods of freeze protection in hydronic systems. This mixture will protect the boiler

to approximately -35 °F (-37 °C). To maintain the same temperature rise across the boiler

increase the G.P.M. flow by 15% and the head loss by 20%.

A snow screen should be installed to prevent snow and ice accumulation around the boiler.

Regular inspections should be made to ensure that air intake and vent are free of snow and ice.

9. WARNING REGARDING CHILLED WATER SYSTEMS

When a boiler is connected to an air conditioning system where the same water is used for

heating and cooling, the chiller must be piped in parallel with the boiler. Appropriate flow control

valves; manual or motorized must be provided to prevent the chilled water from entering the

boiler. (See figure 2)

Figure 1

When a boiler is connected to heating coils located in air handling units (where they may be

exposed to refrigerated air circulation), the boiler piping system shall be equipped with a flow

control valve or other automatic means to prevent gravity circulation of chilled water through the

boiler. Chilled water in the boiler will create condensate on the boiler tubes, which will collect in

the combustion chamber causing corrosion.

10. PIPING OF BOILER TO THE SYSTEM (FIG.3)

Check all applicable local heating, plumbing and building safety codes before proceeding.

Be sure to provide unions and gate valves at inlet and outlet to boiler so that it can be easily

isolated for service.

This boiler is of a low mass design, which provides for instant heat transfer. Special attention to

water flow rates will ensure that temperature rise does not exceed 35 °F (19.4 °C). The following

table 2 is provided as a guide.

For application in areas known to have hard water conditions, contact factory for

recommendations.

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