Camus Hydronics 102 Service manual
INSTALLATION OPERATION
AND SERVICE MANUAL
GAS FIRED COMMERCIAL CONDENSING STAINLESS
STEEL TUBE BOILERS
DynaForce SERIES
HYDRONIC HEATING
Models; DRH300, 350 400, 500, 600, 800, 1000, 1200,
1400, 1600, 1800, 2000, 2500, 3000, 3500, 4000, 4500,
5000
HOT WATER HEATER
Models; DRW300, 350 400, 500, 600, 800, 1000, 1200,
1400, 1600, 1800, 2000, 2500, 3000, 3500, 4000, 4500,
5000
H
HLW
WARNING:
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
o Do not try to light any appliance,
o Do not touch any electrical switch; do not
use any phone in your building,
o Immediately call your gas supplier from a
neighbour’s phone. Follow the gas
supplier’s instructions,
o If you cannot reach your gas supplier, call
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.
6226 Netherhart Road, Mississauga, Ontario, L5T 1B7
99-0171
Rev. 0.4
Table of Contents
PART 1
1.1
1.2
1.3
1.4
1.4.1
1.4.2
1.5
1.6
1.7
1.8
1.9
1.10
PART 2
2.1
2.1.1
2.1.2
2.1.3
2.1.4
2.1.5
2.1.6
2.1.7
2.1.8
2.1.9
2.1.10
2.1.11
2.2
2.2.1
2.2.2
2.3
2.4
2.4.1
2.4.2
2.4.3
2.4.4
PART 3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.7.1
3.8
3.9
3.10
3.11
PART 4
4.1
GENERAL INFORMATION ......................................................................................................................... 1
INTRODUCTION....................................................................................................................................... 1
SPECIAL INSTRUCTIONS TO OWNER ........................................................................................................ 1
CHECKING EQUIPMENT ........................................................................................................................... 1
HOW IT OPERATES (SEQUENCE OF OPERATION)...................................................................................... 1
HEAT TRANSFER PROCESS ....................................................................................................................... 2
END OF SEQUENCE.................................................................................................................................. 2
CODES..................................................................................................................................................... 3
WARRANTY ............................................................................................................................................. 3
REMOVAL OF EXISTING APPLIANCE ......................................................................................................... 3
BOILER ROOM OPERATING CONDITION................................................................................................... 4
CLEARANCE FROM COMBUSTIBLE MATERIAL .......................................................................................... 4
INSTALLATION PROCEDURE AND LOCATION OF UNIT .............................................................................. 5
VENTING ................................................................................................................................................. 7
GENERAL VENTING GUIDE ....................................................................................................................... 7
CATEGORY II AND CATEGORY IV VENTING ............................................................................................... 7
VENTING GUIDELINES FOR CATEGORY II AND/OR IV VENTING................................................................. 7
APPROVED VENTING MATERIALS ............................................................................................................ 8
VENT TERMINATION CLEARANCES .......................................................................................................... 8
INLET CAP FOR ROOFTOP TERMINATION................................................................................................. 8
LOCATION OF A ROOFTOP AIR INLET AND VENT CAPS ............................................................................. 9
AIR INLET DAMPER .................................................................................................................................. 9
MASONARY CHIMNEY INSULATIONS ....................................................................................................... 9
VERTICAL VENTING TERMINATION .......................................................................................................... 9
COMBINED COMBUSTION AIR INLET ....................................................................................................... 9
DRAIN TEE............................................................................................................................................. 10
CONVENTIONAL VENTING (INDOOR) INSTALLATIONS ............................................................................ 10
AIR REQUIRED FOR COMBUSTION AND VENTILATION ........................................................................... 10
EXHAUST FANS...................................................................................................................................... 10
OUTDOOR VENTING .............................................................................................................................. 11
SIDEWALL VENTING .............................................................................................................................. 11
SIDEWALL VENT TERMINAL & SIDEWALL INTAKE AIR TERMINAL ........................................................... 11
LOCATION OF A SIDEWALL VENT TERMINATION ................................................................................... 11
LOCATION OF A SIDEWALL AIR INLET TERMINAL ................................................................................... 11
LENGTH OF AIR INLET PIPE .................................................................................................................... 11
GAS CONNECTION ................................................................................................................................. 12
GAS CONNECTION ................................................................................................................................. 12
GAS PIPING ........................................................................................................................................... 12
INSTALL PIPING ..................................................................................................................................... 12
AIR/GAS RATIO VALVE ........................................................................................................................... 13
DIFFERENTIAL AIR PRESSURE (DR2000 – DR5000) ................................................................................. 14
GAS MANIFOLD DIFFERENTIAL PRESSURE ADJUSTMENT (DR2000 – DR5000) ........................................ 14
CHECKING GAS SUPPLY PRESSURE......................................................................................................... 14
Regulated Gas Supply Pressures for DynaForce Boilers & Water Heaters............................................... 15
CHECKING DIFFERENTIAL AIR AND GAS PRESSURES (DR2000 – DR5000)................................................ 15
GAS TRAIN AND CONTROLS ................................................................................................................... 15
VENTING OF GAS VALVES AND PRESSURE SWITCHES ............................................................................ 16
BURNER ................................................................................................................................................ 16
WATER CONNECTION ............................................................................................................................ 16
FREEZE PROTECTION ............................................................................................................................. 17
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.11.1
4.12
PART 5
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.7.1
5.7.2
5.8
5.9
PART 6
6.1
6.2
6.3
6.4
6.5
6.6
6.7
PART 7
7.1
7.2
7.3
7.4
7.5
7.6
PART 8
8.1
8.2
8.3
8.4
PART 9
PART 10
10.1
10.2
10.3
10.4
10.4.1
WARNING REGARDING CHILLED WATER AND HEATING COIL SYSTEMS.................................................. 17
INLET AND OUTLET CONNECTIONS........................................................................................................ 17
MINIMUM PIPE SIZE REQUIREMENTS .................................................................................................... 17
HEAT EXCHANGER ................................................................................................................................. 17
LOW WATER TEMPERATURE SYSTEMS .................................................................................................. 18
INSTANTANEOUS WATER HEATER ......................................................................................................... 18
WATER FLOW SWITCH .......................................................................................................................... 18
LOW WATER CUTOFF (If Equipped) ...................................................................................................... 18
RELIEF VALVE ........................................................................................................................................ 19
CIRCULATING PUMP SELECTION ............................................................................................................ 19
CIRCULATING PUMP OPERATION OF HEAT EXCHANGER ........................................................................ 19
∆T HEAT EXCHANGER ALGORITHM........................................................................................................ 19
ELECTRICAL & CONTROLS ...................................................................................................................... 20
ELECTRICAL CONECTIONS...................................................................................................................... 20
VARIABLE FREQUENCY DRIVE (DR1200 – 5000) ..................................................................................... 20
DIFFRENTIAL AIR PRESSURE SWITCH ..................................................................................................... 21
BLOCKED FLUE SWITCH ......................................................................................................................... 21
DIFFERENTIAL GAS AND LOW GAS PRESSURE SWITCHES ....................................................................... 21
HIGH LIMIT ........................................................................................................................................... 21
DYNAFORCE SOLA ................................................................................................................................. 21
SERVICE PARTS ...................................................................................................................................... 21
IGNITION MODULE LOCKOUT FUNCTIONS............................................................................................. 21
DYNAFORCE CONTROLLER .................................................................................................................... 22
ERROR TABLE ........................................................................................................................................ 22
CONTROL PANEL ................................................................................................................................... 23
APPLIANCE TEMPERATURE CONTROLLER .............................................................................................. 23
CONFIGURE MENU ................................................................................................................................ 40
LEAD LAG SETUP ................................................................................................................................... 42
LOCAL/REMOTE SWITCH ....................................................................................................................... 43
COMM. PORT 2 ACTIVATION ................................................................................................................. 43
VARIABLE FREQUENCY DRIVE ................................................................................................................ 44
FROST PROTECTION .............................................................................................................................. 44
COMPONENTS ...................................................................................................................................... 44
HOT SURFACE IGNITER (GLOW BAR)...................................................................................................... 44
FLAME SENSOR ..................................................................................................................................... 44
COMBUSTION AIR FAN .......................................................................................................................... 45
INNER JACKET ....................................................................................................................................... 45
OUTER JACKET ..................................................................................................................................... 45
VENTING TRANSITION .......................................................................................................................... 45
FIELD STARTUP PROCEDURE ................................................................................................................. 45
CHECKING THE INSTALLATION ............................................................................................................... 45
CHECKING THE CONSTRUCTION ............................................................................................................ 45
GAS VALVE ADJUSTMENT PROCEDURE.................................................................................................. 46
COMISSIONING APPLIANCE ................................................................................................................... 48
TROUBLESHOOTING .............................................................................................................................. 49
MAINTANANCE ..................................................................................................................................... 56
EXAMINE THE VENTING SYSTEM ........................................................................................................... 56
VISUALLY CHECK MAIN BURNER FLAMES .............................................................................................. 56
FLUE GAS PASSAGEWAYS CLEANING PROCEDURES ............................................................................... 56
CONDENSATION TREATMENT ............................................................................................................... 56
CONDENSATE VOLUME ......................................................................................................................... 57
10.5
10.5.1
10.5.2
10.6
10.6.1
10.7
10.8
10.9
10.10
10.11
10.12
10.13
10.14
PART 11
11.1
11.2
11.3
11.4
11.5
11.6
11.7
11.8
11.9
11.10
11.11
11.12
PART 12
PART 13
BURNER MAINTENANCE........................................................................................................................ 57
BURNER REMOVAL................................................................................................................................ 57
BURNER CLEANING PROCEDURE ........................................................................................................... 57
CHANGING THE HOT SURFACE IGNITER ................................................................................................. 58
RE-INSTALLING THE IGNITER ................................................................................................................. 58
HEAT EXCHANGER INSPECTION ............................................................................................................. 58
RE-INSTALL HEAT EXCHANGER .............................................................................................................. 58
COMBUSTION AIR FAN .......................................................................................................................... 58
COMBUSTION AND VENTILATION AIR ................................................................................................... 58
CONTROL CIRCUIT VOLTAGE ................................................................................................................. 58
COMBUSTIBLE MATERIALS .................................................................................................................... 58
FREEZE PROTECTION ............................................................................................................................. 58
FREEZE PROTECTION FOR A HEATING BOILER SYSTEM (Optional) .......................................................... 59
INSTALLATIONS ..................................................................................................................................... 59
CHECKING THE INSTALLATION ............................................................................................................... 59
CHECKING THE INSTALLTION ................................................................................................................. 59
INSPECT & RECHARGE CONDENSATE COLLECTION & NEUTRALIZING RESERVOIR ................................... 59
HEATING BOILER INSTALLATIONS .......................................................................................................... 60
WATER CONNECTIONS .......................................................................................................................... 60
PIPING LENGTHS ................................................................................................................................... 60
INTERMITTENT PUMP OPERATION ........................................................................................................ 60
SUMMARY ............................................................................................................................................ 60
DOMESTIC HOT WATER HEATER............................................................................................................ 61
WATER VELOCITY CONTROL .................................................................................................................. 62
TEMPERATURE RISE AT FULL FIRING RATE ............................................................................................. 62
WATER HEATERS ................................................................................................................................... 62
EXPLODED VIEW ................................................................................................................................... 63
ELECTRICAL DIAGRAMS ......................................................................................................................... 71
PART 1
1.1
GENERAL
INFORMATION
INTRODUCTION
The DynaForce is a condensing fan assisted appliance
based on a push through design which offers several
venting options. Heat output is controlled by a one to one
air/gas ratio control gas valve which provides seamless
modulation. The DynaForce provides central heating or
domestic hot water at working pressures up to 160 PSI. It is
designed for use with a fully pumped and pressurized
system. The boiler/water heater will automatically modulate
to provide heat outputs between 100% and down to 20%.
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 mishandled. Verify total number of pieces shown on
packing slip with those actually received. In case there is
damage or a shortage, immediately notify carrier.
Figure 2: Checking the DynaForce
The DynaForce works on the principle of differential
pressure. The operation of the fan will generate a
differential pressure, which the gas/air ratio control gas
valve will match on the gas side. The steady state efficiency
is maintained across the entire range of modulation. Air and
gas are metered in precise proportion (1:1 Ratio) to
modulation signal, allowing combustion characteristics
which determine efficiency to remain the same over entire
operating range.
Figure 1: DynaForce
Do not attempt to pry any panel off. To begin disassembly
you must first remove the two ¼” machine screws from the
top of the lid. Only then will you be able to remove the lid
and disassemble the three outer panels.
Once you have removed the lid carefully check and confirm
that all ¼” copper tubing connections are intact and have
not broken or loosened in shipment. Leaks at any
connections on these lines will result in erratic appliance
operation.
1.4
1.2
SPECIAL INSTRUCTIONS TO OWNER
This manual supplies information for the installation,
operation and servicing of the appliance. It is strongly
recommended that this manual be reviewed completely
before proceeding with an installation
CAUTION
It is important that all gas appliances are installed by a
qualified installer/technician that is trained by Camus
Hydronics. It is in your own interest and that of safety to
ensure that all local codes, and all the following “NOTES”
and “WARNINGS” are complied with.
Installing, servicing or adjusting this appliance should be
performed only by a qualified installer/technician that is
trained by Camus Hydronics. The serviceman must utilize a
combustion analyzer with CO2, CO, and draft gauge, to set
the
appliance
according
to
Camus
Hydronics’
recommendations, prior to commissioning.
NOTE
RETAIN THIS MANUAL FOR FUTURE REFERENCE
1
2
3
4
5
6
7
HOW IT OPERATES (SEQUENCE OF
OPERATION)
Supply power connection as per table 10.
The power switch is placed in the “ON” position.
120 VAC power is supplied to the control transformer.
24 VAC is supplied to the ignition module and low
voltage controls for all models.
After the appliance water pump starts, flow is proven
by the flow switch and water pressure switch. The
water pressure switch is set to close at 30 PSI and is
installed in the unit. The flow switch is to be mounted in
a tee at the outlet of the appliance. Take care to
properly trim the flow switch paddles so as not to jam
the switch in the tee. The normally open dry contacts in
the low water cutoff (LWCO) are to be wired in series
with the normally open contacts of the flow switch.
Locate the probe type LWCO in the piping above the
highest point of the heat exchanger. The low water
cutoff and flow switch are shipped loose. In all cases
check with local codes.
The DynaForce controller receives a call for heat via
the remote operator contacts and the Demand
parameter reads Central Heating or DHW.
DR 300 – DR 1000: The DynaForce controller
energizes the pump contacts and starts to ramp up the
voltage to the electrically commutated DC motor of the
combustion fan after internal safety checks are
satisfied.
1
8
9
10
11
12
13
14
DR1200 – DR5000: The local thermostat energizes the
motor stop/start relay which closes the initiate contacts
to the variable frequency drive (VFD) which starts to
ramp up the frequency to the 230V 3 phase motor of
the combustion fan. If the VFD is not in fault mode the
frequency will accelerate at the preprogrammed rate
towards maximum speed using the modulating signal
provided by the on board modulating control or the
remote operating system.
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 satisfied. Once complete
the DynaForce will target the ignition fan speed.
DR 300 – DR 2500 (Direct Ignition): The hot surface
igniter will be energized for 22 seconds followed by
energizing the main valve for 4 seconds. A signal of
0.8dVdc must be recognized by the controller at the
flame sensor to keep the main gas valve in an open
position. The fan is kept at ignition speed until the
stabilization timer is satisfied.
DR 3000 – DR 5000 (Proven Pilot): The DynaForce
controller will activate the hot surface igniter for 22
seconds followed by powering the pilot valve for 10
seconds, whereupon a signal of 0.8Vdc must be
recognized by the controller at the flame sensor to
keep the main gas valve in an open position. The fan is
kept at ignition speed until the stabilization timer is
satisfied.
If the flame signal is not reached the module will stop
the ignition sequence after the trial for ignition.
The fan speed will slowly decrease as the heat request
nears the heat demand. The modulation rate is
controlled via Pulse Width Modulation (DR300 – 800)
and a 4-20mA signal (DR1000 – 5000). If the heat
demand is sustained for a long duration of time the
boiler will get to a point of steady-state and the fan will
rotate at constant speed.
When the heat demand is satisfied or is removed the
burner will shut off and the fan speed will ramp up to
the preset Post-Purge speed until the Post-Purge timer
is satisfied.
The pump continues to circulate until the post-purge
time is satisfied.
The boiler will then go into Standby as it waits for the
next heat demand.
Figure 3: DynaForce Ignition Cycle
Note:
1. If a flame signal is detected at the end of the pre-purge
period an error statement to that effect will appear.
2. If at the end of the safety period (6 sec) no flame is
detected the control will go to post-purge to remove the
unburned gas. After this, a re-ignition attempt is started
following the same cycle. 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 sequence follows.
2
4.
The hot surface igniter is de-energized at the end of
the ignition period to allow for ionisation detection.
1.4.1
1
2
3
Burner input continues to increase until water
temperature reaches the set point temperature.
Burner input may stabilize at a fixed rate when demand
equals input.
Burner input will decrease rate when water
temperature approaches temperature set point.
1.4.2
1
2
3
4
HEAT TRANSFER PROCESS
END OF SEQUENCE
Set point temperature is satisfied.
Power to the gas valves is turned off.
Combustion air fan ramps to a stop over the factory
preprogrammed time period of 60 seconds.
Thermostat is now in a standby mode waiting for the
next “Call for Heat”.
WARNING
To minimize the possibility of serious personal injury, fire or
damage to your appliance, never violate the following
safety rules.
WARNING
IMPROPER
INSTALLATION,
ADJUSTMENT,
ALTERATION, SERVICE OR MAINTENANCE can cause
injury or property damage. Refer to this manual. For
additional information, consult a qualified installer, service
agency or gas supplier.
DO NOT
Do not use this appliance if any part of it has been under
water. The possible damage to a flooded appliance can be
extensive and present numerous safety hazards. Any
appliance that has been under water must be replaced
WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliance. • Do not touch any electric
switch: do not use any phone in your building. •
Immediately call your gas supplier from a neighbor’s phone.
Follow the gas supplier’s instructions. • If you cannot reach
your gas supplier, call the fire department.
IMPORTANT
Consult and follow local Building and Fire Regulations and
other Safety Codes that apply to this installation. Contact
the local gas utility company to authorize and inspect all
gas 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 off or disconnect the electrical supply to the
pump. Shut off the gas supply at a location external to the
appliance.
•
•
Boilers and water heaters are heat producing
appliances. To avoid damage or injury, do not store
materials against the appliance or the vent-air intake
system. Use proper care to avoid unnecessary contact
(especially children) with the appliance and vent-air
intake components.
Never cover your appliance, lean anything against it,
store trash or debris near it, stand on it or in any way
block the flow of fresh air to your appliance.
•
•
1.5
UNDER NO CIRCUMSTANCES may flammable
materials such as gasoline or paint thinner be used or
stored in the vicinity of this appliance, vent-air intake
system or any location from which fumes could reach
the appliance or vent-air intake system.
A gas appliance that draws combustion air from the
equipment room where it is installed must have an
adequate supply of fresh air circulating around it during
burner operation for proper gas combustion and proper
venting.
CODES
The equipment shall be installed in accordance with
those installation regulations in force in the local area
where the installation is to be made. These shall be
carefully followed in all cases. Authorities having jurisdiction
shall be consulted before installations are made. In the
absence of such requirements, the installation shall
conform to the latest edition of the National Fuel Gas Code,
ANSI Z223.1 and/or CAN/CGAB149 Installation Code. All
electrical wiring must be done in accordance with the
requirements of the authority having jurisdiction or, in the
absence of such requirements, with National Electrical
Code, ANSI/NFPA70 and/or the Canadian Electrical Code
part 1 CSA C22.1. Where required by the authority having
jurisdiction, the installation must conform to American
Society of Mechanical Engineers Safety Code for Controls
and Safety Devices for Automatically Fired Boilers, ASME
CSD-1. All boilers conform to the latest edition of the
ASME Boiler and Pressure Vessel Code, Section II. Where
required by the authority having jurisdiction, the installation
must comply with the CSA International, CAN/CGA-B149
and/or local codes. This appliance meets the safe lighting
performance criteria with the gas manifold and control
assembly provided, as specified in the ANSI standards for
gas-fired units, ANSI Z21.13.
1.6
WARRANTY
•
Factory warranty (shipped with unit) does not
apply to units improperly installed or improperly
operated.
Factory warranty shall apply only when the
appliance is installed in accordance with local
plumbing and building codes, ordinances and
regulations, the printed instructions provided with it
and good industry practices.
Excessive water hardness causing a lime buildup in the stainless steel coils or tubes is not a fault
of the appliance and is not covered by warranty.
Consult the factory for recommendations for use in
hard water areas (See Water Treatment and
Water Chemistry).
Using or storing corrosive chemicals in the
vicinity of this appliance can rapidly attack the
stainless steel tubes and coils and voids warranty.
Damage caused by freezing or dry firing voids
warranty.
This appliance is not to be used for temporary
heating of buildings under construction.
System operating water pressure at boiler not
drop below 30 PSIG.
The manufacturer 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
When an existing appliance is removed from a common
venting system, the common venting system is likely to be
too large for proper venting of the appliances remaining
connected to it. At the time of removal of an existing
appliance, the following steps must be followed with each
appliance remaining connected to the common venting
system placed in operation, while the other appliances
remaining connected to the common venting system are
not in operation.
•
Seal any unused openings in the common venting
system.
•
Visually inspect the venting system for proper size
and horizontal pitch and determine that there is no
blockage, restriction, leakage, corrosion or other
deficiency, which could cause an unsafe condition.
•
Insofar as is practical, close all building doors and
windows and all doors between the space in which
the appliances remaining connected to the
common venting system are located and other
spaces of the building. 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 maximum speed.
Do not operate a summer exhaust fan. Close
fireplace dampers.
•
Place in operation the appliance being inspected.
Follow the lighting instructions. Adjust thermostat
so that appliance operates continuously.
•
If provided, test for spillage at the draft control
device relief opening after 5 minutes of main
burner operation. Use a cold mirror, the flame of a
match, or candle or smoke from a cigarette.
•
After it has been determined that each appliance
remaining connected to the common venting
system properly vents when tested as outlined
above, return doors, windows, exhaust fans,
fireplace dampers and any other gas-burning
appliance to their previous condition of use.
•
Any improper operation of the common venting
system should be corrected so that the installation
conforms to the National Fuel Gas Code, ANSI
Z223.1/NFPA 54 and/or the Natural Gas and
Propane Installation Code, CAN/CGA B149.1,
Installation Codes. When resizing any portion of
the common venting system, the common venting
system should be resized to approach the
minimum size as determined using the appropriate
tables in Chapter 13 of the National Fuel Gas
Code, ANSI Z223.1/NFPA 54 and /or the Natural
Gas and Propane Installation Code, CAN/CGA
B149.1, Installation Codes.
Heat exchanger surfaces and vent piping should be
checked every six months for deterioration and carbon
deposits. Remove all soot or other obstructions from the
chimney and flue, which might impede draft action. Replace
any damaged or deteriorated parts of the venting system.
A qualified service technician should follow this procedure
when inspecting and cleaning the heat exchanger and vent
pipe.
3
1.
Turn off electrical power and main manual gas shut-off
and allow appliance to cool down.
2. Remove the vent pipe running to the chimney and
check heat exchanger, vent and chimney for
obstruction and clean as necessary.
3. Remove burner from appliance and carefully clean as
required. Never brush or wipe the knitted metal fiber
surface, use a garden hose to rinse burner.
Caution: Never use a pressure washer to clean the
burner.
4. Use a pressure washer to clean heat exchanger if
necessary.
5. Reinstall parts removed in steps 2 and 3. Be sure that
vent pipe has proper pitch and is properly sealed.
Replace any damaged gasket. Note that the burner is
supplied with two gaskets; a high temperature
graphite-backed ceramic paper gasket under the
burner flange and a stamped silicon gasket between
the burner flange and fan flange. Tighten fan flange
mounting nuts to 20 ft-lb on DR300 – 1000 and 25 ft-lb
on DR1200 - 5000.
6. Restore electrical power and gas supply to appliance.
7. Place appliance in operation using lighting instructions
provided.
8. Confirm proper operation of all safety devices
9. Check for gas leaks and proper vent operation.
NOTE:
Experience has shown that improper installation or
system design, rather than faulty equipment, is the
cause of most operating problems
1.8
•
1.9
BOILER ROOM OPERATING CONDITION
Due to low jacket losses from the appliance,
temperatures in a typical boiler room may drop
significantly; supplemental heat is required to maintain
ambient temperature at acceptable levels.
CLEARANCE FROM COMBUSTIBLE
MATERIAL
This appliance is suitable for alcove (a closet without a
door) installation with minimum clearances to combustibles
as follows:
Table 1: Clearances from combustibles
TOP
SIDES
Clearances from Combustibles
12"
REAR
12"
VENT
12"
6"
Figure 4: Clearance from Combustibles
4
When placing the appliance be aware that a minimum
clearance of 24” (60cm) must be provided at the front to
allow easy access to the heat exchanger.
When installed directly on combustible flooring, the
appliance shall be installed on a metal panel extending
beyond the full width and depth of the appliance by at least
3 inches (76.2mm) in any direction. The floor must be
strong enough to support the full weight of the heater.
NOTE: Clearances from combustible construction are
noted on the appliance rating plate
Maintain minimum specified clearances for adequate
operation. All installations must allow sufficient space for
servicing the vent connections, water pipe connections,
circulating pump, bypass piping and other auxiliary
equipment, as well as the appliance
Table 2: Service Clearances
Service Clearances
Service Clearance, Inches (cm)
Right
Left
Top
Back
Front
Side
Side
24”
12”
12”
24”
300
*
(60cm) (30cm) (30cm)
(60cm)
24”
12”
12”
24”
350
*
(60cm) (30cm) (30cm)
(60cm)
24”
12”
12”
24”
400
*
(60cm) (30cm) (30cm)
(60cm)
24”
12”
12”
24”
500
*
(60cm) (30cm) (30cm)
(60cm)
24”
12”
12”
24”
600
*
(60cm) (30cm) (30cm)
(60cm)
24”
12”
12”
24”
800
*
(60cm) (30cm) (30cm)
(60cm)
24”
12”
12”
24”
1000
*
(60cm) (30cm) (30cm)
(60cm)
24”
12”
12”
24”
1200
*
(60cm) (30cm) (30cm)
(60cm)
24”
12”
12”
24”
1400
*
(60cm) (30cm) (30cm)
(60cm)
24”
12”
12”
24”
24”
1600
(60cm) (30cm) (30cm) (60cm) (60cm)
24”
12”
12”
24”
24”
1800
(60cm) (30cm) (30cm) (60cm) (60cm)
24”
12”
12”
24”
24”
2000
(60cm) (30cm) (30cm) (60cm) (60cm)
24”
12”
12”
24”
24”
2500
(60cm) (30cm) (30cm) (60cm) (60cm)
24”
12”
12”
24”
24”
3000
(60cm) (30cm) (30cm) (60cm) (60cm)
24”
12”
12”
30”
24”
3500
(60cm) (30cm) (30cm) (76cm) (60cm)
24”
12”
12”
30”
24”
4000
(60cm) (30cm) (30cm) (76cm) (60cm)
24”
12”
12”
36”
24”
4500
(60cm) (30cm) (30cm) (91cm) (60cm)
24”
12”
12”
36”
24”
5000
(60cm) (30cm) (30cm) (91cm) (60cm)
*Allow adequate space for the venting in addition to 6”
clearance to combustibles.
Model
1.10
INSTALLATION PROCEDURE AND
LOCATION OF UNIT
Install this appliance in a clean, dry location with adequate
air supply.
•
Do not locate this appliance in an area where it will
be subject to freezing unless precautions are
taken. Radiant losses from the DynaForce are
minimal and should not be relied on to keep the
appliance room warm.
•
The appliance should be located close to a floor
drain in an area where leakage from the appliance
or connections will not result in damage to the
adjacent area or to lower floors in the structure, it
is recommended that a suitable drain pan,
adequately drained, be installed under the unit.
Under no circumstances is the manufacturer to be
held responsible for water damage in connection
with this unit, or any of its components.
•
If the appliance is installed above the level of the
building’s radiation system, a low water cut-off
device must be installed above the heat
exchanger inlet/outlet connections. Some local
codes require the installation of a low water cut-off
on all systems
•
When placing the appliance be aware that a
minimum clearance of 24” must be provided at the
front to allow easy access to the heat exchanger.
•
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 are protected from water
(dripping, spraying, etc.) during appliance
operation and service (circulator replacement,
control replacement, etc.)
•
Appliances located in a residential garage and in
adjacent spaces that open to the garage and are
not part of the living space of a dwelling unit must
be installed so that all burners and burner ignition
devices have a minimum clearance of not less
than 18" (46cm) above the floor. The appliance
must be located or protected so that it is not
subject to physical damage by a moving vehicle.
•
DO NOT install this appliance in any location
where gasoline or flammable vapors are likely to
be present.
•
DO NOT install this appliance on top of carpet
flooring
•
Appliance must be installed on a level floor.
Maintain required clearances from combustible
surfaces.
•
The appliance designed for indoor installation
(Indoor Models) must be installed indoors where it
is protected from exposure to wind, rain and
weather.
•
The appliance designed for outdoor installation
(Outdoor Models) must be installed outdoors. For
outdoor installations, always consider the use of a
shelter such as a garden shed in lieu of direct
exposure of the appliance to the elements. The
additional protection afforded by the shelter will
help to minimize nuisance problems with electrical
connections and will allow easier servicing of the
appliance under severe weather conditions.
5
Condensate drain
Service drains
Table 3: Appliance Dimensions and Specifications
DynaForce Dimensions
Dim.
"A" (in.)
Model
Dim.
"B" (in.)
Dim.
"C" (in.)
Dim.
"D" (in.)
Dim.
"E" (in.)
Dim.
"F" (in.)
Dim.
"G" (in.)
Dim.
"H" (in.)
Dim. "I"
(in.)
Dim.
"J" (in.)
Dim. "K"
(in.)
Ø Dim.
"L"
(in.)
Air
Inlet
(As
shipped)
Ø (in.)
Air
Inlet
up to
100
Ft.
Equiv.
Length
Ø Dim.
"V" (in.)
Vent
CAT. IV
up to
100 Ft.
Equiv.
Length
(As
Shipped)
Ø
Dim.
"V"
(in.)
Vent
CAT.
II
Dim.
"M"
(in.)
Ø
Dim.
"W"
(in.)
Water
Ø
Dim.
"X"
(in.)
Gas
Weight
(lbs.)
0300
25
27
42
15 1/2
34 7/8
9 3/4
31 1/4
6 3/4
4 3/4
11 7/8
6
6
4
4
4
5
1 1/2
3/4
380
0350
25
27
42
15 1/2
34 7/8
9 3/4
31 1/4
6 3/4
4 3/4
11 7/8
6
6
4
4
5
5
1 1/2
3/4
380
430
0400
25
27
48 3/4
16 3/8
41 7/8
10 1/2
39 3/4
9 3/4
3 3/4
12
6
6
5
4
5
5
1 1/2
1
0500
25
27
48 3/4
16 3/8
41 7/8
10 1/2
39 3/4
9 3/4
3 3/4
12
6
6
5
5
5
5
1 1/2
1
430
0600
25
27
55 1/4
18 1/2
46
11 1/2
45 7/8
10 1/2
4 5/8
12
6
8
6
5
6
5
2
1
480
0800
25
27
55 1/4
18 1/2
46
11 1/2
45 7/8
10 1/2
4 5/8
12
6
8
6
6
6
5
2
1
480
1000
25
27
65
20 3/4
57
13
56 5/8
10 3/8
4 3/8
12
6
8
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 1/4
700
1600
29 3/8
31 3/4
73 1/2
22 5/8
62 1/2
14
59 1/4
1 7/8
23
12
6
12
10
7
9
5
2 1/2
1 1/4
880
1800
29 3/8
31 3/4
73 1/2
22 5/8
62 1/2
14
59 1/4
1 7/8
23
12
6
12
10
8
9
5
2 1/2
1 1/4
880
2000
29 3/8
31 3/4
81 1/4
24 5/8
72 3/8
14 3/8
69
1 7/8
22 3/4
12 1/2
6 1/2
12
10
8
10
5
3
1 1/4
910
2500
29 3/8
31 3/4
82 5/8
25
74
15 3/4
69 1/2
1 7/8
22 1/2
11 1/4
6 1/2
12
12
9
10
5 1/2
3
1 1/2
1000
3000
35 3/4
39 1/4
85 1/4
25 5/16
75 3/16
16
70 1/2
1 7/8
27 3/4
14
7 3/4
12
12
9
10
5 1/2
3
1 1/2
1350
3500
35 3/4
39 1/4
93
27 1/4
82 1/4
15 1/2
76 1/4
4 1/2
27 3/4
12
12
12
12
10
12
7
4
2
1500
4000
35 3/4
39 1/4
93
25 1/4
82 1/4
15 1/2
76 1/4
4 1/2
27 3/4
12
12
12
12
10
12
7
4
2
1500
4500
35 3/4
39 1/4
96
29
81 1/4
16 1/2
79 1/4
4 1/2
28
12
12
14
14
12
12
7 1/2
4
2 1/2
1650
5000
35 3/4
39 1/4
102
29 1/2
87 1/2
16 3/4
85 1/2
4 1/2
27 3/4
12
12
14
14
12
12
8
4
2 1/2
1750
6
PART 2
VENTING
•
It is extremely important to follow these venting
instructions carefully. Failure to do so can cause severe
personal injury, death or substantial property damage.
Use of cellular core PVC (ASTM F891), cellular core CPVC
or Radel® (polyphenosulfone) in venting systems shall be
prohibited.
2.1
Outdoor
Venting
Standard
Venting
Sidewall Venting and
Combustion Air Inlet
The DynaForce is a category II condensing appliance, up to
99% efficient unit.
•
•
•
•
•
•
•
GENERAL VENTING GUIDE
Figure 5: Venting Configurations
•
•
The DynaForce may be vented with manufactured
prefabricated UL/ULC listed vents of AL29-4C or 316L
stainless steel or with plastic vent certified to UL/ ULC
S636, such as, IPEX System 636 CPVC, IPEX System
636 PVC or IPEX System 636 PP as permitted by local
jurisdictions.
The DynaForce boiler must be vented and supplied with
combustion and ventilation air as described in this section.
Ensure that the venting and combustion air supply
complies with these instructions regarding the vent
system, air system, and combustion air quality.
Vent installations for connection to gas vents or chimneys
must be in accordance with Part 7, “Venting of
Equipment,” of the latest edition of the National Fuel Gas
Code, ANSI Z223.1, in Canada, the latest edition of
CAN/CGA Standard B149 Installation Codes for Gas
Burning Appliances and Equipment or applicable
provisions of the local building codes.
The distance of the vent terminal from adjacent buildings,
windows that open and building openings MUST comply
with the latest edition of the National Fuel Gas Code, ANSI
Z223.1, in Canada, the latest edition of CAN/CGA
Standard B149 Installation Code for Gas Burning
Appliances and Equipment.
Vent connection is made directly to the flue outlet opening
on the back of the unit.
For indoor installations venting must be in accordance with
Part 7, Venting of Equipment, of the National Fuel Gas
Code, ANSI Z223.1, or Section 7, Venting of Equipment
and Air Supply for Appliances, of the CAN/CGA B149,
Installation Codes, or applicable provisions of the local
building codes.
Horizontal runs of vent pipe shall be securely supported
(approximately every 4 feet) to prevent sagging and
maintain a minimum upward slope of ¼" per foot from the
appliance to the vent terminal.
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. When a Positive
vent system 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 fireplace is vented through the
chimney.
2.1.1
CATEGORY II AND CATEGORY IV VENTING
A Category II venting system operates with a negative
pressure in the vent.
The Category IV venting system operates with positive
pressure generated by the internal combustion air fan
which operates the combustion process and also exhausts
the flue products from the building.
•
The Category II flues from multiple appliances can be
combined into a common vent, this special venting
system must be engineered by venting manufacturer
and to be approved by local authority.
•
The Category IV flues from multiple appliances CAN
NOT be combined into a common vent.
•
The Category IV flue must be a dedicated stack.
•
The Category IV Flue appliance must have all vent
joints and seams sealed gas-tight
•
The flue products in the vent system will be cooled
below their dew point and form condensate in the flue
and must use AL29-4C, 316L Stainless, S636 CPVC,
and S636 PVC and PPE up to 12” diameter.
•
The flue from a Category II and IV vent system must
have a condensate drain with provisions to properly
collect and dispose of any condensate that may
occur.
2.1.2
•
•
•
VENTING GUIDELINES FOR CATEGORY II
AND/OR IV VENTING
The installed length of the positive pressure category
IV flue from the appliance to the point of termination,
outside of the building, must not exceed a maximum
of 100 equivalent feet (30.5M) in length. Depending
on diameter and centerline radius subtract from 7 to
19 feet per 90° elbow using published data. Subtract
half this value for each 45° elbow.
For site conditions exceeding 100 equivalent feet an
engineered vent system approved by the local
authority will be required.
The flue may terminate either vertically at the roof top
or horizontally on a SIDEWALL. See the information
about the specific vent termination location for
recommended location and clearances.
7
2.1.3
APPROVED VENTING MATERIALS
Exhaust Vent for Use for DynaForce Category ll or lV
Installations
1
Manufactured prefabricated UL/ ULC listed vent of AL294C or equivalent, Single or Double Wall.
316L stainless steel is limited to use in applications where
there is no possibility of contaminants in the air such as
refrigerants, chlorine etc.
“BH” type.
PVC and CPVC Schedule 40 or 80 approved to ULC S636
PVC-DWV approved to comply with ANSI/ASTM D2665
(US Jurisdictions ONLY when permitted)
PVC Schedule 40 approved to comply with ANSI/ASTM
D1785 (US Jurisdictions ONLY when permitted)
CPVC Schedule 40 approved to comply with ANSI/ASTM
F441. (US Jurisdictions ONLY when permitted)
Polypropylene approved to comply with ULC S636 up to
12” diameter.
2
3
4
5
6
7
8
NOTE
1)
2)
1
2
3
4
5
6
7
2.1.4
•
•
Use of cellular core PVC (ASTM F891), cellular core
CPVC or Radel® (polyphenosulfone) in venting systems
shall be prohibited.
Covering non-metallic vent pipe and fittings with thermal
insulation shall be prohibited.
•
•
Table 4: Maximum Flue Temperature for Various Vent Materials
o
Vent Material
Maximum Flue Temperature [ F]
PVC
CPVC
149
194
Polypropylene
AL29-4C
316L Stainless
Steel
300+, limited only by rating of seals
230
300+, limited only by rating of seals
o
Stack temperature is 10-15 F above boiler inlet temperature
when operating at steady-state.
Vent material selection
When selecting vent material take into consideration that
appliances installed near a corrosive or potentially corrosive air
supply must be isolated from it or they will suffer damage to the
appliance and the venting system.
The corrosion resistance of AL29-4C is typically higher than
that of 316L. Always choose the venting system which best
satisfies the requirements of the application.
This recommendation does not supersede local codes or
the provision of the B149 in Canada or the National Fuel
Gas Code in the United States
Single wall air intake pipes are to be insulated 5 feet from wall
toward the interior of the building to minimize external
sweating.
Intake Air (Supply Air, or Fresh Air) Piping for Direct Vent
Applications
Air intake material must be of a type listed by a nationally
recognized testing agency.
8
PVC Non Foam Core Pipe.
CPVC Non Foam Core Pipe.
Polypropylene
ABS (Acrylonitrile-Butadiene-Styrene).
Manufactured prefabricated UL/ ULC listed vent of
AL29-4C or equivalent, Single or Double Wall.
316L stainless steel is limited to use in applications
where there is no possibility of contaminants in the air
such as refrigerants, chlorine etc.
“BH” type.
•
•
•
•
•
•
VENT TERMINATION CLEARANCES
Do not terminate the vent in a window well, stairwell,
alcove, courtyard or other recessed area. The vent
cannot terminate below grade. The bottom of the vent
terminal shall be located at least 12 inches (30cm)
above grade and above normal snow levels. In all
cases the appliance shall be installed in accordance
with local codes.
The vent outlet MUST NOT terminate below a forced
air inlet at any distance.
The vent cannot terminate below grade. Position the
vent termination where vapours will not damage walls
or plants or may otherwise be objectionable.
The vent terminal shall not be installed closer than 3
feet (1 m) from an inside corner of an L-shaped
structure, window well, stairwell, alcove, courtyard or
other recessed area as wind eddies could affect boiler
performance or cause recirculation.
DO NOT terminate closer than 4 feet (1.25m)
horizontally and vertically from any electric meter, gas
meter, regulator, relief valve, or other equipment. In
all cases local codes take precedence
Position terminations so they are not likely to be
damaged by foreign objects, or exposed to a build-up
of debris.
The vent piping must terminate in an elbow pointed
outward or away from the air inlet.
To avoid a blocked flue condition, keep the vent
cap/terminal clear of snow, ice, leaves, debris, etc.
Flue gases from this appliance may contain large
amounts of water vapour that will form a white plume
in winter. Plume could obstruct a window view.
Flue gas condensate can freeze on exterior walls or
on the vent cap. Frozen condensate on the vent cap
can result in a blocked flue condition. Some
discoloration to exterior building surfaces can be
expected. Adjacent brick or masonry surfaces should
be protected with a rust resistant sheet metal plate.
2.1.5
INLET CAP FOR ROOFTOP TERMINATION
The air inlet cap consists of two 90° elbows installed at the
point of termination for the air inlet pipe. The first 90°
elbow is installed on the rooftop at the highest vertical
point of the air inlet pipe and turned horizontal; the second
90° elbow is screened and is installed on the horizontal
outlet of the first elbow and turned down. A 90° elbow and
a 90° street elbow may be used to make this assembly. If
a straight piece of pipe is used between the two elbows, it
should not exceed 6" (150mm) in length.
2.1.6
•
•
•
•
•
LOCATION OF A ROOFTOP AIR INLET AND VENT
CAPS
The point of termination for the combustion air inlet cap
MUST be at least 3 feet (0.91M) below the point of flue
gas termination (vent cap) if it is located within a 5 foot
(1.5M) radius of the flue outlet. Use care to ensure that the
90° elbow assembly is properly installed on the air inlet
pipe.
The termination point of the combustion air inlet cap must
be installed at least 3 feet (0.91M) above the rooftop and
above normal snow levels.
The vent cap assembly MUST be listed by nationally
recognized agencies.
Combustion air supplied from outdoors must be free of
contaminants. To prevent recirculation of flue products in
to the combustion air inlet, follow all instructions in this
section.
Incorrect installation and/or location of the air inlet cap can
allow flue products to be drawn back into the appliance.
This can result in incomplete combustion and potentially
hazardous levels of carbon monoxide in the flue products.
This will cause operational problems with the appliance
and if left uncorrected, will lead to conditions that can
cause personal injury or death.
Figure 6: Vertical Direct Venting Configuration
condensing, positive pressure vent system. Corrosion
resistant chimney liner systems are typically made from a
high grade of corrosion resistant stainless steel such as
AL29-4C or equivalent. 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 chimney must
be capped and sealed to provide a dead air space around
the sealed corrosion resistant liner.
Consult with local code officials to determine code
requirements or the advisability of using a masonry
chimney with a sealed corrosion resistant liner
system.
2.1.9
•
•
•
•
VERTICAL VENTING TERMINATION
Follow Category II or IV vent termination and all
General instructions.
The vent terminal should be vertical and exhaust
outside the building at least 2 feet (0.61M) above the
highest point of the roof within a 10 foot (3.05M)
radius of the termination.
The vertical termination must be a minimum of 3 feet
(0.91M) above the point of exit.
A vertical termination less than 10 feet (3.05M) from a
parapet wall must be a minimum of 2 feet (0.61M)
higher than the parapet wall.
Vent
2.1.10
Air inlet must be 36”
min. below vent
opening
AIR INLET DAMPER
In cold climates it is essential to provide a motorized air inlet
damper to control the supply of combustion air and prevent
nuisance condensation.
Figure 6: Air Inlet Damper Connection inside J-Box
BLACK
BLUE
YELLOW
RED
2.1.8
The air inlet pipes from multiple appliances can be
combined to a single common connection if the common
air inlet pipe has a cross sectional area equal to or larger
than the total area of all air inlet pipes connected to the
common air inlet pipe.
2
Air Intake
2.1.7
COMBINED COMBUSTION AIR INLET
CALL FOR HEAT
TO IGNITION
24VAC, COMMON
24VAC, CONST.
POWER
MASONARY CHIMNEY INSULATIONS
Always follow local codes when venting this appliance into a
masonry chimney. A standard masonry chimney must NOT be
used to vent the products of combustion from the flue of a
condensing, positive or negative pressure appliance (Category
II or IV). If a masonry chimney is to be used, the chimney
MUST use a sealed, corrosion resistant liner system to vent
flue products from this high efficiency appliance. Sealed,
metallic, corrosion resistant liner systems (AL29-4C or
equivalent, single wall or double-wall, or flexible or rigid
metallic liners) must be rated for use with a high efficiency
2
2
Equivalent pipe diameter = Sq Root [(d1) + (d2) + (d3) +
2
2
(d4) +……+ (dn) ], d, pipe diameter
Example: What is equivalent pipe diameter of three
air inlet pipes, 8" (20.3 cm), 10” (25.4 cm) and 12”
(30.5 cm)
2
2
2
Equivalent pipe diameter = Sq Root [(8) + (10) + (12) ] =
Sq Root (308) = 17.5”, Select 18” (82.8 cm) diameter pipe
or larger.
The air inlet point for multiple boiler air inlets must be
provided with an exterior opening which has a free area
equal to or greater than the total area of all air inlet pipes
connected to the common air inlet. This exterior opening
for combustion air must connect directly to the outdoors.
The total length of the combined air inlet pipe must not
exceed a maximum of 100” (30.5M) equivalent feet. You
must deduct the restriction in area provided by any
screens, grills or louvers installed in the common air inlet
point. Screens, grills or louvers installed in the common air
inlet can reduce the free area of the opening from 25% to
75% based on the materials used. Calculate and
compensate accordingly for the restriction.
9
2.1.11
DRAIN TEE
IN GENERAL
Figure 7: Drain “T” and Neutralizer Cartridge Installation
•
Flue Outlet
Flue In
Condensate
Drain
•
Drain Tee
•
4” Loop from Top
to Bottom
Drain Tubing
Condensate neutralization system
A drain line must be connected to the boiler condensate drain
and to a tee installed in the vent pipe to collect and dispose of
any condensate that may occur in the boiler and vent system.
The drain tee should be installed at the point where the flue
turns vertical for a roof top termination or as one of the first
fittings in a horizontal flue that will terminate on a SIDEWALL.
Ensure that horizontal portions of the vent are properly sloped
away from the appliance to allow condensate to be evacuated
at the drain tee. Plastic drain tubing, sized per the vent
manufacturer’s instructions, shall be provided as a drain line
from the tee and from the boiler condensate line. The drain
tubing from the tee must have a trap provided by a 4" (10cm)diameter circular trap loop in the drain tubing and the boiler
drain shall be normal with no loop and tied into the tee drain
tubing with a tee at a point after the 4" loop and before the
neutralizer. Prime the trap loop by pouring a small quantity of
water into the drain hose before assembly to the vent. Secure
the trap loop in position with nylon ties. Use caution not to
collapse or restrict the condensate drain line with the nylon
wire ties. The common condensate drain must be routed to the
condensate neutralization system or a suitable drain for
disposal of condensate that occurs in both the boiler and in the
vent system. Ensure that the drain from the condensate tee is
not exposed to freezing temperature.
2.2
•
•
•
10
CONVENTIONAL VENTING (INDOOR)
INSTALLATIONS
The DynaForce is a category II appliance and is approved
for venting into a common Chimney. On single appliance
installations with dedicated chimney, if drafts are
excessive (above negative 0.15 Inches W.C.), we
recommend a single acting barometric damper.
A qualified professional using a proven vent-sizing
program with input of accurate operating parameters must
properly do sizing of the venting system. In applications
where flue gas temperatures are lower than can support a
Category II with conventional negative draft, it will be
determined at the venting design stage that a positive
pressure will be developed in the vent. It will then be
necessary to either provide separate vents as for Category
IV, pressurize the room or to provide an extractor at the
chimney outlet interlocked with the appliance operating
circuit in order to maintain a negative draft in the chimney
and allow common venting.
Approval of the installation will be at the discretion of
authorities having jurisdiction.
•
The operation of 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 circumstances an engineered air supply is
necessary.
If the appliance is to be installed near a corrosive or
potentially corrosive air supply, the appliance must be
isolated from it and outside air should be supplied as
per code.
Potentially corrosive atmospheres will result from
exposure to permanent wave solution, chlorinated
waxes and cleaners, chlorine, water softening
chemicals, carbon tetrachloride, halogen based
refrigerants, Freon cleaning solvents, hydrochloric
acid, cements and glues, masonry washing materials,
antistatic fabric softeners, dry cleaning solvents,
degreasing liquids, printing inks, paint removers, etc.
The equipment room MUST be provided with properly
sized openings to assure adequate combustion air
and proper ventilation when the unit is installed with a
proper venting system.
2.2.1
AIR REQUIRED FOR COMBUSTION AND
VENTILATION
If air is taken directly from outside the building with no
duct, provide two permanent openings:
a) Net free area for combustion air opening shall be in
accordance with all applicable codes. In the absence
of such codes provide combustion air opening with a
minimum free area of one square inch per 7000 Btuh
input (5.5 cm per kW) up to 1,000,000 Btuh and one
square inch per 14,000 Btuh in excess of 1.000,000
Btuh. This opening must be ducted no .higher than
18” nor less than 6” above the floor. Provide a
ventilation air opening located as high as practical in
the room sized no less than 10% of the air supply
opening.
b) Provision for combustion and ventilation must be in
accordance with :
•
Applicable sections of The National Fuel Gas ode
ANSI Z223.1
•
Applicable sections
of
CAN/CGA B149
installation Codes
•
Applicable provisions of the local building codes.
NOTE
Outside air openings shall directly communicate with the
outdoors.
CAUTION
Under no circumstances should the mechanical room ever
be under a negative pressure. Particular care should be
taken where exhaust fan, attic fans, clothes dryers,
compressors, air handling units, etc., may take away air
from the unit.
2.2.2
EXHAUST FANS
Any fan or equipment which exhausts air from the
equipment room may deplete the combustion air supply
and/or cause a downdraft in the venting system through a
barometric damper if installed. Spillage of flue products
from the venting system into an occupied living space can
cause a very hazardous condition that must be
immediately corrected.
2.3
OUTDOOR VENTING
The DynaForce windproof cabinet protects the unit from
weather, when fitted with the factory supplied air intake and UL
approved vent cap (93-0298), it will be self-venting and
suitable for outdoor installation.
Outdoor models must be installed outdoors and must use
the air intake and vent cap supplied by Camus Hydronics.
2. Periodically check to ensure that air intake and vent cap
are 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
building can spill onto appliance.
For outdoor installations, always consider the use of a shelter
such as a garden shed in lieu of direct exposure of the
appliance to the elements. The additional protection afforded
by the shelter will help to minimize nuisance problems with
electrical connections and will allow easier servicing of the
appliance under severe weather conditions.
2.4.2
•
•
1.
2.4
•
•
•
•
•
SIDEWALL VENTING
When fitted with the factory supplied vent terminal, the
DynaForce can vent up to 100 equivalent feet. Elbows can
range from 7 to 19 feet in equivalent length depending on
centreline radius. Refer to table 3 for vent sizes.
•
Appliances may be installed with either a horizontal sidewall
vent or vertical roof top vent. Terminals differ with each
application. Use single wall vent and seal all joints or use
pressure rated double wall vent.
When using single wall vent, all vent connector seams and
joints must be sealed with pressure sensitive aluminium tape
or silicone sealant as specified by the vent manufacturer.
Aluminium tape must meet the provisions of SMACNA AFTS100-73 Standard.
Periodically check to ensure that 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 the flue.
Combustion air is drawn from the equipment room. Sidewall
terminations are available from the factory. Refer to local
codes for proper installation and location of vent terminals.
2.4.1
•
•
•
•
•
A
SIDEWALL
LOCATION OF A SIDEWALL AIR INLET
TERMINAL
The termination point of the sidewall air inlet must be
installed a minimum of 3 feet above ground level and
above normal levels of snow accumulation.
The point of termination for the sidewall combustion
air inlet terminal MUST be located a minimum of 3
feet (1M) horizontally and 12 inches (0.30M) below
the point of flue gas termination (vent cap) if it is
located within a 10 foot (3M) radius of the flue outlet.
Vent
SIDEWALL VENT TERMINAL & SIDEWALL
INTAKE AIR TERMINAL
The sidewall vent terminal kit includes the wall penetration
assembly and the discharge screen assembly.
The opening through the wall for installation of the sidewall
vent terminal must provide an air space clearance of 1
inch (2.5cm) around the flue pipe. The diameter of the
opening for installation of the sidewall vent terminal will be
2 inches (5cm) larger than the nominal diameter of the
installed vent pipe to the sidewall vent cap. The diameter
of the opening for the air inlet cap will be the same as the
nominal size of the pipe.
Install the proper vent pipe to the vent terminal (provided
by Camus Hydronics).
Follow all requirements in the General Venting sections for
venting flue products to the outdoors.
VENT
The vent terminal shall terminate at least 3 ft (1M)
above any forced air inlet within 10 ft (3M)
horizontally.
The vent terminal MUST NOT terminate below a
forced air intake at any distance.
Do not terminate the vent in a window well, stairwell,
alcove, courtyard or other recessed area. The vent
cannot terminate below grade.
The vent shall not terminate less than 7 ft above a
public walkway due to the normal formation of water
vapour in the combustion process.
The vent system shall terminate at least 3 foot (1M)
above grade, above normal snow levels and at least 7
ft (2.15M) above grade when located adjacent to
public walkways.
The vent terminal shall not be installed closer than 3 ft
(1M) from an inside corner of an L-shaped structure.
The vent terminal should have a minimum clearance
of 4 ft (1.25M) horizontally from and in no case above
or below, unless a 4 ft (1.25 m) horizontal distance is
maintained from electric meters, gas meters,
regulators and relief equipment. In all cases local
codes take precedence.
Flue gas condensate can freeze on exterior walls or
on the vent terminal. Frozen condensate on the vent
cap can result in a blocked flue condition. Some
discoloration to exterior building surfaces can be
expected. Adjacent brick or masonry surfaces should
be protected with a rust resistant sheet metal plate.
2.4.3
•
LOCATION
OF
TERMINATION
12” (30 cm)
Minimum
Air
Intake
2.4.4
LENGTH OF AIR INLET PIPE
The maximum total length of the sidewall or vertical roof
top combustion air inlet pipe as installed from the
appliance to the air inlet terminal must not exceed (100 ft)
equivalent feet (30.5m) in length. Subtract 7 (2.13 m) to 19
feet (5.8 m) of equivalent length depending on centreline
radius for each 90° elbow installed in the air inlet pipe
system. Pressure drop in 45° elbow will be half as much.
11
PART 3
Verify that the appliance is supplied with the type of gas
specified on the rating plate. Consult factory for installations at
high altitude.
3.1
•
GAS CONNECTION
Safe operation of unit requires properly sized gas supply
piping. See gas line 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 manual main gas shutoff valve, outside of the
appliance gas connection as require by local codes.
A trap (drip leg) MUST be provided in the inlet gas
connection to the appliance.
Optional gas controls may require routing of bleeds and
vents to the atmosphere, outside the building when
required by local codes.
Larger models of this appliance may be supplied with a
gas pressure relief valve. This valve is designed to relieve
lockup pressure in excess of the high gas pressure switch
setting. It must be piped to discharge excess gas pressure
through the valve to a safe location in accordance with
local codes. Follow table 5 for sizing the vent line.
•
•
•
•
•
•
Table 6: Recommended Gas Pipe Size
Single Appliance Installation
(For distance from natural gas meter or propane second
stage regulator)
GAS CONNECTION
Table 5: Gas Pressure Relief Valve – Vent Manifold
Sizing Chart
Size of Combined Vent Line (Sch. 40
pipe)*
Input
Btu/Hr,
x1000
300
0-100 FT
101-200 FT
201-300 FT
NAT.
L.P.
NAT.
L.P.
NAT.
L.P.
1 ¼“
1“
1 ½”
1 ¼“
1 ½“
1 ¼“
350
1 ¼“
1“
1 ½”
1 ¼“
1 ½“
1 ¼“
400
1 ¼“
1“
1 ½“
1 ¼“
2“
1 ½“
500
1 ½“
1 ¼“
2“
1 ½“
2“
1 ½“
600
1 ½“
1 ¼“
2“
1 ½“
2“
1 ½“
800
2“
1 ½“
2“
1 ½“
2 ½”
2”
1000
2“
1 ½“
2“
1 ½“
2 ½”
2”
1200
2”
1 ½“
2 ½”
2”
2 ½”
2”
1400
2 ½”
2”
2 ½”
2”
3”
2 ½”
1600
2 ½”
2”
3”
2 ½”
3”
2 ½”
1800
2 ½”
2”
3”
2 ½”
3”
2 ½”
2000
2 ½”
2”
3”
2 ½”
3”
2 ½”
2500
3”
2 ½”
3”
2 ½”
3 1/2”
3”
3000
3”
2 ½”
3”
2 ½”
3 1/2”
3”
3500
3”
2 ½”
3 ½”
3”
4”
3 ½”
4000
3 ½”
3”
4”
3 ½”
4”
3 ½”
4500
3 ½”
3”
4”
3 ½”
4”
3 ½”
5000
4”
3 ½”
4”
3 ½”
5”
4”
Qty. of Pressure
Relief Valves
being combined
Pressure Relief
Valve Size - 3/4"
NPT
Pressure Relief
Valve Size - 1"
NPT
1
3/4"
1"
2
1"
1 1/4"
All gas connections must be made with pipe joint
compound resistant to the action of liquefied petroleum
and natural gas. All piping must comply with local codes
and ordinances.
3
1 1/4"
1 1/2"
3.3
4
1 1/4"
2"
5
1 1/2"
2"
6
1 1/2"
2"
7
2"
2 1/2"
8
2"
2 1/2"
* Up to 50 feet. Increase by one pipe size for every 50 feet or
part thereof that the vent line extends beyond the initial 50 feet.
The increase is to be made at the connection to the relief
valve.
12
3.2
•
GAS PIPING
INSTALL PIPING
The gas line should be sufficient to handle the total
installed capacity. Verify pipe size with gas supplier.
•
Use new, properly threaded black iron pipe free from
burrs. Avoid flexible gas connections. Internal
diameter of flexible gas lines may not provide
appliance with proper volume of gas.
•
Install a manual main gas shutoff valve at the
appliance gas inlet, outside of the appliance and
before the gas valve. Install a joint union at the
appliance gas line connection for ease of service and
removal of the gas train.
•
Run gas pipe to appliance gas inlet.
•
Install a sediment trap in the supply line to the
appliance gas inlet.
•
Apply a moderate amount of good quality pipe
compound.
•
For LP gas, consult your LP gas supplier for expert
installation.
The appliance and its individual gas shut-off valve must be
disconnected from the supply piping when pressure
testing the gas supply piping at pressures above ½ PSI
Table 7: Gas Pressures at Inlet to Appliance
Minimum (inches W.C.)
Maximum (inches W.C.)
PROPANE
NATURAL GAS
11
11
4.5*
14
Figure 8: DR300 – 400 1:1 Negative Pressure Air/Gas
Ratio Control Valve
Low fire air/gas ratio adjustment
(use T-40 for adjustment,
clockwise increases CO2)
* 7” w.c. recommended regulator setting
The gas supply line must be of adequate size to prevent undue
pressure drop and must never be smaller than the size of the
connection on the appliance. Sizing based on Table 6 is
recommended.
Before operating the appliance, the complete gas train and all
connections 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
3
gas are to be between 950 and 1010 Btu/ft . Consult factory if
heating values are outside this range or if a gas with a mixture
of constituents is being used.
3.4
AIR/GAS RATIO VALVE
The main gas valves supplying gas to the burner for models
2000 to 5000 on this appliance utilize a servo pressure
regulator providing a slow opening, fast closing safety shut off
and an air/gas ratio control valve for the gas combustion
process. This gas valve controls the pressure difference across
the flow orifice in the manifold supply line as a function of the
pressure difference across the combustion air supply to the
burner. The actuator maintains a constant air to gas ratio as
the volume of air changes based on the operation of the
combustion air fan. The valve is a 1:1 differential pressure
air/gas ratio controller. The valve generates the same pressure
difference on the gas side as it senses on the air side. Models
300 to 1800 utilize a 1:1 ratio dual seat negative pressure gas
valve. Models 2000 – 3000 utilize a 1:1 air/gas ratio control
valve and a safety solenoid valve. Models 3500 – 5000 utilize a
1:1 air/gas ratio control and regulating gas valve. The
regulating gas valve performs the functions of a pressure
regulator, safety shutoff. Full closing of the valve seat occurs in
less than 0.8 seconds when the valve is de-energized.
Operation of the gas valve in combination with the combustion
air fan allows the burner input rate to vary from 20% to 100%
based on temperature demand. The inlet gas supply pressure
must be maintained within the specified minimum and
maximum pressures.
High fire air/gas ratio adjustment
(use slotted screwdriver for
adjustment, counter-clockwise
increases CO2)
Figure 9: DR500 – 1800 1:1 Negative Pressure Air Gas
Ratio Control Valve
Lift top cover to access high fire
air/gas ratio adjustment
(use 3mm allen key for adjustment,
counter-clockwise increases CO2)
Low fire air/gas ratio adjustment
(use T-40 for adjustment,
clockwise increases CO2)
Gas Inlet
Figure 10: DR2000 - 5000 1:1 Air/Gas Ratio Control
Valve
Low fire adjustment screw
Located under cap
(Turning clockwise increases gas flow)
Junction box for
power with
actuator position
indicator
Actuator
Flange
Valve
Flange
Figure 11: DR3500 – 5000 SKP25 Regulating Gas
Valve Actuator & SSOV
The air/gas ratio is preset at the factory and adjustment is not
usually required if gas supply pressure is maintained within the
specified range.
There are no serviceable parts on the dual seat negative
pressure air/gas ratio valve control.
A reduction of up to 30% is permitted in the inlet gas pressure
between light off and full fire conditions.
If the manifold differential pressure is to be measured, refer to
section 3.8 Checking Differential Air and Gas Pressures for
proper measurement.
13
3.5
•
•
•
•
•
•
•
•
3.6
DIFFERENTIAL AIR PRESSURE (DR2000 –
DR5000)
The DynaForce 2000 – 5000 operates on the principle of
differential pressures. Operation of the fan generates a
signal which is matched on the gas side by the 1 to 1
air/gas ratio control valve.
The differential air pressure measurement is made
between the high and low pressure taps across the fan
discharge and the fan static discharge. All differential air
pressures are noted at full firing rate. There are two
pressure taps at the fan discharge and care must be taken
to tee into the correct line. The correct line may be
identified by tracing it back to the ratio control valve where
the identification of the tapping is stamped into the die cast
actuator.
The differential gas pressure measurement is made
between the high and low pressure taps across the in- line
metering gas orifice. Check this value to confirm that it
matches the differential air pressure while the appliance is
firing.
The controls on this appliance may fire the burner from
20% up to 100 % of rated input.
Differential manifold gas pressure will be reduced as
burner input is reduced.
All reference gas pressure measurements must be made
at 100% of rated burner input.
The differential gas manifold pressure is pre-set at the
factory through the ratio gas valve. Adjustment of manifold
pressure is not normally required for proper operation. It
may be necessary to adjust the low fire adjustment screw
located on the ratio control valve actuator in order to
achieve acceptable light off under soft start field
conditions.
Always check settings posted on boiler test label.
GAS MANIFOLD DIFFERENTIAL PRESSURE
ADJUSTMENT (DR2000 – DR5000)
Tampering with gas valve adjustments after startup and
commissioning will void the warranty on the gas valve
assembly and the burner.
The appliance’s manifold gas pressure IS NOT field adjustable
after startup and commissioning. The gas valve pressure ratios
have been factory set with an internal bias adjustment to
ensure a 1:1 air/gas ratio on operation. Tampering with this
adjustment will 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 7 for minimum allowable inlet gas supply
pressure) while firing at full rate will ensure full burner input.
The manifold pressure supplied to the burner is a differential
pressure. This pressure is the result of the difference in two
gas pressure measurements. A differential manifold gas
pressure measurement should not be made until you have
measured the gas supply pressure. Gas supply pressure must
be at least at minimum allowed with all appliances on the gas
line firing at full rate before a manifold pressure measurement
is made. Use the following procedure to check gas supply
pressure with a manometer connected to the inlet pressure tap
on the gas line connection at the rear of the appliance.
14
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.
3.9
Operating the DynaForce at lockup pressures exceeding the
recommended levels can lead to delayed ignitions and damage
to the appliance.
3.8
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
rating plate. The opposite will occur with tall stacks
where drafts exceed negative 0.15“W.C.
If the appliance will not light off it will be necessary to
adjust the low fire as explained in the detailed start-up
procedure.
GAS TRAIN AND CONTROLS
Figure 13: Typical Gas Train (DR2000 – 3000)
CHECKING DIFFERENTIAL AIR AND GAS
PRESSURES (DR2000 – DR5000)
Figure 12: Checking Differential Air and Gas Pressures
(DR2000 – DR5000)
To Fan Discharge
Figure 14: Typical Gas Train (DR 3500 – 5000)
Metering
Valve
Low Gas Switch
Regulator Valve
Differential High
Gas Switch
Low Gas Switch
Control Valve
Regulator Valve
Differential High
Gas Switch
Metering
Valve
Firing
Valve
Firing
Valve
To
Appliance
Vent
Main Manual
Valve
Main Manual
Valve
Fan Inlet
•
•
•
Fan Inlet
Control Valve
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.
15
3.10
VENTING OF GAS VALVES AND PRESSURE
SWITCHES
The optional gas pressure switches may be provided with
threaded termination points to be vented to the atmosphere,
outside the building. The gas pressure regulation function is
provided by the ratio gas valve which does not require
installation of a vent line. The optional gas pressure switches
are installed in the upper chamber of the appliance. Threaded
vent line connections from components requiring an external
vent line are provided on the component. These vent line
connection points may be accessed by removing the top of the
appliance. Local codes may require the routing of these bleeds
and vents to the atmosphere, outside the building. Proper
routing of vent lines to the atmosphere from the factory
supplied termination points is the responsibility of the installing
contractor.
3.11
PART 4
∗
∗
∗
∗
∗
BURNER
Figure 15: Burner
∗
This appliance uses a single cylindrical burner installed
vertically into the cavity located in the center of the heat
exchanger. There is a unique burner for each one of the 18
models.
Burners MAY NOT be interchanged between different Btu/hr
input models. The burner consists 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 of the
mixing tube is attached to a stainless steel perforated sleeve.
This stainless steel sleeve is covered with a knitted alloy
material that forms the burner port surface. The knitted burner
port material is a metal fiber material which is a unique alloy of
iron, chrome, aluminum and several rare earth metals. This
alloy is designed to operate stress free as a burner port
surface. The burner port surface can sustain operation from a
blue flame down to infrared conditions as the burner input
varies. In order to maximize the operating life of the burner, the
normal operating mode for the DynaForce is a blue flame.
Infrared operation will occur only if air to gas adjustments are
incorrect. If infrared operation is noted the cause must be
corrected.
Model 300 – 2500: Direct ignition is standard. The burner
mounting flange provides a flame view port and the mounting
point for the hot surface igniter and the flame sensor.
Model 3000 – 5000: Proven pilot ignition is standard. The
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 removable from
the burner mounting flange without removing the burner
assembly from the heat exchanger.
Never use an open flame (match, lighter, etc.) to check gas
connections.
16
∗
∗
∗
∗
WATER CONNECTION
Check all applicable local heating, plumbing and
building safety codes before proceeding.
If the appliance is installed above radiation level it
must be provided with a low water cut-off device at
the time of appliance installation (available from
factory). Some local codes require the installation of a
low water cut-off on all systems.
A pressure relief valve is supplied with each
DynaForce. The relief valve must be mounted in a
vertical position and piped to the floor in a
manner acceptable to the enforcing authority.
Minimum water operating system pressure should
not drop below 30 PSIG.
Be sure to provide unions and gate valves at inlet and
outlet to the appliance so that it can be easily isolated
for service. The provision of a flow setter valve at the
appliance outlet will facilitate setting of the proper flow
at the desired temperature rise at high fire. It is
particularly important to confirm proper temperature
rise for domestic hot water applications. Improper
flows can lead to premature tube failure from scaling
and will not be covered by warranty.
This appliance is a low mass design which provides
for instant heat transfer. Special attention to water
flow rates will ensure that temperature rise is not
excessive. See Table 8 and 9.
To eliminate trapped air, install venting devices at
high points in the system as well as in the piping on
the suction of the pump and in the piping on the
discharge of the appliance.
Use suitable pipe hangers or floor stands to support
the weight of all water and gas piping.
Always pump 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.
DynaForce must be installed so that the gas ignition
system components are protected from water
(dripping, spraying, rain, etc.) during appliance
operation and service (circulator replacement, control
replacement, etc.)
Figure 16: Typical Space Heating System
4.1
∗
Figure 17: Chilled Water System
FREEZE PROTECTION
Appliance installations are not recommended outdoors 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. This mixture will protect
the appliance to approximately -35ºF (-37ºC). To maintain
the same temperature rise across the appliance increase
the GPM flow by 15% and the head loss by 20%.
Supply
Return
The following example demonstrates the procedure to follow
for calculating the revised head for the heat exchanger when
using a water / glycol mixture.
•
•
•
•
∗
4.2
Given that Camus is showing a heat exchanger flow
and head loss of 100 gpm @ 10 feet
Increasing the flow by 15% now results in a head loss of
13 feet at 115 gpm (from B&G system syzer). At this
increased flow Camus now recommends to increase the
head loss by 20%.
The requirement for the heat exchanger with water /
glycol mixture will now be 115 gpm @ 15.6 feet. (ie.
1.2 x 13ft. = 15.6 ft.)
A similar procedure must be followed to calculate the
additional head loss in pipe and fittings in order to
arrive at the proper pump selection.
For outdoor installations in colder climates a snow screen
should be installed to prevent snow and ice accumulation
on and around the appliance. Regular inspections should
be made to ensure that air intake and vent are free of
snow and ice. Always consider the use of a shelter such
as a garden shed in lieu of direct exposure of the
appliance to the elements. The additional protection
afforded by the shelter will help to minimize nuisance
problems with electrical connections and will allow easier
servicing of the appliance under severe weather
conditions.
WARNING REGARDING CHILLED WATER
AND HEATING COIL SYSTEMS
When an appliance is connected to a refrigeration system
where the same water is used for heating and cooling, the
chiller must be piped in parallel with the appliance. Appropriate
flow control valves; manual or motorized must be provided to
prevent the chilled water from entering the appliance.
The appliance piping system of a hot water boiler connected to
heating coils located in air handling units where they may be
exposed to refrigerated air circulation must be equipped with
flow control valves or other automatic means to prevent gravity
circulation of the boiler water during the cooling cycle.
System
Pump
4.3
•
•
4.4
INLET AND OUTLET CONNECTIONS
All water connections are groove-lock fittings.
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 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 arrive at the total equivalent feet of
straight pipe in the field installed piping to the appliance.
See the piping requirements in Part 11 - Installation
section of this manual. Consult factory if longer piping
distances are required for a specific application.
4.5
HEAT EXCHANGER
This appliance uses stainless steel fin tubing to maximize
the heat transfer process. The heat exchanger is
comprised of vertical tubes welded directly into two
circular stainless steel headers. This heat exchanger is
designed to withstand 160 PSIG working pressure. A
series of “V” shaped baffles are installed between the
individual tubes to control the movement of the flue
products over the finned tubes to maximize efficiencies.
When servicing, take special care to ensure that baffles
are properly located and maintained in factory condition.
Replace any damaged baffles including factory supplied
ceramic facing tape.
A factory recommended circulating pump ensures proper
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 the heat
exchanger are controlled by the selection of a properly
sized circulating pump.
The Camus designs are versatile and user friendly, they
deliver optimal performance by taking full advantage of
existing site conditions in order to maximize energy
savings.
17
4.6
In applications where the heating system requires supply water
temperatures below 110°F, connections may be made directly
o
to the DynaForce. At incoming temperatures of 80 F or lower
the DynaForce achieves maximum efficiency. Inlet
o
temperatures must not drop below 40 F to prevent
freezing.
4.7
Table 9: Flow and Pressure Drop at a Given
Temperature Rise (DR1200-5000)
LOW WATER TEMPERATURE SYSTEMS
INSTANTANEOUS WATER HEATER
An instantaneous water heater is designed to deliver hot water
without the use of a storage tank. It is suitable for applications
with variable load such as restaurants, condominiums,
apartments and motels and typically used in conjunction with
tempering valves to achieve temperature control. In some
applications it may be appropriate to provide a flow through
tank to act as a buffer. Consult factory for recommendations.
(See Figure 15)
o
20 F Rise
o
o
25 F Rise
30 F Rise*
Model
US GPM
∆P-Ft.
US GPM
∆P-Ft.
US GPM
∆P-Ft.
1200
113.8
1400
132.8
10.0
91.0
6.6
75.8
4.7
14.0
106.2
9.2
88.5
6.5
1600
151.8
14.1
121.4
9.3
101.2
6.5
1800
170.9
14.3
136.7
9.4
113.8
6.7
2000
189.8
20.8
151.8
13.6
126.4
9.7
2500
237.2
27.1
189.8
17.7
158.0
12.5
3000
284.6
27.3
227.7
17.8
189.6
12.7
3500
331.8
33.0
265.4
21.5
221.2
15.3
4000
379.5
36.9
303.6
24.0
253.0
17.1
4500
426.9
55.8
341.5
36.3
284.6
25.6
5000
474.0
60.0
379.2
39.0
316.0
27.5
Figure 18: Typical Instantaneous Water Heating System
∗
Use for hydronic heating applications only
4.8
WATER FLOW SWITCH
A water flow switch is mounted and installed in the outlet
piping on all heating boilers and hot water supply boilers.
The flow switch is wired in series with the 24VAC safety
control circuit.
4.9
Table 8: Flow and Pressure Drop at a Given Temperature
Rise (DR300-1000)
10oF Rise
15oF Rise
20oF Rise*
LOW WATER CUTOFF (If Equipped)
If this boiler is installed above radiation level, a low water
cut-off device must be installed at the time of boiler
installation. Some local codes require the installation of a
low water cut-off on all systems. Electronic low water cutoffs are available as a factory supplied option on all
models. Low water cut-offs should be tested every six
months, including flushing of float types. The normally
open switch contact of the low water cutoff is to be wired
in series with the flow switch. A red diagnostic light will be
indicated on the control display on a low flow condition.
Model
US GPM
∆P-Ft.
US GPM
∆P-Ft.
US GPM
∆P-Ft.
300
57.0
0.5
38.0
0.3
-
-
350
66.5
0.7
44.3
0.4
-
-
400
76.0
1.0
50.1
0.5
-
-
500
95.0
1.6
63.3
0.8
-
-
600
113.9
2.5
75.9
1.3
-
-
800
152.0
6.6
101.3
3.2
76.0
1.9
1000
189.8
11.4
126.5
5.4
95.0
3.2
Caution: remove jumper when connecting to 24 VAC
circuit.
Figure 19: Low Water Cut Off Electrical Connections
(Watts)
Connection detail for placing
L.W.C.O in 24V circuit
WARNING: Be sure to remove the
jumper between H and P1
* Use for hydronic heating applications only
Pressure Switch
From
Flow
Switch
To High Limit
18
Figure 20: Low Water Cut Off Electrical Connections (ITT)
Safety Signal In
Wired in series as
part of Burner
Control Circuit
Safety Signal Out
4.10
RELIEF VALVE
This appliance is supplied with a relief valve sized in
accordance with ASME Boiler and Pressure Vessel Code,
Section IV (“Heating Boilers”). The relief valve is 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 shall
be piped to a suitable floor drain for disposal when relief
occurs. No reducing couplings or other restrictions shall be
installed in the discharge line. The discharge line shall allow
complete drainage of the valve and line. Relief valves should
be manually operated at least once a year. If a relief valve
discharges periodically, this may be due to thermal expansion
in a closed water supply system. Contact the water supplier or
local plumbing inspector on how to correct this situation. Do
not plug the relief valve.
•
temperature rise across the main heat exchanger of
10ºF to 25 ºF (5.5ºC-13.8ºC) depending on the size of
the heater. If necessary use a flow setter valve to
achieve the desired temperature rise.
For DHW applications with other than normal water
hardness choose a pump for the local water hardness
conditions. When hardness levels exceed 17 grains
per gallon consult factory for recommendations.
NOTE
The use of a system sensor is required in lead lag
operation.
1) When variable speed main circulators ARE NOT used
the system sensor is to be placed into the return
system piping.
2) When variable speed main circulators are used the
system sensor is to be placed into the supply system
piping.
4.12
∆T HEAT EXCHANGER ALGORITHM
The DynaForce is constantly monitoring the inlet and
outlet water temperatures on the DynaForce, when the ∆T
o
approaches 40 F the burner will modulate down, and
when this temperature is exceeded the gas valve will deenergize to prevent overheating the heat exchanger.
CAUTION
Avoid contact with hot discharge water
4.11
CIRCULATING PUMP SELECTION
The appliance has a low mass stainless steel finned tube heat
exchanger for fast response and high heat absorption.
Selecting the proper pump will ensure that temperature rise
does not exceed the maximum recommended for the
application and that the heat exchanger tubes are not
prematurely scaled or eroded.
4.11.1 CIRCULATING PUMP OPERATION OF HEAT
EXCHANGER
MOST IMPORTANT
This appliance is designed for continuous pump operation
when the burner is firing. The pump control option allows
the appliance circulating pump to be cycled “ON” prior to
the burner firing and cycled “OFF” some time after the set
point is satisfied.
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 temperature difference between inlet and outlet connections
to the appliance. The SOLA can directly operate pumps up to
1/6 HP. Larger pumps will require a separate relay or
contactor.
To select the proper pump it is strongly recommended to
consider the following:
•
Need to know the required flow (GPM) and pressure drop
for your appliance (see Table 8 and 9)
•
Type of application: hydronic heating or domestic hot
water (DHW).
•
For hydronic heating and DHW applications with normal
water hardness choose a pump which will result in a
19
PART 5
ELECTRICAL &
CONTROLS
DynaForce
Model
IT IS EXTREMELY IMPORTANT THAT THIS UNIT BE
PROPERLY GROUNDED!
5.1
ELECTRICAL CONECTIONS
Table 10: Minimum Power Requirements
Model
300 1000
1200 2000
2500
Maximum Over
Current
Protection
Full Load
Amps
[Amperes]
[Amperes]
120VAC, 60Hz
20
8.0
120VAC, 60Hz
20
14.0
120VAC, 60Hz
30
18.0
Voltage
Requirement
3000 208/230VAC,
30
20.0
3500
60Hz*
4000 208/230VAC,
30
18.0
5000
60Hz, 3 Phase**
*This is a 4-wire power supply requiring two (2) lives, a neutral
and a ground
**This is a 5-wire power supply requiring three (3) lives, a
neutral and a ground
DynaForce boilers supplied at 460/3/60 voltage, differ from the
standard unit per the following:
CAUTION!
While working with 460V circuits it is imperative that extra
precautions be taken
- Ensure that lock-out/ tag-out procedures are strictly enforced
- Only properly trained and authorized personnel should be
permitted to work on live electrical circuits
- All electrical workers should be trained in electrical rescue
techniques and CPR
Each unit has an internal factory mounted 500VA transformer
to supply the 115V necessary for the ignition circuit. For the
incoming power, a 3-wire connection, is made at the rear
junction box. A new variable frequency drive replaces the
standard VFD, and the combustion blower fan has been
configured to operate at 460/3/60V (using the standard fan).
Part numbers as well as FLA and MOCP information is below.
500VA transformer: DC0500UH
VFD:
T234
T235
T237
T238
Model Range:
DR-1200 to DR-1800 (1hp)
DR-2000 to DR-2500(1.5hp)
DR-3000 to DR-4000 (3hp)
DR-4500 to DR-5000 (5hp)
1200 1800
2000
2500
3000
3500 4000
4500 5000
Voltage
Requirement
Maximum
Over Current
Protection
[Amperes]
Full Load
Amps
[Amperes]
1.4
460VAC, 60Hz, 3
Phase
10
1.8
2.1
3.5
5.3
6.8
The combustion air fan motor operates on 230 VAC, 3
phase, 60 Hz on models DR1200 - 5000. Three phase
voltage is generated by the VFD and supplied directly to
the fan motor on models 1200 - 5000. Refer to Table 10
for appropriate supply voltage to the appliance. 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 external to the appliance must be
enclosed in approved conduit or approved metal clad
cable.
•
The pump must run continuously when appliance is
firing.
•
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 (DR1200
– 5000)
This appliance uses a 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 4-20mA modulating signal from the SOLA 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. Once
the self checks are completed by the SOLA, 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 is generated by the VFD to vary 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
20
5.3
DIFFRENTIAL AIR PRESSURE SWITCH
Models 300 to 1000 use a fan speed sensing line in the PWM
control to prove air flow. 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 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 an open Interrupted
Air Switch (ILK Off) 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.
5.4
DIFFERENTIAL GAS AND LOW GAS PRESSURE
SWITCHES
A manual reset differential gas pressure switch is standard on
DR3000 – 5000 and available as an option on DR300 - 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
DYNAFORCE SOLA
DR300 – DR2500 models utilize a hot surface ignition
system. DR3000 – DR5000 models utilize a proven pilot.
The ignition control proves the presence of the flame using
a flame rectification voltage (0.8Vdc), energizes the main
gas valve, proves the presence of main burner flame, and
provides for lockouts. The Alarm light will be lit on the
ignition control module in the event of a fault.
Figure 21: Ignition Module
BLOCKED FLUE SWITCH
All models use a normally closed blocked flue switch to shut
down the appliance under the following conditions:
1) Air intake 50% blocked
2) Vent outlet 80% blocked
5.5
5.7
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
10ºF (5.5°C) below the manual reset limit to prevent nuisance
tripping
5.7.1
SERVICE PARTS
The electronic ignition module is not repairable. Any
modification or repairs will invalidate the warranty and may
create hazardous conditions that result in property
damage, personal injury, fire, explosion and/or toxic
gases. A faulty hot surface igniter or ignition module
MUST BE replaced with a new factory approved unit only.
A factory approved igniter, ignition control module and
flame sensor for this specific unit is available from your
local distributor. DO NOT use general purpose field
replacement ignition modules, igniters or sensors. Each
appliance has one ignition module, one hot surface igniter
and one flame sensor.
5.7.2
IGNITION MODULE LOCKOUT FUNCTIONS
The ignition module may lockout in either a hard lockout
condition requiring pushing of the reset button to recycle
the control for a CSD1 requirement or a soft lockout
condition which may be reset automatically once the error
clears. A typical hard lockout fault can occur with single a
trial for ignition CSD1 module. Pushing the reset button on
the ignition control is the only way to reset an ignition
module that is in a hard lockout condition. The reset button
is located on the ignition module. Turning the main power
“OFF” and then “ON” or cycling the thermostat will not
reset a hard lockout condition. Wait until the display shows
the temperatures on screen before pushing the reset
button when the ignition module is in a hard lockout.
The DynaForce 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 alert condition. Once
the fault is corrected, the boiler will automatically return to
normal operating state.
21
5.8
Figure 22: Lockout Condition
DYNAFORCE CONTROLLER
Table 11: Connector Description
Connector
J1
J2
J3
J4
J5
J6
J8
J9
5.9
Connector Description
Flame Sensor, Ground Rod
Fan Modulation (DR300 – 1000)
Display, Lead lag, Modbus Comm.
24VAC Power, Pump, VFD
Gas Valve, Safety Interlock String
Safety Annunciation, Remote Operator
24VAC Power, Inlet, Outlet Sensor
DHW, Stack Sensor
ERROR TABLE
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).
To eliminate the lockout error,
1) Press the red bar, indicating a Lockout condition
2) Press the [Lockouts] button
Figure 23: Lockout History
When the control is in error the pump will be running. This is
done to prevent the freezing of the central heating circuit when
the boiler is in error during the winter period. For some nonvolatile lockouts the pump will not be running, see table below
for more details.
Table 12: Lockout codes
#
0
1-31
47
48
49
64
67
79
Description
None
Internal hardware error*
Flame rod to ground leakage
Static Flame
24VAC low/high
Fan speed not proved, ignition failure
Blocked flue condition
Heater Outlet high limit tripped
o
o
Stack limit tripped (PVC: 149 F, CPVC: 194 F,
82
o
250 F)
91
Inlet sensor fault
92
Outlet sensor fault
93
DHW sensor fault
95
Stack sensor fault
105
Flame detected out of sequence
Flame lost if Main Flame Establishing Period
106
(MFEP)
107
Flame lost early in run
108
Flame lost in run
109
Ignition 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.
22
3)
Press [Clear Lockout]
Table 13: Alert Codes
#
Description
0
None
29
Burner switch turned OFF
30
Burner switch turned ON
47
Flame rod to ground leakage
49
Abnormal 24Vac voltage
50
Modulation Fault (DR300 – 1000 ONLY)
61
Anti-short Cycle
62
Fan speed not proved
63
LCI off, safety circuit is open
67
Interlock Off, safety circuit is open
69
Pilot test hold
78
Demand lost in run
79
Outlet high limit tripped
o
81
Delta-T limit exceeded (30 F)
91
Inlet sensor fault
92
Outlet sensor fault
93
DHW sensor fault
95
Stack sensor fault
96
Outdoor sensor fault
97- Internal Fault*
99
128 Fan speed failed during prepurge
129 Fan speed failed during preignition
130 Fan speed failed during ignition
131 Fan movement detected during standby
132 Fan speed failed during run
137 Interlock failed to close, safety circuit is open
110 Ignition failure occurred
111 Flame current below threshold (0.8Vdc)
149 Flame detected
150, Flame not detected
291
301 Interlock Off, safety circuit is open
309
460 Interlock off during burn, safety circuit is open
* If an internal hardware fault is detected contact Camus
technical support for troubleshooting procedure.
PART 6
6.1
CONTROL PANEL
APPLIANCE TEMPERATURE
CONTROLLER
The appliance is provided with a control panel at the front.
Operating controls are installed inside the control box and
are accessible by undoing the thumb screw and swinging
opening the door. The diagnostic information centre as
well as the on/off switch and the appliance temperature
controls reside on the control box door the ignition control
module, VFD, transformer and relays are mounted on the
internal panel.
Figure 24: Touchscreen Display
The SOLA icons will appear in one of four colours
indicating the boiler status:
Colour
Description
Blue
Normal Operation
Red
Lockout Condition
Yellow
Holding Mode
Grey
Communication Error
The Boiler Temperature Controller for this appliance is the
Honeywell SOLA . It initiates the local call for heat and
sets the target return (appliance inlet) water temperature.
This controller offers a range of operation modes which
provides set point as well as modulating control. It
provides the following:
∗
Readings of inlet and outlet water temperatures as
well as flame signal.
∗
Operation as an auto reset limit.
∗
Operation as a control for inlet water temperature,
outlet temperature, system temperature.
o
∗
40 F ∆T heat exchanger protection algorithm
∗
Available tank mounted sensor used in conjunction
with inlet sensor.
∗
Adjustable; target temp, inter-stage differential, on
delay between 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 of service.
∗
Error message display in text
∗
Manual override of boiler input rate for combustion
∗
Pump exercising feature runs pump 10 seconds every
three days in the event of no pump operation.
23
Levels of Access
Two levels of access to simplify the use of the boiler.
User – Access to general boiler and display settings and
adjustments to the central heating and domestic hot water
setpoint.
Installer – Access to all user parameters and allows for
changes to additional boiler parameters to allow for ease of
startup and serviceability.
NOTE
Due to the sensitivity of the touchscreen controller, using the
backend of a pen/pencil or stylus is recommended for accuracy
Figure 25: Home Screen
PARAMETER
Demand
DESCRIPTION
Central Heating (DRH)
Domestic Hot Water (DRW)
Burner State
Current Status of DynaForce
Firing Rate
Target Firing Rate
Fan Speed
Actual Firing Rate (DR300 – 1000)
Inlet
Inlet Water Temperature [ F]
Outlet
Outlet Water Temperature [ F]
Stack
Stack Temperature [ F]
o
o
o
o
DHW
DHW Temperature [ F] ], if equipped
Lead Lag/ CH
Header Temperature [ F], if equipped
Outdoor
Outdoor Temperature [ F], if equipped
4-20mA
4-20mA input, if equipped
BUTTON
o
o
DESCRIPTION
Diagnostics
Access DynaForce parameters (CH
Parameters, DHW Parameters, Outdoor
Reset, Pump Configuration etc.)
Details of boiler operation (Set point, Firing
Rate, Pump Status, Safety circuit)
Manual firing rate, Analog/ Digital Status
Details
History, Pump Status, Outlet Temperature
Configure
Operation
24
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 – 5000, N/O)
25
DRH
Modulation: Boiler Inlet, Boiler Fixed Setpoint Operation (Standalone)
Description
Electrical Connection(s)
• Boiler operates at a fixed
setpoint
• Modulates on boiler inlet
sensor (default)
• Heat demand is generated
when Remote Operator is
closed.
26
1)
2)
3)
4)
5)
6)
7)
Programming Instructions
Place both toggle switches to LOCAL
Press
and
, enter “sola”
Press [CH – Central Heat Configuration]
Press the
to arrive at Setpoint
Select Setpoint source: Local
Enter desired Setpoint
Place right hand toggle switch to REMOTE for remote enable operation (if
required)
Modulation: Boiler Inlet, Outdoor Reset Operation (Standalone)
Description
Electrical Connection(s)
• Boiler operates with variable
setpoint determined by
outdoor reset curve
• Modulates on inlet sensor
(default)
• Heat demand is generated
when Remote Operator is
closed.
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)
15)
16)
Programming Instructions
Connect outdoor sensor to System/Outdoor contacts
Place both toggle switches to LOCAL
Press
and
, enter “sola”
Press Outdoor Reset Configuration
Press the
to arrive at Central Heat
Select Enable: Enable
Select Maximum outdoor temperature (WWSD)
Select Minimum outdoor temperature (Outdoor
Design)
Select Low Water Temperature (Min. Water Temp.)
Select Outdoor boost maximum off point (Design
Max.)
Press [CH – Central Heat Configuration]
Select Outdoor Reset = Enabled
Set CH Setpoint = Maximum off point
Press Sensor Configuration
Select Outdoor temperature source = S5 (J8-11)
sensor
Place right hand toggle switch to REMOTE for remote
operation (if required)
27
Modulation: System Sensor, Outdoor Reset Operation (Standalone)
NOTE: Outdoor Reset Module (PN: 50022037-001) and outdoor sensor (PN: C7089U1006) required
Description
Electrical Connection(s)
• Boiler operates with variable
setpoint determined by
outdoor reset curve
• Modulates on system sensor
• Heat demand is generated
when Remote Operator is
closed.
28
Programming Instructions
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
and
, enter “sola”
6) Press Outdoor Reset Configuration
7) Press the
to arrive at Central Heat
8) Select Enable: Enable
9) Select Maximum outdoor temperature (WWSD)
10) Select Minimum outdoor temperature (Outdoor
Design)
11) Select Low Water Temperature (Min. Water
Temp.)
12) Select Outdoor boost maximum off point
(Design Max.)
13) Press [Show Line] to confirm reset curve
14) Press Sensor Configuration
15) Selet S5 (J8-11) sensor: 10K NTC single nonsafety
16) Select Outdoor temperature source =
EnviraCOM outdoor sensor
17) Place right hand toggle switch to REMOTE for
remote enable operation (if required)
4-20mA/ 2-10Vdc Setpoint Operation (Standalone)
Description
Electrical Connection(s)
• Boiler operates with variable
setpoint determined by 420mA incoming signal
• Modulates on boiler inlet
sensor (default)
• Heat demand is generated
when Remote Operator is
closed and 4-20mA or 210Vdc signal is present.
1)
2)
3)
4)
5)
6)
7)
8)
Programming Instructions
Place both toggle switches in LOCAL
Press
and
, enter “sola”
Press [CH – Central Heat Configuration]
Press the
to arrive at Setpoint
Select Setpoint Source = S2 (J8-6) 4-20mA
Select 4mA water temperature
Select 20mA water temperature
Place right hand toggle switch to REMOTE for remote operation (if required)
29
4-20mA/ 2-10Vdc Firing Rate Operation (Standalone)
Description
Electrical Connection(s)
• Boiler operates with variable
setpoint determined by 420mA incoming signal
• Modulates on header sensor
• Heat demand is generated
when Remote Operator is
closed and 4-20mA or 210Vdc signal is present.
System Sensor Enable (Standalone)
Description
• Method to enable system
sensor for Standalone
applications
30
1)
2)
3)
4)
5)
6)
7)
Programming Instructions
Place both toggle switches in LOCAL
Press
and
, enter “sola”
Press [Lead Lag Master Configuration]
Press [Advanced Settings >]
Press the
to arrive at Central Heat
Select Modulation rate source = S2 (J8-6) 4-20mA and burner on/off
Place right hand toggle switch to REMOTE for remote operation (if required)
Electrical Connection(s)
Programming Instructions
1)
2)
3)
4)
5)
6)
Press
and
, enter “sola”
Press [Sensor Configuration]
Select S5 (J8-11) Sensor: 10K NTC Single Non-Safety
The control will proceed into a Lockout 2 condition
Press [Verify] > [Begin] > [Yes]
Press the reset button on the ignition control within the alotted time
DRW
Modulation: Fixed Setpoint Operation (Standalone)
Description
Electrical Connection(s)
• Boiler operates at a fixed
DHW setpoint
• Modulates on boiler inlet
sensor (default)
• Heat demand is generated
when Remote Operator is
closed.
Programming Instructions
1) Place both toggle switches to LOCAL
2) Press
and
, enter “sola”
Inlet Sensor operation
3) Press [DHW – Domestic Hot Water Configuration]
4) Select Demand Switch: Modulation sensor only
5) Select Modulation sensor: Inlet Sensor. Proceed to Step 12
DHW Sensor/ Stat, if required.
1)
2)
3)
4)
5)
DHW Sensor/Stat operation
Press [Sensor Configuration]
Select S6S7 (J9-1,3) Sensor (DHW): 10K NTC Single Non-Safety
The control will proceed into a Lockout 2 condition
Press [Verify] > [Begin] > [Yes]
Press the reset button on the ignition control within the alotted time
DHW Sensor operation
6) Press [DHW – Domestic Hot Water Configuration]
7) Select Demand Switch: Modulation sensor only
8) Select Modulation sensor: DHW Sensor. Proceed to Step 12
DHW Stat operation
9) Press [DHW – Domestic Hot Water Configuration]
10) Select Demand Switch: Modulation sensor only
11) Select Modulation sensor: DHW (S6) switch & inlet sensor
12) Enter desired Setpoint
31
13) Place right hand toggle switch setting to REMOTE for remote operation (if
required)
32
DR(H,W) Lead lag Operation
Master Boiler
Description
• Master boiler lead lag setup
Electrical Connection(s)
1)
2)
3)
4)
5)
Programming Instructions
Place both toggle switches to LOCAL
Press
and
, enter “sola”
Select System Identification & Access
Verify MB1 Modbus address = 1
Verify MB2 Modbus address = 1
6) Select Lead Lag Master Configuration
7) Select Master Enabled = Enabled
Fixed Setpoint operation
8) Enter CH Setpoint (Fixed setpoint)
4-20mA/ 0-10Vdc setpoint operation
9) Select [Advanced Settings >]
10) Press the
to arrive at Central Heat
11) Select Setpoint Source = S2 (J8-6) 4-20mA
12) Select 4mA water temperature
13) Select 20mA water temperature
33
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: Local burner demand
20) On Options: Local Lead Lag Service Active
21) Force On: Outlet high limit
Slave Boiler
Description
• Slave boiler lead lag setup
34
Electrical Connection(s)
1)
2)
3)
4)
Programming Instructions
Place both toggle switches to LOCAL
Press
and
, enter “sola”
Select System Identification & Access
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:
7) Select Pump Configuration
8) Press [Advanced Options >>]
9) Press the
to arrive at Central Heat Pump or DHW Pump
10) On Options: Local burner demand
11) On Options: Local Lead Lag Service Active
12) Force On: Outlet high limit
35
Master Boiler, System Sensor
Description
• Master boiler system sensor
configuration
Electrical Connection(s)
1)
2)
3)
4)
Programming Instructions
Press
and
, enter “sola”
Press [Sensor Configuration]
Select S5 (J8-11) Sensor
Connector Type: 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
Outdoor Sensor connected to Slave boiler 2 (DRH ONLY)
Description
Electrical Connection(s)
• Slave boiler outdoor sensor
configuration
• When done correctly, the
outdoor temperature will be
shown on the Master boiler
Programming Instructions
Slave Boiler
1) Press
and
, enter “sola”
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] > [Begin] > [Yes]
7) Press the reset button on the ignition control within the alotted time
36
Master Boiler
8) Press
and
, enter “sola”
9) Press [Lead Lag Master Configuration]
10) Press [Advanced Settings >]
11) Press the
to arrive at Outdoor Reset
12) Select Enable: Enabled
13) Select Maximum outdoor temperature
14) Select Minimum outdoor temperature
15) Select Low Water Temperature
16) Select Outdoor boost maximum off point
17) Press [Show Line] to confirm reset curve
18) Press the
to arrive at Warm Weather Shutdown
19) Select Enable = Shutdown after demand ends
37
Rotation schedule adjustment
Description
• Standard rotation schedule is
based on equalizing run time
on a 1-hour schedule
• To vary the rotation to a fixed
schedule based on (hours,
days)
Base load rate adjustment
Description
• Upon a call for heat the lead
boiler will fire to the specified
base load rate (80%). If the
temperature is not within
Error threshold (5oF) of
setpoint after Interstage
delay (2 minutes) a lag boiler
will be brought online and
will also fire at the base load
rate specified.
• Modulation of boilers will
only occur after all boilers in
the Lead Lag system are firing
at the specified base load
rate (80%).
38
Electrical Connection(s)
1)
2)
3)
4)
5)
6)
7)
Electrical Connection(s)
Programming Instructions
Press
and
, enter “sola”
Press [Lead Lag Master Configuration]
Press [Advanced Settings >]
Press the
to arrive at Algorithms
Select Lead selection method: Sequence order
Select Lag selection method: Sequence order
Select Lead rotation time: (user defined)
Programming Instructions
1)
2)
3)
4)
5)
and
, enter “sola”
Press
Press [Lead Lag Master Configuration]
Press [Advanced Settings >]
Press the
to arrive at Rate Allocation
Select Base load common: (user defined)
Adjust staging of boilers
Description
• Upon a call for heat the lead
boiler will fire to the specified
base load rate (80%). If the
temperature is not within
Error threshold (5oF) of
setpoint after Interstage
delay (2 minutes) a lag boiler
will be brought online and
will also fire at the base load
rate specified.
• This method will then be
repeated for the next lag
boiler, if available.
Electrical Connection(s)
1)
2)
3)
4)
5)
6)
Programming Instructions
Press
and
, enter “sola”
Press [Lead Lag Master Configuration]
Press [Advanced Settings >]
Press the
to arrive at Add Stage
Select Error threshold
Select Interstage delay
39
6.2.2
6.2
CONFIGURE MENU
Figure 26: Configure Menu
Menu
Group
Selection
Pump Configuration
SubMenu
Group
Selection
Parameter
Selection
Auto
Parameter
Description
Product Type
Commercial Hydronic Boiler
OS number
Part Number of SOLA Controller
Software Version
Software version
Date Code:
Release date of software
Boiler Name
DynaForce Model Number
Installation
Type of application
ON
Pump Output
Pump B
Over run time
1..5 min
Auto
Pump Control
ON
Pump Output
Pump A
Over run time
1..5 min
DHW Pump
Pump Control
ON
Pump Output
Pump B
Over run time
1..5 min
Auto
Pump Control
System Pump
Pump Configuration
Refer to above
(Default)
Refer to above
Specify pump
contact
Post pump time
(Default: 1 min)
Use for local
(Stand-alone)
demands
Use for Lead
Lag Master
demands
Auto
ON
Pump Output
Over run time
40
Assigns the
method for
SOLA to control
a Central
Heating pump
(Default: Auto,
Pump is
activated
whenever a call
for heat is
present)
ON: Pump is
constantly
powered
Specify pump
contact
Post pump time
(Default: 1 min)
Use for local
(Stand-alone)
demands
Use for Lead
Lag Master
demands
Boiler Pump
System Identification &
Access
Menu
Group
Selection
System Identification & Access
Pump Configuration
6.2.1
Central Heat Pump
Pump Control
Description
None
1..5 min
Refer to above
(Default)
ON: Pump is
constantly
powered
Specify pump
contact
Post pump time
(Default: 1 min)
Refer to above
(Default)
ON: Pump is
constantly
powered
Specify pump
contact
Post pump time
(Default: 1 min)
Menu
Group
Selection
SubMenu
Group
Selection
Parameter
Selection
Description
Displays the
number of cycles
the boiler pump
has been activated
Displays the
number of cycles
the burner has
been activated
Displays burner
run time in hours
Displays the
number of cycles
the CH pump has
been activated
Displays the
number of cycles
the DHW pump
has been activated
Displays the
number of cycles
the system pump
has been activated
Boiler
pump
cycles
Burner
cycles
Burner run
time
CH pump
cycles
DHW pump
cycles
System
pump
cycles
6.2.4
6.2.5
Statistics Configuration
Burner Control Timing and Rates
Menu
Group
Selection
Burner Control Ignition
SubMenu
Group
Selection
Parameter
Selection
Lightoff
rate
DR300-1000:
3000 RPM
DR1200 –
5000: 20.0%
Burner
Control
Ignition
6.2.3
Sensor Configuration
Menu Group
Selection
SubMenu
Group
Selection
Parameter
Selection
Description
S1 (J8-4)
sensor
10K NTC
single nonsafety
Inlet Sensor
S2 (J8-6)
sensor
S3S4 (J8-8,
10) sensor
Sensor
Configurations
S5 (J8-11)
sensor
S6S7 (J91,3) sensor
S8S9 (J94,6) sensor
SubMenu
Group
Selection
Parameter
Burner Control Timing and Rates
Prepurge
rate
Prepurge
time
Run
Stabilization
Time
Selection
3000 RPM
25 sec..
5 mins
10 sec
Postpurge
rate
3000 RPM
Postpurge
time
25 sec..
5 mins
Ignition Fan
speed
6.2.6
Figure 27: Burner Control Timing and Rates
Menu
Group
Selection
Description
4-20mA
10K NTC
dual safety
10K NTC
single nonsafety
10K NTC
single nonsafety
10K NTC
single nonsafety
4-20mA
Input Signal
Outlet
Sensor
Outdoor
Sensor:
Standalone
boiler or
Slave boiler
Header
sensor:
Master
boiler
DHW
Sensor
(DRW Only)
Stack
Sensor
Description
Prepurge fan
speed (Default:
DR300 – 1000:
3000 RPM,
DR1200 – 5000:
100.0%)
Prepurge time
(Default: 25 sec)
Main flame
establishing
period
Postpurge fan
speed (Default:
DR300 – 1000:
3000 RPM,
DR1200 – 5000:
100.0%)
Postpurge time
(Default 25 sec)
41
6.3
LEAD LAG SETUP
The following components are needed for a Lead Lag setup
1)
10kΩ System Sensor
Turn off all the boilers before beginning the setup process.
To setup the DynaForce Lead Lag system follow the
instructions:
System Sensor
Insert the supplied 10kΩ system sensor into the building loop.
The wires coming out of the system sensor should be
connected to Sys/Outdr terminals in the junction box.
NOTE
The use of a system sensor is required in lead lag operation.
1) When variable speed main circulators ARE NOT used
the system sensor is to be placed into the return
system piping.
2) When variable speed main circulators are used the
system sensor is to be placed into the supply system
piping.
All SOLA controllers are programmed with a default address of
1. The address of the slave controllers in the system must
have a unique address (1..8).
Rotation
Rotation time is configurable based on equalized run time
(default) or a fixed rotation schedule.
Interstage Delay
The length of time to wait between requesting a slave
SOLA to fire and detecting that it has failed to start.
(Default: 2 minutes)
Base Load Rate
When a call for heat is initiated the lead boiler runs at the
desired base load rate (Default: 80%) and continues to
operate in this fashion based on the above 3 scenarios. If
the lead lag temperature is not satisfied a second boiler is
fired at they would both operate at 80% fire rate.
Slave State
Unknown
Available
Add Stage
Suspend
Stage
Disabled
Recovering
Sequence of Operation:
When a boiler is set as Lead Lag Master = Enabled and
Modbus address = 1, the controller of this boiler will drive the
lead lag operation.
The outdoor temperature sensor connected to the slave boiler
2 (ie. B-2) will be the outdoor sensor for the lead lag system
•
•
The system temperature sensor connected to boiler 1
in terminals labeled “Outdr/Sys” in the junction box
will be the control sensor for lead lag operation.
The start/stop signal connected to boiler 1 at
terminals labeled “Remote Operator” will be the heat
demand input for lead lag operation.
When demand for heat is present the lead boiler will start and
uses the lead lag parameters for boiler modulation. After a
period of “Interstage delay” the master boiler compares the
lead lag temperature with the lead lag set point and will check
if:
1)
An additional boiler is needed
Lead lag < 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 < Lead lag setpoint + Drop stage Error
threshold
3)
A boiler should stop
Lead lag > Lead lag setpoint + Drop stage Error
threshold
If the lead lag master system is interrupted the remaining
boilers will operate as standalone boilers based on the Central
Heat or DHW parameters when set to “Enabled”.
42
Slave Status Manager
Table entry is unused or empty
Slave is operational and ready to use
Stage is getting ready to fire
Stage was getting ready but is not needed
Slave is locked out or disabled
Slave is in time delay to verify that it is
operational before considered to be
available
Wiring the Lead Lag Setup
Use Cascade terminals in the junction box to wire lead lag
appliances
J3, MB2
Master
Slave 2
..
Slave 7
A
A
..
A
B
B
..
B
C
C
..
C
Figure 28: Lead lag Wiring Setup (Left: Master, Right: Slave)
NOTE
Recycle power on all boilers after programming is complete if
lag boilers are not discovered automatically
NOTE
CH Setpoint or DHW Setpoint must match Setpoint located in
Lead Lag Master Configuration in order for the system to
operate correctly.
NOTE
The Local/Remote switch (explained below) must be set in
the “Local” position on ALL lag boilers.
6.4
LOCAL/REMOTE SWITCH
Verify activity on COM2 port
The right hand local remote switch mounted inside the control
box is designed to generate a call for heat either relying on an
external contact closure (Remote) or enabling the boiler locally
(local). When Remote is selected via the SPDT switch the
Remote Operator contacts in the junction box must be closed
to initiate a call for heat. When Local is selected via the SPDT
switch a constant call for heat is generated which will enable
the boiler to proceed to a trial for ignition. When
troubleshooting the DynaForce it is suggested to switch to
Local mode.
6.5
COMM. PORT 2 ACTIVATION
>
>
>
>
> Select Gateway tab
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:
1)
2)
3)
Select Gateway tab
Check Enable Modbus gateway
Select Gateway on COM2 port
http://www.camus-hydronics.com/Downloads/930238%20DynaForceDynaFlame%20Protocol%20Setup.pdf
1)
2)
Select COM2 tab
Check Enable COM2 port
43
6.6
VARIABLE FREQUENCY DRIVE (DR1200 5000)
The variable frequency drive (VFD) has a factory set security
code which has to be entered before any adjustments can be
made. The VFD has 50 parameters, which can be adjusted. At
present only the following are pertinent:
Table 13: Variable Frequency Drive Parameters
Parameter
Function
Settings
#
1
High/Low Voltage
Input Voltage 120, 220- 01
240, 460-480
02
2
Carrier Frequency
03
4
Stop Method
03
5
Standard Speed Source
04
19
Acceleration Time
120 sec
20
Deceleration Time
60 sec
28
Fixed Boost
1.0
36
Preset Speed
29
38
Skip Bandwidth
3.0
45
Speed at Minimum
Consult factory test
Signal
sticker
46
Speed at Maximum
Consult factory test
Signal
sticker
50
Fault History
View Only
51 thru 58 Miscellaneous
View Only
6.7
FROST PROTECTION
The DynaForce is equipped with a heat exchanger frost
protection algorithm where if the boiler inlet or outlet
o
o
temperature sensors drop below 41 F (5 C) the boiler pump is
o
o
enabled. If the temperature continues to drop to 38 F (3.3 C)
the burner will be fired to bring the inlet and outlet
o
o
temperatures to 50 F (10 C) to prevent freezing of the heat
exchanger.
PART 7
7.1
COMPONENTS
HOT SURFACE IGNITER (GLOW BAR)
The silicon carbide igniter is inserted directly through the
fan flange and held in place by two screws. A hold down
bracket as well as sealing gasket above and below the
igniter assures a good seal. Care must be taken when
removing and/or installing the igniter since the silicon
carbide element is brittle. Always remove the igniter prior
to removing the fan assembly for inspection of the burner
and heat exchanger. A properly prepared igniter will have
a bead of silicone sealing the end mounting bracket to the
ceramic shaft.
Figure 29: Hot Surface Igniter
During trial for ignition a properly operating igniter will
generate 3.2+/-0.2A which is above the flame signal
required by the ignition module for reliable and consistent
operation. It is recommended that the hot surface igniter
be replaced every 4,000 hours of appliance operation to
maintain peak ignition efficiency.
7.2
FLAME SENSOR
The flame sensor is inserted directly through the fan
flange and is screwed into the fan flange. Care must be
taken, when installing the flame sensor, to align it
perpendicular to the fan flange and parallel to the burner
tube and not to over tighten. Always remove the flame
sensor prior to removing the fan assembly for inspection of
the burner and heat exchanger.
Figure 30: Flame Sensor
The ignition module relies on the flame sensor to provide a
flame rectification signal. Oxide deposits, improper
placement or damaged ceramic insulator will result in
insufficient signal leading to ignition module lock out. For
proper operation minimum 0.8 Vdc must be fed back to
the module. Oxide deposit on the sensor rod must be
removed with steel-wool. Do not use sand-paper since this
will contaminate the surface.
44
7.3
COMBUSTION AIR FAN
PART 8
DR300 – 1000
Uses a modulating air fan to provide combustible air/gas mix to
the burner and push the products of 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 120 VAC, Single-Phase EC/DC electric motor. The
fan housing and motor assembly is fully sealed and SHOULD
NOT be field serviced. The power draw of the motor is
proportional to the modulated gas input rate of the appliance.
8.1
•
•
•
DR 1200 - 5000
Figure 31: Fan, Burner, Hot Surface Igniter and Flame
Sensor Arrangement (DR 1200 – 5000)
•
•
•
•
Uses a sealed air fan to provide combustible air/gas mix to the
burner and push the products of combustion through the heat
exchanger and venting system. The fan assembly consists of a
sealed housing and fan wheel constructed from spark resistant
cast aluminum. The fan is operated by a fully enclosed 230
VAC, 3 Phase electric motor. The fan housing and motor
assembly is fully sealed and SHOULD NOT be field serviced.
The power draw of the motor is proportional to the modulated
gas input rate of the appliance.
7.4
INNER JACKET
The inner jacket assembly is constructed from a special
corrosion resistant stainless steel. All screws, bolts, nuts and
fasteners used for assembly of the inner jacket are also
stainless steel.
DO NOT mix stainless steel and standard plated fasteners
when disassembling and reassembling the inner jacket
sheet metal components. Standard plated fasteners will be
damaged by the flue product condensate when used on
the inner jacket assemblies.
7.5
OUTER JACKET
The outer jacket assembly is constructed from mirror finish
stainless steel. This ensures a long life for the jacket assembly,
with full integrity
7.6
8.2
•
•
•
•
•
•
•
•
VENTING TRANSITION
All appliances are shipped with a round stainless steel adapter.
Depending on the appliance category an increaser will be
required for the proper vent configuration. Please refer to Table
3 dimensions and specifications.
When installing Category II or IV appliances care must be
taken to properly seal all joints and provide slope for drainage
of condensate away from the boiler.
•
FIELD STARTUP
PROCEDURE
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.
DR2000 – 5000: Connect a manometer to obtain the
differential air pressure between negative and positive
ports, see Figure 10.
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. All
boilers are test fired and factory set. A test sticker with
actual reading is affixed to the unit.
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 DynaForce controller is set in the
proper mode. 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 icon becomes green.
Once all lights past the operator are green the SOLA
will try for ignition. When the igniter is hot enough, the
gas valve actuator is energized and if ignition is
accomplished the Burner State will show “Run”. If
ignition is not accomplished, the Burner State will
show “Safe Startup”. 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.
Repair any leaks prior to the next step.
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 CO2 metering valve
may require some minor adjustment at full input.
Refer to Table 14. 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 CO2.
45
8.3
Figure 33: DR 500 - 1800 Gas Valve
GAS VALVE ADJUSTMENT PROCEDURE
Lift top cover to access high fire
air/gas ratio adjustment
(use 3mm allen key for adjustment,
counter-clockwise increases CO2)
Table 14: Combustion Values
DynaForce Combustion Values
Natural Gas
CO2
CO
Propane
CO2
Low fire air/gas ratio adjustment
(use T-40 for adjustment,
clockwise increases CO2)
CO
Max.
Fire
8.5% - 9.0%
<100
PPM
9.5% - 10.0%
<100
PPM
Min.
Fire
8.0% - 8.5%
<100
PPM
9.0% - 9.5%
<100
PPM
Gas Inlet
To adjust the low fire setting (DR 300 – 1800)
If adjustment of the gas valve is required use the following
procedure.
It is imperative that the coldest system water temperature
possible is used when setting up low fire combustion. These
cold system temperatures create large amounts of flue
condensate resulting in large amounts of condensate build up
on the stainless steel finned heat transfer tubes. These
conditions create the highest back pressure through the boiler
and makes for the most critical combustion set up point when
running 20% input. This set up must be achieved quickly to
ensure low system temperatures are maintained throughout
the set up of single or multiple boiler installations.
Light off the boiler at low fire and make the initial adjustment to
the low fire bias to obtain the specified CO2, CO, at 20% gas
input.
While maintaining the lowest possible water temperature,
observe the differential gas pressure. The differential gas
pressure must not drop below a minimum of 0.25” w.c. If
necessary increase the VFD (Hz) setting until this pressure is
met. Once the boiler has run for at least 5 minutes with dead
cold water, there should be a maximum amount of condensate
in the lower heat exchanger. At this point adjust the
combustion for CO2.
The boiler must continue to run with stable combustion without
making any howling noise which usually happens from an
overly rich mixture. Once settings are complete at low fire,
continue to run the machine for at least 5 more minutes and
record the final low fire input and the combustion data.
To ensure the coldest possible water temperatures for set up
on multiple boiler systems, the low fire combustion should be
established on all boilers before setting any boiler high fire
combustion rates.
In order to perform adjustments to the gas valve the
DynaForce must be firing before proceeding.
Figure 32: DR 300 – 400 Gas Valve
Low fire air/gas ratio adjustment
(use T-40 for adjustment,
clockwise increases CO2)
High fire air/gas ratio adjustment
(use slotted screwdriver for
adjustment, counter-clockwise
increases CO2)
46
Use the DynaForce Control Panel:
1)
Press [DIAGNOSTICS] button
2)
Press [Diagnostic Tests] button
3)
Move the firing rate slider to 1600 RPM
4)
Press [Start Test] to operate the boiler at max
fire for 5 minutes.
The DynaForce should respond immediately and fire at
1600 RPM. When this is achieved locate the low fire
adjustment screw as illustrated in Figure 30 and 31.
Low Fire
Adjustment
Increase CO2
Decrease CO2
Clockwise
CounterClock Wise
When the correct combustion values are achieved
replace the screw cap back on to the gas valve.
•
•
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 through the PWM 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. Always make adjustments
to meet the recommended CO2 levels. Adjust low fire
first followed by high fire adjustment.
To adjust the high-fire setting (DR 300 – 1800)
After the low fire settings are stable, ramp the boiler firing
rate to 100% using the boiler control and bring the system
temperatures up to 130F or to highest system design
temperatures 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 test sticker
4)
Press [Start Test] to operate the boiler at max
fire for 5 minutes.
Locate the input adjustment screw on the top side of the gas
valve.
High Fire
Adjustment
Increase CO2
Decrease CO2
CounterClock Wise
Clockwise
After adjusting the screw wait a moment for the combustion
levels to stabilize before attempting to make any further
adjustments. Continue this procedure until combustion levels
are satisfied.
To adjust the high-fire setting (DR 2000 – 5000)
One or more manometers should be connected to the
DynaForce before proceeding to the next step to monitor
the air and gas signal. Refer to Section 3.7 of this manual
for details on connecting manometers.
After the low fire settings are stable, ramp the boiler firing
rate to 100% using the boiler control and bring the system
temperatures up to 130F or to highest system design
temperatures to minimize or eliminate condensate.
Use the DynaForce Control Panel:
1)
Press [DIAGNOSTICS] button
To adjust the low-fire setting (DR 2000 – 5000)
2)
Press [Diagnostic Tests] button
Figure 34: SKP 55 Gas Valve
3)
Move the firing rate slider to 100.0%
4)
Press [Start Test] to operate the boiler at max
fire for 5 minutes.
Figure 35: DR3500 – 5000 Gas Train Layout
1
2
3
4
5
6
Adjustment of low fire bias
Connection for air pressure (+) sensing line
Connection for the air pressure (-) sensing line
Connection for the gas pressure (-) sensing line
Connection for the gas pressure (+) sensing line
Position indicator
Locate the metering valve on the gas train.
High Fire
Adjustment
Use the DynaForce Control Panel
1)
Press [DIAGNOSTICS] button
2)
Press [Diagnostic Tests] button
3)
Move the firing rate slider to 20.0%
4)
Press [Start Test] to operate the boiler at max fire for
5 minutes.
Low Fire
Adjustment
Increase CO2
Decrease CO2
Clockwise
CounterClock Wise
When the correct combustion values are achieved replace the
screw cap back on to the gas valve.
Increase CO2
Decrease CO2
CounterClock Wise
Clockwise
Turn the screw 1/8 turn in either way for each adjustment
to keep track of the adjustments. After adjusting the screw
wait a moment for the combustion levels to stabilize before
attempting to make any further adjustments. Continue this
procedure until combustion levels are satisfied.
To reset the metering valve to factory settings refer to the
chart below and the step-by-step instructions that follow.
Table 15: Inline metering valve setting
LP Gas (Propane)
Natural Gas
# of Turns Clockwise
# of Turns Clockwise
DR 2000
3 3/4
2 1/2
DR 2500
3 5/8
2 7/8
DR 3000
4
3
DR 3500
5 3/4
4
DR 4000
5 7/8
5
DR 4500
7¾
5
DR 5000
7 3/4
5
Model
47
Step 1: Fully open inline metering valve (counter- clockwise)
Step 2: Close inline metering valve to preset level
Step 3: Above table shows initial settings only, fine-tuning will
be required with the use of an analyzer.
•
•
•
•
•
•
•
•
•
8.4
•
•
•
48
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
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. 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 CO2
levels. Adjust high fire first followed by low fire adjustment.
Allow the water temperature to rise so that the heater
cycles on the operator.
Check the temperature rise across the heat exchanger.
This will be indicated by taking a difference between the
inlet and outlet temperatures on the DynaForce control.
For hydronic applications and for domestic hot water, a
rise exceeding 30ºF is not normally recommended.
Allow the unit to cycle on the limit. This can be done by
gradually restricting outlet water flow. The auto reset limits
are set at 200ºF for domestic hot water and hydronic
heating.
Remove fan inlet filter. At full input, block 50% of the fan
inlet opening. The display should show ‘LCI not closed’. If
it does not, slowly turn the adjustment on the normally
closed blocked flue switch counterclockwise until the
blocked flue switch indicator energizes.
Check the air proving switch. Remove the restriction from
the fan inlet and reset the power on the control panel. A
properly set air switch will cause the interrupted air 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 ignition should commence within 30
seconds.
COMISSIONING APPLIANCE
Remove manometers and replace inlet gas pressure test
plug.
Fill out start up report for each heater. Be sure to record all
settings and readings. Retain a copy of report for future
reference.
Start up is now complete and heater may be placed into
service.
PART 9
TROUBLESHOOTING
COMPONENT
Incoming Power
Transformer
Tripped
Relief Valve
Flow Switch
Water Pressure
Switch
FAILURE MODE
• Two wires interchanged
• The 24Volts and 120 Volts wired
are interchanged
• Alert: 49
• Lockout: 53
• System pressure exceeds relief
valve setting
• Flow Switch contacts are open
• Alert: 63, 67, 137, 276-281
• LCI OFF
• Pressure Switch contacts are open
• Alert: 63, 67, 137, 276-281
• LCI OFF
• The boiler has failed to ignite the
burner
• Alert: 110, 149, 150
Flame Failure
ANALYSIS
• No effect on safety
• Live and Neutral wires are interchanged.
• Breaker on transformer trips
• Replace the standard relief valve with a higher rated valve
up to the maximum pressure of the heat exchanger.
• Improperly sized expansion tank.
• Verify that pump is operating
• Verify for closed valves or obstructions in boiler piping
• Verify that all air has been purged from the system
• Verify that wiring is correct
• Verify that minimum water pressure exceeds 30 PSI
• Verify that pump is operating
• Verify for closed valves or obstructions in boiler piping
• Verify that all air has been purged from the system
• Verify that wiring is correct
• 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 errors
• DR 300 – 2500: Verify igniter is glowing
• DR 3000 – 5000: Verify pilot is lit
• Inspect flame sensor and associated wiring. Replace if
necessary
• Verify that boiler is properly grounded
• Verify incoming gas supply pressure and that it coincides
with Table 7.
• Verify that the vent/ air inlet piping (if equipped) are
correctly installed and obstructions are not present.
• Verify 24 VAC (DR 300 – 1800) and 115VAC (DR 2000 –
5000) is being supplied to the gas valve relay from the
DynaForce Controller during ignition. Check wiring from
DynaForce Controller and Gas Valve Relay. If a signal
cannot be detected, the DynaForce Controller needs to be
replaced
• If 24 VAC is present, check the outlet of the valve to ensure
that gas is flowing. When the valve is energized a change
in pressure should occur, if no change is detected the gas
valve has failed to open or it is passing insufficient amount
of gas. If this is an initial startup increase the low fire gas
setting by ¼ turn clockwise.
• Inspect the burner. Refer to Burner Maintenance in section
10.5
• Replace the DynaForce Controller, if necessary
49
COMPONENT
FAILURE MODE
• The DynaForce boiler was running
and flame signal suddenly
disappeared.
• Lockout: 106, 107, 108, 109
• Alert 149, 150
Flame Disappears
During a Run
Cycle
• Supply Gas Issue
• Air/Gas Mixture Issue
Noisy Operation
• Air Inlet and/or Vent configuration
• Dirty/ Damaged Burner
• Fan is vibrating
• Air in the piping system
• The outlet temperature has
exceeded the set point
temperature specified.
• Alert: 63, 67, 79, 137, 276-281,
303-309
• ILK OFF
Auto Reset High
Limit Trips
50
ANALYSIS
• Verify that all air has been purged from gas line
• Verify that boiler is properly grounded
• Inspect flame sensor and associated wiring. Replace if
necessary
• Check for flame sensor cracks in the insulator or continuity
to ground
• Adjust the air proving switch. Turn counter-clockwise to
reduce sensitivity
• Adjust the blocked flue switch. Turn clockwise to reduce
sensitivity
• Verify incoming gas supply pressure and that it coincides
with Table 7.
• Verify that the gas line connections to the boiler are
adequate. Refer to Table 6.
• Verify that the vent/ air inlet piping (if equipped) are
correctly installed and obstructions are not present
• Verify that 24 VAC is being supplied to the gas valve during
operation. If a signal cannot be detected, the transformer
needs to be replaced
• Inspect the burner. Refer to Burner Maintenance in section
10.5
• Replace the DynaForce Controller if necessary
• Refer to Part 3 Gas Connection in this manual.
• Natural Gas Pressure reads between 3” w.c. and 14” w.c.
• L.P. Gas Pressure should be at 11” w.c.
• Refer to Section 8.3 Gas Valve Adjustment Procedure for
proper combustion setting.
• Refer to Part 2 Air Inlet and Venting
• Refer to Burner Maintenance in section 10.5 of this manual
for the burner removal and inspection procedure. Clean or
replace the burner, if required.
• Check that all fan bolts are torqued to 20 lb-ft (DR300 –
1000), 25 lb-ft (DR1200 – 5000)
• Purge all air from the piping system
• Verify that the system is full of water and that all air has
been properly purged from the system.
o
• Verify that ∆T does not exceed 30 F across the heat
exchanger
• Verify that the boiler is piped properly.
• Verify that 120VAC is being supplied to the boiler pump on
a call for heat. If voltage cannot be detected check wiring.
• Verify that the pump is circulating when 120VAC is
detected. If not, pump impeller may be stuck. Use a flat
head screwdriver on face of pump to turn impeller manually
• If 120VAC is present during a call for heat, but the pump still
does not circulate, replace the pump.
• Replace the main DynaForce Controller if necessary
SYMPTOM
Manual Reset High
Limit Trips (if
equipped)
FAILURE MODE
• Manual Reset Safety High Limit
tripped, outlet temperature in
o
excess of 210 F
• Alert: 63, 67, 79, 137, 276-281,
303-309
• ILK OFF
• Outlet temperature has exceeded
o
40 F over inlet temperature
• Alert: 124
Delta-T Limit
Tripped
• Stack temperature has exceeded
the limit temperature.
• Alert: 125
Temperature
Overshoot
Sensor Not
Connected
Fan Not Turning
Air Proving Switch
Blocked Flue
Switch
• Outlet temperature has exceeded
limit temperature.
• Alert: 63, 67, 79, 137, 276-281,
303-309
• LCI OFF
• Inlet sensor, Alert: 91
• Outlet sensor, Alert: 92
• DHW sensor, Alert: 93
• Flue sensor, Alert: 95
• Outdoor sensor, Alert: 96
• Fan refuses to rotate
• Alert 122, 123, 128, 129, 130, 131,
132
• Interrupted Air Switch error
• Alert: 63, 67, 79, 137, 276-281, 182
• ILK OFF
• IAS OFF
• LCI error
• Alert: 63, 67, 79, 137, 276-281,
303-309
• LCI OFF
ANALYSIS
• Verify that the capillary tube is broken. If this is the case,
replace Manual Reset High Limit
• Verify that the system is full of water and that all air has
been properly purged from the system.
• Verify that the boiler is piped properly.
• Verify that 120 VAC is being supplied to the boiler pump on
a call for heat. If voltage cannot be detected check wiring.
• Verify that the pump is circulating when 120 VAC is
supplied. If so, pump impeller may be stuck. Use a flat
head screwdriver on face of pump to turn impeller
manually.
• If 120 VAC is present during a call for heat, but the pump
still does not circulate, replace pump.
Verify that the system is full of water and that all air has been
properly purged from the system.
• Verify that the boiler is piped properly.
• Verify that 120VAC is being supplied to the boiler pump on
a call for heat. If voltage cannot be detected check wiring.
• Verify that the pump is circulating when 120VAC is
detected. If not, pump impeller may be stuck. Use a flat
head screwdriver on face of pump to turn impeller manually
• If 120VAC is present during a call for heat, but the pump still
does not circulate, replace the pump.
• Purge all air from the piping
• Verify boiler water pressure exceeds 30 PSI
• The stack temperature has exceeded the maximum
temperature allowed.
o
• PVC: 149 F
o
• CPVC: 194 F
o
• AL29-4C, Stainless Steel: 250 F
• Measure the resistance of the flue sensor at room
temperature, it should be approximately 10kΩ.
• Verify that the system is full of water and that all air has
been properly purged from the system
• Verify that the boiler is piped properly.
• Verify that adequate power is supplied to pump on a call for
heat. If voltage cannot be detected check wiring
• Verify pump is circulating when power is supplied. If so,
pump impeller may be stuck.
• If power is present during a call for heat, but the pump still
does not circulate, replace the pump.
• Replace the DynaForce Controller, if necessary.
• Verify sensors are connected
• Verify wiring.
• Measure resistance of sensors, 10kΩ sensors.
• Replace sensor if necessary
• Check fan power wires
• Fan signal wires are interchanged
• Minimum fan speed must be greater than 1600 RPM
• Air Switch wire(s) is/are loose
• Air Switch is set too tight, reduce sensitivity by turning
screw ¼ turn counter-clockwise.
• Blocked Flue Switch wire(s) is/are loose
• Blocked Flue Switch is set too tight, reduce sensitivity by
turning screw ¼ turn clockwise.
51
SYMPTOM
Flame Detection is
out of Sync
Blank Display
Screen
Internal Fault
FAILURE MODE
• Flame detection is present when no
visible signs of a flame exist
• Lockout: 105, 158
• Blank display screen
• Alert: 3-9, 20-31
• Lockout: 10-18, 32-46, 58-60, 9799, 143-148
Table 16: Lockout Codes
#
0
1-31
47
48
49
64
67
79
Description
None
Internal hardware error
Flame rod to ground leakage
Static Flame
24VAC low/high
Fan speed not proved, ignition failure
Blocked flue condition
Heater Outlet high limit tripped
o
o
Stack limit tripped (PVC: 149 F, CPVC: 194 F,
82
o
250 F)
91
Inlet sensor fault
92
Outlet sensor fault
93
DHW sensor fault
95
Stack sensor fault
105
Flame detected out of sequence
Flame lost if Main Flame Establishing Period
106
(MFEP)
107
Flame lost early in run
108
Flame lost in run
109
Ignition 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.
52
ANALYSIS
• Verify supply voltage for proper polarity.
• Check external wiring for voltage feedback
• Check internal wiring for proper connections
• Check the flame sensor and verify that it is clean
• Replace DynaForce Controller, if necessary
• Check wire connections from DynaForce Controller to
touchscreen display
• Reset SOLA,
• If fault persists, replace SOLA
Table 17: Alert Codes
#
Description
0
None
29
Burner switch turned OFF
30
Burner switch turned ON
47
Flame rod to ground leakage
49
Abnormal 24Vac voltage
50
Modulation Fault (DR300 – 1000 ONLY)
61
Anti-short Cycle
62
Fan speed not proved
63
LCI off, safety circuit is open
67
Interlock Off, safety circuit is open
69
Pilot test hold
78
Demand lost in run
79
Outlet high limit tripped
o
81
Delta-T limit exceeded (30 F)
91
Inlet sensor fault
92
Outlet sensor fault
93
DHW sensor fault
95
Stack sensor fault
96
Outdoor sensor fault
97- Internal Fault
99
128 Fan speed failed during prepurge
129 Fan speed failed during preignition
130 Fan speed failed during ignition
131 Fan movement detected during standby
132 Fan speed failed during run
137 Interlock failed to close, safety circuit is open
110 Ignition failure occurred
111 Flame current below threshold (0.8Vdc)
149 Flame detected
150, Flame not detected
291
301 Interlock Off, safety circuit is open
309
460 Interlock off during burn, safety circuit is open
* If an internal fault is detected contact Camus technical
support for troubleshooting procedure.
Alert 291: Abnormal Recycle: Flame was not on at end of ignition
Alert 294: Abnormal Recycle: Flame was lost during Run
Alert 324: Abnormal Recycle: Hardware flame bias
Alert 377: Abnormal Recycle: Hardware flame bias delta
This error occurs when a flame signal is not detected by the flame sensor. A minimum signal of 0.2Vdc 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
surface igniter
for minimum
3.0A reading
No
Replace igniter
Yes
Check flame
sensor for
carbon
deposit
Yes
Clean and/or replace
No
Verify
differential air
signal is at
0.35” w.c. at
o
80 F return
water
temperature
No
Adjust VFD parameter 45 (speed at minimum signal)
until 0.35” w.c. is reached across air differential.
53
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-igntion
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
Alert 460: LCI lost in run
This error 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.
Open
Red
Check flow switch
Flow Switch
Check flow switch paddle
Closed
Check water
pressure switch
Open
Must have minimum 30
PSIG in water system
Green
Closed
Check blocked
flue switch
Open
Open
Red
Reset high limit
Check high limit
High Limit
Check vent & inlet for
obstruction
Green
Open
Red
Low gas switch
Gas Pressure Switch
Check inlet gas pressure
> 3” w.c.
Closed
Green
Open
High gas switch
Red
Air Switch
Check air proving
switch
Green
Check J5-2
connector SOLA
for 24Vac signal
54
Proceed to
ignition sequence
Open
Check inlet gas pressure
< 14” w.c.
Turn set screw CCW 1/2
to 1-1/2 turns
Alert 354: Abnormal Recycle Delta-T limit
o
This safety was breached as the inlet and outlet temperature difference exceeded 40 F. This is done to prevent damage to the
heat exchanger. 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 water lines
Check pump wiring
Check pump wiring
Current reading
within spec
Check pump curves to
compare with flow and
pressure drops in Part 4
of DynaForce I&O Manual
Out of spec
Upgrade Pump
55
PART 10
MAINTANANCE
CAUTION
It is important that all gas appliances to be serviced by a
Camus trained service technician. It is in your own interest
and that of safety to ensure that all local codes, and all the
“NOTES” and “WARNINGS” in this manual are complied
with. To service or adjust this appliance, it is imperative
that the Camus trained service technician utilize a
combustion analyzer to read CO2, CO and flue pressure
according to Camus Hydronics recommendation
CAUTION
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and dangerous
operation, verify proper operation after servicing.
Listed below are items that must be checked to ensure safe
reliable operations. Verify proper operation after servicing.
10.1
EXAMINE THE VENTING SYSTEM
Examine the venting system at least once a year. Check
more often in the first year to determine inspection interval.
Check all joints and pipe connections for tightness,
corrosion or deterioration. Flush the condensate drain hose
with water to clean. Clean screens in the venting air intake
system as required. Have the entire system, including the
venting system, periodically inspected by a qualified service
agency.
10.2
VISUALLY CHECK MAIN BURNER
FLAMES
At each start up after long shutdown periods or at least
every six months. A burner view port is located on the
burner mounting flange.
CAUTION
The area around the burner view port is hot and direct
contact could result in burns.
NOTE
Check torque on fan mounting nuts using a torque wrench.
DR300 – 1000: 20 lb-ft
DR1200 – 5000: 25 lb-ft
Figure 36: Normal Burner Flame Profile (short dense and
blue)
•
•
•
•
56
Normal Flame: A normal flame at 100% of burner input
is blue, with slight yellow tips a well defined flame and
no flame lifting.
Yellow Tip: Yellow tipping can be caused by blockage
or partial obstruction of air flow to the burner.
Yellow Flames: Yellow flames can be caused by
blockage of primary air flow to the burner or excessive
gas input. This condition MUST be corrected
immediately.
Lifting Flames: Lifting flames can be caused by over
firing the burner, excessive primary air or high draft in
excess of 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
Any sign of soot around the jacket, flue pipe connections,
burner or in the areas between the fins on the stainless
steel heat exchanger indicates a need for cleaning. The
following cleaning procedure must only be performed by a
Camus trained service technician. Proper service is
required to maintain safe operation. Properly installed and
adjusted units seldom need flue cleaning.
All gaskets/sealant on disassembled components or jacket
panels must be replaced with new gaskets/sealant on reassembly. Gasket and sealant kits are available from the
factory
CAUTION
When the vent system is disconnected for any reason it must
be reassembled and resealed according to vent
manufacturer’s instruction
10.4
CONDENSATION TREATMENT
This high efficiency appliance may operate as a condensing
appliance for extended periods of time based on return
water temperatures. Condensate occurs when the products
of combustion are cooled below their dew point in the heat
transfer process. The liquid condensate formed from this
high efficiency heat transfer process is mildly acidic. The
condensate will typically have a pH ranging from 4.0 to 5.0
as it is discharged from the condensate drain on the rear of
the appliance. The lower jacket and base pan where
condensate is collected is constructed from a corrosion
resistant stainless steel. All materials external to the
appliance in contact with the condensate must be corrosion
resistant. This is typically accomplished by using PVC
plastic pipe and synthetic tubing. Condensate must be able
to flow freely from the appliance. All condensate flow is
accomplished by gravity requiring a minimum downward
slope of 1/4” per foot (21mm/m) to ensure proper flow to the
condensate management system and/or a suitable drain.
The neutralizer MUST always be mounted on the same
level or lower than the bottom of the appliance cabinet and
downstream of the condensate trap. All condensate piping
and connections must be easily accessible for routine
maintenance and inspection.
10.4.1
CONDENSATE VOLUME
There are several factors effecting amount of condensation
created by the appliance however for rough approximation
use.
Condensation Volume, US Gallon/Hr = Input, MBH/1000 x
5.0
Many codes will require the acidic condensate to be
neutralized before it can be placed in a drain system. A
neutralizer to control the pH of the liquid discharged to a
drain system is recommended with every appliance. The
neutralizer consists of an industrial grade, non-corrosive
reservoir for collection of the condensate. As the reservoir
fills, it provides an extended residency time to neutralize the
condensate. The neutralized condensate exits from the
reservoir outlet. A ‘P’ trap is installed upstream of
neutralizer at the heat exchanger. Prime the installed
assembly with water to prevent flue gas spillage from the
drain. Use standard ½" vinyl, PVC, CPVC or suitable hose
to run to floor drain.
When the condensate level in the reservoir rises to the
drain, it spills out into the condensate bin and from there
exits to the external neutralizer. As the pH number
increases in numerical value, the relative acidity of the
discharge decreases. The neutralized condensate may
then be discharged into a suitable drain system without fear
of damage to the drain system. Always check with local
codes for specific pH requirements. Neutralizers may be
used in series to raise pH.
The condensate collection box supplied with the DynaForce
is supplied with an initial charge of neutralizer medium. This
neutralizer medium is expected to last approximately 3 to 6
months depending on the amount of condensate produced.
Neutralizer refills are available from Camus.
10.5
10.5.1
Access to the burner will require the following steps:
•
•
•
•
•
•
•
•
•
•
•
•
Turn off main electrical power to the appliance.
Turn off main manual gas shutoff to the
appliance
Remove the top cover.
Disconnect the gas supply connection to the fan
inlet.
Disconnect the fan motor power wires at the
harness.
Remove the hot surface igniter and the flame
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 silicone gasket may adhere to
the underside of the fan’s flange. Carefully pry the
flange away from the gasket prior to removing the
fan assembly.
The burner can now be lifted vertically out of the
heat exchanger cavity. A graphite-backed ceramic
paper gasket is located directly under the burner
flange. This gasket must be replaced if it is
damaged.
Use care to prevent damage to the knitted metal
fiber of the burner surface.
Check all gaskets and replace as necessary.
Gaskets affected by heat will not reseal properly
and must be replaced.
Replace the burner in the reverse order that it was
removed. Insert the igniter and sensor before
doing the final tightening on the fan mounting nuts.
Evenly tighten the nuts to 20 ft-lbs (models 300 –
1000) and 25 ft-lbs (models 1200 – 5000)
BURNER MAINTENANCE
The burner should be removed for inspection and cleaning
on an annual basis. An appliance installed in a dust or dirt
contaminated environment will require inspection and
cleaning on a more frequent schedule. The fan assisted
combustion process may force airborne dust and dirt
contaminants, contained in the combustion air, into the
burner. With sustained operation, non-combustible
contaminants may reduce burner port area, reduce burner
input or cause non-warrantable damage to the burner.
Airborne contaminants such as dust, dirt, concrete dust or
dry wall dust can be drawn into the burner with the
combustion air and block the burner port area. An external
combustion air filter is provided with the appliance. An
additional filter is located at the fan inlet (DR1200 – 5000)
and like the external filter may be washed in the sink under
the tap. This internal filter should be checked and cleaned
at the time of appliance commissioning and on a six month
interval or more often in a contaminated environment.
BURNER REMOVAL
NOTE:
When the combustion air fan is removed for any reason,
the inlet to the burner must be covered to prevent further
foreign objects from falling into the burner. Always look
inside the burner to check for dents. Do not place a burner
back into operation if the inner distribution screen has been
dented during the service operation, call the factory for
recommendations. Use care when removing and handling
the burner, Sharp objects or impact may damage or tear
the metal fiber surface rendering the burner unfit for
service.
10.5.2
BURNER CLEANING PROCEDURE
Remove any visible dust or dirt blockage from the surface
of the burner using water from a garden house. Wash the
burner with low pressure water. Never wipe or brush the
surface of the burner nor use high pressure water or air.
The burner may best be cleaned by immersing the burner
port area in a solution of dishwashing detergent and hot
water. Allow the burner to remain in the solution for a
short period of time to remove dust, dirt and oil or grease
laden contaminants. Rinse the burner thoroughly with
clean water to remove any residue from the detergent
cleaner. The burner should be air dried after removal
from the cleaning solution and rinsing. DO NOT use
chlorine based solvents or cleaning agents on the burner.
57
10.6
•
•
•
•
•
•
•
•
The hot surface igniter is to be checked at least after
every 4000 hours of operation and more frequently
under high cycling conditions. This will maintain peak
ignition efficiency.
Turn off main electrical power to the appliance.
Turn off main manual gas shutoff to the appliance.
Locate the hot surface igniter.
Disconnect the two power leads to the hot surface
igniter.
Loosen and remove the two screws that hold the
igniter.
Lift the igniter vertically out of the burner mounting
flange. Use care, do not hit or break the silicon carbide
igniter. DO NOT pull out by leads.
Ensure that the ceramic paper gaskets used to seal the
base and top of the igniter are reinstalled on the new
igniter.
10.6.1
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
58
RE-INSTALLING THE IGNITER
Confirm that the end of the replacement igniter has a
bead of silicone sealing the gap between the metal
mounting flange and the ceramic shaft of the igniter.
Carefully insert the igniter into the mounting point on
the burner flange and push into position on top of the
fan’s flange. The word ‘OUTSIDE’ on igniter faces you
when inserting igniter.
Reinstall the two mounting head screws and tighten by
hand only.
Ensure that the igniter ceramic paper gaskets are
properly installed and seal the point of contact between
the igniter and fan mounting flange.
Reconnect the power leads to the igniter.
Turn on main gas supply.
Turn on main power.
Test fire the appliance to ensure proper operation.
The igniter must generate 3A to reliably prove the
ignition system.
10.7
•
CHANGING THE HOT SURFACE IGNITER
HEAT EXCHANGER INSPECTION
The heat exchanger should be inspected at the time of
burner maintenance.
Turn off all power to the appliance.
Turn off main gas to the appliance.
Remove top cover.
Remove fan assembly and burner as detailed in the
Burner and Cleaning section.
Check the heat exchanger surface for soot. If soot is
present, heat exchanger must be cleaned
Remove the front outer jacket door.
Remove the top wrap to expose the baffles.
Remove baffles from the exchanger.
Use detergent water pressure wash to remove soot
from heat exchanger and surfaces of the inner wrap.
When necessary, the heat exchanger can be removed
by disconnecting all water piping and removing the six
flange mounting bolts at the rear of the appliance. The
heat exchanger can now be removed from the front of
the appliance.
Reinstall baffles, stainless steel 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 and water piping. Test for gas
leaks.
Reassemble outer jacket panels. Keep top cover off.
Cycle unit and check for proper operation.
Once proper operation is confirmed replace the top
cover.
10.8
•
•
•
•
•
RE-INSTALL HEAT EXCHANGER
Carefully reinstall the heat exchanger if removed from
the appliance
Check all silicon and viton gaskets and replace if
damaged
Reassemble inner wrap
Cycle unit and check for proper operation
Replace the top cover
10.9
COMBUSTION AIR FAN
Combustion air fan should be checked every 6 months.
Clean the internal filter as required when installed in a dust
or dirt contaminated location. The motor and bearings on
the combustion air fan are sealed and permanently
lubricated requiring no addition of oil or lubricants.
10.10
COMBUSTION AND VENTILATION AIR
Check frequently to be sure that the flow of combustion and
ventilation air to the appliance is not obstructed.
Combustion and ventilation air must be provided to the
mechanical room with openings sized per the requirements
of the B149 or National Fuel Gas Code. The optional
outdoor air kit brings combustion air from the outdoors
directly to the appliance.
10.11
CONTROL CIRCUIT VOLTAGE
This appliance uses a transformer to supply a low voltage
control circuit. The voltage on the secondary side should be
24 to 28VAC when measured with a voltmeter. A secondary
voltage of 21VAC or less supplied to 24VAC components
may cause operational problems. A 4A circuit breaker is
provided on the secondary side of the transformer. A
tripped circuit breaker indicates a short in the 24VAC
controls and must be corrected.
10.12
COMBUSTIBLE MATERIALS
CAUTION
Keep appliance clear from combustible materials; do not
store GASOLINE and other flammable vapors and liquids
in the proximity of the appliance.
10.13
FREEZE PROTECTION
Installations are not recommended in areas where the
danger of freezing exists. Proper freeze protection must be
provided for appliances installed outdoors, in unheated
mechanical rooms or where temperatures may drop to the
freezing point or lower. If freeze protection is not provided
for the system, a low ambient temperature alarm is
recommended for the mechanical room. Damage to the
appliance by freezing is non-warrantable.
•
Location - Heating boilers, hot water supply boilers or
water heaters must be located in a room having a
temperature of at least 50ºF (10ºC)
•
•
•
o
o
o
o
o
Caution - A mechanical room operating under a
negative pressure may experience a downdraft in the
flue of an appliance that is not firing. The cold outside
air may be pulled down the flue and freeze a heat
exchanger. This condition must be corrected to provide
adequate freeze protection.
Freeze protection for the appliance using an indirect
coil can be provided by using hydronic system
antifreeze. Follow the manufacturer’s instructions. DO
NOT use undiluted or automotive type antifreeze.
Shut-down and draining - If for any reason, the unit is
to be shut off where danger of freezing exists, the
following precautionary measures must be taken:
Shut off gas supply
Shut off water supply
Shut off electrical supply
Drain the heat exchanger completely
Ensure the pump and connecting piping are fully drained
10.14
•
•
•
•
•
FREEZE PROTECTION FOR A HEATING
BOILER SYSTEM (Optional)
Use only properly diluted inhibited glycol antifreeze
designed for hydronic systems.
Follow the instructions from the antifreeze
manufacturer. Quantity of antifreeze required is based
on total system volume including expansion tank
volume.
Antifreeze is denser than water and changes the
viscosity of the system. The addition of antifreeze will
decrease heat transfer and increase frictional loss in
the boiler and related piping. Where antifreeze has
been used, to maintain the temperature rise across the
appliance confirm that the recommended GPM for pure
water has been increased by 15% and the head loss
by 20%.
Local codes may require a back flow preventer or
actual disconnect from city water supply when
antifreeze is added to the system.
When filling or topping-up the system with water mixed
with the antifreeze always used distilled or RO (reverse
osmosis) water. This will prevent the reaction of the
water with antifreeze which can create sludge.
PART 11
INSTALLATIONS
WARNING
Before starting the boiler, smell near the floor and around
the boiler for any gas odours 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 start
the boiler
WARNING
Propane boilers ONLY – Your local propane supplier adds
an odorant to the propane gas to allow for propane gas
leak detection. In some cases, the added odorant can fade
and the gas may not give off any noticeable odour. Before
startup have the local propane supplier check for the
correct odorant level in the gas.
11.1
CHECKING THE INSTALLATION
•
•
Inspect the connections for water, gas and electricity.
Inlet gas pressure must be a minimum of 7” 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.
Refer to Section 8.3 Gas Valve Adjustment Procedure of
the manual for recommendations on setting combustion
characteristics
11.2
•
•
•
•
•
11.3
1)
2)
3)
4)
5)
6)
CHECKING THE INSTALLTION
Check the boiler wiring to see that it agrees with
the wiring diagram supplied.
Confirm that all terminal strips and field
connections are identified.
With the boiler running, check for flue gas leaks
along the inner cabinet joints and around the flue
outlet.
Repair any leaks prior to proceeding to the next
step.
At the factory, adjustments were made to achieve
proper input and acceptable burner performance
at full input and at minimum input.
INSPECT & RECHARGE CONDENSATE
COLLECTION & NEUTRALIZING RESERVOIR
Inspect the ‘P’ trap and condensate reservoir in the
DynaForce, making sure the collection box is intact.
Remove screws holding lid on to condensate collection
box. Remove lid from the condensate collection box.
Fill with fresh water until the water begins to flow out of
drain.
Re-install the lid and hold-down screws on the
condensate collection box.
Inspect the condensate neutralizer supplied on site and
confirm that it contains sufficient calcium carbonate to
operate effectively to neutralize condensate to required
level.
Check pH level of condensate.
59
WARNING
The condensate collection box must be filled with water to
prevent flue gas emissions from escaping during boiler
operation.
11.4
HEATING BOILER INSTALLATIONS
The appliance MUST always be installed in a
primary/secondary reverse return piping system for proper
operation. Before beginning the installation, consult local
codes for specific plumbing requirements. The installation
should provide unions and valves at the inlet and outlet of
the appliance so it can be isolated for service. An air
separation device must be supplied in the installation piping
to eliminate 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 expansion tank is
used. The expansion tank must be installed close to the
boiler and on the suction side of the system pump
(appliance Inlet) to ensure proper operation. Caution: This
appliance should not be operated at less than 30 PSIG.
Water piping must be supported by suitable hangers or
floor stands, NOT by the appliance. Pipe systems will be
subject to considerable expansion and contraction. Pipe
supports could allow the pipe to slide resulting in noise
transmitted into the system. Padding is recommended. The
boiler pressure relief valve must be piped to a suitable floor
drain. See Section 4.10.
CAUTION
1) A leak in a boiler “System” will cause the “System” to
intake fresh water constantly, which may cause the
tubes to accumulate a lime/scale build up. This will be
a NON-WARRANTABLE FAILURE.
2)
3)
11.5
If boiler pumps are not operated when treated water
is introduced, a corrosion cell may be created in the
boilers leading to a failure which is not covered by
warranty.
Target water quality of treated water to be stable and
neutral with regards to corrosive/scaling properties.
Damage to or failure of the heat exchanger as a
result of scaling or corrosive water quality is not
covered by warranty.
WATER CONNECTIONS
All models have groove locked inlet and outlet stainless
steel connections. Pipe size must be in accordance with
Table 3 and, between supply and return lines, must not
exceed 80 feet of equivalent length. Any reduction in
recommended pipe size may decrease flow resulting in
high water temperatures, boiler noise, flashing to steam
and non-warrantable heat exchanger damage.
11.6
PIPING LENGTHS
The appliance circulator provides the water flow from the
primary boiler piping, through the boiler and back to the
primary system. Pipe diameter and length are critical to
ensure proper flow through the boiler.
The secondary 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 diameter as the installed
piping. If flow control is required, other means of flow
control such as globe valve or flow setter should be used.
60
11.7
INTERMITTENT PUMP OPERATION
An intermittent pump operation signal is standard and can
be used to operate a separate pump contactor. A 1/6 hp
pump delay relay is standard, and a 1 hp pump delay relay
is available. When utilizing this feature, the boiler’s integral
circulating pump will cycle on at each call for heat, before
the burner fires. The pump will continue to operate while
the burner is firing. The pump will run for a post-pump
period after the temperature set point is satisfied. This will
remove any residual heat from the combustion chamber
before turning the pump off. See wiring diagram shipped
with the unit.
11.8
SUMMARY
a)
Typical Boiler Installations
General Plumbing Rules
1 Check all local codes.
2 For serviceability of boiler, always install
unions.
3 Always pipe pressure relief valve to an open
drain.
4 Locate system air vents at highest point of
system.
5 Expansion tank must be installed near the
boiler and on the suction side of the system
pump.
6 Support all water piping.
b)
Placing the Boiler in Operation
Pre-Start Check List
1 Review the location of the boiler, clearances
from combustible surfaces and available service
clearances.
2 Review Part 2 Venting. Ensure that all vent
components are fabricated from the correct
category of materials with adequate clearance
from combustibles.
3 Ensure that the boiler condensate drain and all
vent system condensate drains are properly
routed to an acceptable floor drain or
neutralization system.
4 Review the vent termination point for proper
location and clearances.
5 Ensure that proper volumes of combustion and
ventilation air are provided to the mechanical
room. If a separate combustion air pipe is used,
ensure that it is properly sized, sealed and
terminated.
6 Review the water piping from the boiler to the
system. The boiler must be installed in a
primary/ secondary piping system. Review the
diameter and equivalent length of the installed
piping to and from the boiler for proper flow.
7 Ensure that a properly sized primary system
pump is installed with an expansion tank.
8 Check system pressure. Ensure a minimum of
30 PSIG with the system hot and not more than
90% of the rated pressure of the relief valve.
9 Review the installed gas piping from the meter
to the boiler. Ensure that the gas pipe, meter
and any regulators are adequately sized.
10 Review the field 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 water. Bleed all air from the pump
housing and secondary loop.
2 Check system for any water leaks.
3 Check system for installation of glycol or
water treatment where required. Where glycol
has been used to maintain the temperature
rise across the appliance confirm that the
recommended flow for pure water has been
increased by 15% and the head loss by 20%.
4 Turn on power to the primary system pump
and the appliance secondary pump and verify
operation.
Boiler Operational Checks
1 Turn the boiler main power switch to the “ON”
position.
2 Program the adjustable points.
3 Turn the switch to the “ON” position to start
boiler operation.
4 Push the resets for low water level, high water
temperature and alarm.
5 Install a manometer on the gas supply to the
boiler and verify minimum gas supply
pressure as the burner 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 wire at
the sensor. Main flame must extinguish within
4 sec. If flame does not extinguish replace
the ignition control.
Boiler Operation
1 Appliance should begin the start-up process
for the sequence of operation.
2 The boiler will fire down to 20% on initial startup and adjust input as required to meet
system demand.
3 Based on system demand, the appliance will
modulate accordingly.
4 As system demand is satisfied, the burner will
cycle off and the combustion air fan will
decelerate at a pre-programmed rate before
the appliance shuts down.
DR 300 – DR 2500
DR 3000 – DR 5000
11.9
DOMESTIC HOT WATER HEATER
Hot water heaters are designed for installation with a
storage tank. The operation of the properly sized circulating
pump, the piping between the tank and heater and the
control of water velocity, as explained below, are important
for correct operation of your hot water heater.
61
11.10
WATER VELOCITY CONTROL
To ensure proper velocity through the heat exchanger(s), it
is necessary to select the proper pump. Temperature rise
at full fire will be an indication of flow. This must be done
on initial installation and periodically rechecked.
Excessive lime/scale build-up in the heat exchanger tubes
is a result of restricted flow and too little velocity in the
tubes. Care should be taken to maintain required water
velocity based on water condition as follows:
11.11
TEMPERATURE RISE AT FULL FIRING
RATE
1
The pump must run continuously when the burner is
firing.
2 With the pump running and the burner in the appliance
in the off cycle, the inlet temperature and outlet
temperature readings on the display should read
approximately the same temperatures.
3 Turn the hot water heater on and allow time for the
temperature to stabilize. Check the temperature rise
when the burner is firing at 100% of rated input.
4 Compare the temperature rise on the DynaForce
display with the required temperature rise at the
required flow rate based on water condition (Soft,
Normal, and Hard). Should adjustment be needed,
proceed as follows:
If the temperature rise is too high, the water velocity is
too low. Adjust as follows:
1 Check for flow restrictions. Check for debris in strainers
2 Check diameter and equivalent length of the piping
between the storage tank and hot water heater.
3 Be sure all valves are open between the hot water
heater and the storage tank. Ensure that all ball valves
are fully ported.
4 Check the pump to be sure it is running properly and
that the pump motor is running in the proper direction.
5 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. If maximum
equivalent length for the specified pipe diameter is
exceeded, larger diameter pipe may have to be
installed to achieve correct flow and temperature rise.
6 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. 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 heater to the storage
tank to achieve the proper temperature rise.
2 Sustained high water velocity and low temperature rise
may result in pitting or erosion of the stainless steel
tubes in the heat exchangers. This is a nonwarrantable failure. Temperature rise must be properly
adjusted to achieve the specified flow rate.
62
The required temperature rise and the recommended pump
size are based on the heating of potable water with normal
hardness within a typical range of 7.5 to 17.0 grains per
gallon. Consult the factory when heating potable water
exceeding these specifications. Damage to the heat
exchanger as a result of scaling or corrosive water
conditions in non-warrantable.
CAUTION
Temperature rise cannot be adjusted when the burner is
firing at less than 100% of input rate.
11.12
WATER HEATERS
The manufacturer recommends the use of a properly sized
thermostatic mixing valve to supply domestic hot water at
temperatures less than 140°F (60°C). Storing the water at a
higher temperature and thermostatically mixing the water
will decrease the size of the storage tank and increase the
available quantity of mixed hot water.
•
Piping components connected to the water heater for a
space heating application shall be suitable for use with
potable water.
•
Toxic chemicals, used for boiler treatment, shall not be
introduced into the potable water used for space
heating
•
A water heater which will be used to supply potable
water shall not be connected to any heating system or
component(s) previously used with a non-potable
water heating appliance
•
When a system requires water for space heating at
temperatures higher than required for other uses, a
means such as a mixing valve shall be installed to
temper the water for those uses in order to reduce
scald hazard potential.
CAUTION
Adequate care MUST be taken to prevent potential scald
injury when storing water at 140°F (60°C) and hotter.
WARNING
Should overheating occur or the gas supply fail to shut off,
do not turn off or disconnect the electrical supply to the
pump, instead, shut off the gas supply at a location
external to the appliance.
PART 12
EXPLODED VIEW
17
16
14
15
1
13
2
3
19
20
12
18
11
10
4
5
8
9
6
7
63
56
23
24
26
25
22
21
35
34
33
32
31
30
27
29
28
43
36
37
42
40
64
38
39
66
65
64
67
63
62
44
34
60
27
Red Silicone Gasket
Burner
59
White-Graphite Ceramic Gasket
61
Graphite Gasket
59
White Ceramic Gasket (Only required if heat exchanger surface
is rough or uneven.
1
Heat Exchanger
65
Heat Exchanger
(Incl. “V” Baffles)
X
X
15-2006
15-2007
X
15-2008
X
15-2009
X
15-2010
15-2011
X
15-2012
90-14005
X
X
X
90-9100-04
X
X
90-15209
X
X
90-14011
X
X
90-14013
X
90-15209
2
X
X
Wrap Assembly
90-15210
X
90-14017
X
90-15099
X
90-2010
X
X
90-2011
X
90-2012
14-1025
X
X
X
X
X
X
X
X
14-1073
5
X
X
X
X
X
X
X
X
Base Support
14-1018
X
X
14-1071
14-1024
7
Condensate Bin
Assembly
X
X
X
X
X
X
X
X
X
X
X
8
Base Panel
X
X
X
X
X
14-5206A
14-6007A
X
X
X
X
X
X
X
X
X
X
X
X
10
14-5212A
14-5312
66
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
14-5207A
14-6010A
X
X
X
X
X
X
X
14-5307
Base Support Stiffener
Under Leg
X
X
14-5306
Base Support Leg
X
X
14-1017
X
X
X
14-1010
14-5012A
9
5000
X
4500
X
3000
X
4000
1
2500
X
2000
X
15-2005
3500
15-2004
1800
X
1400
X
1600
15-2003
1200
X
1000
X
800
15-2002
600
X
500
X
400
15-2001
350
Part ID
300
Part Name
ALL
DynaForce Models
Ref
#
X
X
X
X
X
X
X
X
X
14-1012
14-1004
X
14-1027
X
14-1006
X
14-1064
14-1014
12
Bezel
13
Control Box
14
Condensate Neutralizer
Box
15
16
17
18
Side Panel Left
Top Cover
Back Panel
Side Panel Right
X
14-1068
90-10015
90-10011
90-10019
90-10009
90-10002
90-10001
90-10003
14-1030
14-1005
90-10030
14-1047
14-1043
14-1057
14-1022
14-1061
14-8085
14-1008
14-1028
14-1015
14-1065
14-1049
14-1069
14-6030A
14-5228A
14-5329-45-50
14-5329-60
14-1046
14-1042
14-1056
14-1021
14-1060
14-1011
14-1121
14-1000
14-1026
14-1002
14-8088
14-8089
14-8090
14-1048
14-1044
14-1058
14-1023
14-1062
14-8084
14-1007
14-1029
14-1016
14-1066
14-1050
14-1070
5000
X
4500
4000
3000
2500
X
2000
X
3500
Front Panel
X
X
14-1059
11
1800
14-1020
1600
X
1400
X
1200
X
1000
X
14-1055
800
14-1041
600
X
500
X
400
14-1045
350
Part ID
300
DynaForce Models
Part Name
ALL
Ref
#
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
67
5000
X
66-5005
X
X
X
X
X
X
X
X
X
X
VGG10.404U
Gas Valve Body
4500
13-0026
13-0027
22
4000
X
3500
X
3000
X
2500
X
2000
1800
X
1600
X
1400
X
X
VMU300A1046
Venturi/ Air Gas Inlet
Adapter
X
X
45900450-010
21
1200
X
1000
X
800
X
600
On/Off Switch
500
20
S7999D1006 (7”
screen)
C6000ALBBXCHLI
400
DynaForce Display
350
19
Part ID
300
Part Name
ALL
DynaForce Models
Ref
#
X
X
X
VGG10.504U
(Requires 2)
VGG10.654U
VR8615B1044
X
X
X
V8730C1015
X
V8730C1023
X
X
Gas Valve
23
V8730C1031
X
X
V4734C1002
X
X
X
SKP55
X
V4295A1049
X
X
X
X
X
X
X
X
X
Gas Valve Solenoid
24
V4295A1056
Gas Valve Regulator
SKP 25
X
X
X
X
25
Gas Valve Regulator Body
VGG10.404U
X
X
X
X
26
Low gas Switch
C6097A
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
DR-300-BRN
X
X
DR-400-BRN
X
X
DF-500-BRN
X
X
DR-1000-BRN
27
Main Burner
X
X
DF-1200-BRN
X
DF-1500-BRN
X
DF-1750-BRN
X
X
DF-2000-BRN
X
DF-3000-BRN
X
DR-4000-BRN
271RSHORT
28
Hot Surface Igniter
29
Flame Rod
30
31
32
X
X
X
X
271R
PSE-CH5
X
Sight Glass Holder
14-0049
X
View Port Glass
TG-94010-040
X
Igniter Mounting
Flange
13-5335
X
14-5560
13-5052
33
Fan Flange
13-5330
13-5331
13-5332
68
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
5000
X
4500
X
4000
X
3500
X
3000
1800
X
2500
1600
X
2000
1400
X
1200
X
X
G1G170
X
150232-07
34
1000
X
800
X
600
X
55667.14002
500
400
150563-00
350
Part ID
300
DynaForce Models
Part Name
ALL
Ref
#
Combustion Fan
AF9
AF10
AF12
AF15
X
1 HP, D393
X
X
X
X
1 1/2 HP, D394
35
Electrical Motor
X
X
2 HP, D395
X
3 HP, D396
X
5 HP, C204B
36
Control Box Plate
14-1005-03
X
37
Honeywell SOLA
R7910A1001
X
38
Relay(s)
1649341-8
X
HCT-01J2BB07
X
ETISO-V
X
39
40
42
115/24Vac
Transformer
0-10Vdc Converter (if
equipped)
24V Contactor
Variable Frequency
Drive
43
Variable Frequency
Drive (460V/60/3)
T92P7A22-24
SM005S
SM010S
SM015S
T217
T228
T234
T235
T237
T238
14-5560
11-0015
SMD 8021205256
X
X
44
45
46
Transition Arm
Pilot Tube
Blocked Flue Switch
47
Air Proving Switch
SML 8021210034
Intake Adapter
10”, GZ-GFIF-2000-CH
& GAA1A-1100-CH
10”, GZ-GFIF-2000-CH
& GAA1A-1500-CH
12”, GFIF-3000-CH &
GAA1A-3000-CH
14”, GFIF-5000-CH &
GAA1A-5000-CH
48
6”, DM-14-0117
8”, DM-14-0118
49
Rear Fan Intake Filter
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
10”, DF-14-0119
X
X
X
12”, DF-14-0120
X
X
X
X
14”, DF-14-0121
AF9
AF10
50
Fan Intake Filter
AF12
X
X
X
X
X
X
X
X
X
X
AF15
X
69
Differential Gas Switch
C6097B
X
Water High Limit
L6008A1242 (Auto
Reset)
L4008E1313 (Manual
Reset)
57
58
Water Pressure Switch
HB26A218L
Graphite-Backed White
Ceramic Gasket(1)
X
X
X
X
X
X
X
X
X
X
X
3000
X
33-5237
33-5238
X
X
X
X
X
X
X
62
63
64
65
66
67
68
69
70
71
72
73
74
75
Part
Stainless to Plastic
Adapter
X
X
X
Wire Harness
1” White Ceramic Gasket
(Baffles, primary wrap)
2” White Ceramic Gaske
(Stiffener, primary ring)
Black Viton Solid Gasket
(Secondary heat
exchanger)
Black Viton Foam Gasket
(Secondary wrap)
Snap Action Thermostat
Manual Shutoff Kit
Not shown in exploded view
Recommended spare parts
70
X
33-0057
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
16-0016
33-0038
X
X
X
X
X
X
X
X
33-0058
X
X
X
16-0015
33-0037
X
X
X
X
X
X
4” to 4”, 300142
X
X
X
5” to 6”, 300143
6” to 6”, 300144
X
X
7” to 8”, 300145
X
X
X
X
X
X
X
X
X
EKA-114-58
50002653-001
X
X
X
33-5239
33-5237
33-5238
33-5240
8” to 8”, 300146
77-0038
X
X
33-5224
33-5230
DR600-800 1/8” Red
Gasket for Mixing
Chamber
Air Inlet to Fan Adapter
RG175 Fan Gasket
DR300-400 1/8” Red
Gasket
Air Inlet to Fan Adapter
RG148 Fan Gasket
X
X
33-5227
Graphite Gasket (1)
X
X
33-5218
61
X
X
33-5221
Red Silicone Gasket (1)
X
X
33-5240
60
X
X
33-5239
59
X
5000
56
4500
X
4000
X
14-0263
3500
NTC-Sensor-003
Electrical Box
2500
Flue Sensor
55
2000
54
1800
X
1600
NTC-Sensor-004
1400
X
Outdoor Sensor
1200
Tekmar 070/071
53
1000
X
800
X
50001464-005/B
600
198799Z/U
Outlet Sensor
500
Inlet Sensor
52
400
51
350
Part ID
300
Part Name
ALL
DynaForce Models
Ref
#
X
X
X
X
X
X
PART 13
ELECTRICAL DIAGRAMS
71
72
73
AIR INLET DAMPER
8
7
6
5
4
3
2
1
+
IGN
24V
COM
-
G
G
-
+
}
}
115V To/From
Pump
Contact
PUMP B
}
L1
L2
L3
N
Field Supply
115/230V
Call
REMOTE
OP.
4-20mA
(2-10VDC)
STATUS
ON/OFF
FLAME
FAILURE
}
}
}
DynaForce, Boiler #1
CASCADE
OUTDR/
SYS
BMS
+
-
G
G
-
+
}
}
DynaForce, Boiler #2
CASCADE
C
99-5095-2
1
1
00
BK - BLACK
BL - BLUE
BR- BROWN
P - PURPLE
W - WHITE
R - RED
To Next Boiler
DynaForce Junction Box Layout
OUTDR/
SYS
BMS
74
Y
O
BR
Y
BK
AIR INLET
DAMPER
CONNECTION
MOTOR
POWER OPEN
POWER CLOSED
AIR INLET
DAMPER
Y - TO TERMINAL 1
(COMMON RETURN)
BL - PROCEEDS TO IGNITION
CONTROL BOX TERMINALS
R - FROM TERMINAL 8
(CONSTANT POWER)
BK - FROM TERMINAL 6
(CALL FOR HEAT)
EFFIKAL AIR INLET DAMPER SCHEMATIC
BL
BK
R
BK - BLACK
BL - BLUE
BR - BROWN
O - ORANGE
P - PURPLE
R - RED
W - WHITE
Y - YELLOW
R
R
R
BL
Y
Y
R
Y
MOTOR
END
SWITCH
AIR INLET
DAMPER
CONNECTION
KC
29/04/2011
C
93-0195-17
1
1
POWER OPEN
SPRING RETURN
CLOSED
AIR INLET
DAMPER
Spring Return Air Inlet Damper
Connection Detail with
Local/Remote Switch
FAMCO AIR INLET DAMPERSCHEMATIC
Y
BK
Y - TO TERMINAL 1
(COMMON RETURN)
00
BL - PROCEEDS TO IGNITION
CONTROL BOX TERMINALS
R - FROM TERMINAL 8
(CONSTANT POWER)
BK - FROM TERMINAL 6
(CALL FOR HEAT)
75
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 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. The repaired or
replacement part will be warranted for only the unexpired
portion of the original warranty. This limited warranty does
not cover failures or malfunctions resulting from: (1) Failure
to properly install, operate or maintain the equipment in
accordance with Camus’ manual; (2) Abuse, alteration,
accident, fire, flood, foundation problems and the like; (3)
Sediment or lime build-up, freezing, or other conditions
causing inadequate water circulation; (4) Pitting and
erosion caused by high water velocity; (5) Failure of
connected systems devices, such as pump or controller;
(6) Use of non-factory authorized accessories or other
components in conjunction with the system; (7) failing to
eliminate air from, or replenish water in, the connected
water system; (8) Chemical contamination of combustion
air or use of chemical additives to water; (9) Production of
noise, odours, discolouration or rusty water; (10) Damage
to surrounds or property caused by leakage or malfunction;
(11) All labour costs associated with the replacement
and/or repair of the unit; (12) Any failed component of the
hydronic system not manufactured as part of the boiler.
Any limited warranty, including the warranty of
merchantability imposed on the sale of the boiler under the
laws of the state or province of sale are limited in duration
to one year from date of original installation.
STATE LAW & LIMITED WARRANTY
Some states or provinces do not allow:
a. Limitations on how long an implied warranty lasts
b. Limitations on incidental or consequential damages.
The listed limitations may or may not apply to you. This
warranty gives you specific legal rights, and you may also
have other rights which may vary from state to state and
province to province.
CONDITIONS
We will not:
a) Repair or replace any boiler, or part, subject to
conditions outlined in ‘This Limited Warranty Does
Not Cover’
b) Reimburse any costs associated with repair
and/or replacement
c) Replace and/or repair any boiler without complete
model number/serial number
d) Replace any boiler without prior receipt of actual
rating plate from the appliance.
HOW TO MAKE A CLAIM
Any claim under this warranty shall be made directly to
Camus Hydronics Limited Canadian Head Office
HEAT EXCHANGER
SERVICE LABOR RESPONSIBILITY
If within TEN years after initial installation of the appliance,
a heat exchanger shall prove upon examination by Camus
to be defective in material or workmanship, Camus will
exchange or repair such part or portion. Heat Exchanger
shall be warranted for (20) years from date of installation
against “Thermal Shock” (excluded, however, if caused by
appliance operation at large changes exceeding 150ºF
between the water temperature at inlet and appliance
o
temperature or operating at temperatures exceeding 200 F
o
(DRH) , 210 F (DRW).
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.
BURNER
DISCLAIMERS
Camus shall not be responsible for any water damage.
Provisions should be made 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
If within FIVE years after initial installation of the appliance
a burner shall prove upon examination by Camus to be
defective in material or workmanship, Camus will exchange
or repair such part or portion.
Name of
Dealer
ANY OTHER PART
Address
If any other part fails within one (1) year after installation,
or eighteen (18) months from date of factory shipment
based on Camus' records, whichever comes first. Camus
will furnish a replacement or repair that part. Replacement
parts will be shipped f.o.b. our factory.
Model No.
Serial #:
Date of
Installation:
Date of Initial
Operation:
6226 Netherhart Road, Mississauga, Ontario, L5T 1B7, CANADA
DURATION OF LIMITED WARRANTY
76
CAMUS Hydronics is a
manufacturer
of
replacement parts for
most copper finned
water heaters
and
heating
boilers as well
as a
The
CAMUS
CERTIFIED!
Seal
assures
you
that
Reliability, Efficiency &
serviceability are built
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 CAMUS
Hydronics Limited, call
905-696-7800 today.
CAMUS HYDRONICS LTD.
6226 Netherhart Road, Mississauga, Ontario L5T 1B7
TEL: 905·696·7800 FAX: 905·696·8801
www.camus-hydronics.com
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