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Camus Hydronics DFH1100 - User Manual

Camus Hydronics DFH1100
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6226 Netherhart Road, Mississauga, Ontario, L5T 1B7
99-0050
Rev. 04
INSTALLATION OPERATION
AND SERVICE MANUAL
GAS FIRED COMMERCIAL COPPER TUBE BOILERS
DynaFlame SERIES
FOR HYDRONIC HEATING
Models; DFH500, 750, 1100, 1200, 1500, 1750, 2000, 2500, 3000,
3500, 4000, 4500, 5000
HOT WATER SUPPLY
Models; DFW500, 750, 1100, 1200, 1500, 1750, 2000, 2500, 3000,
3500, 4000, 4500, 5000
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 Installer: 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

Part 1: General Information

1.1 Introduction

Overview of the DynaFlame boiler's design, operation, and features.

1.2 Special Instructions for Owners

Important safety and operational notes for appliance owners.

1.3 Checking Equipment

Procedure for inspecting equipment for shipping damage and verifying contents.

1.4 Appliance Indicator Lights

Explanation of the meaning of each indicator light on the appliance.

1.5 Appliance Operation Sequence

Detailed step-by-step description of the appliance's operating sequence.

1.5.1 Ignition Process

Detailed steps involved in the ignition process of the appliance.

1.5.2 Heat Transfer Process

Explanation of how heat is transferred within the appliance.

1.5.3 End of Sequence

Description of the final steps when the appliance operation cycle concludes.

1.6 Codes

Regulations and standards that apply to the installation of the equipment.

1.7 Warranty

Details of the limited warranty provided by Camus Hydronics.

1.8 Removal of Existing Appliance

Procedure for removing an existing appliance from a common venting system.

1.9 Boiler Room Operating Condition

Requirements for the boiler room environment for optimal operation.

1.10 Installation Location

Guidelines for selecting the proper location for unit installation.

1.11 Clearance from Combustibles

Required clearances from combustible materials for safe installation.

Part 2: Venting

2.1 General Venting Guide

General guidelines and principles for appliance venting systems.

2.1.1 Category I and Category III Venting

Venting requirements for Category I and Category III appliances.

2.1.2 Venting Guidelines for Category I and;or III

Specific guidelines for Category I and Category III venting systems.

2.1.3 Category II and Category IV Venting

Venting requirements for Category II and Category IV appliances.

2.1.4 Venting Guidelines for Category II and;or IV

Specific guidelines for Category II and Category IV venting systems.

2.1.5 Approved Venting Materials

List of approved materials for exhaust vents for DynaFlame models.

2.1.6 Vent Termination Clearances

Required clearances for vent termination points.

2.1.7 Inlet Cap for Rooftop Termination

Details on the installation of rooftop air inlet caps.

2.1.8 Rooftop Air Inlet and Vent Cap Location

Guidelines for locating rooftop air inlet and vent caps.

2.1.9 Air Inlet Damper

Information and considerations for air inlet dampers.

2.1.10 Masonry Chimney Insulations

Guidance on insulating masonry chimneys for venting.

2.1.11 Vertical Venting Termination

Requirements for vertical vent termination locations and clearances.

2.1.12 Combined Combustion Air Inlet

Guidelines for combining multiple combustion air inlet pipes.

2.1.13 Drain Tee

Instructions for installing a drain tee for condensate management.

2.2 Conventional Venting (Indoor) Installations

Venting requirements for indoor installations.

Non-Condensing Indoor Venting

Venting requirements for non-condensing DynaFlame models indoors.

Condensing Indoor Venting

Venting requirements for condensing DynaFlame models indoors.

2.2.1 Air Required for Combustion and Ventilation

Requirements for adequate combustion and ventilation air.

2.2.2 Exhaust Fans

Information regarding exhaust fans and their impact on air supply.

2.3 Outdoor Venting

Guidelines and requirements for outdoor installation and venting.

2.4 Thruwall Venting

Specific instructions and requirements for thruwall venting.

2.4.1 Thruwall Vent Cap and Intake Cap

Details on the thruwall vent cap and air intake cap.

2.4.2 Thruwall Vent Termination Location

Guidelines for proper location of thruwall vent terminations.

Part 3: Gas Connection

3.1 Gas Connection

General information and safety requirements for gas connections.

3.2 Gas Piping

Guidelines for gas piping installation, including material and sizing.

3.3 Install Piping

Step-by-step instructions for installing gas piping.

3.4 Differential Air Pressure

Explanation of differential air pressure and its role in appliance operation.

3.5 Gas Manifold Differential Pressure Adjustment

Instructions for adjusting gas manifold differential pressure.

3.6 Checking Gas Supply Pressure

Procedure for checking the gas supply pressure to the appliance.

3.7 Checking Differential Air and Gas Pressures

Method for checking differential air and gas pressures.

3.8 Gas Train and Controls

Overview of the gas train components and control system.

3.9 Ratio Gas Valve

Details regarding the air/gas ratio control valve.

3.10 Venting of Gas Valves and Pressure Switches

Instructions for venting gas valves and pressure switches.

3.10 Burner

Description of the appliance's burner assembly.

Part 4: Water Connection

4.1 Freeze Protection

Precautions and methods for protecting the appliance from freezing.

4.2 Warning: Chilled Water Systems

Warnings regarding connecting the appliance to chilled water systems.

4.3 Inlet and Outlet Connections

Requirements for connecting water inlet and outlet lines.

4.4 Minimum Pipe Size Requirements

Specifies minimum pipe sizes for water connections.

4.5 Primary Heat Exchanger

Details on the design and function of the primary heat exchanger.

4.6 Low Water Temperature Systems (Non-Condensing)

System setup recommendations for low water temperatures.

4.7 Instantaneous Water Heater (Non-Condensing)

Information on instantaneous water heater applications.

4.8 Condenser Heat Recovery Module (CHRM)

Details on the Condenser Heat Recovery Module and its function.

4.9 CHRM, Flow and Pressure Drop

Information on CHRM flow rates and pressure drop.

4.10 Water Flow Switch

Installation and function of the water flow switch.

4.11 Low Water Cutoff (If Equipped)

Installation and testing of low water cutoff devices.

4.12 Relief Valve

Information and installation requirements for the relief valve.

4.13 CHRM Piping Configurations

Piping configurations for the Condensing Heat Recovery Module.

CHRM in Series with Primary Heat Exchanger

Piping configuration for CHRM in series with the primary heat exchanger.

4.14 Circulating Pump Selection

Guidelines for selecting the appropriate circulating pump.

Circulating Pump Operation: Primary Heat Exchanger

How the circulating pump operates with the primary heat exchanger.

Circulating Pump Selection: Condenser

Guidelines for selecting a circulating pump for the condenser.

Part 5: Electrical & Controls

5.1 Electrical Connections

Details on electrical connections for the appliance, including power requirements.

5.2 Variable Frequency Drive (VFD)

Information on the VFD and its role in controlling the combustion fan.

5.3 Differential Air Pressure Switch

Function and operation of the differential air pressure switch.

5.4 High and Low Gas Pressure Switches

Details on optional high and low gas pressure switches.

5.5 High Limit

Operation and setting of the high limit control.

5.6 Ignition Control Module

Information on the ignition control module's function and operation.

Part 6: Control Panel

6.1 Appliance Temperature Controller

Overview of the appliance temperature controller and its settings.

Part 7: Components

7.1 Hot Surface Igniter (Glow Bar)

Description, installation, and function of the hot surface igniter.

7.2 Flame Sensor

Description, installation, and function of the flame sensor.

7.3 Combustion Air Fan

Details on the combustion air fan assembly.

7.4 Inner Jacket

Information regarding the inner jacket assembly.

7.5 Outer Jacket

Information regarding the outer jacket assembly.

7.6 Venting Transition

Details on the venting transition adapter component.

Part 8: Field Startup Procedure

8.1 Checking the Installation

Procedure to verify all connections and the installation integrity.

8.2 Checking the Construction

Procedure to check appliance wiring, connections, and control settings.

8.3 Fire Testing

Steps for testing burner ignition, operation, and combustion.

8.4 Commissioning Appliance

Final steps for appliance commissioning and placing into service.

Part 10: Maintenance

10.1 Examine the Venting System

Procedure for inspecting the venting system annually.

10.2 Visually Check Main Burner Flames

How to visually inspect burner flames for proper operation.

10.3 Flue Gas Passageways Cleaning Procedures

Steps for cleaning flue gas passageways.

10.4 Condensation Treatment

How to treat condensate generated from high-efficiency operation.

10.4.1 Condensate Volume

Formula for estimating the volume of condensate produced.

10.5 Burner Maintenance

General guidance for annual burner inspection and cleaning.

10.5.1 Burner Removal and Cleaning

Steps for removing and cleaning the burner assembly.

10.5.2 Burner Cleaning Procedure

Procedure for cleaning the burner using water and detergent.

10.6 Changing the Hot Surface Igniter

Steps for replacing the hot surface igniter.

10.6.1 Re-installing the Igniter

Steps for correctly reinstalling the igniter.

10.7 Primary Heat Exchanger Inspection

Procedure for inspecting the primary heat exchanger.

10.8 CHRM Inspection

Procedure for inspecting the Condensing Heat Recovery Module.

10.9 Re-install Heat Exchangers

Steps for reinstalling heat exchangers after inspection.

10.10 Combustion Air Fan

Maintenance check for the combustion air fan.

10.11 Combustion and Ventilation Air

Ensuring proper airflow for combustion and ventilation.

10.12 Control Circuit Voltage

Checking the control circuit voltage.

10.13 Combustible Materials

Precautions regarding combustible materials near the appliance.

10.14 Freeze Protection

Measures to protect the appliance from freezing.

10.15 Freeze Protection for Heating Boiler System

Optional freeze protection for heating boiler systems.

Part 11: Installations

11.1 Heating Boiler Installations

General installation guidelines for heating boilers.

11.2 Water Connections

Requirements and procedures for water connections.

11.3 Piping Lengths

Critical pipe diameter and length considerations for proper flow.

11.4 Intermittent Pump Operation

How intermittent pump operation is utilized.

11.5 Summary

Summary of key installation and operational points.

Typical Boiler Installations

General plumbing rules for typical boiler installations.

Placing the Boiler in Operation

Pre-start checklist for placing the boiler into operation.

11.6 Domestic Hot Water Heater

Installation considerations for domestic hot water heaters.

11.7 Water Velocity Control

Ensuring proper water velocity for heat exchanger performance.

11.8 Temperature Rise at Full Firing Rate

Procedure for checking and adjusting temperature rise.

11.9 Water Heaters

Specific considerations for water heater installations.

Part 12: Exploded View

Part 13: Electrical Diagrams

Part: Warranty

General Warranty

General terms and conditions of the appliance warranty.

Heat Exchanger Warranty

Specific warranty terms for heat exchangers.

Burner Warranty

Specific warranty terms for the burner.

Other Part Warranty

Warranty terms for all other appliance parts.

How to Make a Claim

Procedure for making a warranty claim.

Service Labor Responsibility

Camus' responsibility regarding service labor costs.

Disclaimers

Disclaimers regarding water damage and other potential issues.

Camus Hydronics DFH1100 Specifications

General IconGeneral
BrandCamus Hydronics
ModelDFH1100
CategoryBoiler
LanguageEnglish

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