Camus Hydronics DFH/W1100 Скачать руководство пользователя страница 28

 

 

23 

 

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 
operating  cycle  and  for  a  post  purge  period  based  on 
temperature difference between inlet and outlet connections to 
the appliance. 

To  select  the  proper  pump  it  is  strongly  recommended  to 
consider the following: 

 

Need to know the required flow (GPM) and pressure drop 
for your appliance (see Table 8 or 9) 

 

Type  of  application,  hydronic  heating  or  Domestic  Hot 
Water (DHW). 

 

Copper or Copper Nickel Heat Exchanger: For hydronic 
heating and DHW applications with normal water hardness 
choose  a  pump  which  will  result  in  a  temperature  rise 
across  the  main  heat  exchanger  of  30ºF  to  35  ºF  (17ºC-
19ºC). If necessary use a flow setter valve to achieve the 
desired temperature rise. 

 

Stainless  Steel  Heat  Exchanger:  For  hydronic  heating 
and DHW applications with normal water hardness choose 
a  pump  which  will  result  in  a  temperature  rise  across  the 
main  heat  exchanger  of  20ºF  to  25  ºF  (11ºC-14ºC).  If 
necessary  use  a  flow  setter  valve  to  achieve  the  desired 
temperature rise. 

 

For  DHW  applications  with  other  than  normal  water 
hardness  choose  a  pump  for  the  local  water  hardness 
conditions.  Alternatively  run  the  pump  continuously  and 
soften  the  water  to  normal  levels.  Damage  to  the  heat 
exchanger  as  a  result  of  scaling  or  corrosive  water 
conditions is non-warrantable. 
 

4.14.2 

 CIRCULATING PUMP SELECTION CONDENSOR 

The operation  of the circulating pump may be continuous  or it 
may  be  in  parallel  with  the  main  heat  exchanger  pump.  Size 
the  secondary  pump  for  a  minimum  flow  of  10%  of  the  flow 
through  the  main  heat  exchanger  and  a  maximum  of  30%  of 
the main heat exchanger flow up to 60 GPM. 
 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

PART 5 

ELECTRICAL & 
CONTROLS 

 

IT IS EXTREMELY IMPORTANT THAT THIS UNIT BE 

PROPERLY GROUNDED! 

5.1 

ELECTRICAL CONECTIONS 

Table 11: Minimum Voltage Requirements 

Model 

Voltage 

Requirement 

Maximum 

Over Current 

Protection 

Full Load 

Amps  

[Amperes] 

[Amperes] 

500 - 

1200 

120VAC, 60Hz 

15 

1500 - 

2000 

120VAC, 60Hz 

20 

11 

2500  

120VAC, 60Hz 

20 

14 

3000-

4000 

230VAC, 60Hz, 

Single Phase 

20 

16 

4500-

4504 

230VAC, 60Hz, 

Single Phase* 

30 

24 

5000, 
5004, 

6004 

230VAC, 60Hz, 3 

Phase** 

30 

17.8 

*This  is  a  4-wire  power  supply  requiring  two  (2)  lives,  a 
neutral and a ground 
**This is a 5-wire power supply requiring three (3) lives, a 
neutral and a ground 

DynaFlame®  boilers  supplied  at  460/3/60  voltage,  differ 
from the standard unit per the following: 

CAUTION! 

While working with 460V circuits it is imperative that extra 
precautions be taken 
- Ensure that lock-out/ tag-out procedures are strictly  
enforced 
- Only properly trained and authorized personnel should 
be permitted to work on live electrical circuits 
- All electrical workers should be trained in electrical 
rescue techniques and CPR 

Each  unit  has  an  internal  factory  mounted  500VA 
transformer  to  supply  the  single  leg  115V  necessary  for 
the  ignition  circuit,  which  is  factory  mounted.    The  boiler 
itself  is  a  single  point  power  connection.    A  new  Variable 
Frequency  Drive  replaces  the  standard  VFD,  and  the 
combustion blower fan has been  configured  to operate  at 
460/3/60V (using the standard fan).  Part numbers as well 
as FLA and MOCP information is below. 

500VA transformer: DC0500UH 

VFD:  

 

Model Range: 

T232 

 

DF-500 to DF-1200 (0.5hp) 

T234 

 

DF-1500 to DF-2000 (1hp) 

T235 

 

DF-2500 (1.5hp) 

T237 

 

DF-3000 to DF-4504 (3hp) 

T238 

 

DF-5004 to DF-6004 (5hp) 

 
 
 
 
 
 

Содержание DFH/W1100

Страница 1: ...result causing 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...

Страница 2: ......

Страница 3: ...INATION CLEARANCES 9 2 1 7 INLET CAP FOR ROOFTOP TERMINATION 10 2 1 8 LOCATION OF A ROOFTOP AIR INLET AND VENT CAPS 10 2 1 9 AIR INLET DAMPER 10 2 1 10 MASONARY CHIMNEY INSULATIONS 10 2 1 11 VERTICAL...

Страница 4: ...LATING PUMP OPERATION PRIMARY HEAT EXCHANGER 22 4 14 2 CIRCULATING PUMP SELECTION CONDENSOR 23 PART 5 ELECTRICAL CONTROLS 23 5 1 ELECTRICAL CONECTIONS 23 5 2 VARIABLE FREQUENCY DRIVE VFD 24 5 3 DIFFRE...

Страница 5: ...Y HEAT EXCHANGER INSPECTION 62 10 8 CONDENSING HEAT RECOVERY MODULE CHRM INSPECTION 62 10 9 RE INSTALL HEAT EXCHANGERS 62 10 10 COMBUSTION AIR FAN 62 10 11 COMBUSTION AND VENTILATION AIR 62 10 12 CONT...

Страница 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...

Страница 7: ...he on board modulating control or the remote operating 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 sa...

Страница 8: ...and flue connections Installation and service must be performed by Camus qualified factory trained service technicians WARNING Should overheating occur or the gas supply fails to shut off DO NOT turn...

Страница 9: ...If applicable turn on the clothes dryers and any appliances not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximu...

Страница 10: ...rances from Combustibles Clearances from Combustibles TOP 12 SIDES 12 REAR 12 VENT 6 Figure 4 Clearance from Combustibles When placing the appliance be aware that a minimum clearance of 24 60cm must b...

Страница 11: ...through both sides and could be placed adjacent to each other with zero clearance For condensing units a minimum clearance of 12 must be provided on the right side for access to the Condensing Heat Re...

Страница 12: ...9 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 1 2 6004...

Страница 13: ...tem 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 firep...

Страница 14: ...t low fire for long periods 3 C Vent Canada ONLY 4 Equivalent or higher rated than above Exhaust Vent for Use for DynaFlame Non condensing Category lll Installations 1 Corrosion resistant stainless st...

Страница 15: ...y MUST use a sealed metallic corrosion resistant liner system to vent flue products from this high efficiency appliance Sealed metallic corrosion resistant liner systems AL29 4C or equivalent single w...

Страница 16: ...ture 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 venting...

Страница 17: ...not obstructed 3 Locate appliance at least 3 feet away from any overhang 4 Locate appliance at least ten feet from building air intake 5 Avoid installation in areas where runoff from adjacent buildin...

Страница 18: ...ot 3M radius of the flue outlet 2 4 4 LENGTH OF AIR INLET PIPE The maximum total length of the THRUWALL or vertical roof top combustion air inlet pipe as installed from the appliance to the air inlet...

Страница 19: ...plate Heating values of local natural gas are to be between 950 and 1010 Btu ft 3 Consult factory if heating values are outside this range or if a gas with a mixture of constituents is being used 3 4...

Страница 20: ...void the warranty on the gas valve assembly and the burner An appliance supplied with a properly sized gas line properly sized meter and a minimum gas supply pressure See Table 8 for minimum allowable...

Страница 21: ...RENTIAL AIR AND GAS PRESSURES DF2000 DF6000 Figure 11 Differential Air Pressure Manometer Connection The 1 to1 air gas ratio control actuator has embossed markings identifying air air gas gas connecti...

Страница 22: ...burner mounting flange provides a flame view port the mounting point for the hot surface igniter a connection to the pilot tube and the flame sensor The hot surface igniter and flame sensor are remov...

Страница 23: ...dard Pipe Threads NPT For ease of service install unions on inlet and outlet of the appliance The connection to the appliance marked Inlet on the header should be used for return from the system The c...

Страница 24: ...lications including open water reservoir heating Recirculation loops required for these applications can be set up in the field or they can be supplied pre piped from the factory In applications where...

Страница 25: ...he appliance facing the appliance The CHRM is constructed from all stainless steel headers and special multiple horizontal stainless tubes This CHRM is designed to maximize heat transfer efficiency by...

Страница 26: ...and debris by using a listed chimney cap Approval of the installation will be at the discretion of authorities having jurisdiction Sidewall and Vertical Venting The maximum vent length is 100 equival...

Страница 27: ...um for 10 of the input of the appliance and is to be piped to drain in a manner similar to the appliance relief valve 4 13 1 CHRM IN SERIES WITH PRIMARY HEAT EXCHANGER INTEGRATED LOOP The supply water...

Страница 28: ...mp Size the secondary pump for a minimum flow of 10 of the flow through the main heat exchanger and a maximum of 30 of the main heat exchanger flow up to 60 GPM PART 5 ELECTRICAL CONTROLS IT IS EXTREM...

Страница 29: ...age wiring 5 3 DIFFRENTIAL AIR PRESSURE SWITCH A normally open differential air pressure switch is used to prove operation of the combustion air fan The pressure switch sensing points are installed at...

Страница 30: ...naFlame 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...

Страница 31: ...ff safety circuit is open Thermal Disc in control box and or upper cabinet Flow Switch LWCO Blocked Flue Switch 283 Demand off during measured purge time 291 Abnormal Recycle Flame was not on at end o...

Страница 32: ...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...

Страница 33: ...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...

Страница 34: ...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...

Страница 35: ...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...

Страница 36: ...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...

Страница 37: ...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...

Страница 38: ...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...

Страница 39: ...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...

Страница 40: ...35...

Страница 41: ...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...

Страница 42: ...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...

Страница 43: ...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...

Страница 44: ...e 10K NTC Single Non Safety 5 The control will proceed into a Lockout 2 condition 6 Press Verify Begin Yes 7 Press the reset button on the ignition control within the alotted time Master Boiler 8 Pres...

Страница 45: ...40 17 Press Show Line to confirm reset curve 18 Press the to arrive at Warm Weather Shutdown 19 Select Enable Shutdown after demand ends...

Страница 46: ...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...

Страница 47: ...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...

Страница 48: ...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...

Страница 49: ...an speed Default DF0500 6004 100 0 Prepurge time 30 sec 5 mins Prepurge time Default 15 sec Run Stabilization Time 10 sec Main flame establishing period Postpurge rate 100 0 Postpurge fan speed Defaul...

Страница 50: ...threshold 2 Number of boilers remain the same Lead lag temp Lead lag setpoint Add stage Error threshold AND Lead lag temp Lead lag setpoint Drop stage Error threshold 3 A boiler should stop Lead lag...

Страница 51: ...to boiler 2 and the outdoor sensor for boiler 9 requires the use of the outdoor sensor module PN W8735S1000 wired to the ECOM connection on the Honeywell SOLA Additional details can be found on page 7...

Страница 52: ...ec 20 Deceleration Time 60 sec 28 Fixed Boost 1 0 36 Preset Speed 29 38 Skip Bandwidth 3 0 45 Speed at Minimum Signal Consult factory test sticker 46 Speed at Maximum Signal Consult factory test stick...

Страница 53: ...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...

Страница 54: ...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...

Страница 55: ...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...

Страница 56: ...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...

Страница 57: ...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...

Страница 58: ...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...

Страница 59: ...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...

Страница 60: ...xceeds 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 S...

Страница 61: ...tion 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 A...

Страница 62: ...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...

Страница 63: ...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...

Страница 64: ...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...

Страница 65: ...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...

Страница 66: ...sensor Remove the sensing 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...

Страница 67: ...remaining deposits If necessary the heat exchanger can be removed by disconnecting all water piping and lifting it out from the side 10 9 RE INSTALL HEAT EXCHANGERS Carefully reinstall the heat excha...

Страница 68: ...te trapped air in the system Locate a system air vent at the highest point in the system The system must also have a properly sized expansion tank installed Typically an air charged diaphragm type exp...

Страница 69: ...eld wiring and electrical service for both the boiler controls and pump Ensure that the electrical service s is adequately sized Boiler Set Up 1 Ensure that the boiler and piping system are full of wa...

Страница 70: ...ble failure Temperature rise must 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 nor...

Страница 71: ...66 PART 12 EXPLODED VIEW...

Страница 72: ...67 3 44 10 45 46 47 28 31 26 52 57 58 59 54 60 61 SOLA Control Panel 39 4...

Страница 73: ...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...

Страница 74: ...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...

Страница 75: ...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 5202 15A 17A 20A 25A 35A 40A...

Страница 76: ...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...

Страница 77: ...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...

Страница 78: ...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...

Страница 79: ...7A 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 45 White Ceramic Gasket Under Burner Flange 33 5242 X X...

Страница 80: ...Actuator V8730C1015 X V8730C1023 X V8730C1031 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...

Страница 81: ...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...

Страница 82: ...77 PART 13 ELECTRICAL DIAGRAMS...

Страница 83: ...78...

Страница 84: ...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...

Страница 85: ...80...

Страница 86: ...81...

Страница 87: ...82...

Страница 88: ...lame DHW COPPER CU NI HTX DF Cond Secondary HTX 1 100 100 100 100 2 100 100 100 100 3 100 100 100 100 4 100 100 100 100 5 100 100 100 100 6 100 40 7 100 35 8 100 30 9 100 25 10 100 20 The exchanged or...

Страница 89: ...that in the event of a water appliance or fitting leak the resulting flow of water will not cause damage to its surroundings Name of Owner Name of Dealer Address Address Model No Serial No Date of In...

Страница 90: ...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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