Camus Hydronics DFH/W1100 Скачать руководство пользователя страница 29

 

 

24 

 

Model 

Voltage 

Requirement 

Maximum 

Over Current 

Protection  

Full Load 

Amps 

[Amperes] 

[Amperes] 

500 - 

1200 

460VAC, 60Hz, 3 

Phase 

10 

0.9 

1500 - 

2000 

1.4 

2500 

1.8 

3000 

2.1 

3500 

3.5 

4000 - 

5004 

5.3 

6004 

6.8 

The combustion air fan motor operates on 230 VAC, 3 phase, 
60  Hz.  This  three  phase  voltage  is  generated  by  the  variable 
frequency  drive  (VFD)  and  supplied  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,  with  the 
latest  edition  of  the  National  Electrical  Code  ANSI/NFPA  No. 
70. When the unit is installed in Canada, it must conform to the 
Canadian Electrical Code, C22.1, Part 1 and/or local Electrical 
Codes.  

 

All wiring between the appliance and field installed devices 
shall  be  made  with  wire  having  minimum  220ºF  (105ºC) 
rating.  

 

Line  voltage  wire  exterior  to  the  appliance  must  be 
enclosed  in  approved  conduit  or  approved  metal  clad 
cable.  

 

The pump must run continuously when appliance is being 
fired.  

 

To  avoid  serious  damage,  DO  NOT  ENERGIZE  the 
appliance  until  the  system  is  full  of  water.  Ensure  that  all 
air  is  removed  from  the  pump  housing  and  piping  before 
beginning  initial  operation.  Serious  damage  may  result  if 
the appliance is operated without proper flow.  

 

Provide the appliance with proper overload protection. 

5.2 

VARIABLE FREQUENCY DRIVE (VFD) 

This  appliance  uses  a  Variable  Frequency  Drive  (VFD)  which 
provides power to the combustion fan. The fan motor operates 
on  230VAC  3  phase  power.  This  three  phase  voltage  is 
generated  by  the  VFD  and  supplied  directly  to  the  fan  motor. 
The VFD receives a modulating signal (4-20 mA) from 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  combustion  air  fan  from  20%  up  to  100%  of  capacity 
corresponding  to the  same variation  in burner input. The VFD 
is  driven  towards  100%  during  the  pre-purge  portion  of  the 
start-up  sequence.  Once  control  self  checks  are  completed, 
the VFD  is provided with a signal to operate at  soft start level 
for  initial  burner  ignition.  After  main  burner  ignition  is 
established, the modulating signal provided will use the VFD to 
vary the fan speed based VFD to vary the fan speed based on 
desired water temperature set point.  

CAUTION 

The voltage output from the variable frequency drive to the 
combustion air fan is 230VAC, 3 Phase. AVOID contact 
with high voltage 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 the fan outlet as the 
air moves into the inlet of the burner. One point measures 
total pressure (+air) and is connected to a pitot tube facing 
the  flow  from  the  fan  paddle  wheel.  The  other  point 
measures  static  pressure.  Differential  pressure  at  the 
switch  will  be  affected  by  blockages  at  the  fan  inlet  or  at 
the flue discharge. A minimum differential pressure across 
the sensing points of the pressure switch proves operation 
of  the  combustion  air  fan.  This  is  set  in  the  factory  and 
may  be  adjusted  for  field  conditions.  The  diagnostics 
display  will  exhibit  a  Status  of  no  Air  Flow  when  the 
differential  pressure  switch  detects  a  sustained  low  air 
condition. This condition could be caused by a number of 
factors including: 

 

Sensing line broken or loose fitting. 

 

Dirty filter or blocked vent. 

 

Steady high wind condition exceeding 40 MPH. 

 

Incorrectly set switch. 

 

Missing bleed restrictor on total pressure side air line.  

5.4 

BLOCKED FLUE SWITCH 

A normally closed block flue switch is used to shut down 
the appliance under the following conditions: 

1)  Air intake 50% blocked 
2)  Vent outlet 80% blocked 

 

5.5 

HIGH and LOW GAS PRESSURE 
SWITCHES (Optional) 

A manual reset differential gas pressure switch is standard 
on  models  3000  –  5000  and  available  as  an  option  on 
models  500  -  2500.  If  differential  gas  pressure  exceeds 
the maximum setting of the pressure switch, the appliance 
will  shut  down  and  an  open  gas  pressure  switch  will  be 
shown  on  the  display.  A  low  gas  pressure  switch  is 
standard  and  monitors  the  minimum  incoming  gas  supply 
pressure  supplied  to  the  gas  train.  If  gas  pressure  falls 
below  the  minimum  setting  of  the  pressure  switch,  the 
appliance will shut down and an open gas pressure switch 
will be shown on the display. 

5.6 

HIGH LIMIT 

A high limit aqua-stat control is located at the back of the 
appliance  and  the control bulb is  installed  in a dry well  in 
the  heat  exchanger  header  outlet.  The  setting  of  this 
control  limits  maximum  discharge  water  temperature.  A 
manual  reset  high limit  will have a red  reset button which 
must  be  pushed  whenever  water  temperature  has 
exceeded  the  set  point  of  the  manual  reset  limit.  The 
temperature of the water in the heat exchanger must drop 
a  minimum  of  15°F  (8.3°C)  below  the  setting  of  the  high 
limit  control  before  the  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

ºF 

(5.5°C) below the manual reset limit. This will prevent 

nuisance tripping of the manual reset. 

 
 
 

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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