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  5. Installation, Operation And Service Manual

Camus Hydronics DFH1100 Installation, Operation And Service Manual

Manual is about: Gas Fired Commercial Copper Tube Boilers Dynaflame Series

Summary of DFH1100

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    6226 netherhart road, mississauga, ontario, l5t 1b7 99-0050 rev. 04 installation operation and service manual gas fired commercial copper tube boilers dynaflame series for hydronic heating models; dfh500, 750, 1100, 1200, 1500, 1750, 2000, 2500, 3000, 3500, 4000, 4500, 5000 hot water supply models; ...

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

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    5.4 high and low gas pressure switchs (optional) ...................................................................................................................21 5.5 high limit .........................................................................................................................

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    1 part 1 general information 1.1 introduction the dynaflame boiler is a fan assisted boiler based on 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 boiler provides central hea...

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    2 1.4 what the lights mean on your camus appliance • power light off means there is no power to the appliance. • operator light on indicates demand for operation (temperature or external control). • high limit light off means high limit on back of unit tripped. • water flow light off means no flow/l...

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    3 control valve and will immediately go into lockout mode for csd1, or proceed to two more trials before locking out in the standard version. 14 the ignition module will go into lockout if it does not see the flame rectification signal due to the flame sensor being insulated from oxide deposits or f...

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    4 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 mech...

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    5 replace any damaged gasket. Note that the burner is supplied with two gaskets; a high temperature 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. 6. Restore electrical power and gas su...

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    6 table 2 service clearances service clearance, inches (cm) model numbers top right side left side back 500 24” (60cm) 12” (30cm) 12” (30cm) * 750 24” (60cm) 12” (30cm) 12” (30cm) * 1100 24” (60cm) 12” (30cm) 12” (30cm) * 1200 24” (60cm) 12” (30cm) 12” (30cm) * 1500 24” (60cm) 12” (30cm) 12” (30cm) ...

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    7 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. Foam core pipe, pvc, cpvc are not to be used in any part of the venting system. 2.1 general venting guide figure 1 the d...

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    8 venting • the installed length of the positive pressure flue from the appliance to the point of termination, outside of the building, must not exceed a maximum of 100 equivalent feet (30.5 m) in length. Depending on diameter and centreline radius subtract from 7 to 19 feet per 90 ° elbow using pub...

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    9 • 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 a...

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    10 condensate neutralization system or a suitable drain for disposal of condensate that may occur in the vent system. Ensure that the drain from the condensate tee is not exposed to freezing temperature. 2.2 conventional venting (indoor) installations • non – condensing • the dynaflame non-condensin...

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    11 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 dynaflame windproof cabinet pro...

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    12 structure. • the vent cap should have a minimum clearance of 4 feet (1.25m) horizontally from and in no case above or below, unless a 4-foot (1.25 m) horizontal distance is maintained from electric meters, gas meters, regulators and relief equipment. In all cases local codes take precedence. • fl...

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    13 3.2 gas piping 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. 3.3 install piping • the gas line should sufficient to handle the total installed capacity. Verify pipe ...

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    14 3.6 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. • remove the 1/8" hex plug from the gas pressure test port located on the in...

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    15 3.8 gas train and controls figure 4 – typical gas train 3.9 ratio gas valve figure 5 – 1:1 air/gas ratio control valve the main gas valve supplying gas to the burner on this appliance utilizes a pressure regulating electro hydraulic actuator providing a slow opening, fast closing safety shut off ...

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

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    17 4.3 inlet and outlet connections • all water connections meet american national standard pipe threads (npt). • 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 conn...

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    18 4.7 instantaneous water heater (non- condensing) 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 tem...

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    19 consult vent pipe manufacturer’s instructions for proper method of sealing vent pipe sections and fittings. In the absence of instructions, make sure that pipe and fittings are clean by swabbing with alcohol. Use dow corning 736 or 732 rtv, polybar # 500 rtv or sil-bond 4500 or 6500 to seal vent ...

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    20 figure 13 – low water cut off electrical connections 4.12 relief valve (shipped loose) 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 to be installed in the vertical position and mou...

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    21 part 5 electrical & controls it is extremely important that this unit be properly grounded! 5.1 electrical conections minimum 120vac 60hz single phase (15a. Circuit) is supplied to the control junction box models df-500 through df-2000 and 120vac (20a circuit ) models df-2500 thru df-3000 and 120...

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    22 source much like a proven standing pilot before the gas valves are energized. The ignition control proves the presence of the proper ignition temperatures from the hot surface igniter using a proof current (2.7a +/- 0.2), energizes the main gas valves, proves the presence of main burner flame, an...

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    23 minimum 2.0 µa d.C. If the signal is less than this it could indicate oxide on the metal rod, a partial ground through the ceramic insulator or an improperly placed sensor. If oxide is evident on the sensing rod use steel wool to remove it. Do not use emery paper since the silica will foul the se...

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    24 mode 2 is intended for hydronic heating based on pid logic. The set-point for supply water sensor s3 is pre-set to 180°f and the auto re-set limit is set to 230°f. The supply sensor set-point can be adjusted, however the limit is fixed. In addition to the auto reset limit the factory installs a m...

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    25 in the electrical enclosure across the contacts to be used for connection to the remote operator. The fixed auto re-set limit is set to 230°f. In addition to the auto reset limit the factory installs a manual re-set limit set to 250°f. The control provides pump operation. Staging operation is pro...

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    26 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 2.0 µa dc must be fed back to the module. Ox...

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    27 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. Some minor leakage is acceptable. • repair any major leaks prior to ...

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    28 part 9 trouble shooting.

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    29.

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    30 part 10 maintanance caution it is important that all gas appliances to be serviced by a competent person. 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 i...

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    31 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 plasti...

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    32 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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    33 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...

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    34 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 ...

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    35 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 ...

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    36 part 12 exploded view.

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    37.

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    38.

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    39 sheet metal components ref # name of part part id model sizes all 500 750 1100 1200 1500 1750 2000 2500 3000 3500 4000 4500 5000 14-6004 x x x x 1 outer jacket front panel 14-5221 x x x x x x x x x 14-5210 x x x x 2 combustion chamber door 14-5204 x x x x x x x x x 14-5012 x x x x 3 base panel 14...

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    40 14-0350 x 14-0351 x 14-0352 x 14-0353 x 14-0354 x 14-0355 x 14-0356 x 14-0357 x 14-0358 x 27 vee baffle sets 14-0371 x x x x 28 outer jacket top wrap 14-5226 x 29 outer jacket top cover 14-5227 x gfh 6" x gfh 8" x x x gfh 10" x x gfh 12" x x x 30 outside air intake housing gfh 14" x x x x miscell...

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    41 51 valve body vgg10.2544 x 66-5000 x x x 66-5001 x 66-5003 x x x 66-5004 x x 52 air gas inlet adapter 66-5005 x x x x gfh-500-ch x gfh-750-ch x gfh-1100-ch x gfh-1200-ch x gfh-1500-ch x gfh-1750-ch x gfh-2000-ch x gfh-2500-ch x gfh-3000-ch x gfh-3500-ch x gfh-4000-ch x gfh-4500-ch x 53 filter hol...

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    42 33-0013 x x x x 58 flange gasket 33-0014 x x x x x x x x x electrical components ref # name of part part id model sizes all 500 750 1100 1200 1500 1750 2000 2500 3000 3500 4000 4500 5000 sm005s x x x x sm010s x x x sm015s x x 60 variable frequency drive (1/2hp, 1hp, 1 1/2hp, 3hp) sm23s x x x x 61...

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    43 part 13 electrical diagrams.

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    44.

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    45.

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    46.

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    47.

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    48.

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    49 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 ...

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    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 products....