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  5. Installation, Operation And Service Manual

Camus Hydronics DMC083 Installation, Operation And Service Manual

Manual is about: DynaMax SERIES GAS FIRED WALL HUNG & FLOOR MOUNT RESIDENTIAL COMMERCIAL STAINLESS STEEL BOILERS

Summary of DMC083

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    6226 netherhart road, mississauga, ontario, l5t 1b7 99-0056 rev. 3.2 installation operation and service manual gas fired wall hung & floor mount residential commercial stainless steel boilers dynamax series hydronic heating models; dmh081, 101, 151, 201, 251, 211, 261, 291, 391, 501, 601, 701, 801 h...

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    Contents part 1 general information ............................................................................................................................................ 1 1.1 introduction............................................................................................................

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    5.4.1 manual reset codes .................................................................................................................................................. 20 5.4.2 automatic reset codes ....................................................................................................

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    11.12 freeze protection for indoor & outdoor installations ............................................................................ 57 11.13 freeze protection for a heating boiler system (optional) ............................................................................ 58 part 12 installati...

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

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    2 1.5.2 end of sequence 1) setpoint temperature is satisfied. 2) power to the gas valve is turned off. 3) combustion air fan ramps to a stop over the factory preprogrammed time period. 4) thermostat is now in standby mode waiting for the next “call for heat”. Warning to minimize the possibility of s...

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    3 deficiency, which could cause an unsafe condition. • insofar as is practical, close all building doors and windows and all doors between the spaces in which the appliances remaining connected to the common venting system are located and other spaces of the building. If applicable turn on the cloth...

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    4 • 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. Always consider the use of a shelter such as a ga...

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    5 table 2: dynamax wall hung service clearances model service clearance, inches (cm) front top right side left side rear 80 24” (61cm) 3” (8 cm) 4” (10 cm) 4” (10 cm) 0” (0 cm) 100 24” (61cm) 3” (8 cm) 4” (10 cm) 4” (10 cm) 0” (0 cm) 150 24” (61cm) 3” (8 cm) 4” (10 cm) 4” (10 cm) 0” (0 cm) 200 24” (...

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    6 table 4: dynamax floor mount service clearances model service clearance, inches (cm) front top right side left side rear 210 12” (31cm) 24” (61cm) 0” (0cm) 12” (31cm) 14” (36 cm) 260 12” (31cm) 24” (61cm) 0” (0cm) 12” (31cm) 14” (36 cm) 299 12” (31cm) 24” (61cm) 0” (0cm) 12” (31 cm) 14” (36cm) 399...

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    7 figure 5: dynamax wall hung service clearances figure 6: dynamax floor mount service clearances.

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    8 part 2 air inlet and 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. 2.1 general venting guide the dynamax wall hung is a category iv condensing appliance, 97% efficient unit....

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    9 table 6: maximum flue temperature for various vent materials vent material maximum flue temperature [ o f] pvc 149 cpvc 194 ppe 230 al29-4c 300+, limited only by rating of seals 316l stainless steel 300+, limited only by rating of seals stack temperature is between 15-30 o f above inlet water temp...

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    10 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 tota...

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    11 location of a sidewall air inlet cap 1) total length of piping for air inlet must not exceed the limits stated in table 7. 2) point of termination for the sidewall air inlet cap must be located a minimum of 12 inches (0.30m) away from the flue gas termination, but never above. 3) air piping must ...

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    12 location of a vertical air inlet opening 1) the total length of piping for inlet air must not exceed the limits given in table 8. 2) the air inlet consists of two 90 o elbows installed at the point of termination for the vertical air inlet pipe. A 90 o elbow and a 90 o street elbow may be used to...

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    13 part 3 gas connection 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 ...

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    14 important upon completion of initial installation or following any repair work 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 i...

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    15 regulated gas supply pressures for dynamax boilers & water heaters a stable gas supply pressure is important to avoid rough starts with machines like the dynamax which use a 1 to 1 ratio control valve for internal gas pressure regulation. Camus requires that all dynamax models be supplied with no...

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    16 4.2 warning regarding chilled water systems when an appliance is connected to an air conditioning 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...

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    17 table 11: flow and pressure drop at a given temperature rise (hydronic heating) input, btu/hr 30 °f (16.7 °c) 35 °f (19.4 °c) temp rise temp rise usgpm (min. Flow) ∆∆∆∆ p ft. Usgpm. (min. Flow) ∆∆∆∆ p ft. 80,000 5.0 8.2 4.3 6.2 100,000 6.3 12.3 5.4 9.4 150,000 9.5 10.4 8.1 7.8 199,000 12.6 7.2 10...

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    18 4.8 flow proving device (wall mount models and combination models only) figure 19: flow proving device the flow proving device is designed to detect when flow is present. This is done by detecting the amount of current (amperes) that exists in the neutral wire from the pump. When the current beco...

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    19 part 5 electrical & controls it is extremely important that this unit be properly grounded! 5.1 electrical conections table 14: dynamax electrical requirements dynamax maximum amp draw model voltage requirement full load amps [amperes] maximum over current protection [amperes] 81, 82, 83 120vac, ...

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    20 and then “on” or cycling the thermostat will not reset a hard lockout condition. Wait five seconds after turning on the main power before pushing the reset button when the dynamax controller is in a manual reset condition. Wait for the status lcd display to refresh indicating that the dynamax con...

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    21 part 6 control panel 6.1 dynamax controller the appliance is provided with an operator interface panel at the front. On a dynamax wall hung boiler the dynamax controller can be accessed by removing the upper stainless steel jacket and the lower black sheetmetal jacket which are each held on by tw...

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    22 mode 2: central heating with outdoor reset this mode will only function when an outdoor sensor is connected. The set point is calculated depending on the outdoor temperature. The central heating set point is calculated as follows: ch_setpoint = t_day_ref + [(68 – t_outdoor) * slope] t_day_ref is ...

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    23 part 7 components 7.1 direct spark igniter the direct spark igniter is inserted directly through the combustion chamber front door and held in place by two torx-20 screws. Care must be taken when removing and/or installing the igniter. Always remove the igniter prior to removing the fan assembly ...

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    24 part 8 labvision software note labvision software is available on request from the factory and is not shipped with the boiler/ water heater. Labvision is compatible with windows xp (32-bit, 64-bit) / windows 7 (32-bit, 64-bit) operating systems. To operate labvision software a laptop and a usb a-...

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    25 • go to options > communication > preferences • a preferences screen will pop up • under the project tab in the protocol box select the argus link connection figure 29: selecting argus link protocol • click on the communication tab • in the communication port pull down menu select the address of ...

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    26 table 18: appliance type designations appliance type dynamax model appliance type dynamax model 0 80 7 299 1 100 8 399 2 150 9 500 3 200 10 600 4 210 11 700 5 250 12 800 6 260 note only change the fan speed settings with the associated boiler, as only this will have an effect on boiler performanc...

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    27 the anti_cycle_period is designed to prevent the boiler from short-cycling. The preset time must be satisfied before the boiler will start up. 8.5.2 central heating mode = 1, 2, 3 installer level figure 37: central heating mode = 1, 2, 3 settings the following parameters can be adjusted: table 21...

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    28 the following parameters can be adjusted: table 22: dhw mode 1, 2 parameters parameter parameter description dhw_setpoint to provide a target set point for the storage tank. (default: 120 o f) dhw store hyst up to detect the start of a storage tank demand. (default: 4 o f) dhw store hyst down to ...

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    29 dhw priority when both a ch demand and dhw demand exist simultaneously, dhw will always have priority. When dhw demand ends the boiler will check the outlet temperature sensor or system sensor and room thermostat switch to determine if ch demand exists. Flame rod current in µa can be observed. Fa...

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    30 staging operation the control supports a function to rotate the boilers on a timely basis. With parameter cc_stage_time the time can be set after which the start and stop sequence of the cascade boilers changes. Table 25: staging sequence cc_stage_time start/stop sequence 1 x cc_stage_time 1-2-3-...

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    31 feature disabled the log file will be dependent on time as opposed to memory size. Figure 49: unlimited log file size when logging is complete click on logging > stop logging. Notice that the status bar has changed from red to blue. This informs that logging is complete. To view a log file, camus...

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    32 8.9 error history labvision has the ability to record past blocking (e) and lockout (a) errors. To access this feature use the pull down menu and select history. Figure 50: error history the blocking and lockout errors are separated into their own respective rows and are identified by their respe...

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    33 up down • press to change boiler parameter values (setpoint temperature, date & time) • press to enter main menu. This provides access to system monitor, settings, programs and errors • press to reset a lockout error. • press to enter to confirm selection or to confirm a parameter change next • p...

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    34 9.1 introduction to the dynamax control panel for times when a notebook computer is not available, a service technician will still be able to perform all the functions described in labvision, except for the logging aspect. The menu structure for the dynamax control panel was designed to be intuit...

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    35 9.2 menu screen from temperature and status display; 1) press [menu] button. Display display readout description system monitor monitor central heating and dhw settings, if equipped. System monitor will be open to all levels of access. Display options changes to languages, date and time, and unit...

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    36 9.3 system monitor display from menu display; 1) use [next] to select ‘system monitor’ 2) press [enter] display display readout description active program master boiler is designated as a master boiler in the cascade setup slave boiler is designated as a slave boiler in the cascade setup pump on ...

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    37 9.4 display options display from menu display; 1) use [previous]/[next] button to select ‘display options’. 2) press enter display display readout description language allows the control to be set to english (default), french or spanish date and time allows the date and time to be changed units a...

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    38 9.5 central heating display 1) use [previous]/[next] button to select ‘appliance settings’. 2) press enter display display readout description central heating enters central heating branch of display setpoint allows adjustment of setpoint. The setpoint is controlled to the boiler outlet sensor. (...

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    39 display display readout description t_night_reduction (mode 2,3) temperature for night time usage this parameter is only engaged when the external clock is satisfied. (default: 18 o f). Weather_setpoint (mode 2) when the outdoor temperature is below the preset weather_setpoint a ch demand is crea...

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    40 display display readout description dhw_store_hyst_up (mode 1) used to end a call for heat (default: 9 o f) dhw_store_hyst_down (mode 1) used to start a call for heat (default: 4 o f) dhw_store_supply_extra (mode 1) increases the target outlet temperature (default: 20 o f) dhw_supp_hyst_up (mode ...

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    41 9.7 cascade control 1) use [previous]/[next] button to select ‘appliance settings’. 2) press enter display display readout description cascade control enters cascade branch of display master/slave selection 1) use [up]/[down] to select the option of a ‘master boiler’ or ‘slave boiler’. 2) press [...

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    42 9.8 boiler control 1) use [previous]/[next] button to select ‘boiler control’. 2) press enter display display readout description boiler control enters boiler control branch of display appliance type selection select the appliance model parameters associated with each model ignition fan speed adj...

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    43 part 10 troubleshooting table 29: troubleshooting table 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 • transformer immediately burns o...

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    44 symptom failure mode analysis flame failure (pressing the manual reset on the dynamax control panel will be required to restart the ignition sequence) • the boiler has failed to ignite the burner after 3 unsuccessful attempts • verify that all air has been purged from gas line • inspect spark ele...

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    45 symptom failure mode analysis noisy operation • supply gas issue • refer to part 3 gas connection in this manual. • natural gas pressure should read between 3” w.C. And 14” w.C. • l.P. Gas pressure should be at 11” w.C. • air/gas mixture issue • refer to gas valve adjustment procedure in section ...

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    46 symptom failure mode analysis flue gas error • stack temperature has exceeded the limit set on the boiler. • measure the resistance of the flue sensor at room temperature, it should be approximately 10k Ω . • pvc: 149 o f • cpvc: 194 o f • stainless steel, al29-4c: 210 o f sensor not connected • ...

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    47 ignition error displayed on screen an ignition error occurs when 3 consecutive attempts at lighting the burner have failed. This is a manual reset error where the technician must press reset to clear the error. Check for constant spark for 6 seconds across spark igniter no yes adjust igniter gap ...

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    48 fan error displayed on screen a fan error is displayed when the difference between the target and actual fan speed is greater than 300 rpm apart for over a minute. This is a manual reset error where the technician must press reset to clear the error. Replacement of ignition module: - software upd...

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    49 blocked flue error displayed on screen this error can indicate a blocked flue or blocked intake condition, low gas pressure switch tripped (optional) or high gas pressure switch tripped (optional). To identify the safety that is open use the continuity setting on your multimeter and go across the...

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    50 flow switch not closed displayed on screen the flow switch is not closed or the low water cutoff (lwco, optional) was tripped. This is an automatic reset error and as soon as flow is proven this error resolves itself. To identify the safety that is open use the continuity setting on your multimet...

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    51 flue gas error displayed on screen a flue gas error occurs when the stack temperature has exceeded the maximum limit allowed by the vent material. This is an automatic reset error, when the stack temperature drops 20 o f below the limit allowed the boiler is allowed to restart and an ignition att...

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    52 flame appears and disappears within 4 seconds of ignition this type of failure indicates a flame rectification signal issue through the flame rod. Is flame sensor plug secure? No fasten flame sensor plug securely to flame sensor wire and check for corrosion deposits at wire terminals yes check co...

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    53 10.1 setting the correct combustion 1) switch the main power off to the boiler by placing the toggle switch in the ‘off’ position 2) switch the main power on to the boiler and adjust set point so that boiler begins ignition sequence. 3) observe the boiler as it goes through its startup cycle and ...

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    54 dm 299 – 399 figure 57: dm 299 – 399 gas valve to adjust the high-fire setting use the dynamax control panel press the [menu] button > select appliance settings and press [enter] > select boiler control and press [enter] > enter the correct installer passcode. Select ‘maximum power’ for high powe...

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    55 part 11 maintenance caution it is important that all gas appliances be serviced by a qualified technician trained by camus hydronics. 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 ad...

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    56 note all gaskets on disassembled components must be replaced with new gaskets/sealant on re-assembly, if required. Gasket 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 instructio...

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    57 • remove the direct spark igniter and the flame sensor. • remove the t-25 screws holding the front burner flange in place to gain access to the burner. • the burner can now be pulled horizontally out of the heat exchanger cavity. • use care to prevent damage to the knitted metal fiber of the burn...

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    58 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 ...

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    59 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 4.11. 12.4 inspect & recharge condensate collection/neutralizing reservoir 1) before starting t...

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    60 boiler operation 1) appliance should begin the start-up process for the sequence of operation. 2) the boiler will fire at approximately 50% of rated input on initial start-up and adjust input as required to meet system demand. 3) based on system demand, the appliance will modulate accordingly. 4)...

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    61 table 32: temperature rise across heat exchanger (hydronic heating) temperature rise across heat exchanger model [btu/hr] 30 o f (16.7 o c) 35 o f (19.4 o f) usgpm ∆ p-ft. Usgpm ∆ p-ft. 80,000 5.0 8.2 4.3 6.2 100,000 6.3 12.3 5.4 9.4 150,000 9.5 10.4 8.1 7.8 199,000 12.6 7.2 10.8 5.8 250,000 15.8...

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    62 figure 62: text display switch setup wiring setup refer to figure 63 for a pictorial description of how to connect the cascade system together. Master boiler the following needs to be done to the master text display: 1) connect the “to 848mn control” connector to the dynamax ignition control boar...

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    63 slave boiler turn on the dynamax slave boiler and wait until the date and time to appear. 11) press [menu] 12) select “appliance settings” using the [next] button and press [enter]. 13) select “cascade control” using the [next] button and press [enter]. 14) enter the pin number to gain access. Th...

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    64 table 34: modbus configuration modbus configuration protocol modbus rtu default slave address 0x01 (settable with labvision) supported modbus commands read holding registers (0x03) write single holding register (0x06) baud rate 9600 bps data length 8 parity none stop bits 1 physical layer rs-485 ...

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    65 table 38: manual reset error manual reset errors decimal hex description e2prom_read_error 0 0 no communication with e2prom ignit_error 1 1 three unsuccessful ignition attempts in a row gv_relay_error 5 5 problems with gas valve relay = internal hardware error safety_relay_error 6 6 problems with...

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    66 12.14 write functionality the dynamax ignition module may be only reset when it is in error. Only manual reset errors can be reset by writing 0x4000 to the reset & r/w control holding register (0x001a) of the modbus interface (this sets the mn reset bit of the reset & r/w control holding register...

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    67 12.15 alarm output (if equipped) this is a feature that is offered on the 848if. An alarm output is available to signal was sensed in the connected heating system. Once an alarm is signalled by the alarm output it can be reset by means of the external reset input. The alarm output is a normally o...

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    68 12.19 ignition cycle the ignition cycle is shown in the table below. The values are the default factory settings. Table 44: dynamax ignition cycle state standby pre purge safety on safety off 6 ignit_0 ignit_1 burn post purge_0 time 0s 5s after fan speed is within 600 rpm 2 sec 6 sec limited to 2...

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    69 part 13 piping diagrams figure 69: single boiler hydronic heating zoned piping arrangement this piping arrangement is designed for: central heating mode: 0, 1, 2, or 3 dhw mode: 0 boiler address: 100 note: 1) size main header to minimize induced flow through zones 2) separate boiler loop as shown...

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    70 figure 70: single combination boiler zoned piping arrangement central heating mode: 0, 1, 2, or 3 dhw mode: 4 boiler address: boiler address = 100 pressure reducing valve pressure gauge ball valve air separator expansion tank zone circulator flow check valve dynamax boiler temperature / pressure ...

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    71 figure 71: single boiler hydronic heating & indirect storage tank zoned piping arrangement central heating mode: 0, 1, 2, or 3 dhw mode: 1, or 2 boiler address: boiler address = 100 pressure reducing valve pressure gauge ball valve air separator expansion tank zone circulator flow check valve dyn...

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    72 figure 73: single boiler hydronic heating & direct storage tank zoned piping arrangement central heating mode: 0 dhw mode: 1 or 2 boiler address: boiler address = 100 cold water in dhw sensor union direct dhw tank anti-scald mixing valve cold water in hot water out.

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    73 figure 74: multiple boiler hydronic heating zoned piping arrangement central heating mode: 0, 1, 2, 3 dhw mode: 0 boiler address: master boiler address = master boiler 1 (m1) slave boiler address = slave boiler 2 (s2) pressure reducing valve pressure gauge air separator expansion tank ball valve ...

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    74 part 14 exploded view & parts list dynamax wall hung.

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    75 dynamax floor mount.

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    76 ref # name of part part id dynamax models all 80 100 150 200 210 250 260 299 399 500 600 700 800 1 heat exchanger 4 + 1 wall x x 5 + 2 wall x 8 + 4 wall x x 8 + 4 floor x x 10 + 6 floor x 15 + 8 floor x 18 + 10 floor x 21 +11 floor x 24 + 12 floor x 2 burner 80,000 btu x x 100,000 btu x 150,000 b...

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    77 ref # name of part part id dynamax models all 80 100 150 200 210 250 260 299 399 500 600 700 800 14 hydronic heating/ combination pump 110223-305 x x 110223-307 x x x pl30 x x x pl36 x x e12 x e30 x x dhw pump e7b x x e9b x x x x x e12b x x e33b x 127091.1.1 x x x 15 mixing chamber gm20-70-011-01...

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    78 ref # name of part part id dynamax models all 80 100 150 200 210 250 260 299 399 500 600 700 800 32 electrical conduit plate 14-5415 x x x 14-5415-250 x x 33 electrical strip plate 14-5416 x x x x x 34 plastic bezel 15-6001-a x x x x x 35 bracket for neutralizer box 14-5419 x x x x x 36 air inlet...

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    79 ref # name of part part id dynamax models all 80 100 150 200 210 250 260 299 399 500 600 700 800 55 floor bracket left 14-5518-20-25 x x 14-5518 x x x x x x 56 floor rear bracket 14-5520-20-25 x x 14-5520 x x x x x x x x 57 top cover assembly 14-5521 x x x x x x x x 58 dashboard dashboard #2 x x ...

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    80 ref # name of part part id dynamax models all 80 100 150 200 210 250 260 299 399 500 600 700 800 80 40va transformer hct- 01e0bb06 x 81 supply/return sensor ntc- sensor-002 x 82 flue sensor ntc- sensor-003 x 83 outdoor sensor ntc- sensor-004 x 84 sensor wire cable harness x 85 dhw sensor ntc- sen...

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    81 ref # name of part part id dynamax models all 80 100 150 200 210 250 260 299 399 500 600 700 800 102 plastic to stainless steel vent adapter 300566 x x x x x x x 300611 x x x stainless to plastic vent adapter fs0604pvcr x 300537 x x 103 rubber air sleeve 1056-22 x x x x x x x x x 1056-33 x 1056-4...

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    82 part 15 electrical diagrams 15.1 dm 80- 250 internal wiring diagram (wall hung models) -- -- f ie l d s u p p l ie d ··· ·· o p t io n a l e q u ip m e n t b k - b l a c k b l - b l u e b r - b r o w n g - g r e e n o - o r a n g e p - p u r p l e w - w h it e y - y e l l o w r - r e d 8 0 -2 5 0...

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    83 15.2 dm 210-299 internal wiring diagram (floor mount models) -- -- f ie l d s u p p l ie d ··· ·· o p t io n a l e q u ip m e n t b k - b l a c k b l - b l u e b r - b r o w n g - g r e e n o - o r a n g e p - p u r p l e w - w h it e y - y e l l o w r - r e d 2 1 0 -2 9 9 , d y n a m a x f l o o...

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    84 15.3 848if interface module wiring schematic -- -- f ie l d s u p p l ie d ··· ·· o p t io n a l e q u ip m e n t b k - b l a c k b l - b l u e b r - b r o w n g - g r e e n o - o r a n g e p - p u r p l e w - w h it e y - y e l l o w r - r e d n o te : 1 ) i f a n y o f t h e o rig in a l w ire ...

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    85 15.4 field wiring all wires being placed into the terminal block should be horizontal for at least an inch to ensure sufficient electrical conductivity. 15.4.1 system sensor the temperature of the primary return can be controlled by installing a system sensor. The system sensor must be used in al...

  • Page 91

    86 15.5 detailed connector description connector pin # connector description j2 provides 120vac to the dynamax controller 1 earth/ ground 2 120vac neutral 3 120vac live j6 3-way diverter valve 1 dhw 120vac live 2 ch 120vac live 3 120vac neutral j7 on-board pump 1 not used 2 pump 120vac neutral 3 not...

  • Page 92

    87 condensing boiler limited warranty 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 replac...

  • Page 93

    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....