installation operation and service manual
Contents
1. NOTE REFER TO REPLACEMENT PARTS LIST FOR DETAILS REV 0 22 CERA FLAME REPLACEMENT PARTS LIST KEY ITEM DESCRIPTION MODEL 450 550 650 1 CERA FLAME BASE PANEL ASSEMBLY 14 0009 14 0009 14 0009 2 CERA FLAME BURNER SKIRT FRONT 14 0032 14 0032 14 0032 3 CERA FLAME BURNER SKIRT REAR 14 0031 14 0031 14 0031 4 CERA FLAME AIR GAS MIX TUBE 50 0001 50 0001 50 0001 5 CERA FLAME BURNER ASSEMBLY 66 0050 66 0050 66 0050 6 CERA FLAME COIL SUPPORT BASE 14 0041 14 0041 14 0041 72 COPPER COIL RETAINING RODS 4 12 0001 12 0001 12 0001 8 CENTER OUTER JACKET REAR PANEL 14 0034 14 0035 14 0035 9 CERA FLAME OUTER JACKET FRONT PANEL 14 0067 14 0068 14 0068 10 SPACER RING HEAT EXCHANGER LOCATER FRAME 14 0020 14 0020 14 0020 11 UPPER REAR PANEL 14 0018 14 0018 14 0018 12 CERA FLAME TOP PANEL 14 0047 14 0047 14 0048 13 CERA FLAME FLUE COLLECTOR 14 0055 14 0055 14 0056 14 CERA FLAME TOP PANEL SEALING RING 14 0053 14 0053 14 0054 15 CERA FLAME OUTDOOR VENT CAP 14 0038 14 0038 14 0066 16 HEAT EXCHANGER CORE ASSEMBLY 15 0020 15 0020 15 0020 17 COPPER COIL WELDMENT 15 0040 15 0050 15 0050 18 VENT TERMINAL THRU WALL 4 0043 14 0043 14 0044 19 AIR INTAKE THRU WALL 14 0045 14 0045 14 0046 20 OPTIONAL STAND 14 0005 14 0005 14 0005 21 ELECTRICAL ENCLOSURE 14 0070 14 0070 14 0070 22 FLAME RADIATION SHIELD 7 0001 17 0001 17 0001 23 GAS MANIFOLD PIPE 66 0053 66 0053 66 0053 24 CERA FLAME HEAT EX PIPE CLOSURE B2. Aluminum tape must meet the provisions of SMACNA AFTS 100 73 Standard When venting through unheated spaces with single wall vent insulation should be wrapped around the vent pipe to prevent flue gas condensation inside the vent Periodically check to ensure that the vent terminal is unobstructed 6 3 OUTDOOR AIR KIT kit 14 0058 When fitted with the factory supplied fan inlet ring and air intake terminal the Cera Flame can draw outdoor air over an equivalent length of 60 feet Air intake is 6 for models 450 550 and 8 for model 650 Boilers may be installed with either a horizontal sidewall vent or vertical roof top terminal Terminals differ with each application The following applies to outdoor air installations 1 Use only factory supplied air intake terminal 2 Periodically check to ensure that air intake is not obstructed 3 Refer to local codes for proper installation and location of vent terminals Vertical vent terminal must be at least 3 feet above the highest point where it is located above the roof of a building and at least two feet higher than any part of the building within a horizontal distance of ten feet 4 Locate the air intake five feet away from the vent discharge For sidewall venting locate the air intake below the vent outlet if possible 6 4 FILTER KIT kit 14 0057 A filter kit is provided with the air inlet ring The filter is washable and accounts for an additional pressure loss of less th
3. 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 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 Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so that appliance operates continuously 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 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 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 ve
4. the resulting flow of water will not cause damage to its surroundings 4 4 C 4 F Name of Owner Name of Dealer Address Address Model No Serial No Date of Installation Date of Initial Operation 6226 Netherhart Road Mississauga Ontario L5T 1B7 CANADA 25 CAMUS Hydronics is a The CAMUS CERTIFIED manufacturer of Seal assures you that replacement parts for Reliability Efficiency amp most copper finned serviceability are built water heaters z into every and heating single unit boilers as well 5 For more asa information supplier of specialty on our innovative HVAC products Our products from CAMUS service line is open 24 Hydronics Limited call hours 7 days a week 905 696 7800 today CAMUS HYDRONICS LTD 6226 Netherhart Road Mississauga Ontario L5T 187 TEL 905 696 7800 FAX 905 696 8801
5. 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 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 clos
6. 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 The repaired or replacement part will be warranted for only the unexpired portion of the original warranty This warranty does not cover failures or malfunctions resulting from 1 Failure to properly install operate or maintain the equipment in accordance with Camus manual 2 Abuse alteration accident fire flood foundation problems and the like 3 Sediment or lime buildup freezing or other conditions causing inadequate water circulation 4 Pitting and erosion caused by high water velocity 5 Failure of connected systems devices such as pump or controller 6 Use of non factory authorized accessories or other components in conjunction with the system 7 failing to eliminate air from or replenish water in the connected water system 8 Chemical contamination of combustion air or use of chemical additives to water HEAT EXCHANGER If within TEN years after initial installation of the appliance a heat exchanger shall prove upon examination by Camus to be defective in material or workmanship Camus will exchange or repair such part or portion on the following pro rated limited warranty 1 Years one through five standard warranty 2 Years six through ten replacement purchase price pro rated at the following schedule Year six 60 Year seven 65 Year
7. eight 70 Year nine 75 Year ten 80 of the current list price of the current list price This term is reduced to FIVE years if the appliance is used for other than hydronic space heating Heat Exchanger shall be warranted for 20 years from date of installation against Thermal Shock excluded however if caused by appliance operation at large changes exceeding 150 F between the water temperature at intake and appliance temperature or operating at appliance temperatures exceeding 230 F BURNER If within FIVE years after initial installation of the appliance a burner shall prove upon examination by Camus to be defective in material or workmanship Camus will exchange or repair such part or portion ANY OTHER PART If any other part fails within one 1 year after installation or eighteen 18 months from date of factory shipment based on Camus records whichever comes first Camus will furnish a replacement or repair that part Replacement parts will be shipped f o b our factory HOW TO MAKE A CLAIM Any claim under this warranty shall be made directly to Camus Hydronics Limited Canadian Head Office SERVICE LABOR RESPONSIBILITY Camus shall not be responsible for any labour expenses to service repair or replace the components supplied Such costs are the responsibility of the owner DISCLAIMERS Camus shall not be responsible for any water damage Provisions should be made that in the event of a water appliance or fitting leak
8. is satisfactory open the pilot gas and allow the pilot burner to light Once air has been purged from the pilot line the pilot flame should appear almost instantly at the initiation of spark Cycle the pilot several times to confirm reliability A properly set pilot will appear blue and will engulf the igniter and ground electrode See figure 7 Open the firing valve and allow the main burner to light The pilot must not extinguish After running for 15 minutes cycle the appliance to ensure that the pilot remains stable 16 OPERATIONS AND SERVICE OPERATION Before operating the boiler the entire system must be filled with water purged of air and checked for leaks Do not use Stop leak or other boiler compounds The gas piping must also be leak tested Any safety devices including low water cutoff flow switch and high limit used in with this boiler must receive periodic inspection every six months to assure proper operation A low water cutoff of the float type should be flushed every six months All relief valves should be inspected and manually operated every six months For your safety follow the lighting and operating instructions below and on the boiler To turn on main burner slowly open firing valve after pilot is established Set primary system controller to desired temperature To turn off boiler close main manual gas valve close pilot manual valve and turn off electric power to system SERVICE Disconnect main power and
9. rise across boiler to ensure adequate water flow e f necessary increase static water pressure and decrease gas pressure 19 19 TYPICAL GAS TRAIN Main _ Pilot Burner __ Combo Gas Valve Hring Valve Pressure Mixing Tube 20 ELECTRICAL DIAGRAMS Each Cera Flame boiler will be provided with its own wiring diagram to guarantee that any options ordered with the unit are properly detailed The following diagrams 99 5051 and 99 5053 are provided as typical samples only 20 1505 66 DAC SIN 30wOs 207 01 3194 capas 4D5u53 4D4 2225 2 SOT 46 Bugu zurquaaduz jopragou Bua panoda aq acu 3r pavots aq paru sauaqdda adu ayy 4D Au Q B40N NOLLOGNWOS LI SIIMIGTAH SNAHY PLE 2 1 149432 ve IND 2524 21 2505 66 DAQ d ud SIN 37925 20 2 01 3190 capas ipd 4D4 2 521 2 SOI 370 aur u_acduz IAA parodas garu 4 pasedes aq paru aqu 40 AU 34 NMILLTOGNHAOUS LI SIMIHTAH SNHYJ ERIS 2 ARE 09 IND 12540 22 21 EXPLODED VIEW CERAFLAME EXPLODED VIEW MODELS 450 550 650
10. turn off gas supply before servicing unit To remove and clean the burner follow the detailed procedure in section 15 of this manual After the first season of operation inspect the heat exchanger and venting Follow the detailed instructions in section 6 of this manual CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing Any audible sounds in the equipment like pinging crackling or hissing are indications of scaling or lack of sufficient water flow Under these conditions the boiler must be shut down immediately and the heat exchanger and coils checked for damage If the exchanger is damaged from scaling it is not covered by warranty 17 Should your equipment subjected to fire flood some other unusual condition turn off all gas and electrical supply if you are unable to turn off the gas call your gas company or gas supplier at once Do not put the unit back in operation until it has been checked by a qualified agency to ensure that all controls are functioning properly Units that are not operated for a period of 60 days or more are considered seasonal operations It is recommended that before returning one of these units to service the proper operation of all controls be checked by a qualified service technician 17 LIGHTING INSTRUCTIONS 1 Turn off electric power to boiler 2 Close main manual val
11. ACKPLATE 14 0030 14 0030 14 0030 29 CERA FLAME IGNITER ASSEMBLY 66 0038 66 0038 66 0038 26 CERA FLAME PILOT BURNER SHIELD 66 0049 66 0049 66 0049 27 FLAME BURNER TILE 66 0054 66 0054 66 0054 28 PILOT VIEWPORT GLASS 50 0011 50 0011 50 0011 29 PILOT VIEWPORT FRAME 14 0049 14 0049 14 0049 30 MANUAL RESET HI LIMIT hydronic heating 78 0002 78 0002 78 0002 domestic hot water 78 0003 78 0003 78 0003 31 CERA FLAME ORIFICE CAP natural gas 0 2000 ft 3 0 W C 66 0042 66 0043 66 0044 natural gas 2000 4500 ft 3 0 W C 66 0046 66 0047 66 0048 L P 0 2000 ft 7 0 W C 66 0055 66 0056 66 0057 L P 2000 4500 ft 7 0 W C 66 0058 66 0059 66 0060 32 CERA FLAME BLOCKED FLUE SWITCH 78 0004 78 0005 78 0006 33 PILOT VIEWPORT OUTER 50 0012 50 0012 50 0012 34 PILOT VIEWPORT OUTER FRAME 14 0051 14 0051 14 0051 35 GAS MANIFOLD SUPPORT BRACKET 14 0037 14 0037 14 0037 36 1 4 hp 3500 RPM 115V venter assembly 55 0001 55 0001 55 0001 37 AIR INLET amp FILTER HOLDER ASSEMBLY 14 0040 14 0040 14 0040 NOTE All replacement parts available through CAMUS HYDRONICS LTD 24 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
12. Al i Oa uya uay 18 18 TROUBLE SHOOTING GUIDE nan ci as peace ARA 19 I0 dE PIC ALAS NAN aoi pu Eo tubus oH Menon ete 20 20 BEECTRICAL DIAGRAMS oai ped up dete Vedere a Qiu aa ui 20 21 EXPLODED VIEW auld eden tiene uA oui ns Quae edes qe Mab piae eee ue qa Nes 23 22 GERAHLAMEREPEACBEMBNE PARES HST oo oci phe ai berg bene 24 WARRANTY as cR 25 INTRODUCTION Camus Hydronics proudly introduces its Cera 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 1 CSA C22 1 Electrical Code Vent installations must be in accordance with Part 7 Venting of Equipment of the National Fuel Gas Code ANSI 2223 1 or Section 7 Venting Systems and Air Supply for Appliances of the CAN CGA
13. CTRICAL WIRING Su a QNEM Dio NO Rp Ost aaa NS iu aiii 3 vOLNSOSUPPLY AND PIPING ea i cest erts ata dee up Rees aqa ove Pun dae A 3 6 VENTING arnica rd ttn uito tegi uu R aS AO 4 6 1 OUTDOOR VENTING kit 14 0059 Ma ep bir 7 6 2 SIDEWALL VENTING terminals 14 0043 14 0044 0 7 6 3 OUTDOORZTIE REE Kit 14 0058 a ii otto lsi 7 6 4 FILTER usa wna abb eoe ee toot amp 6 5 STANDARD AEN TING iss aoi w ada ak nb hunaq OE 8 Te RBI VALPEVEZ GO dus 8 8 FREEZE PROTEC TON wuss lacy O 9 9 WARNING REGARDING CHILLED WATER 5 5 5 9 10 PIPINGOESYTSTEM TO Ga aut E MESH Mo PES GIN ee urea u ilapa 10 11 PEACING BOILER IN OPERATION R lany adi ha RA 12 12 IGNITION SYSTEM SAFETY SHUT OFF DEVICE sea a odr 13 132 O WWATERIEMPERATURESYSTEM Sok i O A 13 14 INSTANTANEOUS WATER HEATER ap 14 I5 PIEOT AND MAIN BURNER FLAMES GA Costa HRS 15 15 1 MAIN BURNER ae duit P QI asuanata id 15 15 2 PILOT BURNER naa sasana rd dor asa sawa asas asss 16 167 OPERATIONS AND SER VICE eroe ege nA h A BA 17 17 LIGHTING INSTRUCTIONS a aaa
14. INSTALLATION OPERATION AND SERVICE MANUAL GAS FIRED COMMERCIAL COPPER TUBE BOILERS CERA FLAME SERIES CERTIFIED FOR HYDRONIC HEATING Models CFH450 550 650 HOT WATER SUPPLY Models CFW450 550 650 H WARNING If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury or death e Do not store or use gasoline or other flammable vapours and liquids in the vicinity of this or any other appliance e WHAT TO DO IF YOU SMELL GAS o Do nottry 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 e 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 6226 Netherhart Road Mississauga Ontario 57 187 99 0034 Rev 04 Table of Contents INTRODUCTION m 1 GENERAL INSTRUCTIONS cioe O A O 1 2 BOIEFELOCANON Ra AO n doi ai dy 2 3 PROVIDE AIR FOR COMBUSTION AND VENTILATION een 2 4 ELE
15. L VENTING OP TIONAL BAROMETRIC DAMPER FIGURE 1 61 OUTDOOR VENTING kit 14 0059 When fitted with the factory supplied rain shield and UL approved vent cap the Cera Flame 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 4 Locate boiler at least ten feet from building air intake 5 Avoid installation in areas where runoff from adjacent building can spill onto boiler 6 2 SIDEWALL VENTING terminals 14 0043 14 0044 When fitted with the factory supplied vent terminal the Cera Flame can vent up to 60 equivalent feet Elbows can range from 5 to 9 feet in equivalent length depending on centerline radius Vent sizes are 6 for the 450 and 550 models and 8 for the 650 model Boilers may be installed with either a horizontal sidewall vent or vertical roof top terminal Terminals differ with each application Horizontal lengths over 5 feet must be installed using corrosion resistant stainless steel Use single wall vent and seal all joints or use pressure rated double wall vent Refer to local codes for proper installation and location of vent terminals When using sidewall vent all vent connector seams and joints must be sealed with pressure sensitive aluminum tape or silicone sealant as specified by the vent manufacturer
16. PROPANE SECOND STAGE REGULATOR Input 0 100 FT 100 200 FT 200 300 FT Btu Hr NAT LP NAT LP NAT LP 450 000 1 1 1 1 2 1 550 000 1 2 2 1 650 000 1 2 2 1 6 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 1 2 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 Seal any unused openings in the common venting system
17. 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 GAS SUPPLY AND PIPING This boiler is intended to operate at inlet gas pressures not exceeding 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 1 2 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 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 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
18. an 0 05 W C Highly recommended for dusty environments The filter kit can also be provided when using the outdoor air kit 6 5 STANDARD VENTING The Cera Flame is a category 1 appliance and is approved for venting into a common standard chimney If chimney height is much greater than 30 feet or if drafts are excessive it may be preferable to provide a single acting barometric damper directly above the vent collar This damper will ensure smooth light off and minimize standby loss through the boiler Be sure to position the damper at least 6 away from the wall of the vent connector 7 RELIEF VALVE A pressure relief valve is supplied as standard equipment The relief valve protects against damage that could be caused by malfunctioning controls or excessive water pressure If a relief valve is not used warranty is void 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 method of freeze protection in hydronic systems This mixture will protect the boiler to approximately 35 F 37 C 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
19. 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 1 Supply 7 Return gt Chiller ZS see Boiler Pump 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 SYSTEM BOILER 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 rec
20. 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 Figure 13 Low Water Cut off Electrical Connections WARNING Be sure to remove the between H and P1 HL CH Connection detail for placing L W C O SIE ele in 24V circuit in series with flow switch G H PI 247 FLOW SWITCH w TO AIR SWITCH 11 10 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
21. 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 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 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
22. e 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 5 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 e Section 5 3 Air for combustion and Ventilation of the National Fuel Gas Code ANSI Z223 1 or e Sections 7 2 7 3 or 7 4 of CAN CGA B149 Installation Codes and e Applicable provisions of the local building codes The operation of exhaust fans compressors air handling units etc can rob air from the room
23. n If the safety control is functioning properly power to the gas valve will be shut off within 4 seconds of the pilot gas being shut off If shut down takes longer ignition control or gas valve may be defective 13 LOW WATER TEMPERATURE SYSTEMS In applications where the heating system requires supply water temperatures below 110 F a bypass line must be installed upstream of the boiler pump so that outlet water can be re circulated to raise the inlet temp to a minimum of 110 F Balancing valves preferably globe valves are used to adjust flow See figure 4 Figure 4 13 e Adjustment procedure Fully open bypass and outlet valves With boiler running read inlet temperature after 15 minutes If the inlet temperature is less than 110 F slowly close outlet valve until the inlet temperature climbs to 110 F d Ifthe inlet temperature is greater than 110 F but not greater than 140 F no further adjustment is required e Check the inlet temperature after 5 minutes and make final adjustments 14 INSTANTANEOUS WATER HEATER An instantaneous water heater is designed to deliver hot water without the use of a storage tank It is suitable for applications with variable load such as restaurants condominiums apartments and motels See figure 5 Call factory for recommendations Figure 5 14 15 PILOT AND MAIN BURNER FLAMES To maintain safe operation and the greatest efficiency of the boiler check the main b
24. nd 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 coil support base Failure to properly locate the burner will result in erratic flame operation with the possibility of delay on burner ignition 5 Restore electrical power and gas supply to the boiler e Following the lighting instructions put the boiler back into operation e Check for gas leaks and proper boiler and vent operation 15 2 PILOT BURNER Turn the pilot firing valve to off position and allow the appliance to try for ignition Observe the spark making sure that it is strong and continuous If the spark is not acceptable the igniter will have to be adjusted This can be readily accomplished after removing the main burner The spark gap should be 1 8 to 3 16 Make sure that 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 replace all gaskets and seals These seals are intended to prevent the bypass of air around the pilot Ground Electrode Pilot Burner Tube Igniter Primary Air Opening Pilot Orifice Figure 7 16 Once the spark
25. nting 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 2223 1 or CAN CGA 8149 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 2 Turn off electrical power and close main manual gas shut off and allow boiler to cool down Remove the vent pipe running to chimney Check heat exchanger vent and chimney for obstruction and clean as necessary Remove burner from boiler and vacuum burner top heat exchanger and coils Reinstall parts removed in steps 2 and 3 be sure that vent pipe has proper pitch and is properly sealed Restore electrical power and gas supply to boiler Place boiler in operation using lighting instructions provided Check for gas leaks and proper vent operation The is a category 1 appliance Three venting options are available for this boiler See Figure 1 for details OUTDOOR VENTING UL APPROVED VENT CAP RAIN COVER 40 uz STANDARD VENTING SIDEWAL
26. nual valve is open e Follow lighting instructions to bleed air out of pilot line e Remove main burner and inspect for moisture or dirt in pilot or in pilot line e Verify that pilot is sealed to main burner base e Verify that gas connections are tight 4 Pilot lights momentarily goes out e Observe pilot for proper flame Adjust if necessary and then sparks again repeatedly e Check pilot flame signal Properly set pilot to generate 1 5 D C on average e Hemove main burner and ensure that igniter and ground electrodes are positioned properly Clean with steel wool if necessary e 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 Verify that high limit is set high enough to prevent fire short cycling e Check pilot flame signal e Adjust pilot pressure for steady flame e Remove main burner Check position of igniter and ground electrode Clean with steel wool if necessary 6 Main burner lights but cycles off after e Verify that high limit is set high enough to prevent a few minutes short cycling e Adjust pilot pressure for steady flame e Remove main burner Adjust pilot shield and clean ignition sensor 7 Boiler starts to whine as the e Verify that all air is bled from system temperature rise increases e Verify that the static pressure in cold system is at least 15 psig e Check temperature
27. ommendations Table 2 Model US g p m TEMP HEAT EX RISE F AP Ft CF450 37 0 20 0 1 7 CF550 70 0 12 3 4 0 CF650 70 0 13 8 4 0 Figure 3 10 If the boiler is installed above radiation level it must be provided with low water cutoff device at the time of boiler installation Available from factory A pressure relief valve is supplied with each Cera Flame boiler The relief valve must be piped to the floor in a manner acceptable to the enforcing authority To eliminate trapped air install venting devices at high points in the system as well as in the piping on the suction of the pump and in the piping on the discharge of the boiler Suitable pipe hangers must support the weight of all water and gas piping or floor stands Do not allow the boiler to run with inlet water temperature below 110 F The boiler 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 10 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 10 2 LOW WATER CUTOFF If Equipped If this
28. 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 CAUTION Avoid contact with hot discharge water 11 PLACING BOILER IN OPERATION The Cera Flame boiler should be installed and started up by qualified personnel With the boiler off open makeup water valve and allow system to fill slowly Adjust the pressure regulator to provide at least 15 PSIG at the highest point in the system With all air vents open run system circulating pump for a minimum of 30 minutes with the boiler off Open all strainers in the circulating system and check for debris Check liquid level in expansion tank With system full of water at 15 PSIG the level of water in the expansion tank should not exceed of the total volume with the balance filled with air Start up boiler following instructions provided Operate entire system including pumps and radiation for at least 1 hour Check water level in expansion tank If level exceeds 1 2 of tank volume air is still trapped in system Shut down boiler and continue to run pumps Within 3 days of start up recheck all air vents and expansion tank as described above 12 12 IGNITION SYSTEM SAFETY SHUT OFF DEVICE After initial fill while the main burner is firing shut off gas to the pilot and clock the time taken for the main gas valve to shut dow
29. urner and pilot burner every six months for proper flame characteristics 15 1 MAIN BURNER The main burner figure 6 should display the following characteristics Acceptable CO and levels for complete combustion Light off smoothly Reasonably quiet while running Stable flame with minimum of lifting Blue flame with natural gas yellow tips with propane gas Air Gas Inlet Figure 6 If burner characteristics do not match the above check for proper air box pressure Also look for accumulation of lint and other foreign material at fan air inlets Typical air box settings are as follows MODEL AIR BOX W C FLUE SWITCH RECYCLE POINT with burner firing W C 450 0 52 0 42 550 0 60 0 48 650 0 70 0 58 Depending on field conditions air box will have to adjusted accordingly Always set the appliance for a CO2 level in the range of 7 5 to 8 0 15 Aqualified service technician should follow this when burner needs cleaning 1 Shuloff power and close main manual gas valve e Allow burner to cool before removal 2 Remove access cover screws Disconnect pilot gas at bulkhead fitting Disconnect ground wire and ignition wire Remove two wing nuts holding down burner Gently pull down and forward to disengage burner e Remove burner being careful to not damage the pilot shield 3 Thoroughly clean burner Check all ports a
30. ve and main firing valve and wait 5 minutes 3 Set primary system controller to desired temperature 4 Open pilot valve 5 Turn on electric power to boiler The electrode at the pilot should begin to spark after pre purge is complete The pilot valve will open to permit gas flow to the pilot 6 There is a 15 second trial for ignition which is enough time to light the pilot if air is not present in the pilot line 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 strap 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 If not repeat lighting procedure steps 1 thru 7 TO TURN OFF BOILER Close main manual valve and main firing valve and turn off electric power to system 18 18 TROUBLE SHOOTING GUIDE SYMPTOM SOLUTION 1 Power light is not lit when switch is e Check wiring to switch flipped to ON e Check circuit breaker e Check luse 2 Water flow light remains off e Verify that pump is running e Check wiring to flow switch 3 Pilot sparks but does not light e Verify that main ma
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