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15 

 

3.7 

 CHECKING GAS SUPPLY PRESSURE 

 

Turn the main power switch to “OFF” position.  

 

Shut  off  gas  supply  at  the  manual  gas  cock  in  the  gas 
piping  to  the  appliance.  If  fuel  supply  is  LP  gas,  shut  off 
gas supply at the tank.  

 

Models  300  –  3000:  Remove  the  1/8"  hex  plug  from  the 
gas  pressure  test  port  located  on  the  inlet  gas  supply 
connection  at  the  rear  of  the  appliance.  Install  a  fitting  in 
the  inlet  pressure  tapping  suitable  to  connect  to  a 
manometer  or  magnahelic  gauge.  Range  of  scale  should 
be 0 to 14 inch W.C. or greater to check inlet pressure  

 

Models  3500  –  5000:  Remove  the  1/8”  hex  plug 
downstream  of  the  SKP25.  Install  a  fitting  in  the  inlet 
pressure  tapping  suitable  to  connect  to  a  manometer  or 
magnahelic gauge. Range of scale should be 0 to 14 inch 
W.C. or greater to check inlet pressure  

 

Turn on gas supply at the field installed manual gas cock; 
turn on LP gas at tank if required.  

 

Turn the power switch to “ON” position.  

 

Adjust the thermostat set point to call for heat.  

 

Observe  the  gas  supply  pressure  as  the  burner  fires  at 
100% of rated input.  

 

Ensure  inlet  pressure  is  within  specified  range.  Minimum 
and maximum gas supply pressures are specified in Table 
7.  

 

If gas pressure is out of range, contact the gas utility, gas 
supplier, qualified installer or service agency to determine 
necessary  steps  to  provide  proper  gas  pressure  to  the 
control.  

 

If  gas supply  pressure  is  within  normal  range,  proceed  to 
remove  gas  manometer  and  replace  pressure  tap  fittings 
in the gas piping to the appliance.   

 

Turn on gas supply at the manual valve; turn on 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 performance by cycling the system while 
you  observe  burner  response.  The  burner  should  ignite 
promptly.    Flame  pattern  should  be  stable,  see 
“Maintenance-Normal Flame Pattern.” Turn system off and 
allow  burner  to  cool,  then  cycle  burner  again  to  ensure 
proper ignition and flame characteristics.  

IMPORTANT 

Upon completion of any testing on the gas system, leak test all 
gas connections with a soap solution while the main burner is 
firing.  Immediately  repair  any  leak  found  in  the  gas  train  or 
related components. DO NOT operate an appliance with a leak 
in the gas train, valves or related gas piping.

 

3.7.1 

Regulated Gas Supply Pressures for Dynaforce® 
Boilers & Water Heaters 

A stable gas supply pressure is important to avoid rough starts 
with  machines  like  the  Dynaforce®  which  use  a  1  to  1  ratio 
control valve for internal gas pressure regulation.  

Camus®  requires  that  all  Dynaforce®  models  equipped  with 
the  SKP25  be  supplied  with  no  more  than  1  PSI  incoming 
supply  pressure.  This  means  that  lockup  pressure  must  not 
exceed  1  PSI.  For  models  NOT  incorporating  the  SKP25, 
lockup pressure must not be in excess of 14” w.c. 

A  suitable  lockup  regulator  with  internal  or  external  relief  will 
not exceed running pressure by more than 20%. 

When required a final stage gas regulator is to be located 
as  close  as  possible  but  no  more  than  10  feet  from  the 
appliance. 

It  is  paramount  that  maximum  lockup  pressure  be 
confirmed  before  any  attempt  is  made  to  start  up  the 
appliance. 

Operating the Dynaforce®  at lockup  pressures exceeding 
the recommended levels can lead to delayed ignitions and 
damage to the appliance. 

3.8 

 CHECKING  DIFFERENTIAL  AIR  AND 
GAS PRESSURES (DR2000 – DR5000) 

Figure 12: Checking Differential Air and Gas Pressures 

(DR2000 – DR5000) 

 

 

 
 

 

The 1 to1 air/gas ratio control actuator has embossed 
markings  identifying  +  air,  –  air,  +  gas  &  -  gas 
connections.  Using  a  test  hose  assembly  fitted  with 
tees,  connections  can  be  made  from  the  manometer 
to the appropriate ports on the actuator.  

 

Using  tees  connect  a  hose  from  the  positive  air  and 
the  negative  air  to  each  of  the  two  sides  of  a 
manometer. This will allow the two pressure points to 
be measured while at the same time the actuator still 
receives the proper operating signal.  

 

If  a  second  manometer  is  available  it  can  be 
connected  to  the  appropriate  gas  ports. Typically  the 
gas  signal  will  closely  follow  the  air  signal  on  all 
models.  If  the  incoming  gas  pressure  reduces 
significantly  as  the  VFD  accelerates  to  maximum 
speed the gas signal may lag behind the air signal by 
up  to  15%.  This  will  occur  once  the  actuator  has 
driven  downwards  as  far  as  it  can  go.  The  amount 
that  the  actuator  has  opened  is  registered  by  an 
indicator  arm  which  is  visible  through  the  view 
window. 

 

As  the  appliance  comes  on  and  fires,  record  the 
maximum  inches  of  water  column  which  is  achieved 
at  maximum  speed  on  the  VFD  using  start-up  report 
form  (93-0130).  To  adjust  this  differential  pressure 
when commissioning the appliance, use the adjusting 
screw  on  the  air  shutter  to  the  fan.  In  all  cases  the 
final  adjustment  is  to  be  made  using  a  combustion 
analyzer.  Depending  on  field  conditions  differential 
pressures  will  have  to  be  adjusted  accordingly. 
Typically  with  long  lateral  runs  the  differential  signal 
as read will be reduced from the value shown on the 

Fan Inlet 

Firing 
Valve 

Metering 
Valve 

Differential High 
Gas Switch 

Control Valve 

Regulator Valve 

Main Manual 
Valve 

Low Gas Switch 

To Fan Discharge 

To  
Appliance 
Vent 

Содержание DRH300

Страница 1: ...ury 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 light any appliance o Do not...

Страница 2: ......

Страница 3: ...TICAL VENTING TERMINATION 9 2 1 10 COMBINED COMBUSTION AIR INLET 9 2 1 11 DRAIN TEE 10 2 2 CONVENTIONAL VENTING INDOOR INSTALLATIONS 10 2 2 1 AIR REQUIRED FOR COMBUSTION AND VENTILATION 10 2 2 2 EXHAU...

Страница 4: ...7 2 IGNITION MODULE LOCKOUT FUNCTIONS 22 5 8 DYNAFORCE CONTROLLER 22 5 9 ERROR TABLE 22 PART 6 CONTROL PANEL 24 6 1 APPLIANCE TEMPERATURE CONTROLLER 24 6 2 CONFIGURE MENU 40 6 3 LEAD LAG SETUP UP TO 8...

Страница 5: ...S 58 10 13 FREEZE PROTECTION 58 10 14 FREEZE PROTECTION FOR A HEATING BOILER SYSTEM Optional 59 PART 11 INSTALLATIONS 59 11 1 CHECKING THE INSTALLATION 59 11 2 CHECKING THE INSTALLTION 59 11 3 INSPECT...

Страница 6: ......

Страница 7: ...RENCE 1 3 CHECKING EQUIPMENT Check for signs of shipping damage upon receiving equipment Pay particular attention to parts accompanying the boiler which may show signs of being hit or otherwise being...

Страница 8: ...The number of re ignition attempts is limited to 2 after which a lockout occurs 3 The burner can only be on continuously for a period of 24 hours After this the burner is switched off and a restart se...

Страница 9: ...turer shall NOT be held liable for any personal injury or property damage due to ice formation or the dislodging of ice from the vent system or the vent termination 1 7 REMOVAL OF EXISTING APPLIANCE W...

Страница 10: ...tibles as follows Table 1 Clearances from combustibles Clearances from Combustibles TOP 12 REAR 12 SIDES 12 VENT 6 Figure 4 Clearance from Combustibles When placing the appliance be aware that a minim...

Страница 11: ...burner The appliance must be installed so that the ignition system components are protected from water dripping spraying etc during appliance operation and service circulator replacement control repl...

Страница 12: ...8 6 7 5 2 1 580 1200 29 3 8 31 3 4 70 1 2 20 3 4 59 1 2 13 56 3 8 1 7 8 23 1 4 12 6 10 8 7 8 5 2 1 2 1 1 4 620 1400 29 3 8 31 3 4 73 1 2 22 5 8 62 1 2 14 59 1 4 1 7 8 23 1 4 12 6 10 8 7 8 5 2 1 2 1 1...

Страница 13: ...rest on the unit Adequate support of the venting system must be provided in compliance with local codes and other applicable codes All connections should be secured and sealed per the vent manufactur...

Страница 14: ...ne Styrene Single wall vent pipes to be insulated 5 feet from wall toward the interior of the building to minimize external sweating 2 1 4 VENT TERMINATION CLEARANCES Do not terminate the vent in a wi...

Страница 15: ...alent The corrosion resistant liner must be properly sized and fully sealed throughout the entire length If the flue is contained within the masonry chimney both the top and the bottom of the masonry...

Страница 16: ...f exhaust fans compressors air handling units etc can rob air from the room creating a negative pressure condition leading to reversal of the natural draft action of the venting system Under these cir...

Страница 17: ...at the vent terminal is unobstructed This venting system uses the appliance s internal combustion air fan to force the flue products out horizontally The Dynaforce fan generates a positive pressure in...

Страница 18: ...sizing data Gas pipe size may be larger than appliance connection Installation of a union at the appliance gas line connection is required for ease of service and removal of the gas train Install a ma...

Страница 19: ...onnections must be tested using soap solution Verify that the appliance is supplied with the type of gas specified on the rating plate Heating values of local natural gas are to be between 950 and 101...

Страница 20: ...control valve actuator in order to achieve acceptable light off under soft start field conditions Always check settings posted on boiler test label 3 6 GAS MANIFOLD DIFFERENTIAL PRESSURE ADJUSTMENT DR...

Страница 21: ...e the Dynaforce which use a 1 to 1 ratio control valve for internal gas pressure regulation Camus requires that all Dynaforce models equipped with the SKP25 be supplied with no more than 1 PSI incomin...

Страница 22: ...ists of a round mounting flange welded to a mixing tube The top side of the mixing tube provides the transition which mounts the discharge from the combustion air fan into the burner The bottom side o...

Страница 23: ...oors in areas where danger of freezing exists unless precautions are taken Maintaining a mixture of 50 water and 50 propylene glycol is the preferred method of freeze protection in hydronic systems Th...

Страница 24: ...r water flow during burner operation and creates enough water turbulence inside the stainless steel tubes and header that prevents the formation of sediments Temperature rise and scale formation in th...

Страница 25: ...installed in the vertical position and mounted in the hot water outlet No valve is to be placed between the relief valve and the appliance To prevent water damage the discharge from the relief valve...

Страница 26: ...event overheating the heat exchanger PART 5 ELECTRICAL CONTROLS IT IS EXTREMELY IMPORTANT THAT THIS UNIT BE PROPERLY GROUNDED 5 1 ELECTRICAL CONECTIONS Table 10 Minimum Power Requirements Model Voltag...

Страница 27: ...low A normally open differential air pressure switch is used to prove operation of the combustion air fan on the DR1200 5000 The pressure switch sensing points are installed at the fan outlet where ai...

Страница 28: ...naforce 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 29: ...19 Using backup Lead Lag header sensor due to sensor failure 229 Lead lag slave communication timeout 275 281 LCI off safety circuit is open 283 Demand off during measured purge time 291 Abnormal Recy...

Страница 30: ...e 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 of service Error message display i...

Страница 31: ...witch Flow Switch Low water cutoff if equipped Water Pressure Switch 30 PSI Gas Pressure Switch Low gas pressure switch 4 5 w c N O High gas pressure swtich 14 w c N C Blocked flue switch N C Interrup...

Страница 32: ...ed setpoint Modulates on boiler inlet sensor default Heat demand is generated when Remote Operator is closed 1 Place both toggle switches to LOCAL 2 Press and 3 Press CH Central Heat Configuration 4 P...

Страница 33: ...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 34: ...when Remote Operator is closed 1 Connect Remote Operator 2 Connect System sensor to System Outdoor contacts 3 Connect Outdoor Sensor to J3 ECOM connector 4 Place both toggle switches in LOCAL 5 Press...

Страница 35: ...tion s Programming Instructions Boiler operates with variable setpoint determined by 4 20mA incoming signal Modulates on boiler inlet sensor default Heat demand is generated when Remote Operator is cl...

Страница 36: ...tion 4 Press Advanced Settings 5 Press the to arrive at Central Heat 6 Select Modulation rate source S2 J8 6 4 20mA and burner on off 7 Place toggle switch to REMOTE for remote operation if required S...

Страница 37: ...sensor Inlet Sensor Proceed to Step 12 DHW Sensor Stat operation 1 Press Sensor Configuration 2 Select S6S7 J9 1 3 Sensor DHW 10K NTC Single Non Safety 3 The control will proceed into a Lockout 2 cond...

Страница 38: ...32 13 Place toggle switch setting to REMOTE for remote operation if required...

Страница 39: ...System Identification Access 4 Verify MB1 Modbus address 1 5 Verify MB2 Modbus address 1 6 Select Lead Lag Master Configuration 7 Select Master Enabled Enabled Fixed Setpoint operation 8 Enter CH Setp...

Страница 40: ...Lead Lag master The following steps are performed at the factory and verifying on site will be sufficient 16 Select Pump Configuration 17 Press Advanced Options 18 Press the to arrive at Central Heat...

Страница 41: ...sequential order 5 Select Lead Lag Slave Configuration 6 Select Slave Enabled Enable slave for built in Lead Lag master The following steps are performed at the factory and verifying on site will be s...

Страница 42: ...in Yes 7 Press the reset button on the ignition control within the alotted time Outdoor Sensor connected to Slave boiler 2 DRH ONLY Description Electrical Connection s Programming Instructions Slave b...

Страница 43: ...o arrive at Outdoor Reset 12 Select Enable Enabled 13 Select Maximum outdoor temperature WWSD 14 Select Minimum outdoor temperature Outdoor Design 15 Select Low Water Temperature Min Water Temp 16 Sel...

Страница 44: ...tation time user defined Base load rate adjustment Description Electrical Connection s Programming Instructions Upon a call for heat the lead boiler will fire to the specified base load rate 80 If the...

Страница 45: ...is not 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 repea...

Страница 46: ...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 47: ...0 RPM DR1200 5000 100 0 Prepurge time 25 sec 5 mins Prepurge time Default 25 sec Run Stabilization Time 10 sec Main flame establishing period Postpurge rate 3000 RPM Postpurge fan speed Default DR300...

Страница 48: ...mp Lead lag setpoint Add stage Error threshold 2 Number of boilers remain the same Lead lag Lead lag setpoint Add stage Error threshold AND Lead lag temp Lead lag setpoint Drop stage Error threshold 3...

Страница 49: ...up to a maximum of 4 boilers 9 Boiler Outdoor Reset Wiring The use of outdoor reset requires two outdoor sensors for this setup Network 1 outdoor sensor is wired to boiler 2 and the outdoor sensor fo...

Страница 50: ...s 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 Deceleration...

Страница 51: ...combustion through the heat exchanger and venting system The fan assembly consists of a sealed housing and fan wheel constructed from spark resistant material The fan is operated by a fully enclosed 1...

Страница 52: ...performance at full input and at minimum input Depending on field conditions the CO2 metering valve may require some minor adjustment at full input Refer to Table 14 Adjustment at minimum input can be...

Страница 53: ...eratures to minimize or eliminate condensate Use the Dynaforce Control Panel 1 Press DIAGNOSTICS button 2 Press Diagnostic Tests button 3 Move the firing rate slider to maximum RPM as indicated by the...

Страница 54: ...up towards full input through the 4 20mA from the controller Shut power off to the heater and open the firing valve Switch power back on and allow the burner to fire Ignition should be smooth Normall...

Страница 55: ...the burner Alert 110 291 294 To reset the module refer to section 5 8 2 Verify that all air has been purged from gas line Inspect hot surface igniter and related wiring for damage and connection erro...

Страница 56: ...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 Gas Valve Adjustment Procedure for proper combustion setting Air Inlet and or Vent confi...

Страница 57: ...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 Stainle...

Страница 58: ...12 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 17 Alert Hold Cod...

Страница 59: ...tected by the flame sensor A minimum signal of 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 bun...

Страница 60: ...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 flow switch Green Op...

Страница 61: ...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 62: ...egative 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 A...

Страница 63: ...should be checked and cleaned at the time of appliance commissioning and on a six month interval or more often in a contaminated environment 10 5 1 BURNER REMOVAL Access to the burner will require the...

Страница 64: ...bands and stainless steel wrap Replace any damaged gaskets to ensure a proper air seal Replace any ceramic facing tape damaged on the baffles Reinstall the burner and fan assembly Reassemble all gas a...

Страница 65: ...or any unusual odour Remove the stainless steel jacket and smell the interior of the boiler If there is any sign of a gas leak do not proceed with startup Repair all the leaks before attempting to sta...

Страница 66: ...ry loop piping to and from the appliance must have a fully ported ball valve installed in both the inlet and outlet side piping and will be used for isolation only The ball valves must be the same dia...

Страница 67: ...fires at 100 of rated input 6 Verify operation of safeties as necessary low water cut off high limit gas pressure etc 7 Once the boiler is running and the flame has stabilized remove the flame sensor...

Страница 68: ...ow the water velocity is too high Adjust as follows 1 Temperature rise can be increased by slowly closing the flow control valve globe valve or flow setter in the outlet piping from the hot water heat...

Страница 69: ...63 PART 12 EXPLODED VIEW 19 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 20...

Страница 70: ...64 21 22 23 24 26 35 34 33 32 31 30 29 28 27 25 36 37 38 39 40 42 43 56...

Страница 71: ...59 61 59 1 34 27 44 Red Silicone Gasket White Graphite Ceramic Gasket White Ceramic Gasket Only required if heat exchanger surface is rough or uneven Graphite Gasket Burner Heat Exchanger 62 63 64 65...

Страница 72: ...15209 X X 90 14011 X X 90 14013 X 90 15209 X X 90 15210 X 90 14017 X 90 15099 X 90 2010 X X 90 2011 X 90 2012 X 5 Base Support 14 1025 X X X X X X X X X 14 1073 X X X X X X 14 1018 X X 14 1071 X X X...

Страница 73: ...14 1005 X X X X X X X X X X X 14 Condensate Neutralizer Box 90 10030 X 15 Side Panel Left 14 1047 X X 14 1043 X X 14 1057 X X 14 1022 X 14 1061 X 14 8085 X X X 14 1008 X 14 1028 X 14 1015 X 14 1065 X...

Страница 74: ...X V8730C1031 X V4734C1002 X X X SKP55 X X X X X X X 24 Gas Valve Solenoid V4295A1049 X V4295A1056 X X Gas Valve Regulator SKP 25 X X X X 25 Gas Valve Regulator Body VGG10 404U X X X X 26 Low gas Switc...

Страница 75: ...O V X 42 24V Contactor T92P7A22 24 X X X X X 43 Variable Frequency Drive T204 X X X X T205 X X T217 X X T228 X X X Variable Frequency Drive 460V 60 3 T234 X X X X T235 X X T237 X X X T238 X X 44 Trans...

Страница 76: ...5230 X X X X 61 Graphite Gasket 1 33 5239 X X X X X X X X X 33 5237 X X X X 33 5238 X 33 5240 X X X X 62 DR600 800 1 8 Red Gasket for Mixing Chamber 33 0057 X X X X X X X 63 Air Inlet to Fan Adapter 1...

Страница 77: ...71 PART 13 ELECTRICAL DIAGRAMS...

Страница 78: ...72...

Страница 79: ...73...

Страница 80: ...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 81: ...75...

Страница 82: ...76...

Страница 83: ...77...

Страница 84: ...vice Dynaforce 1 100 6 100 2 100 7 100 3 100 8 100 4 100 9 100 5 100 10 100 The exchanged or repaired heat exchanger will carry the balance of the remaining original warranty provided with the applian...

Страница 85: ...e components supplied Such costs are the responsibility of the owner DISCLAIMERS Camus shall not be responsible for any water damage Provisions should be made that in the event of a water appliance or...

Страница 86: ......

Страница 87: ...eaters 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 products from...

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