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Camus Hydronics DynaFlame Series - User Manual

Camus Hydronics DynaFlame Series
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6226 Netherhart Road, Mississauga, Ontario, L5T 1B7
99-0435 Rev. 00
DynaFlame Series
Installation and Service Manual
Gas Fired Commercial Copper Tube and Stainless Steel Boilers
Non-Condensing Models DFH/DFW500 thru DFH/DFW6004
Near-Condensing Models DFH/DFW501 thru DFH/DFW6014
Condensing Models DFH/DFW502 thru DFH/DFW6024
WARNING
If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury
or death.
WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliance,
Do not touch any electrical switch; do not use any phone in your building,
Immediately call your gas supplier from a neighbour’s phone. Follow the gas supplier’s instructions,
If you cannot reach your gas supplier, call the fire department.
A Qualified installer, service agency or the gas supplier must perform installation and service.
WARNING
Do not store or use gasoline or other flammable vapours and liquids in the vicinity of this or any other appliance.
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.
H
HLW

Table of Contents

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Summary

PART 1 GENERAL INFORMATION

1.1 OVERVIEW

Describes the DynaFlame boiler styles and features.

1.2 INTRODUCTION

Explains the DynaFlame's operation principle and modulation capabilities.

1.3 SPECIAL INSTRUCTIONS TO OWNER

Provides essential installation and servicing guidelines for safe operation.

PART 1 GENERAL INFORMATION

1.4 CHECKING EQUIPMENT

Details steps to inspect the appliance for shipping damage and internal connections.

1.5 HOW IT OPERATES (SEQUENCE OF OPERATION)

Outlines the step-by-step process of the boiler's heating cycle.

1.6.1 IGNITION PROCESS

Describes the sequence of events during burner ignition and flame establishment.

PART 1 GENERAL INFORMATION

1.7 CODES

Specifies installation compliance with national and local codes and standards.

1.8 WARRANTY

Outlines warranty conditions for installation and operation.

PART 1 GENERAL INFORMATION

1.11 CLEARANCE FROM COMBUSTIBLE MATERIAL

Specifies minimum clearance requirements for safe installation near combustible materials.

1.12 INSTALLATION PROCEDURE AND LOCATION OF UNIT

Guides on selecting the proper location and installation procedures for the appliance.

PART 2 AIR SUPPLY & VENTING

2.1 GENERAL VENTING GUIDE

Provides fundamental principles for venting the DynaFlame appliance according to its category.

2.1.1 CATEGORY I AND CATEGORY III VENTING

Details venting requirements for non-condensing DynaFlame models based on vent category.

PART 2 AIR SUPPLY & VENTING

2.1.3 CATEGORY II AND CATEGORY IV VENTING

Outlines venting requirements for condensing DynaFlame models based on vent category.

2.1.5 APPROVED VENTING MATERIALS

Lists approved materials for venting DynaFlame appliances, including specific types.

PART 2 AIR SUPPLY & VENTING

2.1.8 LOCATION OF A ROOFTOP AIR INLET AND VENT CAPS

Details the proper placement of air inlet and vent caps for rooftop installations.

2.1.10 MASONARY CHIMNEY INSULATIONS

Provides guidance on venting into masonry chimneys, emphasizing liner requirements.

2.2 CONVENTIONAL VENTING (INDOOR) INSTALLATIONS

NON - CONDENSING

Outlines venting requirements for non-condensing DynaFlame units using conventional systems.

CONDENSING

Details venting requirements for condensing DynaFlame units using conventional systems.

2.3 OUTDOOR VENTING

2.4 THRUWALL VENTING

2.4.5 SIDEWALL CLEARANCE SPECIFICATIONS

Tables and diagrams detailing required sidewall clearances for vent terminals.

PART 3 GAS CONNECTION

3.1 GAS CONNECTION

General requirements for connecting the gas supply to the appliance.

3.3 INSTALL PIPING

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

PART 3 GAS CONNECTION

3.4 AIR;GAS RATIO VALVE

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

3.5 DIFFERENTIAL AIR PRESSURE (DF2000 - 6004)

Details how differential air pressure is measured and its role in appliance operation.

PART 3 GAS CONNECTION

3.7 CHECKING GAS SUPPLY PRESSURE

Provides procedures for verifying the incoming gas supply pressure.

3.7.1 Regulated Gas Supply Pressures for DynaFlame Boilers & Water Heaters

Specifies required gas supply pressures and lockup pressures for proper operation.

PART 3 GAS CONNECTION

3.8 CHECKING DIFFERENTIAL AIR AND GAS PRESSURES (DF2000 - DF6000)

Describes how to measure and interpret differential air and gas pressures.

3.11 BURNER

Describes the burner assembly, its materials, and operation.

PART 4 WATER CONNECTION

4.1 FREEZE PROTECTION

Provides guidelines and recommendations for preventing freeze damage to the appliance.

4.2 WARNING REGARDING CHILLED WATER & HEATING COIL SYSTEMS

Offers warnings and installation advice for systems involving chilled water and heating coils.

PART 4 WATER CONNECTION

4.5 PRIMARY HEAT EXCHANGER

Describes the construction and operating requirements of the primary heat exchanger.

4.6 LOW WATER TEMPERATURE SYSTEMS

Provides guidance for operating the appliance in low water temperature applications.

PART 4 WATER CONNECTION

4.8 CONDENSER HEAT RECOVERY MODULE (CHRM)

Details the CHRM's function, installation, and water flow requirements.

PART 4 WATER CONNECTION

4.15 WATER CHEMISTRY RECOMMENDATIONS

Crucial recommendations for maintaining water chemistry to prevent damage.

PART 5 ELECTRICAL & CONTROLS

5.1 ELECTRICAL CONECTIONS

Details minimum voltage requirements and electrical connections for various models.

5.2 VARIABLE FREQUENCY DRIVE (VFD)

Explains the role and operation of the VFD in controlling the combustion air fan.

PART 5 ELECTRICAL & CONTROLS

5.3 DIFFERENTIAL AIR PRESSURE SWITCH

Describes the function of the differential air pressure switch for fan operation proof.

5.4 BLOCKED FLUE SWITCH

Explains the function of the blocked flue switch for safety shutdown.

5.6 HIGH LIMIT

Details the high limit aqua-stat control for limiting maximum discharge water temperature.

PART 5 ELECTRICAL & CONTROLS

5.9 ERROR TABLE

Lists and explains various alert and lockout codes generated by the appliance.

PART 6 SOLA CONTROL PANEL

6.1 APPLIANCE TEMPERATURE CONTROLLER

Introduces the Honeywell SOLA controller and its capabilities for managing boiler operations.

PART 6 SOLA CONTROL PANEL

6.2 CONFIGURE MENU

Provides access to various configuration settings for the DynaFlame appliance.

6.2.1 System Identification & Access

Parameters for identifying the boiler, software version, and installation type.

6.2.2 Pump Configuration

Settings for configuring pump control, output, and run time for different zones.

PART 6 SOLA CONTROL PANEL

6.3 LEAD LAG SETUP

Instructions for setting up the lead lag system for multiple boilers.

PART 7 COMPONENTS

7.1 HOT SURFACE IGNITER (GLOW BAR)

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

7.2 FLAME SENSOR

Details the flame sensor, its function, and proper installation to ensure reliable flame detection.

PART 7 COMPONENTS

7.3 COMBUSTION AIR FAN

Explains the function and construction of the combustion air fan assembly.

7.6 VENTING TRANSITION

Information on the vent transition adapter and requirements for Category II or IV appliances.

PART 8 FIELD STARTUP PROCEDURE

8.1 CHECKING THE INSTALLATION

Step-by-step checks to ensure the appliance is installed correctly before startup.

8.3 FIRE TESTING

Procedures for testing the burner's ignition, flame, and combustion settings.

PART 9 TROUBLE SHOOTING

PART 10 MAINTENANCE

Monthly Maintenance

Routine checks performed by the owner/operator on a monthly basis.

Semi-Annually Maintenance

Checks performed by owner/operator every six months, including safety controls.

Annually Maintenance (Service Technician)

Comprehensive annual service performed by a qualified technician.

PART 10 MAINTENANCE

10.1 EXAMINE THE VENTING SYSTEM

Instructions for inspecting the venting system for leaks, corrosion, and blockages.

10.4 CONDENSATION TREATMENT

Addresses condensation management, pH levels, and material compatibility.

PART 10 MAINTENANCE

10.5 BURNER MAINTENANCE

Procedures for inspecting and cleaning the burner assembly.

10.5.1 BURNER REMOVAL AND CLEANING

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

PART 10 MAINTENANCE

10.10 COMBUSTION AIR FAN

Maintenance recommendations for the combustion air fan.

10.14 FREEZE PROTECTION

Advice on preventing freeze damage, especially for outdoor installations.

PART 11 INSTALLATIONS

11.1 HEATING BOILER INSTALLATIONS

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

11.3 PIPING LENGTHS

Critical factors for pipe diameter and length to ensure proper flow.

PART 11 INSTALLATIONS

11.7 WATER VELOCITY CONTROL

Importance of controlling water velocity for heat exchanger longevity and performance.

11.9 WATER HEATERS

Important considerations for water heater installations, including tempering and mixing valves.

PART 12 EXPLODED VIEW

PART 13 ELECTRICAL DIAGRAMS

WARRANTY

HEAT EXCHANGER

Pro-rated warranty coverage for heat exchangers based on years of service.

BURNER

Warranty coverage for the burner assembly against material or workmanship defects.

Camus Hydronics DynaFlame Series Specifications

General IconGeneral
TypeCondensing Boiler
Fuel TypeNatural Gas or Propane
EfficiencyUp to 95% AFUE
Heat Exchanger MaterialStainless Steel
Modulation Ratio5:1

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