Camus Hydronics DRH300 Installation, Operation And Service Manual Download

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CAMUS® HYDRONICS LTD.

6226 Netherhart Road, Mississauga, Ontario L5T 1B7

TEL: 905·696·7800 FAX: 905·696·8801

www.Camus®-hydronics.com

Summary of Contents for DRH300

Page 1: ...ury 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...

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Page 3: ...TICAL VENTING TERMINATION 9 2 1 10 COMBINED COMBUSTION AIR INLET 9 2 1 11 DRAIN TEE 10 2 2 CONVENTIONAL VENTING INDOOR INSTALLATIONS 10 2 2 1 AIR REQUIRED FOR COMBUSTION AND VENTILATION 10 2 2 2 EXHAU...

Page 4: ...7 2 IGNITION MODULE LOCKOUT FUNCTIONS 22 5 8 DYNAFORCE CONTROLLER 22 5 9 ERROR TABLE 22 PART 6 CONTROL PANEL 24 6 1 APPLIANCE TEMPERATURE CONTROLLER 24 6 2 CONFIGURE MENU 40 6 3 LEAD LAG SETUP UP TO 8...

Page 5: ...S 58 10 13 FREEZE PROTECTION 58 10 14 FREEZE PROTECTION FOR A HEATING BOILER SYSTEM Optional 59 PART 11 INSTALLATIONS 59 11 1 CHECKING THE INSTALLATION 59 11 2 CHECKING THE INSTALLTION 59 11 3 INSPECT...

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Page 7: ...RENCE 1 3 CHECKING EQUIPMENT Check for signs of shipping damage upon receiving equipment Pay particular attention to parts accompanying the boiler which may show signs of being hit or otherwise being...

Page 8: ...The number of re ignition attempts is limited to 2 after which a lockout occurs 3 The burner can only be on continuously for a period of 24 hours After this the burner is switched off and a restart se...

Page 9: ...turer shall NOT be held liable for any personal injury or property damage due to ice formation or the dislodging of ice from the vent system or the vent termination 1 7 REMOVAL OF EXISTING APPLIANCE W...

Page 10: ...tibles as follows Table 1 Clearances from combustibles Clearances from Combustibles TOP 12 REAR 12 SIDES 12 VENT 6 Figure 4 Clearance from Combustibles When placing the appliance be aware that a minim...

Page 11: ...burner The appliance must be installed so that the ignition system components are protected from water dripping spraying etc during appliance operation and service circulator replacement control repl...

Page 12: ...8 6 7 5 2 1 580 1200 29 3 8 31 3 4 70 1 2 20 3 4 59 1 2 13 56 3 8 1 7 8 23 1 4 12 6 10 8 7 8 5 2 1 2 1 1 4 620 1400 29 3 8 31 3 4 73 1 2 22 5 8 62 1 2 14 59 1 4 1 7 8 23 1 4 12 6 10 8 7 8 5 2 1 2 1 1...

Page 13: ...rest on the unit Adequate support of the venting system must be provided in compliance with local codes and other applicable codes All connections should be secured and sealed per the vent manufactur...

Page 14: ...ne Styrene Single wall vent pipes to be insulated 5 feet from wall toward the interior of the building to minimize external sweating 2 1 4 VENT TERMINATION CLEARANCES Do not terminate the vent in a wi...

Page 15: ...alent The corrosion resistant liner must be properly sized and fully sealed throughout the entire length If the flue is contained within the masonry chimney both the top and the bottom of the masonry...

Page 16: ...f 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 cir...

Page 17: ...at the vent terminal is unobstructed This venting system uses the appliance s internal combustion air fan to force the flue products out horizontally The Dynaforce fan generates a positive pressure in...

Page 18: ...sizing data Gas pipe size may be larger than appliance connection Installation of a union at the appliance gas line connection is required for ease of service and removal of the gas train Install a ma...

Page 19: ...onnections 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 101...

Page 20: ...control valve actuator in order to achieve acceptable light off under soft start field conditions Always check settings posted on boiler test label 3 6 GAS MANIFOLD DIFFERENTIAL PRESSURE ADJUSTMENT DR...

Page 21: ...e the Dynaforce which use a 1 to 1 ratio control valve for internal gas pressure regulation Camus requires that all Dynaforce models equipped with the SKP25 be supplied with no more than 1 PSI incomin...

Page 22: ...ists of a round mounting flange welded to a mixing tube The top side of the mixing tube provides the transition which mounts the discharge from the combustion air fan into the burner The bottom side o...

Page 23: ...oors in areas where danger of freezing exists unless precautions are taken Maintaining a mixture of 50 water and 50 propylene glycol is the preferred method of freeze protection in hydronic systems Th...

Page 24: ...r water flow during burner operation and creates enough water turbulence inside the stainless steel tubes and header that prevents the formation of sediments Temperature rise and scale formation in th...

Page 25: ...installed in the vertical position and mounted in the hot water outlet No valve is to be placed between the relief valve and the appliance To prevent water damage the discharge from the relief valve...

Page 26: ...event overheating the heat exchanger PART 5 ELECTRICAL CONTROLS IT IS EXTREMELY IMPORTANT THAT THIS UNIT BE PROPERLY GROUNDED 5 1 ELECTRICAL CONECTIONS Table 10 Minimum Power Requirements Model Voltag...

Page 27: ...low A normally open differential air pressure switch is used to prove operation of the combustion air fan on the DR1200 5000 The pressure switch sensing points are installed at the fan outlet where ai...

Page 28: ...naforce 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 29: ...19 Using backup Lead Lag header sensor due to sensor failure 229 Lead lag slave communication timeout 275 281 LCI off safety circuit is open 283 Demand off during measured purge time 291 Abnormal Recy...

Page 30: ...e 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 of service Error message display i...

Page 31: ...witch Flow Switch Low water cutoff if equipped Water Pressure Switch 30 PSI Gas Pressure Switch Low gas pressure switch 4 5 w c N O High gas pressure swtich 14 w c N C Blocked flue switch N C Interrup...

Page 32: ...ed setpoint 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 3 Press CH Central Heat Configuration 4 P...

Page 33: ...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 34: ...when Remote Operator is closed 1 Connect Remote Operator 2 Connect System sensor to System Outdoor contacts 3 Connect Outdoor Sensor to J3 ECOM connector 4 Place both toggle switches in LOCAL 5 Press...

Page 35: ...tion s Programming Instructions Boiler operates with variable setpoint determined by 4 20mA incoming signal Modulates on boiler inlet sensor default Heat demand is generated when Remote Operator is cl...

Page 36: ...tion 4 Press Advanced Settings 5 Press the to arrive at Central Heat 6 Select Modulation rate source S2 J8 6 4 20mA and burner on off 7 Place toggle switch to REMOTE for remote operation if required S...

Page 37: ...sensor Inlet Sensor Proceed to Step 12 DHW Sensor Stat operation 1 Press Sensor Configuration 2 Select S6S7 J9 1 3 Sensor DHW 10K NTC Single Non Safety 3 The control will proceed into a Lockout 2 cond...

Page 38: ...32 13 Place toggle switch setting to REMOTE for remote operation if required...

Page 39: ...System Identification Access 4 Verify MB1 Modbus address 1 5 Verify MB2 Modbus address 1 6 Select Lead Lag Master Configuration 7 Select Master Enabled Enabled Fixed Setpoint operation 8 Enter CH Setp...

Page 40: ...Lead Lag master The following steps are performed at the factory and verifying on site will be sufficient 16 Select Pump Configuration 17 Press Advanced Options 18 Press the to arrive at Central Heat...

Page 41: ...sequential order 5 Select Lead Lag Slave Configuration 6 Select Slave Enabled Enable slave for built in Lead Lag master The following steps are performed at the factory and verifying on site will be s...

Page 42: ...in Yes 7 Press the reset button on the ignition control within the alotted time Outdoor Sensor connected to Slave boiler 2 DRH ONLY Description Electrical Connection s Programming Instructions Slave b...

Page 43: ...o arrive at Outdoor Reset 12 Select Enable Enabled 13 Select Maximum outdoor temperature WWSD 14 Select Minimum outdoor temperature Outdoor Design 15 Select Low Water Temperature Min Water Temp 16 Sel...

Page 44: ...tation time user defined Base load rate adjustment Description Electrical Connection s Programming Instructions Upon a call for heat the lead boiler will fire to the specified base load rate 80 If the...

Page 45: ...is not 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 repea...

Page 46: ...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 47: ...0 RPM DR1200 5000 100 0 Prepurge time 25 sec 5 mins Prepurge time Default 25 sec Run Stabilization Time 10 sec Main flame establishing period Postpurge rate 3000 RPM Postpurge fan speed Default DR300...

Page 48: ...mp Lead lag setpoint Add stage Error threshold 2 Number of boilers remain the same Lead lag Lead lag setpoint Add stage Error threshold AND Lead lag temp Lead lag setpoint Drop stage Error threshold 3...

Page 49: ...up to a maximum of 4 boilers 9 Boiler Outdoor Reset Wiring The use of outdoor reset requires two outdoor sensors for this setup Network 1 outdoor sensor is wired to boiler 2 and the outdoor sensor fo...

Page 50: ...s Parameter Function Settings 1 High Low Voltage Input Voltage 120 220 240 460 480 01 02 2 Carrier Frequency 03 4 Stop Method 03 5 Standard Speed Source 04 19 Acceleration Time 120 sec 20 Deceleration...

Page 51: ...combustion through the heat exchanger and venting system The fan assembly consists of a sealed housing and fan wheel constructed from spark resistant material The fan is operated by a fully enclosed 1...

Page 52: ...performance at full input and at minimum input Depending on field conditions the CO2 metering valve may require some minor adjustment at full input Refer to Table 14 Adjustment at minimum input can be...

Page 53: ...eratures to minimize or eliminate condensate Use the Dynaforce Control Panel 1 Press DIAGNOSTICS button 2 Press Diagnostic Tests button 3 Move the firing rate slider to maximum RPM as indicated by the...

Page 54: ...up towards full input through the 4 20mA from the controller Shut power off to the heater and open the firing valve Switch power back on and allow the burner to fire Ignition should be smooth Normall...

Page 55: ...the burner Alert 110 291 294 To reset the module refer to section 5 8 2 Verify that all air has been purged from gas line Inspect hot surface igniter and related wiring for damage and connection erro...

Page 56: ...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 Gas Valve Adjustment Procedure for proper combustion setting Air Inlet and or Vent confi...

Page 57: ...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 Stainle...

Page 58: ...12 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 17 Alert Hold Cod...

Page 59: ...tected by the flame sensor A minimum signal of 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 bun...

Page 60: ...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 flow switch Green Op...

Page 61: ...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 62: ...egative 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 A...

Page 63: ...should be checked and cleaned at the time of appliance commissioning and on a six month interval or more often in a contaminated environment 10 5 1 BURNER REMOVAL Access to the burner will require the...

Page 64: ...bands and stainless steel wrap Replace any damaged gaskets to ensure a proper air seal Replace any ceramic facing tape damaged on the baffles Reinstall the burner and fan assembly Reassemble all gas a...

Page 65: ...or any unusual odour Remove the stainless steel jacket and smell the interior of the boiler If there is any sign of a gas leak do not proceed with startup Repair all the leaks before attempting to sta...

Page 66: ...ry loop piping to and from the appliance must have a fully ported ball valve installed in both the inlet and outlet side piping and will be used for isolation only The ball valves must be the same dia...

Page 67: ...fires at 100 of rated input 6 Verify operation of safeties as necessary low water cut off high limit gas pressure etc 7 Once the boiler is running and the flame has stabilized remove the flame sensor...

Page 68: ...ow the water velocity is too high Adjust as follows 1 Temperature rise can be increased by slowly closing the flow control valve globe valve or flow setter in the outlet piping from the hot water heat...

Page 69: ...63 PART 12 EXPLODED VIEW 19 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 20...

Page 70: ...64 21 22 23 24 26 35 34 33 32 31 30 29 28 27 25 36 37 38 39 40 42 43 56...

Page 71: ...59 61 59 1 34 27 44 Red Silicone Gasket White Graphite Ceramic Gasket White Ceramic Gasket Only required if heat exchanger surface is rough or uneven Graphite Gasket Burner Heat Exchanger 62 63 64 65...

Page 72: ...15209 X X 90 14011 X X 90 14013 X 90 15209 X X 90 15210 X 90 14017 X 90 15099 X 90 2010 X X 90 2011 X 90 2012 X 5 Base Support 14 1025 X X X X X X X X X 14 1073 X X X X X X 14 1018 X X 14 1071 X X X...

Page 73: ...14 1005 X X X X X X X X X X X 14 Condensate Neutralizer Box 90 10030 X 15 Side Panel Left 14 1047 X X 14 1043 X X 14 1057 X X 14 1022 X 14 1061 X 14 8085 X X X 14 1008 X 14 1028 X 14 1015 X 14 1065 X...

Page 74: ...X V8730C1031 X V4734C1002 X X X SKP55 X X X X X X X 24 Gas Valve Solenoid V4295A1049 X V4295A1056 X X Gas Valve Regulator SKP 25 X X X X 25 Gas Valve Regulator Body VGG10 404U X X X X 26 Low gas Switc...

Page 75: ...O V X 42 24V Contactor T92P7A22 24 X X X X X 43 Variable Frequency Drive T204 X X X X T205 X X T217 X X T228 X X X Variable Frequency Drive 460V 60 3 T234 X X X X T235 X X T237 X X X T238 X X 44 Trans...

Page 76: ...5230 X X X X 61 Graphite Gasket 1 33 5239 X X X X X X X X X 33 5237 X X X X 33 5238 X 33 5240 X X X X 62 DR600 800 1 8 Red Gasket for Mixing Chamber 33 0057 X X X X X X X 63 Air Inlet to Fan Adapter 1...

Page 77: ...71 PART 13 ELECTRICAL DIAGRAMS...

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Page 80: ...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 84: ...vice Dynaforce 1 100 6 100 2 100 7 100 3 100 8 100 4 100 9 100 5 100 10 100 The exchanged or repaired heat exchanger will carry the balance of the remaining original warranty provided with the applian...

Page 85: ...e components supplied Such costs are the responsibility of the owner DISCLAIMERS Camus shall not be responsible for any water damage Provisions should be made that in the event of a water appliance or...

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Page 87: ...eaters 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...

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