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Installation Operation and Service Manual

1. 12 NOD mM Mx M MED 12 Sad NEL S 12 linis gi VENTING 4 E 12 THRUWALL VENT CAP 14 0090 THRUWALL INTAKE AIR CAP 14 0101 12 LOCATION OF THRUWALL VENT TERMINA TION 13 LOCATION THRUMALE AIRANEET iussi ctun timeo ERA One Esau rua ou gusti iss eds 13 TPIP lc 13 GAS CONNECTION 13 GASCONNEC HON TUR 13 E T 14 INSTALLEPIPING 14 AIRGAS RATIO VAY 14 DIFFERENTIAL AIR PRESSURE DF2000 26004 15 GAS MANIFOLD DIFFERENTIAL PRESSURE ADJUSTMENT DF2000 6004 2 15 CHECKING GAS SUPRPEV PRESS ORE 15 CHECKING DIFFERENTIAL AIR AND GAS PRESSURES DF2000 6 16 3 9 3 10 3 11 PART 4 4 1 4 2 4 3 4 4 4 5 4 6 4 4 8 4 9 4 10 4 11 4 12 4 13 4 13 1 4 14 4 14 1 4 14 2 PART 5 5 1 252 2 3 5 4 5 5 5 6 5 7 354 1 9 7 2 5 8 5 9 PART 6 6 1 6 2 6 3 6 4 6 5 6 6 6 7 6 8 PART 7 7 1 7 2 rs 7 4 7 5 7 6 PART 8 8 1 GAS TRAIN AND
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7. 2 sss ess ze mre 378 78 in 332 Lem ps p n p i pw om e sn per p pnm pase sone ssa wu prp me pss 2 22 32 178 8 2 Lem _ sin asso 212 pue ss om gt Copper and copper nickel heat exchanger Stainless steel heat exchanger 500 1200 appliance inlet outlet connections are 2 NPT 500 1200 appliance inlet outlet connections are 2 groove lock 1500 5000 appliance inlet outlet connections are 3 NPT 1500 2500 appliance inlet outlet connections are 2 1 2 groove lock 3000 5000 appliance inlet outlet connections are 3 groove lock 4504 6004 appliance inlet outlet connections are 4 groove lock Table 4 Vent Sizes for a Single Appliance DynaFlame Non Condensing DynaFlame Near Condensing DFX DynaFlame Condensing Vent Diameter Inches Vent Diameter Inches Vent Diameter Inches Cat Ill Cat IV Outdoor Up to Up to Outdoor 0501 0751 1101 1201 1501 0502 0752 1102 1202 1502 1751 1752 2001 2002 2501 2502 3 p 401 4002 3
8. Select System Identification amp Access Verify MB1 Modbus address 1 Verify MB2 Modbus address 1 DynaFlame stem Identification amp Access CASCADE SOLA Product type Commercial Hydronic Boiler OS number R7910A1001 R7910A1001sin Software Version 3468 2550 Date code 1114 Application revision 14 Safety revision 10 Model 247 OEM password OEM ID 1 Modbus address 1 MB2 Modbus address 1 5 Select Lead Lag Master Configuration 6 Select Master Enabled Enabled Fixed Setpoint operation 7 Enter CH Setpoint Fixed setpoint Lead Lag Master enable Enabled CH setpoint 1609F CH time of day setpoint 1309 SYSTEM OUTDOOR Modbus port Operation enable 4 20mA 0 10Vdc setpoint operation Select Advanced Settings gt to arrive at Central Heat 10 Select Setpoint Source 52 J8 6 4 20 11 Select 4mA water temperature 12 Select 20mA water temperature DynaFl Lead Lag Master Configuration Central Heat Demand switch STAT terminal Setpoint source 52 28 6 4 20mA Setpoint 1609F Time of day setpoint 1309F 4 mA water temperature 1009F C 20 m water temperature 1609F 13 Select Lead Lag Slave Configuration 14 Select Slave enabled Enable slave for built in Lead Lag master 36 DynaFlame n Slave Configuration Slave enable En
9. V Ur a ubt 62 CONDBIUSTHON TIO ERA oi etin 62 CONTROE CIRCUIT VOLTAGE PR 62 COMBUSTIBLE MATERIALES A PM M C UE 62 FREEZE PROTECTION Mm 62 FREEZE PROTECTION FOR A HEATING BOILER SYSTEM 63 INSTALLATION Rep 63 HEARING BOILERINSTALLATIONS i aaa a a aM 63 WATER CONNECTIONS d IM MEM I D MEE IPM 63 PIPING LENGTH bal luu pe eddy ta em tuned _ ________ ___ 63 INLTERIIFEFENT PONIP OPERATION REUNIR SUELOS UN ERU ERES 64 ER 64 DOMESTICHOT WATER HEATER edi a tona xd M 64 WATER VELOCI CONTROL sabia vu awh ent abu i D Me Ae 64 TEMPERATURE RISEJATDEDEEFUISUNG RAPE EE UR QU 65 eec 65 EX VIEW 66 ELECTRIC GIA 77 pde 83
10. nw sngpo 105 4299591 01 pue 801019 duipying ul Jayjadoy 504 15 Aau pue 54051186 8 55 nw u2e3 u31SVIN Jajiog ZAW LAN Qss 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 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 warranty does not cover failures or malfunctions resulting from 1 Failure to properly install operate or maintain the equipment in accordance with Camus amp 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 compo
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12. suu CE ve m b aes 27 _ 43 BEAD EA ct T 45 LEAD LAG SETUP FOR UP TO 12 APPLIANCES tis Urt ese oe RR adea 46 LOCAJ REMOTE WAC i 2051 46 COMM 2 AGTIVATON 5 46 VARIABLE FREQUENCY DRIVE dta 47 FROST PROTECTION 47 COMPONENT 52255525 01558 eae 48 HOTSURFACEIGNITER GLOW BAR J eic EN EE PU COE Ya vU T AREE 48 FLAME SENSOR CL M 48 COMBUSTION AIR FAN x 48 INNER JACKE Turonio 48 OUTERJA OKET aeia A E 48 VENTING TRANSITION Ae AT E Oea 48 FIELD STARTUP PROGEDURE 55 dot E TT 49 CHECKING TEE NS TON d Meteo 49 8 2 8 3 8 4 9 PART 10 10 1 10 2 10 3 10 4 10 4 1 10 5 10 5 1 10 5 2 10 6 10 6 1 10 7 10 8 10 9 10 10 10 11 10 12 10 13 10 14 10 15 PART 11 11 1 11 2 11 3 11 4 11 5 11 6 11 7 11 8 11 9 PART 12 PART 13 CHECKING THE CONSTRUCTIO
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15. Stainless Steel Heat Exchanger Heat exchanger shall be warranted for 20 years of the appliance having declared FOB from Camus Thermal Shock excluded however if caused by appliance operation at large changes exceeding 150 F between the water temperature at intake and appliance temperature or operating at appliance temperatures exceeding 210 F BURNER within FIVE years of the appliance having declared FOB from Camus a burner shall prove upon examination by 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 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 f o b our factory 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 83 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 Owner Name of Dealer Address Address M
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17. Displays burner run time in hours Menu 5 Group Parameter Description Group Selection Selection Prepurge fan Prepurge speed Default rate PUO DF0500 6004 100 0 Prepurge 30 sec Prepurge time time 5 mins Default 15 sec Run Main flame Stabilization establishing Time period Postpurge fan Postpurge speed Default rate DFO500 6004 100 0 Postpurge 30 sec Postpurge time time 5 mins Default 1 min 6 2 5 Burner Control Ignition O gt Sub Menu Menu Group Parameter Description Selection Selection Ignition Ignition Fan rate 6004 20 0 6 2 6 Sensor Configuration Sub Menu Group Menu Pate Parameter Description Selection Group Selection 10K NTC single non Inlet Sensor safety sensor Input Signal 10 sensor dual safety Sensor Outdoor Sensor Standalone Sensor 55 8 11 10 51 18 4 sensor Configurations single non Slave boiler safety Header sensor Master boiler 10K NTC DHW single non Sensor safety DRW Only sensor S6S7 J9 1 3 sensor 5859 19 m Stack single non Sensor safety 4 6 sensor 44 6 3 LEAD LAG SETUP The following components are needed for a Lead Lag setup 1 10kQ System Sensor Turn off all the boilers before beginning the setup process To set
18. Condensing 1 1 9 V 2 La ee A 66 REFER TO NEXT PAGE FOR BURNER GASKET DETAIL SOLA Control Panel 67 14 5214 11 102752 102753 1 Lip Protector 14 5214 30A 14 5214 35 50A 14 5315 Bottom 14 5235A Transition Inner to Outer Jacket OE OO 14 5328 DF 500 HTX DF 750 HTX DF 1100 HTX DF 1200 HTX DF 1500 HT DF 1750 HT gt lt DF 2000 HT gt lt Copper Nickel Heat Exchanger V Baffles Included DF 2500 HT DF 3000 HT gt lt _ _ HEN a DF 3500 HTX DF 4000 HTX DF 4500 HTX DF 5000 HTX DF 4504 HTX X DF 5004 HTX 68 DF 6004 HTX 1111 d _ _ LLL _ ed d 08 1 1 _ _ LL LL IL LL 1 LI 66 5005 13 0027 66 5011 DF 14 0121 DF 14 0120 DF 14 0119 14 0150 14 0315 A 14 0316A 14 0317A Included 109023 Stainless Steel 109025 109026 109028 109029 5 gt Q 2 9 lt Primary Heat Exchanger V Baffles Inlet Adapter Outside Air Intake Literature Pocket gt 9 Fan Air Gas 69 EN 35 50
19. Connect outdoor sensor to System Outdoor contacts Press and ex Press Outdoor Reset Configuration 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 55 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 gt Begin gt 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 DynaFlame Outdoor Reset Configuration 4 Central Heat lt Maximum outdoor temperature Minimum outdoor temperature Low water temperature Minimum boiler water temperature 40 F Outdoor boost maximum off point 1859F Show Line 30 Modulation System Sensor Outdoor Reset Operation Standalone NOTE Outdoor Reset Module W8735S1000 required Boiler operates with variable Connect Remote Operator setpoint determind by Connect System sensor to System Outdoor outdoor reset curve contacts Modulates on system sensor Connect Outdoor Sensor to J3 ECOM connector Heat dem
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21. 4 Compare the temperature rise on the display with the required temperature rise at the required flow rate based on water condition Soft Normal and 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 flow restrictions Check for debris in strai 2 ners 3 Check diameter and equivalent length of the piping between the storage tank and hot water heater 4 Be sure all valves are open between the hot water heater and the storage tank Ensure that all ball valves are fully ported 5 Check the pump to be sure it is running properly and that the pump motor is running in the proper direction 6 sure the pipes between the hot water heater and storage tank are not more than a total of 80 equivalent feet between supply and return 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 7 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 temperatur
22. 6 7 Table of Contents PART 1 1 1 1 2 1 3 1 4 1 5 1 6 1 1 6 2 1 6 3 1 7 1 8 1 9 1 10 1 11 1 12 PART 2 2 1 2511 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 1 12 2 1 13 2 2 2 2 1 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 8 GENERALINEORIMVIATIOT 1 SA 1 INTRODUC E 1 SPECIALAINSTRUCTHONS euin 1 2 A 2 16151 119 PROCES 3 HEAT TRANSBER PROCESS 3 ER 3 CODE ETT 3 WARRANTY 4 REVIOVALOREXISTING APPLIAN GE at ET aes 4 BOILER ROONVOPERATING CONDITION 5 CLEARANCE FROM COMBUSTIBLE MATERIAL 5 INSTALLATION PROCEDURE AND LOCATION OF 2 4404
23. the base load rate specified This method will then be repeated for the next lag boiler if available CASCADE SYSTEM OUTDOOR Press and Press Lead Lag Master Configuration Press Advanced Settings gt Select Error threshold Select Interstage delay DynaFlame Master Configuration Method 1 threshold Detection time 1 30 secs Error threshold 5 F Interstage delay 42 6 2 2 Configuration 6 2 CONFIGURE MENU Sub Menu Figure 28 Configure Menu Group Parameter Description Selection DynaForce Selection Confi Assigns the method for SOLA to control a Central Heating pump Auto Default Auto Pump is Pump Control whenever a call for heat is present ON Pump is constantly powered if contact j Post pump time 1 Sandal uration Menu Select Configuration Group System Identification amp Access Central Heat Configuration Outdoor Reset Configuration DHW Domestic Hot Water Configuration DHW Plate Heat Exchanger Warm Weather Shutdown Configuration Demand Priority Configuration Modulation Configuration Central Heat Pump 6 2 1 System Identification amp Access Menu Group Parameter Description Selection Stand alone demands Use for Lead Lag Master v Default ON Refer to above contact demands Use for Lead Lag Master v
24. train e Run pipe to the Appliance gas inlet e Install a sediment trap in the supply line to the Appliance gas inlet e Apply a moderate amount of good quality pipe compound e 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 7 PSI Table 7 Gas Pressures at Inlet to Appliance PROPANE NATURAL GAS Minimum inches W C _Maximum inchesW C 11 14 3 for 500 750 models 3 5 for 1100 and 1200 models 4 5 for models 1500 6000 Recommended regulator settings is 7 0 w c The gas supply line must be of adequate size to prevent undue pressure drop and must never be smaller than the size of the connection on the appliance Sizing based on Table 7 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 gas specified on the rating plate Heating values of local natural gas are to be between 950 and 1010 Consult factory if heating values are outside this range or if gas with a mixture of constituents 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 closi
25. 1 1 1 OVERVIEW DynaFlame is available in the following body styles e 23 x 27 footprint DynaFlame As non condensing 85 efficient available in models 500 750 1100 1200 As near condensing DFX 88 efficient DFX available in models 501 751 1101 1201 As full condensing 95 efficient available in models 502 752 1102 1202 e 29 1 2 x 34 footprint DynaFlame As non condensing 85 efficient available in models 1500 1750 2000 2500 3000 3500 4000 4500 5000 As near condensing DFX 88 efficient available in models 1501 1751 2001 2501 3001 3501 4001 4501 5001 As full condensing 95 efficient available in modes 1502 1752 2002 2502 3002 3502 4002 4502 5002 e 35 3 4 x 39 1 4 footprint DynaFlame Mega As non condensing 85 efficient available in models 4504 5004 6004 As near condensing DFX 8896 efficient DFX available in models 4514 5014 6014 As full condensing 95 efficient available in models 4524 5024 6024 1 2 INTRODUCTION The DynaFlame is a forced draft appliance utilizing a premix power burner based on 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 DynaFlame provides central heating and or domestic hot water at working pressure up to 160 PSI It is designed for use with a fully pumped and pressurized system The boiler water heater wil
26. 1 in Canada the latest edition of CAN CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment Vent connection is made directly to the flue outlet opening on the back of the unit The connection from the appliance vent to the stack must be made as direct as possible Appliances for outdoor installation are intended to vent using a listed vent cap For indoor installations venting must be in accordance with Part 7 Venting of Equipment of the National Fuel Gas Code ANSI 2223 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 Vent connectors serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under positive pressure Horizontal runs of vent pipe shall be securely supported approximately every 4 feet to prevent sagging and maintain a minimum upward slope of 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 All 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 e Do not us
27. 20 which means that the regulator must be capable of rated gas flow with a maximum running supply pressure of 7 5 W C When required the boiler should be installed with a final stage gas regulator that is to be located as close as possible but no more than 10 feet from the appliance is paramount that maximum lockup pressure be confirmed before any attempt is made to start up the appliance Operating the DynaFlame 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 DF2000 DF6000 Figure 11 Differential Air Pressure Manometer Connection To Fan Discharge Positive Air Negative Air Manometer High Fire Adjustment Metering Valve Firing Valve LE Control Valve Main Manual Valve Fan Inlet Solenoid Valve To Appliance Vent The 1 101 air gas ratio control actuator has embossed markings identifying 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 If a second ma
28. 9 RE INSTALL HEAT EXCHANGERS e Carefully reinstall the heat exchanger if removed from the appliance Check all gaskets and replace if damaged Replace heat exchanger cover Reassemble outer jacket panels Cycle unit and check for proper operation Replace the top cover 10 10 COMBUSTION AIR FAN Combustion air fan should be checked every 6 months Clean internal filter to fan as required when installed in a dust or dirt contaminated location See Combustion Air Fan in the component section for cleaning procedure The motor and bearings on the combustion air fan are sealed and permanently lubricated requiring no addition of oil or lubricants 10 11 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 149 or National Fuel Gas Code The optional outdoor air kit brings combustion air from the outdoors directly to the appliance 10 12 CONTROL CIRCUIT VOLTAGE This appliance uses a transformer to supply a low voltage control circuit The voltage on the secondary side should be 24 to 28VAC when measured with a voltmeter A secondary voltage of 21VAC or less supplied to 24VAC components may cause operational problems A 4A circuit breaker is provided on the secondary side of the transformer The circuit breaker is located on the
29. Confirm that all terminal strips and field connections are identified e Confirm that the SOLA control is set in the proper mode Auto reset limits are fixed all modes of 8 0 8 5 4100 PPM 9 5 10 0 lt 100 operation PPM Condensing DynaFlame e With the firing valve in the off position switch on power p to the boiler The fan motor will accelerate until the 7 5 8 0 lt 100 PPM 9 0 9 5 PPM airflow light energizes If a light remains off past the STAT light the ignition sequence will not proceed e Once lights past the STAT are energized the ignition ES module will try for ignition When the igniter is hot enough the ratio gas valve actuator is energized and if co ignition is accomplished the Burner State changes to 85 9 0 lt 100 PPM 10 0 11 5 lt 100 Run If ignition is not accomplished two more ignition trials will be made 15 seconds apart The control will then proceed to lockout and must be reset by 7 5 8 0 momentarily interrupting power It is normal during initial start up when air is being purged from the piping to require two to three tries before successful ignition Propane e With the boiler running check for flue gas leaks along the inner cabinet joints and around the flue outlet MaxFire 80 90 lt 100 PPM 9 5 11 5 Some minor leakage is acceptable 207 e Repair any major leaks prior
30. 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 exterior to the appliance must be enclosed in approved conduit or approved metal clad cable he pump must run continuously when appliance is being fired e To avoid serious damage DO NOT ENERGIZE the appliance until the system is full of water Ensure that all is removed from the pump housing and piping before beginning initial operation Serious damage may result if the appliance is operated without proper flow e Provide the appliance with proper overload protection 5 2 VARIABLE FREQUENCY DRIVE VFD This appliance uses a Variable Frequency Drive 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 receives a modulating signal 4 20 mA from the local modulating control or a remote source based on water temperature 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 20 up to 100 of capacity corresponding to the same variation in burner input The VFD is driven towards 100 during the pre purge portion of the start up Sequence Once control self checks are completed the VFD is provided with a signal to operate at soft start level
31. Refer to above mute Default Pump Control EM ON Pump is constantly powered Pump Configuration Pump Control Product Type Commercial Hydronic Boiler 9 4 9 gt N Stand alone Pump Output Pump B Specify pump contact i Post pump time 1 Refer to above Default Pump Control ON Pump is constantly powered Pump Output None Specify pump contact Post pump time ile Pump Configuration 5 gt 5 I ea 5 4 gt N 43 6 2 3 Statistics Configuration Sub Menu Menu Um Group Parameter Description Selection Selection Displays the number of cycles the boiler pump has been activated Displays the Burner number of cycles cycles the burner has been activated time Displays the CH pump number of cycles cycles the CH pump has been activated Displays the DHW pump number of cycles cycles the DHW pump has been activated Displays the number of cycles the system pump has been activated Boiler pump cycles 6 2 4 Figure 29 Burner Control Timing and Rates Burner Control Timing and Rates DynaForce Burner Control Timings amp Rates Prepurge 100 0 Prepurge time 15 secs Preignition time 22 secs Run stabilization time 10 sess THIS PARAMETER REQUIRES SAFETY VERIFICATION
32. TRAIN AND CONTROLS Figure 12 Typical Gas Train DF2000 3000 Metering Valve Firing Valve Fan Inlet Solenoid Valve Figure 13 Typical Gas Train DF 3500 6004 Differential High Low Gas Switch Meteri Gas Switch etering Control Valve Regulator Valve o N 72 Dig Firing Valve Main Manual Valve Fan Inlet 16 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 3 11 BURNER Figure 14 Burner This appliance uses a single cylindrical burner installed vertically into the cavity located in the center of the primary heat exchanger There is a unique burner for each one of the sixteen mo
33. 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 DynaFlame Controller if necessar Blank Display Blank display screen Check wire connections from DynaFlame Controller to Screen touchscreen display Lockout 3 46 58 60 97 99 143 Reset SOLA Flame Detection is out of Sync Table 17 Lockout codes 82 Stack limit tripped PVC 149 F CPVC 194 F 250 F 91 96 Outdoor sensor fault 0 0 106 Flame lost if Main Flame Establishing Period MFEP Flame lost early in run Flame lost in run 110 Pilot test flame timeout Flame circuit timeout Flame detected If an internal hardware error is detected contact Camus technical support for troubleshooting procedure Table 18 Alert Hold Codes 68 Setpoint was overridden due to sensorfault 69 Modulation was overridden due to sensorfault 219 Using backup Lead Lag header sensor due to sensor failure Lead lag slave communication timeout off safety circuit is open 281 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 Abnormal Recycle Flame was lost early in Run Abnormal Recycle Flame was lost during Run Interlock Off safety circuit is op
34. a white plume in winter Plume could obstruct a window view e 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 plate 2 1 7 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 eloow 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 8 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 e The vent cap assembly MU
35. and domestic hot water 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 is recommended for accuracy Figure 27 Home Screen DynaFlame Demand OFF Firing rate 0 0 Burner state Initiate 5 secs Setpoint Inlet Outlet DHW 4 20mA Flame 1890F 2029F 779F LOCAL 0 00V Setpoints Pumps ON Modulation OFF Central Heat 150 F 160 F 170 F History Diagnostics Details PARAMETER DESCRIPTION Central Heating DRH Demand Domestic Hot Water DRW Configure Operation Outdoor Outdoor Temperature F if equipped 4 20mA 4 20mA input if equipped BUTTON DESCRIPTION Access DynaFlame parameters CH Parameters DHW Parameters Outdoor Reset Pump Configuration etc Oneration 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 Troubleshooting STAT Pump B DynaFlame Pump Pilot Valve DF3000 5000 Pump B Flow Switch C Open Blocked Flue Switch O Closed LCI Blower High Limit Gas Pressure Switch Air Proving Switch Interlock Pilot Valve O Main Valve Flow Swit
36. 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 e 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 e 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 of water and that all air has limit temperature been properly purged from the system Alert 63 67 79 137 276 281 e Verify that the boiler is
37. closure Remote or enabling the boiler 1 Enabled Bytes Packets locally local When Remote is selected via the SPDT switch the Remote Operator contacts in the junction box must close to deliver an enable signal When Local is selected via the SPDT switch a constant enable signal is present When troubleshooting the DynaFlame it is recommended to switch to Local mode 6 6 COMM PORT 2 ACTIVATION Display Setup Seip gt Select Gateway tab 1 Select Gateway tab 2 Check Enable Modbus gateway 3 Select Gateway on COM2 port Display Setup 1 1 2011 12 06 PM General COM 1 COM 2 This port is 2 Modbus address range to maximum range 1 250 Modbus baud rate 38400 bps 8 data bits No parity bits 1 stop bit Date Time About Save 1 Select COM2 tab 2 Check Enable COM2 port Verify activity on COM2 port Display gt Diagnostics gt Display Diagnostics Version 1 3 Memory 16 3MB out of 38 4MB available Build 73 USB Status NOT FOUND Receive 412262 23358 Transmit 186918 23365 2 Enabled Bytes Packets Rate bps Receive 44475 5555 576 Transmit e 47146 5534 Calibrate Audio Video Screen Display Screen Test Test Snapshot Reset COM 1 Modbus data between 15 and SOLA 2 Modbus data between display and front end Modbus
38. 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 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 CHRM however for rough approximation use Condensation Volume US Gallon Hr Input MBH 1000 x 60 5 0 Many codes will require the acidic condensate to be neutralized before it can be placed in a drain system A neutralizer to control the pH of the liquid discharged to a drain system is provided with every condensing appliance The neutralizer consists of an industrial grade non corrosive plastic reservoir for collection of the condensate The condensate collects in the reservoir where it is in direct contact with the calcium carbonate As the reservoir fills it provides an extended residence time to neutralize the condensate The neutralized condensate exits from the reservoir outlet A P trap must be installed upstream of neutralizer see Figure 2 above 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 the pH is controlled to a range of 5 5 to 6
39. condensing boiler water heaters 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 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 Intake Air Supply Air or Fresh Air Piping 1 PVC Non Foam Core Pipe 2 CPVC Chlorinated Polyvinyl Chloride 3 ABS Acrylonitrile Butadiene Styrene 4 Single wall galvanized stainless steel Single wall vent pipes are to be insulated 5 feet from wall toward the interior of the building to minimize external sweating 2 1 6 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 e To 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
40. 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 and problem corrected Remove the front outer jacket door Remove the front inner jacket door Check V baffles on the exchanger Use detergent water pressure wash to remove soot from heat exchanger and surfaces of the inner chamber When necessary the heat exchanger can be removed by disconnecting all water piping and removing the eight flange mounting bolts at the rear of the appliance The heat exchanger can now be removed from the front of the appliance Reinstall inner jacket door Replace any damaged gaskets to ensure a proper air seal Reinstall the burner and fan assembly Reassemble all gas and water piping Test for gas leaks Reassemble outer jacket panels Keep top cover off Cycle unit and check for proper operation Once proper operation is confirmed replace the top cover 10 8 CONDENSING HEAT RECOVERY MODULE CHRM INSPECTION Inspect the CHRM annually Turn off all power to the appliance Turn off main gas to appliance Remove the top cover front and right side outer panels Remove the CHRM access cover Pressure wash the heat exchanger Use a soft bristle brush to remove any remaining deposits necessary the heat exchanger can be removed by disconnecting all water piping and lifting it out from the side 10
41. equipment room where it is installed must have a supply of fresh air circulating around it during burner operation for proper gas combustion and proper venting 1 7 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 2223 1 and or CAN CGAB149 Installation Code electrical wiring must be done in accordance with the requirements of the authority having jurisdiction or in the absence of such requirements with National Electrical Code ANSI NFPA70 and or the Canadian Electrical Code part 1 CSA C22 1 Where required by the authority having jurisdiction the installation must conform to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers ASME CSD 1 All boilers conform to the latest edition of the ASME Boiler and Pressure Vessel Code Section 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 standa
42. 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 77 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 details can be found on page 78 6 5 LOCAL REMOTE SWITCH Display Setup 1 1 2011 6 18 PM sneralj COM 1 FOM 2 Gateway Screen Saver Home Page Fnable Modbus gateway Gateway 1 port 8 Gateway 2 port Set Date Time About Save The local remote switch mounted inside the control box is designed to deliver an enable signal either relying on an external contact
43. or Protonode For more instructions on interfacing with Modbus Bacnet LonWorks Metasys N2 network http www camus hydronics com Downloads 93 0238 DynaFlame DynaForc DynaMaxHS Advantus Protocol Setup pdf 46 6 7 VARIABLE FREQUENCY DRIVE 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 Settings 000 High Low Voltage Input Voltage 120 220 01 240 460 480 02 0 Preset Speed Skip Bandwidth Speed at Minimum Consult factory test Signal sticker Speed at Maximum Consult factory test Signal sticker Fault History View Only 51 thru 58 Miscellaneous View Only 6 8 FROST PROTECTION The DynaFlame with SOLA control panel is equipped with a heat exchanger frost protection algorithm where if the boiler inlet or outlet temperature sensors drop below 41 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 F 10 C to prevent freezing of the heat exchanger 1 2 4 5 19 20 28 36 38 45 46 50 28 Fixed Boost 47 PART 7 COMPONENTS 7 1 HOT SURFACE IGNITER GLOW BAR The silicon carbide igniter is inserted directly throug
44. 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 Minimum water pipe connections are as follow for DynaFlame for single unit installations The equivalent number of straight feet of pipe for each valve and fitting in the connecting piping must be considered to properly arrive at the total equivalent feet of straight pipe in the field installed piping to the appliance See the piping requirements in Part 12 Installation section of this manual Consult factory if longer piping distances are required for a specific application 4 5 PRIMARY HEAT EXCHANGER This appliance uses copper or stainless finned tubing to maximize the heat transfer process The copper heat exchanger is comprised of vertical tubes rolled directly into two circular bronze headers The stainless heat exchanger is an all welded construction It is comprised of two rows of vertical tubes welded into two circular stainless steel headers Both heat exchangers are designed 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 A factory recommended circulating pump ensures proper water flow during burner operation
45. 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 call for heat but the pump still does not circulate replace the pump Replace the DynaFlame Controller if necessary Inlet sensor Alert 91 Verify sensors are connected Outlet sensor Alert 92 e Verify wiring DHW sensor Alert 93 Measure resistance of sensors 10kO sensors Flue 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 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 e IAS OFF screw 1 4 turn counter clockwise Temperature Overshoot Sensor Not Connected e LCI error e Blocked Flue Switch wire s is are loose e Alert 63 137 276 281 e Blocked Flue Switch is set too tight reduce sensitivity by Blocked Flue e LCI OFF turning screw turn clockwise Switch 55 SYMPTOM FAILURE MODE ANALYSIS Flame detection is present when no Verify supply voltage for proper polarity visible signs of
46. sensor Modulation rate source 52 28 6 4 20mA and burner on off P gain 200 I gain D gain System Sensor Eliae Standalone e Method to enable system Press Configure sensor for Standalone Press Sensor Configuration applications Select 55 18 11 Sensor 10K NTC Single Non Safety The control will proceed into a Lockout 2 condition Press Verify gt Begin gt Yes Press the reset button on the ignition control within the alotted time DynaFlame CASCADE Sensor Configuration S1 28 4 sensor Inlet or Return 10K NTC single non safety 52 28 6 sensor 4 20mA remote 4 20mA 354 28 8 10 sensor Outlet or Supply 10K NTC dual safety S5 28 11 10 NTC single non safety 5657 19 1 3 sensor DHW 10K NTC single non safety Outdoor temperature source UNCONFIGURED DFW Modulation Boiler Inlet Fixed Setpoint Operation Standalone Lead La Electrical Connection s DHW Sensor Stat if required 11 81 8BL cab Boiler operates at a fixed DHW setpoint Modulates on boiler inlet sensor default Heat demand is generated when Remote Operator is closed Programming Instructions 9 Press and Inlet Sensor operation Press DHW Domestic Hot Water Configuration Select Demand Switch Modulation sensor only Select Modulation sensor Inlet Sensor Proceed to Step 12 Demand swit
47. sensor DHW 10K NTC single non safety Outdoor temperature source 55 28 11 sensor uS 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 Master Boiler 8 Press cenae 9 Press Lead Lag Master Configuration 10 Press Advanced Settings gt 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 CASCADE DynaFlame Master Configuration Outdoor Reset gt Maximum outdoor temperature 809 Minimum outdoor temperature Low water temperature Minimum boiler water temperature Outdoor boost maximum off point Outdoor boost step Show Line 17 Press Show Line to confirm reset curve 18 Press the to arrive at Warm Weather Shutdown DynaFlame Master Configuration Warm Weather Shutdown gt Enable Disabled ea Setpoint 609F 02 40 41 Rotation schedule adjustment adi ustment 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 adjustme
48. the vent manufacturer Aluminium tape must meet the provisions of SMACNA AFTS 100 73 Standard e The flue products in a category vent system may be cooled below their dew point and form condensate in the flue Corrosion resistant stainless steel must be used for the venting e When venting category appliance thru unheated spaces insulation should be wrapped around single wall vent pipe to minimize the possibility of flue gas condensation inside the vent unless AL29 4C or equivalent special venting is used The authorities have jurisdiction must approve venting prior to insulating e The flue a Category vent system must have provisions to properly collect and dispose of any condensate that may occur in the venting system 2 1 2 VENTING GUIDELINES FOR CATEGORY AND OR VENTING e The installed length of the positive pressure flue from the appliance to the point of termination outside of the building must not exceed a maximum of 100 8 equivalent feet 30 5 in length Depending on diameter and centreline radius subtract from 7 to 19 feet per 90 elbow using published data Subtract half this value for each 45 elbow The flue may terminate either vertically at the roof top or horizontally on a THRUWALL See the information about the specific vent termination location for recommended location and clearances 2 1 3 CATEGORY II AND CATEGORY IV VENTING A Category or IV venting system for the flue prod
49. the desired water temperature so the appliance will call for heat e Check appliance performance by cycling the system while you observe burner response The burner should ignite promptly Flame pattern should 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 DynaFlame Boilers amp Water Heaters A stable gas supply pressure is extremely important to avoid rough starts with machines like the DynaFlame which use a 1 to 1 ratio control valve for internal gas pressure regulation Camus requires that all DynaFlame models equipped with the SKP25 be supplied with no more than 1 PSI incoming supply pressure This means that lockup pressure must not exceed 1 PSI For models NOT incorporating the SKP25 lockup pressure must not be in excess of 14 w c is paramount that maximum lockup pressure be confirmed before any attempt is made to start up the appliance A suitable lockup regulator with internal or external relief will not exceed running pressure by more than
50. through the CHRM is summarized in Table 10 Figure 19 Typical Condensing System Condensate from the DynaFlame must be treated before being discharged to drain PH level of the condensate is to be checked regularly and the neutralizing medium is to be replaced as required A neutralizing cartridge is available from the factory The condensing DynaFlame must be vented using only special venting AL29 4C stainless steel or equivalent please follow instructions detailed below 20 When supplied with the CHRM the DynaFlame is 95 efficient category Il or IV appliance which requires the use of a special venting system fabricated from AL29 4C or equivalent material Only venting components listed by a nationally recognized testing agency may be used This appliance may be installed with conventional sidewall or vertical venting Conventional vented appliances operate with negative pressure in the vent pipe and require a special vent adapter to increase the flue outlet diameter Sidewall and vertically vented appliances operate with positive pressure in the vent pipe and may be directly connected to the flue outlet without the use of an increaser Consult the vent pipe manufacturers instructions for minimum clearances combustible material for vent components In the absence of instructions the minimum clearance to combustible material is six inches Consult vent pipe manufacturers instructions for proper method of se
51. to the next step 80 90 lt 100 PPM At the factory adjustments were made to achieve proper input and acceptable burner performance at full input and at minimum input e Depending on field conditions the trim valve may require some minor adjustment at full input Refer to Figure 11 Always set the appliance for a CO level in the range of 7 5 to 8 5 at full fire and 7 0 to 7 5 at low for fire for non condensing units For condensing units be set in the range of 8 5 to 9 0 at 9 5 10 5 49 Figure 34 DF 500 1750 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 use T 40 for adjustment B clockwise increases Gas Inlet To adjust the high fire setting DF 500 1750 Use the DynaFlame Control Panel 1 Press DIAGNOSTICS button 2 Press Diagnostic Tests button 3 Move the firing rate slider to maximum firing rate 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 Increase CO2 Decrease CO2 High Fire v gt gas valve 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
52. with flow and pressure drops in Part 4 of DynaFlame I amp O Out of spec Upgrade Pump 59 PART 10 MAINTENANCE 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 complied with To service or adjust this appliance it 1 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 Listed below are items that must be checked to ensure safe reliable operations Verify proper operation after servicing 10 1 EXAMINE THE VENTING SYSTEM Examine the venting system at least once a year Check blockage of primary air flow to the burner or excessive gas input This condition MUST corrected immediately 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 improper 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 inner jacket outer jacket flue pipe con
53. 0 before exiting the system A pH of 7 is neutral 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 requirements Neutralizers may be used in series to raise pH Neutralizer refills are available from Camus 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 combustion air into the burner With sustained operation non combustible contaminants may reduce burner port area reduce burner input or cause non warrantable damage to the burner 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 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 REMO
54. 1 10 BOILER ROOM OPERATING CONDITION e Due to low jacket losses from the appliance temperatures in a typical boiler room may drop significantly supplemental heat is required to maintain ambient temperature at acceptable levels e Cold fresh air intakes must be located to minimize the effects on venting and subsequent condensation in the flue of Category installations When necessary consider the use of insulation or corrosion resistant venting material Camus DynaFlame boilers and water heaters are approved at 85 efficiency which allows the equipment to be vented as a Category appliance using either single wall C vent or double wall B vent Certain conditions in the field however lead to condensation in the vent and render these products unsuitable These conditions include and are not necessarily limited to Low boiler room temperature Low return water temperature Long periods of low fire operation Oversized breeching in common venting applications 5 Proximity to combustion air openings Given the frequency of these conditions occurring in the field we are recommending the use of corrosion resistant stainless steel venting wherever possible 1 11 CLEARANCE FROM COMBUSTIBLE MATERIAL This appliance is suitable for alcove a closet without a door installation with minimum clearances to combustibles as follows Table 1 Clearances from Combustibles Clearances from Combustibl
55. 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 e Verify that 24 VAC 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 DynaFlame 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 Fire Testing for proper combustion Noisy Operation setting y VP 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 all fan bolts are torqued to 20 Ib ft Air in the piping system Purge all air from t
56. 15 F 46 C The appliance piping system of a 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 Figure 16 Chilled Water System PS 2 0 Chiller Boiler 18 Return Water Temperatures Required for DynaFlame Boilers amp Water Heaters Minimum acceptable return water temperatures are determined by the category of the heater This is true for all manufacturers A category machine like the non condensing version of the DynaFlame 85 efficient model can be operated with return water temperatures as low as 115 F 46 C provided that the control algorithm is correct Proper operation requires initial startup of the machine followed by ramp up to high fire This sequence minimizes initial condensation and generates stack temperatures which dry up initial condensation in the vent Category machines like the near condensing version DynaFlame 88 efficient model DFX and the condensing DynaFlame 95 efficient can be operated down to 20 firing rate from initial startup These machines must be operated with a return water temp of at least 130 F 55 C to the primary heat exchanger in order to avoid condensation there For these appliances con
57. 4046 6 AIR SUPPE amp VENTING S oii dudo tit t NOS IG ERU 8 GENERAL VENTING GUIDE M ud uS a Mane M utm Same 8 CATEGORY TAND CATEGOR WIN VEIN THING bod Se e Eae ditio no Eo Or asi Eee ts 8 VENTING GUIDELINES FOR CATEGORY AND OR III 8 CATEGORY ILAND CATEGORY IV VENTING 9 VENTING GUIDELINES FOR CATEGORY AND OR IV 9 APPROVED VENTING MATERIALS eta tM Latis SRI E 9 CLEARANCES 22535329 rave scaredondenteaspaaniediavessetesastess ERN OPE SEE 9 INLET CAP FOR ROOFTOP TERMINA TON re TEES 10 LOCATION OF ROOFTOP AIR INLET AND VENT CAPS heme 10 AIBANEEISDANIPEI x bun 10 MASONARY CHIMNEY IINSULATIONS ccc ea etd tun dM SRM 10 VERTICAL VENTING TERMINA FION 10 COMBINED CONBUSTIONAIR INDE naan EA a 10 DRAIN EE 11 CONVENTIONAL VENTING INDOOR 5 65 11 AIR REQUIRED FOR COMBUSTION AND
58. 73 LO co NUN 70St lt 0006 5 1808 ici 55 White Ceramic Gasket Burner Flange HN xxxi __ xix 1 15100111 EE www www xix _ www __ x _ _ ____ pes _ We ow ___ pom _ __ ow xl ow xxx EE pom Drive O o 9 gt gt gt o gt lt 92 Silicone Gasket Frequency gt Qo 2 LL Burner Flange Red Drive Standard Optional 460V 60 3 Valve Body 51 75 75 oo Differential 56 Pressure NS2 1427 00 Switch Control Box Honeywell 0 10Vdc 62 Tou
59. 9 32 10 sor 30 gt 2 AIR SUPPLY amp VENTING It is extremely important to follow these venting instructions carefully Failure to do 0 can cause severe personal injury death or substantial property damage Foam Core Pipe are not to be used in any of the venting system 2 1 GENERAL VENTING GUIDE Figure 5 Venting Configurations Non Condensing Sidewall Venting and Combustion Air Inlet Outdoor Venting Condensing Standard Venting Sidewall Venting and Combustion Air Inlet Outdoor Venting The DynaFlame is a category 85 efficient unit supplied as a non condensing appliance When supplied with the Condenser Heat Recovery Module CHRM The DynaFlame is 95 efficient and is considered to a category ll appliance 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 2223 1 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 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 Z223
60. Abnormal Recycle ILK off during Main Flame Alert 309 Abnormal Recycle ILK off during Ignition Period 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 mp Gray Flow Switch Check flow switch Check flow switch paddle Green Check blocked flue switch Check vent amp inlet for obstruction Reset high limit Gray Open High Limit Check high limit Green Gray Check inlet gas pressure gt 3 W C Gas Pressure Switch Low gas switch Closed Green Check inlet gas pressure High gas switch 21A wc Gray Air Switch Check air proving Turn set screw CCW 1 2 switch to 1 1 2 turns Green Check J5 2 connector Proceed to SOLA for ignition sequence 24Vac signal 58 Alert 354 Abnormal Recycle Delta T limit This safety was breached as the inlet and outlet temperature difference exceeded 40 F 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
61. CONTROLS eee 16 VENTING OF GAS VALVES AND PRESSURE SWITCHES 17 BURNER E peer 17 17 FREEZE PROTECTION 5 18 WARNING REGARDING CHILLED WATER amp HEATING COIL 5 5 18 INEET AND OUTEET CONNECTIOINS iiti 18 MINIMUM PIPE SIZE REQUIREMENT 5 18 PRIMARY HEAT EXCHANGEB occa dp a 18 LOW WATER TEMPERATURE SYSTEMS e Lese tico 19 INSTANTANEOUS WATER HEATER 1 1 1 19 CONDENSER HEAT RECOVERY MODULE CHRM 20 FLOW and PRESSURE DROP eaan 21 WATER FLOW SWITCH shipped 10656 2202 pi a d er HIP Ide edP 21 LOWS WATER CUTOEF TftEquipDetl s ss es pote lenta ODE bcn pi dudo uh as m __ 22 RELIEF VALVE shipped OOS E imonni beate utu te Ya
62. INSTALLATION OPERATION AND SERVICE MANUAL GAS FIRED COMMERCIAL COPPER TUBE AND STAINLESS STEEL BOILERS Hydronics Ltd NON CONDENSING Models DFH W500 750 1100 1200 1500 1750 2000 2500 3000 3500 4000 4500 4504 5000 5004 6004 NEAR CONDENSING DFX E Models DFH W501 751 1101 1201 1501 1751 2001 2501 3001 3501 4001 4501 4514 5001 5014 6014 Coast CONDENSING MD Models DFH W502 752 1102 1202 1502 1752 2002 2502 3002 CERTIFIED 3502 4002 4502 4524 5002 5024 6024 WARNING If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury or death Do not store or use gasoline or other flammable vapours and liquids in the vicinity of this or any other appliance 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 This booklet contains important information about this appliance Retain for future reference 6226 Netherhart Road Mississauga Ontario L5T 1B7 99 0050 Rev
63. In all cases local codes take precedence e 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 plate e The THRUWALL vent cap MUST be purchased as a kit from the factory to ensure proper operation Locally purchased or fabricated THRUWALL vent caps should not be used 2 4 3 LOCATION OF A THRUWALL AIR INLET CAP he termination point of the THRUWALL air inlet must be installed a minimum of 3 feet above ground level and above normal levels of snow accumulation e The point of termination for the THRUWALL combustion air inlet cap 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 3M radius of the flue outlet 2 4 4 LENGTH OF AIR INLET PIPE The maximum total length of the THRUWALL or vertical roof top combustion air inlet pipe as installed from the appliance to the air inlet cap 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 Do not exceed limits for the combustion air i
64. 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 can be caused by blockage or partial obstruction of air flow to the burner Yellow Flames Yellow flames can be caused 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 internal jacket area where the condensate is collected CHRM is constructed from a special 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
65. RM is mounted in a stainless steel inner jacket chamber at the right side of the appliance facing the appliance The CHRM is constructed from all stainless steel headers and special multiple horizontal stainless tubes This CHRM is designed to maximize heat transfer efficiency by fully condensing flue products and is suitable to resist the low PH of condensate CHRM must be supplied with adequate water flow at all times during operation Do not operate the appliance with the CHRM piped out or isolated The CHRM is mounted in the discharge of the flue products from the primary heat exchanger This allows additional heat to be absorbed from the flue products exhausted from the combustion process If isolation valves are provided on the CHR M the provision of a relief valve at the outlet of the CHRM is recommended This valve is to be sized at minimum for 10 of the input of the appliance and is to be piped to drain When cold water supply with temperatures less than 130 F 54 C passes through the CHRM it will cool the flue products below dew points resulting in the formation of condensation Furthermore the volumetric flow rate of the flue gases will be reduced Never supply water at less than 35 F to the CHRM The appliance CHRM loop may be used in condensing mode for a variety of application including domestic hot water and hydronic space heating Recommended piping arrangement is shown in Figure 18 Maximum recommended flows
66. RTANT Control Circuit This appliance is designed for continuous pump operation when the burner is firing The circulating pump will run continuously when the power switch is in the ON position As an optional feature a pump control system can be provided The pump control option allows the appliance circulating pump to be cycled ON prior to the burner firing and cycled OFF some time after the set point is satisfied operation of the circulating pump is controlled by the SOLA temperature control 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 To select the proper pump it is strongly recommended to consider the following 4 14 2 Need to know the required flow GPM and pressure drop for your appliance see Table 8 or 9 Type of application hydronic heating or Domestic Hot Water DHW Copper or Copper Nickel Heat Exchanger 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 30 F to 35 F 17 C 19 C If necessary use a flow setter valve to achieve the desired temperature rise Stainless Steel Heat Exchanger For hydronic heating and DHW applications with normal water hardness choose a pump which will result in a tempera
67. RUWALL vent cap will be 2 inches 5cm larger than the nominal diameter of the installed vent pipe to the THRUWALL 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 cap provided by Camus Hydronics e Follow all requirements in the General Venting sections for venting flue products to the outdoors 12 2 4 2 LOCATION OF THRUWALL VENT TERMINATION e The vent cap shall terminate at least 3 feet 1M above any forced air inlet within 10 feet 8M horizontally e The vent cap MUST NOT terminate below a 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 feet above a public walkway due to the normal formation of water vapour in the combustion process e The vent system shall terminate at least 3 foot 1M above grade above normal snow levels and at least 7 feet 2 15M above grade when located adjacent to public walkways e The vent terminal shall not be installed closer than 3 feet 1M from an inside corner of an L shaped structure e The vent cap should have a minimum clearance of 4 feet 1 25M horizontally from and in no case above or below unless a 4 foot 1 25 m horizontal distance is maintained from electric meters gas meters regulators and relief equipment
68. ST 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 allow flue products to be drawn back into the appliance This can result 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 21 9 AIR INLET DAMPER In warmer climates during cold weather the use of ducted outdoor air may result in the formation of condensation on the interior panels of the combustion chamber It may be possible for this condensation to accumulate and drip out of the appliance jacket If this is not acceptable it is advisable to install a motorized combustion air damper in the combustion air duct interlocked with the appliance s start circuit 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 CALLFOR HEAT BLUE 5265 TO IGNITION YELLOW 3 24VAC COMMON RED 24VAC CONST POWER 2 1 10 MASONARY CHIMNEY INSULATIONS Always follow local codes when
69. USGPM min min flow flow 0 7 24 0 0 5 2 58 3 71 9 83 9 119 9 143 9 169 8 194 5 218 3 242 5 218 3 242 5 31 8 291 0 24 1 dd Ez ad 4 1 4 4 4 Nh 0 O gt e gt Table 9 Flow and Pressure Drop Given Temperature Rise Stainless Steel Heat Exchanger Heat 20 F 11 1 25 F 14 C Exchanger Temp Rise Temp Rise Water Content USGPM AP USGPM AP min min DF500 2 5 42 0 33 6 0 DF 7 50 63 0 3 0 DF1100 DF1200 102 0 DF1500 125 9 DF175 135 0 0 200 167 9 DF250 209 9 DF300 251 9 DF350 297 2 DF400 340 4 DF450 382 1 DF500 424 4 450 382 1 DF500 424 4 DF600 11 1 909 3 4 0 03 2 81 6 100 7 117 5 134 3 167 9 201 5 237 8 272 3 305 7 339 5 305 7 339 5 407 4 OJO O 1 OJIN 3 N NO O IN 24 No 2012 gt 38 48 CONDENSER HEAT RECOVERY MODULE CHRM The DynaFlame ALL Stainless Steel CH
70. VAL AND CLEANING Access to the burner will require the following steps e Turn off main electrical power to the appliance 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 61 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 vertically out of the heat exchanger cavity A 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 Wash the burner with low pressure water Never wipe or brush the surface of the burner nor use high pressure water or air Check all gaskets and replace as necessary Gaskets affected by heat will not reseal properly and must be replaced 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 When the combu
71. aFlame Control Panel 1 Press DIAGNOSTICS button Press Diagnostic Tests button 3 Move the firing rate slider to 100 0 Press Start Test to operate the boiler at max fire for 5 minutes Figure 35 DF2000 3000 Gas Train Layout Metering Valve Firing Valve Solenoid Valve Figure 36 DF3500 6004 Gas Train Layout Low Gas Switch Differential Gas Switch Control Metering Valve Valve Regulator Valve gt 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 50 adjust the low fire setting DF 2000 6004 Table 16 Inline trim valve setting Figure 37 SKP 55 Gas Valve LP Gas Propane VFD Hz High Fire of Turns of Turns Clockwise Clockwise DF 500 3 1 2 2 1 2 DF 2000 3 3 4 21 2 Consult Factory Test Sticker Adjustment of low fire bias 3 5 8 2 7 8 Connection for air pressure sensing line DF 3000 Connection for the air pressure sensing line Connection for the gas pressure sensing line DF 3500 5 3 4 NE Connection for the gas pressure sensing line DF 4000 5 7 8 Position indicat
72. able slave for built in Lead Lag ma Slave mode Equalize run time 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 15 Select Pump Configuration 16 Press Advanced Options gt gt 17 Press the 4 to arrive at Central Heat Pump or DHW Pump 18 On Options Local burner demand 19 On Options Local Lead Lag Service Active 20 Force On Outlet high limit Slave Boiler e Slave boiler lead lag setup Press aree ang Select System Identification amp Access Verify Modbus address To be in sequential order CASCADE Product type Commercial Hydronic Boiler OS number R7910A1001 R7910A1001sin Software Version 3468 2550 Date code 1114 Application revision 14 Safety revision 10 Model 247 BMS OEM password ompl 1 Modbus address 2 emus MB2 Modbus address 2 Factory data SYSTEM OUTDOOR Select Lead Lag Slave Configuration Select Slave Enabled Enable slave for built in Lead Lag master un uration Slave sequence ode Demand to firing delay Fan rate during off cycle Modbus port MB2 The following steps are performed at the factory and verifying on site will be sufficient Select Pump Configuration Press Advanced Options gt gt to arrive at Central Hea
73. ablishing Period Wait until the display shows the temperatures on screen before 106 pushing the reset button when the ignition module 1 in hard 107 lockout 108 DynaFlame Controller will go into an alert condition for 109 example if the supply sensor is disconnected flow switch or 110 air switch are not made If the fault is not corrected the boiler will stay in an alert condition Once the fault is corrected the boiler will automatically return to normal operating state If an internal hardware error is detected contact Camus technical support for troubleshooting procedure 25 Figure 24 Lockout Condition DynaForce Demand OFF Firing 0 0 Burner state Lockout Setpoint Inlet Outlet Stack DHW 4 20mA Flame 13497 1319F 789F 77 F LOCAL 0 00V Setpoints Pumps ON Modulation OFF Central Heat 150 F 160 F 170 F Lockout 2 Waiting for safety data verification Operation Diagnostics Details To eliminate the lockout error 1 Press the red bar indicating a Lockout condition 2 Press the Lockouts button Configure Figure 25 Lockout History DynaForce Lockout Time Cycle Description 04 12 12 01 28 01 PM 4 2 Waiting for safety data 2 verification 42 2 Clear lockout Alerts gt gt 1 28 23 3 Press Clear Lockout Table 14 Alert Hold Codes 29 30 47 61 62 63 29 Description 123 124 215 Using backup Le
74. ad Lag header sensor due to sensor failure LCI off safety circuit is open Thermal Disc in control box and or upper cabinet Flow Switch LWCO Blocked Flue Switch 283 201 Recycle Flame was not on at end of Ignition period 292 Abnormal Recycle Flame was lost during Main Flame Establishing Period 293 294 Abnormal Recycle Flame was lost during Run Interlock Off safety circuit is open A Air Inlet Damper end switch High Limit Automatic Manual Gas Pressure Switch Low High Low Air Proving Switch 324 Hardware flame bias Flame sensor wire needs to 3 4 bere routed 379 352 355 357 359 460 550 internal hardware fault is detected contact Camus technical support for troubleshooting procedure alarm LED and alarm contacts are closed and will remain closed until the RESET button is pressed 2 NI 310 Q2 26 6 SOLA 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 two 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 26 C
75. aling vent pipe sections and fittings In the absence of instructions make sure that pipe and fittings are clean by swabbing with alcohol Use Dow Corning 736 or 732 RTV Polybar 500 RTV or Sil bond 4500 or 6500 to seal vent pipe Do not use other sealants or adhesives except as expressly permitted by vent manufacturer s instructions Consult vent pipe manufacturer s instructions for vent system assembly Follow vent pipe manufacturer s instructions if those instructions differ from this section Conventional Venting Multiple appliances may be vented into a conventional chimney The chimney must be lined with AL29 4C or equivalent and a barometric damper is to be provided as required for each appliance to control the draft A qualified professional using a proven vent sizing program with input of accurate operating parameters must properly calculate sizing of the venting system In applications where flue gas temperatures are lower than can support a Category II with conventional negative draft it will be determined at the venting design stage that a positive pressure will be developed in the vent It will then be necessary to either provide separate vents as for Category IV to pressurize the boiler room or to provide an extractor at the chimney outlet in order to maintain a negative draft in the chimney and allow common venting The chimney must be protected from down drafts rain and debris by using a listed chimney cap Approval of t
76. and PRESSURE DROP Figure 20 Secondary Heat Exchanger Flow for 15 F rise at high fire 410 WATER FLOW SWITCH shipped loose A water flow switch is shipped loose on copper and copper nickel heat exchangers and is to be installed in the outlet piping on all heating boilers and hot water supply boilers equipped with the copper heat exchanger Stainless steel heat exchanger DynaFlame s are equipped with a flow switch that is mounted and installed in the outlet boiler hot water heater connection The flow switch is mounted and installed on the outlet piping of a stainless steel heat exchanger DynaFlame The flow switch is wired in series with the 24VAC safety control circuit A diagnostic light will be indicated on the control display on a low flow condition 4 11 LOW WATER CUTOFF If Equipped 4 12 RELIEF VALVE shipped loose If this boiler is installed above radiation level a low water cut This appliance is supplied with a relief valve sized in off device must be installed at the time of boiler installation accordance with ASME Boiler and Pressure Vessel Code Some local codes require the installation of a low water cut off Section IV Heating Boilers The relief valve is to be on all systems Electronic low water cut offs are available as a installed in the vertical position and mounted in the hot factory supplied option on all models Low water cut offs water outlet No valve is to be placed between the relie
77. and creates enough water turbulence inside the finned tubes and header that prevents the formation of sediments Temperature rise and erosion prevention in the primary heat exchanger are controlled by the selection of a properly sized circulating pump To ensure proper operation and ensure longevity of this heat exchanger minimum inlet water temperatures of 115 F 46 C MUST BE maintained for non condensing models and 130 F 55 C for near condensing and condensing models When an appliance is connected to an air conditioning system where the same water is used for heating and cooling the chiller must be piped in parallel with the appliance Appropriate flow control valves manual or motorized must be provided to prevent the chilled water from entering the appliance When return water temperatures are below the recommended temperature the flue products passing over the copper finned tubes will be cooled below their dew point resulting in the formation of corrosive condensation on the copper which shorten its life Under these conditions condensation will collect in the base of the inner combustion chamber Follow the piping recommendations given for low water temperature systems if water temperatures expected to be below the recommended value During initial operation of the appliance in a system some condensation will be generated but it will be quickly evaporated once the system return temperature reaches 1
78. 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 2 Turn off electrical power and main manual gas shut off and allow appliance to cool down Remove the vent pipe running to the chimney and check heat exchanger vent and chimney for obstruction and clean as necessary Remove burner from appliance and carefully clean as required Never brush or wipe the knitted metal fiber Surface use a garden hose and wash instead Caution Never use pressure washer to clean the burner Use pressure wash to clean heat exchanger if necessary 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 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 Restore electrical power and gas supply to appliance Place appliance in operation using lighting instructions provided Confirm proper operation of all safety devices Check for gas leaks and proper vent operation Experience has shown that improper installation or system design rather than faulty equipment is the cause of most operating problems
79. and is generated FLAME Press 02925 ang 2971 when Remote Operator is Press Outdoor Reset Configuration closed to arrive at Central Heat Select Enable Enable Select Maximum outdoor temperature WWSD Select Minimum outdoor temperature Outdoor REMOTE Dessen OPERATOR 10 Select Low Water Temperature Min Water Temp 11 Select Outdoor boost maximum off point Design Max Central Heat CASCADE Enable Enabled Maximum outdoor temperature 60 F Minimum outdoor temperature O F Low water temperature 1009F Minimum boiler water temperature Outdoor boost maximum off 1859F Show Line 12 Press Show Line to confirm reset curve 13 Press Sensor Configuration 14 Selet S5 J8 11 sensor 10K NTC single non safety 15 Select Outdoor temperature source EnviraCOM outdoor sensor 16 Place toggle switch to REMOTE for remote enable operation if required DynaFlame Sensor Configuration 51 28 4 sensor Inlet or 10K NTC single non safety 22 28 6 sensor 4 20mA remote 4 20mA 5354 28 8 10 sensor Outlet or Supply 10K NTC dual safety 55 38 11 sensor 10K NTC single non safety 5657 39 1 3 sensor DHW 10K NTC single non safety Outdoor temperature source EnviraCOM outdoor sensor 4 2 0 Operation Standalone Lead Lag Electrical Co
80. aster boiler compares the lead lag temperature with the lead lag set point and will check if 1 An additional boiler is needed Lead lag temp lt Lead lag setpoint Add stage Error threshold 2 Number of boilers remain the same Lead lag temp gt Lead lag setpoint Add stage Error threshold AND Lead lag temp lt Lead lag setpoint Drop stage Error threshold 3 boiler should stop Lead lag temp gt Lead lag setpoint Drop stage Error threshold 4 All boilers off Lead lag temp gt Lead lag setpoint off hysteresis 45 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 Rotation Rotation time is configurable based on equalized run time default or a fixed rotation schedule Interstage Delay The length of time to wait between requesting a slave SOLA to fire and detecting that it has failed to start Default 2 minutes Base Load Rate When a call for heat is initiated the lead boiler runs at the desired base load rate Default 8096 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 at they would both operate at 80 fire rate Slave State Slave Status Manager Stage was getting ready but is not needed Slave is locked out or disabled Slave is in time delay to verify that it is operational befo
81. ater temperature to rise so that the heater cycles on the operator e Check the temperature rise across the heat exchanger For hydronic applications and for domestic hot water a rise exceeding 30 F is not normally recommended Stainless Steel Heat Exchanger 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 210 F for domestic hot water and hydronic heating Copper Copper Nickel Heat Exchanger Allow the When the correct combustion values are achieved replace the screw cap back on to the gas valve 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 230 F for hydronic heating utilizing a copper heat exchanger addition the heaters are equipped with a manual reset high limit set at 210 F for domestic hot water and 250 F for hydronic heating 51 At full input block 50 of the fan inlet opening The display should show LCI not closed it does not slowly turn the adjustment on the normally closed blocked flue switch counter clockwise until the blocked flue indicator 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 Low Air Switch indicator to turn green at a fan speed between 15Hz and 20Hz on the VFD Check th
82. binet protects the unit from weather when fitted with the factory supplied air intake and UL approved 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 THRUWALL VENTING When fitted with the factory supplied vent terminal the DynaFlame 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 4 for vent sizes Appliances may be installed with either horizontal sidewall vent or vertical roof top vent Terminals differ with each application Horizontal lengths over 5 feet must be installed using corrosion resistant stainless steel Use single wall vent and seal al
83. 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 or corrosive water quality is not covered by warranty 112 WATER CONNECTIONS Copper and copper nickel heat exchanger models have FIP inlet and outlet bronze connections Stainless steel heat exchanger models have groove locked inlet and stainless steel connections Pipe size must in accordance with Table 5 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 3 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 supply and return side piping and will be used for isolation only The ball valves must be the sam
84. ceives a call for heat via the remote operator contacts and the Demand parameter reads Central Heating or DHW 7 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 AUN combustion fan If the VFD is not 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 8 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 DynaFlame will target the ignition fan speed 9 DF 500 DF 2500 Direct Ignition The hot surface igniter 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 DF 3000 DF 5000 Proven Pilot The DynaFlame 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 spe
85. ch Flow Switch Low Water Cutoff if equipped Gas Pressure Switch Low gas pressure switch 4 5 w c N O High gas pressure swtich 14 w c N C Air Pressure Switch Blocked flue switch N C Air Proving Switch N O 28 29 DFH Modulation Boller Boiler Fixed Setpoint Operation Standalone Electrical Connection s Programming Instructions Boiler operates at a fixed setpoint Modulates on boiler inlet E sensor default FLAME Heat demand is generated when Remote Operator is 4 20mA closed 0 10Vdc REMOTE OPERATOR Press Conte and 22 Press CH Central Heat Configuration to arrive at Setpoint Select Setpoint source Local Enter desired Setpoint Place toggle switch to REMOTE for remote enable operation if required DynaFlame Central Heat Configuration Setpoint Setpoint source Local Setpoint 1609F Time of day setpoint 1609F Off hysteresis 109 On hysteresis 109F 4 m water temperature 1209F 20 m water temperature 1609F Modulation Boller Outdoor Reset Operation Standalone Electrical Connection s Programming Instructions Boiler operates with variable setpoint determind by outdoor reset curve Modulates on inlet sensor default Heat demand is generated when Remote Operator is closed O FLAME FAILURE 4 20mA 0 10Vdc REMOTE OPERATOR CASCADE
86. ch Modulation sensor only Modulation sensor Inlet sensor DHW Sensor Stat operation Press Sensor Configuration Select 5657 J9 1 3 Sensor 10K NTC Single Non Safety The control will proceed into a Lockout 2 condition Press Verify gt Begin gt Yes Press the reset button on the ignition control within the alotted time DynaFlame Sensor Configuration 61 28 4 sensor Inlet or Return 10K NTC single non safety 52 28 6 sensor 4 20mA remote 4 20mA 6354 28 8 10 sensor Outlet or Supply 10K NTC dual safety 55 28 11 sensor 10K NTC single non safety 5657 9 13 sensor DHW 10K NTC single non safety mmm 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 Press DHW Domestic Hot Water Configuration Select Demand Switch Modulation sensor only 10 Select Modulation sensor DHW S6 switch amp inlet sensor Demand switch DHW 56 switch 11 Enter desired Setpoint 12 Place toggle switch setting to REMOTE for remote operation if required 34 35 1 DynaFlame Domestic Hot Water Configuration Off hysteresis DF H W Lead Lag Operation Master Boiler Master boiler lead lag setup Press Configure
87. chscreen S7999D1016 X Display Not shown exploded view Recommended spare parts 76 PART 13 ELECTRICAL DIAGRAMS aq aha soupi jo amp yaccud s 5 EX OL DE A021 4015 Kousfusur3 zug jell 318 VIBVA vulgzer 4 0021 005 ow 4 59 MOT N31VM 4 H21IMS 0 1 3m4 8 140 SVD HOIH QuVOS 8 9 72051409 0 2 55 LIWI1H9IH 9 1 09 4 4 ae d 4 4 Here 100 TYNSIS HGET amp wawy Sue 801 1041409 Z H LIMS HOLIMS i TWNYALXS MOT13A 2 31IHM M x us 128 S uoivusao 4 monay 9 0 NMOUG eno1 18 2 1 38 140 SLOVINOD 40153
88. cm 30cm 60cm Allow space for the venting in addition to 6 clearance to combustibles 1 12 INSTALLATION PROCEDURE AND LOCATION OF UNIT Install this appliance in a clean dry location with adequate air supply and close to a good vent connection Do not locate this appliance in an area where it will be subject to freezing unless precautions are taken Radiant losses from the DynaFlame are minimal and should not be relied on to keep the appliance room warm If the appliance is installed in cold room and or on a cold floor isolating the appliance from the cold floor and heating the room is recommended The appliance should be located close to a floor drain in an area where leakage from the appliance or connections will not result in damage to the adjacent area or to lower floors in the structure it is recommended that a suitable drain pan adequately drained be installed under the unit Under no circumstances is the manufacturer to held responsible for water damage in connection with this unit or any of its components If the appliance is installed above the level of the building s radiation system a low water cut off device must be installed 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 primary heat exc
89. creens 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 10 2 1 13 DRAIN TEE Figure 7 Drain and Neutralizer Cartridge Installation A Flue Out Flue Outlet Appliance outlet transision Flue In 4 ae Tee 4 Loop From Top to Bottom b Tubing A drain tee MUST be installed in the Condensing vent pipe to collect and dispose of any condensate that may occur in the vent system The drain tee should be installed at the point where 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 THRUWALL Ensure that horizontal portions of the vent are properly sloped to allow condensate to be evacuated at the drain tee Plastic drain tubing sized per vent manufacturers instructions shall be provided as a drain line from the tee The drain tubing must have a trap provided by a 4 10cm diameter circular trap loop in the drain tubing 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 condensate drain must be routed to the condensate neutralization system or a suitable d
90. d appliance inlet temperature after 15 minutes If inlet temperature is less than the recommended temperature slowly close outlet valve until the inlet temperature climbs to slightly above the recommended temperature d If inlet temperature is greater than the recommended temperature but not greater than 140 F no further adjustment is required e Check inlet temperature after 5 minutes and make final adjustments f Remove handle of balancing valve to prevent tempering Note For applications where large volumes of water are heated from ground water temperatures to process temperatures it will be necessary to provide a modulating three way valve or thermostatic valve in lieu of a fixed bypass line 4 7 INSTANTANEOUS WATER HEATER non condensing An instantaneous water heater is designed to deliver hot water without the use of a storage tank It is suitable for applications with variable load such as restaurants condominiums apartments and motels 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 17 Figure 18 Typical Instantaneous Water Heating System Table 8 Flow and Pressure Drop at a Given Temperature Rise Copper Copper Nickel Heat Exchanger Heat 30 F 16 7 35 F 19 4 Exchanger Temp Rise Temp Rise Water USGPM
91. d the control will go to post purge to remove the unburned gas After this a re ignition attempt is started following the same cycle The number of re ignition attempts is limited to 2 after which a lockout occurs 3 The burner can only be on continuously for a period of 24 hours After this the burner is switched off and a restart sequence follows 4 hot surface igniter is de energized at the end of the ignition period to allow for ionisation detection 1 6 1 IGNITION PROCESS 1 Ignition module supplies voltage to the Air Gas Ratio Control Valve 2 Air Gas Ratio Control Valve senses the pressure differential between the Combustion Air Fan outlet and the vent outlet and supplies gas to the orifice and into the Fan inlet to pre mix with air 3 Gas Air mixture is forced into the Burner and out of the Burner Ports under pressure at soft start input rate 4 Hot Surface Igniter lights the Gas Air mixture and the Flame Sensor serves as a means to prove Main Burner Flame by rectification Burner is now firing at soft start input rate Variable Frequency Drive adjusts fan speed based on desired water temperature set point or input signal from remote operator 4 20 mA or 2 10VDC signal must be specified at time of placing order 7 Burner input rate is variable down to approximately 30 of rate or up to 100 of rate as required to satisfy the set point 1 6 2 HEAT TRANSFER PROCESS 1 Burner Input con
92. dels 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 from 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 called metal fiber 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 DynaFlame is a blue flame Infrared operation will occur only if air to gas adjustments is incorrect If infrared operation is noted the cause must be corrected Model 500 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 6000 Proven pilot ignition is standard 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 f
93. densation in the vent is not an issue because they are installed with a special venting system designed to withstand the corrosive action of condensate 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 IMPORTANT Operating this appliance at return water temperatures below the recommended temperature except initial heat up may cause primary heat exchanger to fail and may eventually cause hazardous conditions that may result in personal injury or non warrantable damage to the unit 4 6 LOW WATER TEMPERATURE SYSTEMS All DynaFlame heaters can be configured for low water temperature applications including open water reservoir heating Recirculation loops required for these applications can be set up in the field or they can be supplied pre piped from the factory In applications where the heating system requires supply water temperatures below the recommended temperature a bypass line must be installed upstream of the appliance pump so that outlet water can be re circulated to raise the inlet temp to a minimum of the recommended temperature Balancing valves preferably circuit setter or globe valves are used to adjust flow See Figure 16 19 Figure 17 Typical Low Water Temperature System Non Condensing Adjustment Procedure a Fully open bypass and outlet valves b With appliance running rea
94. e an existing chimney as a raceway if another appliance or fireplace is vented through the chimney 2 1 1 CATEGORY AND CATEGORY VENTING A Category or venting system for the flue products is required on all non condensing models DynaFlame without CHRM A Category venting system operates with a negative pressure in the vent The Category Ill venting system operates with positive pressure generated by the internal combustion air fan e The Category flues from multiple appliances can be combined into a common vent using recommendations from published venting tables e Controls of single or multiple Category appliances may subject appliances to low fire operation for long periods depending on control strategies being used Under this condition the venting does not reach the temperatures required for evaporation of flue gas condensation generated from initial start up To prevent nuisance condensation avoid this operating condition or use corrosion resistant stainless steel venting e The Category Ill flues from multiple appliances CAN NOT be combined into a common vent e The Category lll flue must be a dedicated stack The Category Ill Flue appliance must have all vent joints and seams gas tight Unless a special venting system made from AL29 4C or equivalent is used which has integral seals all vent connector seams and joints must be sealed with pressure sensitive aluminium tape or silicone sealant as specified by
95. e appliance MUST always be installed in a primary secondary 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 can 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 15 PSIG cold Pressure will rise when hot Expansion tank sizing will determine the pressure when the system is hot Do not operate the system at less than 30 PSIG when hot 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 oee Section 4 12 CAUTION A leak in a boiler System will cause the System to intake fresh water constantly which may
96. e diameter as the installed piping flow control is required other means of flow control such as globe valve or flow setter should be used 11 4 INTERMITTENT PUMP OPERATION An intermittent pump operation signal is standard and can be used to operate a separate pump contactor A 1 hp pump delay relay is available as an option When equipped with this option 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 firing 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 5 SUMMARY a Typical Boiler Installations General Plumbing Rules 1 Check all local codes 2 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 combu
97. e 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 Allow the water temperature to rise so that the heater cycles on the operator COMISSIONING APPLIANCE Remove manometers and replace inlet gas pressure test plug Fill out start 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 52 PART 9 TROUE SHOOTING COMPONENT FAILURE MODE 00000000 Two wires interchanged effect on safety The 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 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 wiring for damage and connectio
98. e in condensing mode Damage caused by freezing or dry firing voids warranty This appliance is not to be used for temporary heating of buildings under construction The manufacturer shall NOT 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 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 the common venting system Visually inspect the venting system for proper size and horizontal pitch and determine that there is no blockage restriction leakage corrosion or other deficiency which could cause an unsafe condition Insofar as is practical close all building doors and windows and all doors between the spaces in which the appliances remaining connected to the common venting system are located and other spaces of the building If applicable turn on the clothes dryers and any appliances not connected to the common venting system Turn on any exhaust fans such as range hoods a
99. e outlet of the primary Heat Exchanger Figure 22 Low Water Cut Off Electrical Connections ITT Provisions must be made to prevent cold water below 115 F 46 C entering to the Primary Heat Exchanger BOILER APPLICATION HYDRONIC HEATING In case of boilers Hydronic heating boiler application the return water Supply water may be more than 115 F 46 C therefore there is no need for a recirculation loop and the primary heat exchanger and CHRM can be piped in parallel Since the inlet water temperature to CHRM exceeds 110 F 44 C it will not condense fully and therefore the CHRM will not perform to its maximum efficiency capacity If water colder than 110 F 44 C is available it can be fed to the CHRM WATER HEATER APPLICATION HOT WATER SUPPLY In case of domestic water supply Water Heating the fresh inlet water temperature will be less than 110 F 44 C in this case the CHRM may be fed directly with part of the supply water using a secondary pump 4 14 CIRCULATING PUMP SELECTION The appliance has a low mass finned tube heat exchanger for fast response and high heat absorption Selecting the proper pump will ensure that temperature rise does not exceed recommended maximum that heat HOT NEUTRAL SAFETY SIGNAL IN SAFETY SIGNAL OUT 7 exchanger tubes are not prematurely scaled or eroded 4 14 1 CIRCULATING PUMP OPERATION PRIMARY wired in Series HEAT EXCHANGER as part of Burner MOST IMPO
100. e rise 2 Sustained high water velocity and low temperature rise may result in pitting or erosion of the copper tubes in the heat exchangers This is a non warrantable failure Temperature rise must be properly adjusted to achieve the specified flow rate 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 firing at less than 100 of input rate 65 119 WATER HEATERS Incorrect piping of the cold water supply to the system may result excessive low temperature operation causing condensate formation on the primary heat exchanger and operational problems The cold water supply piping must be installed in the discharge piping from the heater to the storage tank This allows the cold water to be tempered in the storage tank before entering the heater The manufacturer recommends the use of a properly sized thermostatic mixing valve to supply domestic hot water at temperatures less than 140 F 60 C Storing the water at a higher temperature and thermostatically mixing the water will decrease the size of the storage tank and increase the availab
101. each 45 elbow For Category IV site conditions exceeding 100 equivalent feet an engineered vent system approved by the local authority will be required The flue may terminate either vertically at the roof top or horizontally on a THRUWALL See the information about the specific vent termination location for recommended location and clearances 2 1 5 APPROVED VENTING MATERIALS Exhaust Vent for Use for DynaFlame Non condensing Category Installations 1 2 AC type Stainless Steel Single Wall required when operating appliance at low fire for long periods Vent Canada ONLY Equivalent or higher rated than above Exhaust Vent for Use for DynaFlame Non condensing Category Ill Installations 1 Corrosion resistant stainless steel single wall 2 129 4 or equivalent single or double wall Exhaust Vent for Use for DynaFlame Condensing Category Il or IV Installations 1 AL29 4Cor equivalent Single or Double Wall 2 BH type Vent material selection for condensing and near condensing applications Camus condensing and near condensing boilers water heaters are category or IV appliances and the exhaust vent material must be UL ULC listed for use with category IV appliances operating under positive pressure condensing flue gas service Currently manufactured prefabricated UL ULC listed vents of AL29 4C or 316L stainless steel must be used with the Camus condensing and near
102. ed until the stabilization timer is satisfied 10 If the flame signal is not reached the module will stop the ignition sequence after the trial for ignition 11 The fan speed will slowly decrease as the heat request nears the heat demand The modulation rate is controlled via a 4 20mA signal 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 12 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 13 The pump continues to circulate until the post purge time is satisfied 14 The boiler will then go into Standby as it waits for the next heat demand IGNITER MAN FLAME REQUIRED FALURE TO IGNITE OPTIONS U COUNT RECYCLES THEN LOCKOUT COUNT RECYCLES THEN DELAY MM SS RECYCLE NO LIMIT RUN STABLIZATION 08 MAY BE ZERO STANDBY PREPURGE FIXED 45 RUN jm FLAME REQUIRED LOCKOUT OR RECYCLE RECYCLE DUE TO es FALURE TO IGNITE RECYCLEDUETOFLAME CLEAR THE FAILURE TO IGNITE FAL URE N RUN p RETRY COUNTER MAY BE ZERO P REIGN TION Note 1 Ifa signal is detected at the end of the pre purge period an error statement to that effect will appear 2 If at the end of the safety period 6 sec no flame is detecte
103. eel This ensures a long life for the jacket assembly with full integrity 7 6 VENTING TRANSITION All appliances are shipped with a rectangular to round stainless steel adapter Depending on the appliance category an increaser will be required for the proper vent configuration Please refer to Table 5 dimensions and specifications When installing Category or IV appliances care must taken to properly seal all joints and provide slope for drainage of condensate 48 8 FIELD STARTUP full fire and 7 5 to 8 0 at low fire For propane reading will be approximately 1 5 higher Adjustment PROCEDURE at minimum input can be done at the low fire adjustment screw by first removing the brass cap 8 1 CHECKING THE INSTALLATION Inspect the connections for water gas and electricity Confirm that water is being pumped 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 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 plug
104. en 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 single leg 115V necessary for the ignition circuit which is factory mounted The boiler itself is a single point power connection 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 500VA transformer DCO500UH VFD Model Range 1232 DF 500 to DF 1200 0 5hp 234 DF 1500 to DF 2000 1 235 DF 2500 1 5hp 237 DF 3000 to DF 4504 3hp T238 DF 5004 to DF 6004 5hp 460 60Hz 3 Phase 1 The combustion air motor operates on 230 VAC 3 phase 60 Hz This three phase voltage is generated by the variable frequency drive VFD and supplied directly to the fan motor 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
105. en 310 324 Hardware flame bias Flame sensor wire needs to 3 4 bere routed 379 If an internal fault is detected contact Camus technical support for troubleshooting procedure 56 Alert 291 Abnormal Recycle Flame was on at end of ignition Alert 294 Abnormal Recycle Flame was lost during Run Alert 324 Abnormal Recycle Hardware flame bias Alert 377 Abnormal Recycle Hardware flame bias delta This 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 Within harness bundle Check flame Move flame sensor wire away from harness bundle sensor wire Separated from harness bundle Check hot No surface igniter for minimum 3 0A reading Replace igniter Yes Check flame Yes sensor for carbon deposit Clean and or replace No Verify differential air signal is at No 0 35 wc at Adjust VFD parameter 45 speed at minimum signal 115 F return water temperature until 0 35 w c is reached across air differential 57 Hold 63 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
106. er The appliances 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 by a non factory trained technician 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 8 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 inlet pressure tap on the gas line connection at the rear of the appliance 3 7 CHECKING GAS SUPPLY PRESSURE Turn 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 500 3000 Remove the 1 8 hex plug from the
107. es 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 primary heat exchanger NOTE Clearances from combustible construction are noted on the appliance rating plate 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 Maintain minimum specified clearances for adequate operation All installations must allow sufficient space for servicing the vent connections water pipe connections circulating pump bypass piping and other auxiliary equipment as well as the appliance Table 2 Service Clearances Service Clearances Side side Back Fr 60 24 12 12 24 60cm 30cm 30cm 60cm Legion 9 adem dem 160 tus acm a 0 oem eoem eoem _ oon oem O adem oem __ 1 uo B 60cm 24 12 12 24 60cm 30cm 30cm 60cm 24 12 12 24 en en oem ee Tum 09 8 60cm EX 60cm 30cm 30cm 60cm oon soom oem Bn ER EAR EA 30cm 30cm 60cm 12 12 24 102cm 30cm 30cm 60cm S04 tem oem 60cm 30cm 30cm 60cm 84cm 30
108. f should be tested every six months The normally open switch valve and the appliance To prevent water damage the contact of the low water cutoff is to be wired in series with the discharge from the relief valve shall be piped to a suitable flow switch A diagnostic light will be indicated on the control floor drain for disposal when relief occurs No reducing display on a low flow condition couplings or other restrictions shall be installed in the Caution remove jumper when connecting to 24 VAC circuit discharge line The discharge line shall allow complete drainage of the valve and line Relief valves should be manually operated at least once a year CAUTION Avoid contact with hot discharge water 4 13 CONDENSING HEAT RECOVERY MODULE PIPING CONFIGURATIONS Caution If isolation valves are provided on the CHRM the provision of a relief valve at the outlet of the secondary is recommended This valve is to be sized at minimum for 10 of the input of the appliance and is to be piped to drain in a manner similar to the appliance relief valve Figure 21 Low Water Cut Off Electrical Connections Watts WARNING Be sure to remove the jumper between H and Pl Connection detail for placing L W C O in 24V circuit in series with flow switch 247 FLOW SWITCH 4 13 1 CHRM IN SERIES WITH PRIMARY HEAT EXCHANGER INTEGRATED LOOP e SWITCH The supply water Cold water is pre heated by CHRM and fed into th
109. for initial burner ignition After main burner ignition 15 established the modulating signal provided will use the VFD to vary the fan speed based VFD to vary the 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 A normally open differential air pressure switch is used to prove operation of the combustion air fan The pressure switch sensing points are installed at the fan outlet as the air moves into the inlet of the burner One point measures total pressure and is connected to a pitot tube facing the flow from the fan paddle 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 no Air Flow when the differential pressure switch detects a sustained low air condition This condition could be caused by a number of factors including e 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 t
110. front control panel A tripped circuit breaker indicates a short in the 24VAC controls and must be corrected 10 13 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 14 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 e 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 62 e 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 the appliance using an indirect coil can be provided by using hydronic system antifreeze Follow the manufacturer s instructions DO NOT use undiluted or automotive type antifreeze Shut down and draining If for any reason the unit
111. gas pressure test port located on the inlet gas supply connection at the rear of the appliance Install a fiting 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 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 e Observe the gas supply pressure as the burner fires at 10096 of rated input e Ensure inlet pressure is within specified range Minimum and maximum gas supply pressures are specified in Gas Supply section of this manual f gas pressure is out of range contact the gas utility gas supplier qualified installer or service agency to determine necessary steps to provide proper gas pressure to the control e 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
112. h 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 Properly prepared igniter will have a bead of silicone sealing the end mounting bracket to the ceramic shaft Figure 31 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 15 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 inspection of the burner and heat exchanger Figure 32 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 8Vdc mus
113. hanger Non condensing units do not require access through both sides and could be placed adjacent to each other with zero clearance For condensing units a minimum clearance of 12 must be provided on the right side for access to the Condensing Heat Recovery Module The appliance must be installed so that the ignition system components protected from water dripping spraying etc during appliance operation and service circulator replacement control replacement etc Appliances located in a residential garage and in adjacent spaces that open to the garage and are not part of the living space of a dwelling unit must be installed so that all burners and burner ignition devices have a minimum clearance of not less than 18 46cm above the floor The appliance must be located or protected so that it is not subject to physical damage by a moving vehicle DO NOT install this appliance in any location where gasoline or flammable vapors are likely to be present Appliance must be installed on a level floor Maintain required clearances from combustible surfaces The appliance designed for indoor installation Indoor Models must be installed indoors where it is protected from exposure to wind rain and weather The appliance designed for outdoor installation Outdoor Models must be installed outdoors For outdoor installations always consider the use of a shelter such as a garden shed in lieu of direct exposure of the appliance to t
114. he installation will be at the discretion of authorities having jurisdiction Sidewall and Vertical Venting The maximum vent length is 100 equivalent feet Vent pipe may be run through a vertical or horizontal chase provided that minimum clearances to combustible materials are maintained The vent should terminate a minimum 12 inches above grade plus normally expected snow accumulation or 7 feet above grade if located adjacent to public walkways Do not install over public walkway where local experience indicates condensation or vapour from the boiler creates a nuisance or hazard Minimum 3 feet above any forced air inlet located within 10 feet of vent termination Minimum 4 feet below 4 feet horizontally or above any door window or gravity air inlet Minimum 4 feet horizontally from electric meters gas meters regulators and relief valves Use appropriately designed thimbles when passing through combustible walls or roofs Install fire stops where vent passes through floors ceilings or framed walls The fire stop must close the opening between the vent pipe and the structure Locate vent terminal above 21 combustion air intake terminal if used and no closer than 2 feet vertically or horizontally Vertical venting requires flashing and a storm collar to prevent moisture from entering the structure Vertical vent termination must be at least 2 feet plus the expected snow accumulation above the roof penetration height 4 9 CHRM FLOW
115. he 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 Box i Gas Water Connections Secondary Water Connections 9 1 LL Ier Side View Back View Side View Back View Front View Condensing Condensing Non Condensing Non Condensing Near Condensing Near Condensing Table 3 Appliance Dimensions and Specifications in Water Conn Water Air Inlet Flue Height Air Inlet Gas Conn Sec Grooved Conn D E E Dia W Optional ee dus 2339 13 so po pou pe ee ose ome oe po 2 poss sx s oe 1 3 pes pe puis pas Width A Depth B Height C Cs rra uere s pe parse sss mur sss ese s 378 178 i2 7992 sess 378 178 2
116. he 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 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 f 120VAC is present during a call for heat but the pump still does not circulate replace the pump Replace the main DynaFlame Controller if necessary Auto Reset High Limit Trips 54 SYMPTOM FAILURE MODE ANALYSIS Manual Reset Safety High Limit e 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 e Verify that the boiler is piped properly ILK OFF Verify that 120 VAC 15 being supplied to the boiler pump a call for heat If voltage cannot be detected check wiring e Verify that the pump is circulating when 120 VAC is supplied If so pump impeller may
117. ing into a common properly designed chimney single appliance installations with dedicated chimney if drafts are excessive above negative 0 15 Inches W C we recommend a single acting barometric damper A 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 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 Approval of the installation will be at the discretion of authorities having jurisdiction IN GENERAL The operation of exhaust fans compressors air handling units etc can rob air from the room creating a negative pressure condition leading to reversal of the natural draft action of the venting system Under these circumstances an engineered air supply is necessary If the appliance is to be installed near a corrosive or potentially corrosive air supply the appliance must be isolated from it and outside air should be supplied as per code Potentially corrosive atmospheres will result fr
118. ir 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 Figure 8 DF500 1750 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 Low fire air gas ratio adjustment Vo use T 40 for adjustment FP e clockwise increases CO a Gas 14 Actuator Will Not Powered if P O C Switch is Open Figure 9 DF2000 60041 1 Air Gas Ratio Control Valve Low Fire Adjustment Screw Located Under Cap Turning Clockwise Increases Gas Flow Actuator Position View Port Actuator Flange Junction Box for Power and Proof of Closure Switch Valve Flange Figure 10 DR3500 5000 SKP25 Regulating Gas Valve Actuator amp SSOV 3 5 DIFFERENTIAL AIR PRESSURE DF2000 6004 15 The DynaFlame 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 The differential air pressure measurement is made between the high and low pressure taps across the fan discharge and the flue vent All differential air pressures are noted at f
119. is to be shut off in a space where danger of freezing exists the following precautionary measures must be taken o Shut off gas supply o Shut off water supply o Shut off electrical supply o Drain the main exchanger and the secondary exchanger if supplied completely o Ensure that the pump and connecting piping are fully drained 10 15 FREEZE PROTECTION FOR A HEATING BOILER SYSTEM Optional e Use only properly diluted inhibited glycol antifreeze designed for hydronic systems Follow the instructions antifreeze manufacturer Quantity of antifreeze required is based on total system volume including expansion tank volume e 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 e Local codes may require a back flow preventer or actual disconnect from city water supply when antifreeze is added to the system e 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 63 PART 11 INSTALLATIONS 11 1 HEATING BOILER INSTALLATIONS Th
120. itted down to 20 of input 1 GENERAL INFORMATION Figure 1 DynaFlame Non Condensing DynaFlame Condensing In this series most of the sensible heat value is being transferred into the water The unused portion of the sensible heat and most of the latent heat is absorbed by the Condenser Heat Recovery Module CHRM Figure 2 DynaFlame Condensing 1 3 SPECIAL INSTRUCTIONS TO OWNER This manual supplies information for installation operation and servicing of the appliance It is strongly recommended that this manual be reviewed completely before proceeding with an installation CAUTION is important that all gas appliances are installed by a competent person It is in your own interest and that of safety to ensure that all local codes and all the following NOTES and WARNINGS is complied with To install service or adjust this appliance it is imperative that a competent serviceman that is qualified by Camus amp Hydronics utilize a combustion analyzer with and draft gauge to set the appliance according to Camus amp Hydronics recommendation prior to commissioning NOTE NOTE RETAIN THIS MANUAL FOR FUTURE REFERENCE 1 4 CHECKING EQUIPMENT Check for signs of shipping damage upon receiving equipment Pay particular attention to parts accompanying the boiler which may show signs of being hit or otherwise being mishandled Verify total number of pieces shown on packing sli
121. l automatically modulate to provide heat outputs between 100 to approximately 35 of rated input condensing models and down to 20 on near condensing DFX and condensing models The DynaFlame works on the principle of differential pressure The 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 DynaFlame Non Condensing In this series most of the sensible heat value is being transferred into the water The unused portion of the sensible heat and all the latent heat is released through the exhaust vent The overall efficiency of the DynaFlame is being improved by incorporating preheat of intake combustion air which consequently maintains the outer panels cool and thus reduces jacket loss DynaFlame Near Condensing In this series most of the sensible heat value is being transferred into the water The unused portion of the sensible heat is too small to maintain flue products in a gaseous state Therefore condensation is formed in the vent The defining characteristics of the DFX are reduced vent sizes at reduced equivalent vent lengths of 50 ft and continuous modulation perm
122. l 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 specified by the vent manufacturer Aluminium tape must meet the provisions of SMACNA AFTS 100 73 Standard When venting through unheated spaces use venting material which will minimize flue gas condensation inside the vent Provisions must be made for collecting and disposing of any condensation which may occur The authorities having jurisdiction must approve venting Periodically check to ensure that the vent terminal is unobstructed This venting system uses appliance s internal combustion air fan to force the flue products out horizontally Vent cap and venting must be listed type Category IV vent materials The DynaFlame fan generates a positive pressure in the flue Combustion air is drawn from the equipment room The THRUWALL termination caps are available from the factory as a kit Refer to local codes for proper installation and location of vent terminals 241 THRUWALL VENT 14 0090 THRUWALL INTAKE AIR CAP 14 0101 e The THRUWALL vent cap kit includes the wall penetration assembly and the discharge screen assembly e The opening through the wall for installation of the THRUWALL vent cap must provide an air space clearance of 1 inch 2 5cm around the flue pipe The diameter of the opening for installation of the TH
123. lame 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 17 PART 4 WATER CONNECTION 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 DynaFlame The relief valve must be mounted in a vertical position and piped to the floor in a manner acceptable to the enforcing authority Minimum operating system pressure should not drop below 30 PSIG Be sure to provide unions and gate valves at inlet and outlet to the appliance so that it can be easily isolated for service The provision of a flow setter valve at the appliance outlet will facilitate setting of the proper flow at 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 erosion or 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
124. le codes In the absence of such codes provide combustion air opening with a minimum free area of one square 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 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 DynaFlame windproof ca
125. le quantity of mixed hot water Caution Adequate care MUST be taken to prevent potential scald injury when storing water at 140 F 60 C and hotter 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 Awater 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 e 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 F 60 C and hotter 2 WARNNG 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 No holes Non Condensing Back Cover Plate Condensing Back Cover Plate 2 N a 9 Pm N 7 i Ji ee NU N 24 2 Exchanger
126. med rate before the appliance shuts down 11 6 DOMESTIC HOT WATER HEATER 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 11 7 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 done 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 Excessive pitting or erosion in the tube is caused by high water flow and too much velocity through the tubes 64 Care should be taken to maintain required water velocity based on water condition as follows 11 8 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 water heater or hot water supply boiler in the off cycle the Return Inlet temperature and Supply Outlet temperature readings on the display should read approximately the same temperatures 3 the hot water heater on and allow time for the temperature to stabilize Check the temperature rise when the burner is firing at 10096 of rated input
127. n errors e DF 500 2500 Verify igniter is glowing DF 3000 6000 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 Verify 24 VAC DF 500 1200 and 115VAC DF 1400 6000 is being supplied to the gas valve relay from the DynaFlame Controller during ignition Check wiring from DynaFlame Controller and Gas Valve Relay If a signal cannot be detected the DynaFlame Controller needs to be replaced If 24 VAC is present check the outlet of the valve to ensure 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 turn clockwise Inspect the burner Refer to Burner Maintenance in section 10 5 Replace the DynaFlame Controller if necessary Flame Failure 53 FAILURE MODE ANALYSIS e The DynaFlame 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 sensor and associated wiring Replace if Lockout 106 107 108
128. n 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 4 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 Verify operation of the Fuji and Diagnostic Display 3 Program the adjustable points 4 Turn the switch to the ON position to start boiler operation 5 Push the resets for low water level high water temperature and flame failure 6 Install manometer on the gas supply to the boiler and verify minimum gas supply pressure as the burner fires at 10096 of rated input 7 Verify operation of safeties as necessary low water cut off high limit gas pressure etc Boiler Operation 1 Appliance should begin the start up process for the sequence of operation 2 boiler will fire down to 20 for condensing and near condensing appliances and 35 for non condensing appliances on initial start up and adjust input as required to meet system demand 3 Ensure that inlet water temperature does not fall below 115 F 46 C for non condensing and 130 F 55 C for condensing and near condensing 4 Based on system demand the appliance will modulate accordingly 5 system demand is satisfied the burner will cycle off and the combustion air fan will decelerate at a pre program
129. nd 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 spilage 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 Test for spillage at the draft control device relief opening after 5 minutes of main burner operation After it has been determined that each appliance remaining connected to the 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 and or CAN CGA B149 Installation Codes When resizing any portion of the common venting system the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code ANSI Z223 1 and CAN CGA B149 Installation Codes Heat exchanger surfaces and vent piping should be checked every six months for deterioration and carbon deposits Remove all soot or other obstructions from the chimney
130. nections burner or in the areas between the fins on the copper heat exchanger indicates a need for cleaning The following cleaning procedure must only be performed by a qualified serviceman or installer Proper service is required to maintain safe operation Properly installed and adjusted units seldom need flue cleaning more often in the first year to determine inspection interval Check all joints and pipe connections for tightness panels must be replaced with new gaskets sealant on re corrosion or deterioration Flush the condensate drain hose assembly Gasket and sealant kits are available from the with water to clean Clean screens in the venting air intake factory All gaskets sealant on disassembled components or jacket 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 Evenly tighten the nuts to 20 ft lbs Carefully examine the area adjacent to the fan flange for signs of overheating which are an indication that gaskets are in need of replacement Figure 38 Normal Burner Flame Profile short dense and blue e
131. nents 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 HEAT EXCHANGER Within 10 years of the appliance having declared FOB from Camus heat exchanger shall prove upon examination by Camus to be defective in material or workmanship Camus will exchange or repair such part or portion based on the following pro rated limited warranty Percentage shown is the amount that would be covered by Camus Hydronics Limited if deemed warranty based on the number of years the appliance has been in service STEEL NI HTX 7 The exchanged or repaired heat exchanger will carry the balance remaining of the 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 Copper Cu Ni Heat Exchanger 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 intake and appliance temperature or operating at appliance temperatures exceeding 230 F
132. ng 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 500 to 1750 utilize a 1 1 ratio dual seat negative pressure gas valve Models 2000 3000 utilize a 1 1 air gas ratio control valve and a safety solenoid valve Models 3500 6000 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 The air gas ratio is preset at the factory and adjustment is not usually required if gas supply pressure is maintained within the specified range There are no serviceable parts on the dual seat negative pressure a
133. nlet piping lengths 13 PART 3 GAS CONNECTION Verify that the appliance is supplied with the type 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 e A trap drip leg MUST be provided in the inlet gas connection to the appliance e Optional gas controls may require routing of bleeds and vents to the atmosphere outside the building when required by local codes 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 6 for sizing the vent line Table 5 Gas Pressure Relief Valve Vent Manifold Sizing Chart Size of Combined Vent Line Sch 40 _ Pressure Relief Valve Size 3 4 Pressure Relief Valve Size 1 Qty of Pressure Relief Valves being combined NPT to 50 fee
134. nnection s Programming Instructions Boiler operates with variable setpoint determined by 4 20mA incoming signal Modulates on boiler inlet sensor default Heat demand is generated when Remote Operator is closed 4 20 or 0 10Vdc signal is present FLAME FAILURE O REMOTE OPERATOR Press and Press CH Central Heat Configuration to arrive at Setpoint Select Setpoint Source S2 J8 6 4 20mA Select 4mA water temperature Select 20mA water temperature Place toggle switch to REMOTE for remote operation if required DynaFlame Central Heat Configura Setpoint Setpoint source Setpoint Time of day setpoint Off hysteresis On hysteresis 4 mA water temperature 20 mA water temperature 52 28 6 4 20 160 F 160 F 10 F 10 F 32 4 20 0 Rate Operation Lead Lag Boiler operates with variable Press _ setpoint determined by 4 Press Lead Lag Master Configuration 20mA incoming signal Press Advanced Settings gt Modulates on header sensor FLAME to arrive at Central Heat Heat demand is generated FAILURE Select Modulation rate source S2 J8 6 4 20mA and burner on off when Remote Operator is Place toggle switch to REMOTE for remote operation if required closed and 4 20mA or 0 al ee du NN Central Heat Configuration 10Vdc signal is present gt Modulation REMOTE Modulation
135. nometer is available it can 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 Variable Frequency Drive 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 Readings are to correspond to the values shown on the test sticker 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 test sticker The opposite will occur with tall stacks where drafts exceed negative 0 15 W C the appliance will not light off and the blue main flame light is coming on but not staying on then it will be necessary to adjust the low fire as explained in the detailed start up procedure 3 9 GAS
136. not excessive See Table 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 Do not allow the appliance to run with inlet water temperature below 115 F 46 C for non condensing and 130 F 55 C for near condensing condensing appliances DynaFlame must be installed so that the gas ignition system components are protected from water dripping spraying rain etc during appliance operation and service circulator replacement control replacement etc Figure 15 Typical Space Heating System Appliance installations not recommended outdoors in areas where danger of freezing exists unless precautions are taken Maintaining a mixture of 50 water and 50 propylene glycol is the preferred method of freeze protection in hydronic systems This mixture will protect the appliance to approximately 35 F 37 C To maintain the same temperature rise across the appliance increase the GPM flow by 15 and the head loss by 20 The following example demonstrates the
137. nt adi stmt 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 Modulation of boilers will only occur after all boilers in the Lead Lag system are firing up to the specified base load rate 80 CASCADE SYSTEM OUTDOOR CASCADE SYSTEM OUTDOOR Press and Press Lead Lag Master Configuration Press Advanced Settings gt Press the Select Lead selection method Sequence order Select Lag selection method Sequence order Select Lead rotation time user defined DynaFlame Master Confi Algorithms Press and Press Lead Lag Master Configuration Press Advanced Settings gt Press the to arrive at Rate Allocation Select Base load common user defined B DynaFlame Lead Lag Master Configuration Rate Allocation Base load common 80 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 80 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
138. odel No Serial No Date of Date of Initial Installation Operation 6226 Netherhart Road Mississauga Ontario L5T 187 CANADA 84 CAMUS Hydronics is a manufacturer of replacement parts for most copper finned water heaters and heating boilers as well asa supplier of specialty HVAC products Our service line is open 24 hours 7 days a week CAMUS CERTIFIED The CAMUS CERTIFIED Seal assures you that Reliability Efficiency amp serviceability are built into every single For more information on our innovative products from CAMUS Hydronics Limited call 905 696 7800 today CAMUS HYDRONICS LTD 6226 Netherhart Road Mississauga Ontario 157 187 TEL 905 696 7800 FAX 905 696 8801
139. om exposure to permanent wave solution chlorinated waxes and cleaners chlorine water softening chemicals carbon tetrachloride halogen based refrigerants Freon cleaning solvents hydrochloric acid cements and glues masonry washing materials antistatic fabric softeners dry cleaning solvents degreasing liquids printing inks paint removers etc The equipment room MUST be provided with properly sized openings to assure adequate combustion air and proper ventilation when the unit is installed with a proper venting system 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 applicab
140. ontrol Panel Front The SOLA icons will appear in one of four colours indicating the boiler status Normal Operation Red Lockout Condition Holding Mode The Boiler Temperature Controller for this appliance is the Honeywell SOLA It initiates the local call for heat and sets the target return appliance inlet water temperature This controller offers a range of operation modes which provides set point as well as modulating control It provides the following Readings of inlet and outlet water temperatures as well flame signal e Operation as an auto reset limit e Operation as a control for inlet water temperature outlet temperature system temperature e 40 F AT heat exchanger protection algorithm e Available tank mounted sensor used in conjunction with inlet sensor e Adjustable target temp inter stage differential on delay between stages minimum on time per stage minimum off time per stage e 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 27 Levels of Access Two levels of access to simplify the use of the boiler User Access to general boiler and display settings and adjustments to the central heating
141. or DF 4500 7 3 4 Use the DynaFlame Control Panel DF 5000 73 4 Press DIAGNOSTICS button 6000 7 3 4 Press Diagnostic Tests button 5 Step 1 Fully open inline metering valve counter 3 Move the firing rate slider to 20 0 clockwise Step 2 Close inline metering valve to preset level 4 Press Start Test to operate the boiler at min fire 9 P for 5 minutes Step 3 Above table shows initial settings only fine tuning will be required with the use of an analyzer Increase CO2 Decrease CO2 e This boiler is designed for low fire soft start At the start 5 Cy of trial for ignition the fan will decelerate to minimum fire and will light off at low fire before ramping up Low Fire Clockwise Counter towards full input through the 4 20mA the Adjustment Clock Wise 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 Normally the differential gas pressure will be identical to the differential air pressure Actual differential pressure may vary from the numbers To reset the trim valve to factory settings refer to the chart on the test label due to the field conditions and sample below and the step by step instructions that follow variations Always make adjustments to meet the recommended levels Adjust high fire first followed by low fire adjustment e Allow the w
142. ot repairable Any Table 13 Lockout codes modification or repairs will invalidate the warranty and may e cription create hazardous conditions that result in property damage personal injury fire explosion and or toxic gases A faulty hot surface igniter or ignition module MUST BE replaced with a aiting for safety data verification new factory approved unit only A factory approved igniter ignition control module and flame sensor for this specific unit is 47 available from your local distributor 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 79 5 7 2 IGNITION MODULE LOCKOUT FUNCTIONS 81 The ignition module may lockout in either hard lockout Stack limit tripped 149 F CPVC 194 condition requiring pushing of the reset button to recycle the 250 control for a CSD1 requirement or a soft lockout condition 91 which be reset automatically once the error clears 92 typical hard lockout fault can occur with single a trial for ignition 93 CSD1 module Pushing the reset button on the ignition control 94 is the only way to reset an ignition module that is in hard 95 lockout condition The reset button is located on the ignition module Turning the main power OFF and then ON or 105 cycling the thermostat will not reset a hard lockout condition Flame lost if Main Flame Est
143. otal pressure side air line 5 4 BLOCKED FLUE SWITCH A normally closed block flue switch is used to shut down the appliance under the following conditions 1 Airintake 50 blocked 2 Ventoutlet 8096 blocked 5 5 HIGH and LOW GAS PRESSURE SWITCHES Optional A manual reset differential gas pressure switch is standard on models 3000 5000 and available as an option on models 500 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 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
144. p tese Dem t Peut tad 22 CONDENSING HEAT RECOVERY MODULE PIPING CONFIGURATIONS eene 22 CHRM IN SERIES WITH PRIMARY HEAT EXCHANGER INTEGRATED 22 CIRCULATING PUMP SELECTION 22 CIRCULATING PUMP OPERATION PRIMARY HEAT 22 CIRCULATING PUMP SELECTION 23 ELECTRICAL 2 meae Bcc CD 23 ELECTRICAE CONECTIONS ci 23 VARIABLE FREQUENCY DRIVE MED 24 DIFFRENTIAL AIR PRESSURE SWLITGELD 5 24 BEO CKED FLUE SWITCH 24 HIGH LOW GAS PRESSURE 5 24 IVI ______ ___ _ 24 DY NAFEAIVIE eR 25 SERVICE PART 25 IGNITION MODULE LOCKOUT FUNCTIONS 25 DYNAFLAME CONTROLLER S 25 ERROR Hm M U 25 SOIT ONTBROEPANELBs d dett es Samet tere A 27 APPLIANCE TEMPERATURE CONTROLLER we e EL
145. p with those actually received In case there is damage or a shortage immediately notify carrier Figure 3 Checking the DynaFlame Do not attempt to pry any panel off To begin disassembly you must first remove the two 14 bolts 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 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 5 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 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 are to be wired in series with the normally open contacts of the flow switch Locate the probe type LWCO in the piping above the boiler inlet outlet connection The low water cutoff and flow switch are shipped loose In all cases check with local codes 6 DynaFlame controller re
146. 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 10 feet 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 amp now recommends to increase the head loss by 20 e he requirement for the heat exchanger with water glycol mixture will now be 115 gpm 15 6 feet ie 1 2 x 13ft 15 6 ft 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 WARNING REGARDING CHILLED WATER amp HEATING COIL SYSTEMS 4 3 INLET AND OUTLET CONNECTIONS Al water connections meet American National Standard Pipe Threads NPT e For ease of service install unions on inlet and
147. rain for disposal of condensate that may occur in the vent system Ensure that the drain from the condensate tee is not exposed to freezing temperature 2 2 CONVENTIONAL VENTING INDOOR INSTALLATIONS NON CONDENSING The DynaFlame non condensing is a category appliance and is approved for venting into a common standard chimney On single appliance installations with dedicated chimney if drafts are excessive above negative 0 15 Inches W C install a single acting barometric damper directly past the appliance s flue outlet A minimum draft of 0 05 Inches W C is required for operation This damper will control excessive draft amp minimize standby losses e Multiple appliances may be vented into a conventional chimney The chimney must be lined And a single acting barometric damper must be provided for each appliance 11 Vent diameters are to be increased over and above those recommended in Table 5 The chimney must be protected from down drafts rain and debris by using a listed chimney cap If the appliance is located in a room maintained at low temperature and is being run for extended periods of time at low fire it is likely that condensation will be formed in the vent Consideration must be given to heating the room or providing a special venting system similar to that used for condensing appliance application CONDENSING The DynaFlame condensing version is a category II appliance and is approved for vent
148. rds for gas fired units ANSI Z21 13 1 8 1 9 WARRANTY Factory warranty shipped with unit does not 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 copper coils or tubes is not a fault of the appliance and is not covered by warranty Consult the factory for recommendations for use in hard water areas See Water Treatment and Water Chemistry Excessive pitting and erosion on the inside of the copper tube may be an indication of an undersized heater or may be caused by too much water velocity through the tubes and is not covered by the manufacturers warranty See Boiler Flow Rates Temperature Rise for requirements Using or storing corrosive chemicals in the vicinity of this appliance can rapidly attack the copper tubes and coils and voids warranty case of Condensing or Non Condensing DynaFlame The Main Primary Heat Exchanger is intended to operate under non condensing conditions Inlet water temperatures must be maintained at 115 F 46 C or higher for non condensing models and 130 F 55 C or higher for near condensing DFX and condensing models Warranty is void if the Primary heat exchanger is allowed to operat
149. re considered to be available Wiring the Lead Lag Setup Use Cascade terminals in the junction box to wire lead lag appliances Figure 30 Lead lag Wiring Setup Left Master Right Slave RAM LS 0000000 000000 0000000 0000 gt 20 ce c OO00000 0000 Recycle power on all boilers after programming is complete if lag boilers are not discovered automaticall NOTE CH Setpoint or DHW Setpoint must match Setpoint located in Lead Lag Master Configuration in order for the system to operate correctly NOTE The Local Remote switch explained below must be set in the Local position on ALL lag boilers 6 4 LEAD LAG SETUP FOR UP 12 APPLIANCES Honeywell SOLA can only support up to 8 boiler 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 1 activated on a time delay algorithm where the timer is initiated when boiler 8 begins the ignition sequence The delay timer is set based on the number of boilers in network 1 Pump C Delay Timer Register 4293 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 become lead boiler Operation is not impacted regardless of lead boiler
150. s Connect a manometer to obtain the differential air pressure between negative and positive ports See Turning adjustment screw clockwise will increase CO FIRE TESTING 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 depending on the 4 20 mA signal 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 meet the recommended levels Adjust high fire first followed by low fire adjustment Table 15 Combustion Values Figure 11 e The air gas ratio controller automatically adjusts to Non Condensing DynaFlame amp match the air signal on the gas side In this way true Shea mass flow control of air gas mix is achieved All boilers test fired and factory set A test sticker with actual reading is affixed to the unit 7 5 8 5 9 0 10 0 8 2 CHECKING THE CONSTRUCTION e Check the boiler wiring to see that it agrees with the wiring diagram supplied 8 5 9 0 7 0 7 5 lt 100 Near Condensing DynaFlame e
151. stibles 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 a primary secondary piping system Review the diameter and equivalent length of the installed piping to and from the boiler to ensure 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 2 Check system for any water leaks 3 Check system for installation of glycol or water treatment where required Where glycol has bee
152. stion 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 The burner may best be cleaned by immersing the 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 10 6 CHANGING THE HOT SURFACE IGNITER e 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
153. t 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 1 7 x 2 2 2 2 3 2 2 7 6 000 4 112 1 0 1 1 0 2 x A 2 Ve 2 Ve 2 3 3 3 3 SESS SIRS S w 02 Sum 3 1 2 i A 19 E Ju 221012 27 2 27 27 BE UNE UR 39 2 3 3 3 INCUN NE CU E 3 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 e The gas line should be sufficient to handle the total installed capacity Verify pipe size with gas supplier e Use new properly threaded black iron pipe free from burrs Avoid flexible gas connections Internal diameter of flexible gas lines may not provide appliance with proper volume of gas e 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
154. t Pump or DHW Pump On Options Local burner demand 10 On Options Local Lead Lag Service Active 11 Force On Outlet high limit Master Boiler System Sensor e Master boiler system sensor Press Configure and configuration Press Sensor Configuration Select S5 J8 11 Sensor Connector Type 10K NTC Single Non Safety DynaFlame Sensor Configuration S1 28 4 sensor Inlet or Return 10K NTC single non safety 52 28 6 sensor 4 20mA remote 4 20mA 6354 J8 8 10 sensor Outlet or Supply 10K NTC dual safety 555 0641 sensor 10K NTC single non safety mss 5657 9 1 3 sensor DHW Outdoor temperature source The control will proceed into a Lockout 2 condition Press Verify gt Begin gt Yes Press the reset button on the ignition control within the alotted time CASCADE 38 Outdoor Sensor to Slave boiler 2 DRH ONLY Electrical Connection s Programming Instructions Slave boiler outdoor sensor Slave Boiler configuration Press Lexi ang 2271 When done correctly the Press Sensor Configuration outdoor temperature will be Select 55 J8 11 Sensor shown on the Master boiler Connector Type 10K NTC Single Non Safety 28 4 sensor Inlet Return 10K NTC single non safety 52 28 6 sensor 4 20mA remote 4 20mA 354 28 8 10 sensor Outlet or Supply 10K NTC dual safety 55 28 11 sensor 10K NTC single non safety md 5657 J9 1 3
155. t 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 by Camus qualified factory trained service technicians WARNING Should overheating occur or the gas supply fails to shut off DO NOT turn off or disconnect the electrical supply to the pump Shut off the gas supply at a location external to the appliance Operation of Non Condensing DynaFlame at low fire less than 10096 of input for long periods of time will increase the possibility of forming condensation in the flue particularly in Spring Fall operation 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 tt 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 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 e A gas appliance that draws combustion air from the
156. t 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 Figure 33 Fan Burner Hot Surface Igniter and Flame Sensor Arrangement DynaFlame 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 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 This includes both the primary heat exchanger chamber and the secondary heat exchanger chamber All screws and fasteners used for assembly of the inner jacket and secondary heat exchanger chamber 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 on the inner jacket assemblies 7 5 OUTER JACKET The outer jacket assembly is constructed from mirror finish stainless St
157. t point of the roof within a 10 foot 3 05M radius of the termination e The vertical termination must be a minimum of 3 feet 0 91M above the point of exit A vertical termination less than 10 feet 3 05M from a parapet wall must be a minimum of 2 feet 0 61M higher than the parapet wall 2 1 12 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 di d2 d3 d4 04 1 d pipe diameter 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 5 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 area provided by any screens grills or louvers installed in the common air inlet point S
158. the appliance e Locate the Hot Surface Igniter e Disconnect the two power leads to the hot surface igniter e Loosen and remove the two screws that hold the igniter e 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 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 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 Carefully insert the igniter into the mounting point on the burner flange and push into position on top of the fan s flange Reinstall the two mounting head screws and tighten by hand only Ensure that the igniter ceramic paper gaskets are properly installed and seal the point of contact between the igniter and fan mounting flange Reconnect the power leads to the igniter Turn on main gas supply Turn on main power Test fire the appliance to ensure proper operation The igniter must generate a minimum of 3A to reliably light the main burner DF 500 2500 and pilot models DF3000 6000 10 7 PRIMARY HEAT EXCHANGER INSPECTION The primary 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
159. tinues to increase until water temperature reaches the Set Point temperature 2 Burner Input may stabilize at a fixed rate where demand equals input 3 Burner Input wil decrease rate when water temperature approaches temperature Set Point 1 6 3 END OF SEQUENCE 1 Set Point temperature is satisfied 2 Powerto the gas valves is turned off 3 Combustion Air Fan ramps 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 your gas supplier call the fire department IMPORTANT Consul
160. ture rise across the main heat exchanger of 20 F to 25 F 11 C 14 C If necessary use a flow setter valve to achieve the desired temperature rise 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 CIRCULATING PUMP SELECTION CONDENSOR The operation of the circulating pump may be continuous or it may be in parallel with the main heat exchanger pump Size the secondary pump for a minimum flow of 1096 of the flow through the main heat exchanger and a maximum of 3096 of the main heat exchanger flow up to 60 GPM 23 PART5 ELECTRICAL amp CONTROLS IT IS EXTREMELY IMPORTANT THAT THIS UNIT BE PROPERLY GROUNDED 5 1 ELECTRICAL CONECTIONS Ta ents ble 11 Minimum Voltage Requirem is a 4 wire power supply requiring two 2 lives a neutral and a ground This is 5 wire power supply requiring three 3 lives a neutral and a ground 120VAC 60Hz 120VAC 60Hz 120 60 2 Single Phase 230VAC 60Hz 30 Single Phase 230VAC 60Hz 3 30 Phase DynaFlame 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 tak
161. ucts 1 required all condensing models DynaFlame with CHRM A Category II 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 products from the building The Category 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 The Category IV flues from multiple appliances CAN NOT be combined into a common vent The Category IV flue must be a dedicated stack The Category IV Flue appliance must have all vent joints and seams sealed gas tight 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 material The flue from a Category and IV vent system must have a condensate drain with provisions to properly collect neutralize and dispose of any condensate that may occur 214 VENTING GUIDELINES FOR CATEGORY II AND OR IV VENTING The installed length of the Positive pressure flue from the appliance to the point of termination outside of the building must not exceed a maximum of 100 equivalent feet 30 5M length Depending on diameter and centerline radius subtract from 7 to 19 feet per 90 elbow using published data Subtract half this value for
162. ull 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 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 The controls on this appliance may fire the burner from 35 up to 100 for non condensing and from 20 up to 100 for near condensing and condensing of rated input Differential manifold gas pressure will be reduced as burner input is reduced All reference gas pressure measurements must be made at 100 of rated burner input 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 In the field it may be necessary to adjust the low fire adjustment 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 DF2000 DF6004 Tampering with gas valve adjustments after startup and commissioning will void the warranty on the gas valve assembly and the burn
163. until combustion levels are satisfied adjust the low fire setting DF 500 1750 Use the DynaFlame Control Panel 1 Press DIAGNOSTICS button Adjustment Clockwise Press Diagnostic Tests button 3 Move the firing rate slider to minimum firing rate Press Start Test to operate the boiler at min fire for 5 minutes The DynaFlame should respond immediately and fire at minimum firing rate When this is achieved locate the low fire adjustment screw as illustrated above Increase CO2 Decrease 2 Low Fire 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 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 PWM 4 20mA 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 levels Adjust high fire first followed by low fire adjustment To adjust the high fire setting DF 2000 6004 One or more manometers should be connected to the DynaFlame 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 Use the Dyn
164. up the DynaFlame Lead Lag system follow the instructions System Sensor 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 system piping When variable speed main circulators are used the system sensor is to be placed into the supply system piping All SOLA controllers are programmed with a default address of 1 The address of the slave controllers in the system must have a unique address 1 8 Sequence of Operation When a boiler is set as Lead Lag Master Enabled and Modbus address 1 the controller of this boiler will drive the lead lag operation The outdoor temperature sensor connected to the slave boiler 2 ie B 2 will be the outdoor sensor for the lead lag system e The system temperature sensor connected to boiler 1 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 at terminals labeled Remote Operator will be the heat demand input for lead lag operation 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 m
165. venting this appliance into a 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 masonry chimney is to be used the chimney MUST use a sealed metallic corrosion resistant liner system to vent flue products from this high efficiency appliance Sealed metallic corrosion resistant liner systems AL29 4C or 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 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 metallic 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 11 VERTICAL VENTING TERMINATION Follow Category or IV vent termination General instructions e The vent terminal should be vertical and exhaust outside the building at least 2 feet 0 61M above the highes
166. 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 This will prevent nuisance tripping of the manual reset 24 5 7 DYNAFLAME SOLA 5 8 DYNAFLAME CONTROLLER DF500 DF2500 models utilize a hot surface ignition system Table 12 Connector Description DF3000 DF6000 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 J1 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 52 Fan Modulation DR300 1000 module in the event of a fault J3 Display Lead lag Modbus Comm din DERE 777247 24 Power Pump VFD 24 Power Inlet Outlet Sensor 5 9 ERROR TABLE The following tables provide a description of all the possible errors with the DynaFlame 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 n

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