Camus Hydronics DMW082 Installation, Operation And Service Manual Download Page 45

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SYMPTOM

FAILURE MODE

ANALYSIS

Temperature
Overshoot

• Stack temperature has exceeded

the limit set on the boiler.

• Alert 125, 353

• PVC: Reduce desired setpoint to less than 140

• Measure the resistance of the flue sensor at room

temperature, it should be approximately 10k

Ω

• PVC: 149

• CPVC: 194

• PPE: 230

• Stainless Steel, AL29-4C: 250

• Outlet temperature has exceeded

limit temperature

• Alert 63, 67, 79, 137, 276-281
• ILK OFF

Verify that the system is full of water and that all air has

been properly purged from the system

• Verify that the boiler is piped properly.
• Verify that adequate power is supplied to pump on a call

for heat. If voltage cannot be detected check wiring

• Verify pump is circulating when power is supplied. If so,

pump impeller may be stuck.

• If power is present during a call for heat, but the pump still

does not circulate, replace the pump.

• Replace the DynaMax Controller, if necessary.

Sensor Not
Connected

• Inlet sensor, Alert: 91
• Outlet sensor, Alert: 92
• DHW sensor, Alert: 93
• Flue sensor, Alert: 95
• Outdoor sensor, Alert: 96

• Verify that the sensors are connected
• Verify that they are wired correctly.
• Measure the resistance of the sensors, 10k

Ω

sensors.

• Replace the sensor if necessary

Fan Not Turning

• Fan refuses to rotate
• Alert 122, 123, 128, 129, 130,131,
132

• Check fan power wires
• Fan signal wires are interchanged
• Minimum fan speed must be greater than 1500 RPM

Blocked Flue Switch

• Check gas pressure switches, if
equipped
• Alert 63, 67, 79, 137, 276-281
• ILK OFF

• Blocked flue switch wire(s) is/are loose
• Blocked flue switch is set too light if it trips at full fan

speed, reduce sensitivity by turning screw 1 turn
clockwise.

Flame Detection is
out of Sync

• Flame detection is present when no

visible signs of a flame exist

• Lockout 105, 158

• Verify supply voltage for proper polarity.
• Check external wiring for voltage feedback
• Check internal wiring for proper connections
• Check the flame sensor and verify that it is clean
• Replace DynaMax HS Controller

Blank Display
Screen

• Blank display screen

• Check S4 switch position on ignition module. Switch is

pushed towards J5 connector

• Check that display is connected to the standalone

connector on the back of the display

Replace fuse with factory 3.15A fuse.
• DO NOT use alternates as it may damage the DynaMax

HS Controller

Internal Fault

• Alert 3-9, 20-31
• Lockout 10-18, 32-46, 58-60 ,97-
99, 143-148

• Reset SOLA
• If fault persists, replace SOLA

Summary of Contents for DMW082

Page 1: ...amage 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 canno...

Page 2: ......

Page 3: ...INATION AND AIR INLET CLEARANCES 10 2 5 1 Sidewall Venting 10 2 5 2 Sidewall Air Inlet 10 2 5 3 Sidewall Concentric Vent Air 11 2 6 Vertical Direct Venting 11 PART 3 GAS CONNECTION 13 3 1 GAS CONNECTION 13 3 2 GAS PIPING 13 3 3 INSTALL PIPING 13 3 4 CHECKING GAS SUPPLY PRESSURE 13 3 5 HIGH and LOW GAS PRESSURE SWITCHES Optional 14 3 6 AIR GAS RATIO VALVE 14 3 7 BURNER 14 PART 4 WATER CONNECTION 15...

Page 4: ...ENANCE 51 9 1 EXAMINE THE VENTING SYSTEM 51 9 2 VISUALLY CHECK MAIN BURNER FLAMES 51 9 3 CLEANING BOILER HEAT EXCHANGER 51 9 4 CONDENSATE TREATMENT 52 9 5 IGNITER AND FLAME SENSOR ELECTRODES 52 9 6 CHECK IGNITER GROUND WIRING 52 9 7 BURNER MAINTENANCE 52 9 7 1 Burner Removal and Cleaning 53 9 8 REMOVAL OF COMBUSTION CHAMBER LINING 53 9 9 COMBUSTION AND VENTILATION AIR 53 9 10 GAS VALVE VOLTAGE 54 ...

Page 5: ...10 12 LOCAL REMOTE SWITCH 59 10 13 MODBUS LOCAL SWITCH 59 10 14 APPLIANCE 59 PART 13 PIPING DIAGRAMS 60 PART 14 EXPLODED VIEW PARTS LIST 65 PART 15 ELECTRICAL DIAGRAMS 73 15 1 DM 80 299 INTERNAL WIRING DIAGRAM 73 15 2 DM 399 800 INTERNAL WIRING DIAGRAM 74 15 2 FIELD WIRING 76 15 2 1 System Sensor 76 15 2 2 Lead Lag Setup 76 ...

Page 6: ...EQUENCE OF OPERATION 1 Power switch is placed in the ON position 2 Minimum 120 VAC 60Hz single phase 15A circuit is supplied to the DynaMax HS field connection board 3 24Vac power is supplied to the DynaMax HS Controller which provides all setup and ignition control functions 4 After the appliance water pump starts flow is proven by the flow proving device or flow switch The normally open dry cont...

Page 7: ...mbustion and proper venting 1 6 INSTALLATION CODES The equipment shall be installed in accordance with those installation regulations enforced in the local area where the installation is to be made These shall be carefully followed in all cases Authorities having jurisdiction shall be consulted before installations are made In the absence of such requirements the installation shall conform to the ...

Page 8: ...specting and cleaning the heat exchanger and vent pipe 1 Turn off electrical power and main manual gas shut off and allow appliance to cool down 2 Remove the vent pipe at connection to heat exchanger and check heat exchanger and vent for obstruction and clean as necessary 3 Remove burner from appliance and carefully clean as required Never brush or wipe the knitted metal fiber surface Use a garden...

Page 9: ...indoors where it is protected from exposure to wind rain and weather The appliance designed for outdoor installation Outdoor Models must be installed outdoors Always consider the use of a shelter such as a garden shed in lieu of direct exposure of the appliance to the elements The additional protection afforded by the shelter will help to minimize nuisance problems with electrical connections and ...

Page 10: ...cifications Model Depth Dim A in Dim B in Equivalent Length of Vent Air Intake Pipes at Recommended Diameter in Water Connection at Boiler in NPT Gas Connection at Boiler in NPT Over 25 and up to 100 Over 15 and up to 25 Up to 15 80 16 1 2 12 3 3 2 1 1 2 100 16 1 2 12 3 3 2 1 1 2 150 16 1 2 12 3 3 2 1 1 2 200 23 1 2 19 3 3 2 1 1 2 250 23 1 2 19 3 3 2 1 1 4 1 2 Maintain minimum specified clearances...

Page 11: ...at Recommended Diameter in Water Conn at Heater in NPT Gas Conn at Boiler in NPT Category IV CAT II Comb Vents Over 25 and up to 100 Over 15 and up to 25 Up to 15 210 36 22 3 4 14 1 4 23 24 1 4 34 1 4 32 3 3 2 4 1 1 2 260 36 22 3 4 14 1 4 23 24 1 4 34 1 4 32 3 3 2 4 1 1 4 1 2 299 47 1 8 34 7 8 14 23 29 7 8 33 7 8 32 4 3 3 5 1 1 4 3 4 399 47 1 8 34 7 8 14 23 29 7 8 33 7 8 32 4 3 3 5 1 1 2 1 500 47 ...

Page 12: ...7 Figure 5 DynaMax HS Wall Hung Service Clearances Figure 6 DynaMax HS Floor Mount Service Clearances ...

Page 13: ...itive 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 Inspect completed vent and air supply piping thoroughly to ensure all connections are sealed and are in compliance with the instructions provided and s...

Page 14: ...ional designer acceptable to the authority having jurisdiction 1 The DynaMax HS Floor Mount boiler may be vented as a Category II appliance using sealed vent suitable for a condensing appliance 2 3 1 Approved Venting Materials Category II 1 PVC and CPVC Schedule 40 approved to ULC S636 2 Manufactured prefabricated UL ULC listed vent of AL29 4C or 316L stainless steel Use of 316L is limited to use ...

Page 15: ...enterline radius 4 Vent outlet shall terminate at least 12 0 30m away from any forced air inlet Vent must be at least 7 feet 2 15m above grade when located adjacent to public walkways due to normal formation of water vapour in the combustion process 5 Vent outlet MUST NOT terminate below a forced air inlet at any distance 6 Vent cannot terminate below grade Position vent termination where vapours ...

Page 16: ...edence 7 Position termination so they are not likely to be damaged by foreign objects or exposed to a build up of debris 8 Flue gas condensate can freeze on exterior walls or on the vent cap Frozen condensate on the vent cap can result in a blocked flue condition Keep the vent cap terminal clear of snow ice leaves debris etc Some discolouration to exterior building surfaces is to be expected Adjac...

Page 17: ... Concentric Vent Vertical Venting CAUTION Do not operate appliance with the terminal cap removed as this may result in the recirculation of flue products Water may also flow into the combustion air pipe and into the burner enclosure Length of Air Inlet Pipe The maximum total length of the vertical roof top combustion air inlet pipe as installed from the appliance to the terminal cap must not excee...

Page 18: ...n the size of the connection on the appliance Sizing based on Table 8 is recommended depending on model Before operating the appliance the complete gas train and all connections must be tested using soap solution Verify that the appliance is supplied with the type of gas specified on the rating plate Heating values of local natural gas are to be between 950 and 1010 Btu ft 3 Consult factory if hea...

Page 19: ...cess The valve is a 1 1 negative pressure gas valve The valve performs the functions of a pressure regulator safety shutoff and air gas ratio control Full closing of the valve seat occurs in less than 0 8 seconds when the valve is de energized Operation of the gas valve in combination with the combustion air fan allows the burner input rate to vary from 20 to 100 based on temperature demand The in...

Page 20: ...g If the appliance is installed above radiation level it must be provided with a low water cut off device at the time of appliance installation available from Camus Some local codes require the installation of a low water cut off on all systems Before connecting DynaMax HS to piping in a closed loop system flush system thoroughly and refill with clean water and add chemical treatment to bring into...

Page 21: ...antable heat exchanger damage Table 10 Minimal System Pipe Size Input BTU hr Water Size NPT in 80 000 1 100 000 1 150 000 1 199 000 1 1 4 250 000 1 1 4 299 000 1 1 2 399 000 2 500 000 2 600 000 2 700 000 2 800 000 2 4 5 HEAT EXCHANGER This appliance uses precision formed stainless steel tubing to maximize the heat transfer process and to achieve 97 steady state efficiency The DynaMax HS is designe...

Page 22: ...199 000 12 6 7 2 10 8 5 8 250 000 15 8 11 5 13 5 8 7 299 000 18 9 9 3 16 2 7 0 399 000 25 2 8 4 21 6 6 3 500 000 31 5 9 2 27 0 6 9 600 000 38 8 17 5 32 0 11 8 700 000 45 3 18 2 40 0 14 4 800 000 51 8 23 5 43 0 16 0 Table 12 Flow and Pressure Drop at a Given Temperature Rise DHW Input Btu Hr 20 F 11 1 C Temp Rise USGPM min flow P Ft 80 000 7 5 11 5 100 000 9 4 26 9 150 000 14 0 27 8 199 000 19 2 25...

Page 23: ...sted every six months The normally open switch contact of the low water cutoff is to be wired in series with the flow switch This can be wired into the DynaMax HS terminal labelled Flow Switch CAUTION Remove jumper when connecting to 24 VAC circuit Figure 21 Low Water Cut Off Electrical Connections Watts Figure 22 Low Water Cut Off Electrical Connections ITT 4 11 RELIEF VALVE Figure 23 Relief Valv...

Page 24: ...d be horizontal for at least an inch to ensure sufficient electrical conductivity 5 2 HIGH LIMIT A manual reset fail safe high limit aqua stat control is inside the appliance and the control bulb is installed in a dry well in the heat exchanger outlet The setting of this control limits maximum discharge water temperature to 210 o F CPVC AL29 4C Stainless and 185 o F PVC The temperature of the outl...

Page 25: ...Outdoor sensor fault 105 Flame detected out of sequence 106 Flame lost in Main Flame Establishing Period MFEP 107 Flame lost early in run 108 Flame lost in run 109 Ignition failed 112 Pilot test flame timeout 113 Flame circuit timeout 149 Flame detected To eliminate the hard lockout error 1 Press the button to clear the error on screen 5 4 2 Automatic Reset Codes Table 17 Automatic Reset Codes Des...

Page 26: ...lay between stages minimum on time per stage minimum off time per stage Flame failure signal Error message display in text Manual override of boiler input rate for combustion Pump exercising feature runs pump 10 seconds every three days in the event of no pump operation Levels of Access Two levels of access to simplify the use of the boiler User Access to general boiler and display settings and ad...

Page 27: ...eshooting information on the diagnostic screen Figure 25 Diagnostic Screen PARAMETER DESCRIPTION Boiler pump Pump A Auxilary Pump Pump B 3 way valve diverter operation DHW Pump Pump C Additional contact rated for 1 6hp Sequence of Operation Pump A is energized for any call for heat Pump B is energized on CH Pump C is energized on DHW Interlock Flow switch LWCO if equipped Blocked flue switch N C L...

Page 28: ...oint Modulates on boiler inlet sensor default Heat demand is generated when Remote Operator is closed 1 Place both toggle switches to LOCAL 2 Press and select Login 3 Select Quick Start 4 Select CH Setpoint and enter desired setpoint using 5 way control The setpoint can be chaged on screenby using the or buttons and press 5 Place Local Remote switch to REMOTE for remote enable operation if require...

Page 29: ... switches to LOCAL 2 Press and select Login 3 Select Advanced Setup 4 Select CH Config 5 Select Outdoor Reset Config 6 Select Outdoor Reset and Press and select Enable 7 Set Max outdoor temp Warm weather shutdown WWSD 8 Set Min outdoor temp Outdoor Design 9 Set Low Water temp Min Water Temp 10 Set Outdoor boost max off point Design Max 11 Select Sensor Configuration 12 Select Outdoor temp src and ...

Page 30: ... Connect Outdoor Sensor to J3 ECOM connector 4 Place both toggle switches in LOCAL 5 Press and select Login 6 Select Advanced Setup 7 Select CH Config 8 Select Outdoor Reset Config 9 Select Outdoor Reset and Press and select Enable 10 Set Max outdoor temp Warm Weather shutdown WWSD 11 Set Min outdoor temp Outdoor Design 12 Set Low Water temp Min Water Temp 13 Set Outdoor boost max off point Design...

Page 31: ...nstructions Boiler operates with variable setpoint determined by 4 20mA incoming signal Modulates on header sensor Heat demand is generated when Remote Operator is closed and 4 20mA or 0 10Vdc signal is present 1 Place both toggle switches in LOCAL 2 Press and select Login 3 Select Advanced Setup 4 Select CH Config 5 Select Modulation rate source 4 20mA and burner on off 6 Place right hand toggle ...

Page 32: ...OCAL 2 Press and select Login 3 Select Advanced Setup 4 Select DHW Config Inlet Sensor operation 5 Select Demand switch Sensor only and Press 6 Select Mod sensor Inlet and Press go to step 7 DHW Stat operation 5 Select Demand switch DHW switch and Press 6 Select Mod sensor Inlet and Press go to step 7 DHW Sensor operation 5 Select Demand switch Sensor only and Press 6 Select Mod sensor DHW and Pre...

Page 33: ...Heat demand is generated when Remote Operator is closed DHW Sensor Stat if required 1 Place both toggle switches in LOCAL 2 Press and select Login 3 Select Advanced Setup 4 Select DHW Config 5 Select Demand switch Plate Heat Exch and Press 6 Select Mod sensor DHW 7 Select DHW Setpoint and enter desired setpoint using 5 way control 8 Place right hand toggle switch setting to REMOTE for remote opera...

Page 34: ... address 1 7 Verify MB2 Modbus address 1 8 Select Lead Lag Config 9 Select Lead Lag Master Config 10 Select Master enable Enable Fixed Setpoint operation 11 Select Setpoint and enter desired setpoint using 5 way control 4 20mA 0 10Vdc setpoint operation 11 Select Setpoint Source 4 20mA and Press 12 Consult Additional Boiler Parameters section in manual on page 33 using parameter address 560 and 56...

Page 35: ...tches in LOCAL 2 Press and select Login 3 Select Advanced Setup 4 Select System 5 Select System ID Access 6 Select MB1 Modbus address 2 To be in sequential order 7 Select MB2 Modbus address 2 To be in sequential order 8 Select Lead Lag Config 9 Select Lead Lag Slave Config 10 Select Slave enable Enabled via SOLA master and Press ...

Page 36: ...emp src and Press 6 Select S5 and Press Master Boiler 7 Place both toggle switches in LOCAL 8 Press and select Login 9 Select Advanced Setup 10 Select Lead Lag Config 11 Select Lead Lag Outdoor Reset 12 Select Outdoor reset enable Enable and press 13 Set Max outdoor temp Warm weather shutdown WWSD 14 Set Min outdoor temp Outdoor Design 15 Set Low Water Temp Min Water Temp 16 Set Outdoor boost maxi...

Page 37: ...nt after Interstage delay 2 minutes a lag boiler will be brought online and will also fire at the base load rate specified Modulation of boilers will only occur after all boilers in the Lead Lag system are firing at the specified base load rate 80 1 Place both toggle switches in LOCAL 2 Press and select Login 3 Select Advanced Setup 1 Select Lead Lag Config 2 Select Lead Lag Master Config 3 Select...

Page 38: ...1 equalize run time default Add stage error threshold 718 0 130 o C Default 5 o F 3 o C Add stage inter stage delay 722 0 64800 seconds Default 120 seconds Drop stage threshold 727 0 130 o C Default 5 o F 3 o C Drop stage inter stage delay 731 0 64800 seconds Default 120 seconds Lead rotation time 733 0 64800 minutes Default 60 minutes Standalone Parameters CH Enable 208 0 Disabled 1 Enabled DHW E...

Page 39: ... 23 3 233 0 17 8 178 10 12 2 122 20 6 7 67 30 1 1 11 40 4 4 44 50 10 0 100 60 15 6 156 70 21 1 211 80 26 7 267 90 32 2 322 100 37 8 378 110 43 3 433 120 48 9 489 130 54 4 544 140 60 0 600 150 65 6 656 160 71 1 711 170 76 7 767 180 82 2 822 190 87 8 878 200 93 3 933 ...

Page 40: ...in LOCAL 2 Press and select Login 3 Select Advanced Setup 4 Select Burner Control Ignition 5 Select Adjustable lightoff rate and enter desired lightoff rate using 5 way control and press Adjust stack limit Description Programming Instructions Adjust stack limit based on vent material used PVC 149o F CPVC 1940 F PP AL29 4C Stainless steel 230o F 1 Place both toggle switches in LOCAL 2 Press and sel...

Page 41: ...ription Programming Instructions To view burner run time pump cycles for maintenance and service purposes 1 Place both toggle switches in LOCAL 2 Press and select Login 3 Select Advanced Setup 4 Select System Config 5 Select Statistics Config ...

Page 42: ...de deposit on the sensor rod must be removed with steel wool DO NOT use sand paper or grit cloth since this will contaminate the metal surface 7 3 COMBUSTION AIR FAN DynaMax HS uses a modulating air fan to provide combustible air gas mix to the burner and push the products of combustion through the heat exchanger and venting system The fan assembly consists of a sealed housing and fan wheel constr...

Page 43: ... from the system Verify that wiring is correct Flame Failure Pressing the manual OK button on the DynaMax HS Control Panel to restart the ignition sequence The boiler has failed to ignite the burner after 3 consecutive attempts Verify that all air has been purged from gas line Inspect spark electrode and related wiring for damage and connection errors Verify that the ignition fan speed is set to 3...

Page 44: ...rocedure Clean or replace the burner if required Air in the piping system Purge all air from the piping system Incorrect igniter gap Check that spark gap is 9 64 Auto Reset High Limit Trips The outlet temperature has exceeded the setpoint temperature specified Alert 63 67 79 137 276 281 ILK off Verify that the system is full of water and that all air has been properly purged from the system Verify...

Page 45: ... are wired correctly Measure the resistance of the sensors 10kΩ sensors Replace the sensor if necessary Fan Not Turning Fan refuses to rotate Alert 122 123 128 129 130 131 132 Check fan power wires Fan signal wires are interchanged Minimum fan speed must be greater than 1500 RPM Blocked Flue Switch Check gas pressure switches if equipped Alert 63 67 79 137 276 281 ILK OFF Blocked flue switch wire ...

Page 46: ... Burner switch turned OFF 30 Burner switch turned ON 47 Flame rod to ground leakage 49 Abnormal 24Vac voltage 50 Modulation Fault 61 Anti short Cycle 62 Fan speed not proved 67 Interlock Off safety circuit is open 69 Pilot test hold 78 Demand lost in run 79 Outlet high limit tripped internal limit 81 Delta T limit exceeded 30 o F 91 Inlet sensor fault 92 Outlet sensor fault 93 DHW sensor fault 95 ...

Page 47: ...e turn at a time NO Verify gas valve is being powered by ignition control Check ignition speed is between 2500 to 3000 RPM using System Monitor NO Adjust ignition speed to 3000 RPM YES YES Burner lights off and stays on NO Check flame sensor for carbon deposits and clean if necessary NO Position flame sensor so that it is closer to the burner YES Adjust high fire combustion to 8 5 9 0 CO2 NO CO2 8...

Page 48: ...h tripped optional To identify the safety that is open set the multimeter to Vac and measure the voltage from one contact to ground The contacts produce a 24Vac when the circuit is closed Is vent and or air intake blocked YES Clear vent and or air intake termination NO High Gas Pressure Tripped YES High gas pressure switch C6097B N C set to 14 w c NO YES Check incoming gas pressure and reset high ...

Page 49: ...s closed Is pump powered NO Check pump wiring and pump delay relay YES Is there a current transformer NO Check operation of paddle style flow switch installed on outlet of DynaMax HS YES Use meter to verify amperage draw on pump and verify it with rating label on pump NO Check that automatic air vent thumbscrew is loose YES YES Purge air from water lines Is there a double loop through the current ...

Page 50: ...n 150 o F is selected and PVC venting is used the setpoint must be reduced to below 150 o F to avoid nuisance flame failures If a setpoint greater than 150 o F is required venting with CPVC AL29 4C 316LL or PPE is strongly advised The stack temperature is between 15 30 o F above the incoming return water temperature to the appliance Vent Material Maximum Flue Temperature o F PVC 149 CPVC 194 PPE 2...

Page 51: ... rod Is Flame sensor plug secure NO Fasten flame sensor plug securely to flame sensor wire and check for corrosion deposits at wire terminals YES Check continuity of flame sensor wire from flame sensor to ignition control J1 2 NO YES Remove flame sensor and clean if necessary NO Bend flame sensor closer to burner NO Replace flame sensor and graphite flame sensor gasket Replace sensor wire since co...

Page 52: ...ax HS must be firing before proceeding DM 080 250 260 Figure 56 Venturi Gas Valve Assembly To adjust the high fire setting 1 Press the button 2 Select Test and press 3 Select Forced Rate and press 4 Select Set High Fire Locate the input adjustment screw on the side of the venturi Turn the screw 1 8 turn in either way for each adjustment to keep track of the adjustments After adjusting the screw wa...

Page 53: ...g 1 Press the button 2 Select Test and press 3 Select Forced Rate and press 4 Select Set High Fire Locate the input adjustment screw on the top side of the gas valve Turn the screw 1 8 turn in either way for each adjustment to keep track of the adjustments After adjusting the screw wait a moment for the combustion levels to stabilize before attempting to make any further adjustments Continue this ...

Page 54: ...ruction of air flow to the burner Yellow Flames Yellow flames can be caused by blockage of primary air flow to the burner or excessive gas input This condition MUST be corrected immediately If improper flame is observed examine the venting system ensure proper gas supply and adequate supply of combustion and ventilation air 9 3 CLEANING BOILER HEAT EXCHANGER Figure 32 Heat Exchanger Burner Assembl...

Page 55: ...Replace neutralizer medium as required There are several factors affecting amount of condensation created by the appliance however for rough approximation use Condensation Volume US Gallon Hr Input MBH 1000 x 5 0 Many jurisdictions will require the acidic condensate to be neutralized before it can be placed in a drain system A neutralizer calcium carbonate to control the pH of the liquid discharge...

Page 56: ...are when removing and handling the burner Sharp objects or impact may damage or tear the metal fiber surface rendering the burner unfit for service 9 8 REMOVAL OF COMBUSTION CHAMBER LINING The combustion chamber insulation in this appliance contains ceramic fiber material Ceramic fibers can be converted to cristobalite in very high temperature applications The International Agency for Research on ...

Page 57: ...can be provided by using hydronic system antifreeze Follow the manufacturer s instructions DO NOT use undiluted or automotive type antifreeze Shut down and draining If for any reason the unit is to be shut off in a space where danger of freezing exists the following precautionary measures must be taken o Shut off gas supply o Shut off water supply o Shut off electrical supply o Drain the main exch...

Page 58: ... used The expansion tank must be installed close to the boiler and on the suction side of the system pump appliance Inlet to ensure proper operation Caution This appliance should not be operated at less than 12 PSIG cold Pressure will rise when hot Expansion tank sizing will determine the pressure when the system is hot Do not operate the system at less than 18 20 PSIG when hot Water piping must b...

Page 59: ...ry 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 boil...

Page 60: ...ise 4 Be sure all valves are open between the hot water heater and the storage tank Ensure that all ball valves are fully ported 5 Check the pump to be sure it is running properly and that the pump motor is running in the proper direction 6 Common manifold piping for multiple unit installations will require larger minimum pipe sizes and tank circulating tapping to ensure proper flow The required t...

Page 61: ... remain the same Lead lag Lead lag setpoint Add stage Error threshold AND Lead lag Lead lag setpoint Drop stage Error threshold 3 A boiler should stop Lead lag Lead lag setpoint Drop stage Error threshold If the lead lag master system is interrupted the remaining boilers will operate as standalone boilers based on the Central Heat or DHW parameters when set to Enabled Rotation Rotation time is con...

Page 62: ... Local Remote switch is independent of the 4 20mA 2 10Vdc signal 10 13 MODBUS LOCAL SWITCH The Modbus Local Switch mounted on the terminal board is designed to relay the signal to the boiler display local or accept an incoming signal from Modbus When local is selected via the DPDT switch the boiler display presents all necessary boiler information When Modbus is toggled the boiler display will con...

Page 63: ...header to minimize induced flow through zones 2 Separate boiler loop as shown is recommended for system piping greater than 50 equivalent feet Pressure Reducing Valve Pressure Gauge Ball Valve Air Separator Zone Circulator Flow Check Valve DynaMax HS Boiler Drain Union Temperature Pressure Gauge Expansion Tank ...

Page 64: ... Valve Air Separator Expansion Tank Zone Circulator Flow Check Valve DynaMax HS Boiler Temperature Pressure Gauge Drain Union Anti scald Mixing Valve Note 1 Size main header to minimize induced flow through zones 2 Separate boiler loop as shown is recommended for system piping greater than 50 equivalent feet ...

Page 65: ... Separator Expansion Tank Zone Circulator Flow Check Valve DynaMax HS Boiler Temperature Pressure Gauge Drain Union Anti scald Mixing Valve Note 1 Size main header to minimize induced flow through zones 2 Separate boiler loop as shown is recommended for system piping greater than 50 equivalent feet Indirect DHW Tank Cold Water In Hot Water Out ...

Page 66: ...63 Figure 34 Single Boiler Hydronic Heating Direct Storage Tank Zoned Piping Arrangement Cold Water In DHW Sensor Union Direct DHW Tank Anti Scald Mixing Valve Cold Water In Hot Water Out ...

Page 67: ...r Flow Check Valve DynaMax HS Boiler Master M1 Temperature Pressure Gauge Drain Union DynaMax HS Boiler Slave S2 System Sensor Note 1 Size main header to minimize induced flow through zones 2 Location of system sensor is based on single speed building circulator If a variable speed building circulator is used the system sensor must be placed in the building supply ...

Page 68: ...65 PART 14 EXPLODED VIEW PARTS LIST DYNAMAX HS WALL HUNG ...

Page 69: ...66 DYNAMAX HS FLOOR MOUNT ...

Page 70: ...nge Nuts GM10 05 012 X 5 Igniter GM10 35 108 01 X X X X X X X X X X GM10 35 161 01 X X X 6 Flame Sensor GM10 35 109 01 X X X X X X X X X X GM10 35 162 00 X X X 7 Igniter Flame Sensor Screws GM10 05 020 X 8 DynaMax HS Controller R7910B1009 X 9 DynaMax HS Display DSP49G2094B X 10 Condensate Neutralizer Box 90 15100 X X X X X 90 10030 X X X X X X X X 11 Combustion Fan 150503 00 X X 150563 00 X X X X ...

Page 71: ...X X VCZND6100 U X VBN3EM3POX X X VBN3FP3POX X X X 18 High Limit TCL085A X TCL110A X 19 Turn Lock Wall Hung X Floor Mount X 20 Wall Mount Back Panel 14 5402 X X X 14 5402 250 X X 21 Wall Mount Front Bottom Wrap 14 5403 X X X 14 5403 250 X X 22 Front Upper Wrap 14 5404 X X X 14 5404 250 X X 23 Restrain 14 5405 X X X X X 24 Mounting Bracket 14 5406 X X X X X 25 Lower Bracket 14 5407 X X X X X 26 Wall...

Page 72: ...X X 14 5505 60 75 X X X 43 Side Panel Right 14 5506 20 25 X X 14 5506 X X X 14 5506 60 75 X X X 44 Side Panel Left 14 5507 20 25 X X 14 5507 X X X 14 5507 60 75 X X X 45 Front Panel Bottom 14 5508 X X X X X X X X 46 Side Panel Left Front 14 5509 20 25 X X 14 5509 X X X X X X 47 Control Panel Plate 14 5510 X X X X X X X X 48 HX Support Frame 14 5511 X X X X X 14 5511 60 75 X X X 49 Support Plate 14...

Page 73: ...lange with 3 Street Elbow 44 0009 X 4 Air Intake Box 14 5551 X X 5 Air Intake Box 14 5546 X 69 3 Air Intake Adapter 44 0010 X 4 Air Intake Adapter 14 5559 X X 5 Air Intake Adapter 14 5556 X 70 Condensate Pan 14 5418 X X 14 5414 X 14 5414 250 X X 72 Plate Heat Exchanger Bracket 14 5424 X X X 14 5424 200 X X 73 Transformer Mounting Plate 14 5541 X X X X X 74 Igniter Gasket GM10 25 018 X 75 Flame Sen...

Page 74: ... X X X X 91 DynaMax HS Fan Discharge Orifice 14 0377 80 X X 14 0377 100 X 14 0377 250 X X 92 Expandable Air Inlet Adapter w o Pressure Test Point 14 0378 X X X X X 93 Expandable Air Inlet Adapter 1056 22 X X X X X 94 Flex Pipe 2 Diameter X X X X X X X X X 3 Diameter X 4 Diameter X X 5 Diameter X 95 Flexible Stainless Steel Pipe 1 X 11 66 0075 X 96 Flexible Stainless Steel Pipe 1 2 X 11 66 0073 X 9...

Page 75: ...et Mixing Chamber Gasket 33 0036 X X X X X X X 33 0037 X X X X X X X X X 33 0038 X 33 0043 X X X 33 0057 X X X 106 Air Inlet Gasket 33 0069 X X X 107 Current Transformer Combination Models only RIBXRA X 108 Target disk GM10 25 189 00 X 109 Washer for Target disk GM10 15 014 01 X 110 Counter sunk head screw M4x16 for target disk GM10 05 021 X 111 Vent Gasket GM10 25 153 00 Black X X X GM10 25 178 0...

Page 76: ...73 PART 15 ELECTRICAL DIAGRAMS 15 1 DM 80 299 INTERNAL WIRING DIAGRAM ...

Page 77: ...74 15 2 DM 399 800 INTERNAL WIRING DIAGRAM ...

Page 78: ...75 ...

Page 79: ...rough sequential Modbus addresses Connect the system sensor to the master boiler The master boiler will use the water temperature in the primary loop to control the operation of the lead lag setup If outdoor reset is desired the outdoor sensor needs to be connected to the Outdoor Sensor location on the DynaMax HS terminal board on boiler 2 B 2 If the outdoor sensor is not connected to the Master b...

Page 80: ...us C2 Vdc Display J4 2 3 DHW Pump 1 6hp 4 24Vac or 115Vac for pump contact 5 6 3 way diverter valve 7 Boiler pump contact 10 24Vac return 12 Ground J5 1 Interlock 2 Gas Valve contact J6 1 Blocked Flue 2 Flow switch 7 8 Alarm dry contacts Connector Pin Connector Description J8 1 24Vac for SOLA 2 24Vac return 3 Remote enable disable signal 4 5 Inlet sensor 6 7 4 20mA Input 8 9 10 Outlet sensor high ...

Page 81: ...k excluded however if caused by appliance operation at large changes exceeding 150ºF between the water temperature at inlet and appliance temperature or operating at temperatures exceeding 210o F BURNER If within FIVE years after initial installation of the appliance a burner shall prove upon examination by Camus to be defective in material or workmanship Camus will exchange or repair such part or...

Page 82: ...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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Camus Hydronics DMW082, Installation, Operation And Service Manual

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