Part 8 Field Startup Procedure; Checking The Installation; Checking The Construction; Fire Testing - Camus Hydronics DynaFlame DFW501 Installation, Operation And Service Manual

PART 8 FIELD STARTUP
PROCEDURE
8.1

CHECKING THE INSTALLATION

•
Inspect the connections for water, gas and electricity.
•
Confirm that water is being pumped toward the heat
exchanger inlet. Never pump away from the exchanger
since this will result in a low-pressure zone, which will
allow localized boiling and result in heat exchanger
damage.
•
Power to the boiler and pump must be from the same
circuit to prevent the boiler firing in case the pump is
inadvertently shut off.
•
Inlet gas pressure must be a minimum of 3" W.C. for
natural gas and 11" W.C. for propane.
•
With the boiler off, open the main gas supply valve and
vent the trapped air from the piping leading to the
boiler. Confirm that all gas connections to the heater
are tight and that there are no missing test plugs.
•
Connect a manometer to obtain the differential air
pressure between negative and positive ports. See
Figure 7.
•
The air/gas ratio controller automatically adjusts to
match the air signal on the gas side. In this way true
mass flow control of air/gas mix is achieved. Typical
differential air settings are listed in Table 8. All boilers
are test fired and factory set. A test sticker with actual
reading is affixed to the unit.
Refer to Part 3 of the manual for recommendations on
setting combustion characteristics.
8.2

CHECKING THE CONSTRUCTION

•
Check the boiler wiring to see that it agrees with the
wiring diagram supplied.
•
Confirm that all terminal strips and field connections
are identified.
•
Confirm that the SmartFlame control is set in the
proper mode. In remote mode an external controller
determines the set point and the stage contacts on the
SmartFlame are always closed. Auto reset limits are
fixed in all Modes.
•
With the firing valve in the off position, switch on power
to the boiler. The fan motor will accelerate until the
airflow light denergizes. If a light remains on past the
operator light, the ignition sequence will not proceed.
During trial for ignition the red flame failure light may
light up momentary.
•
Once all lights past the operator are denergized the
ignition module will try for ignition. When the igniter is
hot enough, the ratio gas valve actuator is energized
and if ignition is accomplished the blue main burner
light will come on and remain 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 by momentarily interrupting power. It is
normal during initial start up, when air is being purged
from the piping, 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.
•
Repair any major leaks prior to the next step.
43
•
At the factory adjustments were made to achieve
proper input and acceptable burner performance at full
input and at minimum input.
•
Depending on field conditions, the CO
require some minor adjustment at full input. Refer to
Figure 8. Always set the appliance for a CO
the range of 7.5% to 8.5% at full fire and 7.0% to 7.5%
at low for fire for non-condensing units. For condensing
units CO may be set in the range of 8.5% to 9.0% at
2
full fire and 7.5% to 8.0% at low fire. For propane,
reading will be approximately 1.5% higher. Adjustment
at minimum input can be done at the low fire
adjustment screw by first removing the brass cap.
Turning adjustment screw clockwise will increase CO
8.3

FIRE TESTING

•
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
towards full input depending on the 4 – 20 mA signal
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. Normally the differential gas
pressure will be identical to the differential air pressure.
Actual differential pressure may vary from the numbers
on the test label due to the field conditions and sample
variations. Always make adjustments to meet the
recommended CO levels. Adjust high fire first followed
2
by low fire adjustment.
Table 15: Combustion Values
Non-Condensing DynaFlame
Natural Gas
CO
2
Max.
7.5% - 8.5%
Fire
Min.
7.0% - 7.5%
Fire
Near-Condensing DynaFlame
Natural Gas
CO
2
Max.
8.0% - 8.5%
Fire
Min.
7.5% - 8.0%
Fire
Condensing DynaFlame
Natural Gas
CO
2
Max.
8.5% - 9.0%
Fire
Min.
7.5% - 8.0%
Fire
trim valve may
2
level in
2
Propane
CO CO
2
<100 <100
9.0% - 10.0%
PPM
<100 <100
8.5% - 9.0%
PPM
Propane
CO CO
2
<100 <100
9.5% - 10.0%
PPM
<100 <100
9.0% - 9.5%
PPM
Propane
CO CO
2
<100 <100
10.0% - 11.5%
PPM
<100 <100
9.0% - 9.5%
PPM
.
2
CO
PPM
PPM
CO
PPM
PPM
CO
PPM
PPM