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Installation Operation and Service Manual

1. 1 DISPLAY UNIT CC N 1 SEQUENCE OF OPERATION ie dette ceca haar dele 1 Peat 2 End 1926 50 V OM t UMS 2 INSTALLA NON GODE 2 WARRANT RT 2 REMOVAL OF EXISTING APPLIANGE Opa nae eene E cest i 3 BOILER FURNACE ROOM OPERATING CONDITION eere 3 BOG ATION eee CLEARANCE FROM COMBUSTIBLE 4 R 7 GENERAL VENTING GUIDE 2 e 7 GATEGORY IV VENTING CTH O62 S02 acti bte e e riis 7 Approved Venting Materials Category IV 8 CATEGORY II VENTING TA 202 502 cisx 5 8 Approved Venting Materials Category 8 COMBINED GOMBUSTION AIR INET tes oor anle eee EE pO rco ee etes 9 VENT TERMINATION AND AIR INLET 9 SIde Wall TD mmm 9 S ge wall IBID uet oto R 10 Sidewall Goricentrie V eb IE ed viue si cuc a dct 1
2. 16 TIONG 16 eT cr E 16 THEGON TROLL ae Ras e 16 17 IGNITION Mod le LOCKOUL FUNCIONS cos occi edad 17 ERROR TABLE ee eee 17 OE TERN 17 ACIO elec ic NP DH PDC NR PLI TTC 17 PARTO OONIROLJIADNEL 18 6 1 GON GROLLER M 18 6 2 a a 18 6 3 DOMESTIC HOT WATER OPERATION eh Uc eto eene ve etus ead ite 18 PART adie Me duum 18 7 1 18 7 2 SENSOR 18 7 3 FAN m 19 7 4 AS MADE uu dete tud MM EL LE EDAM LM E E UE 19 TD OUTER 19 PARTE GON TROL PANE scissa tence 20 8 1 INTRODUCTION TO THE TH CONTROL PANEL 20 8 2 USER MODE TET 21 8 3 SE TUP MODE ee 22
3. 43 PARTII INSTALLATIONS a 44 11 1 CHECKING THE INSTALLATION cu cuales ee t edet 44 11 2 CHECKING THE CONSTRUC 44 11 3 INSPECT amp RECHARGE CONDENSATE COLLECTION NEUTRALIZING RESERVOIR 44 11 4 WATER GONNEGOTIONS 44 11 5 44 11 6 TEMPEBRATURE RISE AT FULEFIRING RATE iiis tonis 45 11 7 SETTING THE CORREGT COMBUSTION d eR e o uoo Ret ee setae 45 11 8 45 11 9 IGNITION CYC CE 46 PART 12 SUGGESTED PIPING DIAGRAM Ss casetas tigre deductae esed o bed does 47 PART 13 EXPLODED VIEW PARES teu odes 48 PART TA ELECTRICAL DIAGRAMS uU d eds diem das et dubii Naan 52 14 1 82 502 INTERNALWIRING DIAGRAM eese 52 14 2 DETAILED CONNECTOR DESCRIP TION 1 2 Cueva feuda tutem a eo pa 53 PART 1 GENERAL INFORMATION 1 1 INTRODUCTION The TH Series is a fan assisted heater based on a push through design which offers several venting options Heat Output is controlled by a one to one air gas ratio control gas valve which provides seamless modulation The heater provides domestic hot water at working pressures up to 1
4. 1 Y Y e PES ooo x GMio0 25 098 01 X Y 48 Bumer Retactory LO Automatic Air Vent X T Y 4 FwSesr Nntc sensoroos X 4 Sesrwre X TH Fan Discharge gree Expandable Air 105622 x x 53 Inlet Adapter w o wA ws Point e 221 042 001 Burner Burner Gasket Gas Valve Wire 45900441 015B Harness Fire Valve Metal Latch Strike On Off Switch 56 Standard Displa 57 Upgraded Displa Gas Valve Elbow TH 2 lt 58 59 TH Wire Harness 77 0087 60 InletSensor NTC SENSOR 002 61 Outlet Sensor NTC SENSOR 002 GM10 15 991 01 Rear Vent Adapter GM10 15 992 01 65 Gas Valve Relay 1649341 8 Anode Water Heater Anode High Limit TCLO85A PVC 2 Ami Plastic to 300566 Stainless Steel Vent Adapter 300611 Not shown in Exploded View ri 8 51 PART 14 ELECTRICAL DIAGRAMS TH 82 502 INTERNALWIRING DIAGRAM 14 1 qussuoo YEN p 5 587 noja paldosaypasn ED ey SEES z TET 13 snweg M6 jo padod ayy s spur 19 Z09 Z52H 1 140 MS 3574 21199848 VIO 8 V Sv9
5. NNY 3013 0330018 43 0 9 rY 4 lq SSINOYGAH 5 1 8 180 HOLIMS 91 1 4 SVO 03 2018 9601 jo 7 j pe e de aq 15 82422098 9r ou upa se a3 jeujBpo Aue 1 2 NOIL23NNO2 1 2 gi 3A TVA SYD AbZ Q3MH 7 a ug A t NOSN3S 1 140 M 3207831NI L 330 MOVLS 6 716 svo z MOT B z N33H9 9 NOSN3S i 2 dal Z st amie 19 0 5 32v18 9 LNAWE INOS 10 9 3A WASWO Ave Weviy A A bh BOSN3S F 6 auvos LFLLNO a O31vVHO3LNI 1 t 4 g 9 Lq NOSN3S 4 9 L LIT c 5 197 L zr 22 18 4 i LA M HOW 9 39 X8 ON9 Nid i 02 m OND 2161 Se 120 31033 m 021 4 2509 AGLI M Alddns 07313 M 52 14 2 DETAILED CONNECTOR DESCRIPTION Connector Description Connector Connector Description Flame Sensor and Ground 24VAC Power Outlet Sensor 24VAC Not Used 24 VAC Return Flame Se
6. 1 11 CLEARANCE FROM COMBUSTIBLE MATERIAL This appliance is suitable for alcove a closet without a door installation with minimum clearances to combustibles as follows Table 2 Clearance from Combustibles VENT Vent Adapter Stainless Steel VENT 0 Figure 1 TH Clearance from Combustibles a D 12 REAR M La 6 FRONT T NOTE Clearances from combustible construction are noted on the appliance rating plate Table 3 TH Service Clearances 80 000 O O 24 61 12 61 24 61 24 61 OJO OJO OJO 56 O 0 c 3 3 Combustion age H z 8020 _ 1 4 Condensate Drain Table 4 Appliance Dimensions and Specifications 80000 53 221 4 461 4 463 8 4712 834 978 738 8 3 2 1 12 100 000 53 2214 461 4 463 8 47 1 2 834 978 738 8 3 2 1 12 150000 53 221 4 4614 463 8 47 1 2 834 978 738 8 2 1 12 199 000 53 311 4 3734 4638 471 2 1218 978 738 3 2 4 1 12 250000 53 311 4 373 4 463 8 47 1 2 1218 978 738 3 2 4 114 12 299 000 65 1 2 31 1 4 37 1 2 583 8 53 7 8 1218 113 8 878 4 3 3 5 114 34 399 000 65 1 2 31 1 4 37 1 2 583 8 53 7 8 1218 1138 878 4 3
7. 3 Air inlet must terminate at least 3 feet 1 0m above the roof or normal snow levels and at least 1 foot 0 3m below the vent termination 4 Locate terminations so they are not likely to be damaged by foreign objects or exposed to build up of debris 5 Perform regularly scheduled inspections to ensure that the air inlet terminal is unobstructed Figure 10 Vertical Direct Venting Configuration 45 DEGREE VENT Be 9 AIR INLET MUST BE 12 MIN BELOW _ VENT OPENING AIR INTAKE at AIR INLET 90 DEGREE ELBOW Vertical Concentric Vent Air A concentric vent kit can be used with the TH appliance Both combustion air and vent pipes must terminate outside the structure 1 2 The total length of piping for venting or air must not exceed the limits stated in Table 8 The bottom of the termination shall be located at least 3 feet 1m above grade or above normal snow levels In all cases the appliance shall be installed in accordance with local codes 3 The termination MUST NOT terminate below a forced air inlet at any distance 4 The termination cannot terminate below grade Position the termination where vapours will not damage walls or plants or may be otherwise objectionable 5 The termination shall not be installed closer than 3 feet 1m from an inside corner of an L shaped structure window well stairwell alcove courtyard or other recessed area as wind eddies could affect boiler perfor
8. Ojo O N Burner control rate non firing was invalid vs RPM Flow Switch Blocked Flue Switch Absolute max fan speed was out of range Absolute max fan speed was out of range Absolute min fan speed was out of range 29 30 61 62 6 6 Flow Switch or Blocked Flue Switch tripped during Burn state 353 Stack limit PVC 149 F CPVC 194 F PPE 230 F SS AL29 4C 250 F 981 Communication error with displa C 68 75 76 79 82 91 92 93 95 291 294 818 75 76 79 82 91 92 93 95 291 294 03 09 310 318 17 PART6 CONTROL PANEL 61 CONTROLLER The appliance is provided with an operator interface panel at the front The TH Controller can be accessed by removing the black coloured top cover steel jacket which is held on by two 2 screws The front upper jacket can simply be removed by pulling the panel towards you The boiler temperature controller for this appliance is a proprietary Camus TH Controller It initiates the local call for heat and sets the target temperature inlet water temperature This controller provides the following e Readings of inlet and outlet water temperatures stack temperatures domestic hot water temperature flame current status of heater operation etc Operation as an auto reset high limit Adjustable target temperature Molex and JST connectors for ease of service Error message display
9. pump Shut off the gas supply at a location external to the appliance e Boilers and water heaters are heat producing appliances To avoid damage or injury do not store materials against the appliance or the vent air inlet system Use proper care to avoid unnecessary contact especially children with the appliance and vent air inlet components e Never cover appliance lean anything against it store trash or debris near it stand on it or in any way block the flow of fresh air to appliance e UNDER NO CIRCUMSTANCES flammable materials such as gasoline or paint thinner be used or stored in the vicinity of this appliance vent air inlet system or any location from which fumes could reach the appliance or vent air inlet system e A gas appliance that draws combustion air from the equipment room where it is installed must have a supply of fresh air circulating around it during burner operation for proper gas combustion and proper venting 1 6 INSTALLATION CODES The equipment shall be installed in accordance with those installation regulations enforced in the local area where the installation is to be made These shall be carefully followed in all cases Authorities having jurisdiction shall be consulted before installations are made In the absence of such requirements the installation shall conform to the latest edition or current as amended of the National Fuel Gas Code ANSI Z223 1 and or CAN CGA B149 Installation Co
10. 6 2 SETTING THE TH CONTROLLER Press the Next button to view the desired setting When the desired setting is satisfied press the UP DOWN key and this will save the last setting In normal operating mode the DHW Inlet temperature and the status of the heater is shown 6 3 DOMESTIC HOT WATER OPERATION DHW Storage Tank with Temperature Sensor The DHW temperature is measured with the heat exchanger inlet sensor and set with parameter DHW setpoint When the DHW sensor drops below DHW setpoint DHW on hysteresis the control detects a demand for the storage tank and activates the pump If the DHW temperature continues to drop the ignition sequence will begin When the burner is lit the load is PID modulated so the supply is regulated towards DHW setpoint The burner will fire at steady state or it shall shut off if the DHW temperature is greater than DHW setpoint DHW off hystersis The on board pump will continue to circulate until the pump overrun timer is satisfied Frost Protection To prevent freezing of the heat exchanger the on board pump 15 turned on if the DHW temperature is below 45 F The on board pump remains on until the DHW temperature exceeds 50 F When this occurs the DHW pump continues to circulate until the post pump timer is satisfied If the DHW temperature continues to fall below 38 F the controller requests a minimum modulation fire rate This operation continues until the DHW temperature excee
11. 7 3 COMBUSTION AIR FAN TH uses a modulating air fan to provide combustible air gas mix to the burner and push the products of combustion through the heat exchanger and venting system The fan assembly consists of a sealed housing and fan wheel constructed from spark resistant cast aluminum The fan is operated by a fully enclosed 120 VAC Single Phase EC DC electric motor The fan housing and motor assembly is fully sealed and SHOULD NOT be field serviced The power draw of the motor is proportional to the modulated gas input rate of the appliance 7 4 GAS VALVE Figure 19 Venturi and Gas Valve Arrangement E The Gas Valve supplied with the TH is a combined valve venturi assembly A servo pressure regulator is incorporated into the gas valve to provide stable gas supply Pressure taps are provided to check inlet and outlet gas pressures An internal fine mesh screen is incorporated in the inlet of the gas valve to prevent debris from entering the combustion chamber Gas valves are factory set at low and high fire and modulates to maintain combustion characteristics across the full operating range 7 5 OUTER JACKET The outer jacket assembly is constructed from mirror finish stainless steel This ensures a long life for the jacket assembly with full integrity 19 PART8 TH CONTROL PANEL 8 1 INTRODUCTION TO THE TH CONTROL PANEL The menu structure for the TH Control Panel was designed to be intuitive and easy to
12. PART 3 GAS CONNECTION Verify that the appliance is supplied with the type of gas specified on the rating plate Consult factory for installations at high altitude 3 1 3 2 GAS CONNECTION Safe operation of unit requires properly sized gas supply piping See gas line sizing data Gas pipe size may be larger than appliance connection Installation of a union at the appliance gas line connection is required for ease of service and removal of the gas train Install a manual main gas shutoff valve outside of the appliance gas connection as require by local codes A trap drip leg MUST be provided in the inlet gas connection to the appliance Optional gas controls may require routing of bleeds and vents to the atmosphere outside the building when required by local codes Table 7 Recommended Gas Pipe Size Single Appliance Installation For distance from natural gas meter or propane second stage regulator ow a p T T 201 300 FT o pee pee GAS PIPING U All gas connections must be made with pipe joint compound resistant to the action of liquefied petroleum and natural gas All piping must comply with local codes and ordinances 3 3 INSTALL PIPING The gas line should be sufficient to handle the total installed capacity Verify pipe size with your gas supplier Use approved piping as per code free from burrs Install a manual main gas shutoff valve at the appliance gas inlet outsid
13. Timer is satisfied 16 The pump continues to circulate until the post pump time is satisfied 17 The boiler will then go into Standby as it waits for the next heat demand Figure 1 TH Ignition Cycle IGNITER MAN FLAME REQUIRED FALURE TO IGNITE OPTIONS LOCKOUT AMI CYCLES THEN LOCKOUT OUNT RECYCLES THEN DELAY MMS RECYC LE NOLIMIT RUN STABLIZATION i BE ZERO STANDBY PREPURGE H AT4S RUN POSTPURGE FLAME REQUIRED LOCKOUT OR RECYCLE RECYCLE DUE TO _FALURE TO IGNITE ee FLAME FALURENRUN 7 PREIGNITION MAY BE ZERO 3K CLEAR THE FAILURE TOINTE RETRY COUNTER Note 1 If aflame signal is detected at the end of the pre purge period a lockout will occur 2 If at the end of the safety period 6 sec no flame is detected the control will go to post purge to remove the unburned gas After this a re ignition attempt is started following the same cycle The number of re ignition attempts is limited to 2 after which a lockout occurs 3 The burner can only be on continuously for a period of 24 hours After this the burner is switched off and a restart sequence follows 4 Sparking stops 2 seconds before the end of the ignition period to allow for ionisation detection 1 5 2 Heat Transfer Process 1 Burner input continues to increase until DHW water temperature reaches the setpoint temperature 2 Burner input may stabilize at
14. 7 Venting of Equipment of the latest edition of the National Fuel Gas Code ANSI Z223 1 for US installations or the latest edition of CAN CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment in Canada e The distance of the vent terminal from adjacent buildings windows that open building openings MUST comply with the latest edition of the National Fuel Gas Code ANSI Z223 1 for U S installations Standard B149 Installation Code for Canadian Installations e Vent connection is made directly to the flue outlet opening on the rear of the unit The connection from the appliance vent to the stack must be made as direct as possible The first 3 feet of vent from the appliance flue outlet must be readily accessible for visual inspection e Vent connectors serving appliances vented by natural draft shall not be connected into any portion of a mechanical draft system operating under positive pressure A UL listed concentric vent air intake kit may be used with the TH e Horizontal runs of vent pipe shall be securely supported approximately every 4 feet to prevent sagging and maintain a minimum upward slope of 14 per foot from the appliance to the vent terminal e The weight of the venting system must not rest on the unit Adequate support of the venting system must be provided in compliance with local codes and other applicable codes e All connections should be secured and seal
15. 7800 week today on our innovative products CAMUS HYDRONICS LTD 6226 Netherhart Road Mississauga Ontario 157 187 TEL 905 696 7800 FAX 905 696 8801
16. Adapter 300704 44 0010 l 1X Oen wee x Witch e qo tse _ EB X X l l E838 VK8115V1341 X X X X X 7 Gas VR8615B1044 8730 1015 X Expandable Air 140370 X X X X X X X Inlet Adapter 44009 1 X Transition Arm L 9M20700200 X X X X X X X GMio 15 997 03 459000 444 003 X X 1 T 45000044400 10 Venturi 459000446051 X X 45900450000 J vM30A106 X 460050900 j J j Jj Combustion Ean 15056800 j j 150563 05 56671402 x gt RBerBacke 5911 xX xX j 14659202025 X Xx _ 4 j j l Heat Exchanger ew tore l l Lx Ll r 40 Transformer 01 6 X J J J 15 Pump Relay LY1F Ignition Control R7910B1009 X Control Panel 14 5614 Front 14 5648 Floor
17. EXCHANGER MODEL PFC 11 1 C BTU hr USGPM CAUTION Temperature rise cannot be adjusted when the burner is firing at less than 100 of input rate CAUTION Adequate care MUST be taken to prevent potential scald injury when storing water at 140 F 60 C and hotter WARNING Should overheating occur or the gas supply fail to shut off do not turn off or disconnect the electrical supply to the pump instead shut off the gas supply at a location external to the appliance 11 7 SETTING THE CORRECT COMBUSTION Refer to Section 9 1 Setting the Correct Combustion 11 8 APPLIANCE Remove manometers and tighten test port screws e Fill out start up report for each heater Be sure to record all settings and readings Retain a copy of report for future reference e Start up is now complete and heater may be placed into service 45 11 9 IGNITION CYCLE The ignition cycle is shown in the table below The values are the default factory settings Figure 36 TH Ignition Cycle IGNITER FLAME REQUIRED FALURE TO IGNITE OPTIONS STANDBY PREPURGE LOCKOUT COUNT RECYCLES THEN LOCKOUT COUNT RECYCLES THEN DELAY 55 5 Su RUN STABILIZATION 82 MAY ZERO FE FIXED 45 i RUN POSTPURGE FLAME REQUIRED LOCKOUT OR RECYCLE RECYCLE DUE TO FALURE TO IGNITE RECYCLE DUE TO FLAME FAILURE IN RUN N23037 CLEAR THE
18. FAILURE TO IGNITE RETRY COUNTER p PART 12 SUGGESTED PIPING DIAGRAMS Figure 37 Dedicated DHW Suggested Piping Arrangement HOT WATER SUPPLY HOT WATER BUILDING RETURN TEMPERATURE PRESSURE leg GAUGE 4 1 IAN eT E VALVE 1 f 5 COLD SUPPLY WATER N 1 UNION ANTI SCALD MIXING VALVE Figure 38 Combination Application Suggested Piping Arrangement HOT WATER SUPPLY 5 10 VALVE TANI BALL VALVE COLD WATER SUPPLY utn on HOT WATER BUILDING RETURN ZONE PUMP CHECK VALVE TEMPERATURE PRESSURE GAUGE Note Cold water piping should be below hot water connections to prevent heat migration during times of low heat demand NOTE HEATING ZONE PUMPS MUST BE EXERCISED ON A REGULAR BASIS DURING SUMMER MONTHS WHEN HEATING I NOT REQUIED 47 Em a 06 se ve ec zz Cer or 6 48 ALL 82 102 152 202 252 292 302 soz Outer Jacket 145605 Outer Jacket 14 5629 X X X Top Cover 14 5609 X 44 0008 xX xX x x x 3
19. If not pump impeller may be stuck Use a flat head screwdriver on face of pump to turn impeller manually If 120VAC is present during a call for heat but the pump still does not circulate replace the pump Replace the main TH Controller if necessary 31 SYMPTOM FAILURE MODE ANALYSIS Manual Reset Safety High Limit Verify that the capillary tube is broken If this is the case tripped supply outlet temperature replace Manual Reset High Limit in excess of 210 F Verify that the system is full of water and that all air has Manual Reset High Alert 303 310 been properly purged from the system Limit Trips Verify that the boiler is piped properly Refer to Piping Pressing the Diagrams in Section 12 of this manual manual RESET on e Verify that 120 VAC is being supplied to the boiler pump the TH Control on a for heat If voltage cannot be detected check Panel will be wiring required to restart Verify that the pump is circulating when 120 VAC is the ignition supplied If so pump impeller may be stuck Use a flat sequence head screwdriver on face of pump to turn impeller manually f 120 VAC is present during a call for heat but the pump still does not circulate replace e Actual fan RPM is 30 slower than Verify wiring connections at the fan and TH Controller Fan Speed Too target fan speed Replace the fan Low Alert 60 76 Replace the TH Controller Actual fan RPM is 30 faster than V
20. Jurisdictions ONLY when 399 000 permitted 6 Polypropylene approved to comply with ULC 5636 500 000 4 9 121 9 Consult factory for recommendations applicable to venting combinations not shown above 2 3 CATEGORY II VENTING TH 202 502 Use of cellular core PVC ASTM F891 cellular core CPVC or Radel amp polyphenosulfone in venting systems shall be prohibited u A category Il appliance may be combined into a common Covering non metallic vent pipe and fittings with thermal negative pressure venting system designed to ASHRAE insulation shall be prohibited requirements using a proven vent sizing program Vent designs are to be certified by a qualified professional designer Table 5 Maximum Flue Temperature for Various Vent acceptable to the authority having jurisdiction Materials 1 The TH may be vented as a Category II appliance using sealed vent suitable for condensing appliance Vent Materia aximum Flue Temperature UF 2 3 1 Approved Venting Materials Category Il PVC 149 1 PVC and CPVC Chlorinated Polyvinyl Chloride CPVC 194 Schedule 40 or 80 approved to ULC S636 230 2 Manufactured prefabricated UL ULC listed vent of AL29 __ 4 3161 stainless steel Use of 3161 is limited to use 3 5 30 300 limited only by rating of seals in where there is no possibility of contaminants in the air ainiess such as refrigerants chlorine etc Steel 3 PVC DWV approved to comp
21. 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 9 Production of noise odours discolouration or rusty water 10 Damage to surroundings or property caused by leakage or malfunction 11 All labour costs associated with the replacement and or repair of the unit 12 Any failed component of the hydronic system not manufactured as part of the boiler HEAT EXCHANGER If within TWELVE years after initial installation of the appliance a heat exchanger shall prove upon examination by Camus to be defective in material thermal shock leakage or workmanship Camus will exchange or repair such part or portion on the following pro rated limited warrant eae o o a o This term is reduced to SIX 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 inlet and appliance temperature or operating at temperatures exceeding 210 F BURNER If within FIVE y
22. and hold down screw the condensate collection box WARNING The condensate collection box must be filled with water to prevent flue gas emissions from escaping during boiler operation CAUTION A leak in a boiler System will cause the fill system to introduce fresh water constantly which may cause the tubes to accumulate a line scale build up Lime scale buildup leading to heat exchanger failure is NOT covered by warranty 11 4 WATER CONNECTIONS System pipe size must be in accordance with Table 9 depending on model Connection sizes at the heater are given in Tables 4 Any reduction in recommended pipe size may decrease flow resulting in high temperature rise across the heat exchanger boiler noise flashing to steam and non warrantable heat exchanger damage 11 5 SUMMARY a Typical Heater Installations General Plumbing Rules 1 Check all local codes 2 Forserviceability always install unions 3 Always pipe pressure relief valve to an open drain 4 Locate system air vents at highest point of system 5 Expansion tank must be installed near the heater and on the suction side of the system pump 6 Support all water piping 7 Place drip pan underneath heater if required b Placing the Heater in Operation Pre Start Check List 1 Review the location of the heater clearances from combustible surfaces available service clearances 2 Part 2 Venting Ensure that all ven
23. front to allow easy access to the heat exchanger The appliance must be installed so that the ignition system components protected from water dripping spraying etc during appliance operation and service circulator replacement control replacement etc Appliances located in a residential garage and in adjacent spaces that open to the garage and are not part of the living space of a dwelling unit must be installed so that all burners and burner ignition devices have a minimum clearance of not less than 18 46cm above the floor The appliance must be located or protected so that it is not subject to physical damage by a moving vehicle DO NOT install this appliance in any location where gasoline or flammable vapors are likely to be present Appliance must be installed on a level floor Maintain required clearances from combustible surfaces The appliance designed for indoor installation Indoor Models must be installed indoors where it is protected from exposure to wind rain and weather The appliance designed for outdoor installation Outdoor Models must be installed outdoors 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
24. ignite promptly Flame profile should be stable see section 10 2 Visually Check Main Burner Flames Turn system off and allow burner to cool then cycle burner again to ensure proper ignition and flame characteristics IMPORTANT Upon completion of initial installation or following any repair work on the gas system leak test all gas connections with a soap solution while the main burner is firing Immediately repair any leak found in the gas train or related components DO NOT operate an appliance with a leak in the gas train valves or related gas piping 3 5 HIGH and LOW GAS PRESSURE SWITCHES Optional High and low gas pressure switches are available as an option and are wired in series with the blocked flue switch The high gas pressure switch is used to monitor the differential gas pressure between the outlet of the control valve and the fan inlet If differential gas pressure exceeds the maximum setting of the pressure switch the appliance will shut down and a low air condition will be indicated on the display panel The low gas pressure switch is to monitor the minimum incoming gas supply pressure supplied to the gas train If gas pressure falls below the minimum setting of the pressure switch the appliance will shut down and a low air condition will be displayed on the display panel 3 6 AIR GAS RATIO VALVE The main gas valve supplying gas to the burner on this appliance utilizes a servo pressure regulator providing a sl
25. must be provided with a low water cut off device at the time of appliance installation available from Camus Some local codes require the installation of a low water cut off on all systems e A temperature and pressure relief valve is supplied with each TH The relief valve must be mounted in a vertical position and piped to the floor in a manner acceptable to the enforcing authority sure to provide unions and gate valves at inlet and outlet to the appliance so that it can be easily isolated for service e This appliance is a low mass stainless steel tube design which provides for instant heat transfer All appliances are supplied with an internal suitable specific pump mounted in place When replacing the pump replace with one of equal or better performance air vent is supplied on the heat exchanger header to eliminate trapped air Install venting devices at high points in the system as well to eliminate trapped air in the piping e Use suitable pipe hangers or floor stands to support the weight of all water and gas piping The TH must be installed so that the gas ignition system components protected from water dripping spraying rain etc during appliance operation and service circulator replacement control replacement etc e Pipe cold water supply below hot water connection to prevent heat migration during times of low heat demand 4 1 INLET AND OUTLET CONNECTIONS All water connections mu
26. outlined in This Limited Warranty Does Not Cover b Reimburse any costs associated with repair and or replacement c Replace and or reparir any boiler without complete model number serial number d Replace any boiler without prior receipt of actual rating plate from the appliance 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 the resulting flow of water will not cause damage to its surroundings Name of Owner Name of Dealer Address Model No Serial Date of Date of Initial Installation Operation 6226 Netherhart Road Mississauga Ontario 1 5 187 CANADA 54 CAMUS Hydronics is a manufacturer of replacement parts for most copper finned The CAMUS CERTIFIED Seal assures you that Reliability Efficiency amp serviceability are built water heaters into every and heating single X unit boilers as well as CANUS information supplier of specialty HVAC products Our service line from CAMUS Hydronics is open 24 hours 7 days Limited call 905 696
27. reset a lockout condition Wait five seconds after turning on the main power before pushing the RESET button when the TH Controller is in a lockout condition Wait for the status LCD display to refresh indicating that the TH Controller is ready before releasing the reset button The TH Controller will go into an alert condition for example if the supply sensor is disconnected flow switch or air switch are not made If the fault is not corrected the boiler will stay in an alert condition Once the fault is corrected the boiler will automatically return to normal operating state 5 4 ERROR TABLE The following tables provide a description of all the possible errors with the TH boiler Errors can be divided into two groups Alert errors will disappear when error is gone and lockout errors can only be reset by the RESET button When the control is in error the pump will be running This is done to prevent the freezing of the central heating circuit when the boiler is in error during the winter period For some non volatile lockouts the pump will not be running see table below for more details 5 4 1 Lockout Codes Table 12 Lockout Codes Description 31 Zn E Fan speed not proved ignition failure 1 0 2 1 93 Flame lost during run Ignition Failure Occurred 132 Fan Speed Fault 5 4 2 Alert Codes Table 13 Alert Codes Description 3 5 9 9 105 106 a
28. spaces in which the appliances remaining connected to the common venting system are located and other spaces of the building If applicable 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 control device relief opening after 5 minutes of main burner operation After it has been determined that each appliance remaining connected to the 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 should be corrected so that the installation conforms to the National Fuel Gas Code ANSI Z223 1 and or 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 7223 1 and or CAN CGA B149 Installation Codes Heat exchanger surfaces and vent piping should be checked ev
29. use for a first time user To maintain the TH boiler at its correct settings three levels of security is provided User Setup and Diagnostic with an increasing amount of parameters that can be adjusted with each higher level of access This is done to provide an easy means of communication for the end user and a more in depth approach for factory and installers when installing and troubleshooting Figure 20 TH Control Panel Layout Table 14 TH Control Panel Key Functions Reset Lockout errors Scroll forward through the CONFIRM NEXT parameter structure Store parameter value Pressing the button changes the setpoints in one degree increments Pressing and holding the button changes the setpoints in five degree increments Pressing the button changes the setpoints in one degree decrements Pressing and holding the button changes the setpoints in five degree decrements DOWN Startup Display Upon startup of the TH all text on the LCD will be shown for 2 seconds followed by the software version number for an additional 2 seconds The Version relates to the version of software uploaded onto the boiler control The display panel then defaults to the outlet temperature display and communicates with the TH Controller At this time dashes will be displayed in the numerical part of the LCD along with Outlet and Figure 21 TH Home Screen After a certain period of user inactivity the display times
30. 0 Mae Bem alins t I S MM 10 25 CETUR 12 GAS 12 aces at eee ae 12 FS ee a te a 12 CHEGKING GAS SUPPLY PRESSURE 13 HIGH and LOW GAS PRESSURE SWITCHES Optional 13 ALVE 13 BURNER 14 WATER DOIN duit 15 INLE FAND OUTLET CONNEC TIONS 25 15 512 REQUIREMENTS reete tren ae euet ken 15 tmd T 15 LOW WATER TEMPERATURE SYSTEMSS iie cat Ga Hie e videas 15 PIPING ARRANGEMENTS utendi eee 15 Field Supplied COMPONETS 00 02 Eat o rat bie dantur 15 FLOW PROVING DE VIOE 16 TRP RELIEF VALVE pau ee anc eee RU ec rut tutem 16 STAINLESS STEEL STORAGE TANK ats 16 S CONTROLS
31. 20 F Main value 011 Fan speed Lol Alarm Ott Flame signal 0 00 uA Interlock CILE Ori Firing rate et ed 6 2 input oad Control n STAT Demand fin Sustem sensor Outlet Time 01 Dau Off Safety relay DESCRIPTION Pressing p provides additional temperature information Auxilary Purit Pump B 3 way valve diverter operation DHW Pump Pump C Additional contact rated for 1 6hp Sequence of Operation srAT Q Pump interlock Pilot Valve Pump is energized on DHW Interlock Flow switch LWCO if equipped Blocked flue switch N C Low gas switch 4 5 w c High gas switch 14 w c N C 26 Domestic Hot Water Programming Instructions Modulation Fixed Setpoint Operation Standalone Electrical Connection s Boiler operates at a fixed DHW setpoint Modulates on boiler inlet sensor default Heat demand is generated when Remote Operator is Outdoor closed al 9 Sensor 0 4 20 A H 112 DHW Sensor Stat if required 15 Alarm 27 Lag T 17 18 519 oo0000 20 wal Modbus Press X and select Login 3 Select Advanced Setup Advanced Setup Quick Start Login Advanced Setup Display Diagnostics 1 Setup Select DHW Config Inlet Sensor operation Select Demand switch Sensor only and Press OK Select Mod sensor Inlet and Press go to s
32. 3 5 imn 1 500 000 65 1 2 31 1 4 371 2 58 3 8 53 7 8 1218 1138 878 4 3 3 6 11121 1 CO CO 0210240 O O IO Maintain minimum specified clearances for adequate operation All installations must allow sufficient space for servicing the vent connections water pipe connections circulating pump bypass piping and other auxiliary equipment as well as the appliance Figure 3 TH Service Clearances PART2 AIR INLET AND VENTING It is extremely important to follow these venting instructions carefully Failure to do so can cause severe personal injury death or substantial property damage 2 1 GENERAL VENTING GUIDE e Single pipe vent with common air from room Figure 4 Venting Configuration VERTICAL VENTING DIRECT VENTING The TH is a category condensing appliance 97 efficient unit The TH may be vented with manufactured prefabricated UL ULC listed vents of AL29 4C or 316L stainless steel or with plastic vent certified to UL ULC S636 such as IPEX System 636 CVPC or IPEX System 636 PVC or as permitted by local jurisdictions The TH must be vented and supplied with combustion and ventilation air as described in this section Ensure that the venting and combustion supply complies with these instructions regarding the vent system air system and combustion air quality e Installations must be in accordance with Part
33. 60 PSI It is designed for use with a fully pumped and pressurized water system The water heater will automatically modulate to provide heat outputs from 100 down to approximately 20 of rated input The TH utilizes a negative pressure gas valve The operation of the fan will generate a negative pressure in the venturi which draws in a matching amount of gas through the valve During operation the TH maintains a steady state efficiency across the entire range of modulation Air and gas are metered in precise proportion 1 1 allowing combustion characteristics which determine efficiency to remain the same over the entire operating range The TH is designed so that all of the sensible heating value and most of the latent heat is being transferred to the water 1 2 SPECIAL INSTRUCTIONS TO OWNER This manual supplies information for the installation operation and servicing of the appliance is strongly recommended that this manual be reviewed completely before proceeding with an installation CAUTION It is important that all gas appliances are installed by a qualified installer technician that is trained by Camus Hydronics It is in your own interest and that of safety to ensure that all local codes and all the following NOTES and WARNINGS are complied with Installing servicing or adjusting this appliance should be performed only by a qualified installer technician that is trained by Camus Hydronics The servi
34. 8 4 eed 23 8 5 SETTING THE TANK HEATER HS CONTROLLER 25 PARTS TROUBLESHOOTING iiio tud 30 9 1 SETTING THE CORREGT GCOMBUS 38 9 2 GAS VALVE ADJUSTMENT PROCEDURE oto extenta tt e nat pesci Corne denotes 38 FTA IPT INN 225565 26 22522 2 n P 40 10 1 EXAMINE THE VENTING SYSTEM EUM reru 40 10 2 VISUALLY CHECK MAIN BURNER FLAMES soisin a sonne enne 40 10 3 CLEANING BOILER HEAT EXGHANGER IA 41 10 4 CONDENSATE TREATMENT 41 1041 Condensate 41 10 5 IGNIFER AND FLAME SENSOR 42 10 6 CHECK IGNITER GROUND WIRING sas cadena tsi emos ot he EE 42 10 7 BURNER MAINTENANG E E a 42 10 7 1 Burner Removal and 42 10 8 REMOVAL OF COMBUSTION CHAMBER LINING 42 10 9 COMBUSTION AND VENTILATION 43 CONTROL CIRCUIT VOLTAGE be pan tees 43 10 11 COMBUSTIBLE MATERIALES 43 10 12 FREEZE PROTECTION FOR INDOOR amp OUTDOOR
35. CONTROLLER CAMUS rece LAF Back button to return to orevious menu The 5 way control pad allows for easy access to various p functions on the Tank Heater HS controller A button allows for immediate information concerning boiler operation including temperatures boiler status and any errors that are occurring The Boiler Temperature Controller for this appliance is the Honeywell SOLA It initiates the local call for heat and sets the target return appliance inlet water temperature This controller offers a range of operation modes which provides set point as well as modulating control It provides the following e Readings of inlet and outlet water temperatures as well as flame signal Operation as an auto reset limit Operation as a control for inlet water temperature outlet temperature system temperature e Available tank mounted sensor used in conjunction with inlet sensor e Adjustable target temp inter stage differential on delay between stages minimum on time per stage minimum off time per stage Flame failure signal Error message display in text Manual override of boiler input rate for combustion Pump exercising feature runs pump 10 seconds every three days in the event of no pump operation Levels of Access Two levels of access to simplify the use of the boiler User Access to general boiler and display settings and adjustments to the central heating and domestic hot wat
36. Display Diagnostics a Setup 4 Select Stack Limit 5 Select Preferred Stack limit and enter desired stack limit rate using 5 way control and press OK 28 View burner run time pump cycles Programming Instructions To view burner run time 1 Place both toggle switches in LOCAL pump cycles for maintenance 2 Press X and select Login and service purposes 3 Select Advanced Setup Advanced Setup Quick Start Login Advanced Setup Display Diagnostics 1 Setup 4 Select System Config 5 Select Statistics Config 29 PART9 TROUBLESHOOTING COMPONENT FAILURE MODE ANALYSIS Two wires interchanged No effect on safety Live and Neutral wires are interchanged Transformer The 24Volts and 120 Volts wired Transformer immediately burns out replace transformer Tripped are interchanged Wiring Issue Check that wires are correctly wired from the TH Controller to the pump delay relay Check that 24VAC is delivered to pump coil Faulty Pump on a wet rotor pump Pump impeller may be stuck Use a flat head screwdriver Pump Fails to face of pump to turn impeller manually Circulate e Replace Pump Air in the piping system Purge all air from the piping system Internal Fault on TH Controller Replace TH Controller System pressure exceeds relief Replace the standard relief valve with a higher rated valve Relief Valve valve setting up to the maximum pressure of the heat e
37. ES Adjust low fire combustion to 8 0 8 5 CO YES high fire combustion 8 5 9 0 CO NO NO NO NO Adjust ignition speed to 3000 RPM Adjust igniter gap to 3 16 and or clean ianiter Check regulator for proper static incoming gas supply pressure Verify gas valve is being powered by ignition control Check flame sensor for carbon deposits and clean if necessarv lt 8 5 Turn high fire screw counter clockwise lt 8 0 Turn low fire screw clockwise Replace igniter and graphite igniter gasket Position flame sensor so that it is closer to the burner gt 9 0 Turn high fire screw clockwise gt 8 5 Turn low fire screw counter clockwise at lighting the burner have failed This is a manual reset error where the 33 Hold 67 ILK OFF Flow Switch LWCO Gas Pressure Switch Blocked Flue Switch Alert 303 Abnormal Recycle ILK off during drive to Purge Alert 304 Abnormal Recycle ILK off during Measured purge time Alert 305 Abnormal Recycle ILK off during Drive to Pre igntion Alert 306 307 Abnormal Recycle ILK off during Pre ignition Alert 308 Abnormal Recycle ILK off during Main Flame Alert 309 Abnormal Recycle ILK off during Ignition Period This error can indicate a blocked flue or blocked intake condition low gas pressure switch tripped optional or high gas pressure switch tripped optional To identify the
38. INSTALLATION OPERATION AND SERVICE MANUAL 52589 GAS FIRED RESIDENTIAL AND COMMERCIAL STAINLESS STEEL TAN HEATERS CAMUS lt Hydronics Ltd US TH SERIES WATER SUPPLY ENERGY STAR South Coast A Models THO82 102 152 202 252 292 392 502 If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury or death Gy Do not store or use gasoline or other flammable vapours and liquids in the vicinity of this or any other appliance Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbour s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Qualified installer service agency or the gas supplier must perform installation and service After installation these instructions must be given to the end user or left on or near the appliance To the End User This booklet contains important information about this appliance Retain for future reference 6226 Netherhart Road Mississauga Ontario L5T 1B7 99 0079 Rev 0 3 TABLE OF CONTENTS RT 1 GENEBAL INFORMATION 1 JN RHRZIS PISCINES 1 SPECIALINSTRUGTIONS TO OW NER 1 CHECKING EQUIPMENT sirere a
39. K 8 Select Set Low Fire The TH should respond immediately and fire at 1500 RPM When this is achieved locate the low fire adjustment screw When the correct combustion values are achieved replace the screw cap back on to the gas valve Increase CO2 Decrease CO2 Low Fire Adjustment ow Fi ju Counter Clock lockwi Clockwise Wise PART 10 MAINTENANCE CAUTION It is important that all gas appliances be serviced by qualified technician trained by Camus Hydronics It is in your own interest and that of safety to ensure that all local codes and all the NOTES and WARNINGS in this manual are complied with To service or adjust this appliance it is imperative that the serviceman utilize a combustion analyzer to read and CO according to Camus Hydronics recommendations Listed below are items that must be checked to ensure safe reliable operations Verify proper operation after servicing 10 1 EXAMINE THE VENTING SYSTEM Examine the venting system at least once a year Check more often in the first year to determine inspection interval Check all joints and pipe connections for tightness corrosion or deterioration Flush the condensate drain hose with water to clean Clean screens in the venting air inlet system as required Have the entire system including the venting system periodically inspected by a qualified service agency 10 2 VISUALLY CHECK MAIN BURNER FLAMES At each start up after long shutdow
40. M OPERATING CONDITION e Due to low jacket losses from the appliance temperatures in the vicinity of the boiler room may drop significantly supplemental heat is required to maintain ambient temperature at minimum of 40 F 1 10 LOCATION OF UNIT Install this appliance in a clean dry location with adequate service clearance e Do not locate this appliance in an area where it will be subject to freezing unless precautions are taken Radiant losses from the TH are minimal and should not be relied on to keep the appliance room warm e Do not locate this appliance where it may be exposed to a corrosive atmosphere e The appliance should be located close to a floor drain in an area where leakage from the appliance or connections will not result in damage to the adjacent area or to lower floors in the structure it is recommended that a suitable drain pan adequately drained be instaled under the unit Under no circumstances is the manufacturer to held responsible for water damage in connection with this unit or any of its components e If the appliance is installed above the level of the building s radiation system a low water cut off device must be installed in the appliance outlet at a minimum of 3 ft 1M above the heat exchanger inlet outlet connections Some local codes require the installation of a low water cut off on all systems e When placing the appliance beware that a minimum clearance of 24 must be provided at the
41. Mount m NE at o2 me mj Wee 1488 6 ront Bottom 22 BezeSupot 14 5615 X Y mp EN wo fx 19021 x X X aj pega 25 wes 14888 0X 6 Neutralizer Box Condensate 9015100 X i X 1 1 1 sete oe 27 Base 12 5631 poms 1451 l 1 x 28 SupportLeq 51 og Stiffmerunder 14 5622 X x X f Syprtleg 15502 x aa T 145623 X X 1 508 X X X X 44 OuterJacket 1452060 X X J Jj Right 14500 X X 32 Hx Suppo 14502 33 Flame Sensor 10 35 109 01 X 34 Igniter GM103510801 X T Y 5 mesme x 36 RightBraket 41455132025 X T Y Bm 219 ed 14558482025 X X Heat Exchanger GM206502 01 X X X J f J Flange GM20 65 033 01 X X x VERE owes Lll meme 40 90009 x ensor Screws 41 IgniterGasket_ GM102501 8 X
42. NATION AND AIR INLET CLEARANCES 2 5 1 Sidewall Venting e The first feet 1m of vent from the appliance flue outlet must be readily accessible for inspection Figure 5 Sidewall Vertical Configuration BOILER CORB THO AUD IMTAEI i AU oF A gt 1 5 i i E aU 1 MIN Proh BOR OR nom SHOW LEVELS VENT PIFE E pet P r FIA OR SHIN LEVEE Always check local codes for minimum distance above ground or snow levels SCREEH RECOMMENDED Ta WERE PIPE Figure 6 Sidewall Horizontal Configuration ro gon ck INTAKE IE LL 1 U 1 FRON EH l d 19 d M Mam ADVE og PORE SHOW 2 GE cien Hk SHOW LEVEL Always check local codes for minimum distance above ground or snow levels Location of Vent Termination 1 2 10 11 12 The total length of vent piping must not exceed the limits stated in Table 6 The bottom of the vent terminal shall be located at least 3 feet 10 above grade or above normal snow levels In all cases the appliance shall be installed in accordance with local codes The TH can vent up to 100 equivalent feet Elbows can range from 3 to 5 feet in equivalent length depending on the centerline radius Vent sizes are 3 for Models 82 to 252 and 4 for Models 292 to 502 for equivalent vent len
43. OWN buttons for 3 seconds 2 The Setup icon will be displayed in the Operating Mode portion of the display The user can change screens by pressing the Next button NOTE Accessing the Setup Mode will put the TH Control Board into Standby If the heater is firing the TH Control Board will post purge and go to Standby The system will remain in Standby until the Done button is pressed or the inactive timeout time has elapsed Display Display Readout Temperature Scale LBTHODLOD not used Remote Firing Address Lead Lag not used Lead Lag Hysteresis not used Base load not used Warm Weather Shutdown not used Set display to either degrees Fahrenheit or degrees Celcius Range F C Low Boiler Reset Temperature Range Off On 32 to 230 F 0 110 C Default Off High Outdoor Reset Temperature Range Off On 40 to 230 40 110 Default Off Low Outdoor Reset Temperature Range Off On 40 to 230 40 110 Default Off Setting the Modbus address on the Honeywell SOLA Default 1 Current status of Lead Lag is shown Ldr master SLA slave or OFF along with the setup icon On Off hysteresis Default 10 F Indicates current base load in percentage Default 8096 The icon will blink when waiting for the current WWSD value from the R7910 22 Preset time must be satisfied before heater is allowed t
44. a fixed rate where demand equals input 3 Burner input will decrease when DHW water temperature approaches temperature setpoint 1 5 3 End of Sequence 1 Setpoint temperature is satisfied 2 Powerto the gas valve is turned off 3 Combustion air fan ramps to a stop over the factory preprogrammed time period WARNING To minimize the possibility of serious personal injury fire or damage to your appliance never violate the following safety rules Do not use this appliance if any part of it has been under water The possible damage to a flooded appliance can be extensive and present numerous safety hazards Any appliance that has been under water must be replaced WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach gas supplier call the fire department IMPORTANT Consult and follow local Building and Fire Regulations and other Safety Codes that apply to this installation Contact the local gas utility company to inspect and authorize all gas and flue connections Installation and service must be performed by a qualified technician installer and trained by Camus Hydronics WARNING Should overheating occur or the gas supply fails to shut off DO NOT turn off or disconnect the electrical supply to the
45. adjustment counter clockwise increases Low fire air gas ratio adjustment use slotted screwdriver for adjustment clockwise increases 4 __ Gas Inlet 3 7 BURNER Figure 15 TH Burner This appliance uses a single cylindrical burner installed horizontally into the cavity located in the center of the heat exchanger There is a unique burner for each one of the TH models Burners may NOT be interchanged between different Btu hr input models The burner consists of a round mounting flange welded to a ported stainless steel mixing tube This stainless steel tube is covered with a close fitting knitted stainless steel metal fiber alloy material that forms the burner outer surface The burner is setup to operate in blue mode and infrared operating condition should be avoided Infrared operation will occur only if air to gas adjustments is incorrect If infrared operation is noted the cause must be corrected The burner should be removed for inspection and cleaning on an annual basis An appliance installed in a dust or dirt contaminated environment will require inspection and cleaning on a more frequent schedule The fan assisted combustion process may force airborne dust and dirt contaminants contained in the combustion air into the burner With sustained operation non combustible contaminants may reduce burner surface area reduce burner input or cause non warrantable damage to the burner Air
46. alve and vent the trapped air from the piping leading to the heater Confirm that all gas connections to the heater are tight and that there are no missing test plugs Refer to Section 9 1 Setting the Correct Combustion of the manual for recommendations on setting combustion characteristics 11 2 CHECKING THE CONSTRUCTION e Check the boiler wiring to see that it agrees with the wiring diagram supplied e Confirm that all terminal strips and field connections are identified e Confirm that the TH Controller control is set in the proper mode In remote mode an external controller determines the set point and the stage contacts on the TH Controller are always closed Auto reset limits are fixed in all Modes e With the heater running check for flue gas leaks along the inner cabinet joints and around the flue outlet e Repair any leaks prior to proceeding to the next step e At the factory adjustments were made to achieve proper input and acceptable burner performance at full input and at minimum input 11 3 INSPECT amp RECHARGE CONDENSATE COLLECTION NEUTRALIZING RESERVOIR 1 Inspect the condensate reservoir in the TH making sure the collection box is intact 2 Remove screw holding lid on to condensate collection box Remove lid from the condensate collection box 3 Examine neutralizer medium and refill as necessary with fresh medium 4 Fill with fresh water until the water begins to flow out of drain 5 Re install the lid
47. as failed to open or it is passing insufficient amount of gas If this is an initial startup increase the low fire gas setting by 1 4 turn clockwise Inspect flame sensor and associated wiring Replace if necessary Inspect the burner Refer to Burner Maintenance in section 10 7 Replace the TH Controller Flow Proving Device Panel will be required to restart the ignition sequence SYMPTOM Flame Disappears During a Run Cycle Pressing the manual RESET on the TH Control Panel will be required to restart the ignition sequence Noisy Operation Auto Reset High Limit Trips FAILURE MODE ANALYSIS e The TH boiler was running and Verify that minimum fan speed is greater than 2500 RPM flame signal suddenly Verify that all air has been purged from gas line disappeared This condition Inspect spark electrode and related wiring for damage and occurred 3 times connection errors e Lockout 47 Verify that boiler is properly grounded e Alert 291 292 293 294 Verify incoming gas supply pressure and that it coincides with Table 8 Verify that the gas line connections to the boiler are adequate Verify that the vent air inlet piping if equipped are correctly installed and obstructions are not present Verify 120 VAC is being supplied to the transformer from the TH Controller during ignition If a signal cannot be detected the TH Controller needs to be replaced Verify that 24 VAC is being supp
48. ast 1 foot away and 1 foot above from the air inlet opening which must terminate in a double elbow facing downwards 10 3 The vertical termination must be a minimum of 3 feet 1m above the point of exit 4 A vertical termination less than 10 feet 3 05m from a parapet wall must be a minimum of 2 feet 0 61m higher than the parapet wall 5 DO NOT terminate closer than 4 feet 1 25m horizontally and vertically from any electric meter gas meter regulator relief valve or other equipment In all cases local codes take precedence 6 Position the air inlet and vent terminations so they are not likely to be damaged by foreign objects or exposed to build up of debris 7 Perform regularly scheduled inspections to ensure that the vent terminal is unobstructed Location of a Vertical Air Inlet Opening 1 The total length of piping for inlet air must not exceed the limits given in Table 6 2 The air inlet consists of two 90 elbows installed at the point of termination for the vertical air inlet pipe A 90 elbow and a 907 street elbow may be used to make this assembly If a straight piece of pipe is used between the two elbows it should not exceed 6 0 15m in length The air inlet opening must be at least 1 foot below the vent opening The air piping must be no further than 2 feet 0 6m from the center of the vent pipe This arrangement avoids exhaust gases from re circulating into the inlet air stream Refer to Figure 8
49. ater areas See Water Treatment and Water Chemistry e Using or storing corrosive chemicals in the vicinity of this appliance will attack the stainless steel jacket the stainless steel venting heat exchanger coils wiring and brass fittings and voids warranty 2 Damage caused by freezing or dry firing voids warranty This appliance is not to be used for temporary heating of buildings under construction The manufacturer shall be held liable for any personal injury or property damage due to ice formation or the dislodging of ice from the vent system or the vent termination 1 8 REMOVAL EXISTING APPLIANCE When an existing appliance 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 appliance 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 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
50. ation of glycol or water treatment where required Where glycol has been used to maintain the temperature rise across appliance confirm that the recommended flow for pure water has been increased by 15 and the head loss by 20 Boiler Operational Checks 1 Turn the heater main power switch to the ON position 2 Verify operation of the display on the front panel Program the adjustable points 4 Push the reset button if a lockout error is displayed 5 Install a manometer on the gas supply to the heater and verify minimum gas supply pressure as the burner fires at 100 of rated input 6 Verify operation of safeties as necessary low water cut off high limit gas pressure etc Heater Operation 1 Appliance should begin the start up process for the sequence of operation 2 The boiler will fire at 50 of rated input on initial start up and adjust input as required to meet system demand 3 Based on system demand the appliance will modulate accordingly 4 As system demand is satisfied the burner will fire at minimum fire for the given demand and the heater will cycle off when the demand ceases or 15 interrupted When this occurs the combustion air fan will decelerate at a pre programmed rate before the appliance shuts down 116 TEMPERATURE RISE AT FULL FIRING RATE The pump must run continuously when the burner is firing With the pump running and the burner in the water heater in the off cycl
51. ay Readout Maximum Stack Temperature Minimum Firing Rate Maximum Firing Rate Manual Firing Rate When stack temperature approaches this value the boiler will automatically reduce firing rate If temperature continues to climb this will result in the boiler shutting down while displaying an alert code PVC 149 F 65 C 194 F 90 C PPE 230 F 110 C AL29 4C 300 F 149 C 316L Stainless Steel 300 F 149 C Min icon is flashing and the Diag icon is solid The heater will fire at the displayed modulation rate The firing rate value displayed is alternated with the outlet temperature display After 5 minutes of inactivity or when the Done button is pressed the TH returns to normal operation Max icon is flashing and the Diag icon 15 solid The heater will fire at the displayed modulation rate The firing rate value displayed is alternated with the outlet temperature display After 5 minutes of inactivity or when the Done button is pressed the TH returns to normal operation Max icon is flashing and the Diag icon 15 solid TH is initially forced to 90 of firing rate if not already operating To manually adjust firing rate Press the UP DOWN button once changes the firing rate by 1 Low Fire 10 High Fire 90 After 5 minutes of inactivity or when the Done button is pressed the TH returns to normal operation 24 8 5 SETTING THE TANK HEATER HS
52. borne contaminants such as dust dirt concrete dust or dry wall dust can be drawn into the burner with the combustion air and block the burner surface area DO NOT operate this appliance during construction The spark igniter and flame sensor are removable from the combustion chamber mounting door without removing the burner assembly Never use an open flame match lighter etc to check gas connections Regulated Gas Supply Pressures for Tank Heater A stable gas supply pressure is important to avoid rough starts with machines like the Tank Heater which use a 1 to 1 ratio control valve for internal gas pressure regulation Camus requires that all Tank Heater models be supplied with no more than 14 w c supply pressure This means that lockup pressure must not exceed 14 w c A suitable lockup regulator with internal or external relief will not exceed running pressure by more than 20 When required a final stage gas regulator is to be located as close as possible but no more than 10 feet from the appliance It is paramount that maximum lockup pressure be confirmed before any attempt is made to start up the appliance Operating the Tank Heater at lockup pressures exceeding 14 w c could lead to delayed ignitions and damage to the appliance 14 PART4 WATER CONNECTION e Check all applicable local heating plumbing and building safety codes before proceeding If the appliance is installed above radiation level it
53. by foreign objects or exposed to a build up of debris 8 Flue gas condensate can freeze on exterior walls or on the vent cap Frozen condensate on the vent cap can result in a blocked flue condition Keep the vent cap terminal clear of snow ice leaves debris etc Some discolouration to exterior building surfaces is to be expected Adjacent brick or masonry surfaces should be protected with a rust resistant sheet metal plate 9 Perform regularly scheduled inspections to ensure that the termination is unobstructed 10 Operate the appliance for one heat cycle to ensure combustion air and vent pipes are properly connected to the concentric vent termination connections CAUTION Do not operate appliance with the rain cap removed as this may result in the recirculation of flue products Water may also flow into the combustion air pipe and into the burner enclosure Figure 8 Concentric Sidewall Termination ABOVE ROUND OR HORMAL SHOW LEVELS FG op SHOA LEVEL 5m Figure 9 Concentric Vent Sidewall COMBUSTION AIR COMBUSTION AIR mmm VENT m lt 4 7 VENT vam 2 6 Vertical Direct Venting Location of Vent Termination 1 The total length of piping for venting must not exceed the limits stated in Table 6 2 The vent piping must terminate in a 90 elbow if plastic piping is used or in an approved vent cap if using metal venting The vent outlet must be at le
54. ce shall be vented using sealed positive vent suitable for a condensing appliance with the following venting options 1 Sidewall or rooftop termination where both the vent and combustion air inlet air are in the same zone The inlet and vent terminals are to be installed with a minimum 12 separation distance between centerline of inlet and centerline of exhaust Refer to Fig 5 6 and 7 for sidewall termination and Fig 8 for rooftop termination 2 Sidewall termination with vent and combustion air inlet from separate zones 3 Single pipe thru wall or rooftop venting with combustion air inlet from the boiler room Table 6 Required Vent and Inlet Diameters Length of Vent amp Air Intake at Recommended Diameter Vent Option 3 not recommended for R 2000 homes or equivalent air tight construction 2 2 1 Approved Venting Materials Category IV CategoryIV 1 PVC and CPVC Chlorinated Polyvinyl Chloride Input Category Schedule 40 or 80 approved to ULC S636 BTU hr Over 25 and up 2 Manufactured prefabricated listed vent of AL29 4 or 316L stainless steel Use of 316L is limited to use in 2 02665 US Jurisdictions ONLY when permitted 15000 2 o RNSUASTIN Dira US dur amp delens ONLY when 3 PVC DWV approved to comply with ANSI ASTM permitted 250 000 5 Schedule 40 approved to comply with 299 000 ANSI ASTM F441 US
55. ceman must utilize a combustion analyzer with CO CO to set the appliance according to Camus Hydronics recommendations prior to commissioning NOTE ___ _ RETAIN THIS MANUAL FOR FUTURE REFERENCE 1 3 CHECKING EQUIPMENT Check for signs of shipping damage upon receiving equipment Pay particular attention to parts accompanying the boiler which may show signs of being hit or otherwise being mishandled Verify total number of pieces shown on packing slip with those actually received In case there is damage or a shortage immediately notify carrier 1 4 DISPLAY UNIT The display unit will indicate status and will display selected temperature Refer to Part 8 TH Control Panel which provides details to modes and error codes displayed on the appliance 1 5 SEQUENCE OF OPERATION 1 The power switch is placed in the position 2 Minimum 120 VAC 60Hz single phase 15A circuit is supplied to the Terminal Strip 3 24 VAC power is supplied to the TH Controller which provides all setup and ignition control functions 4 heat request is detected by the DHW Sensor 5 After the appliance water pump starts flow is proven by the flow proving device 6 The TH Controller initiates a start up sequence once it receives a heat demand 7 Voltage is sent to the electrically commutated DC motor of the combustion fan after the internal safety checks are satisfied 8 The fan will run at Pre Purge speed until the P
56. clean if necessary closer to burner NO Replace flame sensor and graphite flame sensor gasket 37 9 1 SETTING THE CORRECT COMBUSTION 1 Switch the main power off to the boiler by placing the toggle switch in the OFF position 2 Switch the main power on to the boiler and adjust setpoint so that boiler begins ignition sequence 3 Observe the boiler as it goes through its startup cycle and operates at high fire This cycle is detailed on Figure 33 in section 11 9 Ignition Cycle 4 Insert the combustion measurement probe into the stack when high fire operation is observed Check to see that fan is running at maximum fan speed using the Control Panel 5 The combustion values should reside in the range listed in Table 18 If combustion values are not within this range refer to Section 9 2 Gas Valve Adjustment Procedure to correct this issue Table 18 Combustion Values 0 pem I _ co co 100 PPM 8 596 9 0 lt 100 95 PPM 10 096 100 8 0 8 5 9 0 9 5 100 6 When the combustion values are satisfied record these values as Camus requires these for warranty purposes 7 Remove the combustion measurement device and switch the main power off to the boiler by placing the toggle switch in the OFF position 8 Replace the flue temperature sensor back to its proper location 9 2 GAS VALVE ADJUSTMENT PROCEDURE If adjustment of the gas val
57. cted to jacket flange e Outside air ducted to jacket flange e Indoor Air e Indoor Air Sealed combustion is required when the TH is placed in a space with other fan assisted appliances 2 4 COMBINED COMBUSTION AIR INLET The TH may be installed with a combined combustion air inlet The combined combustion air inlet pipe sizing can be calculated using the method shown below Equivalent pipe diameter Sq Root 05 1 where individual pipe diameter e Example Find the equivalent pipe diameter of three air inlet pipes 3 7 6cm 3 7 6cm and 4 10 2cm Equivalent pipe diameter Sq Root 3 3 4 2 Root 34 5 8 select 6 15 3cm equivalent diameter pipe The air inlet point for multiple air inlets must be provided with an exterior opening which has a free area equal to or greater than the total area of all air inlet pipes connected to the common air inlet This exterior opening for combustion air must connect directly to the outdoors The total length of the combined air inlet pipe must not exceed a maximum of 100 equivalent feet 30 50 Deduct the restriction in an area provided by any screens grills or louvers installed in the common air inlet point Screens grills or louvers installed in the common air inlet can reduce the free area of the opening from 25 to 75 based on the materials used Calculate and compensate accordingly 2 5 VENT TERMI
58. de All electrical wiring must be done in accordance with the requirements of the authority having jurisdiction or in the absence of such requirements with national electrical code ANSI NFPA70 and or the Canadian electrical code part 1 CSA C22 1 Where required by the authority having jurisdiction the installation must conform to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers ASME CSD 1 All boilers must conform to the latest edition of the ASME Boiler and Pressure Vessel Code Section l Where required by the authority having jurisdiction the installation must comply with the 5 International CAN CGA B149 and or local codes This appliance meets the safe lighting performance criteria with the gas manifold and control assembly provided as specified in the ANSI standards for gas fired units ANSI Z21 10 3b 2008 1 7 WARRANTY Factory warranty shipped with unit does apply to units improperly installed or improperly operated Factory warranty shall apply only when the appliance 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 stainless steel coils or tubes is not a fault of the appliance and is not covered by warranty Consult the factory for recommendations for use in hard w
59. ds 50 F PART 7 COMPONENTS 7 1 DIRECT SPARK IGNITER The direct spark igniter is inserted directly through the combustion chamber front door and held in place by two torx screws Care must be taken when removing and or installing the igniter Always remove the igniter prior to removing the fan assembly for inspection of the burner and heat exchanger Figure 17 Direct Spark Igniter During a trial for ignition Sequence a properly operating igniter will generate a continuous spark with a 9 64 3 6mm spark gap It is recommended to clean the direct spark igniter using steel wool as required DO NOT use sandpaper or grit cloth since this will contaminate the metal surface 7 2 FLAME SENSOR The flame sensor is inserted directly through the combustion chamber front door and is screwed into the combustion chamber front door Care must be taken when installing the flame sensor to align it perpendicular to the fan flange and parallel to the burner tube and not to over tighten Figure 18 Flame Sensor The ignition module relies on the flame sensor to provide a flame rectification signal Oxide deposits improper placement or damaged ceramic insulator will result in insufficient signal leading to ignition module lock out For proper operation minimum 0 8 uA DC must be fed back to the module Oxide deposit on the sensor rod must be removed with steel wool DO NOT use sand paper since this will contaminate the metal surface 18
60. e the Return Inlet temperature and Supply Outlet temperature readings on the TH Control Panel should read approximately the same temperatures Turn the hot water heater on and allow time for the temperature to stabilize Check the temperature rise when the burner is firing at 100 of rated input Compare the temperature rise on the Control Panel with the required temperature rise at the required flow rate on Table 19 Should adjustment be needed proceed as follows 6 The TH uses stainless steel heat exchanger tubes which are not sensitive to higher water velocity If temperature rise is lower than anticipated it is not necessary to reduce flow If the temperature rise is too high the water velocity is too low Adjust as follows 1 Check for flow restrictions Check for debris in strainers 2 Check the pump to be sure it is running properly and that the pump motor is running in the proper direction 3 Common manifold piping for multiple unit installations will require larger minimum pipe sizes The required temperature rise and the recommended pump size are based on the heating of potable water with normal hardness within a typical range of 7 5 to 17 0 grains per gallon Consult the factory when heating potable water exceeding these specifications Damage to the heat exchanger as a result of scaling or corrosive water conditions in non warrantable Table 19 Temperature Rise Across Heat Exchanger TEMPERATURE RISE ACROSS HEAT
61. e air inlet terminal is unobstructed Termination and Fittings 1 The air inlet opening must be at least 12 inches 0 30m away from never above the vent termination and at least 3 feet 1m above grade or above normal maximum snow levels 2 5 3 Sidewall Concentric Vent Air A listed concentric vent kit can be used with the TH appliance Both combustion air and vent pipes must terminate outside the structure 1 The total length of piping for venting or air must not exceed the limits stated in Table 8 2 bottom of the termination shall be located least 3 feet 1m above grade or above normal snow levels In all cases the appliance shall be installed in accordance with local codes 3 The termination MUST NOT terminate below a forced air inlet at any distance 4 The termination cannot terminate below grade Position the termination where vapours will not damage walls or plants or may be otherwise objectionable 5 The termination shall not be installed closer than 3 feet 1m from an inside corner of an L shaped structure window well stairwell alcove courtyard or other recessed area as wind eddies could affect boiler performance or cause recirculation 6 DO NOT terminate closer than 4 feet 1 25m horizontally and vertically from any electric meter gas meter regulator relief valve or other equipment In all cases local codes take precedence 7 Position termination so they are not likely to be damaged
62. e heater Combustion air must be provided to the mechanical room with openings sized per the requirements of the current B149 or National Fuel Gas Code The TH is setup to allow outdoor combustion air to be connected directly to the appliance 10 10 CONTROL CIRCUIT VOLTAGE This appliance uses a transformer to supply a low voltage control circuit The voltage on the secondary side should be 24 to 28VAC when measured with a voltmeter A secondary voltage of 21VAC or less supplied to 24VAC components may cause operational problems 10 11 COMBUSTIBLE MATERIALS CAUTION Keep appliance clear from combustible materials do not store GASOLINE and other flammable vapors and liquids in the proximity of the appliance 10 12 FREEZE PROTECTION FOR INDOOR amp OUTDOOR INSTALLATIONS Installations are not recommended in areas where the danger of freezing exists Proper freeze protection must be provided for appliances installed outdoors in unheated mechanical rooms or where temperatures may drop to the freezing point or lower If freeze protection is not provided for the system a low ambient temperature alarm is recommended for the mechanical room Damage to the appliance by freezing is non warrantable e Location Heating boilers hot water supply boilers or water heaters must be located in a room having a temperature of at least 40 F 5 C e Caution A mechanical room operating under a negative pressure may experience a downdraft in
63. e of the appliance and before the gas valve Run pipe to the Appliance gas inlet Install a sediment trap in the supply line to the Appliance gas inlet Apply a moderate amount of good quality pipe compound For LP gas consult your LP gas supplier for expert installation 12 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 12 PSI Table 8 Gas Pressures at Inlet to Appliance NATURAL Minimum inches W C Maximum inches W C regulator settings is 7 0 w c 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 appliance Sizing based on Table 8 is recommended depending on model Before operating the appliance the complete gas train and all connections must be tested using soap solution Verify that the appliance is supplied with the type of gas specified on the rating plate Heating values of local natural gas to be between 950 and 1010 Btu ft Consult factory if heating values are outside this range or if a gas with a mixture of constituents is being used 3 4 CHECKING GAS SUPPLY PRESSURE e Turn main power switch to OFF position Shut off gas supply at the manual gas cock in the gas piping to the appliance If fuel supply is LP gas shut off gas supply at the tank e Remov
64. e protected with a rust resistant sheet metal plate Perform regularly scheduled inspections to ensure that the vent terminal is unobstructed 2 5 2 Sidewall Air Inlet Figure 7 Sidewall Vent and Air Inlet Configuration 7 EE 45 DEGREE ELBOW MIN 36 MIN ABOVE GROUND OR NORMAL SNOW LEVELS of ee rot a nnd i ah R TRER Please check local codes for minimum distance above ground or snow levels Location of a Sidewall Air Inlet Cap 1 The total length of piping for air inlet must not exceed the limits stated in Table 6 2 The point of termination for the sidewall air inlet cap must be located a minimum of 12 inches 0 30m away from the flue gas termination but never above 3 The air piping must terminate in a down turned elbow to avoid recirculation of flue products into the inlet air stream 4 DO NOT terminate closer than 4 feet 1 25m horizontally and vertically from any electric meter gas meter regulator relief valve or other equipment In all cases local codes take precedence 5 DO NOT terminate the air inlet in a window well stairwell alcove courtyard or other recessed area as wind eddies could affect performance or cause recirculation 6 The air inlet cannot terminate below grade 7 Locate terminations so they are not likely to be damaged by foreign objects or exposed to build up of debris 8 Perform regularly scheduled inspections to ensure that th
65. e the 1 8 hex plug from the gas pressure test port located on the inlet gas supply connection at the rear of the appliance Install a fitting in the inlet pressure tapping suitable to connect to a manometer magnahelic gauge Range of scale should be 0 to 14 inch W C or greater to check inlet pressure urn on gas supply at the field installed manual gas cock turn on LP gas at tank if required e Turn the power switch to ON position e Adjust the thermostat set point to call for heat e Observe the gas supply pressure as the burner fires at 10096 of rated input Supply pressure is to remain stable e Ensure inlet pressure is within specified range Minimum and maximum gas supply pressures are specified in Table 8 f gas pressure is out of range contact the gas utility gas supplier qualified installer or service agency to determine necessary steps to provide proper gas pressure to the control f gas supply pressure is within normal range proceed to remove gas manometer and replace pressure tap fittings in the gas piping to the appliance Turn the power switch to OFF position e Turn on gas supply at the manual valve turn on LP gas at tank if required e Turn the power switch to ON position e Adjust the thermostat temperature set point to the desired water temperature so the appliance will call for heat e Check appliance performance by cycling the system while you observe burner response The burner should
66. ears 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 STAINLESS STEEL STORAGE TANK If within TEN years after initial installation of the appliance a stainless steel storage tank shallprove upon examination by Camus to defective in material or workmanship Camus will exchange or repair such part or potion 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 DURATION OF LIMITED WARRANTY Any limited warranty including the warranty of mechantability imposed on the sale of the boiler under the laws of the state or province of sale are limited in duration to one year from date of original installation STATE LAW amp LIMITED WARRANTY Some states or provinces do not allow a Limitations on how long an implied warranty lasts b Limitations on incidental or consequential damages The listed limitations may or may not apply to you This warranty gives you specific legal rights and you may also have other rights which may vary from state to state and province to province CONDITIONS We will not a Repair or replace any boiler or part subject to conditions
67. eates enough velocity inside the stainless steel tubes and headers that prevents scaling 4 4 LOW WATER TEMPERATURE SYSTEMS In combination applications where the heating system requires supply water temperatures below 110 F connections may be made directly to the TH Refer to Figure 35 At incoming temperatures of 80 F or lower the TH achieves maximum efficiency Inlet temperatures must not drop below 40 F to prevent freezing 4 5 PIPING ARRANGEMENTS 4 5 1 Field Supplied Components 1 Heater system piping Boiler system piping MUST be sized according to Table 9 Reducing the pipe size can restrict the flow rate through the tank and cause an excessive pressure drop 2 Isolation Valves Use only full port ball valves Failure to supply full port ball valves may result in reduced flow rate through the tank 3 Anti Scald Mixing Valve An anti scaled mixing valve is recommended when DHW storage is above 120 F 4 Unions Recommended for ease of serviceability 5 System Temperature Sensor A system temperature sensor is to be installed in the main header at a point to detect controlled temperature and where it will not lead to short cycling of the boiler 15 Table 10 Flow and Pressure Drop at a Given Temperature Rise DHW Input Btu Hr 20 11 1 Temp Rise ETIN 14 0 4 6 FLOW PROVING DEVICE Figure 16 Flow Proving Device The flow proving device is designed to detect when flow is
68. ed per the vent manufacturers specifications When a positive vent system is disconnected for any reason the flue must be reassembled and resealed according to the vent manufacturer s instructions e Do not use an existing chimney as a raceway if another appliance or fireplace is vented through the chimney e Inspect completed vent and supply piping thoroughly to ensure all connections are sealed and are in compliance with the instructions provided and satisfy requirements of all applicable codes All vent pipes must be properly assembled and supported and the exhaust must be pitched a minimum of 1 4 inch per foot back to the boiler All components used to fabricate and assemble the vent system are to originate from the same supplier When determining equivalent inlet air and vent lengths of 3 diameter add 3 to 5 feet for each 90 elbow and 2 to 3 feet for each 45 elbow depending on centerline radius of the elbow Example 30 feet of CPVC pipe 3 x 5 feet 90 elbows 1 3 feet 45 elbow 48 equivalent feet of piping for centerline radius of 1 5D where D is the pipe diameter 2 2 CATEGORY IV VENTING TH 082 502 A category IV appliance is individually vented through a dedicated vent The TH shall be vented as a Category IV condensing appliance as per table 4 For site conditions exceeding 100 equivalent feet an engineered vent system approved by the local authority will be required The applian
69. ent Air Inlet Lengths exceed the maximum allowed what is required equivalent lengths Refer to Air Inlet and Venting Section Fan Speed Too Alert 59 75 in Part 2 of this manual High e Verify that there are no obstructions in the vent air inlet pipes or at terminations Verify wiring connections at the fan and TH Controller Replace the fan Replace the TH Controller e Stack temperature has exceeded The stack temperature has exceeded the maximum the limit set on the boiler temperature allowed Lockout 82 Measure the resistance of the flue sensor at room temperature it should be approximately 10kQ he supply outlet temperature has Verify that the system is full of water and that all air has exceeded the setpoint been properly purged from the system temperature specified Verify that the boiler is piped properly Refer to Piping Alert 79 Diagrams in Section 12 of this manual Verify that 120 VAC is being supplied to the heater pump on a call for heat If voltage cannot be detected check wiring Verify that the pump is circulating when 120 VAC is supplied If so pump impeller may be stuck Use a flat head screwdriver on face of pump to turn impeller manually f 120 VAC is present during a call for heat but the pump still does not circulate replace the pump e Replace the TH Controller if necessary Supply Outlet sensor Alert 92 Verify that the sensors are connected Sensor Not Return Inlet sensor A
70. ent Screen To return to normal operation press Done To adjust the low fire setting on the upgraded display 1 Press the button 2 Select Test and press OK 3 Select Forced Rate and press OK 4 Select Set Low Fire The TH should respond immediately and fire at minimum fan speed When this is achieved locate the low fire adjustment screw This screw is covered with a cap which can be removed using a Torx 40 screwdriver When the correct combustion values are achieved replace the screw cap back on to the gas valve 38 Increase CO2 Decrease CO2 Low Fire 52 V Counter Clock Wise Adjustment Clockwise TH 292 392 Figure 28 TH 292 392 Gas Valve Low fire air gas ratio adjustment use Torx 40 for adjustment clockwise increases CO High fire air gas ratio adjustment Use slotted screwdriver for adjustment counter clockwise increases CO To adjust the high fire setting on the standard display Press and hold the Next button for 3 seconds to enter the diagnostic menu on the TH Control Panel Press Next until the following screen appears Figure 29 High Fire Adjustment Screen 1 To return to normal operation press Done To adjust the high fire setting on the upgraded display 1 Press the button 2 Select Test and press OK 3 Select Forced Rate and press OK 4 Select Set High Fire Locate the high fire adjustment screw on the top side of t
71. er setpoint Installer Access to all user parameters and allows for changes to additional boiler parameters to allow for ease of startup and serviceability Information button Home Button returns screen to home screen Navigation buttons Confirm selection The screenshot below displays the default homescreen Figure 22 Home Screen System setpoint 182 F Operating temp fi F Outlet temp fi F Inlet temp 32 F Outdoor temp 20 F Boiler name Boiler 1 ate Standb Demand Burner switch af Access status User Alert 29 Burner switch was turned OFF Fress OF to clear alert The first five parameters can be user customizable to reflect the most vital information required on the boiler The list of available parameters is outlined in the table below This can be done by pressing 1 2 Scroll to Display Setup press 3 Select the line item that is required to be altered press OK 4 Select parameter and press OK inlet sensor Indicates origin of call for heat DHW E Alert or Lockout Section 5 4 provides rror 2 additional details Pressing 4 provides additional troubleshooting information on the diagnostic screen 25 Figure 23 Diagnostic Screen Boiler pump Ott CH pump Off pump 011 Figure 24 Temperature screen temp Inlet temp Je BlowersHST off DHL temp FE E External ianition Ott Stack temp 102 F Pilot value uit Outdoor temp
72. er and flame sensor electrodes f necessary clean with steel wool DO NOT use sandpaper 5 Remove the fan mixing tube assembly from the heat exchanger door 6 Remove burner 7 Examine burner and clean if required as per 10 7 1 8 Examine heat exchanger surfaces to determine if cleaning is required cleaning is required remove the 6 nuts fastening the heat exchanger flange from the heat exchanger 9 Disconnect the condensate hose from the heat exchanger and connect a 5 8 diameter hose field supplied from the bottom of the heat exchanger to a drain 10 Use water proof material to carefully cover the refractory at the rear of the combustion chamber of the heat exchanger 11 Use a vacuum cleaner to remove any debris that has collected on the heat exchanger surfaces DO NOT use any type of solvent 12 Brush the heat exchanger with a nylon bristle brush DO NOT use a metal brush Re vacuum the heat exchanger 13 2 Finish cleaning by wiping down the boiler heating surfaces with a clean damp cloth 14 Rinse out any additional debris with a low pressure water supply Start rinsing from the rear of the heat exchanger and slowly working your way towards the front of the heat exchanger 15 2 Remove the water proof material after cleaning is complete 16 Re install the heat exchanger door by evenly torquing down the 6 nuts to 3 ft lbs burner igniter and f
73. eramic fibers to cristobalite Abnormal operating conditions would have to be created to convert the ceramic fibers in this appliance to cristobalite The ceramic fiber material used in this appliance is an irritant when handling or replacing the ceramic materials it is advisable that the installer follow these safety guidelines e Avoid breathing dust and contact with skin and eyes o Use NIOSH certified dust respirator N95 This type of respirator is based on the OSHA requirements for cristobalite at the time this documentation was written Other types of respirators may be needed 42 depending on the job site conditions Current NIOSH recommendations can be found on the NIOSH website at http www cdc gov niosh homepage html NIOSH approved respirators manufacturers and phone numbers are also listed on this website Wear long sleeved loose fitting clothing gloves and eye protection e Apply enough water to the combustion chamber lining to prevent airborne dust e Remove the combustion chamber lining from the water heater and place it in a plastic bag for disposal e Wash potentially contaminated clothes separately from other clothing Rinse clothes washer thoroughly NIOSH stated First Aid Eye Irrigate immediately e Breathing Fresh air 10 9 COMBUSTION AND VENTILATION AIR Check frequently to be sure that the flow of combustion air to the appliance is not obstructed unless air is piped directly to th
74. ery 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 main manual gas shut off and allow appliance to cool down 2 Remove the vent pipe at connection to heat exchanger and check heat exchanger and vent for obstruction and clean as necessary 3 Remove burner from appliance and carefully clean as required Never brush or wipe the knitted metal fiber surface Use a garden hose or gently wash under the tap Vacuum out any deposits found in the heat exchanger CAUTION Never use a pressure washer or compressed air to clean the burner 4 Reinstall parts removed in steps 2 and 3 Be sure that vent pipe has proper pitch and is properly sealed Replace any damaged gasket or refractory Tighten fan flange mounting nuts to ft lb 5 Restore electrical power and gas supply to appliance 6 Place appliance in operation using lighting instructions provided 7 Confirm proper operation of all safety devices 8 Check for gas leaks and proper vent operation Experience has shown that improper installation or system design rather than faulty equipment is the cause of most operating problems 1 9 BOILER FURNACE ROO
75. gths of up to 100 The vent outlet shall terminate at least 12 0 30 away from any forced air inlet The vent must be at least 7 feet 2 15m above grade when located adjacent to public walkways due to normal formation of water vapour in the combustion process The vent outlet MUST NOT terminate below a forced air inlet at any distance The vent cannot terminate below grade Position the vent termination where vapours will not damage walls or plants or may be otherwise objectionable The vent terminal shall not be installed closer than 3 feet 1m from an inside corner of an L shaped structure window well stairwell alcove courtyard or other recessed area as wind eddies could affect boiler performance or cause recirculation DO NOT terminate closer than 4 feet 1 25m horizontally and vertically from any electric meter gas meter regulator relief valve or other equipment In all cases local codes take precedence Position terminations so they are not likely to be damaged by foreign objects or exposed to a build up of debris The vent piping must terminate in an elbow pointed outward or away from the air inlet Flue gas condensate can freeze on exterior walls or on the vent cap Frozen condensate on the vent cap can result in a blocked flue condition Keep the vent cap terminal clear of snow ice leaves debris etc Some discolouration to exterior building surfaces is to be expected Adjacent brick or masonry surfaces should b
76. he gas valve The screw can be identified by a red cylinder casing around the screw Turn the screw 1 8 turn in either way for each adjustment to keep track of the adjustments After adjusting the screw wait a moment for the combustion levels to stabilize before attempting to make any further adjustments Continue this procedure until combustion levels are satisfied Increase CO2 Decrease CO2 High Fire Adjustment Counter Clock Clockwise Wise adjust the low fire setting Press and hold the Next button for 3 seconds to enter the diagnostic menu on the TH Control Panel Press Next until the following screen appears Figure 30 Low Fire Adjustment Screen To return to normal operation press Done To adjust the low fire setting on the upgraded display 1 Pressthe button 2 Select Test and press OK 3 Select Forced Rate and press OK 4 Select Set Low Fire The TH should respond immediately and fire at 1500 RPM When this is achieved locate the low fire adjustment screw When the correct combustion values are achieved replace the screw cap back on to the gas valve Increase CO2 Decrease CO2 Low Fire Adjustment ow Fi ju Counter Clock Clockwise Wise TH 502 Figure 31 TH 502 Gas Valve Lift top cover to access high fire air gas ratio adjustment use 3mm P d allen key for adjustment counter x clockwise increases Low fire air gas ratio adjustment use slotted screwdr
77. iping when running condensate line across the floor Check neutralized pH level regularly or as required by local jurisdiction Replace neutralizer medium as required 10 4 4 Condensate Volume There are several factors affecting amount of condensation created by the appliance however for rough approximation use Condensation Volume US Gallon Hr Input MBH 1000 x 5 0 Many codes will require the acidic condensate to be neutralized before it can be placed in a drain system A neutralizer to control the pH of the liquid discharged to a drain system is provided with every TH boiler The neutralizer consists of an industrial grade non corrosive plastic reservoir for collection of the condensate The condensate collects in the reservoir where it is in direct contact with calcium carbonate neutralizer medium As the reservoir fills it provides an extended residence time to neutralize the condensate Residency time in the neutralizer reservoir allows time for the pH to be raised Prime the neutralizer reservoir with 1 litre of water 41 As the condensate migrates through the reservoir in typical applications the pH is controlled to a range of 5 5 to 6 0 before exiting the system Always check with local codes for specific requirements 10 5 IGNITER AND FLAME SENSOR ELECTRODES The direct spark igniter is to be checked at every service interval Clean the direct spark igniter as required to maintain peak ignition efficiency 1 Tur
78. iver for adjustment clockwise increases Gas Inlet To adjust the high fire setting on the standard displa Press and hold the Next button for 3 seconds to enter the diagnostic menu on the TH Control Panel Press Next until the following screen appears Figure 32 High Fire Adjustment Screen To return to normal operation press Done To adjust the high fire setting on the upgraded display 1 Pressthe H 2 Select Test and press OK 3 Select Forced Rate and press OK 39 4 Select Set High Fire Locate the input adjustment screw on the top side of the gas valve Turn the screw 1 8 turn in either way for each adjustment to keep track of the adjustments After adjusting the screw wait a moment for the combustion levels to stabilize before attempting to make any further adjustments Continue this procedure until combustion levels are satisfied Increase CO2 Decrease CO2 Q Counter Clock Wise To adjust the low fire setting on the standard displa High Fire Adjustment Clockwise Press and hold the Next button for 3 seconds to enter the diagnostic menu on the TH Control Panel Press Next until the following screen appears Figure 33 Low Fire Adjustment Screen To return to normal operation press Done To adjust the low fire setting on the upgraded display Press the button 6 Select press OK 7 Select Forced Rate and press O
79. lame sensor and fan mixing tube assembly Fasten the nuts back to the heat exchanger assembly 17 Re connect the fan assembly to the boiler mixing tube 18 Re connect the condensate hose to the heat exchanger All gaskets on disassembled components must be replaced with new gaskets sealant on re assembly if required Gasket kits are available from the factory CAUTION When the vent system is disconnected for any reason it must be reassembled resealed according to vent manufacturer s instruction 10 4 CONDENSATE TREATMENT Condensate occurs when the products of combustion are cooled below their dew point in the heat transfer process The liquid condensate formed from this high efficiency heat transfer process is mildly acidic The condensate will typically have a pH ranging from 4 0 to 5 0 as it is discharged from the condensate drain of the appliance The condensate collection box where the condensate is collected is constructed of a non corrosive plastic All materials external to the appliance in contact with the condensate must be corrosion resistant Condensate must be able to flow freely from the appliance All condensate flow is accomplished by gravity requiring a minimum downward slope of 1 4 per foot 21mm m to ensure proper flow to a suitable drain A neutralizer box is mounted inside each TH All condensate piping and connections must be easily accessible for routine maintenance and inspection Use solid p
80. lert 91 Verify that they are wired correctly Connected sensor Alert 95 Measure the resistance of the sensors 10kO sensors DHW sensor Alert 93 Replace the sensor if necessar Fan refuses to rotate Check fan power wires e Minimum fan speed must be greater than 1500 RPM Blocked flue error Air Switch wire s is are loose Air Switch is set too tight reduce sensitivity by turning screw 1 4 turn clockwise Flame detection is present when no Verify supply voltage for proper polarity visible signs of a flame exist Check external wiring for voltage feedback Lockout 105 158 Check internal wiring for proper connections Temperature Overshoot Flame Detection is out of Sync Check the flame sensor and verify that it is clean Replace TH Controller Blank Display Blank display screen Check wire connections from TH Controller to DyanMax Screen display Ignition Failed displayed on screen Hold 109 Ignition failed An ignition error occurs when 3 consecutive attempts technician must press OK to clear the error Check ignition speed is between 2500 to 3000 RPM using System Monitor Check for constant spark for 6 seconds across spark igniter Check incoming gas pressure is between 3 and 14 w c YES Turn high fire screw counter clockwise turn at a time YES Burner lights off and stays on YES Adjust high fire combustion to 8 5 9 096 CO Y
81. lied to the gas valve during ignition If a signal cannot be detected the transformer needs to be replaced Inspect flame sensor and associated wiring Replace if necessary Inspect the burner Refer to Burner Maintenance in section 10 7 Replace the TH Controller if necessary Supply Gas Issue Refer to Part 3 Gas Connection in this manual e Natural Gas Pressure should read between 3 w c and 14 W C e L P Gas Pressure should be at 11 w c Air Gas Mixture Issue Refer to Gas Valve Adjustment Procedure in section 9 2 of this manual for the proper combustion setting Air Inlet and or Vent configuration Refer to Part 2 Air Inlet and Venting Dirty Damaged Burner Refer to Burner Maintenance in section 10 7 of this manual for the burner removal and inspection procedure Clean or replace the burner if required Air in the piping system Purge all air from the piping system Incorrect Igniter Gap e Check that spark gap is 9 64 he supply outlet temperature has Verify that the system is full of water and that all air has exceeded the setpoint temperature been properly purged from the system specified Verify that the boiler is piped properly Refer to Piping Alert 303 310 Diagrams in Section 12 of this manual Verify that 120VAC is being supplied to the boiler pump a call for heat If voltage cannot be detected check wiring Verify that the pump is circulating when 120VAC is detected
82. ly with ANSI ASTM 02665 o US Jurisdictions ONLY when permitted Stack temperature is typically between 15 30 F above inlet 4 PVC Schedule 40 approved to comply with ANSI ASTM water temperature depending on model size and firing rate D1785 US Jurisdictions ONLY when permitted Air Inlet Supply Air or Fresh Air Piping 5 E m to 28 PVC Non Foam Core Pipe UrSQICTIONS wnen e CPVC Non Foam Core Pipe 6 Polypropylene approved to comply with ULC 5636 Acrylonitrile Butadiene Styrene Air Inlet Supply Air Fresh Air Piping e PPE Polypropylene PVC e Single wall Galvanized CPVC Chlorinated Polyvinyl Chloride e Single wall Stainless steel 5 Acrylonitrile Butadiene Styrene Single wall Aluminum e PPE Polypropylene Single wall air inlet pipes are to be insulated 5 feet from the Single wall wall toward the interior of the building to minimize external e Single wall Stainless stee sweating e Single wall Aluminum Single wall air inlet pipes to be insulated 5 feet from the Air intake material must be of a type listed by a nationally wall toward the interior of the building to minimize external recognized testing agency sweating The following air intake options shall be utilized The following air intake options shall be utilized e Outside air sealed direct vertical or horizontal e Outside air sealed direct vertical or horizontal e Outside air du
83. m total length of the sidewall or vertical roof top combustion air inlet pipe as installed from the appliance to the air inlet cap must not exceed 100 equivalent feet 30 50 in length Subtract 3 to 5 feet 1 to 1 5m of equivalent length depending on centerline radius for each 90 elbow installed in the air inlet pipe system Pressure drop in each 45 elbow will be half as much 2 to 3 feet 0 6 to 1 0m 11 IN GENERAL 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 appliance is to be installed near a corrosive or potentially corrosive air supply the appliance 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 The equipment room MUST be provided with properly sized openings to assure adequate combustion air and proper ventilation when the unit is installed with a proper venting system
84. mance or cause recirculation 6 DO NOT terminate closer than 4 feet 1 25m horizontally and vertically from any electric meter gas meter regulator relief valve or other equipment In all cases local codes take precedence T Position termination so they are not likely to be damaged by foreign objects or exposed to a build up of debris 8 Flue gas condensate can freeze on exterior walls or on the vent cap Frozen condensate on the vent cap can result in a blocked flue condition Keep the vent cap terminal clear of snow ice leaves debris etc Some discolouration to exterior building surfaces is to be expected Adjacent brick or masonry surfaces should be protected with a rust resistant sheet metal plate 9 Perform regularly scheduled inspections to ensure that the termination is unobstructed 10 Operate the appliance for one heat cycle to ensure combustion air and vent pipes are properly connected to the concentric vent termination connections CAUTION Do not operate appliance with the rain cap removed as this may result in the recirculation of flue products Water may also flow into the combustion air pipe and into the burner enclosure Figure 11 Concentric Vent Vertical Venting VENT 12 18 FOR CANADA MIN CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL MAXIMUM or COMBUSTION AIR 24 ABOVE ROOF CONCENTRIC VENT BRACE A VENT 1 COMBUSTION AIR Length of Air Inlet Pipe The maximu
85. n off main electrical power to the appliance 2 Turn off main manual gas shutoff to the appliance 3 Locate the direct spark igniter and flame sensor 4 Disconnect the power lead to the direct spark igniter and flame sensor 5 Loosen and remove the two 2 torx screws that hold the igniter and flame sensor to the heat exchanger flange 6 Pull the igniter horizontally out of the heat exchanger flange Use care do not hit or break the igniter leads 7 Remove any debris that has accumulated on the electrodes using steel wool If the electrodes cannot be cleaned their original appearance replacements are needed Do not use sand paper since this will contaminate the surface 8 Check that the igniter and flame sensor gaskets are still in good condition no tears or seams the gaskets are in good condition the electrodes can be re installed back to the heat exchanger flange 9 Check that the igniter gap is 9 64 10 6 CHECK IGNITER GROUND WIRING 1 Inspect boiler ground wire from the heat exchanger flange to J1 3 of the TH Controller Check boiler ground wire continuity 2 Verify that all wiring is in good condition and is securely anchored 10 7 BURNER MAINTENANCE The burner should be removed for inspection and cleaning on an annual basis An appliance installed in a dust or dirt contaminated environment will require inspection and cleaning on a more frequent schedule The fan assisted combustion proces
86. n periods or at least every six months A burner view port is located on the combustion chamber front door CAUTION The area around the burner view port is hot and direct contact could result in burns Figure 34 Normal Burner Flame Profile short dense and blue e Normal Flame A normal flame at 100 of burner input is blue with a well defined flame and no flame lifting Yellow Tip Yellow tipping can be caused by blockage or partial obstruction of air flow to the burner e Yellow Flames Yellow flames can be caused by blockage of primary air flow to the burner or excessive gas input This condition MUST corrected immediately If improper flame is observed examine the venting system ensure proper gas supply and adequate supply of combustion and ventilation air 40 10 3 CLEANING BOILER HEAT EXCHANGER Figure 35 Heat Exchanger amp Burner Assembly HEAT EXCHANGER FLANGE GNITER MIXING TUBE TRANSITION ARM FLAME SENSOR BURNER GASKET 1 Shut down boiler a Turn the main power off to the boiler b Shut off gas supply at the main manual valve in the gas piping of the main appliance c DO NOT drain the boiler unless it will be exposed to freezing temperatures using antifreeze prevention fluid in the heat exchanger DO NOT drain 2 Allow time for the boiler to cool to room temperature if it has been firing 3 Remove the upper sheetmetal jacket 4 Remove ignit
87. nsor Remote Operator 4 7 Not Used Nerves Outlet Sensor amp High Limit Fan PWM Modulation 11 12 Not Used Used Fan Tachometer Signal Fan Signal DC Fan Pulse Width Modulation PWM Signal 24VAC Power Not Used 24VAC Gas Valve Safety String Safety String Return Flow Switch Flow Switch 4 8 Not Used LI Inlet DHW Sensor Outlet Sensor Spark Igniter 3 Pin 6 1 2 3 m m 22 3 48 53 CONDENSING BOILER LIMITED WARRANTY 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 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 LIMITED WARRANTY DOES NOT COVER 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 Sediment or lime build up freezing or other conditions causing inadequate water circulation 4 Pitting
88. o start the ignition Anti short cycle sequence Range 0 to 10 minutes Default 0 3 A 3 digit code 225 is required to Password restore the controller to its default not used settings A Plug in Module PIM is required to perform a backup 8 4 DIAGNOSTIC MODE From USER mode 1 Press and hold the Next button for 3 seconds 2 The Diag icon will be displayed in the Operating Mode portion of the display The installer can change screens by pressing the Next button Display Display Readout High Fire 20 22 Alerts do not require manual intervention The last received alert code is displayed in User mode To clear the alert code press the Reset Alert Code button Refer to Table 13 in Section 5 4 2 for more details Alerts are automatic reset errors Lockouts cause the boiler to shutdown and require a manual reset to clear the error The last received lockout code is displayed Pressing the Reset button clears the Lockout Lockout Code code and resets the TH Control Refer to Table 12 in Section 5 4 1 for more details Lockouts require a manual reset on the TH display panel When outlet temperature exceeds this value This results in an alert Maximum Outlet Temperature code being flashed Default 210 F 99 C This parameter does not apply to the TH as the inlet sensor to the heat DHW Maximum Temperature exchanger acts as the DHW sensor Default N A Display Displ
89. out and switches to the home screen Setpoint changes made prior to the timeout will be saved Pressing the Done button after changing a setpoint also saves the new setpoint Table 15 Timeouts in User Mode DHW Water Setpoint Temp Outdoor Temp Firing Rate Table 16 Timeouts in Setup Mode Temperature Scale 1 minute Outdoor Reset Remote Firing Control 5 minutes Anti short Cycle Table 17 Timeouts in Diagnostic Mode 5 minutes Minimum Firing Rate Maximum Firing Rate Manual Firing Rate 20 8 2 USER MODE 1 To access the User menu press the Next button to scroll through the parameters Display Display Readout Display current heater Supply Outlet Outlet Water Temperature Water Temperature Display current heater Return Inlet Inlet water Temperature Water Temperature Display delta T temperature Outlet Delta Temperature Temperature Inlet Temperature Display DHW temperature When UP DOWN is pressed this allows the DHW setpoint temperature to be changed Range 32 230 F 0 110 C DHW Temperature Default 145 F 63 C Stack Temperature Display Stack Temperature Display Outdoor Temperature Outdoor Temperature if equipped Firing Rate Display current boiler firing rate value Lead Lag Header Temperature not used Display and modify current Lead Lag setpoint temperature 21 8 3 SETUP MODE From User Mode 1 Press and hold the UP D
90. ow opening fast closing safety shut off and air gas ratio control for the gas combustion process The valve is a 1 1 negative pressure gas valve The valve performs the functions of a pressure regulator safety shutoff and air gas ratio control Full closing of the valve seat occurs in less than 0 8 seconds when the valve is de energized Operation of the gas valve in combination with the combustion air fan allows the burner input rate to vary from 2096 to 10096 based on temperature demand The inlet gas supply pressure must be maintained within the specified minimum and maximum pressures The air gas ratio is preset at the factory and adjustment is not usually required if gas supply pressure is maintained within the specified range There are no serviceable parts on the air gas ratio valve control Figure 12 TH 82 252 1 1 Air Gas Ratio Control Valve High fire adjustment use throttle screw located on venturi Ju Low fire adjustment screw Torx 40m E clockwise increases Gas Inlet Figure 13 TH 292 392 1 1 Air Gas Ratio Control Valve Low fire air gas ratio adjustment use Torx 40 for adjustment clockwise increases CO 91 bo High fire air gas ratio adjustment Use slotted screwdriver for adjustment counter clockwise increases CO 13 Figure 14 TH 502 1 1 Air Gas Ratio Control Valve Lift top cover to access high fire air gas ratio adjustment use 3mm allen key for
91. present This is done by detecting the amount of current amperes that exists in the live wire to the pump When the current becomes too low a flow switch error is displayed indicating a lack of water flow inside the boiler LED Illuminated Symptom TRIP ON Normal operation TRIP OFF Current under trip point 4 7 T amp P RELIEF VALVE This appliance is supplied with a T amp P relief valve sized in accordance with ASME Boiler and Pressure Vessel Code Section IV 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 CAUTION Avoid contact with hot discharge water 4 8 STAINLESS STEEL STORAGE TANK The TH is equipped with a stainless steel storage tank A 20 gallon tank is supplied with TH Models 082 152 and a 40 gallon tank is supplied with TH Models 202 502 The storage tanks are CSA certified and are rated to operate at a maximum working pressure of 160 psig PART5 ELECTRICAL amp CONTROLS IT IS EXTREMELY IMPORTANT THAT THIS UNIT PROPERLY GROUNDED 5 1 ELECTRICAL CONECTIONS Minimum 120VAC 60Hz single phase 15A circuit is required for the TH models TH 082 through TH 502 The appliance when installed mus
92. r to Vac and measure the voltage from one contact to ground The contacts produce a 24Vac when the circuit is closed Is pump powered Use meter to verify amperage draw on pump and verify it with rating label on pump Is there a double loop through the current transformer Check for contact closure across terminals 7 and 8 on field terminal board perform this step after verifying paddle style flow switch is operational YES Check for 24Vac signal at J5 1 NO Check wiring between green field terminal board and ignition module NO YES Check pump wiring and pump delay relay Check that automatic air vent thumbscrew is loose Turn off power to boiler and loop Black 16 wire twice through current transformer Check wiring from current transformer or paddle flow switch to field terminal board Replace ignition control YES Purge air from water lines Insert jumper wire across terminals 7 and 8 on field terminal board temporary measure 35 Stack limit exceeded displayed on screen Alert 125 Modulation was limited due to stack limit Alert 353 Abnormal recycle stack limit A flue gas error occurs when the stack temperature has exceeded the maximum limit allowed by the vent material This is an automatic reset error when the stack temperature drops 20 F below the limit allowed the boiler is allowed to restart and an ignition attempt is made if the call for heat is not yet sati
93. re Purge timer is satisfied Once this is complete the TH Controller provides a signal to modulate down to ignition fan speed 9 The TH Controller supplies voltage to the air gas ratio control valve The air gas ratio control valve senses the pressure across the venturi and supplies gas to pre mix with air 10 The igniter will continue to spark for 6 seconds with the gas valve opened 2 seconds after the initial spark is generated with the fan running at ignition speed 11 Spark igniter lights the air gas mixture The TH Controller looks for a minimum rectification signal of 0 8 pA DC from the flame sensor during the Main Flame Establishing Period If the signal is present the TH Controller will allow the gas valve to remain open The burner is now firing at starting input rate 12 The fan is kept at ignition speed until the stabilization timer is satisfied 13 The boiler will modulate to the correct fan speed to meet the heat demand The modulation rate is controlled via Pulse Width Modulation PWM signals provided by the TH Controller 14 The fan speed will slowly decrease as the heat request nears the heat demand If the heat demand is sustained for a long duration of time the boiler will get to a point of steady state and the fan will rotate at a constant speed 15 When the heat demand is satisfied or is removed the burner will shut off and the fan speed will ramp up to the preset Post Purge speed until the Post Purge
94. s a direct spark ignition control system The operation of the TH Controller for the direct spark igniter proves the presence of main flame using a flame sensor proof current 0 8 A status point alarm of Flame Fail will be displayed on the main panel if the boiler fails to light after three 3 ignition attempts 16 Table 11 Connector Description Safety Annunciation Remote Operator 24VAC Power Outlet Sensor Inlet DHW Stack Sensor Service Parts 5 3 1 The Controller is not repairable Any modification repairs will invalidate the warranty and may create hazardous conditions that result in property damage personal injury fire explosion and or toxic gases A faulty direct spark igniter MUST be replaced with a new factory part DO NOT use general purpose field replacement parts Each appliance has one TH Controller one direct spark igniter and one flame sensor A list of recommended spare parts is available 5 3 2 Ignition Module Lockout Functions The TH Controller may lockout in either a lockout condition requiring pushing the reset button to recycle the control for a CSD1 requirement or an alert condition A typical lockout fault for the TH Controller occurs when the fan modulation signal is disconnected Pushing the reset button on the control panel is the only way to reset the TH Controller that is in a lockout condition Turning the main power OFF and then ON or cycling the thermostat will not
95. s may force airborne dust and dirt contaminants contained in the combustion air into the burner With sustained operation non combustible contaminants may reduce burner port area reduce burner input or cause non warrantable damage to the burner Never operate this appliance during construction Airborne contaminants such as dust dirt concrete dust or dry wall dust can be drawn into the burner with the combustion air and block the burner port area 10 7 1 Burner Removal and Cleaning Access to the burner will require the following steps e Turn off main electrical power to the appliance e Turn off main manual gas shutoff to the appliance e Remove the front cover e Disconnect the gas supply connection to the fan inlet e Disconnect the fan motor power wires at the harness e Remove the direct spark igniter and the flame sensor e Remove the three 3 T 25 screws holding the front burner flange in place to gain access to the burner e The burner can now be pulled horizontally out of the heat exchanger cavity e Use care to prevent damage to the knitted metal fiber of the burner surface e Wash the burner with water such as a garden hose Never wipe or brush the surface of the burner e For optimal results immerse the burner port area a solution of dishwashing detergent and hot water DO NOT use chlorine based solvents or cleaning agents on the burner Allow the burner to remain in the solution for a short period of
96. safety that is open set the multimeter to Vac and measure the voltage from one contact to ground The contacts produce a 24Vac when the circuit is closed Is Blocked flue switch N C closed when fan is not turning Replace blocked flue switch P N 8021205256 Is vent and or air intake Clear vent and or blocked air intake termination Check incoming gas pressure and reset high gas pressure switch High gas pressure YES High Gas Pressure Tripped switch C6097B N C set to 14 w c Check incoming gas pressure and reset low gas pressure switch YES Low gas pressure YES switch C6097A N O set to 3 w c Low Gas Pressure Tripped Z Turn blocked flue switch set screw 1 2 turns clockwise until burner stays on at high fire 34 Hold 67 ILK OFF Flow Switch LWCO Gas Pressure Switch Blocked Flue Switch Alert 303 Abnormal Recycle ILK off during drive to Purge Alert 304 Abnormal Recycle ILK off during Measured purge time Alert 305 Abnormal Recycle ILK off during Drive to Pre igntion Alert 306 307 Abnormal Recycle ILK off during Pre ignition Alert 308 Abnormal Recycle ILK off during Main Flame Alert 309 Abnormal Recycle ILK off during Ignition Period The flow switch is not closed or the low water cutoff LWCO optional was tripped This is an automatic reset error and as soon flow is proven this error resolves itself To identify the safety that is open set the multimete
97. sfied In the event that a setpoint greater than 150 F is selected and PVC venting is used the setpoint must be reduced to below 150 F to avoid nuisance flame failures If a setpoint greater than 150 F is required venting with CPVC AL29 4C 316LL or PPE is strongly advised The stack temperature is between 15 30 F above the incoming return water temperature to the appliance Adjust CH and or Is vent material PVC plastic DHW Setpoint to white in colour 150 F or less to avoid nuisance trips Select the correct vent material setting through boiler display 149 194 230 AL29 4C 300 limited only by rating of seals 316L Stainless Steel 300 limited only by rating of seals 36 Alert 291 Abnormal Recycle Flame was at end of ignition Alert 294 Abnormal Recycle Flame was lost during Run Alert 324 Abnormal Recycle Hardware flame bias Alert 377 Abnormal Recycle Hardware flame bias delta This type of failure indicates a flame rectification signal issue through the flame rod 15 Flame sensor plug Fasten flame sensor plug securely secure to flame sensor wire and check for corrosion deposits at wire terminals YES Replace sensor wire since corrosion can affect the perceived flame signal significantly and position it away from the heat Check continuity of flame sensor wire from flame sensor to ignition control 41 2 exchanger YES Remove flame sensor and NO Bend flame sensor
98. st meet American National Standard Pipe Threads NPT e For ease of service install unions on inlet and outlet of the appliance The connection to the appliance marked Inlet on the header should be used for return from the system The connection on the header marked Outlet is to be connected to the supply side of the system 4 2 MINIMUM PIPE SIZE REQUIREMENTS Minimum water pipe connections are as follows for TH single unit installations The equivalent number of straight feet of pipe for each valve and fitting in the connecting piping must be considered to properly arrive at the total equivalent feet of straight pipe in the field installed piping to the appliance Consult factory if longer piping distances are required for a specific application It is recommended to use copper piping for all system piping to reduce the possibility of the formation of deposits which may result in heat exchanger starvation System pipe size must be in accordance with Table 9 depending on model Connection sizes at the heater are given in Table 4 Table 9 Minimal System Pipe Size ta Input NPT Btu Hr 1 1 4 4 3 HEAT EXCHANGER This appliance uses precision formed stainless steel tubing to maximize the heat transfer process and achieve 9796 steady state efficiency This heat exchanger is designed to withstand 160 PSIG working pressure A factory installed circulating pump ensures proper water flow during burner operation and cr
99. t components are fabricated from the correct category of materials with adequate clearance from combustibles 3 Fill the condensate collector with fresh water until water begins to pour out the drain 4 Ensure that the heater condensate drain and all vent system condensate drains are properly routed to an acceptable floor drain 5 Review the vent termination point for proper location and clearances 6 If a separate combustion air pipe is used ensure that it is properly sized sealed and terminated 7 Review the water piping from the heater to the system The heater must be installed in a primary secondary piping system Review the diameter and equivalent length of the installed piping to and from the heater to ensure proper flow 8 Ensure that a properly sized system pump is installed with an expansion tank 9 Check system pressure Ensure a minimum of 18 20 PSIG with the system hot and not more than 9096 of the rated pressure of the relief valve 44 10 Review the installed gas piping from the meter to the boiler Ensure that the gas pipe meter and any regulators are adequately sized 11 Review the field wiring and electrical service for the heater controls Ensure that the electrical service s is adequately sized Heater Set Up 1 Ensure that the heater and piping system are full of water Bleed all air from the pump housing and secondary loop Check system for any water leaks 3 Check system for install
100. t be electrically grounded in accordance with the requirements of the authority having jurisdiction or in the absence of such requirements with the latest edition of the National Electrical Code ANSI NFPA No 70 When the unit is installed in Canada it must conform to the Canadian Electrical Code C22 1 Part 1 and or local Electrical Codes All wiring between the appliance and field installed devices shall be made with wire having minimum 220 F 105 C rating e Line voltage wire exterior to the appliance must be enclosed in approved conduit or approved metal clad cable The pump must run continuously when appliance is being fired e To avoid serious damage DO NOT ENERGIZE the appliance until the system is full of water Ensure that all air is removed from the pump housing and piping before beginning initial operation Serious damage may result if the appliance is operated without proper flow e Provide the appliance with proper overload protection 5 2 HIGH LIMIT A manual reset fail safe high limit aqua stat control is internal to the TH controller and the control bulb is installed in a dry well in the heat exchanger outlet The setting of this control limits maximum discharge water temperature to 210 F The temperature of the outlet water in the heat exchanger must drop a minimum of 5 F 2 7 C below the setting of the high limit control before the reset function can be activated 5 3 TH CONTROLLER This appliance use
101. tep 7 DHW Stat operation Select Demand switch DHW switch and Press OK Select Mod sensor Inlet and Press go to step 7 DHW Sensor operation Select Demand switch Sensor only and Press OK Select Mod sensor DHW and Press OK Select DHW Setpoint and enter desired setpoint using 5 way control Place right hand toggle switch setting to REMOTE for remote operation if required Programming Instructions 1 Place both toggle switches in LOCAL 27 Domestic Hot Water Setup Programming Instructions Adjust lightoff rate Programming instructions 1 Place both toggle switches in LOCAL 2 Press X and select Login 3 Select Advanced Setup Advanced Setup Adjust ignition speed on lightoff This may need to be adjusted to achieve smooth lightoffs cannot be achieved through combustion settings All Tank Heater s leave the factory with an ignition fan speed of 3000 RPM Adjust stack limit Quick Start Login Advanced Setup Display Diagnostics P Setup 4 Select Burner Control Ignition 5 Select Adjustable lightoff rate and enter desired lightoff rate using 5 way control and press OK Programming Instructions Adjust stack limit based on vent material used PVC 149 F CPVC 194 F PP AL29 4C Stainless steel 230 1 Place both toggle switches in LOCAL 2 Press and select Login 3 Select Quick Start Quick Start Quick Lodin Start Advanced Setup
102. the flue of an appliance that is not firing The cold outside air may be pulled down the flue and freeze a heat exchanger This condition must be corrected to provide adequate freeze protection e Shut down and draining If for any reason the unit is to be shut off in a space where danger of freezing exists the following precautionary measures must be taken o Shut off gas supply o Shut off water supply o Shut off electrical supply o Drain the main exchanger and tank completely o Ensure that the pump and connecting piping are fully drained 43 11 INSTALLATIONS WARNING Before starting the boiler smell near the floor and around the boiler for any gas odours or any unusual odour Remove the stainless steel jacket and smell the interior of the boiler If there is any sign of a gas leak do not proceed with startup Repair all the leaks before attempting to start the boiler Propane boilers ONLY Your local propane supplier adds an odorant to the propane gas to allow for propane gas leak detection In some cases the added odorant can fade and the gas may not give off any noticeable odour Before startup have the local propane supplier check for the correct odorant level in the 11 1 CHECKING THE INSTALLATION e Inspect the connections for water gas and electricity e Inlet gas pressure must be a minimum of 3 W C for natural gas and 11 W C for propane e With the heater off open the main gas supply v
103. time to remove dust dirt and oil or grease laden contaminants e Rinse the burner thoroughly with clean water to remove any residue from the detergent cleaner e The burner should be air dried after removal from the cleaning solution and rinsing e Check all gaskets and replace as necessary Gaskets affected by heat will not reseal properly and must be replaced e Replace the burner in the reverse order that it was removed When the combustion air fan is removed for any reason the inlet to the burner must be covered to prevent further foreign objects from falling into the burner Always look inside the burner to check for dents Do not place a burner back into operation if the inner distribution screen has been dented during the service operation call the factory for recommendations Use care when removing and handling the burner Sharp objects or impact may damage or tear the metal fiber surface rendering the burner unfit for service 10 8 REMOVAL OF COMBUSTION CHAMBER LINING The combustion chamber insulation in this appliance contains ceramic fiber material Ceramic fibers can be converted cristobalite in very high temperature applications The International Agency for Research on Cancer IARC has concluded Crystalline silica in this form of quartz of cristobalite from occupational sources is carcinogenic to humans Group 1 Normal operating temperatures in this appliance are below the level to convert c
104. ve is required use the following procedure In order to perform adjustments to the gas valve the TH must be firing before proceeding 082 252 Figure 25 Venturi amp Gas Valve Assembly LOW FRE __ ADJUSTMENT SCREW HIGH FIRE ADJUSTMENT SCREW GAS VALVE a VENTURI To adjust the high fire setting on standard display Press and hold the Next button for 3 seconds to enter the diagnostic menu on the TH Control Panel Press Next until the following screen appears Figure 26 High Fire Adjustment Screen To return to normal operation press Done To adjust the high fire setting on upgraded display 1 Press the D button 2 Select Test and press OK 3 Select Forced Rate and press OK 4 Select Set High Fire Locate the input adjustment screw on the side of the venturi Turn the screw 1 8 turn in either way for each adjustment to keep track of the adjustments After adjusting the screw wait a moment for the combustion levels to stabilize before attempting to make any further adjustments Continue this procedure until combustion levels are satisfied Increase CO2 Decrease CO2 High Fire v Counter Adjustment Clock Wise Clockwise To adjust the low fire setting on standard displa Press and hold the Next button for 3 seconds to enter the diagnostic menu on the TH Control Panel Press Next until the following screen appears Figure 27 Low Fire Adjustm
105. xchanger Improperly sized expansion tank Flow Proving Device contacts are Verify LED s on current sensing transformer during a heat open demand Verify for closed valves or obstructions in boiler piping Verify that all air has been purged from the system Verify that wiring is correct he boiler has failed to ignite the Verify that all air has been purged from gas line burner after 5 unsuccessful Inspect spark electrode and related wiring for damage and attempts connection errors Verify that the ignition fan speed is set to 3000 RPM through fan diagnostics screen Verify that boiler is properly grounded Verify incoming gas supply pressure and that it coincides with Table 8 Verify that the vent air inlet piping if equipped are correctly installed and obstructions are not present e Verify 24 is being supplied to the gas valve transformer from the TH Controller during ignition Check wiring from TH Controller Gas Valve Transformer and Gas Valve Relay If a signal cannot be detected the TH Controller needs to be replaced If 24 VAC is present check the outlet of the valve to Flame Failure ensure that gas is flowing With a manometer connected to the outlet pressure tap of the gas valve a negative Pressing the manual RESET on pressure should be present during pre purge When the the TH Control valve is energized a change in pressure should occur if no change is detected the gas valve h

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