Camus BFNH-660-2G1 Maintenance Checklist (The BFNH-660-2G1 is a model in the Camus Blue-Flame Series of gas-fired commercial copper-tube hydronic boilers/water heaters, typically rated around 660 MBH input, natural gas configuration with possible 2-stage or specific gas train options indicated by “-2G1”. This checklist is based on the official Camus Blue-Flame Series Installation, Operation & Service Manual (covering BFH/BFW 660 models). Always follow the exact manual for your unit, local codes (e.g., ANSI Z223.1/NFPA 54, ASME CSD-1), and have qualified technicians perform work. Disconnect power and gas supply before any servicing. Warranty requires proper maintenance; scaling/lime buildup, freezing, or dry-firing voids coverage.)

Safety & Preparation (Before Any Maintenance)

  • Shut off main power (115V/60Hz supply) and close main manual gas valve.

  • Allow unit to cool completely.

  • Label all wires before disconnection.

  • Verify proper operation after reassembly/servicing.

  • Use only factory-authorized parts.

  • Wear appropriate PPE; follow lockout/tagout procedures.

Frequency Overview

  • Daily/Operational: Visual checks during normal use.

  • Every 6 months: Flame inspection, safety device testing (mandatory per manual).

  • After first season / Annually: Full service including heat exchanger inspection.

  • As needed: If unusual noises (pinging, crackling, hissing), leaks, error lights, or poor performance occur.

  • Seasonal (60+ days idle): Full control check before restart.

1. Visual & External Inspection (Monthly or Every 6 Months)

  • Inspect cabinet/jacket for damage, corrosion, or leaks.

  • Check all piping (water, gas) for leaks, corrosion, or damage.

  • Verify proper water flow (pump running, no air in system).

  • Ensure clear access for service (burner tray slides out easily).

  • Check for accumulation of dust, lint, or debris around air inlets.

  • Inspect relief valve for leaks or discharge; manually test every 6 months.

2. Burner & Ignition System (Every 6 Months or as Needed)

Main Burner Flame Check (every 6 months):

  • Observe flame: Should be steady blue (natural gas) with minimal lifting, smooth light-off, reasonably quiet operation, and acceptable CO/CO₂ levels.

  • If yellow tips, lifting, noise, or instability: Check for lint/dirt at burner air inlets → clean as below.

Burner Cleaning Procedure (qualified technician):

  1. Shut off power and close main manual gas valve.

  2. Remove burner tray assembly (slide-out design for easy access).

  3. Vacuum or clean burners (remove lint, dust, scale).

  4. Inspect burners for damage or warping; replace if needed.

  5. Reinstall tray with new gaskets if required (heat-affected gaskets must be replaced).

  6. Test for proper flame after reassembly.

Pilot/Igniter Check & Cleaning (every 6 months or with flame issues):

  1. With gas valve off, cycle ignition to observe spark (must be strong and continuous).

  2. Adjust spark gap to 1/8"–3/16" if needed.

  3. Remove igniter/electrode (after removing burner tray).

  4. Clean with fine sandpaper if fouled with carbon.

  5. Reinstall; tighten pilot line connection.

  6. Light pilot: Flame must be blue and fully engulf ignition sensor/ground plate.

  7. Cycle pilot multiple times for reliability.

  8. Turn main gas on; verify pilot stays lit when main burner fires.

  9. Run boiler 15+ minutes and cycle to confirm stability.

3. Heat Exchanger & Water Side (After First Season, Then Annually or as Needed)

  • Inspect for scaling, corrosion, or damage (copper tubes/coils).

  • Listen for pinging/crackling/hissing during operation → immediate shutdown and inspection required (scaling not covered by warranty).

  • Clean if dirty: Follow detailed venting/heat exchanger procedure in manual Section 6 (typically involves removing access panels, vacuuming flue passages, checking for blockages).

  • Check inlet water temperature ≥110°F to prevent condensing (warranty void if condensing occurs).

  • Flush low-water cutoff (float type) every 6 months.

  • Test system water for hardness/chemistry; treat if needed (consult factory for hard water areas).

  • Ensure no “Stop Leak” or boiler compounds used.

4. Venting & Combustion Air (Every 6 Months / Annually)

  • Inspect vent pipe for leaks, corrosion, blockages, or damage.

  • Verify proper venting per manual (Category I or as installed; follow NFPA 54/CAN/CGA B149).

  • Check combustion air supply/intake for obstructions, adequate volume, and no contaminants (corrosive chemicals void warranty).

  • Clean intake screens/filters if present.

  • Confirm draft/venting supports non-condensing operation.

5. Safety Devices & Controls (Every 6 Months – Mandatory)

  • Test low-water cutoff, flow switch, high-limit aquastat, and all safety interlocks for proper operation.

  • Manually operate relief valve(s).

  • Verify ignition safety shut-off functions correctly (per manual Section on check-out).

  • Check all electrical connections for tightness/corrosion.

  • Test pump interlock (circulator must run before burner fires).

  • For seasonal units: Full functional test of all controls by qualified technician.

6. Gas Supply & Piping (Every 6 Months or Annually)

  • Check inlet gas pressure: Natural gas 5–7" WC (min/max per manual); do not exceed ½ psi (14" WC) at inlet.

  • Inspect gas train, valves, and connections for leaks (use soap solution; never open flame).

  • Verify drip leg/trap is clean and functional.

  • For 2-stage models (if applicable to -2G1): Check staging operation and pressures at each stage.

  • Confirm manual shut-off valve and union are accessible.

7. Electrical & General System (Every 6 Months)

  • Verify 115V supply and grounding.

  • Check fuses/breakers (15A typical).

  • Inspect wiring for damage; no splicing recommended.

  • Test all lights/indicators (power, water flow, etc.).

  • Ensure pump operates correctly before burner ignition.

8. Documentation & Records

  • Log all maintenance: Date, technician, findings, parts replaced, test results.

  • Keep manual on-site.

  • Retain proof of maintenance for warranty claims (up to specified years on heat exchanger, 1 year on parts).

Additional Notes & Warnings

  • Qualified personnel only: Installation, service, and adjustments by trained Camus-approved technicians.

  • No temporary construction use.

  • Freeze protection required in cold climates.

  • Excessive hardness or corrosive chemicals void warranty.

  • If unit was exposed to fire/flood: Full inspection before restart.

  • Contact Camus Hydronics or authorized rep for parts (e.g., burners, igniters, gaskets) or model-specific details on BFNH-660-2G1 configuration.

Perform maintenance more frequently in dusty/dirty environments or high-use applications. This checklist ensures safe, efficient, and reliable operation while maximizing longevity of your Camus BFNH-660-2G1 boiler. For the complete illustrated procedures, refer to the official manual (99-0030 Rev. 03.01 or latest)