Camus Hydronics DFH/W3002 - User Manual

6226 Netherhart Road, Mississauga, Ontario, L5T 1B7
99-0050
Rev. 6.7
INSTALLATION OPERATION
AND SERVICE MANUAL
DYNAFLAME® SERIES
GAS FIRED COMMERCIAL COPPER TUBE AND STAINLESS
STEEL BOILERS
NON-CONDENSING
Models; DFH/W500, 750, 1100, 1200, 1500, 1750, 2000, 2500,
3000, 3500, 4000, 4500, 4504, 5000, 5004, 6004
NEAR-CONDENSING (DFX)
Models; DFH/W501, 751, 1101, 1201, 1501, 1751, 2001, 2501, 3001,
3501, 4001, 4501, 4514, 5001, 5014, 6014
CONDENSING
Models; DFH/W502, 752, 1102, 1202, 1502, 1752, 2002, 2502, 3002,
3502, 4002, 4502, 4524, 5002, 5024, 6024
H
HLW
W
W
A
A
R
R
N
N
I
I
N
N
G
G
:
:
If the information in these instructions is not followed
exactly, a fire or explosion may result causing property
damage, personal injury or death
Do not store or use gasoline or other flammable
vapours and liquids in the vicinity of this or any
other appliance.
WHAT TO DO IF YOU SMELL GAS
o Do not try to light any appliance,
o Do not touch any electrical switch; do not
use any phone in your building,
o Immediately call your gas supplier from a
neighbour’s phone. Follow the gas
supplier’s instructions,
o If you cannot reach your gas supplier, call
the fire department.
Qualified installer, service agency or the
gas supplier must perform installation and
service.
To the
I
nstaller:
After installation, these instructions
must be given to the end user or left on or near the
appliance.
To the End User: This booklet contains important
information about this appliance. Retain for future
reference.
CAMUS® HYDRONICS LTD.

Summary

Installation Operation and Service Manual

Critical Safety Warning

Critical safety warning regarding fire or explosion.

Gas Leak Emergency Procedure

Emergency procedure for gas leaks.

Part 1 General Information

1.5 How It Operates (Sequence of Operation)

Explains the step-by-step operational sequence of the appliance.

1.6.1 Ignition Process

Details the process of igniting the burner.

Part 2 Air Supply & Venting

2.1 General Venting Guide

Provides general guidelines for air supply and venting.

2.1.1 Category I and Category III Venting

Guidelines for Category I and III venting systems.

2.1.3 Category II and Category IV Venting

Guidelines for Category II and IV venting systems.

2.1.5 Approved Venting Materials

2.1.6 Vent Termination Clearances

2.2 Conventional Venting (Indoor) Installations

▲ Danger: Venting Instructions

Critical danger warning for venting instructions.

2.2.1 Air Required for Combustion and Ventilation

Specifies air requirements for combustion and ventilation.

Part 3 Gas Connection

3.1 Gas Connection

General information on gas connections.

3.2 Gas Piping

3.4 Air;Gas Ratio Valve

Information about the air/gas ratio valve.

3.5 Differential Air Pressure (DF2000 -6004)

Details on differential air pressure for specific models.

3.7 Checking Gas Supply Pressure

Steps to check gas supply pressure.

3.9 Gas Train and Controls

Overview of the gas train and its controls.

Part 4 Water Connection

4.1 Freeze Protection

4.2 Warning Regarding Chilled Water & Heating Coil Systems

Warnings for systems using chilled water.

4.5 Primary Heat Exchanger

Information on the primary heat exchanger.

Return Water Temperatures

IMPORTANT: Low Return Temperatures

Important note on operating at low return temperatures.

4.6 Low Water Temperature Systems

4.8 Condenser Heat Recovery Module (CHRM)

Information on the Condenser Heat Recovery Module.

4.9 CHRM, Flow and Pressure Drop

4.13 Condensing Heat Recovery Module Piping Configurations

4.14 Circulating Pump Selection

MOST IMPORTANT: Continuous Pump Operation

Crucial note regarding continuous pump operation.

Part 5 Electrical & Controls

▲ Danger: Grounding

Critical danger warning regarding grounding.

5.1 Electrical Connections

Details on electrical connections.

CAUTION!: 460 V Circuits

Caution regarding working with 460V circuits.

5.2 Variable Frequency Drive (VFD)

Information on the Variable Frequency Drive.

Caution: VFD Voltage Output

Caution regarding VFD voltage output.

5.3 Differential Air Pressure Switch

Details on the differential air pressure switch.

5.4 Blocked Flue Switch

5.5 High and Low Gas Pressure Switches (Optional)

5.6 High Limit

5.7 DynaFlame SOLA

Information about the DynaFlame SOLA control system.

5.8 DynaFlame Controller

Details on the DynaFlame controller.

5.9 Error Table

Table of error codes and their descriptions.

Part 6 SOLA Control Panel

6.1 Appliance Temperature Controller

Details on the appliance temperature controller.

6.2 Configure Menu

Instructions for configuring the SOLA control panel.

6.2.1 System Identification & Access

6.2.2 Pump Configuration

Configuration settings for pumps.

6.2.4 Burner Control Timing and Rates

Settings for burner control timing and rates.

6.2.5 Burner Control Ignition

6.2.6 Sensor Configuration

Configuration settings for sensors.

Modulation: Boiler Inlet, Fixed Setpoint Operation

Modulation: Boiler Inlet, Outdoor Reset Operation

Standalone operation with outdoor reset.

4-20 mA;0-10 Vdc Setpoint Operation

Standalone operation with 4-20mA/0-10Vdc setpoint.

4-20 mA;0-10 Vdc Firing Rate Operation

Standalone operation with 4-20mA/0-10Vdc firing rate.

System Sensor Enable (Standalone)

DF(H,W) Lead Lag Operation

Lead lag operation for DF(H,W) models.

Master Boiler, System Sensor Configuration

Outdoor Sensor connected to Slave Boiler

6.3 Lead Lag Setup

Setup procedures for lead lag systems.

Sequence of Operation

6.4 Lead Lag Setup for Up to 12 Appliances

Setup for lead lag systems with multiple appliances.

9 Boiler Outdoor Reset Wiring

10 to 12 Boiler Outdoor Reset Wiring

6.5 Local;Remote Switch

6.6 Comm. Port 2 Activation

6.7 Variable Frequency Drive

Details on the Variable Frequency Drive.

6.8 Frost Protection

Part 8 Field Startup Procedure

8.1 Checking the Installation

Procedure for checking the installation.

8.2 Checking the Construction

Steps for checking the unit's construction.

8.3 Fire Testing

Procedures for fire testing the appliance.

8.4 Comissioning Appliance

Steps for commissioning the appliance.

Part 9 Trouble Shooting

Flame Failure Troubleshooting

Troubleshooting flame failure issues.

Flame Disappears During a Run Cycle

Troubleshooting flame disappearance during operation.

Auto Reset High Limit Trips

Troubleshooting auto reset high limit trips.

Flame Detection Synchronization Issues

Blank Display Screen Troubleshooting

Internal Fault Troubleshooting

Hold 63: LCI OFF Errors

Safety Switch Errors

Alert 354: Abnormal Recycle Delta-T Limit

Manual Reset High Limit Trips

Delta-T Limit Tripped

Sensor Not Connected Troubleshooting

Fan Not Turning Troubleshooting

Air Proving Switch Troubleshooting

Blocked Flue Switch Troubleshooting

Part 10 Maintenance

CAUTION: Servicing Requirements

Caution regarding servicing by trained technicians.

10.1 Examine the Venting System

10.2 Visually Check Main Burner Flames

10.3 Flue Gas Passageways Cleaning Procedures

10.4 Condensation Treatment

10.5 Burner Maintenance

Procedures for burner maintenance.

10.5.1 Burner Removal and Cleaning

10.5.2 Burner Cleaning Procedure

10.6 Changing the Hot Surface Igniter

10.6.1 Re-installing the Igniter

10.7 Primary Heat Exchanger Inspection

10.8 Condensing Heat Recovery Module (CHRM) Inspection

10.10 Combustion Air Fan

10.13 Combustible Materials Caution

Caution regarding combustible materials.

10.14 Freeze Protection

Caution: Negative Room Pressure

Caution regarding negative room pressure and flue downdraft.

10.15 Freeze Protection for Heating Boiler System (Optional)

Part 11 Installations

11.1 Heating Boiler Installations

Installation guidelines for heating boilers.

CAUTIONS: System Leaks & Water Quality

Cautions regarding system leaks and water quality.

Placing the Boiler in Operation

Boiler Set-Up

Boiler Operational Checks

Boiler Operation

11.8 Temperature Rise at Full Firing Rate

CAUTION: Temperature Rise Adjustment

Caution regarding temperature rise adjustment.

CAUTION: Scald Injury Prevention

Caution regarding scald injury.

WARNING: Overheating or Gas Supply Failure

Warning about overheating or gas supply failure.

Honeywell Sola Lead Lag Operation Up to 9 Boilers

Honeywell Sola Lead Lag Operation Up to 12 Boilers

Lead Lag Operation Overview

WARNING: Drawing Purpose

Warning regarding the drawing's purpose.

Warranty Information

Heat Exchanger Warranty

Camus Hydronics DFH/W3002 Specifications

General

Brand	Camus Hydronics
Model	DFH/W3002
Category	Boiler
Language	English