Camus Hydronics DynaFlame DFW501 Installation, Operation And Service Manual Download Page 59 | Manualshive

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Summary of Contents for DynaFlame DFW501

Page 1: ...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 o Do not try to...

Page 2: ......

Page 3: ...INLET AND VENT CAPS 10 2 1 9 AIR INLET DAMPER 10 2 1 10 MASONARY CHIMNEY INSULATIONS 10 2 1 11 VERTICAL VENTING TERMINATION 10 2 1 12 COMBINED COMBUSTION AIR INLET 10 2 1 13 DRAIN TEE 11 2 2 CONVENTI...

Page 4: ...CY DRIVE VFD 29 6 3 DYNAFLAME CONTROL PANEL 30 6 4 GENERAL SYMBOL DESCRIPTION 30 6 5 MODE 1 2 SETPOINT OPERATION VIEW DISPLAY 31 6 6 MODE 1 2 SETPOINT OPERATION ADJUST DISPLAY 32 6 7 MODE 3 DEDICATED...

Page 5: ...BUSTION AND VENTILATION AIR 49 10 12 CONTROL CIRCUIT VOLTAGE 49 10 13 COMBUSTIBLE MATERIALS 49 10 14 FREEZE PROTECTION 49 10 15 FREEZE PROTECTION FOR A HEATING BOILER SYSTEM Optional 50 PART 11 INSTAL...

Page 6: ...ise 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 this series most...

Page 7: ...ntarily light up during ignition trials If appliance fails to start the fan will shut down the air flow light will light up and the flame failure light will stay on continuously On a call for heat any...

Page 8: ...urner surface The A reading can be conveniently taken at the front of the ignition module at the Flame Sense Test terminals 1 5 1 IGNITION PROCESS 1 The Ignition module supplies voltage to the Air Gas...

Page 9: ...shall apply only when the appliance is installed in accordance with local plumbing and building codes ordinances and regulations the printed instructions provided with it and good industry practices...

Page 10: ...kets a high temperature ceramic paper gasket under the burner flange and a stamped silicon gasket between the burner flange and fan flange Tighten fan flange mounting nuts to 20 ft lb 6 Restore electr...

Page 11: ...nces is the manufacturer to be held responsible for water damage in connection with this unit or any of its components If the appliance is installed above the level of the building s radiation system...

Page 12: ...7 Table 4 Appliance Dimensions and Specifications Table 5 Vent Sizes for a Single Appliance...

Page 13: ...le codes All connections 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 acc...

Page 14: ...uired when operating appliance at low fire for long periods 3 C Vent 4 Equivalent or higher rated than above Exhaust Vent for Use for DynaFlame Non condensing Category lll Installations 1 Corrosion re...

Page 15: ...e or negative pressure appliance Category II or IV If a masonry chimney is to be used the chimney MUST use a sealed metallic corrosion resistant liner system to vent flue products from this high effic...

Page 16: ...w temperature 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...

Page 17: ...to the elements The additional protection afforded by the shelter will help to minimize nuisance problems with electrical connections and will allow easier servicing of the appliance under severe wea...

Page 18: ...minimum of 3 feet 1M horizontally and 12 inches 0 30M below the point of flue gas termination vent cap if it is located within a 10 foot 3M radius of the flue outlet 2 4 4 LENGTH OF AIR INLET PIPE Th...

Page 19: ...ifferential air pressures are noted at full firing rate There are two pressure taps at the fan discharge and care must be taken to tee into the correct line The correct line may be identified by traci...

Page 20: ...models 3000 and above be supplied with no more than 9 W C supply pressure This means that lockup pressure must not exceed 9 W C A suitable lockup regulator will not exceed running pressure by more tha...

Page 21: ...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 ga...

Page 22: ...gnition system components are protected from water dripping spraying rain etc during appliance operation and service circulator replacement control replacement etc Figure 12 Typical Space Heating Syst...

Page 23: ...a cold system some condensation will be generated but it will be quickly evaporated once the system return temperature reaches 115 F 46 C Return Water Temperatures Required for Dynaflame Boilers Water...

Page 24: ...nner jacket chamber at the right side of the appliance facing the appliance The CHRM is constructed from all stainless steel headers and special multiple horizontal stainless tubes This CHRM is design...

Page 25: ...provide an extractor at the chimney outlet in order to maintain a negative draft in the chimney and allow common venting The chimney must be protected from down drafts rain and debris by using a list...

Page 26: ...0 F 44 C it will not condense fully and therefore the CHRM will not perform to its maximum efficiency capacity If water colder than 110 F 44 C is available it can be fed to the CHRM WATER HEATER APPLI...

Page 27: ...om the local modulating control or a remote source based on water temperature to vary the frequency of the voltage supplied to the fan motor from 20 Hz up to 60 Hz This varies the output of the combus...

Page 28: ...5 6 1 SERVICE PARTS This appliance uses a proved electronic ignition control module and a hot surface igniter The electronic ignition module is not repairable Any modification or repairs will invalid...

Page 29: ...se emery paper since the silica will foul the sensor surface PART 6 CONTROL PANEL 6 1 APPLIANCE TEMPERATURE CONTROLLER The appliance is provided with a control panel at the front Operating controls ar...

Page 30: ...r pool heating Intermittent pumping provided Mode 3 For DHW control with tank sensor Controls to boiler inlet sensor Intermittent pumping provided Mode 4 For hydronic heating with outdoor reset Temper...

Page 31: ...ature immersion well within the DHW tank to function properly The BTC 1 modulates the boiler based on the boiler inlet sensor to maintain a tank temperature at the DHW sensor An internal heat demand i...

Page 32: ...tinues to circulate until the PUMP DELAY timer expires In this case it is imperative that the system pump operates continuously in order to provide constant circulation past the system sensor The wate...

Page 33: ...eset limit is set to 210 o F and is fixed In addition to the auto reset limit Camus installs a manual reset limit set to 250 o F Figure 30 Mode 7 Piping Electrical Layout Mode 8 External Direct Drive...

Page 34: ...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 03 for 2 10 VDC 19 Acceleration Time 120 sec 20 Deceleration Time 60 sec 28...

Page 35: ...ease of startup and serviceability 6 4 GENERAL SYMBOL DESCRIPTION SYMBOL SYMBOL NAME SYMBOL DESCRIPTION Boiler Pump Shown when boiler pump is in operation DHW Pump Shown when DHW pump is in operation...

Page 36: ...Outlet Temperature Real time Outlet Temperature to Boiler 14 to 266 o F 10 to 130 o C Boiler Inlet Temperature Real time Inlet Temperature to Boiler 14 to 266 o F 10 to 130 o C Boiler Delta T Real tim...

Page 37: ...etpoint for the heating system Setpoint is controlled to the inlet sensor 70 to 220 o F 21 to 104 o C Default 120 o F 49 o C Differential Temperature To provide a modulation rate above and below the B...

Page 38: ...r Inlet Temperature Real time Inlet Temperature to Boiler 14 to 266 o F 10 to 130 o C Boiler Delta T Real time temperature difference between the outlet sensor and the inlet sensor 99 to 252 o F 72 to...

Page 39: ...trolled to the DHW sensor OFF 70 to 190 o F OFF 21 to 88 o C Default 140 o F 54 o C DHW Differential To provide a modulation rate above and below the DHW Target Temperature For example if the value is...

Page 40: ...lable in Mode 5 14 to 266 o F 10 to 130 o C Boiler Outlet Temperature Real time Outlet Temperature 14 to 266 o F 10 to 130 o C Boiler Inlet Temperature Real time Inlet Temperature 14 to 266 o F 10 to...

Page 41: ...reset ratio calculation for the heating system Typically set to the desired building temperature 35 to 150 o F 2 to 66 o C Default 70 o F 21 o C Boiler Design Temperature Boiler design water temperatu...

Page 42: ...C Boiler Outlet Temperature Real time Outlet Temperature to Boiler 14 to 266 o F 10 to 130 o C Boiler Inlet Temperature Real time Inlet Temperature to Boiler 14 to 266 o F 10 to 130 o C Boiler Delta...

Page 43: ...Modes of Operation in this manual 1 to 8 Default 1 Differential Temperature To provide a modulation rate above and below the Boiler Target temperature For example if the value is 10 o F and the Boile...

Page 44: ...e to Boiler 14 to 266 o F 10 to 130 o C Boiler Delta T Real time temperature difference between the outlet sensor and the inlet sensor 99 to 252 o F 72 to 122 o C Modulation Real time modulating outpu...

Page 45: ...will stop operation until all settings in the Adjust menu have been checked by the installer Outlet Sensor Short Circuit If the inlet sensor is operational the control will operate using the inlet sen...

Page 46: ...nd related wiring The error message will clear once the error condition is corrected and a button is pressed Outdoor Sensor Short Circuit The BTC assumes an outdoor temperature of 32 o F 0 o C and con...

Page 47: ...rod must be removed with steel wool Do not use sand paper since this will contaminate the surface 7 3 COMBUSTION AIR FAN Figure 36 Fan Burner Hot Surface Igniter and Flame Sensor Arrangement DynaFlame...

Page 48: ...in lit If ignition is not accomplished the red flame failure light will energize and two more ignition trials will be made 15 seconds apart The control will then proceed to lockout and must be reset b...

Page 49: ...rol to the IN temperature display Remove fan inlet filter During trial for ignition block 50 of the fan inlet opening The air flow light should de energize If it does not slowly turn the adjustment on...

Page 50: ...ion Light Turns On Check for boiler demand No Demand STEP 4 STEP 5 STEP 6 NO YES NO YES YES NO NO YES Light Burnt Out Replace PCB YES High Limit Light Turns On YES Check Manual Reset if equipped Check...

Page 51: ...Check for gas tightness at fittings on Low Gas High Gas connections at actuator Check flame sensor for cracks in the insulator or continuity to ground Check for incoming gas pressure Adjust the air pr...

Page 52: ...ply 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...

Page 53: ...g 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 adhe...

Page 54: ...m the side 10 9 RE INSTALL HEAT EXCHANGERS Carefully reinstall the heat exchanger if removed from the appliance Check all gaskets and replace if damaged Replace heat exchanger cover Reassemble outer j...

Page 55: ...so have a properly sized expansion tank installed Typically an air charged diaphragm type expansion tank is used The expansion tank must be installed close to the boiler and on the suction side of the...

Page 56: ...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 4 Turn on power to the primary system...

Page 57: ...t 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 a hardness of 7 5 to 17 0 grains pe...

Page 58: ...53 PART 12 EXPLODED VIEW...

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Page 61: ...et Right Panel 14 6012 X X X X 14 5223 X X X X X X X X X 14 5323 X X X 7 Flue Outlet Transition 14 5290 X 8 Flue Conduit 14 5014 X X X X 14 5208 X X X X X X X X X 14 5308 X X X 9 Vent Transition Disk...

Page 62: ...X 14 5331 X X X 23 Secondary Heat Exchanger Cover 14 5270 X 26 Electrical Box 14 0263 X 27 Vee Baffle Sets 14 6035 X X X X 14 0354 X X X X X X X X X 14 5314 X X X 28 Outer Jacket Top Wrap 14 6031 X X...

Page 63: ...X 45 White Ceramic Gasket Under Burner Flange 33 0023 X X X X 33 0024 X X X X 33 0022 X X X X X 33 0035 X X X 46 Main Burner 500 BRN X 750 BRN X 1100 BRN X 1200 BRN X 1500 BRN X 1750 BRN X 2000 BRN X...

Page 64: ...X GFH 5000 CH X X X GFH 6000 CH X 54 Fan Intake Filter GFIF 500 CH X GFIF 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 C...

Page 65: ...izes ALL 500 750 1100 1200 1500 1750 2000 2500 3000 3500 4000 4500 5000 4504 5004 6004 60 Variable Frequency Drive 1 2HP 1HP 1 1 2HP 3HP 5HP SM005S X X X X SM010S X X X SM015S X X SM230S X X X X X X S...

Page 66: ...61 PART 13 ELECTRICAL DIAGRAMS...

Page 67: ...62...

Page 68: ...63 Camus DynaFlame PCB Electrical Ladder Diagram...

Page 69: ...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 red...

Page 70: ...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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