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Camus Hydronics DFH/W500 - User Manual

Camus Hydronics DFH/W500
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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.
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.

Table of Contents

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Summary

General Information

Overview of DynaFlame Boiler Models

Detailed overview of DynaFlame® boiler models and their efficiency ratings.

Introduction to DynaFlame Operation

Explains the DynaFlame®'s forced draft design, modulation, and operating principles.

Special Instructions for Owners

Emphasizes following manual instructions and using qualified personnel for installation and service.

Checking Equipment Upon Arrival

Instructions for inspecting equipment for shipping damage and verifying connections.

Sequence of Operation

Describes the step-by-step sequence of operation for the DynaFlame® appliance.

Ignition Process Details

Details the sequence of events during the ignition process of the appliance.

Heat Transfer Process Explanation

Explains how heat is transferred within the appliance during operation.

End of Sequence Procedure

Outlines the steps taken when the heating demand is satisfied and the sequence ends.

Applicable Codes and Standards

Lists relevant codes and standards for appliance installation and safety compliance.

Appliance Warranty Terms

Details the terms and conditions of the factory warranty for the appliance and its components.

Removing Existing Appliances

Provides procedures for removing an old appliance from a common venting system.

Boiler Room Operating Conditions

Discusses optimal boiler room conditions and potential issues like condensation.

Clearances from Combustible Materials

Specifies required clearances from combustible materials for safe installation.

Installation Procedure and Location

Guides on selecting an appropriate location and installation procedure for the appliance.

Air Supply & Venting

General Venting Guidelines

Provides fundamental guidelines for venting the appliance safely and effectively.

Category I and Category III Venting

Explains venting requirements for Category I and III appliances.

Venting Guidelines for Category I;III

Specific guidelines for Category I and III venting systems.

Category II and Category IV Venting

Details venting requirements for Category II and IV appliances, often for condensing units.

Venting Guidelines for Category II;IV

Specific guidelines for Category II and IV venting systems, focusing on condensate.

Approved Venting Materials

Lists approved materials for venting systems based on appliance category.

Vent Termination Clearances

Specifies required clearances for vent terminals to ensure safe exhaust.

Drain Tee Installation

Details the installation and function of a drain tee for condensate management.

Conventional Venting (Indoor) Installations

Covers installation for indoor venting systems, both non-condensing and condensing.

Air Requirements for Combustion and Ventilation

Specifies requirements for providing adequate combustion and ventilation air.

Exhaust Fans Impact

Discusses the impact of exhaust fans on combustion air supply and venting.

Outdoor Venting Guidelines

Information regarding outdoor installation and self-venting capabilities.

Thruwall Venting Procedures

Guidelines for thruwall venting installations, including vent terminal requirements.

Thruwall Vent Cap and Intake Air Cap Details

Details specific thruwall vent and intake air caps and their installation.

Thruwall Vent Termination Locations

Specifies safe and compliant locations for thruwall vent terminations.

Thruwall Air Inlet Cap Locations

Guidelines for positioning thruwall air inlet caps.

Air Inlet Pipe Length Limits

Specifies maximum allowable lengths for thruwall air inlet pipes.

Gas Connection

General Gas Connection Requirements

General requirements and safety precautions for gas connections.

Gas Piping Specifications

Covers proper materials and compliance for gas piping installation.

Gas Piping Installation Steps

Step-by-step instructions for installing gas piping, including shutoff valves and traps.

Air;Gas Ratio Valve Function

Explains the function and types of air/gas ratio control valves used in the appliance.

Differential Air Pressure (DF2000-6004)

Discusses differential air pressure measurement and its role in operation.

Gas Manifold Pressure Adjustment

Details the adjustment of gas manifold differential pressure.

Checking Gas Supply Pressure

Procedures for verifying the gas supply pressure to the appliance.

Checking Differential Air and Gas Pressures

Instructions for checking differential air and gas pressures for proper combustion.

Gas Train and Controls Overview

Overview of the gas train components and their control functions.

Venting Gas Valves and Pressure Switches

Guidelines for venting gas valves and pressure switches to the atmosphere.

Burner Description and Operation

Describes the appliance's burner design, operation, and types.

Water Connection

Freeze Protection Guidelines

Recommendations and procedures for protecting the appliance from freezing.

Warning: Chilled Water & Heating Coil Systems

Warnings and precautions for systems involving chilled water or heating coils.

Inlet and Outlet Water Connections

Information on water inlet and outlet connections and pipe thread standards.

Minimum Water Pipe Size Requirements

Specifies minimum pipe sizes for water connections based on installation type.

Primary Heat Exchanger Details

Details the design and operational requirements of the primary heat exchanger.

Low Water Temperature Systems

Discusses configurations for low water temperature applications and bypass lines.

Instantaneous Water Heater (Non-Condensing)

Information on instantaneous water heaters and their applications.

Condenser Heat Recovery Module (CHRM)

Details the CHRM, its mounting, and its role in heat transfer efficiency.

CHRM Flow and Pressure Drop

Provides data on CHRM head loss and flow rates for different temperature rises.

Water Flow Switch Installation

Explains the installation and function of the water flow switch.

Low Water Cutoff Device

Describes the low water cutoff device, its installation, and testing.

Relief Valve Installation and Maintenance

Information on the supplied relief valve, its installation, and maintenance.

CHRM Piping Configurations

Illustrates piping configurations for the CHRM, including series and parallel setups.

Circulating Pump Selection Guide

Guidelines for selecting the correct circulating pump for optimal performance.

Circulating Pump Operation (Primary Heat Exchanger)

Details the continuous pump operation required during burner firing.

Circulating Pump Selection (Condenser)

Specific pump selection criteria for condensing applications.

Electrical & Controls

Electrical Connections Requirements

Specifies minimum voltage requirements and overcurrent protection for appliance models.

Variable Frequency Drive (VFD) Operation

Explains the function and operation of the VFD for combustion fan speed control.

Differential Air Pressure Switch Function

Details the differential air pressure switch and its role in proving fan operation.

Blocked Flue Switch Operation

Describes the blocked flue switch and the conditions under which it operates.

Gas Pressure Switches (Optional)

Explains the function of high and low gas pressure switches for safety.

High Limit Control

Describes the high limit control for limiting maximum discharge water temperature.

DynaFlame SOLA Control System

Introduces the SOLA control system and its ignition module.

Service Parts for Ignition Module

Information on obtaining factory-approved replacement ignition modules and sensors.

Ignition Module Lockout Functions

Explains lockout conditions for the ignition module and how to reset them.

DynaFlame Controller Connector Descriptions

Lists connector descriptions for the DynaFlame controller.

Error Table and Codes

Provides a description of possible errors, including alert and lockout codes.

SOLA Control Panel

Appliance Temperature Controller Features

Describes the SOLA controller's functions, including temperature readings and auto reset limits.

DFH Modulation: Fixed Setpoint Operation

Configuration for fixed setpoint operation using boiler inlet sensor or remote operator.

Boiler Inlet Outdoor Reset Operation

Configuration for outdoor reset operation based on ambient temperature.

System Sensor Outdoor Reset Operation

Configuration for outdoor reset using a system sensor and an outdoor reset module.

4-20 mA;0-10 Vdc Setpoint Operation

Configuration for setpoint operation using 4-20mA or 0-10Vdc signals.

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

Configuration for firing rate operation using 4-20mA signals in lead lag systems.

System Sensor Enable (Standalone)

Method to enable system sensor for standalone applications in the control panel.

DFW Modulation: Fixed Setpoint Operation

Configuration for Domestic Hot Water (DHW) fixed setpoint operation.

Lead Lag Operation (Master Boiler)

Setup instructions for configuring a boiler as the master in a lead lag system.

Slave Boiler Configuration

Configuration steps for a slave boiler in a lead lag system.

Master Boiler System Sensor Configuration

Configuring the master boiler's system sensor for lead lag operation.

Slave Boiler Outdoor Sensor Configuration

Connecting and configuring an outdoor sensor for a slave boiler in a lead lag system.

Lead Lag Setup for Multiple Appliances

Instructions for setting up lead lag systems involving up to 12 boilers.

Local;Remote Switch Functionality

Explains the function and use of the local/remote switch for boiler control.

Comm. Port 2 Activation

Procedures for activating communication port 2 for Modbus gateway.

Variable Frequency Drive (VFD) Parameters

Details the parameters and settings for the Variable Frequency Drive (VFD).

Frost Protection Algorithm

Describes the frost protection algorithm for the heat exchanger.

Components

Hot Surface Igniter (Glow Bar)

Describes the hot surface igniter, its installation, and maintenance.

Flame Sensor Functionality

Details the flame sensor's function, installation, and troubleshooting.

Combustion Air Fan Assembly

Explains the sealed air fan assembly for combustion air and flue gas.

Inner Jacket Construction

Describes the construction of the inner jacket assembly, including materials.

Outer Jacket Construction

Details the construction of the outer jacket assembly, emphasizing finish and integrity.

Venting Transition Adapter

Information on the venting transition adapter and requirements for Category II/IV appliances.

Field Startup Procedure

Checking the Installation

Pre-startup checks for water, gas, electricity, and pump operation.

Checking the Construction

Verifying wiring, terminal strips, control settings, and checking for flue gas leaks.

Fire Testing Procedures

Procedures for fire testing, including CO2 level adjustments and flame pattern checks.

Appliance Commissioning Steps

Final steps for commissioning the appliance, including report filling and placing into service.

Trouble Shooting

Component Failure Mode Analysis

A table listing components, failure modes, and their corresponding analyses for troubleshooting.

Flame Disappears During Run Cycle

Analyzes causes and solutions when the flame suddenly disappears during operation.

Noisy Operation Troubleshooting

Identifies causes for noisy operation and suggests troubleshooting steps.

Auto Reset High Limit Trips

Explains reasons for auto reset high limit trips and how to address them.

Manual Reset High Limit Trips

Troubleshooting steps for manual reset high limit trips and related alerts.

Delta-T Limit Tripped Troubleshooting

Addresses Delta-T limit trips and associated alerts, focusing on temperature differences.

Temperature Overshoot Troubleshooting

Discusses causes of temperature overshoot and troubleshooting for related alerts.

Sensor Not Connected Troubleshooting

Troubleshooting steps when sensors are not connected or reporting errors.

Fan Not Turning Troubleshooting

Addresses issues with the fan not turning and related alerts.

Air Proving Switch Troubleshooting

Troubleshooting for air proving switch errors and adjustments.

Blocked Flue Switch Troubleshooting

Troubleshooting for blocked flue switch errors and adjustments.

Flame Detection Out of Sync

Troubleshoots issues where flame detection is out of sync with actual flame presence.

Blank Display Screen Troubleshooting

Addresses a blank display screen on the control panel and potential causes.

Internal Fault Troubleshooting

Troubleshooting steps for internal faults and errors detected by the system.

Maintenance

Venting System Examination

Instructions for inspecting the venting system for tightness and condition.

Main Burner Flame Visual Check

Guidelines for visually inspecting main burner flames for proper operation.

Flue Gas Passageways Cleaning

Procedures for cleaning flue gas passageways to remove soot.

Condensation Treatment Procedures

Information on managing condensate formation in high-efficiency appliances.

Condensate Volume Calculation

Discusses factors affecting condensate volume and provides a calculation method.

Burner Maintenance Guidelines

General procedures for burner inspection and cleaning on an annual basis.

Burner Removal and Cleaning

Step-by-step guide for removing and cleaning the burner assembly.

Burner Cleaning Procedure

Specific instructions for cleaning the burner surface using water and detergent.

Hot Surface Igniter Replacement

Procedures for checking and replacing the hot surface igniter for peak efficiency.

Re-installing the Igniter

Instructions for correctly reinstalling the hot surface igniter after replacement.

Primary Heat Exchanger Inspection

Guidelines for inspecting the primary heat exchanger for soot and damage.

CHRM Inspection Guidelines

Annual inspection procedures for the CHRM.

Re-installing Heat Exchangers

Steps for reinstalling heat exchangers, including gasket checks.

Combustion Air Fan Maintenance

Maintenance recommendations for the combustion air fan.

Combustion and Ventilation Air Check

Ensuring adequate combustion and ventilation air supply to the appliance.

Control Circuit Voltage Check

Checking control circuit voltage and troubleshooting issues.

Combustible Materials Safety

Safety warning about keeping combustible materials away from the appliance.

General Freeze Protection

General advice on freeze protection for installations in cold areas.

Optional Freeze Protection for Heating Boiler Systems

Specific optional freeze protection measures for heating boiler systems using antifreeze.

Installations

Heating Boiler Installation Requirements

Requirements for installing heating boilers, including piping systems and expansion tanks.

Water Connections Information

Information on water connections, including pipe sizes and materials.

Piping Length Guidelines

Guidelines on pipe diameter and length for ensuring proper flow through the boiler.

Intermittent Pump Operation

Explains how intermittent pump operation signals are used.

Installation Summary and Checklist

General plumbing rules and a pre-start checklist for typical boiler installations.

Domestic Hot Water Heater Considerations

Design considerations for domestic hot water heaters, including storage tanks and pump control.

Water Velocity Control

Importance of selecting the proper pump for water velocity and preventing scaling or erosion.

Temperature Rise at Full Firing Rate

How to check and adjust temperature rise at full firing rate for proper flow.

Water Heater Operation Guidelines

Considerations for water heaters, including preventing low-temperature operation and scald hazards.

Exploded View

Honeywell SOLA Lead Lag Operation (Up to 9 Boilers)

Honeywell SOLA Lead Lag Operation (Up to 12 Boilers)

Warranty Information

General Limited Warranty Terms

General terms of the limited warranty for Camus® appliances.

Heat Exchanger Warranty

Details the pro-rated limited warranty for heat exchangers based on years of service.

Burner Warranty Coverage

Specifies the warranty period for burner components against defects.

Warranty for Other Parts

Warranty coverage for all other parts within specified timeframes.

How to Make a Warranty Claim

Instructions on how to submit a warranty claim directly to Camus® Hydronics.

Service Labor Responsibility

Clarifies that labor expenses are the owner's responsibility.

Disclaimers

Water Damage Disclaimer

Disclaimer regarding Camus®'s responsibility for water damage to surroundings.

Camus Hydronics DFH/W500 Specifications

General IconGeneral
BrandCamus Hydronics
ModelDFH/W500
CategoryBoiler
LanguageEnglish

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