Camus Hydronics DynaMax DMH081 - PART 12 INSTALLATIONS; Checking the Installation; Checking the Construction; Heating Boiler Installation Guidelines

59
Pipe supports could allow the pipe to slide resulting in noise
transmitted into the system. Padding is recommended. The
boiler pressure relief valve must be piped to a suitable floor
drain. See Section 4.11.
12.4 INSPECT & RECHARGE CONDENSATE
COLLECTION/NEUTRALIZING RESERVOIR
1) Before starting the unit inspect the condensate reservoir
in the DynaMax making sure the collection box is intact.
2) Remove screw holding lid on to condensate collection
box. Remove lid from the condensate collection box
3) Examine neutralizer medium and refill as necessary with
fresh medium
4) Fill with fresh water until the water begins to flow out of
drain
5) Re-install the lid and hold-down screw on the
condensate collection box.
WARNING
The condensate collection box must be filled with water to
prevent flue gas emissions from escaping during boiler
operation.
CAUTION
A leak in a boiler “System” will cause the fill system to
introduce fresh water constantly, which may cause the tubes
to accumulate a line/scale build up. Lime/scale buildup
leading to heat exchanger failure is NOT covered by
warranty.
12.5 WATER CONNECTIONS
System pipe size must be in accordance with Table 10
(depending on model) and, between supply and return lines,
must not exceed 50 feet of equivalent length. Connection
sizes at the heater are given in Tables 3 & 5. Any reduction
in recommended pipe size may decrease flow resulting in
high temperature rise across the heat exchanger, boiler
noise, flashing to steam and non-warrantable heat
exchanger damage.
12.6 PIPING LENGTHS
The appliance circulator provides the water flow from the
primary boiler piping, through the boiler and back to the
primary system. Pipe diameter and length are critical to
ensure proper flow through the boiler.
The secondary loop piping to and from the appliance must
have a fully ported ball valve installed in both the supply and
return side piping and will be used for isolation only. The ball
valves must be the same diameter as the installed piping. If
flow control is required, other means of flow control such as
globe valve or flow setter should be used.
12.7 SUMMARY
a) Typical Boiler Installations
General Plumbing Rules
1) Check all local codes.
2) For serviceability, always install unions.
3) Always pipe pressure relief valve to an open
drain.
4) Locate system air vents at highest point of
system.
5) Expansion tank must be installed near the
boiler and on the suction side of the system
pump.
6) Support all water piping.
7) Place drip pan underneath boiler. (if required)
b) Placing the Boiler in Operation
Pre-Start Check List
1) Review the location of the boiler, clearances
from combustible surfaces and available
service clearances.
2) Review Part 2 Venting. Ensure that all vent
components are fabricated from the correct
category of materials with adequate clearance
from combustibles. Review the vent
termination point for proper location and
clearances.
3) If a separate combustion air pipe is used,
ensure that it is properly sized, sealed and
terminated.
4) Review the water piping from the boiler to the
system. The boiler must be installed in a
primary/ secondary piping system. Review the
diameter and equivalent length of the installed
piping to and from the boiler to ensure proper
flow.
5) Ensure that a properly sized system pump is
installed with an expansion tank.
6) Check system pressure. Ensure a minimum of
18-20 PSIG with the system hot and not more
than 90% of the rated pressure of the relief
valve.
7) Review the installed gas piping from the meter
to the boiler. Ensure that the gas pipe, meter
and any regulators are adequately sized.
8) Review the field wiring and electrical service
for the boiler controls. Ensure that the electrical
service(s) is adequately sized.
9) Fill the condensate collector with fresh water
until water begins to pour out the drain.
10) Ensure that the boiler condensate drain and all
vent system condensate drains are properly
routed to an acceptable floor drain.
Boiler Set-Up
1) Ensure that the boiler and piping system are
full of water. Bleed all air from the pump
housing and secondary loop.
2) Check system for any water leaks.
3) Check system for installation of glycol or water
treatment where required. Where glycol has
been used to maintain the temperature rise
across the appliance confirm that the
recommended flow for pure water has been
increased by 15% and the head loss by 20%
while maintaining a 30-35
o
F rise across the
heat exchanger.
Boiler Operational Checks
1) Turn the boiler main power switch to the “ON”
position.
2) Verify operation of the text display on the front
panel.
3) Program the adjustable points.
4) Push the reset button if a manual reset error is
displayed.
5) Install a manometer on the gas supply to the
boiler and verify minimum gas supply pressure
as the burner fires at 100% of rated input.
6) Verify operation of safeties as necessary (low
water cut-off, high limit, gas pressure, etc.).