Camus Hydronics DFH500 Installation, Operation And Service Manual Download Page 45

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33-0013

58 Flange

Gasket

33-0014

Electrical Components

Ref

Name of Part Part

ID Model

Sizes

ALL 500 750 1100 1200 1500 1750 2000 2500 3000 3500 4000 4500 5000

SM005S

SM010S

SM015S

Variable Frequency

Drive (1/2HP, 1HP,

1 1/2HP, 3HP)

SM23S

Ignition Module

DF 35-67

Control

BTC-2PA

Control

PXZ

On/Off Switch

W51A152A

Indicator Lights

IND.LGT.SET

Fuse

BK/AGC-4

24V/120V Relays

LY1F 24/120

75VA Transformer

HCT-01J28807

1/2 HP

1 HP

1 1/2 HP

69 Electrical

Motor

3 HP

Summary of Contents for DFH500

Page 1: ...asoline 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 Q...

Page 2: ...090 THRUWALL Intake Air Cap 14 0101 11 2 4 2 Location of A THRUWALL Vent Termination 11 2 4 3 LOCATION OF A THRUWALL AIR INLET CAP 12 2 4 4 AIR INLET DAMPER 12 2 4 5 LENGTH OF AIR INLET PIPE 12 PART 3 GAS CONNECTION 12 3 1 GAS CONNECTION 12 3 2 GAS PIPING 13 3 3 INSTALL PIPING 13 3 4 DIFFERENTIAL AIR PRESSURE 13 3 5 GAS MANIFOLD DIFFERENTIAL PRESSURE ADJUSTMENT 13 3 6 CHECKING GAS SUPPLY PRESSURE ...

Page 3: ... 30 10 3 FLUE GAS PASSAGEWAYS CLEANING PROCEDURES 30 10 4 CONDENSATION TREATMENT 30 10 4 1 CONDENSATE VOLUME 30 10 5 BURNER MAINTENANCE 31 10 5 1 BURNER REMOVAL AND CLEANING 31 10 5 2 BURNER CLEANING PROCEDURE 31 10 6 CHANGING THE HOT SURFACE IGNITER 31 10 6 1 RE INSTALLING THE IGNITER 32 10 7 PRIMARY HEAT EXCHANGER INSPECTION 32 10 8 CONDENSING HEAT RECOVERY MODULE CHRM INSPECTION 32 10 9 RE INST...

Page 4: ...d by incorporating preheat of intake combustion air which consequently maintains the outer panels cool and thus reduces jacket loss DynaFlame Condensing In this series most of the sensible heat value is being transferred into the water The unused portion of the sensible heat and most of the latent heat is absorbed by the Condenser Heat Recovery Module CHRM 1 2 SPECIAL INSTRUCTIONS TO OWNER This ma...

Page 5: ...appliance from cycling on its limit if the appliance is switched over to local operation due to a failure in the remote operating system 7 The local thermostat initiates a start up sequence once it receives a heat demand If the appliance is equipped with a local remote switch and if the switch is set in remote a heat demand is available only if the remote system calls for heat 8 The local thermost...

Page 6: ...r gas supplier DO NOT Do not use this appliance if any part of it has been under water The possible damage to a flooded appliance can be extensive and present numerous safety hazards Any appliance that has been under water must be replaced WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas s...

Page 7: ...connected to the common venting system placed in operation while the other appliances remaining connected to the common venting system are not in operation Seal any unused openings in the common venting system Visually inspect the venting system for proper size and horizontal pitch and determine that there is no blockage restriction leakage corrosion or other deficiency which could cause an unsafe...

Page 8: ...t off on all systems When placing the appliance be aware that a minimum clearance of 24 must be provided at the front to allow easy access to the primary heat exchanger Non condensing units do not require access 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 Conden...

Page 9: ... 30cm 12 30cm 1500 24 60cm 12 30cm 12 30cm 1750 24 60cm 12 30cm 12 30cm 2000 24 60cm 12 30cm 12 30cm 2500 24 60cm 12 30cm 12 30cm 3000 24 60cm 12 30cm 12 30cm 3500 24 60cm 12 30cm 12 30cm 4000 30 77cm 12 30cm 12 30cm 4500 35 89cm 12 30cm 12 30cm 5000 40 102cm 12 30cm 12 30cm Allow adequate space for the venting in addition to 6 clearance to combustibles Table 3 Appliance Dimensions and Specificati...

Page 10: ...ns should be secured and sealed per the vent manufacturers specifications When a Positive vent system 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 fireplace is vented through the chimney 2 1 1 CATEGORY I AND CATEGORY Ill VENTING A Category I or Ill venti...

Page 11: ...ent for Use for DynaFlame Non condensing Category lll Installations 1 Corrosion resistant stainless steel single wall 2 Al 294Cor equivalent single or double wall Exhaust Vent for Use for DynaFlame Condensing Category ll or lV Installations 1 AL294Cor equivalent Single or Double Wall 2 BH type Intake Air Supply Air or Fresh Air Piping 1 PVC Non Foam Core Pipe 2 CPVC Chlorinated Polyvinyl Chloride ...

Page 12: ...l General instructions The vent terminal should be vertical and exhaust outside the building at least 2 feet 0 61M above the highest point of the roof within a 10 foot 3 05M radius of the termination The vertical termination must be a minimum of 3 feet 0 91M above the point of exit A vertical termination less than 10 feet 3 05M from a parapet wall must be a minimum of 2 feet 0 61M higher than the ...

Page 13: ... maintain a negative draft in the chimney and allow common venting Approval of the installation will be at the discretion of authorities having jurisdiction IN GENERAL The operation of exhaust fans compressors air handling units etc can rob air from the room creating a negative pressure condition leading to reversal of the natural draft action of the venting system Under these circumstances an eng...

Page 14: ... will minimize flue gas condensation inside the vent Provisions must be made for collecting and disposing of any condensation which may occur The authorities having jurisdiction must approve venting Periodically check to ensure that the vent terminal is unobstructed This venting system uses the appliance s internal combustion air fan to force the flue products out horizontally Vent cap and venting...

Page 15: ...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 cap must not exceed 100 ft equivalent feet 30 5m in length Subtract 7 2 13 m to 19 feet 5 8 m of equivalent length depending on centreline radius for each 90 elbow installed in the air inlet pipe system Pressure drop in 45 elbow will be half as muc...

Page 16: ...acing it back to the ratio control valve where the identification of the tapping is stamped into the die cast actuator The differential gas pressure measurement is made between the high and low pressure taps across the in line metering gas orifice Check this value to confirm that it matches the differential air pressure while the appliance is firing The controls on this appliance may fire the burn...

Page 17: ... firing Immediately repair any leak found in the gas train or related components DO NOT operate an appliance with a leak in the gas train valves or related gas piping 3 7 CHECKING DIFFERENTIAL AIR AND GAS PRESSURES Figure 3 Differential Air Pressure Manometer Connection The 1 to1 air gas ratio control actuator has embossed markings identifying air air gas gas connections Using a test hose assembly...

Page 18: ...ed follow the Gas Manifold Pressure Measurement Procedure for proper measurement There are no serviceable parts on the ratio gas valve actuator 3 10 VENTING OF GAS VALVES AND PRESSURE SWITCHES The optional gas pressure switches may be provided with threaded termination points to be vented to the atmosphere outside the building The gas pressure regulation function is provided by the ratio gas valve...

Page 19: ...s in the piping on the suction of the pump and in the piping on the discharge of the appliance Use suitable pipe hangers or floor stands to support the weight of all water and gas piping Always pump toward the heat exchanger inlet Never pump away from the exchanger since this will result in a low pressure zone which will allow localized boiling and result in heat exchanger damage Do not allow the ...

Page 20: ...re controlled by the selection of a properly sized circulating pump To ensure proper operation and ensure longevity of this heat exchanger minimum inlet water temperatures of 110 ºF 44 ºC MUST BE maintained When return water temperatures are below approximately 110ºF 44 ºC the flue products passing through the copper fined tubes will be cooled below their dew point resulting in the formation of co...

Page 21: ...n of a relief valve at the outlet of the CHRM is recommended This valve is to be sized at minimum for 10 of the input of the appliance and is to be piped to drain When cold water supply with temperatures less than 110 ºF 44 ºC passes through the CHRM it will cool the flue products below dew points resulting in the formation of condensation Furthermore the volumetric flow rate of the flue gases wil...

Page 22: ...tall over public walkway where local experience indicates condensation or vapour from the boiler creates a nuisance or hazard Minimum 3 feet above any forced air inlet located within 10 feet of vent termination Minimum 4 feet below 4 feet horizontally or above any door window or gravity air inlet Minimum 4 feet horizontally from electric meters gas meters regulators and relief valves Use appropria...

Page 23: ...his case the CHRM may be fed directly with part of the supply water using a secondary pump 4 14 CIRCULATING PUMP SELECTION The appliance has a low mass finned tube heat exchanger for fast response and high heat absorption and employs copper tubes for models DF 500 thru DF 3000 and copper nickel tubes for models Df 3500 thru DF 5000 Selecting the proper pump will ensure that temperature rise does n...

Page 24: ...30VAC 3 Phase AVOID contact with high voltage wiring 5 3 DIFFRENTIAL AIR PRESSURE SWITCH A differential air pressure switch is used to prove operation of the combustion air fan The pressure switch sensing points are installed at the fan outlet as the air moves into the inlet of the burner One point measures total pressure air and is connected to a pitot tube facing the flow from the fan paddle whe...

Page 25: ...The reset button is located on the front control panel The reset button is active after the post purge cycle when there is a hard lockout condition as indicated by the Status LED 3 flashes Turning the main power OFF and then ON or cycling the thermostat will not reset a hard lockout condition Wait five seconds after turning on the main power before pushing the reset button when the ignition module...

Page 26: ...lding up and down arrow key simultaneously will reset the counter Flame failure signal 24V Molex connector for ease of service Error message display Test override feature to test pump operation stages 1 2 and alarm Press and hold the UP button to test After one second the pump will turn ON Stage 1 will turns ON after four seconds Stage 2 will turn ON after seven seconds Alarm will turn ON after te...

Page 27: ...oved the control turns off the appliance and operates the appliance pump based on the purge feature Mode 4 is intended for hydronic heating The set point for inlet water control is pre set to 180 F and the auto re set limit is set to 230 F The inlet set point can be adjusted however the limit is fixed In addition to the auto reset limit the factory installs a manual re set limit set to 250 F The c...

Page 28: ... in all settings 0 allows adjustments to all settings 2 allows adjustment of set point only 6 3 VARIABLE FREQUENCY DRIVE VFD The VFD has a factory set security code which has to be entered before any adjustments can be made The VFD has 50 parameters which can be adjusted At present only the following are pertinent Table 14 Parameter Function Settings 2 Carrier Frequency 03 4 Stop Method 03 5 Stand...

Page 29: ... being pumped toward the heat exchanger inlet Never pump away from the exchanger since this will result in a low pressure zone which will allow localized boiling and result in heat exchanger damage Power to the boiler and pump must be from the same circuit to prevent the boiler firing in case the pump is inadvertently shut off Inlet gas pressure must be a minimum of 3 W C for natural gas and 11 W ...

Page 30: ...O2 reading at full fire should not exceed 8 At low fire CO2 will be between 7 and 7 5 For propane reading will be approximately 1 5 higher Allow the water temperature to rise so that the heater cycles on the operator Check the temperature rise across the heat exchanger This will be item ΔT on the SmartFlame control For hydronic applications and for domestic hot water a rise exceeding 35ºF is not n...

Page 31: ...28 PART 9 TROUBLE SHOOTING ...

Page 32: ...29 ...

Page 33: ...te supply of combustion and ventilation air 10 3 FLUE GAS PASSAGEWAYS CLEANING PROCEDURES Any sign of soot around the inner jacket outer jacket flue pipe connections burner or in the areas between the fins on the copper heat exchanger indicates a need for cleaning The following cleaning procedure must only be performed by a qualified serviceman or installer Proper service is required to maintain s...

Page 34: ... flame 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 silicone gasket may adhere to the underside of the fan s flange Carefully pry the flange away from the gasket prior to removing the fan assembly The burner can now be lifted vertically out of t...

Page 35: ...T EXCHANGERS Carefully reinstall the heat exchanger if removed from the appliance Check all gaskets and replace if damaged Replace heat exchanger cover Reassemble outer jacket panels Cycle unit and check for proper operation Replace the top cover 10 10 COMBUSTION AIR FAN Combustion air fan should be checked every 6 months Clean internal filter to fan as required when installed in a dust or dirt co...

Page 36: ...he pressure when the system is hot Do not operate the system at less than 30 PSIG when hot Water piping must be supported by suitable hangers or floor stands NOT by the appliance Pipe systems will be subject to considerable expansion and contraction Pipe supports could allow the pipe to slide resulting in noise transmitted into the system Padding is recommended The boiler pressure relief valve mus...

Page 37: ...of operation 2 The boiler will fire down to 20 of rated input on initial start up and adjust input as required to meet system demand 3 Ensure that inlet water temperature does not fall below 110 F 43 3 C 4 Based on system demand the appliance will modulate accordingly 5 As system demand is satisfied the burner will cycle off and the combustion air fan will decelerate at a pre programmed rate befor...

Page 38: ... chemistry of the water to be heated Water with a hardness of less than 5 grains per gallon will usually have a low pH which can be aggressive and corrosive causing non warrantable damage to the heater pump and associated piping Corrosion due to water chemistry generally shows up first in the hot water system because heated water increases the rate of corrosive chemical reactions CAUTION Temperatu...

Page 39: ...36 PART 12 EXPLODED VIEW ...

Page 40: ...37 ...

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Page 42: ... X X X 9 Vent Transition Disk 14 5279 X 10 Back Cover Plate Non Condensing 14 0346 X X X X X 14 6022 X X X X 11 Transition Inner to Outer Jackets 14 5225 X X X X X X X X X 12 Outer Jacket Rear Panel 14 5224 X 14 5009 X X X X 13 Inner Top Panel 14 5203 X X X X X X X X X 14 0203 X X X X 14 Drain Pan 14 5211 X X X X X X X X X 15 Outer Jacket Left Panel 14 5222 X 16 Electrical Enclosure 14 5260 X 17 I...

Page 43: ...0 3000 3500 4000 4500 5000 40 Flame Rod 66 0023 X 41 Hot Surface Ignitor 3201R X 42 View Port Glass VPORTGLASS X 13 5052 X X X X 13 5330 X X X 13 5331 X 13 5332 X 43 Burner Flange 13 5333 X X X X 33 0020 X X X X 33 0018 X X X X 44 Inlet Outlet Header Top Gasket 33 0019 X 45 Burner Support Ceramic Gasket 33 0023 X X X X 500 BRN X 750 BRN X 1100 BRN X 1200 BRN X 1500 BRN X 1750 BRN X 2000 BRN X 2500...

Page 44: ...IF 750 CH X GFIF 1100 CH X GFIF 1200 CH X GFIF 1500 CH X GFIF 1750 CH X GFIF 2000 CH X GFIF 2500 CH X GFIF 3000 CH X GFIF 3500 CH X GFIF 4000 CH X GFIF 4500 CH X 54 Fan Intake Filter GFIF 5000 CH X 500 HTX X 750 HTX X 1100 HTX X 1200 HTX X 1500 HTX X 1750 HTX X 2000 HTX X 2500 HTX X 3000 HTX X 3500 HTX X 4000 HTX X 4500 HTX X 55 Primary Heat Exchanger Vee Baffles Excluded 5000 HTX X CAM 500 X CAM ...

Page 45: ...M005S X X X X SM010S X X X SM015S X X 60 Variable Frequency Drive 1 2HP 1HP 1 1 2HP 3HP SM23S X X X X 61 Ignition Module DF 35 67 X 62 Control BTC 2PA X 63 Control PXZ X 64 On Off Switch W51A152A X 65 Indicator Lights IND LGT SET X 66 Fuse BK AGC 4 X 67 24V 120V Relays LY1F 24 120 X 68 75VA Transformer HCT 01J28807 X 1 2 HP X X X X 1 HP X X X 1 1 2 HP X X 69 Electrical Motor 3 HP X X X X ...

Page 46: ...43 PART 13 ELECTRICAL DIAGRAMS ...

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Page 52: ...ten replacement purchase price pro rated at the following schedule Year six 60 Year seven 65 Year eight 70 Year nine 75 Year ten 80 of the current list price of the current list price This term is reduced to FIVE years if the appliance is used for other than hydronic space heating Heat Exchanger shall be warranted for 20 years from date of installation against Thermal Shock excluded however if cau...

Page 53: ...built 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 products from CAMUS Hydronics Limited call 905 696 7800 today CAMUS HYDRONICS LTD 6226 Netherhart Road Mississauga Ontario L5T 1B7 TEL 905 696 7800 FAX 905 696 8801 ...

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