Camus Hydronics BLUE-FLAME Series Setup guide

INSTALLATION OPERATION
AND SERVICE MANUAL
GAS FIRED COMMERCIAL COPPER TUBE BOILERS
BLUE-FLAME SERIES
FOR HYDRONIC HEATING
Models; BFH 480, 660, 840, 1020, 1200, 1380, 1560, 1740,
1950
HOT WATER SUPPLY
Models; BFW 480, 660, 840, 1020, 1200, 1380, 1560, 1740,
1950
WARNING: If the information in these instructions is not
followed exactly, a fire or explosion may result causing
property damage, personal injury or death
•Do not store or use gasoline or other flammable
vapours and liquids in the vicinity of this or any other
appliance.
•WHAT TO DO IF YOU SMELL GAS
oDo not try to light any appliance,
oDo not touch any electrical switch; do not use any
phone in your building,
oImmediately call your gas supplier from a
neighbour’s phone. Follow the gas supplier’s
instruction,
oIf you cannot reach your gas supplier, call the fire
department.
•Qualified installer, service agency or the gas supplier
must perform installation and service.
To the installer: After installation, these instructions must
be given to the end user or left on or near the heater.
To the End User: This booklet contains important
information about this heater. Retain for future reference.
CAMUS HYDRONICS LTD.
6226 Netherhart Road, Mississauga, Ontario, L5T 1B7
99-0030
Rev. 03.00

Table of Contents
INTRODUCTION..................................................................................................................................1
1. GENERAL INSTRUCTIONS...........................................................................................................1
2. BOILER LOCATION .......................................................................................................................2
3. PROVIDE AIR FOR COMBUSTION AND VENTILATION ........................................................2
4. ELECTRICAL WIRING...................................................................................................................3
5. GAS SUPPLY AND PIPING............................................................................................................3
6. VENTING.........................................................................................................................................4
7. SAFETY DEVICES ..........................................................................................................................7
7.1 WATER FLOW SWITCH (shipped loose)..................................................................................7
7.2 LOW WATER CUTOFF (If Equipped).......................................................................................7
7.3 RELIEF VALVE (shipped loose)...............................................................................................7
8. FREEZE PROTECTION...................................................................................................................7
9. WARNING REGARDING CHILLED WATER SYSTEMS............................................................ 8
10. PIPING OF BOILER TO THE SYSTEM (FIG.3)..........................................................................8
11. PLACING BOILER IN OPERATION..........................................................................................10
12. CHECK OUT OF IGNITION SYSTEM SAFETY SHUT-OFF DEVICE....................................10
13. LOW WATER TEMPERATURE SYSTEMS..............................................................................10
14. INSTANTANEOUS WATER HEATER.......................................................................................12
15. PILOT AND MAIN BURNER FLAMES......................................................................................12
15.1. MAIN BURNER .........................................................................................................................12
15.2. PILOT BURNER.........................................................................................................................14
16. OPERATION AND SERVICE .....................................................................................................15
17. LIGHTING INSTRUCTIONS .......................................................................................................16
18. TROUBLE SHOOTING GUIDE...................................................................................................17
19. TYPICAL GAS TRAIN.................................................................................................................18
20. ELECTRICAL DIAGRAMS.......................................................................................................... 18
21. EXPLODED VIEW........................................................................................................................21
22. BLUE FLAME REPLACEMENT PARTS LIST ..........................................................................22
WARRANTY ........................................................................................................................................... 23

1
INTRODUCTION
Camus Hydronics proudly introduces its Blue-Flame Series of Water Heaters / Hydronic Boilers.
These machines are thoughtfully designed for easy operation and maintenance. We are confident
that you will come to appreciate the benefits of our product.
1. GENERAL INSTRUCTIONS
The installation of this heater must conform to the requirements of the authority having
jurisdiction or, in the absence of such requirements, to the National Fuel Gas Code, ANSI
Z223.1 or CAN/CGA B149 Installation Codes. All electrical wiring must be done in accordance
with the requirements of the authority having jurisdiction or, in the absence of such
requirements, with the National Electrical Code, ANSI/NFPA 70 or the Canadian Electrical Code
Part I, CSA C22.1 Electrical Code.
Vent installations must be in accordance with Part 7, Venting of Equipment, of the National Fuel
Gas Code, ANSI Z223.1, or Section 7, Venting Systems and Air Supply for Appliances, of the
CAN/CGA B149.1, Installation Codes and applicable provisions of the local building codes.
When required by the authority having jurisdiction, the installation must conform to the Standard
for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1.
The qualified installer shall instruct the end user in the safe and correct operation of this
appliance and shall ensure that the heater is in safe working order prior to leaving the job site.
WARRANTY:
Factory warranty shall apply only when the boiler is installed in accordance with:
•Local codes, standards, ordinances and regulations,
•The printed instructions provided with the boiler and;
•Good industry practices.
Excessive water hardness causing a lime build-up in the copper coils or tubes is not a
fault of the boiler and is not covered by warranty. Consult the factory for
recommendations for use in hard water areas.
Using or storing corrosive chemicals in the vicinity of this boiler can rapidly attack the
copper tubes and coils and voids warranty.
This boiler is intended to operate under non-condensing conditions. Inlet temperatures
must be maintained at 110°F or higher. Warranty is void if heater is allowed to operate in
condensing mode.
Damage caused by freezing or dry firing voids warranty.
This boiler is not to be used for temporary heating of buildings under construction.

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2. BOILER LOCATION
Install this boiler in a clean, dry location with adequate air supply and close to a good vent
connection.
Do not locate this boiler in an area where it will be subject to freezing.
The boiler must not be installed on carpeting and should be located close to a floor drain in an
area where leakage from the boiler or connections will not result in damage to the adjacent area
or to lower floors in the structure.
If necessary a suitable drain pan should be installed under the boiler.
If the boiler is installed above the level of the building’s radiation system, a low water cutoff
device must be installed in the boiler outlet at the time of installation. Some local codes require
the installation of a low water cutoff on all systems.
Locate the boiler so as to provide adequate clearance for inspection and service all around the
unit. It is recommended that 24” be provided for the top and sides and 48” for the front.
This boiler is suitable for alcove installation with minimum clearances to combustibles as
follows:
TOP : 12”
SIDES : 12”
REAR : 12”
VENT : 6”
3. PROVIDE AIR FOR COMBUSTION AND VENTILATION
Provisions for combustion and ventilation air must be in accordance with section 5.3. “Air for
combustion and Ventilation”, of the National Fuel Gas Code, ANSI Z223.1, or Sections 7.2, 7.3
or 7.4 of CAN/CGA B149.1 Installation Codes, and applicable provisions of the local building
codes.
The operation of exhaust fans, compressors, air handling units etc. can rob air from the room,
creating a negative pressure condition leading to reversal of the natural draft action of the
venting system. Under these circumstances an engineered air supply is necessary.
If the heater is to be installed near a corrosive or potentially corrosive air supply, the heater
must be isolated from it and outside air should be supplied as per code.
Potentially corrosive atmospheres will result from exposure to permanent wave solution,
chlorinated waxes and cleaners, chlorine, water softening chemicals, carbon tetrachloride,
halogen based refrigerants, Freon cleaning solvents, hydrochloric acid, cements and glues,
masonry washing materials, antistatic fabric softeners, dry cleaning solvents, degreasing liquids,
printing inks, paint removers, etc.

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4. ELECTRICAL WIRING
All electrical wiring to the boiler must be electrically bonded to ground in accordance with the
requirements of the authority having jurisdiction or, in the absence of such requirements, with
the National Electrical Code, ANSI/NFPA 70 or the Canadian Electrical Code Part I, CSA C22.1,
Electrical Code.
Provide disconnecting means of sufficient rating within sight of the boiler. These heaters require
an 115-V 60-hz supply. Depending on the pump used, a 15-amp breaker is usually sufficient.
Electrical connections must be made so that the circulator will operate before the gas valve can
open. At no time may the control system allow the burner to fire without water flowing in the
system.
Use minimum 18-gauge conductor for 24-volt field wiring to boiler. Splicing of wires is not
recommended.
Use sealed tight conduit suitable for outdoor use for outdoor installations.
For low water cutoff and remote controller, use terminal strip provided inside control panel.
Refer to wiring diagram provided with boiler.
5. GAS SUPPLY AND PIPING
This boiler is intended to operate at inlet gas pressures not exceeding ½ psi (14” water
column). If higher pressures are present, consult the gas company for correction.
When pressure testing the gas supply piping at pressures above ½ psi, the boiler and its
individual gas shut-off valve must be disconnected from the supply piping.
Provide a trap (drip leg) as close to the heater as possible.
Install a good joint union and manual shut-off valve in the gas line near the heater to allow easy
removal of the gas control assembly.
Provide gas pressures at inlet to boiler gas train as follows:
PROPANE NATURAL GAS
Minimum (inches water column) 11 5
Maximum ( inches water column) 11 7
The gas supply line must be of adequate size to prevent undue pressure drop and must never
be smaller than the size of the connection on the heater. Sizing based on Table 1 is
recommended.
Before operating the boiler, the complete gas train and all connections must be tested using
soap solution.

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TABLE 1
DISTANCE FROM NATURAL GAS METER OR PROPANE SECOND STAGE REGULATOR
0-100 FT. 100-200 FT. 200-300 FT.Input
Btu/hr NAT. L.P. NAT. L.P. NAT. L.P.
480,000 1¼” 1” 1½” 1¼” 2” 1½”
660,000 1½” 1¼” 2” 1½” 2” 1½”
840,000 2” 1½” 2½” 2” 2½” 2”
1,020,000 2” 1½” 2½” 2” 2½” 2”
1,200,000 2½” 2” 2½” 2” 3”
2½”
1,380,000 2½” 2” 2½” 2” 3”
2½”
1,560,000 2½” 2” 3”
2½” 3” 2½”
1,740,000 2½” 2” 3”
2½” 3” 2½”
1,950,000 2½” 2” 3”
2½” 3” 2½”
6. VENTING
Boilers for outdoor installation are intended to vent using a listed vent cap.
The BlueFlame windproof cabinet protects the unit from weather, when fitted with the factory
supplied air intake and UL approved vent cap (93-0297), it will be self-venting and suitable for
outdoor installation.
1. Outdoor models must be installed outdoors and must use the Air Intake and Vent Cap
supplied by Camus Hydronics. Alternately, all listed vent cap may be used along with the
Camus supplied air intake
2. Periodically check to ensure that air intake and vent cap are not obstructed.
3. Locate appliance at least 3 feet away from any overhang.
4. Locate appliance at least ten feet from building air intake.
5. Avoid installation in areas where runoff from adjacent building can spill onto appliance.
For outdoor installations, always consider the use of a shelter such as a garden shed in lieu of
direct exposure of the appliance to the elements. The additional protection afforded by the
shelter will help to minimize nuisance problems with electrical connections and will allow easier
servicing of the appliance under severe weather conditions.
For indoor installations the draft hood provided with this boiler must be installed without
alteration. Vent installations must be in accordance with Part 7, Venting of Equipment, of the
National Fuel Gas Code, ANSI Z223.1, or Section 7, Venting of Equipment and Air Supply for
Appliances, of the CAN/CGA B149.1, Installation Codes, and applicable provisions of the local
building codes.
Vent connectors serving appliances vented by natural draft shall not be connected into any
portion of mechanical draft systems operating under positive pressure.
Horizontal runs of vent pipe shall be securely supported (approximately every 4 feet) to prevent
sagging and maintain a minimum upward slope of ¼” per foot from the boiler to the vent
terminal.
When an existing boiler is removed from a common venting system, the common venting
system is likely to be too large for proper venting of the appliances remaining connected to it .At
the time of removal of an existing boiler, the following steps must be followed with each

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appliance remaining connected to the common venting system placed in operation, while the
other appliances remaining connected to the common venting system are not in operation.
a) Seal any unused openings in the common venting system.
b) Visually inspect the venting system for proper size and horizontal pitch and determine
that there is no blockage, restriction, leakage, corrosion or other deficiency, which could
cause an unsafe condition.
c) Insofar as is practical, close all building doors and windows and all doors between the
space in which the appliances remaining connected to the common venting system are
located and other spaces of the building.
Turn on the clothes dryers and any appliances not connected to the common venting system.
Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at
maximum speed, do not operate a summer exhaust fan. Close fireplace dampers.
d) Place in operation the appliance being inspected. Follow the lighting instructions. Adjust
thermostat so that appliance operates continuously.
e) Test for spillage at the draft hood relief opening after 5 minutes of main burner operation.
Use the flame of a match or candle or smoke from a cigarette.
f) After it has been determined that each appliance remaining connected to the common
venting system properly vents when tested as outlined above, return doors, windows,
exhaust fans, fireplace dampers and any other gas-burning appliance to their previous
condition of use.
g) Any improper operation of the common venting system must be corrected so that the
installation conforms to the National Fuel Gas Code, ANSI Z223.1 or CAN/CGA B149,
Installation Codes. When resizing any portion of the common venting system, the
common venting system should be resized to approach the minimum size as determined
using the appropriate tables in Part 11 of the National Fuel Gas Code, ANSI Z223.1 or
CAN/CGA B149, Installation Codes.
Heat exchanger surfaces and vent piping should be checked every six months for deterioration
and carbon deposits. Remove all soot or other obstructions from the chimney and flue, which
might impede draft action. Replace any damaged or deteriorated parts of the venting system.
A qualified service technician should follow this procedure when inspecting and cleaning the
heat exchanger and vent pipe.
1. Turn off electrical power and close main manual gas shut-off and allow boiler to cool
down
2. Remove the boiler draft diverter and vent pipe running to chimney.
•Check heat exchanger, vent and chimney for obstruction and clean as
necessary.
3. Remove burner tray from boiler and vacuum top heat exchanger and coils.
4. Reinstall parts removed in steps 2 and 3.
•Be sure that vent pipe has proper pitch and is properly sealed.
5. Restore electrical power and gas supply to boiler.
•Place boiler in operation using lighting instructions provided.
•Check for gas leaks and proper vent operation.

6
Three venting options are available for this boiler. See Figure 1 below for details.
Standard Venting
Outdoor Venting
Sidewall Venting
Side View
Figure 1

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7. SAFETY DEVICES
7.1 WATER FLOW SWITCH (shipped loose)
A water flow switch is shipped loose and is to be installed in the outlet piping on all heating
boilers and hot water supply boilers. The flow switch is wired in series with the 24VAC safety
control circuit. A diagnostic light will be indicated on the control display on a low flow condition.
7.2 LOW WATER CUTOFF (If Equipped)
If this boiler is installed above radiation level, a low water cut-off device must be installed at the
time of boiler installation. Some local codes require the installation of a low water cut-off on all
systems. Electronic low water cut-offs are available as a factory supplied option on all models.
Low water cut-offs should be tested every six months. The normally open switch contact of the
low water cutoff is to be wired in series with the flow switch. A diagnostic light will be indicated
on the control display on a low flow condition. Caution: remove jumper when connecting to 24
VAC circuit.
7.3 RELIEF VALVE (shipped loose)
This appliance is supplied with a relief valve sized in accordance with ASME Boiler and
Pressure Vessel Code, Section IV (“Heating Boilers”). The relief valve is to be installed in the
vertical position and mounted in the hot water outlet. No valve is to be placed between the relief
valve, and the appliance. To prevent water damage, the discharge from the relief valve shall be
piped to a suitable floor drain for disposal when relief occurs. No reducing couplings or other
restrictions shall be installed in the discharge line. The discharge line shall allow complete
drainage of the valve and line. Relief valves should be manually operated at least once a year.
8. FREEZE PROTECTION
Boiler installations are not recommended in areas where the danger of freezing exists unless
precautions are taken. Maintaining a mixture of 50% water and 50% propylene glycol is the
preferred methods of freeze protection in hydronic systems. This mixture will protect the boiler
to approximately -35 °F (-37 °C). To maintain the same temperature rise across the boiler
increase the G.P.M. flow by 15% and the head loss by 20%.
A snow screen should be installed to prevent snow and ice accumulation around the boiler.
Regular inspections should be made to ensure that air intake and vent are free of snow and ice.

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9. WARNING REGARDING CHILLED WATER SYSTEMS
When a boiler is connected to an air conditioning system where the same water is used for
heating and cooling, the chiller must be piped in parallel with the boiler. Appropriate flow control
valves; manual or motorized must be provided to prevent the chilled water from entering the
boiler. (See figure 2)
Figure 1
When a boiler is connected to heating coils located in air handling units (where they may be
exposed to refrigerated air circulation), the boiler piping system shall be equipped with a flow
control valve or other automatic means to prevent gravity circulation of chilled water through the
boiler. Chilled water in the boiler will create condensate on the boiler tubes, which will collect in
the combustion chamber causing corrosion.
10. PIPING OF BOILER TO THE SYSTEM (FIG.3)
Check all applicable local heating, plumbing and building safety codes before proceeding.
Be sure to provide unions and gate valves at inlet and outlet to boiler so that it can be easily
isolated for service.
This boiler is of a low mass design, which provides for instant heat transfer. Special attention to
water flow rates will ensure that temperature rise does not exceed 35 °F (19.4 °C). The following
table 2 is provided as a guide.
For application in areas known to have hard water conditions, contact factory for
recommendations.

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TABLE 2
20ºF (11ºC) TEMP
RISE
30ºF (16.7ºC) TEMP
RISE
35ºF (19.4ºC) TEMP
RISE
Model U.S
G.P.M.
ΔPft. U.S
G.P.M.
ΔPft. U.S
G.P.M.
ΔP ft.
BF 480 40.0 0.5 26.5 0.3 22.5 0.2
BF 660 55.0 1.1 36.5 0.5 31.0 0.4
BF 840 70.0 2.1 46.5 0.9 40.0 0.7
BF 1020 85.0 3.3 56.5 1.5 48.5 1.2
BF 1200 66.5 2.3 57.0 1.7
BF 1380 76.5 3.3 65.5 2.5
BF 1560 86.0 4.5 74.0 3.4
BF 1740 96.0 5.9 82.0 4.5
BF1950 108.0 6.8 92.5 6.0
Contact Camus for recommendation
Figure 3
If the boiler is installed above radiation level, it must be provided with a low water cutoff device
at the time of boiler installation. (Available from factory)
To eliminate trapped air, install venting devices at high points in the system as well as in the
piping on the suction of the pump and in the piping on the discharge of the boiler.
Use suitable pipe hangers or floor stands to support the weight of all water and gas piping.
Do not allow the boiler to run with inlet water temperature below 110ºF.
The boiler must be installed so that the gas ignition system components are protected from
water (dripping, spraying, rain, etc.) during appliance operation and service (circulator
replacement, control replacement, etc.)

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11. PLACING BOILER IN OPERATION
The Blue-Flame boiler should be installed and started up by qualified personnel.
With the boiler off, open makeup water valve and allow system to fill slowly. Adjust the pressure
regulator to provide at least 15 psig at the highest point in the system.
With all air vents open, run system circulating-pump for a minimum of 30 minutes with the boiler
off.
Open all strainers in the circulating system and check for debris.
Check liquid level in expansion tank. With system full of water at 15 psig, the level of water in
the expansion tank should not exceed 1/4 of the total volume with the balance filled with air.
Start up boiler following instructions provided. Operate entire system including pumps and
radiation for at least 1 hour.
Check water level in expansion tank. If level exceeds ½ of tank volume, air is still trapped in
system. Shut down boiler and continue to run pumps.
Within 3 days of start up, recheck all air vents and expansion tank as described above.
12. CHECK OUT OF IGNITION SYSTEM SAFETY SHUT-OFF DEVICE
After initial fill while the main burner is firing, shut off gas to the pilot and clock the time taken for
the main gas valve to shut down. If the safety control is functioning properly, power to the gas
valve will be shut off within 4 seconds of the pilot gas being shut off. If shut down takes longer,
ignition control or gas valve may be defective.
13. LOW WATER TEMPERATURE SYSTEMS
In applications where the heating system requires supply water temperatures below 110ºF, a
bypass line must be installed upstream of the boiler pump so that outlet water can be re-
circulated to raise the inlet temp to a minimum of 110ºF. Balancing valves, preferably globe
valves are used to adjust flow. (See figure 4)

11
Figure 4
•Adjustment procedure.
a) Fully open bypass and outlet valves.
b) With boiler running, read the inlet temperature after 15 minutes.
c) If the inlet temperature is less than 110 ºF slowly close outlet valve until the inlet
temperature climbs to 110 ºF
d) If the inlet temperature is greater than 110ºF but not greater than 140 ºF no
further adjustment is required.
e) Check the inlet temperature after 5 minutes and make final adjustments.

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14. INSTANTANEOUS WATER HEATER
An instantaneous water heater is designed to deliver hot water without the use of a storage
tank. It is suitable for applications with variable load such as restaurants, condominiums,
apartments and motels. (See figure 5) Call Camus for further recommendations.
Figure 5
15. PILOT AND MAIN BURNER FLAMES
To maintain safe operation and the greatest efficiency of the boiler, check the main burner and
pilot burner every six months for proper flame characteristics.
15.1. MAIN BURNER
The main burner, figure 6 should display the following characteristics;
•Acceptable CO and CO2levels for complete combustion.
•Light off smoothly.
•Reasonably quiet while running.
•Stable flame with minimum of lifting.
•Blue flame with natural gas, yellow tips with propane gas

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Figure 6
If burner characteristics do not match the above, check for accumulation of lint and other foreign
material at burner air inlets.
A qualified service technician should follow this procedure when burners need cleaning.
1. Shut off power and close main manual gas valve.
•Allow burners to cool before removal.
2. Loosen union and remove main burner tray assembly from boiler.
3. Remove and thoroughly clean burners. Check all ports and air channels for blockage.
4. Reinstall the burners.
5. Restore electrical power and gas supply to the boiler.
•Following the lighting instructions put the boiler back into operation
•Check for gas leaks and proper boiler and vent operation.

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15.2. PILOT BURNER
Turn the gas valve control knob counterclockwise to off position and allow the boiler to try for
ignition. Observe the spark making sure that it is strong and continuous.
If the spark is not acceptable the igniter will have to be removed. This can be readily
accomplished by first removing the burners tray assembly from the boiler as detailed in 15.1.
The spark gap should be 1/8” to 3/16”. Make sure that the electrode does not appear
overheated or fouled with carbon. It may be necessary to clean the ignition electrode using
sandpaper. Once the pilot appears to be properly set, reinstall it into the boiler making sure to
properly tighten the pilot line connection.
Once the spark is satisfactory, open the pilot gas and allow the pilot burner to light. Once air has
been purged from the pilot line, the pilot flame should appear almost instantly at the initiation of
spark. Cycle the pilot several times to confirm reliability. A properly set pilot will appear blue and
will engulf the ignition sensor and ground plate. (See figure 7)
Figure 7
Turn the gas control to “ON” and allow the main burner to light. The pilot must not extinguish.
After running for 15 minutes, cycle the boiler to ensure that the pilot remains stable.

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16. OPERATION AND SERVICE
OPERATION:
Before operating the boiler, the entire system must be filled with water, purged of air and
checked for leaks. Do not use Stop leak or other boiler compounds. The gas piping must also
be leak tested.
Any safety devices including low water cutoff, flow switch and high limit used in with this boiler
must receive periodic inspection (every six months) to assure proper operation. a low water
cutoff of the float type should be flushed every six months. All relief valves should be inspected
and manually operated every six months.
For your safety follow the lighting and operating instructions below and on the boiler. To turn on
main burners, slowly turn manual main gas on after pilot is established.
Set primary system controller to desired temperature.
To turn off boiler close main manual gas valve, close pilot manual valve and turn off electric
power to system.
SERVICE:
Disconnect main power and turn off gas supply before servicing unit.
To remove and clean the burners follow the detailed procedure in section 15 of this manual.
After the first season of operation inspect the heat exchanger and venting. Follow the detailed
instructions in section 6 of this manual.
CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can
cause improper and dangerous operation. Verify proper operation after servicing.
Any audible sounds in the equipment, like pinging, crackling or hissing are indications of scaling
or lack of sufficient water flow. Under these conditions the boiler must be shut down immediately
and the heat exchanger and coils checked for damage. If the exchanger is damaged from
scaling, it is not covered by warranty.
Should your equipment be subjected to fire, flood or some other unusual condition, turn off all
gas and electrical supply. If you are unable to turn off the gas, call your gas company or gas
supplier at once. Do not put the unit back in operation until it has been checked by a qualified
agency to ensure that all controls are functioning properly.
Units that are not operated for a period of 60 days or more are considered seasonal operations.
It is recommended that before returning one of these units to service, the proper operation of all
controls be checked by a qualified service technician.

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17. LIGHTING INSTRUCTIONS
1. Turn off electric power to boiler.
2. Close main manual valve and main firing valve and wait 5 minutes.
3. Set primary system controller to desired temperature.
4. Set main manual valve to pilot position.
5. Turn on electric power to boiler. The electrode at the pilot should begin to spark. This
can be observed with a mirror. The pilot valve will open to permit gas flow to the pilot.
6. There is a 15 second trial for ignition, which is enough time to light the pilot if air is not
present in the pilot line. If pilot fails to light and you suspect air in the line, close the main
manual valve and repeat lighting steps 1 thru 5.
7. Once the pilot lights it should envelope the ignition rod and ground strap. Removing the
pilot regulator cover and turning the adjustment screw can adjust the pilot.
8. Open the main firing valve to allow gas to reach the main burners. If the main burners
fail to ignite, turn the main firing valve off to see if the pilot is burning. If not, repeat
lighting procedure steps 1 thru 7.
TO TURN OFF BOILER: Close main manual valve and main firing valve and turn off electric
power to system.

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18. TROUBLE SHOOTING GUIDE
SYMPTOM SOLUTION
1. Power light is not lit when switch is
flipped to “ON”
•Check wiring to switch.
•Check circuit breaker
•Check fuse
2. Water flow light remains off. •Ensure that pump is running
•Check wiring to flow switch
3. Pilot sparks but does not light •Make sure that main manual valve is
open
•Follow lighting instructions to bleed air
out of pilot line.
•Remove pilot burner and inspect for
moisture or dirt in pilot or in pilot line.
4. Pilot lights momentarily, goes out and
then sparks again repeatedly
•Observe pilot for proper flame. Adjust
if necessary
•Remove pilot and ensure that spark
electrode is clean and properly
located.
5. Pilot lights but main burner does not fire. •Ensure that main firing valve is in
“OPEN” position
•Check wiring to valve from ignition
control.
6. Main burner lights but cycles off after a
few minutes
•Make sure that high limit is set high
enough to prevent short cycling.
•Adjust pilot pressure for steady flame
•Remove pilot and clean ignition
sensor.
7. Boiler starts to whine as the temperature
rise increases.
•Make sure that all air is bled from
system.
•Make sure that the static pressure in
cold system is at least 15 psig.
•Check temperature rise across boiler
to ensure adequate water flow.
•If necessary, increase static water
pressure and decrease gas pressure.

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19. TYPICAL GAS TRAIN
20. ELECTRICAL DIAGRAMS
Each Blue-Flame boiler will be provided with its own wiring diagram to guarantee that any
options ordered with the unit are properly detailed.
The following diagrams 99-5020 and 99-5021 are provided as typical samples only.