Camus Hydronics 102 Wartungshandbuch

6226 Netherhart Road, Mississauga, Ontario, L5T 1B7 99-0171 Rev. 0.4 INSTALLATION OPERATION AND SERVICE MANUAL GAS FIRED COMMERCIAL CONDENSING S

41. 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

5 1.10 INSTALLATION PROCEDURE AND LOCATION OF UNIT Install this appliance in a clean, dry location with adequate air supply. • Do not locate this

6 Table 3: Appliance Dimensions and Specifications DynaForce Dimensions Model Dim. "A" (in.)

7 PART 2 VENTING It is extremely important to follow these venting instructions carefully. Failure to do so can cause severe personal injur

82.1.3 APPROVED VENTING MATERIALS Exhaust Vent for Use for DynaForce Category ll or lV Installations 1 Manufactured prefabricated UL/ UL

9 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)

102.1.11 DRAIN TEE Figure 7: Drain “T” and Neutralizer Cartridge Installation A drain line must be connected to the boiler condensate drain and to

11 Air Intake 2.3 OUTDOOR VENTING The DynaForce windproof cabinet protects the unit from weather, when fitted with the factory supplied air

12PART 3 GAS CONNECTION Verify that the appliance is supplied with the type of gas specified on the rating plate. Consult factory for ins

13 Low fire adjustment screw Located under cap (Turning clockwise increases gas flow) Table 7: Gas Pressures at Inlet to Appliance PROPANE NATURAL

143.5 DIFFERENTIAL AIR PRESSURE (DR2000 – DR5000) • The DynaForce 2000 – 5000 operates on the principle of differential pressures. Operation

15 3.7.1 Regulated Gas Supply Pressures for DynaForce Boilers & Water Heaters A stable gas supply pressure is important to avoid rough starts w

163.10 VENTING OF GAS VALVES AND PRESSURE SWITCHES The optional gas pressure switches may be provided with threaded termination points to b

17 4.1 FREEZE PROTECTION ∗ Appliance installations are not recommended outdoors in areas where danger of freezing exists unless precautions are ta

184.6 LOW WATER TEMPERATURE SYSTEMS In applications where the heating system requires supply water temperatures below 110°F, connections may be ma

19 Figure 20: Low Water Cut Off Electrical Connections (ITT) 4.10 RELIEF VALVE This appliance is supplied with a relief valve sized in a

20PART 5 ELECTRICAL & CONTROLS IT IS EXTREMELY IMPORTANT THAT THIS UNIT BE PROPERLY GROUNDED! 5.1 ELECTRICAL CONECTIONS Table 10: Minimum Pow

21 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

225.8 DYNAFORCE CONTROLLER Table 11: Connector Description Connector Connector Description J1 Flame Sensor, Ground Rod J2 Fan Modulation (DR300 – 1

23 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 24

Table of Contents PART 1 GENERAL INFORMATION ...

24Levels of Access Two levels of access to simplify the use of the boiler. User – Access to general boiler and display settings and adjustm

25 Sequence of Operation Flow Switch = Flow Switch, Low water cutoff (if equipped), Water Pressure Switch (30 PSI) Gas Pressure Switch = Low gas

26DRH Modulation: Boiler Inlet, Boiler Fixed Setpoint Operation (Standalone) Description Electrical Connection(s) Programming Instructions • Boil

27 Modulation: Boiler Inlet, Outdoor Reset Operation (Standalone) Description Electrical Connection(s) Programming Instructions • Boiler operate

28 Modulation: System Sensor, Outdoor Reset Operation (Standalone) NOTE: Outdoor Reset Module (PN: 50022037-001) and outdoor sensor (PN: C7089U100

29 13) Press [Show Line] to confirm reset curve 14) Press Sensor Configuration 15) Selet S5 (J8-11) sensor: 10K NTC single non-safety 16) Select Out

304-20mA/ 2-10Vdc Firing Rate Operation (Standalone) Description Electrical Connection(s) Programming Instructions • Boiler operates with variable

31 DRW Modulation: Fixed Setpoint Operation (Standalone) Description Electrical Connection(s) Programming Instructions • Boiler operates at a fixed

3213) Place right hand toggle switch setting to REMOTE for remote operation (if required)

33 DR(H,W) Lead lag Operation Master Boiler Description Electrical Connection(s) Programming Instructions • Master boiler lead lag setup 1) Place

4.2 WARNING REGARDING CHILLED WATER AND HEATING COIL SYSTEMS ... 17 4.3 INLET AND OUTLET CONNECTIO

34 14) Select Lead Lag Slave Configuration 15) Select Slave enabled = Enable slave for built-in Lead Lag master The following steps are performed a

35 5) Select Lead Lag Slave Configuration 6) Select Slave Enabled = Enable slave for built-in Lead Lag master The following steps are performed

36Master Boiler, System Sensor Description Electrical Connection(s) Programming Instructions • Master boiler system sensor configuration 1) Pre

37 Master Boiler 8) Press and , enter “sola” 9) Press [Lead Lag Master Configuration] 10) Press [Advanced Settings >] 11) Press the to

38Rotation schedule adjustment Description Electrical Connection(s) Programming Instructions • Standard rotation schedule is based on equalizing ru

39 Adjust staging of boilers Description Electrical Connection(s) Programming Instructions • Upon a call for heat the lead boiler will fire to the

406.2 CONFIGURE MENU Figure 26: Configure Menu 6.2.1 System Identification & Access Menu Group Selection Parameter Description System Iden

41 6.2.3 Statistics Configuration Menu Group Selection Sub-Menu Group Selection Parameter Selection Description Boiler pump cycles Displays th

426.3 LEAD LAG SETUP The following components are needed for a Lead Lag setup 1) 10k System Sensor Turn off all the boilers before beginning the

43 6.4 LOCAL/REMOTE SWITCH The right hand local remote switch mounted inside the control box is designed to generate a call for heat either relying

10.5 BURNER MAINTENANCE ...

446.6 VARIABLE FREQUENCY DRIVE (DR1200 - 5000) The variable frequency drive (VFD) has a factory set security code which has to be entered before an

45 7.3 COMBUSTION AIR FAN DR300 – 1000 Uses a modulating air fan to provide combustible air/gas mix to the burner and push the products of combusti

468.3 GAS VALVE ADJUSTMENT PROCEDURE Table 14: Combustion Values DynaForce Combustion Values Natural Gas Propane CO2 CO CO2 CO Max. Fire 8.5%

47 Locate the input adjustment screw on the top side of the gas valve. Increase CO2 Decrease CO2 High Fire Adjustment Counter-Clock Wise Cloc

48 Step 1: Fully open inline metering valve (counter- clockwise) Step 2: Close inline metering valve to preset level Step 3: Above table shows initi

49 PART 9 TROUBLESHOOTING COMPONENT FAILURE MODE ANALYSIS Incoming Power • Two wires interchanged • No effect on safety • Live and Neutral wire

50COMPONENT FAILURE MODE ANALYSIS Flame Disappears During a Run Cycle • The DynaForce boiler was running and flame signal suddenly disappeared.

51 SYMPTOM FAILURE MODE ANALYSIS Manual Reset High Limit Trips (if equipped) • Manual Reset Safety High Limit tripped, outlet temperature in exc

52SYMPTOM FAILURE MODE ANALYSIS Flame Detection is out of Sync • Flame detection is present when no visible signs of a flame exist • Lockout: 105, 1

53 Alert 291: Abnormal Recycle: Flame was not on at end of ignition Alert 294: Abnormal Recycle: Flame was lost during Run Alert 324: Abnormal Recyc

54Hold 63: LCI OFF (Load Control Input) Hold 67: ILK OFF (High Limit, Gas Pressure Switch, Air Switch) Alert 303: Abnormal Recycle: ILK off during d

55 Alert 354: Abnormal Recycle Delta-T limit This safety was breached as the inlet and outlet temperature difference exceeded 40oF. This is done to

56PART 10 MAINTANANCE CAUTION It is important that all gas appliances to be serviced by a Camus trained service technician. It is in your own inter

57 10.4.1 CONDENSATE VOLUME There are several factors effecting amount of condensation created by the appliance however for rough approximation use

58 10.6 CHANGING THE HOT SURFACE IGNITER • The hot surface igniter is to be checked at least after every 4000 hours of operation and more f

59 • Caution - A mechanical room operating under a negative pressure may experience a downdraft in the flue of an appliance that is not firi

60WARNING The condensate collection box must be filled with water to prevent flue gas emissions from escaping during boiler operation. 11.4

61 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

6211.10 WATER VELOCITY CONTROL To ensure proper velocity through the heat exchanger(s), it is necessary to select the proper pump. Temperature rise

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

1 PART 1 GENERAL INFORMATION 1.1 INTRODUCTION The DynaForce is a condensing fan assisted appliance based on a push through design whi

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

65 60 59 61 59 1 34 27 44 Red Silicone Gasket White-Graphite Ceramic Gasket White Ceramic Gasket (Only required if heat exchanger surface is rough

66 Ref # Part Name Part ID DynaForce Models ALL 300 350 400 500 600 800 1000 1200 1400 1600 1800 2000 2500 3000 3500 4000 4500 5000 1 Heat Exchan

67 Ref # Part Name Part ID DynaForce Models ALL 300 350 400 500 600 800 1000 1200 1400 1600 1800 2000 2500 3000 3500 4000 4500 5000 11 Front Panel

68Ref # Part Name Part ID DynaForce Models ALL 300 350 400 500 600 800 1000 1200 1400 1600 1800 2000 2500 3000 3500 4000 4500 5000 19 DynaForce Dis

69 Ref # Part Name Part ID DynaForce Models ALL 300 350 400 500 600 800 1000 1200 1400 1600 1800 2000 2500 3000 3500 4000 4500 5000 34 Combustion F

70Ref # Part Name Part ID DynaForce Models ALL 300 350 400 500 600 800 1000 1200 1400 1600 1800 2000 2500 3000 3500 4000 4500 5000 51 Inlet Sensor

71 PART 13 ELECTRICAL DIAGRAMS

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73 1 1 C}}STATUSON/OFFFLAMEFAILUREField Supply115/230V115V To/FromPumpContactREMOTEOP.DynaForce Junction Box Layout99-5095-200}4-20mABK - BLACKBL -

2DR1200 – DR5000: The local thermostat energizes the motor stop/start relay which closes the initiate contacts to the variable frequency drive (VFD)

7493-0195-171 1 00CKCBKYBLRBK - BLACKBL - BLUEBR - BROWNO - ORANGEP - PURPLER - REDW - WHITEY - YELLOWAIR INLETDAMPERPOWER OPENPOWER CLOSEDYOBKBRR -

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76CONDENSING BOILER LIMITED WARRANTY GENERAL Camus Hydronics Limited (“Camus”) extends the following LIMITED WARRANTY to the owner of this ap

CAMUS Hydronics is a manufacturer of replacement parts for most copper finned The CAMUS CERTIFIED! Seal assures you that Reliability, Eff

3 • UNDER NO CIRCUMSTANCES may flammable materials such as gasoline or paint thinner be used or stored in the vicinity of this appliance, vent-