Summary of Contents for Camus Hydronics Dynaforce Series
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Dynaforce® Series Installation and Service Manual Gas Fired Commercial Condensing Stainless Steel Boilers Hydronic Heating Models DRN300 thru DRN5000 Hot Water Heater Models DRW300 thru DRW5000 WARNING If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death.
Table of Contents PART 1 GENERAL INFORMATION ................................6 INTRODUCTION .......................... 6 SPECIAL INSTRUCTIONS TO OWNER ..................6 CHECKING EQUIPMENT ......................6 HOW IT OPERATES (SEQUENCE OF OPERATION) ............... 6 1.4.1 HEAT TRANSFER PROCESS ...................... 7 1.4.2 END OF SEQUENCE ........................7 CODES ............................
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INLET AND OUTLET CONNECTIONS..................21 MINIMUM PIPE SIZE REQUIREMENTS ................. 22 HEAT EXCHANGER ........................22 LOW WATER TEMPERATURE SYSTEMS ................22 INSTANTANEOUS WATER HEATER ..................22 WATER FLOW SWITCH ......................22 LOW WATER CUTOFF (If Equipped) ..................22 4.10 RELIEF VALVE .......................... 23 4.11 CIRCULATING PUMP SELECTION ..................
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10.6 CHANGING THE HOT SURFACE IGNITER ................62 10.6.1 RE-INSTALLING THE IGNITER....................62 10.7 HEAT EXCHANGER INSPECTION ..................63 10.8 RE-INSTALL HEAT EXCHANGER ..................63 10.9 COMBUSTION AIR FAN ......................63 10.10 COMBUSTION AND VENTILATION AIR ................63 10.11 CONTROL CIRCUIT VOLTAGE ....................63 10.12 COMBUSTIBLE MATERIALS ....................
may show signs of being hit or otherwise being mishandled. PART 1 GENERAL INFORMATION Verify total number of pieces shown on packing slip with those actually received. In case there is damage or a shortage, INTRODUCTION immediately notify carrier. The Dynaforce® is a condensing forced draft appliance utilizing Figure 2: Checking the Dynaforce a premix power burner based on a push through design which offers several venting options.
purge timer is satisfied. Once complete the Dynaforce® will preprogrammed time period of 60 seconds. target the ignition fan speed. Thermostat is now in a standby mode waiting for the next DR 300 – DR 2500 (Direct Ignition): The hot surface igniter “Call for Heat”.
before installations are made. In the absence of such any appliances not connected to the common venting requirements, the installation shall conform to the latest edition system. Turn on any exhaust fans, such as range of the National Fuel Gas Code, ANSI Z223.1 and/or CAN/CGA- hoods and bathroom exhausts, so they will operate at B149 Installation Code.
NOTE: 24” 12” 12” 24” Experience has shown that improper installation or (60cm) (30cm) (30cm) (60cm) system design, rather than faulty equipment, is the cause 24” 12” 12” 24” of most operating problems (60cm) (30cm) (30cm) (60cm) 24” 12” 12” 24”...
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A service clearance of 24” must be provided above the • top panel to allow access to the burner. The appliance must be installed so that the ignition • system components protected from water (dripping, spraying, etc.) during appliance operation service (circulator replacement,...
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Condensate Service drains drain Table 3: Appliance Dimensions and Specifications Ø Dim. "V" Ø Air Inlet Vent CAT. IV Ø Dim. Ø Dim. Ø Dim. Shipping Dim. Ø Dim. "L" up to 100 up to 100 Ft. "V" Dim. Model Dim. "A" Dim. "B" Dim. "C" Dim. "D" Dim. "E" Dim. "F" Dim. "G" Dim. "H" Dim. "I" Dim. "J" "W"...
PART 2 VENTING • The weight of the venting system must not 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 manufacturers specifications.
2.1.3 APPROVED VENTING MATERIALS Applications Air intake material must be of a type listed by a nationally Exhaust Vent for Use for Dynaforce® Category ll or lV recognized testing agency. Installations Manufactured prefabricated UL/ ULC listed vent of AL29- PVC Non Foam Core Pipe. 4C or equivalent, Single or Double Wall.
Consult with local code officials to determine code The termination point of the combustion air inlet cap must • requirements or the advisability of using a masonry be installed at least 3 feet (0.91M) above the rooftop and chimney with a sealed corrosion resistant liner system. above normal snow levels.
appliance to allow condensate to be evacuated at the drain tee. Ventilation”, of the National Fuel Gas Code, ANSI Z223.1/NFPA Plastic drain tubing, sized per the vent manufacturer’s 54, or clause 8.2, 8.3, 8.4 of “Natural Gas and Propane instructions, shall be provided as a drain line from the tee and Installation Code”, CAN/CSA B149.1.2, or applicable provisions from the boiler condensate line.
connections and will allow easier servicing of the appliance electric meters, gas meters, regulators and relief under severe weather conditions. equipment. In all cases local codes take precedence. • Flue gas condensate can freeze on exterior walls or on the SIDEWALL VENTING vent terminal.
PART 3 GAS CONNECTION 2 “ 1 ½“ 2“ 1 ½“ 2 ½” 2” 1000 2 “ 1 ½“ 2“ 1 ½“ 2 ½” 2” Verify that the appliance is supplied with the type of gas 1200 specified on the rating plate. Consult factory for installations at 2”...
AIR/GAS RATIO VALVE Figure 10: DR2000 - 5000 1:1 Air/Gas Ratio Control Valve Low fire adjustment screw The main gas valves supplying gas to the burner for models Located under cap 2000 to 5000 on this appliance utilize a servo pressure regulator (Turning clockwise increases gas flow) providing a slow opening, fast closing safety shut off and an air/gas ratio control valve for the gas combustion process.
GAS MANIFOLD DIFFERENTIAL PRESSURE promptly. Flame pattern should be stable, see “Maintenance-Normal Flame Pattern.” Turn system off and ADJUSTMENT (DR2000 – DR5000) allow burner to cool, then cycle burner again to ensure Tampering with gas valve adjustments after startup and proper ignition and flame characteristics.
appliance. Local codes may require the routing of these bleeds If a second manometer is available it can be connected to • and vents to the atmosphere, outside the building. Proper the appropriate gas ports. Typically the gas signal will routing of vent lines to the atmosphere from the factory supplied closely follow the air signal on all models.
PART 4 WATER CONNECTION are taken. Maintaining a mixture of 50% water and 50% propylene glycol is the preferred method of freeze protection in hydronic systems. This mixture will protect the ∗ Check all applicable local heating, plumbing and building appliance to approximately -35ºF (-37ºC).
Figure 18: Typical Instantaneous Water Heating System appliance. The connection to the appliance marked “Inlet” on the header should be used for return from the system. The connection on the header marked “Outlet” is to be connected to the supply side of the system. MINIMUM PIPE SIZE REQUIREMENTS The equivalent number of straight feet of pipe for each valve and fitting in the connecting piping must be considered to properly...
Figure 19: Low Water Cut Off Electrical Connections (Watts) The operation of the circulating pump is controlled by the Dynaforce® temperature control (SOLA). 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 Connection detail for placing temperature difference between inlet and outlet connections to L.W.C.O in 24V circuit...
PART 5 ELECTRICAL & CONTROLS Maximum Full Load Over Current Dynaforce® Voltage Amps Model Requirement Protection [Amperes] [Amperes] 1200 - IT IS EXTREMELY IMPORTANT THAT THIS UNIT BE 2500 PROPERLY GROUNDED! 3000 - 460VAC, 60Hz, 3 ELECTRICAL CONECTIONS 4000 Phase 4500 - Table 10: Minimum Power Requirements 5000...
inlet or at the flue discharge. A minimum differential pressure Figure 21: Ignition Module 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 an open Interrupted Air Switch (ILK Off) when the differential pressure switch detects a sustained low air condition.
ERROR TABLE Figure 23: Lockout History The following tables provide a description of all the possible errors with the Dynaforce® appliance. Errors can be divided into two groups. Alert errors (will disappear when error is gone) and lockout errors (can only be reset by the RESET button). When the control is in error the pump will be running.
PART 6 CONTROL PANEL Levels of Access Two levels of access to simplify the use of the boiler. APPLIANCE TEMPERATURE CONTROLLER User – Access to general boiler and display settings and The appliance is provided with a control panel at the front. adjustments to the central heating, domestic hot water and lead Operating controls are installed inside the control box and are lag setpoint.
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Sequence of Operation Flow Switch = 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) Interrupted Air Switch (DR 1200 –...
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Modulation: Boiler Inlet, Boiler Fixed Setpoint Operation (Standalone) Description Electrical Connection(s) Programming Instructions 1) Place toggle switch to LOCAL • Boiler operates at a fixed setpoint 2) Press • Modulates on boiler inlet 3) Press [CH – Central Heat Configuration] sensor (default) 4) Press the to arrive at Setpoint...
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Modulation: Boiler Inlet, Outdoor Reset Operation (Standalone) Description Electrical Connection(s) Programming Instructions Boiler operates with variable 1) Connect outdoor sensor to System/Outdoor contacts • setpoint determined by 2) Press outdoor reset curve 3) Press Outdoor Reset Configuration • Modulates on inlet sensor 4) Select Enable: Enable (default) 5) Select Maximum outdoor temperature (WWSD)
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NOTE: Outdoor Reset Module (PN: W8735S1000) required. Description Electrical Connection(s) Programming Instructions Boiler operates with variable 1) Connect Remote Operator • 2) Connect System sensor to System/Outdoor setpoint determined by outdoor reset curve contacts 3) Connect Outdoor Sensor to J3 ECOM connector •...
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4-20mA/ 2-10Vdc Setpoint Operation (Standalone) Description Electrical Connection(s) Programming Instructions 1) Place toggle switch in LOCAL • Boiler operates with variable setpoint determined by 4- 2) Press 20mA incoming signal 3) Press [CH – Central Heat Configuration] • Modulates on boiler inlet 4) Press the to arrive at Setpoint sensor (default)
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4-20mA/ 2-10Vdc Firing Rate Operation (Standalone) Description Electrical Connection(s) Programming Instructions 1) Place toggle switch in LOCAL Boiler operates with variable • setpoint determined by 4- 2) Press 20mA incoming signal 3) Press [Lead Lag Master Configuration] • Modulates on header sensor 4) Press [Advanced Settings >] •...
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Modulation: Fixed Setpoint Operation (Standalone) Description Electrical Connection(s) Programming Instructions DHW Sensor/ Stat, if required. 1) Place toggle switch to LOCAL • Boiler operates at a fixed DHW setpoint 2) Press Modulates on boiler inlet • Inlet Sensor operation sensor (default) 3) Press [DHW –...
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DR(H,W) Lead Lag Operation Master Boiler Description Electrical Connection(s) Programming Instructions 1) Place toggle switch to LOCAL • Master boiler lead lag setup 2) Press 3) Select 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...
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14) Select Lead Lag Slave Configuration 15) 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 sufficient: 16) Select Pump Configuration 17) Press [Advanced Options >>] 18) Press the to arrive at Central Heat Pump or DHW Pump 19) On Options:...
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Slave Boiler Description Electrical Connection(s) Programming Instructions 1) Place toggle switch to LOCAL Slave boiler lead lag setup • 2) Press 3) Select System Identification & Access 4) Verify Modbus address. To be in 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 sufficient:...
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Master Boiler, System Sensor Description Electrical Connection(s) Programming Instructions Master boiler system sensor • 1) Press configuration 2) Press [Sensor Configuration] 3) Select S5 (J8-11) Sensor 4) Connector Type: 10K NTC Single Non-Safety 5) The control will proceed into a Lockout 2 condition 6) Press [Verify] >...
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Outdoor Sensor connected to Slave boiler 2 (DRH ONLY) Description Electrical Connection(s) Programming Instructions Slave boiler outdoor sensor Slave Boiler • configuration 1) Press • When done correctly, the 2) Press [Sensor Configuration] outdoor temperature will be 3) Select S5 (J8-11) Sensor shown on the Master boiler 4) Connector Type: 10K NTC Single Non-Safety 5) The control will proceed into a Lockout 2 condition...
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17) Press [Show Line] to confirm reset curve to arrive at Warm Weather Shutdown 18) Press the 19) Select Enable = Shutdown after demand ends...
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Rotation schedule adjustment Description Electrical Connection(s) Programming Instructions Standard rotation schedule is • 1) Press based on equalizing run time 2) Press [Lead Lag Master Configuration] on a 1-hour schedule 3) Press [Advanced Settings >] • To vary the rotation to a 4) Press the to arrive at Algorithms fixed schedule based on...
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Adjust staging of boilers Description Electrical Connection(s) Programming Instructions Upon a call for heat the lead • 1) Press boiler will fire up to the 2) Press [Lead Lag Master Configuration] specified base load rate 3) Press [Advanced Settings >] (80%).
6.2.2 Pump Configuration CONFIGURE MENU Sub- Figure 26: Configure Menu Menu Menu Group Parameter Selection Description Group Selection Selection Assigns the method for SOLA to control a Central Heating pump Auto (Default: Auto, Pump is Pump Control activated whenever a call for heat is present) ON: Pump is...
6.2.3 Statistics Configuration Sub- Menu Menu Group Parameter Selection Description Sub- Group Menu Selection Menu Selection Group Parameter Selection Description Group DR300-1000: Ignition Fan Selection Selection Lightoff 3000 RPM speed Displays the rate DR1200 – Boiler 5000: 20.0% number of cycles pump the boiler pump cycles...
When a boiler is set as Lead Lag Master = Enabled and Modbus Use Cascade terminals in the junction box to wire lead lag address = 1, the controller of this boiler will drive the lead lag appliances operation. Master Slave 2 Slave 7 The outdoor temperature sensor connected to the slave boiler 2...
COM1: Modbus data between display and SOLA COM2: Modbus data between display and front end (Modbus) or Protonode For more instructions on interfacing with Modbus/ Bacnet/ LonWorks/ Metasys N2 network: Select Gateway tab http://www.camus- Check Enable Modbus gateway hydronics.com/media/1296/93_0238_dynaflame_dynaforce_dy Select Gateway on COM2 port namaxhs_advantus_protocol_setup.pdf VARIABLE FREQUENCY DRIVE (DR1200 - 5000)
PART 7 COMPONENTS COMBUSTION AIR FAN DR300 – 1000 HOT SURFACE IGNITER (GLOW BAR) Uses a modulating air fan to provide combustible air/gas mix to The silicon carbide igniter is inserted directly through the fan the burner and push the products of combustion through the flange and held in place by two screws.
PART 8 FIELD STARTUP GAS VALVE ADJUSTMENT PROCEDURE PROCEDURE Table 14: Combustion Values Dynaforce® Combustion Values CHECKING THE INSTALLATION Natural Gas Propane Inspect the connections for water, gas and electricity. • Confirm that water is being pumped toward the heat •...
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Figure 33: DR 500 - 1800 Gas Valve Locate the input adjustment screw on the top side of the gas valve. Lift top cover to access high fire air/gas ratio adjustment (use 3mm allen key for adjustment, Increase CO2 Decrease CO2 counter-clockwise increases CO High Fire Low fire air/gas ratio adjustment...
After the low fire settings are stable, ramp the boiler firing rate • This boiler is designed for low fire soft start. At the start of to 100% using the boiler control and bring the system trial for ignition the fan will decelerate to minimum fire and temperatures up to 130F or to highest system design will light off at low fire before ramping up towards full input temperatures to minimize or eliminate condensate.
PART 9 TROUBLESHOOTING COMPONENT FAILURE MODE ANALYSIS • Two wires interchanged • No effect on safety Incoming Power • Live and Neutral wires are interchanged. • The 24Volts and 120 Volts wired • Breaker on transformer trips Transformer are interchanged Tripped •...
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COMPONENT FAILURE MODE ANALYSIS • Verify that all air has been purged from gas line • The Dynaforce® boiler was • Verify that boiler is properly grounded running and flame signal suddenly • Inspect flame sensor and associated wiring. Replace if disappeared.
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SYMPTOM FAILURE MODE ANALYSIS • Manual Reset Safety High Limit • Verify that the capillary tube is broken. If this is the case, replace tripped, outlet temperature in Manual Reset High Limit excess of 210 • Verify that the system is full of water and that all air has been •...
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SYMPTOM FAILURE MODE ANALYSIS • Flame detection is present when no • Verify supply voltage for proper polarity. visible signs of a flame exist • Check external wiring for voltage feedback Flame Detection is • Lockout: 105, 158 • Check internal wiring for proper connections out of Sync •...
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Table 16: Lockout Codes Table 17: Alert/Hold Codes Description Description Unconfigured safety data Burner switch turned OFF Waiting for safety data verification Burner switch turned ON 3-46 Internal Fault. Replace SOLA Controller Invalid subsystem request occurred Flame rod to ground leakage Modulation Fault (DR300 –...
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Alert 291: Abnormal Recycle: Flame was not on at end of ignition Alert 292: Abnormal Recycle: Flame was lost during Main Flame Establishing Period Alert 293: Abnormal Recycle: Flame was lost early in Run Alert 294: Abnormal Recycle: Flame was lost during Run Alert 324, 374-379: Abnormal Recycle: Hardware flame bias This error occurs when a flame signal is not detected by the flame sensor.
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Hold 63: LCI OFF (Load Control Input) Hold 67: ILK OFF (High Limit, Gas Pressure Switch, Air Switch) Alert 303: Abnormal Recycle: ILK off during drive to Purge Alert 304: Abnormal Recycle: ILK off during Measured purge time Alert 305: Abnormal Recycle: ILK off during Drive to Pre-ignition Alert 306, 307: Abnormal Recycle: ILK off during Pre-ignition Alert 308: Abnormal Recycle: ILK off during Main Flame Alert 309: Abnormal Recycle: ILK off during Ignition Period...
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Alert 354: Abnormal Recycle Delta-T limit F. This is done to prevent damage to the This safety was breached as the inlet and outlet temperature difference exceeded 40 heat exchanger. Before this error appears, the combustion air blower will slow down in an effort to prevent such an error from occurring.
PART 10 MAINTANANCE and ventilation air. 10.3 FLUE GAS PASSAGEWAYS CLEANING CAUTION PROCEDURES It is important that all gas appliances to be serviced by a Camus® trained service technician. It is in your own interest Any sign of soot around the jacket, flue pipe connections, burner and that of safety to ensure that all local codes, and all the or in the areas between the fins on the stainless steel heat “NOTES”...
the drain. Use standard ½" vinyl, PVC, CPVC or suitable hose removed. Insert the igniter and sensor before doing the to run to floor drain. final tightening on the fan mounting nuts. Evenly tighten the nuts to 20 ft-lbs (models 300 – 1000) and When the condensate level in the reservoir rises to the drain, it 25 ft-lbs (models 1200 –...
the main burner (models 300-2500) and pilot (models 3000 indicates a short in the 24VAC controls and must be corrected. – 5000). 10.12 COMBUSTIBLE MATERIALS 10.7 HEAT EXCHANGER INSPECTION CAUTION The heat exchanger should be inspected at the time of Keep appliance clear from combustible materials;...
PART 11 INSTALLATIONS 11.4 HEATING BOILER INSTALLATIONS appliance MUST always installed WARNING primary/secondary reverse return piping system for proper Before starting the boiler, smell near the floor and around operation. Before beginning the installation, consult local codes the boiler for any gas odours or any unusual odour. Remove for specific plumbing requirements.
point is satisfied. This will remove any residual heat from the position. combustion chamber before turning the pump off. See wiring Program the adjustable points. diagram shipped with the unit. Turn the switch to the “ON” position to start boiler operation.
DR 3000 – DR 5000 Check the pump to be sure it is running properly and that the pump motor is running in the proper direction. Be sure the pipes between the hot water heater and storage tank are not more than a total of 80 equivalent feet between inlet and outlet lines.
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VMU300A1046 13-0026 Venturi/ Air Gas Inlet 66-5005 Adapter 13-0027 66-5011 VGG10.404U VGG10.504U (Requires Gas Valve Body VGD40.065U VR8615B1044 V8730C1015 V8730C1023 Gas Valve V8730C1031 V4734C1002 SKP55 V4295A1049 Gas Valve Solenoid V4295A1056 Gas Valve Regulator SKP 25 VGG10.404U Gas Valve Regulator Body Low gas Switch C6097A 66-5015-350...
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CONDENSING BOILER LIMITED WARRANTY GENERAL Camus® Hydronics Limited (“Camus®”) extends the following LIMITED WARRANTY to the owner of this appliance, provided that the product has been installed and operated in accordance with the Installation Manual provided with the equipment. Camus® will furnish a replacement for, or at Camus®...
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HOW TO MAKE A CLAIM Any claim under this warranty shall be made directly to Camus® Hydronics Limited Canadian Head Office SERVICE LABOR RESPONSIBILITY Camus® shall not be responsible for any labour expenses to service, repair or replace the components supplied. Such costs are the responsibility of the owner.
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CAMUS Hydronics is a manufacturer of replacement parts for most copper finned and stainless steel water heaters and heating 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 &...
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