Home

Installation Operation and Service Manual

1. 66 X X 11 Front Panel 14 14408 901001 x CX 9031009 12 Bezel mpg LL Jp L 9 DL ppp j TET ELE PX x 07 F i ax J x C T L j J x T T LT L is gemens j j L x x L j __ J 8 P T L TT x a EL I ELI x x LEX j j esa X 1653294550 j J J j 1452960 J j J j __ 1431046 x j 14122 X x TENE pg X EI x 14106 J jx x j gt __ 141021 x x 141060 x won j jJ gt EN NE 17 Back Panel 141121 j 141000 fL l LXl L 1 14106 l l x l J x 14100 ll Jj 14808 l l 44889 l Ll 14800
2. a 12 LENGTH OF AIR INEETPIPE u u ett enu _ _________ _ _____ _ _ 12 GAS CONNECTION tecti u betta cede iud O SG o 12 GASCONNECHON T SS n a ma h aD Sas HS 12 E 13 PIPING int 13 AIR GAS RATIO VALVE T M 13 DIFFERENTIAL AIR PRESSURE DR2000 DR5000 14 GAS MANIFOLD DIFFERENTIAL PRESSURE ADJUSTMENT DR2000 DR5000 14 CHECKING GAS SUPPLY PRESSURE uy y u u a a 15 Regulated Gas Supply Pressures for Dynaforce Boilers amp Water Heaters 15 CHECKING DIFFERENTIAL AIR AND GAS PRESSURES DR2000 DR5000 15 GAS M 16 VENTING OF GAS VALVES AND PRESSURE SWITCHES ana y enne nter nnns 16 BURNER ______ ______ _ ___ 16 WATER CONNECTION Z uy k Race 17 FREEZE IP ROWE e uy uama m didis inet oseutia es sana d ate ib ab aym RS Ap td mia a 17 4 2 4 3 4 4 4 5 4 6 4 7 4 8 4 9 4 10 4 11 4 11 1 4 12 PART 5 5 1 5 2 5 3 5 4 5 5 5 6 5 7 SZ E 5 7 2 5 8 5 9 PART 6 6 1 6 2 6 3 6
3. MO V IE cit I S snuie 9 eq jou 5141 3216 jo ayy s 5141 1 15 OM AMICI 1291007 4 91 ASTI AO C STI Ajddng gt ddd NVA LH INI dO OGA01 2 L Jo IOH 73 c 30S 00 21 9610 26 2 ON SN Q 3218 U9IIMS Jedujeq 1eju juesuoo S ShUJe peidoo pesn 5141 peyur snuJe Jo Auedoud y s Buimesp SIU Ji SOINOYGAH 102 70 62 OM NMWYC 035019 SNIHdS N3dO 13 INI OIL VIN3HOSHadlNVO L3 INI OOWVA HOLIMS d NOILOANNOO I3 9 TVNIINH3 L M8 H3MOd LNV ISNOO 8 WNIWHSL S 1 IOH LNOO HF IVNINHJL A NOLLINOI OL 18 AN T1V9 a OILVIN3HOS YAdWVd L3 INI 1Vv I3433 095019 H3
4. Flame detected If an internal hardware error is detected contact Camus amp technical support for troubleshooting procedure 22 Figure 22 Lockout Condition DynaForce Demand OFF Firing rate 0 0 Burner state Lockout Setpoint Inlet Outlet Stack DHW 4 20mA Flame Setpoints Pumps ON Modulation OFF Central Heat 1509 160 F 170 F Lockout 2 Waiting for safety data verification Configure Operation Diagnostics Details To eliminate the lockout error 1 Press the red bar indicating a Lockout condition 2 Press the Lockouts button Figure 23 Lockout History DynaForce Lockout Time Cycle Description 04 12 12 01 28 01 PM 4 2 Waiting for safety data verification 4 12 12 Clear lockout 1 28 23 3 Press Clear Lockout Table 13 Alert Hold Codes Burner switch turned OFF Burner switch turned ON Invalid subsystem reset request occurred Modulation Fault DR300 1000 ONLY Fan speed not proved LCI off safety circuit is open 29 30 47 50 61 62 63 123 124 215 sensor failure 229 275 LCI off safety circuit is open 281 283 Demand off during measured purge time 291 Abnormal Recycle Flame was not on at end of Ignition period 292 Abnormal Recycle Flame was lost during Main Flame Establishing Period 293 Abnormal Recycle Flame was lost early in Run 294 Abnormal Recycle Flame was lost during Run D
5. 8212108 2109 19108 I WES m S Q wid cd woods 8 a g wg Suonoeuuoo olIJIO98ds 52 0 25 JO Sauiau2s 0J1U02 o3 solid s3iuo4p H snuu02 2 Ajuo 3u J f J JOf 1205 si 3uaun20p siu f 01 JIa qns si 3uaun20p 5141 asDajay aig SI 0107 5 240jA 5141 uu 1s s 1uaujeSeue N Suip ing SINS 1 ioq 10 S 10j uonjdnajeiu 5 8207 12108 jeuondo JO1JUOD asa 100 3 0 uiajs s ue a3oujaJ 185 3231e JO usi qe1s3 uoneJedo ojnuo2 pue aseq Ja oq usi qe1s3 043u02 5 1945 5 J ioq dn e usi qe1s3 9 yS A1032e snuue2 Jad 5589222 pue 58 1195 104 suonean81ju02 2105 n usi qe1s3 22 05 02030Jd 5 0 55822 pau2e33e 0201014 snqpow ZN UDVE S4J0AAUO
6. 10 091 03 pauinbau sI T SJ8jroq uJ9AO8 5141 10505 pea uo paseg 1945 aui se Sure v10S peaj 5 g 04 dn 541099 5 T x10w39SN uoneJedQo ji z VIOS 9 adsau aq jsnw au pue sjosuas 100p1nQ 55 ney JsNW 9 22adsa1 pue Buipying ur 432039803 5 2 pauonisod aq 3snui pue 5105195 3e7 pea1 95 45 283 JOSUaS snqpow ZAN pea snqpow snapoy pea snqpoy 284 pea 01 7221098 8 03 T ole a JAV IS YILSYIN JAV IS i gt JAVITS YILSYIN 131108 8 291108 J C Soo Door DoD duco BPR YUREE MHOMLAN L MYHOMLAN Sua los OL dN NOlLV3H3dO 9V1 Qv3l V1OS TI3MA3NOH g Cererem srie CONDENSING BOILER LIMITED WARRANTY GENERAL Camus Hydronics Limited Camus extends the following LIMITED WARRANTY to the owner of this appliance provided that the product has been installed and operated in accordance with the Installation Manual provided with the equipment Camus will furnish a replacement for at Camus option repair any part that within the period
7. ng E 3 Select System Identification amp Access 4 Verify Modbus address To be in sequential order DynaF stem atar amp Access Product type Commercial Hydronic Boiler OS number R7910A1001 R7910A1001sin Software Version 3468 2550 Date code 1114 Application revision 14 Safety revision 10 Model 247 1 Modbus address 2 1 1 MB2 Modbus address Factory data 5 Select Lead Lag Slave Configuration 6 Select Slave Enabled Enable slave for built in Lead Lag master DynaForce n Slave Configuration Slave enable Enable slave for built in Lead Lag ma Slave mode Slave sequence order Demand to firing delay 10 mins Fan rate during off cycle Modbus port MB2 Modbus address 2 The following steps are performed at the factory and verifying on site will be sufficient 7 Select Pump Configuration 8 Press Advanced Options gt gt 9 Press the to arrive at Central Heat Pump or DHW Pump 10 On Options Local burner demand 11 On Options Local Lead Lag Service Active 12 Force On Outlet high limit 35 Master Boiler System Sensor stem Sensor Electrical Connection s Programming Instructions e Master boiler system sensor Press cease and m configuration Press Sensor Configuration Select S5 J8 11 Sensor Connector Type 10K NTC Single Non Safety CASCADE DynaForce Sensor Configuration 51 78 4 sensor Inlet or Return 10K NTC single non safety 52 8
8. piping po Stage was getting ready but is not needed All SOLA controllers are programmed with a default address of Disabled Slave is locked out or disabled 1 The address of the slave controllers in the system must Slave is in time delay to verify that it is have a unique address 1 8 Recovering operational before considered to be available Sequence of Operation When a boiler is set as Lead Lag Master Enabled and Wiring the Lead Lag Setup Modbus address 1 the controller of this boiler will drive the Use Cascade terminals in the junction box to wire lead lag lead lag operation appliances The outdoor temperature sensor connected to the slave boiler 2 ie B 2 will be the outdoor sensor for the lead lag system Master Slave2 Slave 7 he system temperature sensor connected to boiler 1 the master in terminals labeled Outdr Sys in the junction box will be the control sensor for lead lag operation e The start stop signal connected to boiler 1 the master at terminals labeled Remote Operator will Fi 28 L laq Wiri Left M Riaht SI be the heat demand input for lead lag operation ME ne is di J POWER N LJ 4 r J When demand for heat is present the lead boiler will start and uses the lead lag parameters for boiler modulation After a period of Interstage delay the master boiler compares the lead lag tempera
9. 1 Ll LX 141048 l l T 14304 Jx x j 4108 j x x 1 23 T d dq eS J 14109 j j LL 18 Side Panel Right 14488 14107 LXl j ll 43109 l l LX l J 1 M06 l l LX J 14106 l x x M60 l l Ll J gt 14100 Li Li 1L iL i x 67 eem r L 20 owofseh x eee x x x l wee Verturi aircasinier 295 Nye sos Loses vemos gt weisen vemos x Gas Valve yaos l J o ses 0
10. 500VA transformer DCO500UH VFD Model Range T234 DR 1200 to DR 1800 1hp T235 DR 2000 to DR 2500 1 5hp 1237 DR 3000 to DR 3500 3hp T238 DR 4000 to DR 5000 5hp 460VAC 60Hz 3 Phase The combustion air fan motor operates on 230 VAC 3 phase 60 Hz on models DR1200 5000 Three phase voltage is generated by the VFD and supplied directly to the fan motor on models 1200 5000 Refer to Table 10 for appropriate supply voltage to the appliance The appliance when installed must 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 e wiring between the appliance and field installed devices shall be made with wire having minimum 220 F 105 C rating e Line voltage wire external to the appliance must be enclosed in approved conduit or approved metal clad cable he pump must run continuously when appliance is firing 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 pro
11. 9 9 eie A AH 98 M MOTIA 02 d Lyg e 6 0 19 m d T 7 wa JST 2 39NYNO O L dB ii NOLLSNEWOD 31034 oo e yg 18 ZH21IMS zz 14 X8 W2v18 WAL IV qm 5 1VNOLLdO 4 A 6 aanaans 071313 22 a E B 6 E NT M3N2S AlddnS 01313 I 2501 TA 8 xa ONS 1sea jo Burney yum HOLIMS O paoejdai aq jsnui paoejda1 snw ouei dde au 4 9 440 NO payddns se jeuiBuo ay jo Aue 330N f6 71 Dyna ywz oose oooe quu Q3 LIWI1 SOINONQAH 5 It T M 4 8 ie ere ors G00 SN3S c T 1 HILIMS 3unss3sd 2601 1sea Je jo Buges aunyesadwiay Burweu aq jsnui y aq payddins se jeuiBuo 343 jo Aue 72 SOINOYGAH EE g 5 eddinbe 14 4 d NIS T 14
12. The corrosion resistance of AL29 4C is typically higher than that of 316L Always choose the venting system which best satisfies the requirements of the application This recommendation does not supersede local codes or the provision of the B149 in Canada or the National Fuel Gas Code in the United States Single wall air intake pipes are to be insulated 5 feet from wall toward the interior of the building to minimize external sweating 94 DO NOT terminate closer than 4 feet 1 25 300 limited only by rating of seals horizontally and vertically from any electric meter gas meter regulator relief valve or other equipment In all cases local codes take precedence e Position terminations so they are not likely to be damaged by foreign objects or exposed to a build up of debris e The vent piping must terminate in an elbow pointed outward or away from the air inlet avoid a blocked flue condition keep the vent cap terminal clear of snow ice leaves debris etc e Flue gases from this appliance may contain large amounts of water vapour that will form a white plume in winter Plume could obstruct a window view 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 Some discoloration to exterior building surfaces can be expected Adjacent brick or masonry surfaces should be protected with a rust resistant sheet metal pl
13. 29 3 8 31 3 4 73 1 2 22 5 8 62 1 2 14 29 3 8 31 3 4 73 1 2 22 5 8 62 1 2 14 29 3 8 31 3 4 81 1 4 24 5 8 72 3 8 14 3 8 29 3 8 31 3 4 82 5 8 25 74 15 3 4 35 3 4 39 1 4 85 1 4 25 5 16 75 3 16 16 35 3 4 39 1 4 93 27 1 4 82 14 15 1 2 35 3 4 39 1 4 93 25 1 4 82 1 4 15 1 2 35 3 4 39 1 4 29 81 1 4 16 1 2 35 3 4 39 1 4 102 29 1 2 87 1 2 16 3 4 2 1 2 Connection at heat exchanger 31 1 4 31 1 4 39 3 4 39 3 4 45 7 8 45 7 8 56 5 8 56 3 8 59 1 4 59 1 4 59 1 4 69 1 2 70 1 2 76 1 4 76 1 4 79 1 4 85 1 2 6 3 4 6 3 4 9 3 4 9 3 4 10 1 2 10 172 10 3 8 1 7 8 1 7 8 1 7 8 1 7 8 1 7 8 1 7 8 1 7 8 4 1 2 4 1 2 4 1 2 4 1 2 4 3 4 4 3 4 3 3 4 3 3 4 4 5 8 4 5 8 4 3 8 23 1 4 23 1 4 23 23 22 3 4 22 1 2 27 3 4 27 3 4 27 3 4 2 27 3 4 12 12 N N 12 N N O Dim L in Air Inlet As shipped 12 N 2 N 1 1 N N eo N A N FRONT VIEW Dim W in Water Groove e 3 3 4 4 1 1 1 1 1 4 1 1 4 1 1 4 1 1 4 1 1 4 910 T T PART2 VENTING 3 7777 a It is extremely important to follow these venting instructions carefully Failure to do so can cause severe personal injury death or substantial property damage Use of cellular core PVC ASTM F891 cellu
14. Boiler operates at a fixed DHW Sensor Stat if required Place both toggle switches to LOCAL DHW setpoint DHW Press El ang Modulates on boiler inlet 2 2 Bl Inlet Sensor operation sensor default Press DHW Domestic Hot Water Configuration Heat demand is generated Select Demand Switch Modulation sensor only when Remote Operator is Select Modulation sensor Inlet Sensor Proceed to Step 12 closed Demand switch Modulation sensor only Modulation sensor Inlet sensor DHW Sensor Stat operation Press Sensor Configuration Select S6S7 J9 1 3 Sensor DHW 10K NTC Single Non Safety The control will proceed into a Lockout 2 condition Press Verify Begin Yes Press the reset button on the ignition control within the alotted time Mose El 51 28 4 sensor Inlet or Return 10K NTC single non safety S2 J8 6 sensor 4 20mA remote 4 20mA 5354 J8 8 10 sensor Outlet or Supply 10K NTC dual safety 55 38 11 sensor 10K NTC single non safety 5657 19 1 3 sensor DHW 10K NTC single non safety 5859 J9 4 6 sensor Stack 10K NTC single non safety Outdoor temperature source UNCONFIGURED DHW Sensor operation Press DHW Domestic Hot Water Configuration Select Demand Switch Modulation sensor only Select Modulation sensor DHW Sensor Proceed to Step 12 Demand switch Modulation sensor only Modulation sensor DHW Stat operation 9 Press
15. Check all applicable local heating plumbing and building safety codes before proceeding If the appliance is installed above radiation level it must be provided with a low water cut off device at the time of appliance installation available from factory Some local codes require the installation of a low water cut off on all systems A pressure relief valve is supplied with each Dynaforce The relief valve must be mounted in a vertical position and piped to the floor in a manner acceptable to the enforcing authority Minimum water operating system pressure should not drop below 30 PSIG Be sure to provide unions and gate valves at inlet and 4 1 FREEZE PROTECTION Appliance installations are recommended outdoors in areas where danger of freezing exists unless precautions are taken Maintaining a mixture of 5096 water and 5096 propylene glycol is the preferred method of freeze protection in hydronic systems This mixture will protect the appliance to approximately 35 F 37 C To maintain the same temperature rise across the appliance increase the GPM flow by 1596 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 e Given that Camus is showing a heat exchanger flow and head loss of 100 gpm 10 feet outlet to the appliance so that it can be easily isolated for service The provision of
16. eee econ xx Tooter o toer 300144 j Xx M ee LEE ee 77 0038 F 1 1 White Ceramic A a Stiffener primary ring Black Viton Solid Gasket Secondary heat exchanger Black Viton Foam Gasket Secondary wrap N O Snap Action Thermostat eee et ILL LI 5 Monualshutoffkt S0o026s3 000 11x tx x x 1 TT T Notshown in exploded view Recommended spare parts 70 PART 13 ELECTRICAL DIAGRAMS 9 19 EI me MOSN3S ho d 4 HO ITI LE l wooaino et 08 8r oc HOLIMS r 25 1 1 4 4 as C Ka gt n f H HILIMS 140 ug H21IMS SVO H X20 T831NI t 3AT1VA SV9 z a 19 t 35v4sns LOH anna z v vr 25 NP zi 9 D 1 4g c L 4 svo EArt 2 d auns Saud d M 19 494 Ly gt 8 s 9 4 SECIS N1VNSIS
17. Default 1 min Use for Lead Lag Master v Pump Control ON Pump is constantly powered contact Refer to above Aut Default Pump Control ON Pump is constantly powered Pump Output None Specify pump contact Menu Group Parameter Description Selection Selection Post pump time 1 Default 1 min demands Refer to above Use for local Stand alone demands demands Auto Refer to above Default 5 Post pump time 1 Default 1 min Post pump time 1 2 L Q o E 2 I Q 2 4 72 gt N 6 2 3 Statistics Configuration 6 2 5 Burner Control Ignition Menu Group Selection Parameter Ignition Fan speed Sub Sub Menu Menu E Menu Parameter Description Group Group Group Selection 5 Selection Selection DR300 1000 Lightoff 3000 RPM rate DR1200 5000 20 096 Displays the number of cycles the boiler pump has been activated Displays the number of cycles the burner has been activated run time in hours Displays the number of cycles the CH pump has been activated Displays the number of cycles the DHW pump has been activated Displays the Boiler pump cycles Ignition 6 2 6 Sensor Configuration Sub Menu A Parameter Description Group Selection S1 J8 4 iiis single non Inlet Sensor sensor safety 4 20mA Input Signal 10K NTC Outlet dual safety
18. DHW Domestic Hot Water Configuration 10 Select Demand Switch Modulation sensor only 11 Select Modulation sensor DHW S6 switch amp inlet sensor Demand switch 56 switch 12 Enter desired Setpoint 31 32 Dyna 13 Place toggle switch setting to REMOTE for remote operation if required DynaForce Domestic Waker Configuration DHW enable Disabled Demand switch Modulation sensor only Modulation sensor Inlet sensor Setpoint Off hysteresis 10 F On hysteresis Hor DHW priority override time osc DR H W Lead lag Operation Master Boiler Electrical Connection s Programming Instructions Master boiler lead lag setup CASCADE OUTDOOR Place both toggle switches to LOCAL Press _ Coe and Select System Identification amp Access Verify 1 Modbus address 1 Verify MB2 Modbus address 1 DynaForce n System Identification amp Access Product type Commercial Hydronic Boiler OS number R7910A1001 R7910A1001s1n Software Version 3468 2550 Date code 1114 Application revision 14 Safety revision 10 Model 247 MB1 Modbus address Modbus Factory data Select Lead Lag Master Configuration Select Master Enabled Enabled Fixed Setpoint operation Enter CH Setpoint Fixed setpoint DynaForce Master Configuration CH setpoint 1609F CH time of day setpoint 1309F M
19. Use for hydronic heating applications only or shipped loose and is installed in the vertical position and mounted in the hot water outlet No valve is to be 4 8 WATER FLOW SWITCH placed between the relief valve and the appliance To A water flow switch is mounted and installed in the outlet piping prevent water damage the discharge from the relief valve on all heating boilers and hot water supply boilers The flow shall be piped to a suitable floor drain for disposal when switch is wired in series with the 24VAC safety control circuit relief occurs No reducing couplings or other restrictions shall be installed in the discharge line The discharge line 4 9 LOW WATER CUTOFF If Equipped shall allow complete drainage of the valve and line Relief valves should be manually operated at least once a year If a relief valve discharges periodically this may be due to thermal expansion in a closed water supply system 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 Contacte On O on all systems Electronic low water cut offs are available as a How t thi vd D th 9 i factory supplied option on all models Low water cut offs sid adc cdi o dd should be tested every six months including flushing of float CAUTION types The normally open switch contact of the low water cutoff
20. is to be wired in series with the flow switch A red diagnostic light will be indicated on the control display on a low flow condition 4 11 CIRCULATING PUMP SELECTION l The appliance has a low mass stainless steel finned tube Caution remove jumper when connecting to 24 VAC circuit heat exchanger for fast response and high heat Figure 19 Low Water Cut Off Electrical Connections Watts absorption Selecting the proper pump will ensure that temperature rise does not exceed the maximum recommended for the application and that the heat Connection detail for placing exchanger tubes are not prematurely scaled or eroded L W C O in 24V circuit 4 11 1 CIRCULATING PUMP OPERATION OF HEAT EXCHANGER MOST IMPORTANT This appliance is designed for continuous pump operation when the burner is firing The pump control option allows WARNING Be sure to remove the jumper between H and P1 Pressure Switch a E ER Flow the appliance circulating pump to be cycled ON prior to the burner firing and cycled OFF some time after the set To High Limit point is satisfied The operation of the circulating pump is controlled by the Dynaforce temperature control SOLA When the appliance is activated by a remote operating signal the pump will start and run for the operating cycle and for a post purge period based on temperature difference between inlet and outlet connections to the appliance Th
21. on total system volume including expansion tank volume Antifreeze is denser than water and changes the viscosity of the system The addition of antifreeze will decrease heat transfer and increase frictional loss in the boiler and related piping Where antifreeze has been used to maintain the temperature rise across the appliance confirm that the recommended GPM for pure water has been increased by 15 and the head loss by 20 Local codes may require a back flow preventer or actual disconnect from city water supply when antifreeze is added to the system When filling or topping up the system with water mixed with the antifreeze always used distilled or RO reverse osmosis water This will prevent the reaction of the water with antifreeze which can create sludge Inspect the connections for water gas and electricity Inlet gas pressure must be a minimum of 7 W C for natural gas and 11 W C for propane With the boiler off open the main gas supply valve and vent the trapped air from the piping leading to the boiler Confirm that all gas connections to the heater are tight and that there are no missing test plugs Refer to Section 8 3 Gas Valve Adjustment Procedure of the manual for recommendations on setting combustion characteristics 11 2 CHECKING THE INSTALLTION Check the boiler wiring to see that it agrees with the wiring diagram supplied e Confirm that terminal connections are identified e With the boiler
22. steel wrap Replace any damaged gaskets to ensure a proper air seal Replace any ceramic facing tape damaged on the baffles Reinstall the burner and fan assembly Heassemble all gas and water piping Test for gas leaks Reassemble outer jacket panels Keep top cover off Cycle unit and check for proper operation e Once proper operation is confirmed replace the top cover 10 8 RE INSTALL HEAT EXCHANGER e Carelully reinstall the heat exchanger if removed from the appliance e Check all silicon and viton gaskets and replace if damaged e HReassemble inner wrap e Cycle unit and check for proper operation e Replace the top cover 10 9 COMBUSTION AIR FAN Combustion air fan should be checked every 6 months Clean the internal filter as required when installed in a dust or dirt contaminated location The motor and bearings on the combustion air fan are sealed and permanently lubricated requiring no addition of oil or lubricants 10 10 COMBUSTION AND VENTILATION AIR Check frequently to be sure that the flow of combustion and ventilation air to the appliance is not obstructed Combustion and ventilation air must be provided to the mechanical room with openings sized per the requirements of the B149 or National Fuel Gas Code The optional outdoor air kit brings combustion air from the outdoors directly to the appliance 10 11 CONTROL CIRCUIT VOLTAGE This appliance uses a transformer to supply a low voltage control circuit
23. suondo 10204029 331lO8 LH59I3 91 JNO IOHLNOO IN31SAS LN3IAN39VNVIN 88 75 5 uagp Joad eau geud qu SSMUED jou Bue S U sojuoip g snwen jo Apadoud ary s Guyer sur an __ Q3LIWNI1 SOINOYGAH 9Z TSP JIM T XJOMJAN 5 Se T JOMIN pea jo 8 p pedw si uonesado 519 dn uonesedo pee1 v10OS Ile MAS 512108 Jo x SUI z 3jnejeg Aejag ageyssajy s aj oq siy 4osuas 3e7 pea uo paseg pue swous S L SNINHVAA 4 7 1 nej q T gt Z lulod1 s pea sJ3 I0q BsOjaq HEIS 0 1duu 11e peaj auio aq g VIOS 5 Jo uone104J ong 910N Jo sajeJado 1815189 Aejag aw 5 dung aouanbas uoniusi sulgaq 8 105 UUM peu SI 941 uo SI 3 TOOL VOT64 4M peuo 5 dung Jo asn 991 usnoJju3 T VIOS Z
24. up on multiple boiler systems the low fire combustion should be established on all boilers before setting any boiler high fire combustion rates In order to perform adjustments to the gas valve the Dynaforce amp must be firing before proceeding Figure 32 300 400 Gas Valve Low fire air gas ratio adjustment use T 40 for adjustment clockwise increases CO use slotted screwdriver for adjustment counter clockwise increases CO High fire air gas ratio adjustment Figure 33 DR 500 1800 Gas Valve Lift top cover to access high fire air gas ratio adjustment use 3mm allen key for adjustment counter clockwise increases CO Low fire air gas ratio adjustment Y use T 40 for adjustment aih clockwise increases CO La z j kanaa Gas Inlet To adjust the low fire setting DR 300 1800 Use the Dynaforce Control Panel 1 Press DIAGNOSTICS button Press Diagnostic Tests button 3 Move the firing rate slider to 1600 RPM Press Start Test to operate the boiler at max fire for 5 minutes The Dynaforce should respond immediately and fire at 1600 RPM When this is achieved locate the low fire adjustment screw as illustrated in Figure 30 and 31 Increase CO2 Decrease CO2 Low Fire C Adjustment Counter Clock Wise When the correct combustion values are achieved replace the screw cap back on to the gas valve e This boiler is designed for low fir
25. wes tr b E Gas Valve Solenoid e106 4 seas j j ef 3 casvaveregustorsow 3 x j j j DRAOOBRN ws LL LLL _ ILL Core Ll Lll ome L L TI T T CECI Tt 1 1 1 RS pi et Surface ie s SSSEESSSSSSSESESESESS rama masa sarasa sassa sarasa sa Pe a Igniter Mounting 13 5335 Flange F FanFlange OE 13 5332 318 ES TI T _ e142 gem oem as ovo gr Lows pf o34 35 xj L IT T T txt ram misa P emm 01 28807 Transformer 0 10Vdc Converter if ETISO V equipped Variable Frequency m Lgs j xx gt oma LL
26. 6 sensor 4 20mA remote 4 20mA 5354 18 8 10 sensor Outlet or Supply 10K NTC dual safety 55 18 11 sensor 10K NTC single non safety 5657 J9 1 3 sensor DHW 10K NTC single non safety 5859 J9 4 6 sensor Stack 10K NTC single non safety Outdoor temperature source UNCONFIGURED The control will proceed into a Lockout 2 condition Press Verify Begin Yes Press the reset button on the ignition control within the alotted time Outdoor Sensor COREE to Slave boiler 2 DRH Slave boiler outdoor sensor Slave Boiler configuration Press Lang cem When done correctly the Press Sensor Configuration outdoor temperature will be Select S5 J8 11 Sensor shown on the Master boiler Connector Type 10K NTC Single Non Safety DynaForce Sensor Configuration S1 J8 4 sensor Inlet or Return 10K NTC 10 NTC single non safety non safety CASCADE 52 J8 6 sensor 4 20mA remote 4 20mA 6354 J8 8 10 sensor Outlet or Supply 10K NTC dual safety 55 J8 11 sensor 10K NTC single non safety 5657 J9 1 3 sensor DHW 10K NTC single non safety 2859 19 4 6 sensor Stack 10K NTC single non safety Outdoor temperature source 55 J8 11 sensor 5 The control will proceed into a Lockout 2 condition 6 Press Verify Begin Yes 7 Pressthe reset button on the ignition control within the alotted time Master Boiler 8 Press feme m
27. DynaForce Demand OFF Firing 0 0 Burner state Standby Setpoint Inlet Outlet Stack 4 20mA Flame DHW Setpoints Pumps ON Modulation OFF Central Heat 1509 160 F 170 F 4 History Configure Operation Diagnostics Details PARAMETER DESCRIPTION Central Heating DRH Demand Domestic Hot Water DRW Burner State Current Status of Dynaforce Firing Rate Target Firing Rate Fan Speed Actual Firing Rate DR300 1000 Inlet Inlet Water Temperature F Outlet Outlet Water Temperature F Stack Stack Temperature F DHW DHW Temperature F if equipped Lead Lag CH Header Temperature F if equipped Outdoor Outdoor Temperature F if equipped 4 20mA 4 20mA input if equipped BUTTON DESCRIPTION Access Dynaforce parameters CH Parameters DHW Parameters Outdoor Reset Pump Configuration etc Operation Details of boiler operation Set point Firing Rate Pump Status Safety circuit Diagnostics Manual firing rate Analog Digital Status Configure Details History Pump Status Outlet Temperature Sequence of Operation roubl Diagnostics STAT Pump B Pump B DynaForce Pump Pilot Valve DR3000 5000 Flow Switch Blocked Flue Switch LCI Closed Blower High Limit Gas Pressure Switch Interrupted Air Switch Interlock Pilot Valve Main Valve Flow Switch Flow Switch Low water cutoff if equipp
28. HEATING BOILERINSTALLATIONS uu RR e Ue des bet aD EM 60 11 5 WATER CONNECTIONS ESSA a a maaa ia aa meus 60 11 6 PIPINGTENGIH Sic mm 60 11 7 INTERMA TENT PUMP OPERATION crnina u EEE Sa SE 60 11 8 SUMMAR a 60 11 9 DOMESTIC THON VATER HEA DER Sau IN OM NONE MIS 61 11 10 WATER VEEOCIPECONJIRODL i d uu uu que Qe RODA a Sa n atte to u a teen nA 62 11 11 TEMPERATURE RSEATFYLCEFIRING enin ashaka kah kasu HRS EE S ERAN dr nh eda iS 62 11 12 WATER HEATERS ail ttu pA uu ud M M Mcd MA MU Mi 62 PART12 EXPLODED VIEW uuu masaspa a maaa _________ _______________ 63 PART TS ELECTRICAL DIAG RAIN IS un uu au xU do Du veste 71 PART1 GENERAL INFORMATION 1 1 INTRODUCTION The Dynaforce amp is a condensing forced draft appliance utilizing a premix power burner 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 Dynaforce amp provides central heating or domestic hot water at working pressures up to 160 PSI It is designed for use with a fully pumped and pressurized system The boiler water heater will automatically modulate to provide heat outputs between 10096 and down to 2090 The Dynaforce works on the principle of differential pressure The
29. IV VENTING nennen nennen 7 APPROVED VENTING MATERIALS c ull l tese _________________ 8 VENT TERMINATION CLEARANCES vsco uuu uQ a uu unn site odisse eiae uci 8 INLE FCAP FOR ROOFTOP TERMINA TON try u u 8 LOCATION OF A ROOFTOP AIR INLET AND VENT 5 a 9 AIR INEET DAMPER a un n DOS a Suasana u aa 9 MASONARY CHININEY INSULATIONS yuyu uu ul utres 9 VERTICAL VENTING TERMINATION sess elise ul a TRE VERI e pela de aus eS 9 COMBINE D CONMBUSIIONAIRINIET uu u uuu e Sues euet 9 DRAIN TEES ukuna Rac o abya uapa Qa s tS 10 CONVENTIONAL VENTING INDOOR 5 10 AIR REQUIRED FOR COMBUSTION AND VENTILATION nenne enne nennen 10 EXHAUST FANS iL S 11 OUTDOOR VEN TINGS u y ___________ 11 SIDEWALEVENTING yu _ ______ ___6_6_ _ _ _ _ _ 11 SIDEWALL VENT TERMINAL amp SIDEWALL INTAKE AIR TERMINAL 11 LOCATION OF A SIDEWALL VENT TERMINATION a enne rennen 11 LOCATION OF A SIDEWALL AIR INLET TERMINAL
30. Sensor Outdoor Sensor Burner cycles Burner run time CH pump cycles Menu Group Selection S2 J8 6 sensor 5354 J8 8 10 sensor DHW pump cycles number of cycles the system pump has been activated Sensor Configurations S5 J8 11 sensor 10K NTC single non Standalone boiler or Slave boiler Header sensor Master boiler 10K NTC DHW single non Sensor safety DRW Only 5859 19 Stack single non 4 6 sensor 5 Sensor safety 6 2 4 Figure 27 Burner Control Timing and Rates Burner Control Timing and Rates DynaForce Burner Control Timings amp Rates S6S7 J9 1 3 sensor Prepurge rate 100 0 Prepurge time 15 secs Preignition time 22 secs Lightoff rate 20 096 safety Run stabilization time 10 secs Postpurge rate 100 096 Postpurge time 1 min THIS PARAMETER REQUIRES SAFETY VERIFICATION Sub Menu Parameter Description Group Selection Prepurge fan speed Default Prepurge DR300 1000 rate 3000 RPM DR1200 5000 100 096 time 5 mins Default 25 sec Run Main flame Stabilization establishing Time period Postpurge fan speed Default Postpurge DR300 1000 rate 3000 RPM DR1200 5000 100 096 Postpurge 25 sec Postpurge time time 5 mins Default 25 sec Menu Group Selection Uu 4 ac xe 6
31. 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 intake 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 shutdown periods or at least every six months A burner view port is located on the burner mounting flange CAUTION The area around the burner view port is hot and direct contact could result in burns NOTE Check torque on fan mounting nuts using a torque wrench DR300 1000 20 Ib ft DR1200 5000 25 Ib ft Figure 36 Normal Burner Flame Profile short dense and blue e Normal Flame A normal flame at 100 of burner input is blue with slight yellow tips a well defined flame and no flame lifting e Yellow Tip Yellow tipping 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 be corrected immediately 56 e Lifting Flames Lifting flames can be caused by over firing the burner excessive primary air or high draft in excess of negative 0 15 W C If impro
32. 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 24 components may cause operational problems A 4A circuit breaker is provided on the secondary side of the transformer A tripped circuit breaker indicates a short in the 24VAC controls and must be corrected 10 12 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 13 FREEZE PROTECTION 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 Location Heating boilers hot water supply boilers or water heaters must be located in a room having a temperature of at least 50 F 10 C Caution A mechanical room operating under negative pressure may experience a downdraft in 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 Freeze protection for t
33. a primary secondary piping system Review the diameter and equivalent length of the installed piping to and from the boiler for proper flow 7 Ensure that a properly sized primary system pump is installed with an expansion tank 8 Check system pressure Ensure a minimum of 30 PSIG with the system hot and not more than 90 of the rated pressure of the relief valve 9 Review the installed gas piping from the meter to the boiler Ensure that the gas pipe meter and any regulators are adequately sized 10 Review the field wiring and electrical service for both the boiler controls and pump Ensure that the electrical service s is adequately sized Boiler Set Up 1 Ensure that the boiler and piping system are full of water Bleed all air from the pump housing and secondary loop Check system for any water leaks Check system for installation of glycol or water treatment where required Where glycol has been used to maintain the temperature rise across the appliance confirm that the recommended flow for pure water has been increased by 15 and the head loss by 20 Turn on power to the primary system pump and the appliance secondary pump and verify operation Boiler Operational Checks 1 Turn the boiler main power switch to the ON position 2 Program the adjustable points 3 Turn the switch to the ON position to start boiler operation 4 Push the resets for low water level high water temperature and alarm 5 Ins
34. be connected to the appropriate gas ports Typically the gas signal will closely follow the air signal on all models lf the incoming gas pressure reduces significantly as the VFD accelerates to maximum speed the gas signal may lag behind the air signal by up to 15 This will occur once the actuator has driven downwards as far as it can go The amount that the actuator has opened is registered by an indicator arm which is visible through the view window e As the appliance comes on and fires record the maximum inches of water column which is achieved at maximum speed on the VFD using start up report form 93 0130 To adjust this differential pressure when commissioning the appliance use the adjusting screw on the air shutter to the fan In all cases the final adjustment is to be made using a combustion analyzer Depending on field conditions differential pressures will have to be adjusted accordingly Typically with long lateral runs the differential signal as read will be reduced from the value shown on the 15 Low Gas Switch Main Manual rating plate The opposite will occur with tall stacks where drafts exceed negative 0 15 W C e the appliance will not light off it will be necessary to adjust the low fire as explained in the detailed start up procedure 3 9 GAS TRAIN AND CONTROLS Figure 13 Typical Gas Train DR2000 3000 Metering Valve Firing Valve Fan Inlet Solenoid Valve Figure 14 Typical Gas Tra
35. doors between the space 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 If provided test for spillage at the draft control device relief opening after 5 minutes of main burner operation Use a cold mirror the flame of a match or candle or smoke from a cigarette After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous condition of use Any improper operation of the common venting system should be corrected so that the installation conforms to the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or the Natural Gas and Propane Installation Code CAN CGA 149 1 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 Cha
36. from a high grade of corrosion resistant stainless steel such as AL29 4C or equivalent The corrosion resistant liner must be properly sized and fully sealed throughout the entire length If the flue is contained within the masonry chimney both the top and the bottom of the masonry chimney must be capped and sealed to provide a dead air space around the sealed corrosion resistant liner Consult with local code officials to determine code requirements or the advisability of using a masonry chimney with a sealed corrosion resistant liner system 2 1 9 VERTICAL VENTING TERMINATION e Follow Category or IV vent termination and all General instructions The vent terminal should be vertical and exhaust outside the building at least 2 feet 0 61M above the highest point of the roof within a 10 foot 3 05M radius of the termination e The vertical termination must be a minimum of feet 0 91M above the point of exit Avertical 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 2 1 10 COMBINED COMBUSTION AIR INLET The air inlet pipes from multiple appliances can be combined to a single common connection if the common air inlet pipe has a cross sectional area equal to or larger than the total area of all air inlet pipes connected to the common air inlet pipe Equivalent pipe diameter Sq Root d1 d3 84 dn d pipe diamet
37. inlet within 10 ft 3M horizontally he vent terminal MUST NOT terminate below forced air intake at any distance e Do not terminate the vent in a window well stairwell alcove courtyard or other recessed area The vent cannot terminate below grade e The vent shall not terminate less than 7 ft above a public walkway due to the normal formation of water vapour in the combustion process he vent system shall terminate at least 3 foot 1M above grade above normal snow levels and at least 7 ft 2 15M above grade when located adjacent to public walkways The vent terminal shall not be installed closer than 3 ft 1M from an inside corner of an L shaped structure he vent terminal should have a minimum clearance of 4 ft 1 25M horizontally from and in no case above or below unless a 4 ft 1 25 m horizontal distance is maintained from electric meters gas meters regulators and relief equipment In all cases local codes take precedence e Flue gas condensate can freeze on exterior walls or on the vent terminal Frozen condensate on the vent cap can result in a blocked flue condition Some discoloration to exterior building surfaces can be expected Adjacent brick or masonry surfaces should be protected with a rust resistant sheet metal plate 11 2 4 5 LOCATION OF A SIDEWALL AIR INLET TERMINAL The termination point of the sidewall air inlet must be installed a minimum of 3 feet above ground level and above norm
38. inspection of the burner and heat exchanger Figure 30 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 Vdc 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 surface 7 3 COMBUSTION AIR FAN DR300 1000 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 material 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 DR 1200 5000 Figure 31 Fan Burner Hot Surface Igniter and Flame Sensor Arrangement DR 1200 5000 7 Uses a sealed 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
39. is generated FLAME when Remote Operator is FAILURE closed 4 20mA 0 10Vdc REMOTE OPERATOR 28 CASCADE Programming Instructions Connect Remote Operator Connect System sensor to System Outdoor contacts Connect Outdoor Sensor to J3 ECOM connector Place both toggle switches in LOCAL Press Contou and E Press Outdoor Reset Configuration Press the to arrive at Central Heat Select Enable Enable Select Maximum outdoor temperature WWSD 10 Select Minimum outdoor temperature Outdoor Design 11 Select Low Water Temperature Min Water Temp 12 Select Outdoor boost maximum off point Design Max cem Central Heat Enable Enabled Maximum outdoor temperature 600 Minimum outdoor temperature 09 Low water temperature 1009F Minimum boiler water temperature 40 F Outdoor boost step O F o Outdoor boost maximum off point 1850F Show Line 13 Press Show Line to confirm reset curve 14 Press Sensor Configuration 15 Selet S5 J8 11 sensor 10K NTC single non safety 16 Select Outdoor temperature source EnviraCOM outdoor sensor 17 Place toggle switch to REMOTE for remote enable operation if required DynaForce Sensor Configuration 51 38 4 sensor Inlet or Return 10K NTC single non safety 52 J8 6 sensor 4 20mA remote 4 20 6354 J8 8 10 sensor Outlet or Supply 10K NTC dual safety 55 J8 11 sensor 10K
40. lb on DR1200 5000 6 Restore electrical power and gas supply to appliance 7 Place appliance in operation using lighting instructions provided 8 Confirm proper operation of all safety devices 9 Check for gas leaks and proper vent operation NOTE Experience has shown that improper installation or system design rather than faulty equipment is the cause of most operating problems 1 8 BOILER ROOM OPERATING CONDITION Due to low jacket losses the appliance temperatures in a typical boiler room may drop significantly supplemental heat is required to maintain ambient temperature at acceptable levels 1 9 CLEARANCE FROM COMBUSTIBLE MATERIAL This appliance is suitable for alcove a closet without a door installation with minimum clearances to combustibles as follows Table 1 Clearances from combustibles COEF Smis When placing the appliance be aware that a minimum clearance of 24 60cm must be provided at the front to allow easy access to the heat exchanger When installed directly on combustible flooring the appliance shall be installed on a metal panel extending beyond the full width and depth of the appliance by at least 3 inches 76 2mm in any direction The floor must be strong enough to support the full weight of the heater NOTE Clearances from combustible construction are noted on the appliance rating plate Maintain minimum specified clearances for adequate operation All install
41. meet the recommended CO levels Adjust high fire first followed by low fire adjustment Allow the water temperature to rise so that the heater cycles on the operator Check the temperature rise across the heat exchanger This will be indicated by taking a difference between the inlet and outlet temperatures on the Dynaforce control For hydronic applications and for domestic hot water rise exceeding 30 F is not normally recommended Allow the unit to cycle on the limit This can be done by gradually restricting outlet water flow The auto reset limits are set at 200 F for domestic hot water and hydronic heating The manual reset limits are set to 210 F Remove fan inlet filter At full input block 5096 of the fan inlet opening The display should show LCI not closed If it does not slowly turn the adjustment on the normally closed blocked flue switch clockwise until the blocked flue switch indicator de energizes Check the air proving switch Remove the restriction from the fan inlet and reset the power on the control panel A properly set air switch will cause the interrupted air switch indicator to turn green at a fan speed between 15Hz and 20Hz on the VFD Check the ignition retries circuit Shut the main gas off to the unit and allow it to try for ignition Trial for ignition should commence within 30 seconds COMISSIONING APPLIANCE Hemove manometers and replace inlet gas pressure test plug Fill out start
42. modes which provides set point as well as modulating control It provides the following _ 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 40 F AT heat exchanger protection algorithm Available tank mounted sensor used in conjunction with inlet sensor Adjustable target temp inter stage differential on delay between stages minimum on time per stage minimum off time per stage Display of run hours for maintenance purposes Counter wraps around at 10000 hours Flame failure signal JST and Molex connectors for ease of service 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 X X x X 24 Two levels of access to simplify the use of the boiler Levels of Access User Access to general boiler and display settings and adjustments to the central heating domestic hot water and lead lag setpoint Installer Access to all user parameters and allows for changes to additional boiler parameters to allow for ease of startup and serviceability NOTE Due to the sensitivity of the touchscreen controller using the backend of a pen pencil or stylus is recommended for accuracy Figure 25 Home Screen
43. of water and that all air has limit temperature been properly purged from the system Alert 63 67 79 137 276 281 Verify that the boiler is piped properly 303 309 Verify that adequate power is supplied to pump on a call for e LCI OFF heat If voltage cannot be detected check wiring Verify pump is circulating when power is supplied If so pump impeller may be stuck f power is present during a call for heat but the pump still does not circulate replace the pump Replace the Dynaforce Controller if necessary Inlet sensor Alert 91 Verify sensors are connected Outlet sensor Alert 92 Verify wiring DHW sensor Alert 93 e Measure resistance of sensors 10kO sensors Stack sensor Alert 95 Replace sensor if necessary Outdoor sensor Alert 96 Fan refuses to rotate Check fan power wires Fan Not Turning Alert 122 123 128 129 130 131 Fan signal wires are interchanged 132 Minimum fan speed must be greater than 1600 RPM Interrupted Air Switch error Alert 67 137 303 310 Air Switch wire s is are loose Air Proving Switch ILK OFF Air Switch is set too tight reduce sensitivity by turning IAS OFF screw turn counter clockwise Temperature Overshoot Sensor Not Connected LCI error Blocked Flue Switch wire s is are loose Alert 63 137 276 281 Blocked Flue Switch is set too tight reduce sensitivity by e LCI OFF turning screw turn clockwi
44. operation of the fan will generate a differential pressure which the gas air ratio control gas valve will match on the gas side The steady state efficiency is maintained across the entire range of modulation Air and gas are metered in precise proportion 1 1 Ratio to modulation signal allowing combustion characteristics which determine efficiency to remain the same over entire operating range 1 2 SPECIAL INSTRUCTIONS TO OWNER his 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 serviceman must utilize a combustion analyzer with CO CO and draft gauge to set the appliance according to Camus Hydronics recommendations prior to commissioning NOTE 1 1 1 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
45. or corrosive water quality is not covered by warranty 11 5 WATER CONNECTIONS All models have groove locked inlet and outlet stainless steel connections Pipe size must be in accordance with Table 3 and between supply and return lines must not exceed 80 feet of equivalent length Any reduction in recommended pipe size may decrease flow resulting in high water temperatures boiler noise flashing to steam and non warrantable heat exchanger damage 11 6 PIPING LENGTHS The appliance circulator provides the water flow from the primary boiler piping through the boiler and back to the primary system Pipe diameter and length are critical to ensure proper flow through the boiler The secondary loop piping to and from the appliance must have a fully ported ball valve installed in both the inlet and Outlet side piping and will be used for isolation only The ball valves must be the same diameter as the installed piping f flow control is required other means of flow control such as globe valve or flow setter should be used 60 Dyna 11 7 INTERMITTENT PUMP OPERATION An intermittent pump operation signal is standard and can be used to operate a separate pump contactor A 1 6 hp pump delay relay is standard and a 1 hp pump delay relay is available When utilizing this feature the boiler s integral circulating pump will cycle on at each call for heat before the burner fires The pump will continue to operate while the burner is fir
46. products from the building he Category ll flues from multiple appliances can be combined into a common vent this special venting system must be engineered by venting manufacturer and to be approved by local authority he Category IV flues from multiple appliances CAN NOT be combined into a common vent e The Category IV flue must be a dedicated stack e The Category IV Flue appliance must have all vent joints and seams sealed gas tight e The flue products in the vent system will be cooled below their dew point and form condensate in the flue and must use AL29 4C 316L Stainless 5636 CPVC and S636 PVC and PPE up to 12 diameter e flue from a Category ll and IV vent system must have a condensate drain with provisions to properly collect neutralize and dispose of any condensate that may occur 2 1 2 VENTING GUIDELINES FOR CATEGORY Il AND OR IV VENTING e The installed length of the positive pressure category IV flue from the appliance to the point of termination outside of the building must not exceed a maximum of 100 equivalent feet 30 5M in length Depending on diameter and centerline radius subtract from 7 to 19 feet per 90 elbow using published data Subtract half this value for each 45 elbow e For site conditions exceeding 100 equivalent feet an engineered vent system approved by the local authority will be required e The flue may terminate either vertically at the roof top or horizontally on a SIDEWA
47. 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 Figure 2 Checking the Dynaforce Do not attempt to pry any panel off To begin disassembly you must first remove the two machine screws from the top of the lid Only then will you be able to remove the lid and disassemble the three outer panels Once you have removed the lid carefully check and confirm that all 4 copper tubing connections are intact and have not broken or loosened in shipment Leaks at any connections on these lines will result in erratic appliance operation 1 4 HOW IT OPERATES SEQUENCE OF OPERATION Supply power connection as per table 10 The power switch is placed in the ON position 120 VAC power is supplied to the control transformer 24 VAC is supplied to the ignition module and low voltage controls for all models After the appliance water pump starts flow is proven by the flow switch and water pressure switch The water pressure switch is set to close at 30 PSI and is installed in the unit The flow switch is to be mounted in a tee at the outlet of the appliance Take care to properly trim the flow switch paddles so as not to jam the switch in the tee The normally open dry contacts in the low water cutoff LWCO are to be wired in series with the normally open contacts of the flow sw
48. up report for each heater Be sure to record all settings and readings Retain a copy of report for future reference Start up is now complete and heater may be placed into service PART9 TROUBLESHOOTING COMPONENT FAILURE MODE ANALYSIS Two wires interchanged effect on safety incoming Power I e and Neutral wires are interchanged he 24Volts and 120 Volts wired Breaker on transformer trips Transformer are interchanged Tripped Alert 49 Lockout 53 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 exchanger Improperly sized expansion tank Flow Switch contacts are open Verify that pump is operating Alert 63 275 281 460 Verify for closed valves or obstructions in boiler piping e LCI OFF e Verify that all air has been purged from the system e Verify that wiring is correct e Pressure Switch contacts are open Verify that minimum water pressure exceeds 30 PSI e Alert 63 275 281 460 e Verify that pump is operating e LCI OFF e Verify for closed valves or obstructions in boiler piping e Verify that all air has been purged from the system e Verify that wiring is correct e The boiler has failed to ignite the e To reset the module refer to section 5 8 2 burner e Verify that all air has been purged from gas line e Alert 110 291 294 e Inspect hot surface igniter and related
49. use in hard water areas See Water Treatment and Water Chemistry Using or storing corrosive chemicals in the vicinity of this appliance can rapidly attack the stainless steel tubes and coils and voids warranty Damage caused by freezing or dry firing voids warranty This appliance is not to be used for temporary heating of buildings under construction System operating water pressure at boiler not drop below 30 PSIG 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 7 REMOVAL OF 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 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
50. wheel The other point measures static pressure Differential pressure at the switch will be affected by blockages at the fan inlet or at the flue discharge A minimum differential pressure across the sensing points of the pressure switch proves operation of the combustion air fan This is set in the factory and may be adjusted for field conditions The diagnostics display will exhibit a status of an open Interrupted Air Switch ILK Off when the differential pressure switch detects a sustained low air condition This condition could be caused by a number of factors including Sensing line broken or loose fitting Dirty filter or blocked vent Steady high wind condition exceeding 40 MPH Incorrectly set switch Missing bleed restrictor on total pressure side air line 5 4 BLOCKED FLUE SWITCH All models use a normally closed blocked flue switch to shut down the appliance under the following conditions 1 Airintake 50 blocked 2 Ventoutlet 8096 blocked 5 5 DIFFERENTIAL GAS AND LOW GAS PRESSURE SWITCHES A manual reset differential gas pressure switch is standard on DR3000 5000 and available as an option DR300 2500 If differential gas pressure exceeds the maximum setting of the pressure switch the appliance will shut down and an open gas pressure switch will be shown on the display A low gas pressure switch is standard and monitors the minimum incoming gas supply pressure supplied to the gas train If gas pressure falls
51. wiring for damage and connection errors e DR 300 2500 Verify igniter is glowing DR 3000 5000 Verify pilot is lit Inspect flame sensor and associated wiring Replace if necessary Verify that boiler is properly grounded Verify incoming gas supply pressure and that it coincides with Table 7 Verify that the vent air inlet piping if equipped are correctly installed and obstructions are not present o Verify 24 DR 300 1200 and 115VAC DR 1400 5000 is being supplied to the gas valve relay from the Dynaforce Controller during ignition Check wiring from Dynaforce amp Controller and Gas Valve Relay If a signal cannot be detected the Dynaforce amp Controller needs to be replaced If 24 is present check the outlet of the valve to ensure Flame Failure that gas is flowing When the valve is energized a change in pressure should occur if no change is detected the gas valve has 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 the burner Refer to Burner Maintenance in section 10 5 Replace the Dynaforce Controller if necessary Water Pressure Switch 49 Dyna COMPONENT FAILURE MODE ANALYSIS e The DynaforceQ boiler was Verify that all air has been purged from gas line running and flame signal suddenly Verify that boiler is properly grounded disappeared Inspect flame
52. xxx Variable Frequency Tass L yf LL L _ 1 xxx x r So Las Transitionarm 314556 E ne AC imas eec LLL 10 GZ GFIF 2000 CH amp GAA1A 1100 CH uu 8 1 1500 Intake A Agapter 12 GFIF 3000 CH amp GAA1A 3000 CH 14 GFIF 5000 CH amp _ 5000 CH ET 8 DM 14 0118 to Rear Fan Intake Filter 10 DF 140119 5 lt 3 2 gt gt gt 00 070 071 x Outdoor Sensor ntesensorooa x wmm x E o ui od rums Reset Water High Limit L4008E1313 Manual Reset wa a exu x x x x x x x x x esu j 33 5243 5 Graphite Backed White Ceramic Gasket 1 X X m _ _ EN NN _ _ NN _ _ _ _ ESES 33 5221 33 5218 33 5224 EN Red Silicone Gasket 1 33 5227 33 5230 X X 33 5239 X X DE ee HB 62 Gasket for Mixing 33 0057 Chamber e _ j j K aco se MM DR300 400 1 8 Red 33 0058 Gasket m mm
53. 1 F 5 C the boiler pump is enabled If the temperature continues to drop to 38 F 3 3 C the burner will be fired to bring the inlet and outlet temperatures to 50 10 to prevent freezing of the heat exchanger PART7 COMPONENTS 7 1 HOT SURFACE IGNITER GLOW BAR The silicon carbide igniter is inserted directly through the fan flange and held in place by two screws A hold down bracket as well as sealing gasket above and below the igniter assures a good seal Care must be taken when removing and or installing the igniter since the silicon carbide element is brittle Always remove the igniter prior to removing the fan assembly for inspection of the burner and heat exchanger A properly prepared igniter will have a bead of silicone sealing the end mounting bracket to the ceramic shaft Figure 29 Hot Surface Igniter During trial for ignition a properly operating igniter will generate a minimum 3 2 0 2A which is the current required for reliable ignition It is recommended that the hot surface igniter be replaced every 4 000 hours of appliance operation to maintain peak ignition efficiency 7 2 FLAME SENSOR The flame sensor is inserted directly through the fan flange and is screwed into the fan flange 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 Always remove the flame sensor prior to removing the fan assembly for
54. 2 1 3 1 4 1 4 1 1 4 2 1 5 1 6 1 7 1 8 1 9 1 10 PART 2 2 1 2 1 1 2 1 2 2 1 3 2 1 4 2 1 5 2 1 6 2 1 7 2 1 8 2 1 9 2 1 10 2 1 11 2 2 2 2 2 2 2 2 3 2 4 2 4 1 2 4 2 2 4 3 2 4 4 PART 3 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 7 1 3 8 3 9 3 10 3 11 PART 4 4 1 GENERALINFORMATION SAS iene uu 1 INTRODUCIIDNZ tcr uuu 1 SPECIAL INSTRUCTIONS TO OWNER Secession amaca _________ ___ 1 CHECKING EQUIPMENT sacrer AREA So 1 HOW IF OPERATES SEQUENCEOFOPERATION Z uu A R 1 HEAT TRANSPFERAPROGESS 5339 052299 __________ 2 END OF SEQUENCE yu uy uy u u _______________ es 2 CODE Sois an 3 WARPBANTY uuu Za 3 REMOVALOFE EXISTING APPLIANCE oat asd pra re D ape e tt Fe deus added 3 BOILER ROOM OPERATING CONDITION uid SSS SASS ue pcd i u S 4 CLEARANCE FROM COMBUSTIBLE nana u u ea 4 INSTALLATION PROCEDURE AND LOCATION OF UNIT 5 VENTIN Giese ta LL LE M Rm M E Ed 7 GENERAL VENTING GUIDES u ee tu tau eaa u eaa uere n ce Ecc esed 7 CATEGORY TL AND CATEGORY IV VENTING u eo S o Qut Dept E orm an ea eH E Rad ds 7 VENTING GUIDELINES FOR CATEGORY Il AND OR
55. 4 6 5 6 6 6 6 6 7 PART 7 7 1 7 2 7 3 7 4 7 5 7 6 PART 8 8 1 8 2 8 3 8 4 PART 9 PART 10 10 1 10 2 10 3 10 4 WARNING REGARDING CHILLED WATER AND HEATING COIL SYSTEMS 17 INLET AND OUTLET CONNECTIONS ccccececccesescscececececececsescscscscscacecsceesassvsvecacaeseacavasatscacacecustatstatseseees 18 MINIMUM PIPE SIZE REQUIREMENTS cccccccccecececececececsecsescecscececacecscsesesavscscacacscsaacscatacacacecsescstststseaes 18 HEAT 18 LOW WATER TEMPERATURE SYSTEMS 18 INSTANTANEOUS WATER HEATER erret tnter reet etna to nets os 18 WATER FLOW SWITCH 19 LOW WATER CUTOFF If Equipped 19 RELIEF EY eee A a 19 CIRCULATING PUMP SELECTION cccccccscecececececcsescscscscecececececscsesasaacasacscsceesevasacasacecsueessvavatssatacecaceceeeees 19 CIRCULATING PUMP OPERATION OF HEAT EXCHANGER aa rent 19 HEAT EXCHANGER ALGORITHM eere tenter rests 20 ELECTRICAL amp CONTROLS 20 ELECTRICAL 5 20 VARIABLE FREQUENCY DRIVE DR1200 5000 I a tentent nn 21 DIFFRENTIAL AIR PRESSURE SWITCH tette rete os 21 BLOCKED FLUE SWITCH 21 DIFFERENTIAL GAS AND LOW GAS PRESSURE SWITCHES aaa aaa nn 21 HIGH LIMIT RR REX 21 DYNAFORCE SOLA ARR 22 SERVICE A 22 IGNITION MODULE LOCKOUT FUNCTIONS tette tnter rete t tenent 22 DYNAFORCE CONTROLLER eer
56. 5 8 VIOS 2 3007 2 T VIOS Z JOM13N 01 sj2e1uo2 2 dung 8 VIOS peaj ui suayiog p JO e 0 dn 510 9 5 7 e uiyym peaj uo jeuonippe jenue 0791 SIT y se Sure T v10S Bej peaj u 8 suajiog 8 o3 dn syoddns T uoneJedo OOOTSSEZ8M 12525 100p3nQ W023 03 aq 04 51 10525 VIOS peal pea snqpoy 2914 UJ UUImXe A pee ZEN 8 01 T Wu31SVIN JAVIS gt 3AV1TS T 8142108 z zum ium MHOMLAN L MHOMLAN pea snqpoy ZAN d31SVIN 49 108 nova zem rem O izuun Oss L VIOS 5437108 6 OL dN NOlLV33dO 9V1 Qv31 V1IOS TISAA3NOH ZT TT 8 SS 03 03 SI 05 85 T pue 8uidid ur 22039803 aq 45 pue 5105185 1 95 45 JOSUaS 76 t ruesuco aveau pue
57. 9 Press Lead Lag Master Configuration 10 Press Advanced Settings 11 Press the to arrive at Outdoor Reset 12 Select Enable Enabled 13 Select Maximum outdoor temperature WWSD 14 Select Minimum outdoor temperature Outdoor Design 15 Select Low Water Temperature Min Water Temp 16 Select Outdoor boost maximum off point Design Max DynaForce Master Confi Outdoor Reset Enable Maximum outdoor temperature Minimum outdoor temperature Low water temperature Minimum boiler water temperature Outdoor boost maximum off point 185 F SES Outdoor boost step UNCON FIGURED w Show Line 17 Press Show Line to confirm reset curve 18 Press the to arrive at Warm Weather Shutdown 19 Select Enable Shutdown after demand ends ak DynaForce Lead Master Configuration 4 Warm Weather Shutdown Enable Shutdown after demand ends Setpoint 37 38 Rotation NEE _ m EC CymaFeree Smis Electrical Connection s Programming Instructions Standard rotation schedule is based on equalizing run time on a 1 hour schedule To vary the rotation to a fixed schedule based on hours days Base load rate adjustment adi CASCADE SYSTEM OUTDOOR Press E and Press Lead Lag Master Configuration Press Advanced Settings gt Press the to arrive at Algorithms Select Lead selection method Sequence order Select Lag selection m
58. E uuu ct uu SESE Saam au au aus a 57 10 5 BURNER MAINTENANCE i SSeS tenet usen ENR EE SSO aspa i eL M o ep Pb 57 TOSE BURNER RENIOVAL S ashata tee ela od ehe eb duae iN UEM 57 10 52 BURNER CLEANING PROCEDURE Mora s na n Re dum Es et da E PI qas asss 57 10 6 CHANGING THE HOT SURFACE TIGNIIER u l a Fun topo vU Sa 58 REINSTALLING teat tes i OD pis kasa ha 58 10 7 HEATEXCHANGEPRINSPECTION uuu nu MEUS i 58 10 8 BE INSEAEE FEA TTEACHAINGEBa iesu tentabat aia ane ntes arto kde eoa tuba pnto tu tates ote ub Ped eg neu tide 58 10 9 COMBUSTION AI EAN sss Z u na Sia etus epis ois odes ber Outre ursa a spa amy 58 10 10 COMBUSTION AND VENTILATION AIR uu a save SSO xe tuta Nea 58 10 11 CONTRO mg IS EUST 58 10 12 COMBUSTIBLE MATERIALS AR ERR ME denti E e du A EU E PUE ER UAE 58 10 13 FREEZEDPROTECTION 2 EN EE 58 10 14 FREEZE PROTECTION FOR A HEATING BOILER SYSTEM Optional 59 PARETI INSTALLATION SES aaa AAS eadeni bon tad E 59 11 1 CHECKING THEINS FALLATIO N s uu u 59 11 2 CHECKING THEINSTAELHON IGE I E px MM E ME bo MEHR 59 11 3 INSPECT amp RECHARGE CONDENSATE COLLECTION amp NEUTRALIZING 59 11 4
59. INSTALLATION OPERATION AND SERVICE MANUAL Dynaforcec Series GAS FIRED COMMERCIAL CONDENSING STAINLESS STEEL TUBE BOILERS CAMUS Hydronics Ltd CERTIFIED HYDRONIC HEATING Models DRH300 350 400 500 600 800 1000 1200 1400 1600 1800 2000 2500 3000 3500 4000 4500 5000 HOT WATER HEATER Models DRW300 350 400 500 600 800 1000 1200 1400 1600 1800 2000 2500 3000 3500 4000 4500 AQMD 5000 Le CERTIFIED HLW 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 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 0171 0 6 Table of Contents PART 1 1 1 1
60. LL See the information about the specific vent termination location for recommended location and clearances 2 13 APPROVED VENTING MATERIALS Exhaust Vent for Use for Dynaforce Category or IV Installations 1 Manufactured prefabricated UL ULC listed vent of AL29 4C or equivalent Single or Double Wall 2 316L stainless steel is limited to use in applications where there is no possibility of contaminants in the air such as refrigerants chlorine etc BH type PVC and CPVC Schedule 40 or 80 approved to ULC 5636 PVC DWV approved to comply with ANSI ASTM 02665 US Jurisdictions ONLY when permitted 6 PVC Schedule 40 approved to comply with ANSI ASTM D1785 US Jurisdictions ONLY when permitted 7 CPVC Schedule 40 approved to comply with ANSI ASTM F441 US Jurisdictions ONLY when permitted approved to comply with ULC 5636 up to 12 diameter amp Use of cellular core PVC ASTM F891 cellular core CPVC or Radel in venting systems is prohibited Covering non metallic vent pipe and fittings with thermal insulation is prohibited Table 4 Maximum Flue Temperature for Various Vent Materials Intake Air Supply Air or Fresh Air Piping for Direct Vent Applications Air intake material must be of a type listed by a nationally recognized testing agency 1 PVC Non Foam Core Pipe 2 CPVC Non Foam Core Pipe 3 Polypropylene 4 ABS Acrylonitrile Butadiene Styrene Single wall vent pi
61. MOd 19 HO LOIN NHNLIH NOINWOO TIVNIAH3I A NOILINDI OL Sq33OOdd LV3H HOS TIVO 9 TVNIIH3L H3MOd LNVLSNOO 8 IWNINYSL S IVNIINSH3 L IOHLNOO N COMI NOILOANNOO I3 NI IV 19 d MOTI3A A JLIHM M dq d d JONVHO O NMOWG HH aNd 19 74 1U9 uCO UC 74 2 SUL pour SWED jo Avedoud u s SUL 02010 pee 5 8 ma 8 eoepeiu OUND 9200 4eUAG SOINOYGAH SNWVD 0 225 uoneunByuoo eoepejur pue pejseb8ns smous siu ONINY YM Jeuondo ejos 0201020 Juipj ng jo UOISISAUOD eu8IS 1 n AI 1020109 sJajioq 8 03 dn 033005 uoneJado BPEISED 5 ZEW BPEISED BPEISED Snapo SINS LEW SING LSIN 5 Lg 3AV1S JAVIS 3AVIS u31SVIN winwixe 0 T
62. NTC single non safety 5657 19 1 3 sensor DHW 10K NTC single non safety 5859 19 4 6 sensor Stack 10K NTC single non safety Outdoor temperature source EnviraCOM outdoor sensor e 4 20mA 2 oint Operation Standalone Electrical Connection s Programming Instructions Boiler operates with variable Place both toggle switches in LOCAL setpoint determined by 4 Press and 20mA incoming signal Press CH Central Heat Configuration Modulates on boiler inlet FLAME Press the to arrive at Setpoint sensor default FAILURE Select Setpoint Source S2 J8 6 4 20mA Heat demand is generated 659 5 5 Select 4mA water temperature when Remote Operator is pm Select 20mA water temperature closed and 4 20mA or 2 Place toggle switch to REMOTE for remote operation if required DynaForce 10Vdc signal is present REMOTE Central feat Configurat 8 E O OPERATOR Setpoint Setpoint source S2 J8 6 4 20mA Setpoint 1609F Time of day setpoint j 1609F Off hysteresis 10 F On hysteresis 10 F 4 mA water temperature 1209F 20 mA water temperature 1609F 29 4 20mA 2 LOMA lal Rate Operation Standalone Electrical Connection s Programming Instructions Boiler operates with variable Place both toggle switches in LOCAL setpoint determined by 4 Press NL and Lum 20mA incoming signal Press Lead Lag Master Configuration Modulates on heade
63. OV 14 Dyna 3 5 DIFFERENTIAL AIR PRESSURE DR200 DR5000 The Dynaforce amp 2000 5000 operates on the principle of differential pressures Operation of the fan generates a signal which is matched on the gas side by the 1 to 1 air gas ratio control valve e The differential air pressure measurement is made between the high and low pressure taps across the fan discharge and the fan static discharge differential air pressures are noted at full firing rate There are two pressure taps at the fan discharge and care must be taken to tee into the correct line The correct line may be identified by tracing it back to the ratio control valve where the identification of the tapping is stamped into the die cast actuator e The differential gas pressure measurement is made between the high and low pressure taps across the in line metering gas orifice Check this value to confirm that it matches the differential air pressure while the appliance is firing e The controls on this appliance may fire the burner from 2096 up to 100 96 of rated input Differential manifold gas pressure will be reduced as burner input is reduced e Al reference gas pressure measurements must be made at 100 of rated burner input e The differential gas manifold pressure is pre set at the factory through the ratio gas valve Adjustment of manifold pressure is not normally required for proper operation It may be necessary to adjust the low fire adj
64. R 300 DR 2500 Direct Ignition The hot surface ighiter will be energized for 22 seconds followed by energizing the main valve for 4 seconds A signal of 0 8dVdc must be recognized by the controller at the flame sensor to keep the main gas valve in an open position The fan is kept at ignition speed until the stabilization timer is satisfied DR 3000 DR 5000 Proven Pilot The Dynaforce controller will activate the hot surface igniter for 22 seconds followed by powering the pilot valve for 10 seconds whereupon a signal of 0 8Vdc must be recognized by the controller at the flame sensor to keep the main gas valve in an open position The fan is kept at ignition speed until the stabilization timer is satisfied If the flame signal is not reached the module will stop the ignition sequence after the trial for ignition The fan speed will slowly decrease as the heat request nears the heat demand The modulation rate is controlled via Pulse Width Modulation DR300 800 and a 4 20mA signal DR1000 5000 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 constant speed 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 timer is satisfied The pump continues to circulate until the post purge time is satisfied The boiler will then go into Standby
65. a flow setter valve at the appliance outlet will facilitate setting of the proper flow at e Increasing the flow by 15 now results in a head loss of 13 feet at 115 gpm from B amp G system syzer At this increased flow Camus now Air charger and Drain System Expansion Suppl Tank uppiy C Flow Make up Switch Water Supply k the desired temperature rise at high fire It is particularly important to confirm proper temperature rise for domestic hot water applications Improper flows can lead to premature tube failure from scaling and will not be covered by warranty This appliance is a low mass design which provides for instant heat transfer Special attention to water flow rates will ensure that temperature rise is not excessive See Table 8 and 9 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 Use suitable pipe hangers or floor stands to support the weight of all water and gas piping Always pump toward the heat exchanger inlet Never pump away from the exchanger since this will result in a low pressure zone which will allow localized boiling and result in heat exchanger damage Dynaforce must be installed so that the gas ignition system components are protected from water dripping spraying rain etc during appliance operation and service circulator replac
66. a fully enclosed 230 VAC 3 Phase 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 INNER JACKET The inner jacket assembly is constructed from a special corrosion resistant stainless steel All screws bolts nuts and fasteners used for assembly of the inner jacket are also stainless steel DO NOT mix stainless steel and standard plated fasteners when disassembling and reassembling the inner jacket sheet metal components Standard plated fasteners will be damaged by the flue product condensate when used inner jacket assemblies 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 7 6 VENTING TRANSITION All appliances are shipped with a round stainless steel adapter Depending on the appliance category an increaser will be required for the proper vent configuration Please refer to Table 3 dimensions and specifications When installing Category 11 or IV appliances care must be taken to properly seal all joints and provide slope for drainage of condensate away from the boiler 45 PART8 FIELD STARTUP PROCEDURE 81 CHECKING THE INSTALLATION 8 2 46 Inspect the connections for water gas and electricity Confirm that water is being pumped toward the heat excha
67. al levels of snow accumulation The point of termination for the sidewall combustion air inlet terminal MUST be located a minimum of 3 feet 1M horizontally and 12 inches 0 30M below the point of flue gas termination vent cap if it is located within a 10 foot radius of the flue outlet Vent 12 30 cm Minimum Air Intake 2 4 4 LENGTH OF AIR INLET PIPE The maximum total length of the sidewall or vertical roof top combustion air inlet pipe as installed from the appliance to the air inlet terminal must not exceed 100 ft equivalent feet 30 5m in length Subtract 7 2 13 m to 19 feet 5 8 m of equivalent length depending on centreline radius for each 90 elbow installed in the air inlet pipe system Pressure drop in 45 elbow will be half as much 12 PART3 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 GAS CONNECTION e Safe operation of unit requires properly sized gas supply piping See gas line sizing data e Gas pipe size may be larger than appliance connection e Installation of a union at the appliance gas line connection is required for ease of service and removal of the gas train e Install a manual main gas shutoff valve outside of the appliance gas connection as require by local codes trap drip leg MUST be provided in the inlet gas connection to the appliance
68. all fan bolts are torqued to 20 Ib ft DR300 1000 25 Ib ft DR1200 5000 Air in the piping system Purge all air from the piping system The outlet temperature has Verify that the system is full of water and that all air has exceeded the set point been properly purged from the system temperature specified e Verify that AT does not exceed 30 F across the heat Alert 67 79 137 303 310 exchanger e ILK OFF e Verify that the boiler is piped properly e Verify that 120VAC is being supplied to the boiler pump on a call for heat If voltage cannot be detected check wiring Verify that the pump is circulating when 120VAC is detected 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 Dynaforce amp Controller if necessary Auto Reset High Limit Trips 50 SYMPTOM FAILURE MODE ANALYSIS Manual Reset Safety High Limit Verify that the capillary tube is broken If this is the case tripped outlet temperature in replace Manual Reset High Limit excess of 210 F Verify that the system is full of water and that all air has Alert 63 67 79 137 276 281 been properly purged from the system 303 309 Verify that the boiler is piped properly ILK OFF Verify that 120 15 being supplied to the boiler pump a call fo
69. als 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 e 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 2 2 1 AIR REQUIRED FOR COMBUSTION AND VENTILATION Provisions for combustion and ventilation air are to be in accordance with the section for Air for Combustion and Ventilation of the National Fuel Gas Code ANSI Z223 1 NFPA 54 or clause 8 2 8 3 8 4 of Natural Gas and Propane Installation Code CAN CSA B149 1 2 or applicable provisions of the local building codes If air is taken directly from outside the building with no duct provide two permanent openings a Ventilation of the space occupied by fuel burning appliance s or equipment shall be supplied by a ventilation opening at the highest practicable point communicating with the outdoors The total cross sectional area of the ventilation opening must be either 10 of the net free area required for combustion air or 10 sq in 6500 mm whichever is greater b Net free area of combustion air opening shall be in accordance with all applicable codes In the absence of such codes provide combustion air opening with a minimum free area of one squ
70. an be isolated for service An air separation device must be supplied in the installation piping to eliminate trapped air in the system Locate a system air vent at the highest point in the system The system must also have a properly sized expansion tank installed Typically an air charged diaphragm type expansion tank is used The expansion tank must be installed close to the boiler and on the suction side of the system pump appliance Inlet to ensure proper operation Caution This appliance should not be operated at less than 30 PSIG Water piping must be supported by suitable hangers or floor stands NOT by the appliance Pipe systems will be subject to considerable expansion and contraction Pipe supports could allow the pipe to slide resulting in noise transmitted into the system Padding is recommended The boiler pressure relief valve must be piped to a suitable floor drain See Section 4 10 CAUTION A leak in a boiler System will cause the System to intake fresh water constantly which may cause the tubes to accumulate a lime scale build up This will be a NON WARRANTABLE FAILURE If boiler pumps are not operated when treated water is introduced a corrosion cell may be created in the boilers leading to a failure which is not covered by warranty Target water quality of treated water to be stable and neutral with regards to corrosive scaling properties Damage to or failure of the heat exchanger as a result of scaling
71. are inch per 7 000 Btuh input 5 5 cm per kW up to 1 000 000 Btuh and one square inch per 14 000 Btuh in excess of 1 000 000 Btuh This opening must be ducted no higher than 18 nor less than 6 above the floor c In extremely cold climates when air supply is provided by natural air flow from the outdoors we recommend sizing the combustion air supply opening with a minimum free area of not less than one square inch per 30 000 Btu hr of the total rated input of the burner provided that this does not conflict with local codes This opening is in addition to the ventilation opening defined in paragraph a above NOTE Outside air openings shall directly communicate with the outdoors CAUTION Under no circumstances should the mechanical room ever be under a negative pressure Particular care should be taken where exhaust fan attic fans clothes dryers compressors air handling units etc may take away air from the unit 2 2 2 EXHAUST FANS Any fan or equipment which exhausts air from the equipment room may deplete the combustion air supply and or cause a downdraft in the venting system through a barometric damper if installed Spillage of flue products from the venting system into an occupied living space can cause a very hazardous condition that must be immediately corrected 2 3 OUTDOOR VENTING The Dynaforce windproof cabinet protects the unit from weather when fitted with the factory supplied air intake and UL appr
72. as it waits for the next heat demand Figure 3 Dynaforce Ignition Cycle IGNITER MAN PREIGNITION MAY BE ZERO RUN STABLIZATION MAY BE ZERO FIXED AT 4S RUN POSTPURGE FLAME REQUIRED LOCKOUT OR RECYCLE STANDBY PREPURGE z RECYCLE DUE TO A FALURE TO IGNITE RECYCLEDUETOFLAME gt FALURE IN RUN pe Note 1 2 If a flame signal is detected at the end of the pre purge period an error statement to that effect will appear 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 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 Dyna 4 The hot surface igniter is de energized at the end of the ignition period to allow for ionisation detection 1 4 1 HEAT TRANSFER PROCESS 1 Burner input continues to increase until water temperature reaches the set point temperature 2 Burnerinput may stabilize at a fixed rate when demand equals input 3 Burner input will decrease rate when water temperature approaches temperature set point 1 4 2 END OF SEQUENCE 1 Set point temperature is satisfied 2 Power to the gas valves is turned off 3 Combustion air fan ra
73. ate 21 5 INLET CAP FOR ROOFTOP TERMINATION The air inlet cap consists of two 90 elbows installed at the point of termination for the air inlet pipe The first 90 elbow is installed on the rooftop at the highest vertical point of the air inlet pipe and turned horizontal the second 90 elbow is screened and is installed on the horizontal outlet of the first elbow and turned down A 90 elbow and a 90 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 150mm in length 2 1 6 LOCATION OF A ROOFTOP AIR INLET AND VENT CAPS The point of termination for the combustion air inlet cap MUST be at least 3 feet 0 91M below the point of flue gas termination vent cap if it is located within a 5 foot 1 5M radius of the flue outlet Use care to ensure that the 90 elbow assembly is properly installed on the air inlet pipe e The termination point of the combustion air inlet cap must be installed at least 3 feet 0 91M above the rooftop and above normal snow levels The vent cap assembly MUST be listed by nationally recognized agencies e Combustion air supplied from outdoors must be free of contaminants To prevent recirculation of flue products in to the combustion air inlet follow all instructions in this section e Incorrect installation and or location of the air inlet cap can allow flue products to be drawn back into the appliance This can result
74. ations 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 Table 2 Service Clearances Service Clearances ide 24 12 12 60cm 30cm 30cm 2 60cm 60cm 30cm 30cm 60cm 60cm 30cm 30cm 60cm 60cm 30cm 30cm 60cm 60cm 30cm 30cm 60cm 60cm 30cm 30cm 60cm ___ 60cm 30cm 30cm 60cm 60cm 30cm 30cm 60cm 60cm 30cm 30cm 60cm ___ 60cm 30cm 30cm 60cm 60cm f 60cm 30cm 30cm 60cm 60cm 60cm 30cm 30cm 60cm 60cm 60cm 30cm 30cm 60cm 60cm Ta 24 12 12 24 24 60cm 30cm 30cm 60cm 60cm UU 60cm 30cm 30cm 76cm 60cm 60cm 30cm 30cm 76cm 60cm 60cm 30cm 30cm 91cm 60cm x 60cm 30cm 30cm 91cm 60cm Allow adequate space for the venting in addition to 6 clearance to combustibles 1 10 INSTALLATION PROCEDURE AND LOCATION OF UNIT Install this appliance in a clean dry location with adequate air suppl e y Do not locate this appliance in an area where it will be subject to freezing unless precautions are taken Radiant losses from the Dynaforce minimal and should not be relied on to keep the appliance room warm The appliance should be located close to a floor drain in an area where leakage from the appliance
75. ative 0 15 Inches W C we recommend a single acting barometric damper qualified professional using a proven vent sizing program with input of accurate operating parameters must properly do sizing of the venting system In applications where flue gas temperatures are lower than can support a Category Il 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 pressurize the room or to provide an extractor at the chimney outlet interlocked with the appliance operating circuit in order to maintain a negative draft in the chimney and allow common venting e Approval of the installation will be at the discretion of authorities having jurisdiction 10 Coyme ence sre IN GENERAL e 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 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 e Potentially corrosive atmospheres will result from exposure to permanent wave solution chlorinated waxes and cleaners chlorine water softening chemic
76. ature possible is used when setting up low fire combustion These cold system temperatures create large amounts of flue condensate resulting in large amounts of condensate build up on the stainless steel finned heat transfer tubes These conditions create the highest back pressure through the boiler and makes for the most critical combustion set up point when running 2096 input This set up must be achieved quickly to ensure low system temperatures are maintained throughout the set up of single or multiple boiler installations Light off the boiler at low fire and make the initial adjustment to the low fire bias to obtain the specified CO2 CO at 2096 gas input While maintaining the lowest possible water temperature observe the differential gas pressure The differential gas pressure must not drop below a minimum of 0 25 w c If necessary increase the VFD Hz setting until this pressure is met Once the boiler has run for at least 10 15 minutes with dead cold water there should be a maximum amount of condensate in the lower heat exchanger At this point adjust the combustion for CO2 The boiler must continue to run with stable combustion without making any howling noise which usually happens from an overly rich mixture Once settings are complete at low fire continue to run the machine for at least 10 15 more minutes and record the final low fire input and the combustion data To ensure the coldest possible water temperatures for set
77. below the minimum setting of the pressure switch the appliance will shut down and an open gas pressure switch will be shown on the display 5 6 HIGH LIMIT A high limit aqua stat control is located at the back of the appliance and the control bulb is installed in a dry well in the heat exchanger header outlet The setting of this control limits maximum discharge water temperature A manual reset high limit will have a red reset button which must be pushed whenever water temperature has exceeded the set point of the manual reset limit The temperature of the water in the heat exchanger must drop a minimum of 15 F 8 3 C below the setting of the high limit control before the reset function can be activated Whenever an appliance is supplied with both an auto reset and manual reset high limit always set the auto reset limit 10 F 5 5 C below the manual reset limit to prevent nuisance tripping 21 Dyna 5 7 DYNAFORCE SOLA 5 8 DYNAFORCE CONTROLLER DR300 DR2500 models utilize a hot surface ignition system Table 11 Connector Description DR3000 DR5000 models utilize a proven pilot The ignition control proves the presence of the flame using a flame rectification voltage 0 8Vdc energizes the main gas valve Flame Sensor Ground Ro proves the presence of main burner flame and provides for lockouts The Alarm light will be lit on the ignition control module in the event of a fault J3 Di
78. burner port area in a solution of dishwashing detergent and hot water Allow the burner to remain in the solution for a short period of time to remove dust dirt and oil or grease laden contaminants Rinse the burner thoroughly with clean water to remove any residue from the detergent cleaner The burner should be air dried after removal from the cleaning solution and rinsing DO NOT use chlorine based solvents or cleaning agents on the burner 57 10 6 CHANGING THE HOT SURFACE IGNITER The hot surface igniter is to be checked at least after every 4000 hours of operation and more frequently under high cycling conditions This will maintain peak ignition efficiency e Turn off main electrical power to the appliance e Turn off main manual gas shutoff to the appliance Locate the hot surface igniter e Disconnect the two power leads to the hot surface igniter Loosen and remove the two screws that hold the igniter e Lift the igniter vertically out of the burner mounting flange Use care do not hit or break the silicon carbide igniter DO NOT pull out by leads e Ensure that the ceramic paper gaskets used to seal the base and top of the igniter are reinstalled on the new igniter 10 6 1 RE INSTALLING THE IGNITER e Confirm that the end of the replacement igniter has a bead of silicone sealing the gap between the metal mounting flange and the ceramic shaft of the igniter e Carefully insert the igniter into the mounting point
79. cified by the vent manufacturer Aluminium tape must meet the provisions of SMACNA AFTS 100 73 Standard Periodically check to ensure that the vent terminal is unobstructed This venting system uses the appliance s internal combustion air fan to force the flue products out horizontally The Dynaforce fan generates a positive pressure in the flue Combustion air is drawn from the equipment room Sidewall terminations are available from the factory Refer to local codes for proper installation and location of vent terminals 2 4 1 SIDEWALL VENT TERMINAL amp SIDEWALL INTAKE AIR TERMINAL e The sidewall vent terminal kit includes the wall penetration assembly and the discharge screen assembly e The opening through the wall for installation of the sidewall vent terminal must provide an air space clearance of 1 inch 2 5cm around the flue pipe The diameter of the opening for installation of the sidewall vent terminal will be 2 inches 5cm larger than the nominal diameter of the installed vent pipe to the sidewall vent cap The diameter of the opening for the air inlet cap will be the same as the nominal size of the pipe e Install the proper vent pipe to the vent terminal provided by Camus Hydronics e Follow all requirements in the General Venting sections for venting flue products to the outdoors 2 4 2 LOCATION OF SIDEWALL VENT TERMINATION e The vent terminal shall terminate at least 3 ft 1M above any forced air
80. ction for air pressure 4 sensing line Connection for the air pressure sensing line Connection for the gas pressure sensing line Connection for the gas pressure 4 sensing line Position indicator con Use the Dynaforce Control Panel Press DIAGNOSTICS button N Press Diagnostic Tests button Co Move the firing rate slider to 20 096 A Press Start Test to operate the boiler at max fire for 5 minutes Increase CO2 Decrease CO2 Low Fire Clockwi Counter Adjustment Clock Wise When the correct combustion values are achieved replace the screw cap back on to the gas valve 47 To adjust the high fire setting DR 2000 5000 One or more manometers should be connected to the Dynaforce before proceeding to the next step to monitor the air and gas signal Refer to Section 3 7 of this manual for details on connecting manometers After the low fire settings are stable ramp the boiler firing rate to 10096 using the boiler control and bring the system temperatures up to 130F to highest system design temperatures to minimize or eliminate condensate Use the Dynaforce amp Control Panel 1 Press DIAGNOSTICS button Press Diagnostic Tests button 3 Move the firing rate slider to 100 096 Press Start Test to operate the boiler at max fire for 5 minutes Figure 35 DR3500 5000 Gas Train Layout Differential Gas Switch Control Metering Valve Valve R
81. d when this temperature is exceeded the gas valve will de energize to prevent overheating the heat exchanger 20 PART5 ELECTRICAL amp CONTROLS IT IS EXTREMELY IMPORTANT THAT THIS UNIT BE PROPERLY GROUNDED 5 1 ELECTRICAL CONECTIONS Table 10 Minimum Power Requirements Maxi NULLE Full Load Voltage Amp Requirement Protection 300 Amperes Amperes 1200 3000 208 230VAC 4000 208 230VAC This is a 4 wire power supply requiring two 2 lives a neutral and a ground This is a 5 wire power supply requiring three 3 lives a neutral and a ground Dynaforce boilers supplied at 460 3 60 voltage differ from the standard unit per the following CAUTION While working with 460V circuits it is imperative that extra precautions be taken Ensure that lock out tag out procedures are strictly enforced Only properly trained and authorized personnel should be permitted to work on live electrical circuits All electrical workers should be trained in electrical rescue techniques and CPR Each unit has an internal factory mounted 500VA transformer to supply the 115V necessary for the ignition circuit For the incoming power a 3 wire connection is made at the rear junction box A new variable frequency drive replaces the standard VFD and the combustion blower fan has been configured to operate at 460 3 60V using the standard fan Part numbers as well as FLA and MOCP information is below
82. des an extended residency time to neutralize the condensate The neutralized condensate exits from the reservoir outlet P trap is installed upstream of neutralizer at the heat exchanger Prime the installed assembly with water to prevent flue gas spillage from the drain Use standard 12 vinyl PVC CPVC or suitable hose to run to floor drain When the condensate level in the reservoir rises to the drain it spills out into the condensate bin and from there exits to the external neutralizer As the pH number increases in numerical value the relative acidity of the discharge decreases The neutralized condensate may then be discharged into a suitable drain system without fear of damage to the drain system Always check with local codes for specific pH requirements Neutralizers may be used in series to raise pH The condensate collection box supplied with the Dynaforce is supplied with an initial charge of neutralizer medium This neutralizer medium is expected to last approximately 3 to 6 months depending on the amount of condensate produced Neutralizer refills are available from 10 5 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 process may force airborne dust and dirt contaminants contained in the combus
83. e SOLA can directly operate pumps up to 1 6 HP Larger pumps will require a separate relay or contactor 19 To select the proper pump it is strongly recommended to consider the following e Need to know the required flow and pressure drop for your appliance see Table 8 and 9 Type of application hydronic heating or domestic hot water DHW e For hydronic heating and DHW applications with normal water hardness choose a pump which will result in a temperature rise across the main heat exchanger of 10 F to 25 F 5 5 C 13 8 C depending on the size of heater If necessary use a flow setter valve to achieve the desired temperature rise e For DHW applications with other than normal water hardness choose a pump for the local water hardness conditions Alternatively run the pump continuously and soften the water to normal levels Damage to the heat exchanger as a result of scaling or corrosive water conditions is non warrantable NOTE The use of a system sensor is required in lead lag operation When variable speed main circulators ARE NOT used the system sensor is to be placed into the return system piping When variable speed main circulators are used the system sensor is to be placed into the supply system piping 4 12 AT HEAT EXCHANGER ALGORITHM The Dynaforce is constantly monitoring the inlet and outlet water temperatures on the Dynaforce when the AT approaches 40 F the burner will modulate down an
84. e The delay timer is set based on the number of boilers in network 1 Pump C Delay Timer Register 293 Interstage Delay Default 2 mins x Number of Boilers This delay timer will allow all boilers in network 1 to perform an ignition attempt before network 2 is initiated Due to the rotation of leaders in network 1 boiler 8 may become lead boiler Operation is not impacted regardless of lead boiler in network 1 as all boilers in network 1 will attempt to start before network 2 is initiated Network 2 operates independently of network 1 and as a result the setpoint for network 2 is recommended to be set at least 2 F lower than network 1 A staggered setpoint approach will reduce the amount of short cycling when all the boilers are viewed as a complete system Network 2 can support up to a maximum of 4 boilers 9 Boiler Outdoor Reset Wiring The use of outdoor reset requires two outdoor sensors for this setup Network 1 outdoor sensor is wired to boiler 2 and the outdoor sensor for boiler 9 requires the use of the outdoor sensor module PN W873581000 wired to the ECOM connection on the Honeywell SOLA Additional details can be found on page 76 10 to 12 Boiler Outdoor Reset Wiring The use of outdoor reset requires two outdoor sensors for this setup Network 1 outdoor sensor is wired to boiler 2 and the outdoor sensor for network 2 is wired to boiler 10 on the System OutD contacts in the junction box Additional de
85. e Optional gas controls may require routing of bleeds and vents to the atmosphere outside the building when required by local codes e Larger models of this appliance may be supplied with a gas pressure relief valve This valve is designed to relieve lockup pressure in excess of the high gas pressure switch setting It must be piped to discharge excess gas pressure through the valve to a safe location in accordance with local codes Follow table 5 for sizing the vent line Table 5 Gas Pressure Relief Valve Vent Manifold Sizing Chart Up to 50 feet Increase by one pipe size for every 50 feet or part thereof that the vent line extends beyond the initial 50 feet The increase is to be made at the connection to the relief valve Table 6 Recommended Gas Pipe Size Single Appliance Installation For distance from natural gas meter or propane second stage 3 2 0 100 FT 101 200 FT 201 300 FT me T Tef iaa Te U Te LES lew gt Tee pee 2 1 2 GAS PIPING 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 gas supplier Use new properly threaded black iron pipe free from burrs Avoid flexible gas connect
86. e for Gas Burning Appliances and Equipment Vent connection is made directly to the flue outlet opening on the back of the unit e For indoor installations venting must be in accordance with Part 7 Venting of Equipment of the National Fuel Gas Code ANSI Z223 1 or Section 7 Venting of Equipment and Air Supply for Appliances of the CAN CGA B149 Installation Codes or applicable provisions of the local building codes e Horizontal runs of vent pipe shall be securely supported approximately every 4 feet to prevent sagging and maintain a minimum upward slope of 1 4 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 Al connections should be secured and sealed 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 Do not use an existing chimney as a raceway if another appliance or fireplace is vented through the chimney 2 1 1 CATEGORY II AND CATEGORY IV VENTING A Category venting system operates with a negative pressure in the vent The Category IV venting system operates with positive pressure generated by the internal combustion air fan which operates the combustion process and also exhausts the flue
87. e soft start At the start of trial for ignition the fan will decelerate to minimum fire and will light off at low fire before ramping up towards full input through the PWM signal from the controller e Shut power off to the heater and open the firing valve Switch power back on and allow the burner to fire Ignition should be smooth Always make adjustments to meet the recommended CO levels Adjust low fire first followed by high fire adjustment To adjust the high fire setting DR 300 1800 After the low fire settings are stable ramp the boiler firing rate to 10096 using the boiler control and bring the system temperatures up to 130F or to highest system design temperatures to minimize or eliminate condensate Use the Dynaforce amp Control Panel 1 Press DIAGNOSTICS button 2 Press Diagnostic Tests button 3 Move the firing rate slider to maximum RPM as indicated by the test sticker 4 Press Start Test to operate the boiler at max fire for 5 minutes Locate the input adjustment screw on the top side of the gas valve Increase CO2 Decrease CO2 High Fire v Adjustment Counter Clock Wise 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 To adjust the low fire setting DR 2000 5000 Figure 34 SKP 55 Gas Valve Clockwise Adjustment of low fire bias Conne
88. ed Water Pressure Switch 30 PSI Gas Pressure Switch lt Low gas pressure switch 4 5 w c N O High gas pressure swtich 14 w c N C Blocked flue switch N C Interrupted Air Switch DR 1200 5000 N O 25 DRH Modulation pole Boiler Fixed Setpoint Operation Standalone Electrical Connection s Programming Instructions Boiler operates at a fixed Place both toggle switches to LOCAL setpoint Press _ Core and L Modulates on boiler inlet dil Press CH Central Heat Configuration sensor default FLAME Press the to arrive at Setpoint Heat demand is generated Select Setpoint source Local when Remote Operator is Enter desired Setpoint 4 20mA closed 0 10Vdc Place toggle switch to REMOTE for remote enable operation if required DynaForce um Central Heat Confi REMOTE sept Setpoint source Setpoint 1609F Time of day setpoint 1609F Off hysteresis 109F On hysteresis 10 F 4 water temperature 1209F 20 mA water temperature 1609F Modulation Boiler Inlet Outdoor Reset Operation Standalone Electrical Connections Boiler operates with variable setpoint determined by outdoor reset curve Modulates on inlet sensor default FLAME Heat demand is generated ENLERE when Remote Operator is 4 20mA closed 0 10Vdc REMOTE OPERATOR CASCADE Programming In
89. ed across air differential 53 Hold 63 LCI OFF Load Control Input Hold 67 ILK OFF High Limit Gas Pressure Switch Air 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 Alert 310 Run was terminated due to ILK was off Alert 460 LCI lost in run This error occurs when one of more of the boiler safety switches are in an open condition when it is to be in a closed condition before the ignition sequence is allowed to proceed VO Flow Switch Check flow switch Check flow switch paddle Must have minimum 30 PSIG in water system Check vent amp inlet for obstruction Reset high limit Check inlet gas pressure gt 3 w c Closed Check water pressure switch Closed Check blocked flue switch Open Check high limit High Limit Green Gas Pressure Switch Gray Low gas switch Closed Green Check inlet gas pressure 14 w c Turn set screw CCW 1 2 to 1 1 2 turns High gas switch Check air proving switch Air Switch Check J5 2 connector SOLA for 24Vac signal Proc
90. eed 1 PSI For models NOT incorporating the SKP25 lockup pressure must not be in excess of 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 Dynaforce at lockup pressures exceeding the recommended levels can lead to delayed ignitions and damage to the appliance 3 8 CHECKING DIFFERENTIAL AIR AND GAS PRESSURES DR2000 DR5000 Figure 12 Checking Differential Air and Gas Pressures DR2000 DR5000 To Fan Discharge F Differential High x Q lt s Gas Switch Metering Valve _ Firing Valve To Appliance Vent Valve Fan Inlet Control Valve e The 1 tol air gas ratio control actuator has embossed markings identifying air air gas amp gas connections Using a test hose assembly fitted with tees connections can be made from the manometer to the appropriate ports on the actuator e Using tees connect a hose from the positive air and the negative air to each of the two sides of a manometer This will allow the two pressure points to be measured while at the same time the actuator still receives the proper operating signal e f a second manometer is available it can
91. eed to ignition sequence 54 Alert 354 Abnormal Recycle Delta T limit This safety was breached as the inlet and outlet temperature difference exceeded 40 This is done to prevent damage to the heat exchanger Before this error appears the combustion air blower will slow down in an effort to prevent such an error from occurring Low current reading Verify pump Purge air from water lines motor load to Check pump wiring pump rated Check pump wiring load Current reading within spec Check pump curves to compare with flow and pressure drops in Part 4 of Dynaforce I amp O Out of spec Upgrade Pump 55 PART 10 MAINTANANCE CAUTION It is important that all gas appliances to be serviced by a Camus trained service technician 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 Camus trained service technician utilize a combustion analyzer to read CO and flue pressure according to Camus Hydronics recommendation CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation verify proper operation after servicing Listed below are items that must be checked to ensure safe reliable operations Verify proper operation after servicing 10 1 EXAMINE
92. egulator Valve Firing Valve Fan Inlet Locate the metering valve on the gas train High Fire Adjustment Counter Clock Wise 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 To reset the metering valve to factory settings refer to the chart below and the step by step instructions that follow Table 15 Inline metering valve setting 48 Step 1 Fully open inline metering valve counter clockwise Step 2 Close inline metering valve to preset level Step 3 Above table shows initial settings only fine tuning will be required with the use of an analyzer This boiler is designed for low fire soft start At the start of trial for ignition the fan will decelerate to minimum fire and will light off at low fire before ramping up towards full input through the 4 20mA from the controller Shut power off to the heater and open the firing valve Switch power back on and allow the burner to fire Ignition should be smooth Normally the differential gas pressure will be identical to the differential air pressure Actual differential pressure may vary from the numbers on the test label due to the field conditions and sample variations Always make adjustments to
93. ement control replacement etc Figure 16 Typical Space Heating System 4 Ws d U d ax es System Air Return Vent ni Q Pump recommends to increase the head loss 20 e he requirement for the heat exchanger with water glycol mixture will now be 115 15 6 feet ie 1 2 x 131 15 6 ft e 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 in colder climates a snow screen should be installed to prevent snow and ice accumulation on and 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 4 2 WARNING REGARDING CHILLED WATER AND HEATING COIL SYSTEMS When an appliance is connected to a refrigeration system where the same water is used for heating and cooling the chiler 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 The appliance piping system o
94. er Example What is equivalent pipe diameter of three air inlet pipes 8 20 3 cm 10 25 4 cm and 12 30 5 cm Equivalent pipe diameter Sq Root 8 10 12 2 Sq Root 308 17 5 Select 18 82 8 cm diameter pipe or larger The air inlet point for multiple boiler 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 30 5M equivalent feet You must deduct the restriction in 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 for the restriction 2 1 11 DRAIN TEE Figure 7 Drain T and Neutralizer Cartridge Installation Flue Outlet Flue In Condensate 7 I Drain Tee 7 4 Loop from gt to Bottom Drain Tubin lt Condensate neutralization system A drain line must be connected to the boiler condensate drain and to a tee installed in the vent pipe to collect and dispose of any condensate that may occur in the boiler and vent system The drain tee should be installed at the point w
95. ertically out of the heat exchanger cavity A graphite backed ceramic paper gasket is located directly under the burner flange This gasket must be replaced if it is damaged e Use care to prevent damage to the knitted metal fiber of the burner surface 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 Insert the igniter and sensor before doing the final tightening on the fan mounting nuts Evenly tighten the nuts to 20 ft lbs models 300 1000 and 25 ft lbs models 1200 5000 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 5 2 BURNER CLEANING PROCEDURE Remove any visible dust or dirt blockage from the surface of the burner using water from a garden house Wash the burner with low pressure water Never wipe or brush the surface of the burner nor use high pressure water or air The burner may best be cleaned by immersing the
96. escription 29 30 47 50 _ 61 62 63 68 69 123 _ 124 26 283 303 Interlock Off safety circuit is open 310 324 Hardware flame bias Flame sensor wire needs to 3 4 bere routed 379 352 355 357 359 460 550 Delta T inlet outlet limit was exceeded f an internal hardware fault is detected contact Camus technical support for troubleshooting procedure The alarm LED and alarm contacts are closed and will remain closed until the RESET button is pressed 23 PART6 CONTROL PANEL 6 1 APPLIANCE TEMPERATURE CONTROLLER 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 2 slotted screws and swinging opening the door The diagnostic information centre as well as the on off switch and the appliance temperature controls reside on the control box door the ignition control module VFD transformer and relays are mounted on the internal panel Figure 24 Touchscreen Display The SOLA icons will appear in one of four colours indicating the boiler status Normal Operation Red Lockout Condition Holding Mode Communication Error 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
97. ethod Sequence order Select Lead rotation time user defined eI Bee E lt Algorithms P Lead selection method Lag selection method Measured run time Lead rotation time 1 hour f Electrical Connection s Programming Instructions Upon a call for heat the lead boiler will fire to the specified base load rate 8096 If the temperature is not within Error threshold 5 F of setpoint after Interstage delay 2 minutes a lag boiler will be brought online and will also fire at the base load rate specified Modulation of boilers will only occur after all boilers in the Lead Lag system are firing at the specified base load CASCADE SYSTEM OUTDOOR Press Lead Lag Master Configuration Press Advanced Settings gt Press the to arrive at Rate Allocation Select Base load common user defined rate 8096 Adjust staging of boilers Electrical Connection s Programming Instructions Upon a call for heat the lead boiler will fire up to the specified base load rate 8096 If the temperature is not within Error threshold 5 F of setpoint after Interstage delay 2 minutes a lag boiler will be brought online and will also fire up to the base load rate specified This method will then be repeated for the next lag boiler if available CASCADE SYSTEM OUTDOOR DynaForce Lead Lag Master Config Rate Allocation Base load common 8096 P
98. f hot water boiler connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation must be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle 17 Figure 17 Chilled Water System Supply Return Chiller lt gt Boiler System Pump 4 3 INLET AND OUTLET CONNECTIONS e All water connections are groove lock fittings 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 4 MINIMUM PIPE SIZE REQUIREMENTS 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 See the piping requirements in Part 11 Installation section of this manual Consult factory if longer piping distances are required for a specific application 4 5 HEAT EXCHANGER This appliance uses stainless steel fin tubing to maximize the heat transfer process The heat exchanger is comprised of vertical tubes welded directly into two circular stainless steel headers This heat exchanger is desig
99. firing at less than 100 of input rate 11 12 WATER HEATERS The manufacturer recommends the use of a properly sized thermostatic mixing valve to supply domestic hot water at temperatures less than 140 60 Storing the water at a higher temperature and thermostatically mixing the water will decrease the size of the storage tank and increase the available quantity of mixed hot water e Piping components connected to the water heater for a space heating application shall be suitable for use with potable water e Toxic chemicals used for boiler treatment shall not be introduced into the potable water used for space heating A water heater which will be used to supply potable water shall not be connected to any heating system or component s previously used with a non potable water heating appliance When a system requires water for space heating at temperatures higher than required for other uses a means such as a mixing valve shall be installed to temper the water for those uses in order to reduce scald hazard potential CAUTION Adequate care MUST be taken to prevent potential scald injury when storing water at 140 60 C and hotter x 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 PART 12 EXPLODED VIEW 9 White Graphi
100. he 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 dual seat negative pressure air gas ratio valve control A reduction of up to 3096 is permitted in the inlet gas pressure between light off and full fire conditions If the manifold differential pressure is to be measured refer to section 3 8 Checking Differential Air and Gas Pressures for proper measurement 13 Figure 8 DR300 400 1 1 Negative Pressure Air Gas Ratio Control Valve Low fire air gas ratio adjustment use T 40 for adjustment clockwise increases CO High fire air gas ratio adjustment use slotted screwdriver for adjustment counter clockwise increases CO Figure 9 DR500 1800 1 1 Negative Pressure Air Gas Ratio Control Valve Lift top cover to access high fire air gas ratio adjustment use 3mm allen key for adjustment counter clockwise increases CO Low fire air gas ratio adjustment V use T 40 for adjustment clockwise increases CO TE P BI anl Qaslnlet Figure 10 DR2000 5000 1 1 Air Gas Ratio Control Valve Low fire adjustment screw Located under cap Turning clockwise increases Actuator Junction box for Flange power with actuator position indicator z Yer 1 Flange Figure 11 DR3500 5000 SKP25 Regulating Gas Valve Actuator amp SS
101. he appliance using an indirect can be provided by using hydronic system antifreeze Follow the manufacturer s instructions DO NOT use undiluted or automotive type antifreeze e Shut down and draining If for any reason the unit is to be shut off 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 heat exchanger completely o Ensure the pump and connecting piping are fully drained PART 11 INSTALLATIONS 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 WARNING 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 gas 11 1 CHECKING THE INSTALLATION 10 14 FREEZE PROTECTION FOR A HEATING BOILER SYSTEM Optional Use only properly diluted inhibited glycol antifreeze designed for hydronic systems Follow the instructions from antifreeze manufacturer Quantity of antifreeze required is based
102. he pipes between the hot water heater and storage tank are not more than a total of 80 equivalent feet between inlet and outlet lines If maximum equivalent length for the specified pipe diameter is exceeded larger diameter pipe may have to be installed to achieve correct flow and temperature rise 6 Common manifold piping for multiple unit installations will require larger minimum pipe sizes and tank circulating tapping to ensure proper flow If the temperature rise is too low the water velocity is too high Adjust as follows 1 Temperature rise can be increased by slowly closing the flow control valve globe valve or flow setter in the outlet piping from the hot water heater to the storage tank to achieve the proper temperature rise 2 Sustained high water velocity and low temperature rise may result in pitting or erosion of the stainless steel tubes in the heat exchangers This is a non warrantable failure Temperature rise must be properly adjusted to achieve the specified flow rate 62 The required temperature rise and the recommended pump size are based on the heating of potable water with normal hardness For DHW applications with other than normal hardness choose a pump for the local water hardness conditions Alternatively soften the water to normal levels Damage to the heat exchanger as a result of scaling or corrosive water conditions in non warrantable CAUTION Temperature rise cannot be adjusted when the burner is
103. here the flue turns vertical for a roof top termination or as one of the first fittings in a horizontal flue that will terminate on a SIDEWALL Ensure that horizontal portions of the vent are properly sloped away from the appliance to allow condensate to be evacuated at the drain tee Plastic drain tubing sized per the vent manufacturers instructions shall be provided as a drain line from the tee and from the boiler condensate line The drain tubing from the tee must have a trap provided by a 4 10cm diameter circular trap loop in the drain tubing and the boiler drain shall be normal with no loop and tied into the tee drain tubing with a tee at a point after the 4 loop and before the neutralizer Prime the trap loop by pouring a small quantity of water into the drain hose before assembly to the vent Secure the trap loop in position with nylon ties Use caution not to collapse or restrict the condensate drain line with the nylon wire ties The common condensate drain must be routed to the condensate neutralization system or a suitable drain for disposal of condensate that occurs in both the boiler and in the vent system Ensure that the drain from the condensate tee is not exposed to freezing temperature 2 2 CONVENTIONAL VENTING INDOOR INSTALLATIONS e The Dynaforce amp is a category appliance and is approved for venting into a common Chimney On single appliance installations with dedicated chimney if drafts are excessive above neg
104. i O x s 41 6 3 LEAD LAG SETUP UP TO 8 BOILERS Rotation Rotation time is configurable based on equalized run time The following components are needed for a Lead Lag setup default or a fixed rotation schedule 1 10kO System Sensor Interstage Delay Turn off all the boilers before beginning the setup process The length of time to wait between starting the next boiler in sequence Default 2 minutes To setup the Dynaforce Lead Lag system follow the instructions Base Load Rate When a call for heat is initiated the lead boiler runs up to System Sensor the desired base load rate Default 80 and continues to operate in this fashion based on the above 4 scenarios If the lead lag temperature is not satisfied a second boiler is fired and they would both operate up to 80 fire rate Insert the supplied 10kQ system sensor into the building loop The wires coming out of the system sensor should be connected to Sys Outdr terminals in the junction box NOTE The use of a system sensor is required in lead lag operation When variable speed main circulators ARE NOT used the system sensor is to be placed into the return Slave State Slave Status Manager Unknown Table entry is unused or empty Available Slave is operational and ready to use Add Stage Stage is getting ready to fire system piping When variable speed main circulators are used the system sensor is to be placed into the supply system
105. in DR 3500 5000 Differential Low Gas High Gas Switch Metering Switch Control Valve N Valve Regulator gt Manual Fan Valve Inlet 3 10 VENTING OF GAS VALVES AND PRESSURE SWITCHES The optional gas pressure switches may be provided with threaded termination points to be vented to the atmosphere outside the building The gas pressure regulation function is provided by the ratio gas valve which does not require installation of a vent line The optional gas pressure switches are installed in the upper chamber of the appliance Threaded vent line connections from components requiring an external vent line are provided on the component These vent line connection points may be accessed by removing the top of the appliance Local codes may require the routing of these bleeds and vents to the atmosphere outside the building Proper routing of vent lines to the atmosphere from the factory supplied termination points is the responsibility of the installing contractor 16 3 11 BURNER Figure 15 Burner This appliance uses a single cylindrical burner installed vertically into the cavity located in the center of the heat exchanger There is a unique burner for each one of the 18 models Burners MAY NOT be interchanged between different Btu hr input models The burner consists of a round mounting flange welded to a mixing tube The top side of the mixing tube provides the transition which mounts the discharge fr
106. in any location where gasoline or flammable vapors are likely to be present DO NOT install this appliance on top of carpet flooring Appliance must be instaled 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 Junction 7T BOX OUTLET G Water Connections W Vent Y Condensate SIDE VIEW drain Air Inlet L m BACK VIEW Service drains Table 3 Appliance Dimensions and Specifications Dynaforce amp Dimensions N N 42 15 1 2 34 7 8 9 3 4 N N N 42 15 1 2 34 7 8 9 3 4 N 48 3 4 16 3 8 41 7 8 10 172 N 48 3 4 16 3 8 41 7 8 10 172 N 55 1 4 18 1 2 46 11 1 2 N 55 1 4 18 1 2 46 11 1 2 N N N 65 20 3 4 57 1 29 3 8 31 3 4 70 1 2 20 3 4 59 1 2 13 29 3 8 31 3 4 73 1 2 22 5 8 62 1 2 14
107. in incomplete combustion and potentially hazardous levels of carbon monoxide in the flue products This will cause operational problems with the appliance and if left uncorrected will lead to conditions that can cause personal injury or death Figure 6 Vertical Direct Venting Configuration A Air inlet must be 36 min below vent opening Air Intake 2 1 7 AIR INLET DAMPER In cold climates it is essential to provide a motorized air inlet damper to control the supply of combustion air and prevent nuisance condensation Figure 6 Air Inlet Damper Connection inside J Box BLACK 1 CALL FOR HEAT BLUE C32 3 TO IGNITION YELLOW 3 24VAC COMMON RED 4 2 1 8 MASONARY CHIMNEY INSULATIONS Always follow local codes when venting this appliance into masonry chimney A standard masonry chimney must NOT be used to vent the products of combustion from the flue of a condensing positive or negative pressure appliance Category or IV If a masonry chimney is to be used the chimney MUST use a sealed corrosion resistant liner system to vent flue products from this high efficiency appliance Sealed metallic corrosion resistant liner systems AL29 4C equivalent single wall or double wall or flexible or rigid metallic liners must be rated for use with a high efficiency condensing positive pressure vent system Corrosion resistant chimney liner systems are typically made
108. ing The pump will run for a post pump period after the temperature set point is satisfied This will remove any residual heat from the combustion chamber before turning the pump off See wiring diagram shipped with the unit 11 8 SUMMARY a Typical Boiler Installations General Plumbing Rules 1 Check all local codes 2 For serviceability of boiler 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 boiler and on the suction side of the system pump 6 Support all water piping b Placing the Boiler in Operation Pre Start Check List 1 Review the location of the boiler clearances from combustible surfaces and available service clearances 2 Review Part 2 Venting Ensure that all vent components are fabricated from the correct category of materials with adequate clearance from combustibles 3 Ensure that the boiler condensate drain and all vent system condensate drains are properly routed to an acceptable floor drain neutralization system 4 Review the vent termination point for proper location and clearances 5 Ensure that proper volumes of combustion and ventilation air are provided to the mechanical room If a separate combustion air pipe is used ensure that it is properly sized sealed and terminated 6 Review the water piping from the boiler to the system The boiler must be installed in
109. ions Internal diameter of flexible gas lines may not provide appliance with proper volume of gas Install a manual main gas shutoff valve at the appliance gas inlet outside of the appliance and before the gas valve Install a joint union at the appliance gas line connection for ease of service and removal of the gas train Run gas pipe to 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 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 1 2 PSI Table 7 Gas Pressures at Inlet to Appliance PROPANE NATURAL GAS Minimum inches W C Maximum inches W C 7 recommended regulator setting 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 6 is recommended 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 are 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 con
110. itch Locate the probe type LWCO in the piping above the highest point of the heat exchanger The low water cutoff and flow switch are shipped loose In all cases check with local codes 6 The Dynaforce controller receives a call for heat the remote operator contacts and the Demand parameter reads Central Heating or DHW 7 DR 300 DR 1000 The Dynaforce controller energizes the pump contacts and starts to ramp up the voltage to the electrically commutated DC motor of the combustion fan after internal safety checks are satisfied O1 10 11 12 13 14 FLAME REQUIRED FALURE IGNITE OPTIONS COUNT RECYCLES THEN LOCKOUT Ki COUNT RECYCLES THEN DELAY SS RECYCLE NO LMIT b CLEAR THE FAILURE TO IGNITE RETRY COUNTER DR1200 DR5000 The local thermostat energizes the motor stop start relay which closes the initiate contacts to the variable frequency drive VFD which starts to ramp up the frequency to the 230V 3 phase motor of the combustion fan If the VFD is not in fault mode the frequency will accelerate at the preprogrammed rate towards maximum speed using the modulating signal provided by the on board modulating control or the remote operating system If temperature high limit water flow and airflow switches are closed the fan will run at pre purge speed until the pre purge timer is satisfied Once complete the Dynaforce will target the ignition fan speed D
111. lar core CPVC or Radel polyphenosulfone in venting systems shall be prohibited 2 1 GENERAL VENTING GUIDE Figure 5 Venting Configurations n Outdoor Standard Venting Venting Sidewall Venting and Combustion Air Inlet The Dynaforce is a category condensing appliance up to 99 efficient unit e The Dynaforce 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 CPVC IPEX System 636 PVC or IPEX System 636 PP as permitted by local jurisdictions e The Dynaforce boiler must be vented and supplied with combustion and ventilation air as described in this section Ensure that the venting and combustion air supply complies with these instructions regarding the vent system air system and combustion air quality e Provisions for combustion and ventilation air are to be in accordance with the section Air for Combustion and Installation Of the National Fuel Gas Code ANSI Z223 1 NFPA 54 or clause 8 2 8 3 8 4 of Natural Gas and Propane Installation Code CAN CSA B149 1 2 or appliance provisions of the local building codes e The distance of the vent terminal from adjacent buildings windows that open and building openings MUST comply with the latest edition of the National Fuel Gas Code ANSI 22231 in Canada the latest edition of CAN CGA Standard B149 Installation Cod
112. le Build 73 USB Status NOT FOUND COM 1 Enabled Bytes Packets Rate bps Clear Receive 412262 23358 4512 Transmit 186918 23365 E 2 Enabled Bytes Packets Rate bps gt Receive 6 44475 5555 576 cear Transmit 47146 5534 o EET Calibrate Audio Video Screen Display Screen Test Test Snapshot Reset COM1 Modbus data between display and SOLA COM2 Modbus data between display and front end Modbus or Protonode a For more instructions on interfacing with Modbus Bacnet LonWorks Metasys N2 network m m http www camus hydronics com Downloads 93 0238 DynaFlame DynaForce DynaMaxHS Advantus Protocol Setup pdf 44 DumeFeree sri 6 6 VARIABLE FREQUENCY DRIVE DR1200 5000 The variable frequency drive VFD has a factory set security code which has to be entered before any adjustments can be made The VFD has 50 parameters which can be adjusted At present only the following are pertinent Table 13 Variable Frequency Drive Parameters EE mn s High Low Voltage Input Voltage 120 220 240 iiim 480 L3 4 StopMetod 03 Signal sticker Signal sticker Fault History View Only 51 thru 58 View Only 6 7 FROST PROTECTION The Dynaforce is equipped with a heat exchanger frost protection algorithm where if the boiler inlet or outlet temperature sensors drop below 4
113. lected is constructed from a corrosion resistant stainless steel All materials external to the appliance in contact with the condensate must be corrosion resistant This is typically accomplished by using PVC or CPVC plastic pipe and synthetic tubing 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 the condensate management system and or a suitable drain The neutralizer MUST always be mounted on the same level or lower than the bottom of the appliance cabinet and downstream of the condensate trap The condensate trap is located external of the boiler and is to be secured to the floor or boiler pad to prevent spillage of condensate water All condensate piping and connections must be easily accessible for routine maintenance and inspection 10 4 1 CONDENSATE VOLUME There are several factors affecting the 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 recommended with every appliance The neutralizer consists of an industrial grade non corrosive reservoir for collection of the condensate As the reservoir fills it provi
114. me of Dealer so Serial Date of Date of Initial Installation Operation 6226 Netherhart Road Mississauga Ontario L5T 1B7 CANADA 79 CAMUS Hydronics is The CAMUS a manufacturer of CERTIFIED Seal replacement parts for assures you that most copper finned Reliability Efficiency amp serviceability are built water heaters into every heating IF single unit boilers as well CANUS For more as a information supplier of specialty on our innovative HVAC products Our products from CAMUS service line is open 24 Hydronics Limited call hours 7 days a week 905 696 7800 today CAMUS HYDRONICS LTD 6226 Netherhart Road Mississauga Ontario L5T 1B7 TEL 905 696 7800 FAX 905 696 8801 www Camus hydronics com
115. mps to a stop over the factory preprogrammed time period of 60 seconds 4 Thermostat is now in a standby mode waiting for the next Call for Heat WARNING To minimize the possibility of serious personal injury fire or damage to your appliance never violate the following safety rules WARNING IMPROPER INSTALLATION ADJUSTMENT ALTERATION SERVICE OR MAINTENANCE can cause injury or property damage Refer to this manual For additional information consult a qualified installer service agency or gas supplier 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 authorize and inspect all gas and flue connections Installation and service must be performed Camus qualified factory trained service technicians WARNING Should overheating occur or the gas supply fails to shut off DO NOT tu
116. n the SOLA will try for ignition When the igniter is hot enough the gas valve actuator is energized and if ignition is accomplished the Burner State will show Run If ignition is accomplished the Burner State will show Safe Startup and two more ignition trials will be made 15 seconds apart The control will then proceed to lockout and must be reset by momentarily interrupting power is normal during initial start up when air is being purged from the piping to require two to three tries before successful ignition With the boiler running check for flue gas leaks along the inner cabinet joints and around the flue outlet Repair any leaks prior to the next step At the factory adjustments were made to achieve proper input and acceptable burner performance at full input and at minimum input Depending on field conditions the metering valve may require some minor adjustment at full input Refer to Table 14 Adjustment at minimum input can be done at the low fire adjustment screw by first removing the brass cap Turning adjustment screw clockwise will increase CO Cernere sre 83 GAS VALVE ADJUSTMENT PROCEDURE Table 14 Combustion Values Dynaforce amp Combustion Values Natural Gas Propane o 100 100 o lt 100 lt 100 eee id did 2 If adjustment of the gas valve is required use following procedure It is imperative that the coldest system water temper
117. nce if service is to be performed Set the thermostat to lowest setting Turn the Manual Gas Cock clockwise to OFF position Do not force See step 5 above and diagrams STKR 001 DR 3000 DR 5000 FOR YOUR SAFETY READ BEFORE OPERATING wu WARNING you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life Boiler Operation 1 Appliance should begin the start up process for the sequence of operation 2 The boiler will fire down to 20 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 cycle off and the combustion air fan will decelerate at a pre programmed rate before the appliance shuts down This appliance is equipped with an ignition which pilot DOMESTIC HOT WATER HEATER 11 9 Hot water heaters are designed for installation with a storage tank The operation of the properly sized circulating pump the piping between the tank and heater and the control of water velocity as explained below are important for correct operation of your hot water heater 61 11 10 WATER VELOCITY CONTROL To ensure proper velocity through the heat exchanger s it is necessary to select the proper pump Temperature rise at full fire will be an indication of flow This must be d
118. ned to withstand 160 PSIG working pressure A series of V shaped baffles are installed between the individual tubes to control the movement of the flue products over the finned tubes to maximize efficiencies When servicing take special care to ensure that baffles are properly located and maintained in factory condition Replace any damaged baffles including factory supplied ceramic facing tape A factory recommended circulating pump ensures proper water flow during burner operation and creates enough water turbulence inside the stainless steel tubes and header that prevents the formation of sediments Temperature rise and scale formation in the heat exchanger are controlled by the selection of a properly sized circulating pump The Camus designs are versatile and user friendly they deliver optimal performance by taking full advantage of existing site conditions in order to maximize energy savings 18 4 6 LOW WATER TEMPERATURE SYSTEMS In applications where the heating system requires supply water temperatures below 110 F connections may be made directly to the Dynaforce At incoming temperatures of 80 F or lower the Dynaforce achieves maximum efficiency Inlet temperatures must not drop below 40 F to prevent freezing 4 7 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 c
119. nger inlet Never pump away from the exchanger since this will result in a low pressure zone which will allow localized boiling and result in heat exchanger damage Power to the boiler and pump must be from the same circuit to prevent the boiler firing in case the pump is inadvertently shut off Inlet gas pressure must be a minimum of 3 W C for natural gas and 11 W C for propane With the boiler off open the main gas supply valve and vent the trapped air from the piping leading to the boiler Confirm that all gas connections to the heater are tight and that there are no missing test plugs DR2000 5000 Connect a manometer to obtain the differential air pressure between negative and positive ports see Figure 10 The air gas ratio controller automatically adjusts to match the air signal on the gas side In this way true mass flow control of air gas mix is achieved All boilers are test fired and factory set A test sticker with actual reading is affixed to the unit CHECKING THE CONSTRUCTION Check the boiler wiring to see that it agrees with the wiring diagram supplied Confirm that all terminal strips and field connections are identified Confirm that the Dynaforce controller is set in the proper mode Auto reset limits are fixed in all modes With the firing valve in the off position switch on power to the boiler The fan motor will accelerate until the airflow icon becomes green Once all lights past the STAT are gree
120. nlet pressure tap on the gas line connection at the rear of the appliance 3 7 CHECKING GAS SUPPLY PRESSURE e Turn the main power switch to OFF position e 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 Models 300 3000 Remove 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 or magnahelic gauge Range of scale should be 0 to 14 inch W C or greater to check inlet pressure e Models 3500 5000 Remove the 1 8 hex plug downstream of the SKP25 Install a fitting in the inlet pressure tapping suitable to connect to a manometer or magnahelic gauge Range of scale should be 0 to 14 inch W C or greater to check inlet pressure e Turn 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 Observe the gas supply pressure as the burner fires at 100 of rated input e Ensure inlet pressure is within specified range Minimum and maximum gas supply pressures are specified in Table 7 e If 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 co
121. ntrol 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 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 Check appliance performance by cycling the system while you observe burner response The burner should ignite promptly Flame pattern should be stable see Maintenance Normal Flame Pattern Turn system off and allow burner to cool then cycle burner again to ensure proper ignition and flame characteristics IMPORTANT Upon completion of any testing 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 7 1 Regulated Gas Supply Pressures for Dynaforce Boilers amp Water Heaters A stable gas supply pressure is important to avoid rough starts with machines like the Dynaforce amp which use a 1 to 1 ratio control valve for internal gas pressure regulation Camus requires that all Dynaforce amp models equipped with the SKP25 be supplied with no more than 1 PSI incoming supply pressure This means that lockup pressure must not exc
122. odbus port MB2 Operation enable 4 20mA 0 10Vdc setpoint operation 9 Select Advanced Settings gt 10 Press the to arrive at Central Heat 11 Select Setpoint Source S2 J8 6 4 20mA 12 Select 4mA water temperature 33 34 13 Select 20mA water temperature DynaForce Master Configuration Central Heat Demand switch STAT terminal Setpoint source S2 J8 6 4 20mA Setpoint 1609F Time of day setpoint 1309F 4 mA water temperature 1009F 20 mA water temperature 1609F ce 14 Select Lead Lag Slave Configuration 15 Select Slave enabled Enable slave for built in Lead Lag master Secs can Slave enable Enable slave for built in Lead Lag ma emm Slave mode Equalize run time Slave sequence order 0 Demand to firing delay 10 mins Fan rate during off cycle 090 Modbus port MB2 Modbus address 2 The following steps are performed at the factory and verifying on site will be sufficient 16 Select Pump Configuration 17 Press Advanced Options gt gt 18 Press the to arrive at Central Heat Pump or DHW Pump 19 On Options Local burner demand 20 On Options Local Lead Lag Service Active 21 Force On Outlet high limit Slave Boiler Electrical Connection s Programming Instructions Slave boiler lead lag setup CASCADE SYSTEM OUTDOOR 1 Place both toggle switches to LOCAL 2 Press
123. om the combustion air fan into the burner The bottom side of the mixing tube is attached to a stainless steel perforated sleeve This stainless steel sleeve is covered with a knitted alloy material that forms the burner port surface The knitted burner port material is a metal fiber material which is a unique alloy of iron chrome aluminum and several rare earth metals This alloy is designed to operate stress free as a burner port surface The burner port surface can sustain operation from a blue flame down to infrared conditions as the burner input varies In order to maximize the operating life of the burner the normal operating mode for the Dynaforce is a blue flame Infrared operation will occur only if air to gas adjustments are incorrect If infrared operation is noted the cause must be corrected Model 300 2500 Direct ignition is standard The burner mounting flange provides a flame view port and the mounting point for the hot surface igniter and the flame sensor Model 3000 5000 Proven pilot ignition is standard The burner mounting flange provides a flame view port the mounting point for the hot surface igniter a connection to the pilot tube and the flame sensor The hot surface igniter and flame sensor are removable from the burner mounting flange without removing the burner assembly from the heat exchanger Never use an open flame match lighter etc to check gas connections PART 4 WATER CONNECTION
124. on the burner flange and push into position on top of the fan s flange e Reinstall the two mounting head screws and tighten by hand only e Ensure that the igniter ceramic paper gaskets properly installed and seal the point of contact between the igniter and fan mounting flange e Reconnect the power leads to the igniter e Turn on main gas supply e Turn on main power the appliance to ensure proper operation e The igniter must generate a minimum of to reliably light the main burner models 300 2500 and pilot models 3000 5000 10 7 HEAT EXCHANGER INSPECTION 58 The heat exchanger should be inspected at the time of burner maintenance Turn off all power to the appliance Turn off main gas to the appliance Remove top cover Remove fan assembly and burner as detailed in the Burner and Cleaning section Check the heat exchanger surface for soot If soot is present heat exchanger must be cleaned Remove the front outer jacket door Remove the top wrap to expose the baffles Remove baffles from the exchanger Use detergent water pressure wash to remove soot from heat exchanger and surfaces of the inner wrap When necessary the heat exchanger can be removed by disconnecting all water piping and removing the six flange mounting bolts at the rear of the appliance The heat exchanger can now be removed from the front of the appliance Heinstall baffles stainless steel bands and stainless
125. on at end of Ignition period Abnormal Recycle Flame was lost during Main Flame Establishing Period Interlock Off safety circuit is open 310 324 Hardware flame bias Flame sensor wire needs to 3 4 bere routed 379 Stack sensor fault Outlet sensor fault DHW sensor fault Inlet sensor fault LCI lost in run Delta T inlet outlet limit was exceeded The alarm LED and alarm contacts are closed and will remain closed until the RESET button is pressed Alert 291 Abnormal Recycle Flame was not on at end of ignition Alert 292 Abnormal Recycle Flame was lost during Main Flame Establishing Period Alert 293 Abnormal Recycle Flame was lost early in Run Alert 294 Abnormal Recycle Flame was lost during Run Alert 324 374 379 Abnormal Recycle Hardware flame bias This error occurs when a flame signal is not detected by the flame sensor A minimum signal of 0 8Vdc must be detected by the flame sensor to prove the flame Check flame sensor wire Within harness bundle Separated from harness bundle Check hot surface igniter for minimum 3 0A reading Yes Check flame sensor for carbon deposit Verify differential air signal is at 0 35 w c at 80 F return water temperature NO Yes Move flame sensor wire away from harness bundle Replace igniter Clean and or replace Adjust VFD parameter 45 speed at minimum signal until 0 35 w c is reach
126. ondominiums apartments and motels and typically used in conjunction with tempering valves to achieve temperature control In some applications it may be appropriate to provide a flow through tank to act as a buffer Consult factory for recommendations See Figure 18 Figure 18 Typical Instantaneous Water Heating System Flow Switch b P d 7 Pump To building service connections A pd gt oaa Water Supply Table 8 Flow and Pressure Drop at a Given Temperature Rise DR300 1000 10 F Rise 20 Rise Ew se o so __ _ Em ws gt Fam so s 9 Dm o s e Fem fase fas Fem so es as Dum 15s wes sa Use for hydronic heating applications only Table 9 Flow and Pressure Drop at a Given Temperature Figure 20 Low Water Cut Off Electrical Connections ITT Rise DR1200 5000 e Ed E ELT O se Dee me se n or sms 57 177 nao 7 ors me me This appliance is supplied with a relief valve sized in 5000 4740 eoo 3792 390 3160 275 accordance with ASME and Pressure Vessel Code Section IV Heating Boilers The relief valve is installed 115Vac HOT 115Vac NEUTRAL 24Vac SAFETY SIGNAL IN 24Vac SAFETY SIGNAL OUT
127. one on initial installation and periodically rechecked Excessive lime scale build up in the heat exchanger tubes is a result of restricted flow and too little velocity in the tubes Care should be taken to maintain required water velocity based on water condition as follows 11 11 TEMPERATURE RISE AT FULL FIRING RATE 1 The pump must run continuously when the burner is firing 2 With the pump running and the burner in the appliance in the off cycle the inlet temperature and outlet temperature readings on the display should read approximately the same temperatures 3 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 4 Compare the temperature rise on the Dynaforce display with the required temperature rise at the required flow rate based on water condition Soft Normal and Hard Should adjustment be needed proceed as follows If the temperature rise is too high the water velocity is too low Adjust as follows 1 Check for restrictions Check for debris in strainers 2 Check diameter and equivalent length of the piping between the storage tank and hot water heater 3 Be sure all valves are open between the hot water heater and the storage tank Ensure that all ball valves are fully ported 4 Check the pump to be sure it is running properly and that the pump motor is running in the proper direction 5 sure t
128. or CAN CGAB149 Installation Code 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 boilers conform to the latest edition of the ASME Boiler and Pressure Vessel Code Section 1 Where required by the authority having jurisdiction the installation must comply with the CSA 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 13 1 6 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
129. 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 adequately drained be installed under the unit Under no circumstances is the manufacturer to be held responsible for water damage in connection with this unit or any of its components If the appliance is installed above the level of the buildings radiation system a low water cut off device must be instaled above the heat exchanger inlet outlet connections Some local codes require the installation of a low water cut off on all systems When placing the appliance be aware that a minimum clearance of 24 must be provided at the front to allow easy access to the heat exchanger A service clearance of 24 must be provided above the top panel to allow access to the burner The appliance must be installed so that the ignition system components are 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
130. ouo smoys siu 1 aq jou SIU SNINHVAA so3 uoJp H smueo jo s s u si llog ZL 01 yj dn pea v1OS SOINOYGAH amo 4 z 3jnejeg T gt Z lulod1 s pea m 5 Z 9340J9q 1 35 0 1duu 1le JIM T Se YAOMJAN pea jo 55 30u si peaj g 105 JO 03 1ON T 7 5129108 JO 1 quunN x suiui Aejag e8e3s4a1u 2678 49151824 5 a2uanbas uou suidaq 8 VIOS SI Y 3J9uM Aejap e uo 515 TOOTVOT6LY uo 5 duung jo asn au YBNI T YTOS Z 8 VIOS T 5 10j8JadQ T 7105 7 palim Sj2e1uo2 5 8 7105 T peaj SureJado si ioq p jo 01 dn 53 1000 5 7 x1033N peaj uo s ie3ap
131. oved vent cap 93 0298 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 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 2 4 SIDEWALL VENTING When fitted with the factory supplied vent terminal the Dynaforce can vent up to 100 equivalent feet Elbows can range from 7 to 19 feet in equivalent length depending on centreline radius Refer to table 3 for vent sizes Appliances may be installed with either a horizontal sidewall vent or vertical roof top vent Terminals differ with each application Use single wall vent and seal all joints or use pressure rated double wall vent When using single wall vent all vent connector seams and joints must be sealed with pressure sensitive aluminium tape or silicone sealant as spe
132. per flame is observed examine the venting system ensure proper gas supply and adequate supply of combustion and ventilation air 10 3 FLUE GAS PASSAGEWAYS CLEANING PROCEDURES Any sign of soot around the jacket flue pipe connections burner or in the areas between the fins on the stainless steel heat exchanger indicates a need for cleaning The following cleaning procedure must only be performed by a Camus trained service technician Proper service is required to maintain safe operation Properly installed and adjusted units seldom need flue cleaning NOTE All gaskets sealant on disassembled components or jacket panels must be replaced with new gaskets sealant on re assembly Gasket and sealant kits are available from the factory CAUTION When the vent system is disconnected for any reason it must be reassembled and resealed according vent manufacturer s instruction 10 4 CONDENSATION TREATMENT This high efficiency appliance may operate as a condensing appliance for extended periods of time based on return water temperatures 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 at the rear of the appliance The condensate trap where condensate is col
133. pes to be insulated 5 feet from wall toward the interior of the building to minimize external sweating 2 1 4 VENT TERMINATION CLEARANCES e Do not terminate the vent in a window well stairwell alcove courtyard or other recessed area The vent cannot terminate below grade The bottom of the vent terminal shall be located at least 12 inches 30cm above grade and above normal snow levels In all cases the appliance shall be installed in accordance with local codes The vent outlet MUST NOT terminate below a forced air inlet at any distance e The vent cannot terminate below grade Position the vent termination where vapours will not damage walls or plants or may otherwise be objectionable e The vent terminal shall not be installed closer than 3 feet 1 m from an inside corner of an L shaped structure window well stairwell alcove courtyard or Vent Material Maximum Temperature F 0 r UU other recessed area as wind eddies could affect boiler performance or cause recirculation Polypropylene AL294C 316L 300 limited only rating of seals Stack temperature is 10 15 F above boiler inlet temperature when operating at steady state Vent material selection When selecting vent material take into consideration that appliances installed near a corrosive or potentially corrosive air supply must be isolated from it or they will suffer damage to the appliance and the venting system
134. posed 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 outlined in This Limited Warranty Does Not Cover b Reimburse any costs associated with repair and or replacement c Replace and or repair any boiler without complete model number serial number d Replace any boiler without prior receipt of actual rating plate from the appliance 78 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 of Na
135. pter 13 of the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or the Natural Gas and Propane Installation Code CAN CGA B149 1 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 main manual gas shut off and allow appliance to cool down 2 Remove the vent pipe running to the chimney and check heat exchanger vent and chimney 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 to rinse burner Caution Never use a pressure washer to clean the burner 4 Use a pressure washer to clean heat exchanger if necessary 5 Reinstall parts removed in steps 2 and 3 Be sure that vent pipe has proper pitch and is properly sealed Replace any damaged gasket Note that the burner is supplied with two gaskets a high temperature graphite backed ceramic paper gasket under the burner flange and a stamped silicon gasket between the burner flange and fan flange Tighten fan flange mounting nuts to 20 ft lb on DR300 1000 and 25 ft
136. r heat If voltage cannot be detected check wiring e Verify that the pump is circulating when 120 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 Outlet temperature has exceeded Verify that the system is full of water and that all air has been 40 F over inlet temperature properly purged from the system Alert 124 Verify that the boiler is piped properly Verify that 120VAC is being supplied to the boiler pump on a call for heat If voltage cannot be detected check wiring Verify that the pump is circulating when 120VAC is detected 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 Purge all air from the piping Verify boiler water pressure exceeds 30 PSI Manual Reset High Limit Trips if equipped Delta T Limit Tripped e Stack temperature has exceeded The stack temperature has exceeded the maximum the limit temperature temperature allowed Alert 125 149 F CPVC 194 F AL29 4C Stainless Steel 250 F Measure the resistance of the flue sensor at room temperature it should be approximately 10 Outlet temperature has exceeded Verify that the system is full
137. r sensor FLAME Press Advanced Settings Heat demand is generated FAILURE Press the to arrive at Central Heat when Remote Operator is 5 Select Modulation rate source lt 52 J8 6 4 20mA and burner on off closed and 4 20mA or 2 Place toggle switch to for remote operation if required 10Vdc signal is present nal res Central Heat Configuration Modulation Modulation sensor Inlet sensor Modulation rate source S2 J8 6 4 20mA and burner on off P gain 200 I gain D gain System Sensor Enable Standalone Method to enable system Press Le Z sensor for Standalone Press Sensor Configuration applications Select S5 J8 11 Sensor 10K NTC Single Non Safety The control will proceed into a Lockout 2 condition Press Verify Begin Yes Press the reset button on the ignition control within the alotted time DynaForce CASCADE Sensor Configuration 51 78 4 sensor Inlet or Return 10K NTC single non safety 22 78 6 sensor 4 20mA remote 4 20mA S3S4 J8 8 10 sensor Outlet or Supply 10K NTC dual safety 55 78 11 sensor 10K NTC single non safety 5657 J9 1 3 sensor DHW 10K NTC single non safety 5859 J9 4 6 sensor Stack 10K NTC single non safety Outdoor temperature source UNCONFIGURED 30 DRW Modulation Fixed Setpoint Operation Standalone Electrical Connection s Programming Instructions
138. r workmanship Camus will exchange or repair such part or portion if deemed warranty based on the number of years the appliance has been in service Years In Years In 100 8 100 100 100 The exchanged or repaired heat exchanger will carry the balance of the remaining original warranty provided with the appliance based on the FOB date In the event a replacement heat exchanger is delivered and if the defective heat exchanger is deemed to be repairable by Camus the repaired heat exchanger will be returned to the customer and a credit will not be issued Heat Exchanger shall be warranted for 20 years of the appliance having declared FOB from Camus 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 DRH amp DRW BURNER If within FIVE years of the appliance having declared FOB from Camus to be defective in material or workmanship Camus will exchange or repair such part or portion ANY OTHER PART If any other part fails within one 1 year after installation or eighteen 18 months of the appliance having declared FOB from Camus whichever comes first Camus will furnish a replacement or repair that part Replacement parts will be shipped FOB our factory DURATION OF LIMITED WARRANTY Any limited warranty including the warranty of merchantability im
139. ress Ernte and oue Press Lead Lag Master Configuration Press Advanced Settings gt Press the to arrive at Add Stage Select Error threshold Select Interstage delay DynaForce Master Configuration Add Stage Method 1 Error threshold Detection time 1 30 secs Error threshold 5 F Rate offset Interstage delay 2 mins 39 6 2 CONFIGURE MENU Figure 26 Configure Menu DynaForce Configuration Menu Select Configuration Group System Identification amp Access PN CH Central Heat Configuration Outdoor Reset Configuration DHW Domestic Hot Water Configuration DHW Plate Heat Exchanger Warm Weather Shutdown Configuration Demand Priority Configuration Modulation Configuration 6 2 1 System Identification amp Access Menu Group Parameter Description Selection Product Type Commercial Hydronic Boiler Installation Type of application 5 o gt 2 40 Central Heat Pump Pump Configuration Pump Control Pump Configuration 6 2 2 Pump Configuration Assigns the method for SOLA to control a Central Heating pump Auto Default Auto Pump is Pump Control activated whenever a call for heat is present ON Pump is constantly powered if contact Use for local Stand alone v Use for Lead Lag Master v demands Refer to above Default Specify pump Pump Output Pump A contact Post pump time 1
140. ributor DO NOT use general 48 purpose field replacement ignition modules igniters or 49 sensors Each appliance has one ignition module one hot 50 surface igniter and one flame sensor 64 67 The ignition module may lockout in either a hard lockout 81 condition requiring pushing of the reset button to recycle the Stack limit tripped PVC 149 F CPVC 194 F control for a CSD1 requirement or a soft lockout condition x which may be reset automatically once the error clears A 91 typical hard lockout fault can occur with single a trial for ignition 92 CSD1 module Pushing the reset button on the ignition control 93 is the only way to reset an ignition module that is in a hard 94 lockout condition The reset button is located on the ignition 95 module Turning the main power OFF and then ON or cycling the thermostat will not reset a hard lockout condition Wait until the display shows the temperatures on screen before 105 Flame detected out of sequence pushing the reset button when the ignition module is in a hard 106 Flame lost if Main Flame Establishing Period lockout MFEP 107 The Dynaforce amp Controller will go into an alert condition for 108 example if the supply sensor is disconnected flow switch or 109 Ignition failed air switch are not made If the fault is not corrected the boiler 110 LOU DEREN will stay in an alert condition Once the fault is corrected the boiler will automatically return to normal operating state
141. rn off or disconnect the electrical supply to the 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 intake system Use proper care to avoid unnecessary contact especially children with the appliance and vent air intake components e Never cover your 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 your appliance e UNDER NO CIRCUMSTANCES may flammable materials such as gasoline or paint thinner be used or stored in the vicinity of this appliance vent air intake system or any location from which fumes could reach the appliance or vent air intake system gas appliance that draws combustion air from the equipment room where it is installed must have an adequate supply of fresh air circulating around it during burner operation for proper gas combustion and proper venting 1 5 CODES The equipment shall be installed in accordance with those installation regulations in force 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 of the National Fuel Gas Code ANSI Z223 1 and
142. running check for flue gas leaks along the inner cabinet joints and around the flue outlet Repair any leaks prior to proceeding to the next stiep e the factory adjustments were made to achieve proper input and acceptable burner performance at full input and at minimum input strips and 11 3 INSPECT amp RECHARGE CONDENSATE COLLECTION amp NEUTRALIZING RESERVOIR Inspect the P trap and condensate reservoir in the Dynaforce making sure the collection box is intact 2 Remove screws holding lid on to condensate collection box Remove lid from the condensate collection box 3 Fill with fresh water until the water begins to flow out of drain 4 Re install the lid and hold down screws on the condensate collection box 5 Inspect the condensate neutralizer supplied on site and confirm that it contains sufficient calcium carbonate to operate effectively to neutralize condensate to required level 6 Check pH level of condensate 59 WARNING The condensate collection box must be filled with water to prevent flue gas emissions from escaping during boiler operation 11 4 HEATING BOILER INSTALLATIONS The appliance MUST always be installed in a primary secondary reverse return piping system for proper operation Before beginning the installation consult local codes for specific plumbing requirements The installation should provide unions and valves at the inlet and outlet of the appliance so it c
143. se Blocked Flue Switch 51 Dyna SYMPTOM FAILURE MODE ANALYSIS 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 e Check the flame sensor and verify that it is clean Replace Dynaforce Controller if necessar Blank Display Blank display screen Check wire connections from Dynaforce amp Controller to Screen touchscreen display Lockout 3 46 58 60 97 99 143 Reset SOLA Flame Detection is out of Sync Table 16 Lockout Codes Description Heater Outlet high limit tripped Delta T Limit go Stack limit tripped PVC 1499 CPVC 194 250 F Inlet sensor fault DHW sensor fault Header sensor fault 96 Outdoor sensor fault O 106 Flame lost if Main Flame Establishing Period MFEP Flame lost early in run Flame lost in run 109 Ignition failed 110 Pilot test flame timeout Flame circuit timeout Flame detected If an internal hardware error is detected contact Camus amp technical support for troubleshooting procedure 52 Table 17 Alert Hold Codes Description Processor brown out Using backup Lead Lag header sensor due to sensor failure Lead lag slave communication timeout LCI off safety circuit is open 281 Demand off during measured purge time 291 Abnormal Recycle Flame was not
144. se only your hand to turn the Manual Gas Cock control handle Never use tools the handle will not turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water 1 Do not operate appliance unless unit is filled with water and inlet valves are fully open FIGURE B POSITION E OPERATING INSTRUCTIONS w 7 Turn Manual Gas Cock counterclockwise to Fig 8 Set thermostat to desired setting 9 Turn on all electric power to the appliance The main burner will be light directly f the main burner fails to ignite follow the instructions To Turn Off Gas to Appliance and Call your service technician or gas supplier input 6 Verify operation of safeties as necessary low water cut off high limit gas pressure etc 7 the boiler is running and the flame has stabilized remove the flame sensor wire at the sensor Main flame must extinguish within 4 sec flame does not extinguish replace the ignition control TO TURN OFF GAS TO APPLIANCE ws STOP READ THE SAFETY INFORMATION ABOVE ON THIS LABEL Turn off all electric power to the applia
145. sensor and associated wiring Replace if Lockout 106 107 108 109 necessary Check for flame sensor cracks in the insulator or continuity to ground Adjust the air proving switch Turn counter clockwise to reduce sensitivity Adjust the blocked flue switch Turn clockwise to reduce Flame Disappears sensitivity During a Run Verify incoming gas supply pressure and that it coincides Cycle with Table 7 Verify that the gas line connections to the boiler are adequate Refer to Table 6 Verify that the vent air inlet piping if equipped are correctly installed and obstructions are not present Verify that 24 is being supplied to the gas valve during operation If a signal cannot be detected the transformer needs to be replaced Inspect the burner Refer to Burner Maintenance in section 10 5 Replace the Dynaforce Controller if necessar Supply Gas Issue Refer to Part 3 Gas Connection in this manual Natural Gas Pressure reads between 3 w c and 14 w c L P Gas Pressure should be at 11 w c Air Gas Mixture Issue Refer to Section 8 3 Gas Valve Adjustment Procedure for oroper combustion setting Noisy Operation Air Inlet and or Vent configuration Refer to Part 2 Air Inlet and Venting Dirty Damaged Burner Refer to Burner Maintenance in section 10 5 of this manual for the burner removal and inspection procedure Clean or replace the burner if required Fanis vibrating e Check that
146. 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 failures or malfunctions resulting from 1 Failure to properly install operate or maintain the equipment in accordance with Camus manual 2 Abuse alteration accident fire flood foundation problems and the like 3 Sediment or lime build up freezing or other conditions causing inadequate water circulation 4 Pitting and erosion caused by high water velocity 5 Failure of connected systems devices such as pump or controller 6 Use of non factory authorized accessories or other components in conjunction with the system 7 failing to eliminate air from or replenish water in the connected water system 8 Chemical contamination of combustion air or use of chemical additives to water 9 Production of noise odours discolouration or rusty water 10 Damage to surrounds 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 Within 10 years of the appliance having declared FOB from Camus a heat exchanger shall prove upon examination by Camus to be defective in material o
147. splay Lead lag Modbus Comm Figure 21 Ignition Module 24VAC Power Pump VFD _ Gas Valve Safety Interlock String _ Safety Annunciation Remote Operator 24VAC Power Inlet Outlet Sensor DHW Stack Sensor 5 9 ERROR TABLE The following tables provide a description of all the possible errors with the Dynaforce appliance 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 5 7 1 SERVICE PARTS see table below for more details The electronic ignition module is not repairable Any Table 12 Lockout codes modification or repairs will invalidate the warranty and may cription create hazardous conditions that result in property damage personal injury fire explosion and or toxic gases A faulty hot I Uncorfigured safety dala figured x alet oala surface igniter or ignition module MUST BE replaced with a 2 Waiting for safety data verification new factory approved unit only A factory approved igniter Internal Fault Replace SOLA Controller ignition control module and flame sensor for this specific unit is 47 available from your local dist
148. stituents is being used 3 4 AIR GAS RATIO VALVE The main gas valves supplying gas to the burner for models 2000 to 5000 on this appliance utilize a servo pressure regulator providing a slow opening fast closing safety shut off and an air gas ratio control valve for the gas combustion process This gas valve controls the pressure difference across the flow orifice in the manifold supply line as a function of the pressure difference across the combustion air supply to the burner The actuator maintains a constant air to gas ratio as the volume of air changes based on the operation of the combustion air fan The valve is a 1 1 differential pressure air gas ratio controller The valve generates the same pressure difference on the gas side as it senses on the air side Models 300 to 1800 utilize a 1 1 ratio dual seat negative pressure gas valve Models 2000 3000 utilize a 1 1 air gas ratio control valve and safety solenoid valve Models 3500 5000 utilize a 1 1 air gas ratio control and regulating gas valve The regulating gas valve performs the functions of a pressure regulator safety shutoff 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 20 to 100 based on temperature demand The inlet gas supply pressure must be maintained within the specified minimum and maximum pressures T
149. structions Connect outdoor sensor to System Outdoor contacts Press Lese and 2 Press Outdoor Reset Configuration Press the to arrive at Central Heat Select Enable Enable Select Maximum outdoor temperature WWSD Select Minimum outdoor temperature Outdoor Design Select Low Water Temperature Min Water Temp Select Outdoor boost maximum off point Design Max 10 Press CH Central Heat Configuration 11 Press Sensor Configuration 12 Select S5 J8 11 Sensor 13 Select Connector Type 10K NTC Single Non Safety 14 Outdoor temperature source S5 J8 11 sensor 15 The control will proceed into a Lockout 2 condition 16 Press Verify Begin Yes 17 Press the reset button on the ignition control within the alotted time 18 Place toggle switch to REMOTE for remote operation if required DynaForce m Outdoor Reset Configuration Central Heat P Enable Enabled Maximum outdoor temperature 609F Minimum outdoor temperature OOF Low watertemperature 100or _ ia Minimum boiler water temperature 40 F Outdoor boost step O F Outdoor boost maximum off point 1859F Show Line 27 Modulation System Sensor Outdoor Reset Operation Standalone NOTE Outdoor Reset Module PN W8735S1000 required Electrical Connection s Boiler operates with variable setpoint determined by outdoor reset curve Modulates on system sensor Heat demand
150. tails can be found on page 77 6 5 LOCAL REMOTE SWITCH The local remote switch mounted inside the control box is designed to deliver an enable signal either relying on an external contact closure Remote or enabling the boiler locally local When Remote is selected via the SPDT switch the Remote Operator contacts in the junction box must be closed to deliver an enable signal When Local is selected via the SPDT switch a constant enable signal is present When troubleshooting the Dynaforce it is recommended to switch to Local mode 6 6 COMM PORT 2 ACTIVATION Setup x Display gt gt Setup Select Gateway tab 4 Display Setup 1 1 2011 6 18 PM Bateway Screen Saver Home Page C e Modbus gateway O Gateway on 1 port Gateway on 2 port Date Time About Save 1 Select Gateway tab 2 Check Enable Modbus gateway 3 Select Gateway on 2 port Display Setup 1 1 2011 12 06 PM General COM j This port is enabled for Modbus Gateway ghe COM2 port Modbus address range to 8 maximum range 1 250 Modbus baud rate 38400 8 data bits No parity bits 1 stop bit Set Date Time About 1 Select COM tab 2 Check Enable COM2 port DynaForce 2000 Master LJ 43 Verify activity on COM2 port Display gt setup gt Diagnostics Display Diagnostics Version 1 3 Memory 16 3MB out of 38 4MB availab
151. tall a manometer on the gas supply to the boiler and verify minimum gas supply pressure as the burner fires at 10096 of rated DR 300 DR 2500 This appliance does not have pilot It is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand BEFORE OPERATING smell around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor 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 NEIGHBOUR S PHONE FOLLOW THE GAS SUPPLIER S INSTRUCTIONS YOU CANNOT REACH YOUR GAS SUPPLIER CALL THE FIRE DEPARTMENT FIGURE A MANUAL gt Mar GAS COCK position J STOP Read the safety information above on this label 1 Turn off all electric power to the appliance Set the thermostat to lowest setting This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand Turn the Manual Gas Cock clockwise to OFF Fig 1 Wait five 5 minutes to clear out any gas Then smell for gas including near the floor you smell gas STOP Follow in the safety information above on this labeL If you don t smell gas go to the next step U
152. te Ceramic Gasket d Graphite Gasket i NR Ld 50 White Ceramic Gasket Only required if heat exchanger surface is rough or uneven od 65 se ee LL um Loses qr s os os __ gt Lose osa m M M M oe ow own J 2 Wrap Assembly Heat Exchanger Incl V Baffles X X X X X X ommo omm ose om rpg omo own ommo 5 Base Support X X X X ems m eee 14 1024 14 1010 Assembly evo Base Panel LIII Low j j bse support Leg pee 14 245807 Base Support Stiffener Under Leg 14
153. te tette rete ENAS AAS DEEA tests Ea Ea ternos 22 ERROR TABLE QNM 22 CONTROL 24 APPLIANCE TEMPERATURE CONTROLLER eerte nente tette 24 CONFIGURE MENU 40 LEAD LAG SETUP UP TO 8 BOILERS nanan aaa ot 42 LEAD LAG SETUP FOR UP 12 APPLIANCES anna n rnnt 43 LOCAL REMOTE SWITCH 43 COMM PORT 2 ACTIVATION annassa 43 VARIABLE FREQUENCY DRIVE DR1200 5000 terrere teet 44 FROST PROTECTION 44 SOLVON EE 45 HOT SURFACE IGNITER GLOW BAR I tete teret tette rettet 45 FLAME SENSOR 45 COMBUSTION AIR FAN ccccecececececececescecscececececsessacecscscscacecucucsasasasacavacecsceecevssacatacecstsasacavatecevstseaceeeeeeen 45 INNER JACKET 45 OUTER JACKET 45 VENTING TRANSITION MM 45 FIELD STARTUP PROCEDURE 46 CHECKING THE INSTALLATION eerte tette tatnen sss 46 CHECKING THE CONSTRUCTION 46 GAS VALVE ADJUSTMENT PROCEDURE I netter trente 46 COMISSIONING APPLIANCE cerent 48 TROUBLESHOOTING 49 MAINTANANCE 56 EXAMINE THE VENTING SYSTEM eee enne 56 VISUALLY CHECK MAIN BURNER FLAMES n nn na teret tentia 56 FLUE GAS PASSAGEWAYS CLEANING PROCEDURES aa tente 56 CONDENSA TON TREATNE gc 56 1041 CONDENSATE VOLUM
154. tection 5 2 VARIABLE FREQUENCY DRIVE DR1200 5000 This appliance uses a VFD which provides power to the combustion fan The fan motor operates on 230VAC 3 phase power This three phase voltage is generated by the VFD and supplied directly to the fan motor The VFD receives a 4 20mA modulating signal from the SOLA to vary the frequency of the voltage supplied to the fan motor from 20 Hz up to 60 Hz This varies the output of the combustion air fan from 2096 up to 10096 of capacity corresponding to the same variation in burner input Once the self checks are completed by the SOLA the VFD is provided with a signal to operate at soft start level for initial burner ignition After main burner ignition is established the modulating signal is generated by the VFD to vary fan speed based on desired water temperature set point CAUTION The voltage output from the variable frequency drive to the combustion air fan is 230VAC 3 Phase AVOID contact with high voltage wiring 5 3 DIFFRENTIAL AIR PRESSURE SWITCH Models 300 to 1000 use a fan speed sensing line in the PWM control to prove air flow A normally open differential air pressure switch is used to prove operation of the combustion air fan on the DR1200 5000 The pressure switch sensing points are installed at the fan outlet where air moves into the inlet of the burner One point measures total pressure air and is connected to a pitot tube facing the flow from the fan paddle
155. tion 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 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 An external combustion air filter is provided with the appliance An additional filter is located at the fan inlet DR1200 5000 and like the external filter may be washed in the sink under the tap This internal filter should be checked and cleaned at the time of appliance commissioning and on a six month interval or more often in a contaminated environment 10 5 1 BURNER REMOVAL Access to the burner will require the following steps e Turn off main electrical power to the appliance Turn off main manual gas shutoff to the appliance e Remove the top cover e Disconnect the gas supply connection to the fan inlet e Disconnect the fan motor power wires at the harness e Remove the hot surface igniter and the flame sensor e Remove the sensing tubes from the air ratio gas valve to the combustion air fan e Remove the 4 nuts holding the fan assembly to the heat exchanger and remove the fan assembly On occasion the red silicone gasket may adhere to the underside of the fan s flange Carefully pry the flange away from the gasket prior to removing the fan assembly e The burner can now be lifted v
156. ture with the lead lag set point and will check if 0000 00000 TITTIITRETTIT 0 0000 1 An additional boiler is needed Lead lag temp Lead lag setpoint Add stage Error threshold 2 Number of boilers remain the same mE Lead lag Lead lag setpoint Add stage Error Recycle power on all boilers after programming is complete if threshold AND lag boilers are not discovered automaticall Lead lag temp Lead lag setpoint Drop stage Error NOTE threshold CH Setpoint or DHW Setpoint must match Setpoint located in Lead Lag Master Configuration in order for the system to 3 Aboiler should stop Operate correctlv Lead lag temp gt Lead lag setpoint Drop stage Error NOTE threshold The Local Remote switch explained below must be set in 4 All boilers off the Local position on ALL lag boilers Lead lag temp gt Lead lag setpoint off hysteresis If the lead lag master system is interrupted the remaining boilers will operate as standalone boilers based on the Central Heat or DHW parameters when set to Enabled 42 6 4 LEAD LAG SETUP FOR UP TO 12 APPLIANCES Honeywell SOLA can only support up to 8 boilers in a single lead lag network to sequence a second network of up to 12 boilers in total this will be activated through Pump C contact of boiler 8 Pump C is activated on a time delay algorithm where the timer is initiated when boiler 48 begins the ignition sequenc
157. ustment screw located on the ratio control valve actuator in order to achieve acceptable light off under soft start field conditions Always check settings posted on boiler test label 3 6 GAS MANIFOLD DIFFERENTIAL PRESSURE ADJUSTMENT DR2000 DR5000 Tampering with gas valve adjustments after startup and commissioning will void the warranty on the gas valve assembly and the burner The appliance s manifold gas pressure IS NOT field adjustable after startup and commissioning The gas valve pressure ratios have been factory set with an internal bias adjustment to ensure a 1 1 air gas ratio on operation Tampering with this adjustment will void the warranty on the gas valve assembly and the burner An appliance supplied with a properly sized gas line properly sized meter and a minimum gas supply pressure See Table 7 for minimum allowable inlet gas supply pressure while firing at full rate will ensure full burner input The manifold pressure supplied to the burner is a differential pressure This pressure is the result of the difference in two gas pressure measurements A differential manifold gas pressure measurement should not be made until you have measured the gas supply pressure Gas supply pressure must be at least at minimum allowed with all appliances on the gas line firing at full rate before a manifold pressure measurement is made Use the following procedure to check gas supply pressure with a manometer connected to the i

Installation Operation and Service Manual

Contents

Download Pdf Manuals

Related Search

Related Contents