Camus Hydronics DFH500 Installation, Operation And Service Manual
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Camus Hydronics DFH500 Installation, Operation And Service Manual

Gas fired commercial copper tube boilers dynaflame series
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INSTALLATION OPERATION
AND SERVICE MANUAL
GAS FIRED COMMERCIAL COPPER TUBE BOILERS
Models; DFH500, 750, 1100, 1200, 1500, 1750, 2000, 2500, 3000,
Models; DFW500, 750, 1100, 1200, 1500, 1750, 2000, 2500, 3000,
W
A
W
A
If the information in these instructions is not followed
exactly, a fire or explosion may 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
Do not try to light any appliance,
o
Do not touch any electrical switch; do not
o
use any phone in your building,
Immediately call your gas supplier from a
o
neighbour's phone. Follow the gas
supplier's instructions,
If you cannot reach your gas supplier, call
o
the fire department.
Qualified installer, service agency or the
gas supplier must perform installation and
service.
To the Installer: After installation, these instructions
must be given to the end user or left on or near the
appliance.
To the End User: This booklet contains important
information about this appliance. Retain for future
reference.
CAMUS
6226 Netherhart Road, Mississauga, Ontario, L5T 1B7
DynaFlame SERIES
FOR HYDRONIC HEATING
3500, 4000, 4500, 5000
HOT WATER SUPPLY
3500, 4000, 4500, 5000
R
N
I
N
G
:
R
N
I
N
G
:
HYDRONICS
LTD.
99-0050
Rev. 04

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Summary of Contents for Camus Hydronics DFH500

  • Page 1 AND SERVICE MANUAL GAS FIRED COMMERCIAL COPPER TUBE BOILERS DynaFlame SERIES FOR HYDRONIC HEATING Models; DFH500, 750, 1100, 1200, 1500, 1750, 2000, 2500, 3000, 3500, 4000, 4500, 5000 HOT WATER SUPPLY Models; DFW500, 750, 1100, 1200, 1500, 1750, 2000, 2500, 3000,...

  • Page 2: Table Of Contents

    Table of Contents PART 1 GENERAL INFORMATION................................1 INTRODUCTION ....................................1 SPECIAL INSTRUCTIONS TO OWNER...............................1 CHECKING EQUIPMENT ..................................1 WHAT THE LIGHTS MEAN ON YOUR CAMUS APPLIANCE ......................2 HOW IT OPERATES (SEQUENCE OF OPERATION) .........................2 1.5.1 IGNITION PROCESS .................................3 1.5.2 HEAT TRANSFER PROCESS ..............................3 1.5.3 END OF SEQUENCE .................................3 CODES........................................3...
  • Page 3 HIGH and LOW GAS PRESSURE SWITCHS (Optional) ........................21 HIGH LIMIT ......................................21 IGNITION CONTROL MODULE................................21 5.6.1 SERVICE PARTS ..................................22 5.6.2 IGNITION MODULE LOCKOUT FUNCTIONS .........................22 5.6.3 DIAGNOSTIC STATUS INDICATION ............................22 5.6.4 FLAME SENSE TEST ................................22 PART 6 CONTROL PANEL..................................23 APPLIANCE TEMPERATURE CONTROLLER ..........................23 MODULATING SIGNAL GENERATOR...............................25 VARIABLE FREQUENCY DRIVE (VFD).............................25 PART 7...

  • Page 4: Part 1 General Information

    PART 1 GENERAL INFORMATION INTRODUCTION DynaFlame Condensing In this series most of the sensible heat value is being The DynaFlame boiler is a fan assisted boiler based on transferred into the water. The unused portion of the push through design which offers several venting options. sensible heat and most of the latent heat is absorbed by the Heat output is controlled by a one to one air/gas ratio Condenser Heat Recovery Module (CHRM).

  • Page 5: What The Lights Mean On Your Camus Appliance

    above the boiler inlet/outlet connection. In all cases WHAT THE LIGHTS MEAN ON YOUR check with local codes. CAMUS APPLIANCE Local or remote operator calls for heat and operator • Light off means there is no power POWER light illuminates. If the appliance is provided with a to the appliance.

  • Page 6: Ignition Process

    control valve and will immediately go into lockout mode DO NOT for CSD1, or proceed to two more trials before locking Do not use this appliance if any part of it has been under out in the standard version. water. The possible damage to a flooded appliance can be 14 The ignition module will go into lockout if it does not extensive and present numerous safety hazards.

  • Page 7: Warranty

    requirements of the authority having jurisdiction or, in the • absence of such requirements, with national electrical code, Seal any unused openings in the common venting ANSI/NFPA70 and/or the Canadian electrical code part 1 system. CSA C22.1. Where required by the authority having •...

  • Page 8: Boiler Room Operating Condition

    Replace any damaged gasket. Note that the burner is replacement, etc.) • supplied with two gaskets; a high temperature ceramic Appliances located in a residential garage and in paper gasket under the burner flange and a stamped adjacent spaces that open to the garage and are not silicon gasket between the burner flange and fan part of the living space of a dwelling unit must be flange.
  • Page 9 Table 2 Service Clearances Service Clearance, Inches (cm) Model Numbers Right Side Left Side Back 24” (60cm) 12” (30cm) 12” (30cm) 24” (60cm) 12” (30cm) 12” (30cm) 1100 24” (60cm) 12” (30cm) 12” (30cm) 1200 24” (60cm) 12” (30cm) 12” (30cm) 1500 24”...

  • Page 10: Part 2 Venting

    draft shall not be connected into any portion of PART 2 VENTING mechanical draft systems operating under positive pressure. • Horizontal runs of vent pipe shall be securely supported (approximately every 4 feet) to prevent It is extremely important to follow these venting sagging and maintain a minimum upward slope of ¼"...

  • Page 11: Category Ii And Category Iv Venting

    Al 294Cor equivalent, single or double wall. Venting • The installed length of the positive pressure flue from Exhaust Vent for Use for DynaFlame Condensing the appliance to the point of termination, outside of the Category ll or lV Installations building, must not exceed a maximum of 100 AL294Cor equivalent, Single or Double Wall.

  • Page 12: Air Inlet Damper

    • inlet pipe has a cross sectional area equal to or larger than Combustion air supplied from outdoors must be free of the total area of all air inlet pipes connected to the common contaminants. To prevent recirculation of flue products air inlet pipe.

  • Page 13: Conventional Venting (Indoor) Installations

    condensate neutralization system or a suitable drain for separate vents as for Category IV, pressurize the room disposal of condensate that may occur in the vent system. or to provide an extractor at the chimney outlet interlocked with the appliance operating circuit in order Ensure that the drain from the condensate tee is not to maintain a negative draft in the chimney and allow exposed to freezing temperature.

  • Page 14: Outdoor Venting

    • Install the proper vent pipe to the vent cap (provided by For outdoor installations, always consider the use of a Camus Hydronics). shelter such as a garden shed in lieu of direct exposure of • Follow all requirements in the General Venting sections the appliance to the elements.

  • Page 15: Location Of A "Thruwall" Air Inlet Cap

    structure. of the gas train. • • The vent cap should have a minimum clearance of 4 Install a manual main gas shutoff valve, outside of the feet (1.25M) horizontally from and in no case above or appliance gas connection as require by local codes. •...

  • Page 16: Gas Piping

    • The differential gas pressure measurement is made GAS PIPING between the high and low pressure taps across the in- All gas connections must be made with pipe joint line metering gas orifice. Check this value to confirm compound resistant to the action of liquefied petroleum and that it matches the differential air pressure while the natural gas.

  • Page 17: Checking Gas Supply Pressure

    CHECKING GAS SUPPLY PRESSURE CHECKING DIFFERENTIAL AIR AND GAS PRESSURES • Turn the main power switch to “OFF” position. • Shut off gas supply at the manual gas cock in the gas Figure 3 – Differential Air Pressure Manometer piping to the appliance. If fuel supply is LP gas, shut off Connection gas supply at the tank.

  • Page 18: Gas Train And Controls

    combustion air fan allows the burner input rate to vary from GAS TRAIN AND CONTROLS 20% to 100% based on temperature demand. The inlet gas Figure 4 – Typical Gas Train supply pressure must be maintained within the specified minimum and maximum pressures. A reduction of up to 30% is permitted in the inlet gas pressure between light off and full fire conditions.

  • Page 19: Part 4 Water Connection

    varies. In order to maximize the operating life of the burner, the normal operating mode for the Dynaflame is a blue flame. Infrared operation will occur only if air to gas adjustments is incorrect. If infrared operation is noted the cause must be corrected.

  • Page 20: Inlet And Outlet Connections

    110ºF (44 ºC), the flue products passing through the copper fined tubes will be cooled below their dew point resulting in INLET AND OUTLET CONNECTIONS the formation of corrosive condensation on the copper which shorten its life. Under these conditions condensation •...

  • Page 21: Instantaneous Water Heater (Non-Condensing)

    heat to be absorbed from the flue products exhausted from INSTANTANEOUS WATER HEATER (non- the combustion process. If isolation valves are provided on condensing) the CHRM, the provision of a relief valve at the outlet of the An instantaneous water heater is designed to deliver hot CHRM is recommended.

  • Page 22: Chrm, Flow And Pressure Drop

    Consult vent pipe manufacturer’s instructions for proper CHRM, FLOW and PRESSURE DROP method of sealing vent pipe sections and fittings. In the Figure 12 – Secondary Heat Exchanger absence of instructions, make sure that pipe and fittings are clean by swabbing with alcohol. Use Dow Corning 736 or 732 RTV, Polybar # 500 RTV or Sil-bond 4500 or 6500 to seal vent pipe.

  • Page 23: Relief Valve (Shipped Loose)

    this case the CHRM may be fed directly with part of the Figure 13 – Low Water Cut off Electrical Connections supply water using a secondary pump. 4.14 CIRCULATING PUMP SELECTION The appliance has a low mass finned tube heat exchanger for fast response and high heat absorption and employs copper tubes for models DF-500 thru DF-3000 and copper nickel tubes for models Df-3500 thru DF-5000, Selecting...

  • Page 24: Part 5 Electrical & Controls

    CAUTION The voltage output from the variable frequency drive to the PART 5 ELECTRICAL & combustion air fan is 230VAC, 3 Phase. AVOID contact with high voltage wiring CONTROLS DIFFRENTIAL AIR PRESSURE SWITCH IT IS EXTREMELY IMPORTANT THAT THIS UNIT BE A differential air pressure switch is used to prove operation PROPERLY GROUNDED! of the combustion air fan.

  • Page 25: Service Parts

    source much like a proven standing pilot before the gas 5.6.2 IGNITION MODULE LOCKOUT FUNCTIONS valves are energized. The ignition control proves the The ignition module may lockout in either a hard lockout presence of the proper ignition temperatures from the hot condition requiring pushing of the reset button to recycle surface igniter using a proof current (2.7A +/- 0.2), the control for a CSD1 requirement or a soft lockout...

  • Page 26: Part 6 Control Panel

    minimum 2.0 µA D.C. If the signal is less than this it could constant circulation DHW, modes 2, 4, and 5 for indicate oxide on the metal rod, a partial ground through the heating , mode 3 for DHW with remote sensing and ceramic insulator or an improperly placed sensor.
  • Page 27 Mode 2 is intended for hydronic heating based on PID logic. The set-point for supply water sensor S3 is pre-set to 180°F Mode 4 is intended for hydronic heating. The set-point for and the auto re-set limit is set to 230°F. The supply sensor inlet water control is pre-set to 180°F and the auto re-set set-point can be adjusted, however the limit is fixed.

  • Page 28: Modulating Signal Generator

    in the electrical enclosure across the contacts to be used Table 14 for connection to the remote operator. The fixed auto re-set Parameter Function Settings limit is set to 230°F. In addition to the auto reset limit the factory installs a manual re-set limit set to 250°F. The Carrier Frequency control provides pump operation.

  • Page 29: Combustion Air Fan

    When installing Category II or IV appliances care must be taken to properly seal all joints and provide slope for The ignition module relies on the flame sensor to provide a drainage of condensate. flame rectification signal. Oxide deposits, improper placement or damaged ceramic insulator will result in PART 8 FIELD STARTUP...

  • Page 30: Fire Testing

    • initial start up, when air is being purged from the Shut the main gas off to the unit and allow it to try for piping, to require two to three tries before successful ignition. Trial for ignition should commence within 30 ignition.

  • Page 31: Part 9 Trouble Shooting

    PART 9 TROUBLE SHOOTING...

  • Page 33: Part 10 Maintanance

    • Lifting Flames: Lifting flames can be caused by over firing the burner, excessive primary air or high draft in PART 10 MAINTANANCE excess of negative 0.15” W.C. CAUTION If improper flame is observed, examine the venting system; It is important that all gas appliances to be serviced by a ensure proper gas supply and adequate supply of competent person.

  • Page 34: Burner Maintenance

    flange away from the gasket prior to removing the Many codes will require the acidic condensate to be fan assembly. neutralized before it can be placed in a drain system. A • The burner can now be lifted vertically out of the neutralizer to control the pH of the liquid discharged to a heat exchanger cavity.

  • Page 35: Re-Installing The Igniter

    side. 10.6.1 RE-INSTALLING THE IGNITER • Confirm that the end of the replacement igniter has a 10.9 RE-INSTALL HEAT EXCHANGERS bead of silicone sealing the gap between the metal • Carefully reinstall the heat exchanger if removed from mounting flange and the ceramic shaft of the igniter. the appliance.

  • Page 36: Freeze Protection For A Heating Boiler System (Optional)

    adequate freeze protection. to considerable expansion and contraction. Pipe supports • could allow the pipe to slide resulting in noise transmitted Freeze protection for the appliance using an indirect into the system. Padding is recommended. The boiler coil can be provided by using hydronic system pressure relief valve must be piped to a suitable floor drain.

  • Page 37: Domestic Hot Water Heater

    service clearances. Boiler Operation Review Part 2 Venting. Ensure that all vent Appliance should begin the start-up process components are fabricated from the correct for the sequence of operation. category of materials with adequate clearance The boiler will fire down to 20% of rated input from combustibles.

  • Page 38: Water Heaters

    equivalent length for the specified pipe diameter is exceeded, larger diameter pipe may have to be installed to achieve correct flow and temperature rise. Common manifold piping for multiple unit installations will require larger minimum pipe sizes and tank circulating tapping to ensure proper flow. If the temperature rise is too low, the water velocity is too high.

  • Page 39: Part 12 Exploded View

    PART 12 EXPLODED VIEW...
  • Page 42 Sheet Metal Components Name of Part Part ID Model Sizes 1100 1200 1500 1750 2000 2500 3000 3500 4000 4500 5000 14-6004 Outer Jacket Front Panel 14-5221 14-5210 Combustion Chamber Door 14-5204 14-5012 Base Panel 14-5206 14-5011 Heat Exchanger Base Support 14-5205 14-5008 Combustion...
  • Page 43 14-0350 14-0351 14-0352 14-0353 14-0354 Vee Baffle Sets 14-0355 14-0356 14-0357 14-0358 14-0371 Outer Jacket Top 14-5226 Wrap Outer Jacket Top 14-5227 Cover GFH 6" GFH 8" Outside Air Intake GFH 10" Housing GFH 12" GFH 14" Miscellaneous Components Name of Part Part ID Model Sizes 1100...
  • Page 44 Valve Body VGG10.2544 66-5000 66-5001 Air Gas Inlet 66-5003 Adapter 66-5004 66-5005 GFH-500-CH GFH-750-CH GFH-1100-CH GFH-1200-CH GFH-1500-CH GFH-1750-CH Filter Holder GFH-2000-CH GFH-2500-CH GFH-3000-CH GFH-3500-CH GFH-4000-CH GFH-4500-CH GFH-5000-CH GFIF-500-CH GFIF-750-CH GFIF-1100-CH GFIF-1200-CH GFIF-1500-CH GFIF-1750-CH Fan Intake Filter GFIF-2000-CH GFIF-2500-CH GFIF-3000-CH GFIF-3500-CH GFIF-4000-CH GFIF-4500-CH GFIF-5000-CH...
  • Page 45 33-0013 Flange Gasket 33-0014 Electrical Components Name of Part Part ID Model Sizes 1100 1200 1500 1750 2000 2500 3000 3500 4000 4500 5000 SM005S Variable Frequency SM010S Drive (1/2HP, 1HP, SM015S 1 1/2HP, 3HP) SM23S Ignition Module DF 35-67 Control BTC-2PA Control...

  • Page 46: Part 13 Electrical Diagrams

    PART 13 ELECTRICAL DIAGRAMS...

  • Page 52: Warranty

    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 option repair, any part that within the period specified below, shall fail in normal use and service at its original installation location due to any defect in workmanship, material or design.
  • Page 53 CAMUS Hydronics is a CAMUS manufacturer CERTIFIED! Seal replacement parts for assures that most copper finned Reliability, Efficiency & serviceability are built water heaters into every heating single unit! boilers as well more as a information supplier specialty innovative HVAC products.

This manual is also suitable for:

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