6226 netherhart road, mississauga, ontario, l5t 1b7 99-0171 rev. 0.6 installation operation and service manual dynaforce® series gas fired commercial condensing stainless steel tube boilers hydronic heating models; drh300, 350 400, 500, 600, 800, 1000, 1200, 1400, 1600, 1800, 2000, 2500, 3000, 3500,...
Table of contents part 1 general information ......................................................................................................................... 1 1.1 introduction .....................................................................................................................
4.2 warning regarding chilled water and heating coil systems .................................................. 17 4.3 inlet and outlet connections ........................................................................................................ 18 4.4 minimum pipe size requirements ............
10.4.1 condensate volume ......................................................................................................................... 57 10.5 burner maintenance ........................................................................................................................ 57 10...
1 part 1 general information 1.1 introduction the dynaforce® is a condensing forced draft appliance utilizing a premix power burner 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 m...
2 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 a...
3 • 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 ...
4 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...
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 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 r...
6 table 3: appliance dimensions and specifications dynaforce® dimensions model dim. "a" (in.) 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 inle...
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. Use of cellular core pvc (astm f891), cellular core cpvc or radel® (polyphenosulfone) in venting systems shall be prohib...
8 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 al29- 4c or equivalent, single or double wall. 2 316l stainless steel is limited to use in applications where there is no possibility of contamin...
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) 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° elbo...
10 2.1.11 drain tee figure 7: drain “t” and neutralizer cartridge installation a drain line must be connected to the boiler condensate drain and to 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 installe...
11 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 exhaust...
12 air intake 2.4.3 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 loc...
13 table 6: recommended gas pipe size single appliance installation (for distance from natural gas meter or propane second stage regulator) input 0-100 ft 101-200 ft 201-300 ft btu/hr, x1000 nat. L.P. Nat. L.P. Nat. L.P. 300 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...
14 low fire adjustment screw located under cap (turning clockwise increases gas flow) figure 8: dr300 – 400 1:1 negative pressure air/gas ratio control valve figure 9: dr500 – 1800 1:1 negative pressure air gas ratio control valve figure 10: dr2000 - 5000 1:1 air/gas ratio control valve figure 11: d...
15 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 por...
16 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. 3.9 gas train and controls figure 13: typical gas train (dr2000 – 3000) ...
17 part 4 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 ...
18 figure 17: chilled water system 4.3 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. Th...
19 table 9: flow and pressure drop at a given temperature rise (dr1200-5000) model 20 o f rise 25 o f rise 30 o f rise* us gpm ∆p-ft. Us gpm ∆p-ft. Us gpm ∆p-ft. 1200 113.8 10.0 91.0 6.6 75.8 4.7 1400 132.8 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...
20 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 nor...
21 dynaforce® model voltage requirement maximum over current protection full load amps [amperes] [amperes] 1200 - 2500 460vac, 60hz, 3 phase 10 2.1 3000 - 4000 5.3 4500 - 5000 6.8 the combustion air fan motor operates on 230 vac, 3 phase, 60 hz on models dr1200 - 5000. Three phase voltage is generat...
22 5.7 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 flam...
23 figure 22: lockout condition to eliminate the lockout error, 1) press the red bar, indicating a lockout condition 2) press the [lockouts] button figure 23: lockout history 3) press [clear lockout] table 13: alert/hold codes # description 29 burner switch turned off 30 burner switch turned on 47 i...
24 part 6 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 (2) slotted screws and swinging opening the door. The diagnostic information centre as w...
25 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).
26 drh 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) place both togg...
27 modulation: boiler inlet, outdoor reset operation (standalone) description electrical connection(s) programming instructions • boiler operates with variable setpoint determined by outdoor reset curve • modulates on inlet sensor (default) • heat demand is generated when remote operator is closed. ...
28 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 determined by outdoor reset curve • modulates on system sensor • heat demand...
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 outdoor temperature source = enviracom outdoor sensor 17) place toggle switch to remote for remote enable operation (if required) 4-20ma/ 2-10vdc setpoint...
30 4-20ma/ 2-10vdc firing rate operation (standalone) 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 4-20ma or 2- 1...
31 drw modulation: fixed setpoint operation (standalone) 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/ stat, if required. 1) p...
32 13) place 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 both toggle switches to local 2) press and 3) select system identification & access 4) verify mb1 modbus address = 1 5) verify mb2 modbus address = 1 6) s...
34 13) select 20ma water temperature 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 >>] 1...
35 slave boiler description electrical connection(s) programming instructions • slave boiler lead lag setup 1) place both toggle switches to local 2) press and 3) select system identification & access 4) verify modbus address . To be in sequential order 5) select lead lag slave configuration 6) sele...
36 master boiler, system sensor description electrical connection(s) programming instructions • master boiler system sensor configuration 1) press and 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...
37 7) press the reset button on the ignition control within the alotted time master boiler 8) press and 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 (wwsd) 14) selec...
38 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...
39 rate (80%). 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 ...
40 6.2 configure menu figure 26: configure menu 6.2.1 system identification & access menu group selection parameter description s y st e 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:...
41 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...
42 6.3 lead lag setup up to 8 boilers 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 dynaforce® lead lag system follow the instructions: system sensor insert the supplied 10k Ω system sensor in...
43 6.4 lead lag setup for up to 12 appliances honeywell sola can only support up to 8 boilers 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 ti...
44 verify activity on com2 port > > 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: http://www.Camus- hydronics.Com/downloads/93_0238_dynaflame_dyn...
45 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...
46 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...
47 figure 33: dr 500 - 1800 gas valve to adjust the low fire setting (dr 300 – 1800) 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. Th...
48 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, ram...
49 part 9 troubleshooting 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 va...
50 component failure mode analysis flame disappears during a run cycle • the dynaforce® 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 ass...
51 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...
52 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...
53 alert 291: abnormal recycle: flame was not on at end of ignition alert 292: abnormal recycle: flame was lost during main flame establishing period alert 293: abnormal recycle: flame was lost early in run alert 294: abnormal recycle: flame was lost during run alert 324, 374-379: abnormal recycle: ...
54 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...
55 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...
56 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 a...
57 10.4.1 condensate volume there are several factors affecting the 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 i...
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 frequently under high cycling conditions. This will maintain peak ignition efficiency. • turn off main electrical power to the appliance. • turn off main manual g...
59 • 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...
60 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 ...
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 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 temperatu...
62 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 ...
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
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 or uneven. Graphite gasket burner heat exchanger 62 63 64 65 66 67.
66 ref # part name part id dynaforce® models a ll 3 0 0 3 5 0 4 0 0 5 0 0 6 0 0 8 0 0 1 0 0 0 1 2 0 0 1 4 0 0 1 6 0 0 1 8 0 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 1 heat exchanger (incl. “v” baffles) 15-2001 x x 15-2002 x x 15-2003 x x 15-2004 x x 15-2005 x 15-2006 x x 15-2007 x 1...
67 ref # part name part id dynaforce® models a ll 3 0 0 3 5 0 4 0 0 5 0 0 6 0 0 8 0 0 1 0 0 0 1 2 0 0 1 4 0 0 1 6 0 0 1 8 0 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 11 front panel 14-1045 x x 14-1041 x x 14-1055 x x 14-1020 x 14-1059 x 14-1012 x x x 14-1004 x 14-1027 x 14-1006 x 14-...
68 ref # part name part id dynaforce® models a ll 3 0 0 3 5 0 4 0 0 5 0 0 6 0 0 8 0 0 1 0 0 0 1 2 0 0 1 4 0 0 1 6 0 0 1 8 0 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 19 dynaforce® display s7999d1006 (7” screen) x 20 on/off switch c6000albbxchli x 21 venturi/ air gas inlet adapter 459...
69 ref # part name part id dynaforce® models a ll 3 0 0 3 5 0 4 0 0 5 0 0 6 0 0 8 0 0 1 0 0 0 1 2 0 0 1 4 0 0 1 6 0 0 1 8 0 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 34 combustion fan 150563-05 x x x 55667.14002 x 150232-07 x x x af9 x x x x af10 x x x af12 x x x af15 x 35 electrical...
70 ref # part name part id dynaforce® models a ll 3 0 0 3 5 0 4 0 0 5 0 0 6 0 0 8 0 0 1 0 0 0 1 2 0 0 1 4 0 0 1 6 0 0 1 8 0 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 51 inlet sensor 198799z/u x 52 outlet sensor 50001464-005/b x 53 outdoor sensor tekmar 070/071 x ntc-sensor-004 x 54 f...
71 part 13 electrical diagrams.
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74 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 m p 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 m in a l 8 (c o n s t a n t p o w e r )...
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78 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 furni...
79 how to make a claim any claim under this warranty shall be made directly to camus® hydronics limited canadian head office service labor responsibility camus® shall not be responsible for any labour expenses to service, repair or replace the components supplied. Such costs are the responsibility o...
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...