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Camus Hydronics DFH1500 - User Manual

Camus Hydronics DFH1500
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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, its features, and operation principles.

1.2 SPECIAL INSTRUCTIONS TO OWNER

Important guidelines for installation, operation, and servicing of the appliance.

1.3 CHECKING EQUIPMENT

Procedures for inspecting equipment for shipping damage and verifying contents.

1.4 WHAT THE LIGHTS MEAN ON YOUR CAMUS APPLIANCE

1.5 HOW IT OPERATES (SEQUENCE OF OPERATION)

Detailed sequence of appliance operation from startup to shutdown.

1.5.1 IGNITION PROCESS

1.5.2 HEAT TRANSFER PROCESS

How heat is transferred within the appliance during operation.

1.5.3 END OF SEQUENCE

The steps involved in the appliance's shutdown sequence.

1.6 CODES

Regulations and standards governing the installation of the equipment.

1.7 WARRANTY

1.8 REMOVAL OF EXISTING APPLIANCE

Procedures for safely removing an old appliance from a common venting system.

1.9 BOILER ROOM OPERATING CONDITION

1.10 INSTALLATION PROCEDURE LOCATION OF UNIT

Guidelines for selecting the proper installation location for the unit.

1.11 CLEARANCE FROM COMBUSTIBLE MATERIAL

PART 2 VENTING

2.1 GENERAL VENTING GUIDE

Essential guidelines for venting the appliance safely and effectively.

2.1.1 CATEGORY I AND CATEGORY III VENTING

2.1.2 VENTING GUIDELINES FOR CATEGORY I AND;OR III

Specific guidance for venting Category I and III systems.

2.1.3 CATEGORY II AND CATEGORY IV VENTING

2.1.4 VENTING GUIDELINES FOR CATEGORY II AND;OR IV VENTING

Specific guidance for venting Category II and IV systems.

2.1.5 APPROVED VENTING MATERIALS

Lists acceptable materials for exhaust vents.

2.1.6 VENT TERMINATION CLEARANCES

2.1.7 INLET CAP FOR ROOFTOP TERMINATION

Details on installing the air inlet cap for rooftop venting.

2.1.8 LOCATION OF A ROOFTOP AIR INLET AND VENT CAPS

Proper placement of air inlet and vent caps for rooftop installations.

2.1.9 AIR INLET DAMPER

2.1.10 MASONARY CHIMNEY INSULATIONS

Guidelines for insulating masonry chimneys.

2.1.11 VERTICAL VENTING TERMINATION

Requirements for vertical vent termination points.

2.1.12 COMBINED COMBUSTION AIR INLET

How to combine combustion air inlets from multiple appliances.

2.1.13 DRAIN TEE

2.2 CONVENTIONAL VENTING (INDOOR) INSTALLATIONS

Procedures for indoor venting of the appliance.

2.2.1 AIR REQUIRED FOR COMBUSTION AND VENTILATION

2.2.2 EXHAUST FANS

How exhaust fans affect combustion air supply.

PART 3 GAS CONNECTION

3.1 GAS CONNECTION

General information and requirements for gas connections.

3.2 GAS PIPING

3.3 INSTALL PIPING

Step-by-step instructions for installing gas piping.

3.4 DIFFERENTIAL AIR PRESSURE

Explanation of differential air pressure in the appliance.

3.5 GAS MANIFOLD DIFFERENTIAL PRESSURE ADJUSTMENT

3.6 CHECKING GAS SUPPLY PRESSURE

How to check the gas supply pressure to the appliance.

3.7 CHECKING DIFFERENTIAL AIR AND GAS PRESSURES

Procedures for checking air and gas pressure differentials.

3.8 GAS TRAIN AND CONTROLS

3.9 RATIO GAS VALVE

Explanation of the air/gas ratio control valve's function.

3.10 VENTING OF GAS VALVES AND PRESSURE SWITCHES

Venting requirements for gas valves and pressure switches.

3.10 BURNER

PART 4 WATER CONNECTION

4.1 FREEZE PROTECTION

Measures to protect the appliance from freezing.

4.2 WARNING REGARDING CHILLED WATER SYSTEMS

Important warnings for connecting to chilled water systems.

4.3 INLET AND OUTLET CONNECTIONS

4.4 MINIMUM PIPE SIZE REQUIREMENTS

Specifications for minimum pipe sizes for water connections.

4.5 PRIMARY HEAT EXCHANGER

Information about the primary heat exchanger's design and operation.

4.6 LOW WATER TEMPERATURE SYSTEMS (NON-CONDENSING)

4.7 INSTANTANEOUS WATER HEATER (NON-CONDENSING)

4.8 CONDENSER HEAT RECOVERY MODULE (CHRM)

Information on the Condenser Heat Recovery Module.

4.9 CHRM, FLOW AND PRESSURE DROP

4.10 WATER FLOW SWITCH (SHIPPED LOOSE)

Installation and function of the water flow switch.

4.11 LOW WATER CUTOFF (IF EQUIPPED)

Information on the low water cutoff device.

4.12 RELIEF VALVE (SHIPPED LOOSE)

4.13.1 CHRM IN SERIES WITH PRIMARY HEAT EXCHANGER (INTEGRATED LOOP)

4.14 CIRCULATING PUMP SELECTION

Guidelines for selecting the correct circulating pump.

4.14.1 CIRCULATING PUMP OPERATION PRIMARY HEAT EXCHANGER

4.14.2 CIRCULATING PUMP SELECTION CONDENSOR

Pump selection criteria for the condenser.

PART 5 ELECTRICAL & CONTROLS

5.1 ELECTRICAL CONECTIONS

Information on electrical connections for the appliance.

5.2 VARIABLE FREQUENCY DRIVE (VFD)

5.3 DIFFERENTIAL AIR PRESSURE SWITCH

Role and function of the differential air pressure switch.

5.4 HIGH AND LOW GAS PRESSURE SWITCHS (OPTIONAL)

5.5 HIGH LIMIT

Information on the high limit control setting and operation.

5.6 IGNITION CONTROL MODULE

Overview of the ignition control module.

5.6.1 SERVICE PARTS

5.6.2 IGNITION MODULE LOCKOUT FUNCTIONS

Explains lockout functions of the ignition module.

5.6.3 DIAGNOSTIC STATUS INDICATION

Codes and meanings for diagnostic status indicators.

5.6.4 FLAME SENSE TEST

Procedure for performing a flame sense test.

PART 6 CONTROL PANEL

6.1 APPLIANCE TEMPERATURE CONTROLLER

Description of the appliance's temperature controller.

6.2 MODULATING SIGNAL GENERATOR

6.3 VARIABLE FREQUENCY DRIVE (VFD)

Details on VFD parameters and settings.

Appliance Temperature Control Modes

PART 7 COMPONENTS

7.1 HOT SURFACE IGNITER (GLOW BAR)

Description and installation of the hot surface igniter.

7.2 FLAME SENSOR

7.3 COMBUSTION AIR FAN

Details of the combustion air fan assembly.

7.4 INNER JACKET

Construction and material of the inner jacket.

7.5 OUTER JACKET

Construction and material of the outer jacket.

7.6 VENTING TRANSITION

Information on the venting transition adapter.

PART 8 FIELD STARTUP PROCEDURE

8.1 CHECKING THE INSTALLATION

Steps to verify the installation of water, gas, and electrical connections.

8.2 CHECKING THE CONSTRUCTION

Procedures for checking wiring and control settings.

8.3 FIRE TESTING

8.4 COMISSIONING APPLIANCE

Steps for commissioning the appliance after startup.

PART 9 TROUBLE SHOOTING

Troubleshooting Flowchart

A step-by-step guide to diagnose and resolve appliance issues.

PART 10 MAINTANANCE

10.1 EXAMINE THE VENTING SYSTEM

Annual inspection of the venting system for integrity and function.

10.2 VISUALLY CHECK MAIN BURNER FLAMES

Procedure to visually inspect the main burner flame profile.

10.3 FLUE GAS PASSAGEWAYS CLEANING PROCEDURES

10.4 CONDENSATION TREATMENT

Managing condensate and its acidic properties.

10.4.1 CONDENSATE VOLUME

10.5 BURNER MAINTENANCE

Routine maintenance for the burner assembly.

10.5.1 BURNER REMOVAL AND CLEANING

10.5.2 BURNER CLEANING PROCEDURE

Detailed procedure for cleaning the burner.

10.6 CHANGING THE HOT SURFACE IGNITER

Instructions for replacing the hot surface igniter.

10.6.1 RE-INSTALLING THE IGNITER

10.7 PRIMARY HEAT EXCHANGER INSPECTION

Procedure for inspecting the primary heat exchanger.

10.9 RE-INSTALL HEAT EXCHANGERS

10.10 COMBUSTION AIR FAN

Maintenance checks for the combustion air fan.

10.11 COMBUSTION AND VENTILATION AIR

Ensuring adequate airflow for combustion and ventilation.

10.12 CONTROL CIRCUIT VOLTAGE

Checking control circuit voltage levels.

10.13 COMBUSTIBLE MATERIALS

10.14 FREEZE PROTECTION

Methods for protecting the appliance from freezing.

10.15 FREEZE PROTECTION FOR A HEATING BOILER SYSTEM (OPTIONAL)

PART 11 INSTALLATIONS

General installation guidelines for heating boilers.

11.1 HEATING BOILER INSTALLATIONS

11.2 WATER CONNECTIONS

Requirements for water connections.

11.3 PIPING LENGTHS

Guidelines for pipe diameter and length.

11.4 INTERMITTENT PUMP OPERATION

How the pump operates intermittently.

11.5 SUMMARY

11.6 DOMESTIC HOT WATER HEATER

Installation considerations for domestic hot water heaters.

11.7 WATER VELOCITY CONTROL

Controlling water velocity for optimal heat exchanger performance.

11.8 TEMPERATURE RISE AT FULL FIRING RATE

11.9 WATER HEATERS

Specific installation notes for water heaters.

PART 12 EXPLODED VIEW

Exploded View Diagrams

Visual representation of appliance components with reference numbers.

PART 13 ELECTRICAL DIAGRAMS

Electrical Diagrams

Wiring diagrams for the appliance's electrical system.

WARRANTY

GENERAL

General terms and conditions of the appliance warranty.

HEAT EXCHANGER

Warranty terms specific to heat exchangers.

BURNER

Warranty terms specific to the burner.

ANY OTHER PART

Warranty terms for all other appliance parts.

Camus Hydronics DFH1500 Specifications

General IconGeneral
BrandCamus Hydronics
ModelDFH1500
CategoryBoiler
LanguageEnglish

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