Camus Hydronics DFH/W500 Installation, Operation And Service Manual Download | Manualshive

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Sequence of Operation

Flow Switch = Flow Switch, Low Water Cutoff (if equipped)

Gas Pressure Switch = Low gas pressure switch (4.5” w.c., N/O), High gas pressure swtich (14” w.c., N/C)

Air Pressure Switch = Blocked flue switch (N/C), Air Proving Switch (N/O)

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Summary of Contents for DFH/W500

Page 1: ...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...

Page 2: ......

Page 3: ...INATION CLEARANCES 9 2 1 7 INLET CAP FOR ROOFTOP TERMINATION 10 2 1 8 LOCATION OF A ROOFTOP AIR INLET AND VENT CAPS 10 2 1 9 AIR INLET DAMPER 10 2 1 10 MASONARY CHIMNEY INSULATIONS 10 2 1 11 VERTICAL...

Page 4: ...LATING PUMP OPERATION PRIMARY HEAT EXCHANGER 22 4 14 2 CIRCULATING PUMP SELECTION CONDENSOR 23 PART 5 ELECTRICAL CONTROLS 23 5 1 ELECTRICAL CONECTIONS 23 5 2 VARIABLE FREQUENCY DRIVE VFD 24 5 3 DIFFRE...

Page 5: ...Y HEAT EXCHANGER INSPECTION 62 10 8 CONDENSING HEAT RECOVERY MODULE CHRM INSPECTION 62 10 9 RE INSTALL HEAT EXCHANGERS 62 10 10 COMBUSTION AIR FAN 62 10 11 COMBUSTION AND VENTILATION AIR 62 10 12 CONT...

Page 6: ...metered in precise proportion 1 1 Ratio to modulation signal allowing combustion characteristics which determine efficiency to remain the same over entire operating range DynaFlame Non Condensing In...

Page 7: ...he on board modulating control or the remote operating system 8 If temperature high limit water flow and airflow switches are closed the fan will run at pre purge speed until the pre purge timer is sa...

Page 8: ...and flue connections Installation and service must be performed by Camus qualified factory trained service technicians WARNING Should overheating occur or the gas supply fails to shut off DO NOT turn...

Page 9: ...If applicable turn on the clothes dryers and any appliances not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximu...

Page 10: ...rances from Combustibles Clearances from Combustibles TOP 12 SIDES 12 REAR 12 VENT 6 Figure 4 Clearance from Combustibles When placing the appliance be aware that a minimum clearance of 24 60cm must b...

Page 11: ...through both sides and could be placed adjacent to each other with zero clearance For condensing units a minimum clearance of 12 must be provided on the right side for access to the Condensing Heat Re...

Page 12: ...9 1 4 83 59 3 4 72 1 4 20 3 4 67 7 8 28 7 8 20 2 1 2 3 1 2 17 7 8 25 5 8 12 14 4 1 1 2 2 1 2 5004 35 3 4 39 1 4 88 1 4 65 77 1 2 26 72 1 4 34 1 8 20 2 1 2 3 1 2 17 7 8 25 5 8 12 14 4 1 1 2 2 1 2 6004...

Page 13: ...tem is disconnected for any reason the flue must be reassembled and resealed according to the vent manufacturer s instructions Do not use an existing chimney as a raceway if another appliance or firep...

Page 14: ...t low fire for long periods 3 C Vent Canada ONLY 4 Equivalent or higher rated than above Exhaust Vent for Use for DynaFlame Non condensing Category lll Installations 1 Corrosion resistant stainless st...

Page 15: ...y MUST use a sealed metallic corrosion resistant liner system to vent flue products from this high efficiency appliance Sealed metallic corrosion resistant liner systems AL29 4C or equivalent single w...

Page 16: ...ture and is being run for extended periods of time at low fire it is likely that condensation will be formed in the vent Consideration must be given to heating the room or providing a special venting...

Page 17: ...not obstructed 3 Locate appliance at least 3 feet away from any overhang 4 Locate appliance at least ten feet from building air intake 5 Avoid installation in areas where runoff from adjacent buildin...

Page 18: ...ot 3M radius of the flue outlet 2 4 4 LENGTH OF AIR INLET PIPE The maximum total length of the THRUWALL or vertical roof top combustion air inlet pipe as installed from the appliance to the air inlet...

Page 19: ...plate Heating values of local natural gas are to be between 950 and 1010 Btu ft 3 Consult factory if heating values are outside this range or if a gas with a mixture of constituents is being used 3 4...

Page 20: ...void the warranty on the gas valve assembly and the burner An appliance supplied with a properly sized gas line properly sized meter and a minimum gas supply pressure See Table 8 for minimum allowable...

Page 21: ...RENTIAL AIR AND GAS PRESSURES DF2000 DF6000 Figure 11 Differential Air Pressure Manometer Connection The 1 to1 air gas ratio control actuator has embossed markings identifying air air gas gas connecti...

Page 22: ...burner mounting flange provides a flame view port the mounting point for the hot surface igniter a connection to the pilot tube and the flame sensor The hot surface igniter and flame sensor are remov...

Page 23: ...dard Pipe Threads NPT For ease of service install unions on inlet and outlet of the appliance The connection to the appliance marked Inlet on the header should be used for return from the system The c...

Page 24: ...lications including open water reservoir heating Recirculation loops required for these applications can be set up in the field or they can be supplied pre piped from the factory In applications where...

Page 25: ...he appliance facing the appliance The CHRM is constructed from all stainless steel headers and special multiple horizontal stainless tubes This CHRM is designed to maximize heat transfer efficiency by...

Page 26: ...and debris by using a listed chimney cap Approval of the installation will be at the discretion of authorities having jurisdiction Sidewall and Vertical Venting The maximum vent length is 100 equival...

Page 27: ...um for 10 of the input of the appliance and is to be piped to drain in a manner similar to the appliance relief valve 4 13 1 CHRM IN SERIES WITH PRIMARY HEAT EXCHANGER INTEGRATED LOOP The supply water...

Page 28: ...mp Size the secondary pump for a minimum flow of 10 of the flow through the main heat exchanger and a maximum of 30 of the main heat exchanger flow up to 60 GPM PART 5 ELECTRICAL CONTROLS IT IS EXTREM...

Page 29: ...age wiring 5 3 DIFFRENTIAL AIR PRESSURE SWITCH A normally open differential air pressure switch is used to prove operation of the combustion air fan The pressure switch sensing points are installed at...

Page 30: ...naFlame Controller will go into an alert condition for example if the supply sensor is disconnected flow switch or air switch are not made If the fault is not corrected the boiler will stay in an aler...

Page 31: ...ff safety circuit is open Thermal Disc in control box and or upper cabinet Flow Switch LWCO Blocked Flue Switch 283 Demand off during measured purge time 291 Abnormal Recycle Flame was not on at end o...

Page 32: ...en stages minimum on time per stage minimum off time per stage Display of run hours for maintenance purposes Counter wraps around at 10000 hours Flame failure signal JST and Molex connectors for ease...

Page 33: ...ration Flow Switch Flow Switch Low Water Cutoff if equipped Gas Pressure Switch Low gas pressure switch 4 5 w c N O High gas pressure swtich 14 w c N C Air Pressure Switch Blocked flue switch N C Air...

Page 34: ...r operates at a fixed setpoint Modulates on boiler inlet sensor default Heat demand is generated when Remote Operator is closed 1 Press and 2 Press CH Central Heat Configuration 3 Press the to arrive...

Page 35: ...Select Enable Enable 6 Select Maximum outdoor temperature WWSD 7 Select Minimum outdoor temperature Outdoor Design 8 Select Low Water Temperature Min Water Temp 9 Select Outdoor boost maximum off poin...

Page 36: ...Connect Outdoor Sensor to J3 ECOM connector 4 Press and 5 Press Outdoor Reset Configuration 6 Press the to arrive at Central Heat 7 Select Enable Enable 8 Select Maximum outdoor temperature WWSD 9 Se...

Page 37: ...al Modulates on boiler inlet sensor default Heat demand is generated when Remote Operator is closed and 4 20mA or 0 10Vdc signal is present 1 Press and 2 Press CH Central Heat Configuration 3 Press th...

Page 38: ...vanced Settings 4 Press the to arrive at Central Heat 5 Select Modulation rate source S2 J8 6 4 20mA and burner on off 6 Place toggle switch to REMOTE for remote operation if required System Sensor En...

Page 39: ...Sensor Stat operation 1 Press Sensor Configuration 2 Select S6S7 J9 1 3 Sensor 10K NTC Single Non Safety 3 The control will proceed into a Lockout 2 condition 4 Press Verify Begin Yes 5 Press the rese...

Page 40: ...35...

Page 41: ...5 Select Lead Lag Master Configuration 6 Select Master Enabled Enabled Fixed Setpoint operation 7 Enter CH Setpoint Fixed setpoint 4 20mA 0 10Vdc setpoint operation 8 Select Advanced Settings 9 Press...

Page 42: ...n Options Local burner demand 19 On Options Local Lead Lag Service Active 20 Force On Outlet high limit Slave Boiler Description Electrical Connection s Programming Instructions Slave boiler lead lag...

Page 43: ...cal Lead Lag Service Active 11 Force On Outlet high limit Master Boiler System Sensor Description Electrical Connection s Programming Instructions Master boiler system sensor configuration 1 Press and...

Page 44: ...e 10K NTC Single Non Safety 5 The control will proceed into a Lockout 2 condition 6 Press Verify Begin Yes 7 Press the reset button on the ignition control within the alotted time Master Boiler 8 Pres...

Page 45: ...40 17 Press Show Line to confirm reset curve 18 Press the to arrive at Warm Weather Shutdown 19 Select Enable Shutdown after demand ends...

Page 46: ...ime user defined Base load rate adjustment Description Electrical Connection s Programming Instructions Upon a call for heat the lead boiler will fire up to the specified base load rate 80 If the temp...

Page 47: ...ot within Error threshold 5o F of setpoint after Interstage delay 2 minutes a lag boiler will be brought online and will also fire up to the base load rate specified This method will then be repeated...

Page 48: ...whenever a call for heat is present ON ON Pump is constantly powered Pump Output Pump B Specify pump contact Over run time 1 5 min Post pump time Default 1 min Use for local Stand alone demands Use f...

Page 49: ...an speed Default DF0500 6004 100 0 Prepurge time 30 sec 5 mins Prepurge time Default 15 sec Run Stabilization Time 10 sec Main flame establishing period Postpurge rate 100 0 Postpurge fan speed Defaul...

Page 50: ...threshold 2 Number of boilers remain the same Lead lag temp Lead lag setpoint Add stage Error threshold AND Lead lag temp Lead lag setpoint Drop stage Error threshold 3 A boiler should stop Lead lag...

Page 51: ...to boiler 2 and the outdoor sensor for boiler 9 requires the use of the outdoor sensor module PN W8735S1000 wired to the ECOM connection on the Honeywell SOLA Additional details can be found on page 7...

Page 52: ...ec 20 Deceleration Time 60 sec 28 Fixed Boost 1 0 36 Preset Speed 29 38 Skip Bandwidth 3 0 45 Speed at Minimum Signal Consult factory test sticker 46 Speed at Maximum Signal Consult factory test stick...

Page 53: ...d with steel wool Do not use sand paper since this will contaminate the surface 7 3 COMBUSTION AIR FAN Figure 33 Fan Burner Hot Surface Igniter and Flame Sensor Arrangement DynaFlame uses a sealed air...

Page 54: ...ing to require two to three tries before successful ignition With the boiler running check for flue gas leaks along the inner cabinet joints and around the flue outlet Some minor leakage is acceptable...

Page 55: ...ecelerate to minimum fire and will light off at low fire before ramping up towards full input through the PWM or 4 20mA signal from the controller Shut power off to the heater and open the firing valv...

Page 56: ...h the use of an analyzer This boiler is designed for low fire soft start At the start of trial for ignition the fan will decelerate to minimum fire and will light off at low fire before ramping up tow...

Page 57: ...ir Switch indicator to turn green at a fan speed between 15Hz and 20Hz on the VFD Check the ignition retries circuit Shut the main gas off to the unit and allow it to try for ignition Trial for igniti...

Page 58: ...nd related wiring for damage and connection errors DF 500 2500 Verify igniter is glowing DF 3000 6000 Verify pilot is lit Inspect flame sensor and associated wiring Replace if necessary Verify that bo...

Page 59: ...nual Natural Gas Pressure reads between 3 w c and 14 w c L P Gas Pressure should be at 11 w c Air Gas Mixture Issue Refer to Section 8 3 Fire Testing for proper combustion setting Air Inlet and or Ven...

Page 60: ...xceeds 30 PSI Temperature Overshoot Stack temperature has exceeded the limit temperature Alert 125 The stack temperature has exceeded the maximum temperature allowed PVC 149 o F CPVC 194 o F AL29 4C S...

Page 61: ...tion failed 112 Pilot test flame timeout 113 Flame circuit timeout 149 Flame detected If an internal hardware error is detected contact Camus technical support for troubleshooting procedure Table 18 A...

Page 62: ...f 0 8Vdc must be detected by the flame sensor to prove the flame Check flame sensor wire Within harness bundle Move flame sensor wire away from harness bundle Separated from harness bundle Check hot s...

Page 63: ...rror occurs when one of more of the boiler safety switches are in an open condition when it is to be in a closed condition before the ignition sequence is allowed to proceed Flow Switch Gray Check flo...

Page 64: ...Before this error appears the combustion air blower will slow down in an effort to prevent such an error from occurring Verify pump motor load to pump rated load Low current reading Purge air from wa...

Page 65: ...negative 0 15 W C If improper flame is observed examine the venting system ensure proper gas supply and adequate supply of combustion and ventilation air 10 3 FLUE GAS PASSAGEWAYS CLEANING PROCEDURES...

Page 66: ...sensor Remove the sensing tubes from the air ratio gas valve to the combustion air fan Remove the 4 nuts holding the fan assembly to the heat exchanger and remove the fan assembly On occasion the red...

Page 67: ...remaining deposits If necessary the heat exchanger can be removed by disconnecting all water piping and lifting it out from the side 10 9 RE INSTALL HEAT EXCHANGERS Carefully reinstall the heat excha...

Page 68: ...te trapped air in the system Locate a system air vent at the highest point in the system The system must also have a properly sized expansion tank installed Typically an air charged diaphragm type exp...

Page 69: ...eld wiring and electrical service for both the boiler controls and pump Ensure that the electrical service s is adequately sized Boiler Set Up 1 Ensure that the boiler and piping system are full of wa...

Page 70: ...ble failure Temperature rise must be properly adjusted to achieve the specified flow rate The required temperature rise and the recommended pump size are based on the heating of potable water with nor...

Page 71: ...66 PART 12 EXPLODED VIEW...

Page 72: ...67 3 44 10 45 46 47 28 31 26 52 57 58 59 54 60 61 SOLA Control Panel 39 4...

Page 73: ...35 50A X X X X 14 5315 X X X 2 Bottom Transition Inner to Outer Jacket 14 5235A X X X X X X X X X X X X X 14 5328 X X X 3 Primary Copper Copper Nickel Heat Exchanger V Baffles Included DF 500 HTX X DF...

Page 74: ...09020 X 109021 X 109022 X 109023 X 109025 X 109026 X 109028 X 109029 X 109030 X 109032 X 109033 X 109034 X 4 Fan Air Gas Inlet Adapter 13 0026 X X X X X X X 66 5005 X 13 0027 X X X 66 5011 X X X X X 5...

Page 75: ...tion Top Panel 14 5009A X X X X 14 5203 15A 25A X X X X 102711 X 14 5203 35 50A X X X X 14 5303 X X X 11 Combustion Chamber Door 14 5010 05A X 14 5008 07A X 102631 X X 14 5202 15A 17A 20A 25A 35A 40A...

Page 76: ...Top Transition Inner to Outer Jackets 14 6025A X X X X 14 5225A X X X X X X X X X 14 5325 X X X 18 Outer Jacket Top Cover Assembly 14 6030A X X X X 14 5228A X X X X X 14 5228A 50 X X X X 14 5329 45 50...

Page 77: ...5052 X X X X 13 5330 X X X 13 5331 X X 13 5332 X X X X X X 13 5333 X 27 Inlet Outlet Header Rear Gasket 33 0013 X X X X 33 0014 X X X X X X X X X 33 0030 X X X 28 Electrical Motor 1 2 HP X X X X 1 HP...

Page 78: ...ue Assembly Non Condensing 14 5290 05A 11A 11A 11A 17A 17A 30A 30A 30A 35 50A 500A 600A Flue Assembly Non Condensing 14 5270 05A 11A 11A 11A 17A 17A 30A 30A 30A 35 50A 500A 600A 35 Interior Seal Plate...

Page 79: ...7A 20A 25A 30A 35A 40A 45A 50A 14 0353 45 50 60 44 Inlet Outlet Header Top Gasket 33 5239 X X X X 33 5237 X X X X 33 5238 X X X X X 33 5240 X X 45 White Ceramic Gasket Under Burner Flange 33 5242 X X...

Page 80: ...Actuator V8730C1015 X V8730C1023 X V8730C1031 X X V4734C1002 X X SKP55 X X X X X X X X X X 51 Valve Body VGG10 404U X X X X X X X VGD40 065U X X VGD40 080U X 51A Solenoid Valve V4295A1049 X V4295A1056...

Page 81: ...54 75VA Transformer HCT 01J2BB07 X 55 Blocked Flue Switch 8021205256 X 56 Differential Pressure Switch NS2 1427 00 X 57 Control Box Plate 14 1005 03 X 58 Honeywell SOLA R7910A1001 X 59 Relay s 164934...

Page 82: ...77 PART 13 ELECTRICAL DIAGRAMS...

Page 83: ...78...

Page 84: ...04 2011 AIR INLET DAMPER CONNECTION BK FROM TERMINAL 6 CALL FOR HEAT BL PROCEEDS TO IGNITION Y TO TERMINAL 1 COMMON RETURN CONTROL BOX TERMINALS BK Y BL R AIR INLET DAMPER POWER OPEN SPRING RETURN CLO...

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Page 88: ...lame DHW COPPER CU NI HTX DF Cond Secondary HTX 1 100 100 100 100 2 100 100 100 100 3 100 100 100 100 4 100 100 100 100 5 100 100 100 100 6 100 40 7 100 35 8 100 30 9 100 25 10 100 20 The exchanged or...

Page 89: ...that in the event of a water appliance or fitting leak the resulting flow of water will not cause damage to its surroundings Name of Owner Name of Dealer Address Address Model No Serial No Date of In...

Page 90: ...uilt water heaters and heating boilers as well as a into every single unit For more information supplier of specialty HVAC products Our service line is open 24 hours 7 days a week on our innovative pr...

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