Camus Hydronics MicoFlame Grande MFH2000 Setup guide

99-0063
Rev. 02
INSTALLATION OPERATION
AND SERVICE MANUAL
MICOFLAME GRANDE
GAS FIRED COMMERCIAL COPPER TUBE BOILERS
FOR HYDRONIC HEATING
Models; MFH2000, 2500, 3000, 3500, 4000
HOT WATER SUPPLY
Models; MFW2000, 2500, 3000, 3500, 4000
WARNING:
If the information in these instructions is not followed
exactly, a fire or explosion may result causing property
damage, personal injury or death
Do not store or use gasoline or other flammable
vapours and liquids in the vicinity of this or any other
appliance.
WHAT TO DO IF YOU SMELL GAS
oDo not try to light any appliance,
oDo not touch any electrical switch; do not use
any phone in your building,
oImmediately call your gas supplier from a
neighbour’s phone. Follow the gas supplier’s
instructions,
oIf you cannot reach your gas supplier, call the
fire department.
Qualified installer, service agency or the gas
supplier must perform installation and service.
To the installer: After installation, these instructions must
be given to the end user or left on or near the heater.
To the End User: This booklet contains important
information about this heater. Retain for future reference.
CAMUS HYDRONICS LTD.
6226 Netherhart Road, Mississauga, Ontario, L5T 1B7

Table of Contents
1 GENERAL INSTRUCTIONS .......................................................................................................... 1
2. LOCATION ......................................................................................................................................1
3. AIR REQUIRED FOR COMBUSTION AND VENTILATION..................................................... 2
4. ELECTRICAL WIRING................................................................................................................... 3
5. GAS SUPPLY...................................................................................................................................3
6. VENTING.........................................................................................................................................4
6.1 OUTDOOR VENTING......................................................................................................................5
6.2 STANDARD VENTING .................................................................................................................. 6
6.3 SIDEWALL VENTING....................................................................................................................6
6.4 OUTDOOR AIR KIT........................................................................................................................6
6.5 FILTER KIT......................................................................................................................................6
6.6 CONDENSER HEAT RECOVERY MODULE (CHRM)...............................................................7
7 WATER PIPING...............................................................................................................................9
7.1 PROTECTION DEVICES................................................................................................................9
7.2 FREEZE PROTECTION ................................................................................................................ 10
7.3 CHILLED WATER SYSTEMS...................................................................................................... 10
7.4 HEATING SYSTEM PIPING ........................................................................................................11
7.5 LOW WATER TEMPERATURE SYSTEMS ...............................................................................11
7.6 INSTANTANEOUS WATER HEATER ....................................................................................... 11
7.7 HOT WATER SYSTEM PIPING................................................................................................... 11
8 INSTRUMENTATION AND CONTROLS...................................................................................15
8.1 SAFETY CONTROLS....................................................................................................................15
8.2 CONTROL PANEL........................................................................................................................15
8.3 CONTROL DEVICES....................................................................................................................18
9 OPERATION..................................................................................................................................19
9.1 START-UP......................................................................................................................................19
9.2 STAGING OPERATION................................................................................................................ 20
9.3 OPERATION SQUENCE...............................................................................................................22
10 PILOT AND MAIN BURNER FLAMES...................................................................................... 23
10.1. MAIN BURNER............................................................................................................................. 23
10.2. PILOT BURNER ............................................................................................................................24
11 OPERATION AND SERVICE....................................................................................................... 25
12 LIGHTING INSTRUCTIONS........................................................................................................ 25
13 TROUBLE SHOOTING GUIDE.................................................................................................... 26
14 TYPICAL GAS TRAIN..................................................................................................................27
15 ELECTRICAL DIAGRAMS..........................................................................................................27
16 EXPLODED VIEW MicoFlame Grande........................................................................................ 30
17 EXPLODED VIEW MicoFlame Grande Outdoor and/or Condensing .......................................... 31
18 MICOFLAME GRANDE REPLACEMENT PARTS LIST..........................................................32
WARRANTY ...........................................................................................................................................33

1
Camus Hydronics proudly introduces MicoFlame
Grande commercial water heaters / hydronic
boilers. The MicoFlame Grande boiler is a fan
assisted boiler based on a push through design
which offers several venting options. These gas-
burning appliances are thoughtfully designed for
easy operation and maintenance. We are
confident that you will come to appreciate the
benefits of our product.
1 GENERAL INSTRUCTIONS
The installation of this heater must conform to
the requirements of the authority having
jurisdiction or, in the absence of such
requirements, to the current National Fuel Gas
Code, ANSI Z223.1 or current 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 current
National Fuel Gas Code, ANSI Z223.1, or
Section 7, Venting Systems and Air Supply for
Appliances, of the current CAN/CGA B149,
Installation Codes and applicable provisions of
the local building codes.
When required by the authority having
jurisdiction, the installation must conform to the
Standard for Controls and Safety Devices for
Automatically Fired Boilers, ANSI/ASME CSD-1.
The qualified installer shall instruct the end user
in the safe and correct operation of this
appliance and shall ensure that the heater is in
safe working order prior to leaving the job site.
WARRANTY:
Factory warranty shall apply only when the
boiler is installed in accordance with local
plumbing and building codes, ordinances and
regulations, the printed instructions provided
with it and good industry practices.
Excessive water hardness causing a lime build-
up in the copper coils or tubes is not a fault of
the boiler and is not covered by warranty.
Consult the factory for recommendations for use
in hard water areas.
Excessive pitting and erosion on the inside of
the copper tube may be caused by high water
velocity or the use of an undersized boiler for a
DHW application and is not covered by
warranty.
Using or storing corrosive chemicals in the
vicinity of this boiler can rapidly attack the
copper tubes and voids warranty.
The primary heat exchanger of this boiler is
intended to operate under non-condensing
conditions. Inlet temperatures must be
maintained at 115°F or higher. Warranty is void
if the primary heat exchanger is allowed to
operate in condensing mode.
Damage caused by freezing or dry firing voids
warranty.
This boiler is not to be used for temporary
heating of buildings under construction.
2. LOCATION
Install this appliance in a clean, dry location with
adequate air supply and close to a good vent
connection.
Do not locate this appliance in an area where it
will be subject to freezing unless precautions are
taken.
The appliance is approved for installation
directly on combustible flooring and 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.
If necessary a suitable drain pan must be
installed under the appliance.
If the appliance is installed above the level of the
building’s radiation system, a low water cutoff
device must be installed in the appliance outlet
at the time of installation. Some local codes
require the installation of a low water cutoff on
all systems.
Locate the appliance 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 appliance is suitable for alcove installation
with minimum clearances to combustibles as
follows:
Table 1 – Clearance to Combustibles
TOP: 12”
SIDES: 12”
REAR: 12”
VENT: 6”
FLOOR 0”

2
Figure 1 – Appliance Dimensions
Table 2 – Appliance Dimensions
B' Dia. Venting E' Dia.
Model ‘I’ ‘K’ ‘L’ ‘W' ‘S’
Water
Connection
Gas
Connection
Outdoor
Condensing
or Sidewall
Standard
Air Inlet
(Optional)
MF2000 6” 68” 34 ⅝” 54 ⅝” 33 3/8” 3” 1 ½” 12” 12” 14” 12”
MF2500 6” 72” 34 ⅝” 78 7/8” 58” 3” 2” 14” 14” 16” 14”
MF3000 6” 72” 34 ⅝” 78 7/8” 58” 3” 2” 14” 14” 16” 14”
MF3500 6” 72” 34 ⅝” 103” 81 ¾” 4” 2 ½” 16” 16” 18” 16”
MF4000 6” 72” 34 ⅝” 103” 81 ¾” 4” 2 ½” 16” 16” 18” 16”
3. AIR REQUIRED 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 current National Fuel
Gas Code, ANSI Z223.1, or;
•Sections 7.2, 7.3 or 7.4 of the current
CAN/CGA B149 Installation Codes, and;
•Applicable provisions of the local
building codes.
The operation of exhaust fans, compressors, air
handling units etc. can rob air from the room,
creating a negative pressure condition leading to
reversal of the natural draft action of the venting
system. Under these circumstances an
engineered air supply is necessary.
If the heater is to be installed near a corrosive or
potentially corrosive air supply, the heater must
be isolated from it and outside air should be
supplied as per code.
Potentially corrosive atmospheres will result
from exposure to permanent wave solution,
chlorinated waxes and cleaners, chlorine, water
softening chemicals, carbon tetrachloride,
halogen based refrigerants, Freon cleaning
solvents, hydrochloric acid, cements and glues,
masonry washing materials, antistatic fabric
softeners, dry cleaning solvents, degreasing
liquids, printing inks, paint removers, etc.

3
4. ELECTRICAL WIRING
All electrical wiring to the appliance 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 appliance. These heaters
require an 115V 60 Hz supply. A 15-amp
breaker is sufficient for appliances with input up
to 3,000 MBTUH. For appliances with input over
3,000 MBTUH, use a 20-amp breaker. The
pump requires a separate power supply.
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 appliance. Splicing of wires is not
recommended. Use sealed tight conduit suitable
for outdoor use for outdoor installations. Use
terminal strip provided inside control panel for
low water cut-off and remote controller. Refer to
wiring diagram provided with appliance.
5. GAS SUPPLY
This appliance is intended to operate at inlet gas
pressures not exceeding ½ PSI (14“W.C.).
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 ½ PSI. 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. The
gas pressure at the appliance’s inlet must be set
in accordance with Table 3.
Table 3 – Gas Pressures at Inlet to Appliance
PROPANE NATURAL
GAS
Minimum (inches W.C.) 11 4
Maximum (inches W.C.) 11 7
The gas supply line must be of adequate size to
prevent undue pressure drop and must never be
smaller than the size of the connection on the
heater. Table 4 lists recommendation for gas
pipe sizes. Before operating the appliance, the
complete gas train and all connections must be
tested using non-corrosive soap solution.
Table 4 – Gas pipe size for distance from
natural gas meter or propane second stage
regulator
0-100 FT*Input
Btu/Hr NAT. L.P.
2,000,000 2 ½” 2”
2,500,000 3” 2 ½”
3,000,000 3” 2 ½”
3,500,000 3” 2 ½”
4,000,000 4” 2 ½”
100-200 FT*Input
Btu/Hr NAT. L.P.
2,000,000 3” 2 ½”
2,500,000 3” 2 ½”
3,000,000 4” 3”
3,500,000 4” 3”
4,000,000 4” 3”
200-300 FT*Input
Btu/Hr NAT. L.P.
2,000,000 3” 2 ½”
2,500,000 4” 3”
3,000,000 4” 3”
3,500,000 4” 3”
4,000,000 4” 3”

4
6. VENTING
Appliances for outdoor installation are intended
to vent using a listed vent cap.
For indoor installations venting must be in
accordance with Part 7, Venting of Equipment,
of the current National Fuel Gas Code, ANSI
Z223.1, or Section 7, Venting of Equipment and
Air Supply for Appliances, of the current
CAN/CGA B149, Installation Codes, and
applicable provisions of the local building codes.
Vent connectors serving appliances vented by
natural draft shall not be connected into any
portion of mechanical draft systems operating
under positive pressure.
Horizontal runs of vent pipe shall be securely
supported (approximately every 4 feet) to
prevent sagging and maintain a minimum
upward slope of ¼” per foot from the appliance
to the vent terminal.
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.
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
current National Fuel Gas Code, ANSI
Z223.1 or the current 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 current National
Fuel Gas Code, ANSI Z223, 1 or the
current CAN/CGA B149, Installation
Codes.
Hydronic heating heat exchanger surfaces and
vent piping should be checked at least yearly for
deterioration and carbon deposits. Domestic hot
water heat exchanger surfaces and vent piping
should be checked every 6 (six) months.
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 appliance
to cool down
2. Remove the vent pipe running to
chimney. Remove top outer panel and
flue collector access panel. Check heat
exchanger, vent and chimney for
obstruction and clean as necessary.

5
3. Remove burner from appliance and
vacuum the burner, and the heat
exchanger. If heat exchanger is
excessively dirty it may be necessary to
remove it from the appliance and wash it
down with proper detergent cleaner. Be
aware that the combustion chamber
base is insulated with ½” thick ceramic
blanket. If this material is damaged or
displaced it must be replaced before
starting up the appliance.
4. Reinstall parts removed in steps 2 and
3. Be sure that vent pipe has proper
pitch and is properly sealed. Repair or
replace any gaskets, which may have
been damaged in steps 2 and 3.
5. CAUTION: When replacing the burner
be careful to fully engage the back of
the burner box into the retaining slot in
the combustion chamber base. Failure
to properly locate the burner will result in
erratic flame operation with the
possibility of delayed ignition on light off.
Once in place make sure that the burner
box is sealed against the seal gasket
provided at the mixing tube.
6. Restore electrical power and gas supply
to the appliance.
7. Place appliance in operation using
lighting instructions provided.
8. While the appliance is operating, check
for flue gas leaks and proper vent
operation. Seal any flue gas leaks using
appropriate gasket or sealing material.
Carefully examine the flue collector
access panel and heat exchanger ends.
The MicoFlame Grande is category 1, 85%
efficient when supplied as a non-condensing
appliance. When supplied with the optional
condensing cartridge, the MicoFlame Grande is
95% efficient and is considered to be a category
II or IV appliance. Three venting options are
available for this appliance in both condensing
and non-condensing configurations. See Figure
2 for details. (Please refer to Table 2 for vent
dimensions)
Figure 2 – Venting Arrangement
6.1 OUTDOOR VENTING
When fitted with the factory supplied rain shields
and UL approved vent cap, the MicoFlame
Grande is self-venting. The following applies to
outdoor installations:
1. Use only factory supplied rain shields.
2. Periodically check to ensure that air
intake and vent cap are not obstructed.
3. Locate 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.

6
6.2 STANDARD VENTING
The MicoFlame Grande is a category I appliance
and is approved for venting into a common
chimney provided it is in good condition and
meeting the local Codes. Typically, the chimney
will be ‘B’ vent or brick with clay or metal liner. If
the chimney height is much greater than 30 feet
or if drafts are in excess of negative 0.05” W.C.,
it may be beneficial to provide a single acting
barometric damper directly above the vent
collar. This damper will ensure smooth light off
and minimize standby loss through the
appliance. Be sure to position the damper at
least 6“ away from the wall of the vent
connector.
6.3 SIDEWALL VENTING
When fitted with the factory supplied vent
terminal, the MicoFlame Grande can vent up to
60 equivalent feet. Elbows can range from 8 to
15 feet in equivalent length depending on
centreline radius. See Table 2 for vent sizes.
Appliances may be installed with either a
horizontal sidewall vent or vertical roof top
terminal. Terminals differ with each application.
Horizontal lengths over 5 feet must be installed
using corrosion resistant stainless steel. Use
single wall vent and seal all joints or use
pressure rated double wall vent.
Refer to local codes for proper installation and
location of vent terminals.
When using sidewall vent, all vent connector
seams and joints must be sealed with pressure
sensitive aluminium tape or silicone sealant as
specified by the vent manufacturer. Aluminium
tape must meet the provisions of SMACNA
AFTS-100-73 Standard.
When venting through unheated spaces with
single wall vent, insulation must be properly
wrapped around the vent pipe to prevent flue
gas condensation inside the vent.
Periodically check to ensure that the vent
terminal is unobstructed.
6.4 OUTDOOR AIR KIT
When fitted with the factory supplied air inlet ring
and air intake terminal, the MicoFlame Grande
can draw outdoor air over an equivalent length
of 60 feet. See Table 2 for vent sizes.
Appliances may be installed with either a
horizontal sidewall vent or vertical roof top
terminal. Terminals differ with each application.
The following applies to outdoor air installations:
1. Use only factory supplied air intake
terminal.
2. Periodically check to ensure that air
intake is not obstructed.
3. Refer to local codes for proper
installation and location of vent
terminals. Vertical vent terminal must be
at least 3 feet above the highest point
where it is located above the roof of a
building
4. Locate the air intake at least five feet
away from the vent discharge. For
sidewall venting locate the air intake
below the vent outlet if possible.
6.5 FILTER KIT
A slot at the bottom of the rear panel is the
standard air inlet configuration for the
MicoFlame Grande. As an option, outside air
could be introduced directly through the back or
top panels. A filter kit is available. The filter is
washable and accounts for an additional
pressure loss of less than 0.05” W.C. Highly
recommended for dusty environments. The filter
kit can also be provided when using the outdoor
air kit.

7
6.6 CONDENSER HEAT
RECOVERY MODULE (CHRM)
The MicoFlame Grande All Stainless Steel
CHRM is mounted in a stainless steel inner
jacket chamber at the back of the appliance. The
CHRM is constructed from all stainless steel
headers and special multiple horizontal stainless
tubes. This CHRM is designed to maximize heat
transfer efficiency by fully condensing flue
products and is suitable to resist the low PH of
condensate.
The CHRM must be supplied with adequate
water flow at all times during operation. Do not
operate the appliance with the CHRM piped out
or isolated.
The CHRM is mounted in the discharge of the
flue products from the primary heat exchanger.
This allows additional heat to be absorbed from
the flue products exhausted from the
combustion process. If isolation valves are
provided on the CHRM, the provision of a relief
valve at the outlet of the CHRM is
recommended. This valve is to be sized at
minimum for 10% of the input of the appliance
and is to be piped to drain.
When cold water supply with temperatures less
than 110ºF (44ºC) passes through the CHRM it
will cool the flue products below dew points
resulting in the formation of condensation.
Furthermore, the volumetric flow rate of the flue
gases will be reduced.
The appliance CHRM loop may be used in
condensing mode for a variety of application
including domestic hot water and hydronic space
heating. Recommended piping arrangement is
shown in Figure 3. Maximum capacity through
the CHRM is summarized in Table 5; flows in
excess of 60 GPM must be bypassed.
Figure 3 – Typical Condensing System
Condensate from the MicoFlame Grande must
be treated before being discharged to drain. pH
level of the condensate is to be checked
regularly and the neutralizing medium is to be
replaced as required. A neutralizing cartridge is
available from the factory. The condensing
MicoFlame Grande must be vented using only
special venting type AL29-4C stainless steel or
equivalent, please follow instructions detailed
below.
When supplied with the CHRM, the MicoFlame
Grande is 95% efficient (category II or IV
appliance) which requires the use of a special
venting system fabricated from AL29-4C or
equivalent material. Only venting components
listed by a nationally recognized testing agency
may be used.
This appliance may be installed with
conventional, sidewall or vertical venting.
Conventional vented appliances operate with
negative pressure in the vent pipe and require a
special vent adapter to increase the flue outlet
diameter. Sidewall and vertically vented
appliances operate with positive pressure in the
vent pipe and may be directly connected to the
flue outlet without the use of an increaser.
Consult the vent pipe manufacturer’s
instructions for minimum clearances to
combustible material for vent components. In the
absence of instructions, the minimum clearance
to combustible material is six inches.

8
Consult vent pipe manufacturer’s instructions for
proper method of sealing vent pipe sections and
fittings. In the absence of instructions, make
sure that pipe and fittings are clean by swabbing
with alcohol. Use Dow Corning 736 or 732 RTV,
Polybar # 500 RTV or Sil-bond 4500 or 6500 to
seal vent pipe. Do not use other sealants or
adhesives except as expressly permitted by vent
manufacturer’s instructions.
Consult vent pipe manufacturer’s instructions for
vent system assembly. Follow vent pipe
manufacturer’s instructions if those instructions
differ from this section.
Conventional Venting
Multiple appliances may be vented into a
conventional chimney. The chimney must be
lined with AL29-4C or equivalent and a single
acting barometric damper must be provided for
each appliance. Vent diameters are to be
increased by one size over the recommended
size downstream of the barometric damper.
A qualified professional using a proven vent-
sizing program with input of accurate operating
parameters must properly calculate sizing of the
venting system. In applications where flue gas
temperatures are lower than can support a
Category II with conventional negative draft, it
will be determined at the venting design stage
that a positive pressure will be developed in the
vent. It will then be necessary to either provide
separate vents as for Category IV, to pressurize
the boiler room, or to provide an extractor at the
chimney outlet in order to maintain a negative
draft in the chimney and allow common venting.
The chimney must be protected from down
drafts, rain and debris by using a listed chimney
cap. Approval of the installation will be at the
discretion of authorities having jurisdiction.
Sidewall and Vertical Venting
The maximum vent length is 100 equivalent feet.
Vent pipe may be run through a vertical or
horizontal chase provided that minimum
clearances to combustible materials are
maintained. The vent should terminate a
minimum 12 inches above grade plus normally
expected snow accumulation, or 7 feet above
grade if located adjacent to public walkways. Do
not install over public walkway where local
experience indicates condensation or vapour
from the boiler creates a nuisance or hazard.
Minimum 3 feet above any forced air inlet
located within 10 feet of vent termination.
Minimum 4 feet below, 4 feet horizontally or
above any door window or gravity air inlet.
Minimum 4 feet horizontally from electric meters,
gas meters, regulators and relief valves. Use
appropriately designed thimbles when passing
through combustible walls or roofs. Install fire
stops where vent passes through floors, ceilings
or framed walls. The fire stop must close the
opening between the vent pipe and the
structure. Locate vent terminal above
combustion air intake terminal (if used) and no
closer than 2 feet vertically or horizontally.
Vertical venting requires flashing and a storm
collar to prevent moisture from entering the
structure. Vertical vent termination must be at
least 2 feet plus the expected snow
accumulation above the roof penetration height.
Figure 4 – Secondary Heat Exchanger
Table 5 – CHRM Head Loss & Flow for 10
o
F Rise
Model US GPM ∆P - Ft.
2000 40.0 5.5
2500 50.0 8.0
3000 60.0 11.5
3500 40.0* 8.5
4000 46.0* 11.0
*Flow for 15°F rise at high fire
.

9
7 WATER PIPING
Check all applicable local heating, plumbing and
building safety codes before proceeding.
The circulating pump must be installed at the
appliance inlet. Always pump toward the heat
exchanger. Minimum operating system pressure
when hot must not drop below 30 PSIG.
Improper piping of this appliance will void the
manufacturer’s warranty. Improper piping
arrangement may cause heat exchanger tube
failure resulting in flooding and extensive
property damage. Excessive water hardness
causing scaling in the copper heat exchanger
tubes in not covered under the manufacturer’s
warranty. Excessive pitting and erosion of the
internal surface of the copper heat exchanger
tubes due to high water velocity or chemicals is
not covered under the manufacturer’s warranty.
Improper operation of this appliance by
permitting return water temperature below 115°F
will result in flue gas condensation leading to
corrosion deposits on the heat exchanger tubes
and will void the warranty.
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 appliance.
Suitable pipe hangers or floor stands must
support the weight of all water and gas piping.
The appliance 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.)
Shut off valves must be installed at the inlet and
outlet connections of the appliance to provide for
isolation of the heat exchanger for servicing. If
the appliance is installed above radiation level, it
must be provided with a low water cutoff device
at the time of appliance installation.
This appliance 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 6 is provided as a
guide. For application in areas known to have
hard water conditions, or for soft water contact
factory for recommendations.
Table 6 – Flow vs. Head Loss for Various
Temperature Rise
20 °F
Model USGPM ∆P ft.
2000 170 5.1
2500 200* 8.2
3000 200* 8.2
3500 200* 10.2
4000 200* 10.2
30 °F
Model USGPM ∆P ft.
2000 113 2.4
2500 141 4.3
3000 170 6.2
3500 198 10.2
4000 200* 10.2
35 °F
Model USGPM ∆P ft.
2000 97.0 1.8
2500 121.0 3.3
3000 146.0 4.5
3500 170.0 7.7
4000 194.0 9.8
* Maximum flow recommended. Temperature rise
will be exceeded. CuNi heat exchanger should be
considered for flow rates exceeding maximum
recommended flows.
7.1 PROTECTION DEVICES
PRESSURE 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.
CAUTION
Avoid contact with hot discharge water

10
LOW WATER CUT-OFF (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 at
least yearly. 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 between H & P1 when connecting to
24 VAC circuit.
Figure 5 – Low Water Cutoff Electrical
Connections
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 FREEZE PROTECTION
•Appliance installations are not
recommended outdoors or in areas
where danger of freezing exists unless
precautions are taken. Maintaining a
mixture of 50% water and 50%
propylene glycol is the preferred method
of freeze protection in hydronic systems.
This mixture will protect the appliance to
approximately -35ºF (-37ºC). To
maintain the same temperature rise
across the appliance increase the GPM
flow by 15% and the head loss by 20%.
The following example demonstrates the
procedure to follow for calculating the revised
head for the heat exchanger when using a water
/ glycol mixture.
•Given that Camus is showing a heat
exchanger flow and head loss of 100
gpm @ 10 feet
•Increasing the flow by 15% now results in
a head loss of 13 feet at 115 gpm (from
B&G system syzer). At this increased flow
Camus now recommends to increase the
head loss by 20%.
•The requirement for the heat exchanger
with water / glycol mixture will now be
115 gpm @ 15.6 feet. (ie. 1.2 x 13ft. =
15.6 ft.)
•A similar procedure must be followed to
calculate the additional head loss in pipe
and fittings in order to arrive at the
proper pump selection.
For Outdoor installations a snow screen should
be installed to prevent snow and ice
accumulation around the appliance. Regular
inspections should be made to ensure that air
intake and vent are free of snow and ice. 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.
7.3 CHILLED WATER SYSTEMS
When an appliance 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 appliance. Appropriate
flow control valves; manual or motorized must
be provided to prevent the chilled water from
entering the appliance. (See figure 6)
Figure 6 – Typical Chilled Water System

11
When an appliance is connected to heating coils
located in air handling units (where they may be
exposed to refrigerated air circulation), the
appliance piping system shall be equipped with
a flow control valve or other automatic means to
prevent gravity circulation of chilled water
through the appliance. Chilled water in the
appliance will create condensate on the
appliance tubes, which will collect in the
combustion chamber causing corrosion.
7.4 HEATING SYSTEM PIPING
In larger systems, it is advisable to connect the
appliance to the piping employing the primary-
secondary pumping system. This system is used
to provide system advantages that would not be
available with a single pumping system.
Primary-secondary pumping is illustrated in
Figure 7.
The following are some advantages of the
primary-secondary pumping system:
•Greatly reduce the stand by losses
through the appliance
•Minimize heat exchanger wear.
•Reduce power consumption
7.5 LOW WATER TEMPERATURE
SYSTEMS
In applications where the heating system
requires supply water temperatures below
115°F, a recirculation line must be installed
upstream of the appliance pump so that outlet
water can be re-circulated to raise the inlet temp
to a minimum of 115 °F. Balancing valves,
preferably globe valves are used to adjust flow.
(See figure 8)
•Adjustment procedure.
a. Fully open bypass and outlet
valves.
b. With appliance running, read
inlet temperature after 15
minutes.
c. If the inlet temperature is less
than 115°F slowly close outlet
valve until the inlet temperature
climbs to 115°F
d. If the inlet temperature is
greater than 115°F but not
greater than 140°F no further
adjustment is required.
e. Check the inlet temperature
after 5 minutes and make final
adjustments.
7.6 INSTANTANEOUS WATER
HEATER
An instantaneous appliance 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 9) Call
manufacturer for recommendations.
7.7 HOT WATER SYSTEM PIPING
Piping and components connected to the
appliance must be suitable for use with potable
water. The appliance should not be connected to
any heating system piping or components
previously used with non potable water. Hot
water storage tanks used in potable water
system must be equipped with temperature and
pressure relief valve. Figure 10 and 11 illustrates
typical water heating piping arrangement for
single appliance and multiple appliances.
The storage tanks must be located as close as
possible to the appliance to prevent excessive
pressure drop. The required flow through the
appliance is based on normal water having
hardness between 7.5 and 17 grains per gallon.
Water hardness above this range will require
higher flow rates to prevent scaling and Copper
Nickel heat exchanger tubes to prevent erosion.
The manufacture should be consulted when
water conditions outside the aforementioned
range are encountered.
The appliance could be fitted with an
economizer (secondary heat exchanger) to
achieve nominal efficiency of 95%. This heat
exchanger is fabricated from stainless steel and
can accept inlet water temperature as low as
40ºF.

12
Figure 7 – Typical Heating System
Figure 8 – Typical Low Water Temperature System

13
Figure 9 – Typical Instantaneous Water System
Figure 10 – Typical Water Heating System

14
Figure 11 – Typical Water Heating System

15
8 INSTRUMENTATION AND
CONTROLS
The appliance is equipped with safety controls
as well as operational controls.
8.1 SAFETY CONTROLS
High Temperature Limit
The high temperature limit is located behind the
appliance’s access doors. A remote capillary
bulb runs to a thermo-well on the outlet side of
the inlet/outlet header. The appliance high limit
is set at the factory to 210ºF for hot water and
230ºF for heating.
Air Flow Switch
A differential air pressure switch is provided to
prove the operation of the fan and adequate air
flow to the burner. The pressure switch sensing
point is at the inlet to the mixing tube where the
air and gas mixes. The LED indicator for air flow
will not illuminate should the pressure switch
detect a sustained low air condition. The
appliance is provided with one air switch per
burner module.
8.2 CONTROL PANEL
The appliance is provided with a control panel at
the front. Operating controls are installed inside
the control box and are accessible by undoing
the thumb screw and opening the door. The
diagnostic information centre as well as the
on/off switch, 24V fuse, and the appliance
temperature controls reside on the control box
door.
Figure 12 – Display, Appliance Temperature
Controller and Indicating LED
The Boiler Temperature Controller (BTC) for this
appliance is a Camus 780014 SmartFlame
control. This controller accommodates up to
four-stage control with six modes of operation
which provides setpoint as well as rest control. It
provides the following:
1. Readings of inlet and outlet water
temperatures as well as ∆T temperature
rise.
2. Six pre-set modes of operation; mode 1, 2,
4, and 5 for heating, mode 3 for DHW and
mode 6 for operation by a remote controller.
3. Operation as an auto reset limit.
4. Operation as a control for inlet water
temperature.
5. Optional tank mounted sensor used in
conjunction with inlet sensor.
6. Adjustable pump delay feature based on
∆T temperature difference between inlet
and outlet temperatures. Accepts 1/6
hp. pump directly across terminals 13 &
14.
7. Adjustable; target temp, inter-stage
differential, on delay between stages,
minimum on time per stage, minimum
off time per stage.
8. Display of run hours for maintenance
purposes. Counter wraps around at
1000 hours.
9. Flame failure signal 24 V.
10. Molex connector for ease of service.
11. Error message display.
12. Test override feature to test pump
operation, stages 1, 2, 3, 4, and 5 and
alarm.
13. Pump exercising feature runs pump 10
seconds every three days of no pump
operation.
Setting the Appliance Temperature Control
1. Press and hold the ITEM, UP and
DOWN buttons simultaneously for 1
second. The appliance will shut down
and pressing the ITEM key and then
selecting the desired setting using the
UP, DOWN buttons, can now make the
settings. Pressing the ITEM key again
will cause the last setting to be
accepted. Once all settings have been
made wait for 30 seconds for the control
to return to normal operating mode. In
normal operating mode the inlet
temperature, outlet temperature, ∆T
temperature and ON hours can be
viewed by repeatedly pressing the ITEM
key only. If you wish to check the setting
you will have to start again by pressing
and holding the ITEM, UP and DOWN
buttons simultaneously for 1 second,
and then use only the ITEM key to scroll
through the settings. After checking the

16
settings allow the control to return to
normal operation on its own.
2. Mode 1 is intended for hydronic heating.
The set-point for inlet water control is
pre-set to 180°F and the auto re-set limit
is set to 230°F. The inlet set-point can
be adjusted, however the limit is fixed.
In addition to the auto reset limit the
factory installs a manual re-set limit set
to 250°F. The control turns on the
appliance pump and stages the
appliance to maintain set-point target
temperature at the appliance inlet
temperature whenever an external heat
demand is present. Once the external
heat demand is removed, the control
turns off the appliance and operates the
appliance pump based on the purge
feature
3. Mode 2 is intended for hydronic heating.
The set-point for inlet water control is
pre-set to 180°F and the auto re-set limit
is set to 230°F. The inlet set-point can
be adjusted, however the limit is fixed.
In addition to the auto reset limit the
factory installs a manual re-set limit set
to 250°F. The control turns on the
appliance pump and stages the
appliance to maintain set-point target
temperature at the appliance inlet
temperature whenever an external heat
demand is present. Once the external
heat demand is removed, the control
turns off the appliance and operates the
appliance pump based on the purge
feature. The control turns on the
appliance pump and stages the
appliance to the set-point target
temperature at the system temperature
whenever an external heat demand is
present. Once the last appliance stage
turns off and the heat demand is still
present, the control then operates the
appliance pump based on the purge
feature. In this case, it is imperative that
the system pump operates continuously
in order to provide constant circulation
past the system sensor. The appliance
pump then turns back on with the first
stage of the appliance. If the heat
demand is removed, the appliance is
turned off and the control operates the
appliance pump P1 based on the purge
feature.
4. Mode 3 is intended for domestic water
heating. The set-point for inlet water
control is pre-set to 140°F and the auto
re-set limit is set to 200°F. The inlet set-
point can be adjusted, however the limit
is fixed. In addition to the auto reset limit
the factory installs a manual re-set limit
set to 210°F. The control turns on the
appliance pump and stages the
appliance to maintain set-point target
temperature at the appliance inlet
temperature. An internal demand is
generated from the DHW sensor which
could be placed in the storage tank
while the external heat demand is
permanently wired or through a timer.
Once the DHW tank is satisfied (internal
demand is removed), the control turns
off the appliance and operates the
appliance pump based on the purge
feature.

17
5. Mode 4 is intended for hydronic heating.
The set-point for inlet water control is
pre-set to 180°F and the auto re-set limit
is set to 230°F. The inlet set-point can
be adjusted, however the limit is fixed.
In addition to the auto reset limit the
factory installs a manual re-set limit set
to 250°F. The control turns on the
appliance pump and stages the
appliance to maintain outdoor reset
target temperature at the appliance
inlet temperature whenever an external
heat demand is present. Once the
external heat demand is removed, the
control turns off the appliance and
operates the appliance pump based on
the purge feature.
6. Mode 5 is intended for hydronic heating.
The set-point for inlet water control is
pre-set to 180°F and the auto re-set limit
is set to 230°F. The inlet set-point can
be adjusted, however the limit is fixed.
In addition to the auto reset limit the
factory installs a manual re-set limit set
to 250°F. The control turns on the
appliance pump and stages the
appliance to maintain outdoor reset
target temperature at the system
temperature whenever an external heat
demand is present. Once the last
appliance stage turns off and the heat
demand is still present, the control then
operates the appliance pump based on
the purge feature. In this case, it is
imperative that the system pump
operates continuously in order to
provide constant circulation past the
system sensor. The appliance pump
then turns back on with the first stage of
the appliance. If the heat demand is
removed, the appliance is turned off and
the control operates the appliance pump
based on the purge feature.
7. Mode 6 is intended for multiple
appliance application and all stages are
closed at all times. In essence there is
no operator at the appliance. A
removable jumper is provided in the
electrical enclosure across the contacts
to be used for connection to the remote
operator. The fixed auto re-set limit is
set to 230 °F. In addition to the auto
reset limit the factory installs a manual
re-set limit set to 250 °F. The control
provides pump operation. Staging
operation is provided by an external
sequencing control. Heat demand is
provided to the external sequencing
control. External sequencing control
then provides heat demand to the
control. Each control turns on its
respective appliance pump and stage 1
contact whenever an external heat
demand is present. Once the external
heat demand is removed from the
control, the control turns off the stage 1
contact and operates the pump to
provide purging. Once the purge period
is complete, the c turns off the appliance
pump.
If this setting is inadvertently chosen the
appliance will cycle on the limits. There is a
danger of scalding if this setting is used in a
DHW application.

18
Figure 13 – Components and Auxiliary Control Connections
8.3 CONTROL DEVICES
Ignition Module
There is one ignition module provided per
burner. The ignition module is mounted on a rail
just behind the outer jacket front access door.
The ignition module provide ignition sequence,
flame monitoring and safety shutoff for the pilot.
Fan Manager
There is one fan manager provided in the control
box per fan. The fan manager provides start and
stop time delay for pre-purge and post-purge
duties.