Camus Hydronics DynaFlame Series Installation And Service Manual Download | Manualshive

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Summary of Contents for DynaFlame Series

Page 1: ...y to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbour s phone Follow the gas supplier s instructions If...

Page 2: ...6226 Netherhart Road Mississauga Ontario L5T 1B7 99 0435 Rev 00...

Page 3: ...ULATIONS 10 2 1 11 VERTICAL VENTING TERMINATION 10 2 1 12 COMBINED COMBUSTION AIR INLET 11 2 1 13 DRAIN TEE 11 2 2 CONVENTIONAL VENTING INDOOR INSTALLATIONS 11 2 2 1 AIR REQUIRED FOR COMBUSTION AND VE...

Page 4: ...5 7 2 IGNITION MODULE LOCKOUT FUNCTIONS 27 5 8 DYNAFLAME CONTROLLER 27 5 9 ERROR TABLE 28 PART 6 SOLA CONTROL PANEL 30 6 1 APPLIANCE TEMPERATURE CONTROLLER 30 6 2 CONFIGURE MENU 45 6 3 LEAD LAG SETUP...

Page 5: ...OTECTION 65 10 15 FREEZE PROTECTION FOR A HEATING BOILER SYSTEM Optional 66 PART 11 INSTALLATIONS 67 11 1 HEATING BOILER INSTALLATIONS 67 11 2 WATER CONNECTIONS 67 11 3 PIPING LENGTHS 67 11 4 INTERMIT...

Page 6: ...metered in precise 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...

Page 7: ...perating system 8 If temperature high limit water flow and airflow switches are closed the fan will run at pre purge speed until the pre purge timer is satisfied Once complete the DynaFlame will targe...

Page 8: ...technicians WARNING Should overheating occur or the gas supply fails to shut off DO NOT turn off or disconnect the electrical supply to the pump Shut off the gas supply at a location external to the a...

Page 9: ...n the appliance being inspected Follow the lighting instructions Adjust thermostat so that appliance operates continuously If provided test for spillage at the draft control device relief opening afte...

Page 10: ...n All installations must allow sufficient space for servicing the vent connections water pipe connections circulating pump bypass piping and other auxiliary equipment as well as the appliance Table 2...

Page 11: ...e and in adjacent spaces that open to the garage and are not part of the living space of a dwelling unit must be installed so that all burners and burner ignition devices have a minimum clearance of n...

Page 12: ...4 35 3 4 39 1 4 83 59 3 4 72 1 4 20 3 4 67 7 8 28 7 8 20 2 1 2 3 1 2 17 7 8 25 5 8 12 14 4 1 1 2 2 1 2 5004 35 3 4 39 1 4 88 1 4 65 77 1 2 26 72 1 4 34 1 8 20 2 1 2 3 1 2 17 7 8 25 5 8 12 14 4 1 1 2 2...

Page 13: ...slope of per foot from the appliance to the vent terminal to provide drainage of the vent towards the nearest drain or the vent termination The venting system must be installed with a means of conden...

Page 14: ...Category IV site conditions exceeding 100 equivalent feet an engineered vent system approved by the local authority will be required The flue may terminate either vertically at the roof top or horizo...

Page 15: ...d potentially hazardous levels of carbon monoxide in the flue products This will cause operational problems with the appliance and if left uncorrected will lead to conditions that can cause personal i...

Page 16: ...rature 2 2 CONVENTIONAL VENTING INDOOR INSTALLATIONS NON CONDENSING The DynaFlame non condensing is a category I appliance and is approved for venting into a common standard chimney On single applianc...

Page 17: ...m the venting system into an occupied living space can cause a very hazardous condition that must be immediately corrected 2 3 OUTDOOR VENTING The DynaFlame windproof cabinet protects the unit from we...

Page 18: ...s a 4 foot 1 25 m horizontal distance is maintained from electric meters gas meters regulators and relief equipment In all cases local codes take precedence Flue gas condensate can freeze on exterior...

Page 19: ...arance to service regulator vent outlet 3 ft 91 cm J Clearance to non mechanical air supply inlet to building or the combustion air inlet to any other appliance 6 15 cm for appliances 10 000 Btuh 3kW...

Page 20: ...regulator vent outlet 3 ft 91 cm J Clearance to non mechanical air supply inlet to building or the combustion air inlet to any other appliance 6 15 cm for appliances 10 000 Btuh 3kW 12 30 cm for appli...

Page 21: ...G All gas connections must be made with pipe joint compound resistant to the action of liquefied petroleum and natural gas All piping must comply with local codes and ordinances 3 3 INSTALL PIPING The...

Page 22: ...ontrol valve The differential air pressure measurement is made between the high and low pressure taps across the fan discharge and the flue vent All differential air pressures are noted at full firing...

Page 23: ...LP gas at tank if required Turn the power switch to ON position Adjust the thermostat temperature set point to the desired water temperature so the appliance will call for heat Check appliance perform...

Page 24: ...points may be accessed by removing the top of the appliance Local codes may require the routing of these bleeds and vents to the atmosphere outside the building Proper routing of vent lines to the atm...

Page 25: ...REEZE PROTECTION Appliance installations are not recommended outdoors in areas where danger of freezing exists unless precautions are taken Maintaining a mixture of 50 water and 50 propylene glycol is...

Page 26: ...nded value During initial operation of the appliance in 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...

Page 27: ...r Nickel Heat Exchanger Model Heat Exchanger Water Content USG 30 F 16 7 C Temp Rise 35 F 19 4 C Temp Rise USGPM min flow P Ft USGPM min flow P Ft DF500 2 5 28 0 0 7 24 0 0 5 DF750 2 9 42 0 1 4 36 0 1...

Page 28: ...components In the absence of instructions the minimum clearance to combustible material is six inches Consult vent pipe manufacturer s instructions for proper method of sealing vent pipe sections and...

Page 29: ...low flow condition 4 11 LOW WATER CUTOFF If Equipped If this boiler is installed above radiation level a low water cut off device must be installed at the time of boiler installation Some local codes...

Page 30: ...point is satisfied The operation of the circulating pump is controlled by the SOLA temperature control When the appliance is activated by a remote operating signal the pump will start and run for the...

Page 31: ...d directly to the fan motor The appliance when installed must be electrically grounded in accordance with the requirements of the authority having jurisdiction or in the absence of such requirements w...

Page 32: ...reset function can be activated Whenever an appliance is supplied with both an auto reset and manual reset high limit always set the auto reset limit 10 F 5 5 C below the manual reset limit This will...

Page 33: ...SOLA Controller 47 Flame rod to ground leakage 48 Static Flame 49 24VAC low high 50 Modulation Fault 64 Fan speed not proved ignition failure 67 Interlock Off safety circuit is open 79 Heater Outlet...

Page 34: ...locked Flue Switch 283 Demand off during measured purge time 291 Abnormal Recycle Flame was not on at end of Ignition period 292 Abnormal Recycle Flame was lost during Main Flame Establishing Period 2...

Page 35: ...en stages minimum on time per stage 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...

Page 36: ...ration Flow Switch Flow Switch Low Water Cutoff if equipped Gas Pressure Switch Low gas pressure switch 4 5 w c N O High gas pressure swtich 14 w c N C Air Pressure Switch Blocked flue switch N C Air...

Page 37: ...r operates at a fixed setpoint Modulates on boiler inlet sensor default Heat demand is generated when Remote Operator is closed 1 Press and 2 Press CH Central Heat Configuration 3 Press the to arrive...

Page 38: ...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 39: ...Connect Outdoor Sensor to J3 ECOM connector 4 Press and 5 Press Outdoor Reset Configuration 6 Press the to arrive at Central Heat 7 Select Enable Enable 8 Select Maximum outdoor temperature WWSD 9 Se...

Page 40: ...al Modulates on boiler inlet sensor default Heat demand is generated when Remote Operator is closed and 4 20mA or 0 10Vdc signal is present 1 Press and 2 Press CH Central Heat Configuration 3 Press th...

Page 41: ...vanced Settings 4 Press the to arrive at Central Heat 5 Select Modulation rate source S2 J8 6 4 20mA and burner on off 6 Place toggle switch to REMOTE for remote operation if required System Sensor En...

Page 42: ...Sensor Stat operation 1 Press Sensor Configuration 2 Select S6S7 J9 1 3 Sensor 10K NTC Single Non Safety 3 The control will proceed into a Lockout 2 condition 4 Press Verify Begin Yes 5 Press the rese...

Page 43: ...38...

Page 44: ...5 Select Lead Lag Master Configuration 6 Select Master Enabled Enabled Fixed Setpoint operation 7 Enter CH Setpoint Fixed setpoint 4 20mA 0 10Vdc setpoint operation 8 Select Advanced Settings 9 Press...

Page 45: ...n Options Local burner demand 19 On Options Local Lead Lag Service Active 20 Force On Outlet high limit Slave Boiler Description Electrical Connection s Programming Instructions Slave boiler lead lag...

Page 46: ...cal Lead Lag Service Active 11 Force On Outlet high limit Master Boiler System Sensor Description Electrical Connection s Programming Instructions Master boiler system sensor configuration 1 Press and...

Page 47: ...ut 2 condition 6 Press Verify Begin Yes 7 Press the reset button on the ignition control within the alotted time Master Boiler 8 Press and 9 Press Lead Lag Master Configuration 10 Press Advanced Setti...

Page 48: ...ime user defined Base load rate adjustment Description Electrical Connection s Programming Instructions Upon a call for heat the lead boiler will fire up to the specified base load rate 80 If the temp...

Page 49: ...ot 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 repeated...

Page 50: ...e demands Use for Lead Lag Master demands Boiler Pump Pump Control Auto Refer to above Default ON Refer to above Pump Output Pump A Specify pump contact Over run time 1 5 min Post pump time Default 1...

Page 51: ...46 pump has been activated DHW pump cycles Displays the number of cycles the DHW pump has been activated System pump cycles Displays the number of cycles the system pump has been activated...

Page 52: ...he boilers before beginning the setup process To setup the DynaFlame Lead Lag system follow the instructions System Sensor Insert the supplied 10k system sensor into the building loop The wires coming...

Page 53: ...ready to use Add Stage Stage is getting ready to fire Suspend Stage Stage was getting ready but is not needed Disabled Slave is locked out or disabled Recovering Slave is in time delay to verify that...

Page 54: ...rameters 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 Decel...

Page 55: ...d with steel wool Do not use sand paper since this will contaminate the surface 7 3 COMBUSTION AIR FAN Figure 33 Fan Burner Hot Surface Igniter and Flame Sensor Arrangement DynaFlame uses a sealed air...

Page 56: ...ing to require two to three tries before successful ignition With the boiler running check for flue gas leaks along the inner cabinet joints and around the flue outlet Some minor leakage is acceptable...

Page 57: ...ecelerate to minimum fire and will light off at low fire before ramping up towards full input through the PWM or 4 20mA signal from the controller Shut power off to the heater and open the firing valv...

Page 58: ...h the use of an analyzer This boiler is designed for low fire soft start At the start of trial for ignition the fan will decelerate to minimum fire and will light off at low fire before ramping up tow...

Page 59: ...ir Switch indicator to turn green at a fan speed between 15Hz and 20Hz on the VFD Check the ignition retries circuit Shut the main gas off to the unit and allow it to try for ignition Trial for igniti...

Page 60: ...nd related wiring for damage and connection errors DF 500 2500 Verify igniter is glowing DF 3000 6000 Verify pilot is lit Inspect flame sensor and associated wiring Replace if necessary Verify that bo...

Page 61: ...nual Natural Gas Pressure 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 Fire Testing for proper combustion setting Air Inlet and or Ven...

Page 62: ...exceeds 30 PSI Temperature Overshoot Stack temperature has exceeded the limit temperature Alert 125 The stack temperature has exceeded the maximum temperature allowed PVC 149o F CPVC 194o F AL29 4C St...

Page 63: ...ion failed 112 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 18 Al...

Page 64: ...f 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 bundle Separated from harness bundle Check hot s...

Page 65: ...rror occurs when 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 flo...

Page 66: ...ore 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 water...

Page 67: ...Owner Operator Test low water cutoff Check flow switch operation Test air proving switch Check boiler piping gas and water for leaks Check condensate media and replenish Annually Owner Operator Ensure...

Page 68: ...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 inner jack...

Page 69: ...ce An additional filter is located at the fan inlet and like the external filter may be washed in the sink under the tap This internal filter should be checked and cleaned at the time of appliance com...

Page 70: ...water piping Test for gas leaks Reassemble outer jacket panels Keep top cover off Cycle unit and check for proper operation Once proper operation is confirmed replace the top cover 10 8 CONDENSING HE...

Page 71: ...pply o Shut off water supply o Shut off electrical supply o Drain the main exchanger and the secondary exchanger if supplied completely o Ensure that the pump and connecting piping are fully drained 1...

Page 72: ...condary loop piping to and from the appliance must have a fully ported ball valve installed in both the supply and return side piping and will be used for isolation only The ball valves must be the sa...

Page 73: ...Inlet temperature and Supply Outlet temperature readings on the display should read approximately the same temperatures 3 Turn the hot water heater on and allow time for the temperature to stabilize C...

Page 74: ...treatment shall not be introduced into the potable water used for space heating A water heater which will be used to supply potable water shall not be connected to any heating system or component s pr...

Page 75: ...70 PART 12 EXPLODED VIEW...

Page 76: ...71 39 52 57 58 59 54 60 61 SOLA Control Panel...

Page 77: ...35 50A X X X X 14 5315 X X X 2 Bottom Transition Inner to Outer Jacket 14 5235A X X X X X X X X X X X X X 14 5328 X X X 3 Primary Copper Copper Nickel Heat Exchanger V Baffles Included DF 500 HTX X DF...

Page 78: ...09020 X 109021 X 109022 X 109023 X 109025 X 109026 X 109028 X 109029 X 109030 X 109032 X 109033 X 109034 X 4 Fan Air Gas Inlet Adapter 13 0026 X X X X X X X 66 5005 X 13 0027 X X X 66 5011 X X X X X 5...

Page 79: ...tion Top Panel 14 5009A X X X X 14 5203 15A 25A X X X X 102711 X 14 5203 35 50A X X X X 14 5303 X X X 11 Combustion Chamber Door 14 5010 05A X 14 5008 07A X 102631 X X 14 5204 15A 17A 20A 25A 35A 40A...

Page 80: ...Top Transition Inner to Outer Jackets 14 6025A X X X X 14 5225A X X X X X X X X X 14 5325 X X X 18 Outer Jacket Top Cover Assembly 14 6030A X X X X 14 5228A X X X X X 14 5228A 50 X X X X 14 5329 45 50...

Page 81: ...5052 X X X X 13 5330 X X X 13 5331 X X 13 5332 X X X X X X 13 5333 X 27 Inlet Outlet Header Rear Gasket 33 0013 X X X X 33 0014 X X X X X X X X X 33 0030 X X X 28 Electrical Motor 1 2 HP X X X X 1 HP...

Page 82: ...ue Assembly Non Condensing 14 5290 05A 11A 11A 11A 17A 17A 30A 30A 30A 35 50A 500A 600A Flue Assembly Non Condensing 14 5270 05A 11A 11A 11A 17A 17A 30A 30A 30A 35 50A 500A 600A 35 Interior Seal Plate...

Page 83: ...20A 25A 30A 35A 40A 45A 50A 14 0353 45 50 60 44 Inlet Outlet Header Top Gasket 33 5239 X X X X 33 5237 X X X X 33 5238 X X X X X 33 5240 X X X 45 White Ceramic Gasket Under Burner Flange 33 5242 X X...

Page 84: ...C1031 X X V4734C1002 X X SKP55 X X X X X X X X X X 51 Valve Body VGG10 404U X X X X X X X VGD40 065U X X VGD40 080U X 51A Solenoid Valve V4295A1049 X V4295A1056 X X Regulator Valve SKP25 X X X X X X X...

Page 85: ...54 75VA Transformer HCT 01J2BB07 X 55 Blocked Flue Switch 8021205256 X 56 Differential Pressure Switch NS2 1427 00 X 57 Control Box Plate 14 1005 03 X 58 Honeywell SOLA R7910A1001 X 59 Relay s 164934...

Page 86: ...81 PART 13 ELECTRICAL DIAGRAMS...

Page 87: ...82...

Page 88: ...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...

Page 89: ...84...

Page 90: ...100 100 100 5 100 100 100 100 6 100 40 7 100 35 8 100 30 9 100 25 10 100 20 The exchanged or repaired heat exchanger will carry the balance remaining of the original warranty provided with the applia...

Page 91: ...86 Name of Owner Name of Dealer Address Address Model No Serial No Date of Installation Date of Initial Operation 6226 Netherhart Road Mississauga Ontario L5T 1B7 CANADA...

Page 92: ...ing boilers as well as a supplier of specialty HVAC products Our service line is open 24 hours 7 days a week The CAMUS CERTIFIED seal assures you that Reliability Efficiency Serviceability are built i...

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