Camus Hydronics DRW1000, Installation And Service Manual

Page: 61 / 82

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PART 10 MAINTANANCE
CAUTION
It is important that all gas appliances to be serviced by a
Camus® trained service technician. It is in your own interest
and that of safety to ensure that all local codes, and all the
“NOTES” and “WARNINGS” in this manual are complied with.
To service or adjust this appliance, it is imperative that the
Camus® trained service technician utilize a combustion
analyzer to read CO
2
, CO and flue pressure according to
Camus® Hydronics recommendation
CAUTION
Label all wires prior to disconnection when servicing controls.
Wiring errors can cause improper and dangerous operation,
verify proper operation after servicing.
Listed below are items that must be checked to ensure safe
reliable operations. Verify proper operation after servicing.
10.1 EXAMINE THE VENTING SYSTEM
Examine the venting system at least once a year. Check more
often in the first year to determine inspection interval. Check all
joints and pipe connections for tightness, corrosion or
deterioration. Flush the condensate drain hose with water to
clean. Clean screens in the venting air intake system as
required. Have the entire system, including the venting system,
periodically inspected by a qualified service agency.
10.2 VISUALLY CHECK MAIN BURNER FLAMES
At each start up after long shutdown periods or at least every six
months. A burner view port is located on the burner mounting
flange.
CAUTION
The area around the burner view port is hot and direct
contact could result in burns.
NOTE
Check torque on fan mounting nuts using a torque wrench.
DR300 – 1000: 20 lb-ft
DR1200 – 5000: 25 lb-ft
Figure 36: Normal Burner Flame Profile (short dense and
blue)
• Normal Flame: A normal flame at 100% of burner input is
blue, with slight yellow tips a well-defined flame and no
flame lifting.
• Yellow Tip: Yellow tipping can be caused by blockage or
partial obstruction 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.
• Lifting Flames: Lifting flames can be caused by over firing
the burner, excessive primary air or high draft in excess of
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
Any sign of soot around the jacket, flue pipe connections, burner
or in the areas between the fins on the stainless steel heat
exchanger indicates a need for cleaning. The following cleaning
procedure must only be performed by a Camus® trained service
technician. Proper service is required to maintain safe operation.
Properly installed and adjusted units seldom need flue cleaning.
All gaskets/sealant on disassembled components or jacket
panels must be replaced with new gaskets/sealant on re-
assembly. Gasket and sealant kits are available from the
factory
CAUTION
When the vent system is disconnected for any reason it must
be reassembled and resealed according to vent
manufacturer’s instruction
10.4 CONDENSATION TREATMENT
This high efficiency appliance may operate as a condensing
appliance for extended periods of time based on return water
temperatures. Condensate occurs when the products of
combustion are cooled below their dew point in the heat transfer
process. The liquid condensate formed from this high efficiency
heat transfer process is mildly acidic. The condensate will
typically have a pH ranging from 4.0 to 5.0 as it is discharged
from the condensate drain at the rear of the appliance. The
condensate trap where condensate is collected is constructed
from a corrosion resistant stainless steel. All materials external
to the appliance in contact with the condensate must be
corrosion resistant. This is typically accomplished by using PVC
or CPVC plastic pipe and synthetic tubing. Condensate must be
able to flow freely from the appliance. All condensate flow is
accomplished by gravity requiring a minimum downward slope
of 1/4” per foot (21mm/m) to ensure proper flow to the
condensate management system and/or a suitable drain. The
neutralizer MUST always be mounted on the same level or lower
than the bottom of the appliance cabinet and downstream of the
condensate trap. The condensate trap is located external of the
boiler and is to be secured to the floor or boiler pad to prevent
spillage of condensate water. All condensate piping and
connections must be easily accessible for routine maintenance
and inspection.
10.4.1 CONDENSATE VOLUME
There are several factors affecting the amount of condensation
created by the appliance however for rough approximation use.
Condensation Volume, US Gallon/Hr = Input, MBH/1000 x 5.0
Many codes will require the acidic condensate to be neutralized
before it can be placed in a drain system. A neutralizer to control
the pH of the liquid discharged to a drain system is
recommended with every appliance. The neutralizer consists of
an industrial grade, non-corrosive reservoir for collection of the
condensate. As the reservoir fills, it provides an extended
residency time to neutralize the condensate. The neutralized
condensate exits from the reservoir outlet. A ‘P’ trap is installed
upstream of neutralizer at the heat exchanger. Prime the
installed assembly with water to prevent flue gas spillage from