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Camus Hydronics DFW1100 - User Manual

Camus Hydronics DFW1100
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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 and its operating principles.

1.2 SPECIAL INSTRUCTIONS TO OWNER

Key recommendations for safe installation, operation, and servicing procedures.

1.3 CHECKING EQUIPMENT

Procedures for inspecting equipment for shipping damage and verifying contents.

PART 2 VENTING

2.1 GENERAL VENTING GUIDE

Essential guidelines for proper venting of DynaFlame appliances to ensure safe operation.

2.2 CONVENTIONAL VENTING (INDOOR) INSTALLATIONS

Specific requirements for venting appliances indoors using standard chimneys.

2.3 OUTDOOR VENTING

Guidelines for installing and operating DynaFlame units designed for outdoor use.

2.4 THRUWALL VENTING

Procedures for venting appliances horizontally through a wall.

PART 3 GAS CONNECTION

3.1 GAS CONNECTION

Initial steps and considerations for connecting the gas supply to the appliance.

3.2 GAS PIPING

Guidance on selecting and installing appropriate gas piping for safe operation.

3.3 INSTALL PIPING

Detailed instructions for the physical installation of gas supply piping.

3.4 DIFFERENTIAL AIR PRESSURE

Explanation of how differential air pressure controls the gas/air mixture.

3.5 GAS MANIFOLD DIFFERENTIAL PRESSURE ADJUSTMENT

Information on factory presets and field adjustment of gas pressure.

3.6 CHECKING GAS SUPPLY PRESSURE

Procedure for verifying the incoming gas supply pressure.

3.7 CHECKING DIFFERENTIAL AIR AND GAS PRESSURES

Method for measuring and comparing air and gas pressure differentials.

3.8 GAS TRAIN AND CONTROLS

Overview of the components and logic within the gas supply system.

3.9 RATIO GAS VALVE

Description of the electro-hydraulic actuator for air/gas ratio control.

3.10 VENTING OF GAS VALVES AND PRESSURE SWITCHES

Requirements for venting optional gas pressure switches.

3.11 BURNER

1.4 WHAT THE LIGHTS MEAN ON YOUR CAMUS APPLIANCE

1.5 HOW IT OPERATES (SEQUENCE OF OPERATION)

1.5.1 IGNITION PROCESS

Detailed process of how the igniter initiates the burner sequence.

1.5.2 HEAT TRANSFER PROCESS

How heat is transferred within the appliance during operation.

1.5.3 END OF SEQUENCE

Steps involved when the appliance satisfies the heating demand.

1.6 CODES

1.7 WARRANTY

1.8 REMOVAL OF EXISTING APPLIANCE

1.9 BOILER ROOM OPERATING CONDITION

1.10 INSTALLATION PROCEDURE LOCATION OF UNIT

1.11 Clearance from Combustible Material

2.1.1 CATEGORY I AND CATEGORY III VENTING

2.1.2 Venting Guidelines for Category I and;or III

2.1.3 CATEGORY II AND CATEGORY IV VENTING

2.1.4 Venting Guidelines for Category II and;or IV Venting

2.1.5 APPROVED VENTING MATERIALS

Exhaust Vent for Use for DynaFlame Non-condensing Category I Installations

Approved vent types for non-condensing Category I.

Exhaust Vent for Use for DynaFlame Non-condensing Category III Installations

Approved vent types for non-condensing Category III.

Intake Air (Supply Air, or Fresh Air) Piping

Acceptable materials for intake air piping.

2.1.6 VENT TERMINATION CLEARANCES

2.1.7 INLET CAP FOR ROOFTOP TERMINATION

2.1.8 LOCATION OF A ROOFTOP AIR INLET AND VENT CAPS

2.1.9 AIR INLET DAMPER

2.1.10 MASONARY CHIMNEY INSULATIONS

2.1.11 Vertical Venting Termination

2.1.12 COMBINED COMBUSTION AIR INLET

2.1.13 DRAIN TEE

2.2.1 Air Required For Combustion and Ventilation

2.2.2 EXHAUST FANS

2.4.1 THRUWALL Vent Cap (14-0090) THRUWALL Intake Air Cap (14-0101)

2.4.2 Location of A THRUWALL Vent Termination

2.4.3 LOCATION OF A THRUWALL AIR INLET CAP

2.4.4 AIR INLET DAMPER

2.4.5 LENGTH OF AIR INLET PIPE

PART 4 WATER CONNECTION

4.1 FREEZE PROTECTION

Methods and precautions to prevent freezing in hydronic systems.

4.2 WARNING REGARDING CHILLED WATER SYSTEMS

Safety precautions when connecting to air conditioning systems.

4.3 INLET AND OUTLET CONNECTIONS

Proper connection points and methods for water inlet/outlet.

4.4 MINIMUM PIPE SIZE REQUIREMENTS

Recommended minimum pipe sizes for water connections based on model.

4.5 PRIMARY HEAT EXCHANGER

Description of the heat exchanger design and requirements for its operation.

4.6 LOW WATER TEMPERATURE SYSTEMS (non-condensing)

4.7 INSTANTANEOUS WATER HEATER (non-condensing)

4.8 CONDENSER HEAT RECOVERY MODULE (CHRM)

4.9 CHRM, FLOW and PRESSURE DROP

4.10 WATER FLOW SWITCH (shipped loose)

4.11 LOW WATER CUTOFF (If Equipped)

4.12 RELIEF VALVE (shipped loose)

4.13 CONDENSING HEAT RECOVERY MODULE PIPING CONFIGURATIONS

BOILER APPLICATION (HYDRONIC HEATING)

Piping configuration for hydronic heating applications.

WATER HEATER APPLICATION (HOT WATER SUPPLY)

Piping configuration for domestic hot water supply.

4.14 CIRCULATING PUMP SELECTION

4.14.1 CIRCULATING PUMP OPERATION PRIMARY HEAT EXCHANGER

Guidelines for operating and selecting pumps for the primary heat exchanger.

4.14.2 CIRCULATING PUMP SELECTION CONDENSOR

Recommendations for selecting pumps for the condenser.

PART 5 ELECTRICAL & CONTROLS

5.1 ELECTRICAL CONECTIONS

Specifications and requirements for electrical connections.

5.2 VARIABLE FREQUENCY DRIVE (VFD)

Details on the VFD's function in controlling the combustion air fan speed.

5.3 DIFFRENTIAL AIR PRESSURE SWITCH

Function of the differential air pressure switch in proving fan operation.

5.4 HIGH and LOW GAS PRESSURE SWITCHS (Optional)

Operation of optional high and low gas pressure monitoring switches.

5.5 HIGH LIMIT

Description and setting of the high limit temperature control.

5.6 IGNITION CONTROL MODULE

Overview of the ignition control module and its role in the start-up sequence.

5.6.1 SERVICE PARTS

5.6.2 IGNITION MODULE LOCKOUT FUNCTIONS

5.6.3 DIAGNOSTIC STATUS INDICATION

5.6.4 FLAME SENSE TEST

PART 6 CONTROL PANEL

6.1 APPLIANCE TEMPERATURE CONTROLLER

Description of the appliance's temperature controller and its settings.

6.2 MODULATING SIGNAL GENERATOR

Function of the signal generator that controls burner firing rate.

6.3 VARIABLE FREQUENCY DRIVE (VFD)

Details on VFD parameters and security codes.

PART 7 COMPONENTS

7.1 HOT SURFACE IGNITER (GLOW BAR)

Information on the hot surface igniter, its function, and replacement.

7.2 FLAME SENSOR

Details about the flame sensor, its installation, and maintenance.

7.3 COMBUSTION AIR FAN

7.4 INNER JACKET

7.5 OUTER JACKET

7.6 VENTING TRANSITION

PART 8 FIELD STARTUP PROCEDURE

8.1 CHECKING THE INSTALLATION

Pre-startup checks for water, gas, electrical connections and airflow.

8.2 CHECKING THE CONSTRUCTION

Verifying wiring, control settings, and indicator light sequence.

8.3 FIRE TESTING

8.4 COMISSIONING APPLIANCE

PART 9 TROUBLE SHOOTING

PART 10 MAINTANANCE

10.1 EXAMINE THE VENTING SYSTEM

Procedure for inspecting the venting system for tightness and deterioration.

10.2 VISUALLY CHECK MAIN BURNER FLAMES

How to visually inspect the burner flame for proper combustion.

10.3 FLUE GAS PASSAGEWAYS CLEANING PROCEDURES

10.4 CONDENSATION TREATMENT

10.5 BURNER MAINTENANCE

10.5.1 BURNER REMOVAL AND CLEANING

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

10.5.2 BURNER CLEANING PROCEDURE

Method for cleaning the burner surface using water and detergent.

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

10.9 RE-INSTALL HEAT EXCHANGERS

10.10 COMBUSTION AIR FAN

10.11 COMBUSTION AND VENTILATION AIR

10.12 CONTROL CIRCUIT VOLTAGE

10.13 COMBUSTIBLE MATERIALS

10.14 FREEZE PROTECTION

10.15 FREEZE PROTECTION FOR A HEATING BOILER SYSTEM (Optional)

PART 11 INSTALLATIONS

11.1 HEATING BOILER INSTALLATIONS

Requirements for installing heating boilers in primary/secondary piping systems.

11.2 WATER CONNECTIONS

11.3 PIPING LENGTHS

11.4 INTERMITTENT PUMP OPERATION

11.5 SUMMARY

a) Typical Boiler Installations

General plumbing rules and best practices for boiler installations.

b) Placing the Boiler in Operation

Pre-start checklist and steps for initial boiler setup and operation.

11.6 DOMESTIC HOT WATER HEATER

11.7 WATER VELOCITY CONTROL

11.8 TEMPERATURE RISE AT FULL FIRING RATE

PART 12 EXPLODED VIEW

PART 13 ELECTRICAL DIAGRAMS

WARRANTY

GENERAL

General terms and conditions of the manufacturer's limited warranty.

HEAT EXCHANGER

Specific warranty terms for the heat exchanger, including pro-rated coverage.

BURNER

Warranty coverage for the appliance burner against defects.

ANY OTHER PART

Warranty period for all other appliance parts, excluding specific exclusions.

HOW TO MAKE A CLAIM

Procedure for submitting a warranty claim to Camus Hydronics.

SERVICE LABOR RESPONSIBILITY

Disclaimer regarding responsibility for labor expenses related to service.

DISCLAIMERS

Camus is not responsible for water damage resulting from leaks.

Camus Hydronics DFW1100 Specifications

General IconGeneral
BrandCamus Hydronics
ModelDFW1100
CategoryBoiler
LanguageEnglish

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