Camus Hydronics DFH/W1100 Installation, Operation And Service Manual - page 21

Manual is about: DYNAFLAME SERIES GAS FIRED COMMERCIAL COPPER TUBE AND STAINLESS STEEL BOILERS

Summary of DFH/W1100

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    6226 netherhart road, mississauga, ontario, l5t 1b7 99-0050 rev. 6.7 installation operation and service manual dynaflame® series gas fired commercial copper tube and stainless steel boilers non-condensing models; dfh/w500, 750, 1100, 1200, 1500, 1750, 2000, 2500, 3000, 3500, 4000, 4500, 4504, 5000, ...

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    Table of contents part 1 general information ......................................................................................................................... 1 1.1 overview .........................................................................................................................

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    3.9 gas train and controls ................................................................................................................... 16 3.10 venting of gas valves and pressure switches ............................................................................ 17 3.11 burner ................

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    8.2 checking the construction ............................................................................................................ 49 8.3 fire testing ........................................................................................................................................ 49 8...

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    1 part 1 general information 1.1 overview the dynaflame® is available in the following body styles: • 23” x 27” footprint, dynaflame® as non-condensing 85% efficient, available in models 500, 750, 1100, 1200. As near condensing (dfx) 88% efficient dfx, available in models 501, 751, 1101, 1201. As fu...

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    2 1.4 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 ...

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    3 1.6.1 ignition process 1 the ignition module supplies voltage to the air/gas ratio control valve. 2 air/gas ratio control valve senses the pressure differential between the combustion air fan outlet and the vent outlet and supplies gas to the orifice and into the fan inlet to pre-mix with air. 3 t...

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    4 1.8 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 pr...

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    5 note: experience has shown that improper installation or system design, rather than faulty equipment, is the cause of most operating problems 1.10 boiler room operating condition • due to low jacket losses from the appliance, temperatures in a typical boiler room may drop significantly; supplement...

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    6 1.12 installation procedure and location of unit install this appliance in a clean, dry location with adequate air supply and close to a good vent connection. • do not locate this appliance in an area where it will be subject to freezing unless precautions are taken. Radiant losses from the dynafl...

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    7 table 3: appliance dimensions and specifications [in.] model width "a" depth "b" height "c" water conn. "d" air inlet "e" flue height "f" gas height "g" "h" "i" "j" "k" "l" "m" "n" air inlet dia. "w" water conn. Prim. Water conn. Sec. Grooved (optional) gas conn. [npt] 500 25 27 45 5/8 27 37 1/4 1...

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    8 part 2 air supply & 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. Foam core pipe, pvc, cpvc are not to be used in any part of the venting system. 2.1 general venting guide f...

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    9 equivalent feet (30.5 m) in length. Depending on diameter and centreline radius subtract from 7 to 19 feet per 90 ° elbow using published data. Subtract half this value for each 45° elbow. • the flue may terminate either vertically at the roof top or horizontally on a thruwall. See the information...

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    10 2.1.7 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 scr...

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    11 2.1.13 drain tee figure 7: drain “t” and neutralizer cartridge installation a drain tee must be installed in the condensingvent pipe to collect and dispose of any condensate that may occur in the vent system. The drain tee should be installed at the point where the flue turns vertical for a roof ...

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    12 2.2.1 air required for combustion and ventilation provisions for combustion and ventilation air are to be in accordance with the section for “air for combustion and ventilation”, of the national fuel gas code, ansi z223.1/nfpa 54, or clause 8.2, 8.3, 8.4 of “natural gas and propane installation c...

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    13 2.4.2 location of a thruwall vent termination • the vent cap shall terminate at least 3 feet (1m) above any forced air inlet within 10 feet (3m) horizontally. • the vent cap must not terminate below a forced air intake at any distance. • do not terminate the vent in a window well, stairwell, alco...

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    14 table 6: recommended gas pipe size single appliance installation (for distance from natural gas meter or propane second stage regulator) input btu/ hr x 1000 0 – 100 ft 101 – 200 ft 201 – 300 ft nat. L.P. Nat. L.P. Nat. L.P. 500 1 ½“ 1 ¼“ 2” 1 ½” 2” 1 ½” 750 2” 1 ½“ 2” 1 ½“ 2 ½” 2” 1,100 2” 1 ½“ ...

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    15 figure 9: df2000-60041:1 air/gas ratio control valve figure 10: dr3500 – 5000 skp25 regulating gas valve actuator &ssov 3.5 differential air pressure (df2000 -6004) • the dynaflame® operates on the principle of differential pressures. Operation of the fan generates a signal which is matched on th...

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    16 • 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 sho...

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    17 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...

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    18 4.1 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 prote...

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    19 return water temperatures required for dynaflame® boilers & water heaters minimum acceptable return water temperatures are determined by the category of the heater. This is true for all manufacturers. A category i machine like the non-condensing version of the dynaflame® 85% efficient model can b...

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    20 figure 18: typical instantaneous water heating system table 8: flow and pressure drop at a given temperature rise (copper, copper nickel heat exchanger) model heat exchanger water content (usg) 30°f (16.7 °c) temp rise 35°f (19.4°c) temp rise usgpm (min. Flow) ∆ p ft. Usgpm. (min. Flow) ∆ p ft. D...

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    21 when supplied with the chrm, the dynaflame® is 95% efficient (category ii or iv appliance) which requires the use of a special venting system fabricated from al29-4c or equivalent material. Only venting components listed by a nationally recognized testing agency may be used. This appliance may be...

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    22 4.11 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 cut-offs are available as ...

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    23 the operation of the circulating pump is controlled by the sola temperature control .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...

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    24 model voltage requirement maximum over current protection full load amps [amperes] [amperes] 500 - 1200 460vac, 60hz, 3 phase 10 0.9 1500 - 2000 1.4 2500 1.8 3000 2.1 3500 3.5 4000 - 5004 5.3 6004 6.8 the combustion air fan motor operates on 230 vac, 3 phase, 60 hz. This three phase voltage is ge...

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    25 5.7 dynaflame® sola df500 – df2500 models utilize a hot surface ignition system. Df3000 – df6000 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 flam...

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    26 figure 24: lockout condition to eliminate the lockout error, 1) press the red bar, indicating a lockout condition 2) press the [lockouts] button figure 25: lockout history 3) press [clear lockout] table 14: alert/hold codes # description 29 burner switch turned off 30 burner switch turned on 47 i...

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    27 part 6 sola control panel 6.1 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 two (2) slotted screws and swinging opening the door. The diagnostic information ce...

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    28 sequence of operation flow switch = flow switch, low water cutoff (if equipped) gas pressure switch = low gas pressure switch (4.5” w.C., n/o), high gas pressure swtich (14” w.C., n/c) air pressure switch = blocked flue switch (n/c), air proving switch (n/o).

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    29 dfh modulation: boiler inlet, boiler fixed setpoint operation (standalone) description electrical connection(s) programming instructions • boiler operates at a fixed setpoint • modulates on boiler inlet sensor (default) • heat demand is generated when remote operator is closed. 1) press and 2) pr...

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    30 modulation: boiler inlet, outdoor reset operation (standalone) description electrical connection(s) programming instructions • boiler operates with variable setpoint determind by outdoor reset curve • modulates on inlet sensor (default) • heat demand is generated when remote operator is closed. 1...

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    31 modulation: system sensor, outdoor reset operation (standalone) note: outdoor reset module (pn: w8735s1000) required description electrical connection(s) programming instructions • boiler operates with variable setpoint determind by outdoor reset curve • modulates on system sensor • heat demand i...

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    32 4-20ma/ 0-10vdc setpoint operation (standalone, lead lag) description electrical connection(s) programming instructions • boiler operates with variable setpoint determined by 4- 20ma incoming signal • modulates on boiler inlet sensor (default) • heat demand is generated when remote operator is cl...

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    33 4-20ma/ 0-10vdc firing rate operation (standalone, lead lag) description electrical connection(s) programming instructions • boiler operates with variable setpoint determined by 4- 20ma incoming signal • modulates on header sensor • heat demand is generated when remote operator is closed and 4-20...

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    34 dfw modulation: boiler inlet, fixed setpoint operation (standalone, lead lag) description electrical connection(s) programming instructions • boiler operates at a fixed dhw setpoint • modulates on boiler inlet sensor (default) • heat demand is generated when remote operator is closed. Dhw sensor/...

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    35.

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    36 df(h,w) lead lag operation master boiler description electrical connection(s) programming instructions • master boiler lead lag setup 1) press and 2) select system identification & access 3) verify mb1 modbus address = 1 4) verify mb2 modbus address = 1 5) select lead lag master configuration 6) ...

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    37 the following steps are performed at the factory and verifying on site will be sufficient: 15) select pump configuration 16) press [advanced options >>] 17) press the to arrive at central heat pump or dhw pump 18) on options: local burner demand 19) on options: local lead lag service active 20) f...

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    38 the following steps are performed at the factory and verifying on site will be sufficient: 6) select pump configuration 7) press [advanced options >>] 8) press the to arrive at central heat pump or dhw pump 9) on options: local burner demand 10) on options: local lead lag service active 11) force...

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    39 outdoor sensor connected to slave boiler 2 (drh only) description electrical connection(s) programming instructions • slave boiler outdoor sensor configuration • when done correctly, the outdoor temperature will be shown on the master boiler slave boiler 1) press and 2) press [sensor configuratio...

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    40 17) press [show line] to confirm reset curve 18) press the to arrive at warm weather shutdown 19) select enable = shutdown after demand ends.

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    41 rotation schedule adjustment description electrical connection(s) programming instructions • 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) 1) press and 2) press [lead lag master configuration] 3) p...

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    42 adjust staging of boilers description electrical connection(s) programming instructions • upon a call for heat the lead boiler will fire up to the specified base load rate (80%). If the temperature is not within error threshold (5 o f) of setpoint after interstage delay (2 minutes) a lag boiler w...

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    43 6.2 configure menu figure 28: configure menu 6.2.1 system identification & access menu group selection parameter description s ys te m i d e n ti fi ca ti o n & a cc e ss product type commercial hydronic boiler os number part number of sola controller software version software version date code: ...

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    44 6.2.3 statistics configuration menu group selection sub- menu group selection parameter selection description boiler pump cycles displays the number of cycles the boiler pump has been activated burner cycles displays the number of cycles the burner has been activated burner run time displays burn...

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    45 6.3 lead lag setup the following components are needed for a lead lag setup 1) 10k Ω system sensor turn off all the boilers before beginning the setup process. To setup the dynaflame® lead lag system follow the instructions: system sensor insert the supplied 10k Ω system sensor into the building ...

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    46 6.4 lead lag setup for up to 12 appliances honeywell sola can only support up to 8 boiler in a single lead lag network, to sequence a second network of up to 12 boilers in total this will be activated through pump c contact of boiler #8. Pump c is activated on a time delay algorithm where the tim...

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    47 6.7 variable frequency drive 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 ...

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    48 part 7 components 7.1 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 inst...

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    49 part 8 field startup procedure 8.1 checking the installation • inspect the connections for water, gas and electricity. • confirm that water is being pumped toward the heat exchanger inlet. Never pump away from the exchanger since this will result in a low-pressure zone, which will allow localized...

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    50 figure 34: df 500 – 1750 gas valve to adjust the high-fire setting (df 500 – 1750) use the dynaflame® control panel: 1) press [diagnostics] button 2) press [diagnostic tests] button 3) move the firing rate slider to maximum firing rate as indicated by the test sticker 4) press [start test] to ope...

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    51 to adjust the low-fire setting (df 2000 – 6004) figure 37: skp 55 gas valve 1 adjustment of low fire bias 2 connection for air pressure (+) sensing line 3 connection for the air pressure (-) sensing line 4 connection for the gas pressure (-) sensing line 5 connection for the gas pressure (+) sens...

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    52 • 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 counter clockwise until the blocked flue indicator energizes. • check the air proving switch. Remove the restriction...

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    53 part 9 trouble shooting component failure mode analysis incoming power • two wires interchanged • no effect on safety • live and neutral wires are interchanged. Transformer tripped • the 24volts and 120 volts wired are interchanged • alert: 49 • lockout: 53 • breaker on transformer trips relief v...

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    54 component failure mode analysis flame disappears during a run cycle • the dynaflame boiler was running and flame signal suddenly disappeared. • lockout: 106, 107, 108, 109 • verify that all air has been purged from gas line • verify that boiler is properly grounded • inspect flame sensor and asso...

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    55 symptom failure mode analysis manual reset high limit trips (if equipped) • manual reset safety high limit tripped, outlet temperature in excess of 210 o f • alert: 63, 67, 79, 137, 276-281, 303-309 • ilk off • verify that the capillary tube is broken. If this is the case, replace manual reset hi...

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    56 symptom failure mode analysis flame detection is out of sync • flame detection is present when no visible signs of a flame exist • lockout: 105, 158 • verify supply voltage for proper polarity. • check external wiring for voltage feedback • check internal wiring for proper connections • check the...

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    57 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...

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    58 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 30...

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    59 alert 354: abnormal recycle delta-t limit this safety was breached as the inlet and outlet temperature difference exceeded 40 o 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 o...

  • Page 65: Part 10  Maintenance

    60 part 10 maintenance 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 a...

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    61 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 provided with every condensing appliance. The neutralizer consists of an industrial grade, non- corrosive pl...

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    62 10.6.1 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 t...

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    63 • 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. • free...

  • Page 69

    64 piping. If flow control is required, other means of flow control such as globe valve or flow setter should be used. 11.4 intermittent pump operation an intermittent pump operation signal is standard and can be used to operate a separate pump contactor. A 1 hp pump delay relay is available as an o...

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    65 care should be taken to maintain required water velocity based on water condition as follows: 11.8 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 water heater or hot water supply boiler in the off cycl...

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    66 part 12 exploded view.

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    67 3 44 10 45 46 47 28 31 26 52 57 58 59 54 60 61 sola control panel 39 4.

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    68 ref # name of part part id dynaflame model a l l 5 0 0 7 5 0 1 1 0 0 1 2 0 0 1 5 0 0 1 7 5 0 2 0 0 0 2 5 0 0 3 0 0 0 3 5 0 0 4 0 0 0 4 5 0 0 5 0 0 0 4 5 0 4 5 0 0 4 6 0 0 4 1 lip protector 14-5214-11a x 102752 x x x 102753 x 14-5214-30a x x x x 14-5214-35-50a x x x x 14-5315 x x x 2 bottom transi...

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    69 ref # name of part part id dynaflame model a l l 5 0 0 7 5 0 1 1 0 0 1 2 0 0 1 5 0 0 1 7 5 0 2 0 0 0 2 5 0 0 3 0 0 0 3 5 0 0 4 0 0 0 4 5 0 0 5 0 0 0 4 5 0 4 5 0 0 4 6 0 0 4 3 stainless steel primary heat exchanger (v baffles included) 109016 x 109017 x 109018 x x 109020 x 109021 x 109022 x 109023...

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    70 ref # name of part part id dynaflame model a l l 5 0 0 7 5 0 1 1 0 0 1 2 0 0 1 5 0 0 1 7 5 0 2 0 0 0 2 5 0 0 3 0 0 0 3 5 0 0 4 0 0 0 4 5 0 0 5 0 0 0 4 5 0 4 5 0 0 4 6 0 0 4 8 electrical box 14-1030 x x x x 14-1005 x x x x x x x x x x x x 9 combustion chamber wrap 14-5008 -05a -07a -11a -11a 14-52...

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    71 ref # name of part part id dynaflame model a l l 5 0 0 7 5 0 1 1 0 0 1 2 0 0 1 5 0 0 1 7 5 0 2 0 0 0 2 5 0 0 3 0 0 0 3 5 0 0 4 0 0 0 4 5 0 0 5 0 0 0 4 5 0 4 5 0 0 4 6 0 0 4 15 outer jacket right panel 14-6012 -05a -07a -11a -11a 14-5223 -15a -17a -20a -25a -30a -35a -40a - 45a -50a 14-5323 -45 -5...

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    72 ref # name of part part id dynaflame model a l l 5 0 0 7 5 0 1 1 0 0 1 2 0 0 1 5 0 0 1 7 5 0 2 0 0 0 2 5 0 0 3 0 0 0 3 5 0 0 4 0 0 0 4 5 0 0 5 0 0 0 4 5 0 4 5 0 0 4 6 0 0 4 25 outer jacket front panel 14-6004 x x x x 14-5221 x x x x x x x x x 14-5321 x x x 26 fan flange 13-5052 x x x x 13-5330 x ...

  • Page 78

    73 ref # name of part part id dynaflame model a l l 5 0 0 7 5 0 1 1 0 0 1 2 0 0 1 5 0 0 1 7 5 0 2 0 0 0 2 5 0 0 3 0 0 0 3 5 0 0 4 0 0 0 4 5 0 0 5 0 0 0 4 5 0 4 5 0 0 4 6 0 0 4 31 fan housing af9 x x x x x x x af10 x x af12 x x x x x x af15 x 32 filter holder df-14-0119 x x x x x x df-14-0120 x x x d...

  • Page 79

    74 ref # name of part part id dynaflame model a l l 5 0 0 7 5 0 1 1 0 0 1 2 0 0 1 5 0 0 1 7 5 0 2 0 0 0 2 5 0 0 3 0 0 0 3 5 0 0 4 0 0 0 4 5 0 0 5 0 0 0 4 5 0 4 5 0 0 4 6 0 0 4 40 flame rod pse-ch5 x 41 hot surface igniter 271r x 42 view port glass tg-94010-040 x 43 vee baffle sets 14-0350 x 14-0351 ...

  • Page 80

    75 ref # name of part part id dynaflame model a l l 5 0 0 7 5 0 1 1 0 0 1 2 0 0 1 5 0 0 1 7 5 0 2 0 0 0 2 5 0 0 3 0 0 0 3 5 0 0 4 0 0 0 4 5 0 0 5 0 0 0 4 5 0 4 5 0 0 4 6 0 0 4 47 burner flange red silicone gasket 33-5218 x x x x 33-5224 x x x x 33-5227 x x x x x 33-5230 x x x 50 valve actuator v8730...

  • Page 81

    76 ref # name of part part id dynaflame model a l l 5 0 0 7 5 0 1 1 0 0 1 2 0 0 1 5 0 0 1 7 5 0 2 0 0 0 2 5 0 0 3 0 0 0 3 5 0 0 4 0 0 0 4 5 0 0 5 0 0 0 4 5 0 4 5 0 0 4 6 0 0 4 53 on/off switch c6000albbxchli x 54 75va transformer hct-01j2bb07 x 55 blocked flue switch 8021205256 x 56 differential pre...

  • Page 82

    77 part 13 electrical diagrams.

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    78.

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    79 9 3 -0 1 9 5 -1 7 1 1 0 0 c k c b k y b l r b k - b l a c k b l - b l u e b r - b r o w n o - o r a n g e p - p u r p l e r - r e d w - w h it e y - y e l l o w a ir i n l e t d a mp e r p o w e r o p e n p o w e r c l o s e d y o b k b r r - f r o m t e r mi n a l 8 (c o n s t a n t p o w e r ) ...

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    80

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    81.

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    82.

  • Page 88

    83 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 a...

  • Page 89

    84 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 name of dealer address address model no. Serial no. Date of inst...

  • Page 90

    Camus® hydronics is a manufacturer of replacement parts for most copper finned the camus® certified! Seal assures you that reliability, efficiency & serviceability are built water heaters and heating boilers as well as a into every single unit! For more information supplier of specialty hvac product...