Armstrong Flo-Direct 2.0 AFD-1000 User manual

Flo-Direct®2.0 Complete Thermal
Exchange Gas Fired Water Heater
Installation, Operation, and Maintenance Manual
Certified to U.S. patent 5,924,391
5
706-EN V7.0
Please read and save
these instructions

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2
Table of Contents
Safety.......................................................................................................................................... 3
Icon Legend:.................................................................................................................. 3
Warnings and Cautions................................................................................. 4
The Flo-Direct® System....................... 5
Typical System........................................................................................................... 5
Specifications............................................................................................................... 7
Heater........................................................................................................................................ 7
Materials of Construction................................................................ 7
Operational Specifications.............................................................. 7
Technical Specifications..................................................................... 7
Dimensions.......................................................................................................... 8
Orientation............................................................................................................. 9
Fuel Train Components.................................................................... 10
Transfer Pump Assembly...........................................................................11
Materials of Construction............................................................. 11
Dimensions and Operational Specifications.......11
Orientation.......................................................................................................... 11
Storage Tank................................................................................................................12
Materials of Construction............................................................. 12
General Specifications....................................................................... 12
Orientation.......................................................................................................... 13
Assembly and Installation ................... 14
Unpacking....................................................................................................................... 14
Installing Large Heaters........................................................................... 14
Installing Small Heaters........................................................................... 16
Installing Exhaust Ducting..................................................................... 17
Installing Intake Air Ducting............................................................... 18
Water Connections............................................................................................ 19
Fuel Connection.....................................................................................................20
Electrical Panels .............................. 21
Control Panel.............................................................................................................21
Disconnect Panel.................................................................................................22
Heater Label...............................................................................................................22
Electrical Connections................................................................................. 23
Top Plate to Upper Canister .................................. 23
Upper to Lower Canister ...................................... 24
Transfer Pump ..................................................... 24
Storage Tank ........................................................ 25
Main Power Connection ....................................... 25
Operation ...................................... 26
Description of Operation.......................................................................... 26
Sequence of Operation............................................................................... 27
Pre-Start-Up Checklist................................................................................. 28
Commissioning ............................... 29
Inspecting Installation................................................................................. 29
Inspecting Water System.........................................................................29
Commissioning....................................................................................................... 30
Periodic Maintenance........................ 31
Maintenance Schedule............................................................................... 31
High Temperature Switch Check..................................................32
Troubleshooting ............................... 33
Troubleshooting Table..................................................................................33
PLC I/Os.............................................................................................................................34
Parts Lists ...................................... 35
Top Plate........................................................................................................................... 35
Water Train....................................................................................................................36
Control Panel.............................................................................................................37
Disconnect Panel.................................................................................................38
Fuel Train......................................................................................................................... 39
Lower Canister........................................................................................................ 40
Storage Tank...............................................................................................................41
Appendix: HMI Interface ..................... 42
Main Screen................................................................................................................ 42
Setpoint and Mode Screen ...........................................................................43
Menu Screen. ..................................................................................................44
I/O List Screen ............................................................................................................45
Trending Screen .....................................................................................................46
Alarms Screen ...............................................................................................................47
Transfer Pump Screen.. ..............................................................................48
Limited Warranty and Remedy ............. 49

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Safety
Icon Legend:
— DANGER! … Injury or death and property damage are imminent.
— WARNING! … Injury or death and property damage are possible.
— CAUTION! … Potential property damage, expensive repairs, and/or voiding the equipment
warranty may result.
— BURN HAZARD! … BURN HAZARD! Direct exposure to steam, hot water, or hot metal surfaces
can cause severe skin burns. Skin contact with 140°F (60°C) water or metal
for only five (5) seconds may cause a second-degree burn.
General Safety Guidelines:
1. Inappropriate use of this product (beyond typical, intended use) could cause damage to the product and
other property. It may also result in personal injury or, in extreme cases, death.
2. Only designated, qualied, and competent personnel should conduct installation, maintenance, and
service in accordance with the directions in this product instruction manual.
3. Installation shall comply with all applicable federal, state, and local, electrical and construction, regulatory
codes.
4. Improper installation, start-up, operation, maintenance, or service may void the product warranty.
5. When installing, commissioning or servicing this product:
a. ALWAYS select and wear appropriate personal protective equipment (PPE) before carrying out any
physical work at the job site. Appropriate PPE may include hard hats, safety glasses, gloves, boots
or shoes w/ non-slip soles and toe guards, and protective overalls.
b. ALWAYS scan the work area and take note of potential hazards before entering. Adjust your travel
path or work position to avoid hazards and personal injury.
c. ALWAYS observe designated safety procedures when working in hazardous locations (areas
containing explosive and combustible gases, vapors, and dusts) and conned spaces (locations
where the breathable air supply may be limited or variable or where entrapment could occur).
d. ALWAYS use appropriate lockout-tagout procedures to disconnect power sources and de-energize
machinery before conducting installation, service, and repair.
e. ALWAYS use great care and appropriate safety gear when working above ground level, especially
on ladders and platforms or in the presence of overhead, electrical power lines.
f. ALWAYS ensure that all “live” steam, water supply, and condensate return lines are isolated before
breaking or loosening any plumbing joints.
g. ALWAYS carefully relieve any residual internal pressure in the system or connecting pipe work
before breaking or loosening any plumbing joints.
h. ALWAYS allow hot parts to cool before commencing work to avoid the risk of skin burns.
Failure to comply with instructions following a safety icon may result in adverse consequences
including, property damage, personal injury, or, in extreme cases, death.

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4
Warnings and Cautions
Warning!
If the information in these instructions is not followed
exactly, a fire or explosion may result causing
property damage, personal injury, or death.
• Do not store or use gasoline or other
flammable vapors and liquids in the vicinity of
this or any other appliance.
• What to do if you smell gas
– Do not try to light any appliance.
– Do not touch any electrical switch; do not
use any phone in your building.
– Immediately call your gas supplier from
a neighbor's phone. Follow the gas
supplier's instructions.
If you cannot reach your gas supplier, call the fire
department.
• Installation and service must be performed
by a qualified installer, service agency, or gas
supplier.
Note: Operating with any safety device bypassed will void the
warranty.
Danger!
Applicable codes must be followed and supersede
any other instructions. Generally applicable codes
in the US include:
• NEC
• NFPA #86
Danger!
Hot water or metal may cause scald burns. Skin
exposure to 140° water or metal for only five
seconds may cause a second degree burn.
Danger!
• Read this manual.
• Improper installation or operation may cause a
fire or explosion resulting in property damage,
personal injury, or death. Armstrong strongly
recommends that a qualified installer be used.
• Service must be performed by a qualified person.
• Improper installation, start-up, operation,
maintenance, or service may void the warranty.
Danger!
• Do not attempt to use the heater if it has been
submerged in water. Contact a qualified service
technician to inspect it and replace compromised
parts.

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5
The Flo-Direct®System
Armstrong's Flo-Direct® water heaters:
• Are designed for industrial applications
• Use complete thermal exchange technology
• Come in sizes from 1 to 12 million Btu/hr
• Heat water up to 185°F maximum
Typical System
Heater Transfer Pump Storage Tank

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6
Flo-Direct® water heaters are highly efficient, low maintenance systems.
• Complete thermal exchange technology means no fuel is used for warm-up or idle time and no energy is lost through
conversion or exchange.
• Without internal moving parts, there is very little to maintain.
• Water conditioning is not required.
Common options:
• Gravity drain (without a transfer pump)
• Standard (consistent incoming water temperature) or modulating burner actuator
• Natural gas or propane fuel
• Remote or integral tank
Other available options include:
• Skid-packaged heaters
• Performance matched components
• Ultra-low NOx emissions
• Non-standard fuels
• Storage tank heating element
Peripheral components:
• Digital mixing valves
• Variable frequency drive pump
• Hose stations
Optional services:
• Turn-key installation
• Installation project management
• System assessment and optimization
• Energy conservation measures (ECM)
Flo-Direct® systems are highly customizable at both a system and component level. The information in this manual generally uses
a 5 million Btu/hr unit and is intended to be typical. Illustrations are not intended to be complete or correct in every detail.
System-specific drawings, including wiring schematics, are provided with each unit and should be referred to when installing
and operating your system.
Note: Armstrong provides separate IOMs for the burner, blower, and for optional components. Consult the appropriate document for
more information.

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7
Operational Specifications
Technical Specifications
Specifications
• Flo-Direct® water heaters are built to UL standard 795
• May be manufactured to comply with various other electrical or water quality standards
• Three-phase power is required; most available voltages may be accommodated
*Consult factory for additional information.
Materials of Construction
Heater
Component Material
Canister 304 SS (10 ga. ≤AFD-9000; 3/16 > AFD-9000)
Canister gasket WARCO white (food grade buna rubber)
Flame tube 304 SS
Gas piping Malleable iron with standard yellow finish
Water piping Welded stainless steel (304)
Spray ring 304/316 SS
Pall ring 304 SS
Spec English Units SI Units
Gas supply pressure 2–6 psig (optimum 4–5.5 psig) 0.14–0.41 bar (optimum 0.28–0.38 bar)
Water supply pressure 30–100 psig with ± 5 psig variation 2.07–6.84 bar with ± 0.34 bar variation
Inlet water temperature 32 °F to 100°F 0 °C to 37.7 °C
Outlet water temperature 180°F 82.2 °C
Water temperature differential 10 °F to 140 °F 5.6 °C to 77.8 °C
NOx emission 60–70 ppm
Thermal efficiency 99.7%

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8
Dimensions
*Connections may be NPT, flanged, or use a sanitary ferrule as required.
*AFD capacity ratings are subject to a +/- 5% total output variance based on supply conditions variables and combustion
requirements. If actual installation conditions differ from those listed in the product IOM then the 5% variance may be additionally
impacted.
Flo-Direct® Dimensions and Weights
Model
Connections Dimensions Weight btu/hr kW1 2 A B C D E
in mm in mm in mm in mm in mm in mm in mm lb kg
AFD-1000 1 25 1 25 95 2413 71 1803 39 991 24 610 8 203 825 375 1,000,000 292
AFD-1500 1 25 1 25 97 2464 73 1854 41 1041 26 660 8 203 850 386 1,500,000 439
AFD-2000 1-1/2 40 1-1/2 40 100 2540 76 1930 44 1118 30 762 10-3/4 273 1500 680 2,000,000 585
AFD-3000 2 50 1-1/2 40 100 2540 76 1930 44 1118 36 914 12 305 1600 725 3,000,000 878
AFD-5000 2-1/2 65 2 50 127 3226 97 2464 65 1651 44 1118 16 406 2500 1136 5,000,000 1464
AFD-6000 3 80 2 50 132 3353 100 2540 70 1778 47 1194 18 457 2900 1316 6,000,000 1757
AFD-7000 3 80 2 50 139 3531 107 2718 77 1956 50 1270 18 457 3200 1455 7,000,000 2050
AFD-9000 3 80 2 50 169 4293 139 3531 107 2718 60 1524 20 508 5000 2273 9,000,000 2635
AFD-10000 3 80 2 50 181 4597 151 3835 119 3023 61 1549 20 508 5200 2405 10,000,000 2928
D
A
E
B
C

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9
Orientation
Lower
Canister
Upper
Canister
Top Plate
Blower
Blower Actuator Exhaust vent
Burner
Water pressure switch
Water inlet
High temp
shut-off switch
Level switches
Hot water outlet
Water temperature
sensor
Gas inlet
(behind pipe)
Drain plug
Fuel actuator
UV scanner
Anchoring tab
Disconnect panel
Water flow volume
adjust valve
Water inlet valve
Control panel See next page
for Fuel Train
components

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10
Low gas pressure switch
High gas pressure switch
Proof of Closure
(POC) switch
Dual blocking valves
Regulator
Regulated pressure display
Visual display of valve state
(white = closed red = open)
Fuel Train Components

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11
Transfer Pump Assembly
Component Material
Piping 304 OR 316 stainless steel
Braided flex hose Stainless steel
Pump Stainless steel (TEFC motor)
Globe valve Stainless steel
Stand Carbon steel (painted)
Model
Maximum
Flow Rate
Inlet
Connection
Outlet
Connection
Flow Control
Valve
Pump
Power
GPM m3/hr in. mm in. mm in. mm HP kW
TP-50 50 11.4 1-1/2 40 1-1/2 40 1 25 2 1.49
TP-90 90 20.4 1-1/2 40 2 50 1-1/2 40 3 2.24
TP-135 135 30.7 2 50 2-1/2 65 2 50 5 3.73
TP-200 200 45.4 2-1/2 65 3 80 2 50 7-1/2 5.59
TP-275 275 62.5 2-1/2 65 4 100 2-1/2 65 10 7.46
TP-350 350 79.5 3 80 4 100 3 80 10 7.46
Materials of Construction
Dimensions and Operational Specifications
Orientation
Pump
Water inlet

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12
Storage Tank
Design standard ASTM D49097-00
Maximum pressure Atmospheric
Vacuum None
Maximum temperature 180°F (82.2 °C)
Specific gravity 1.2
Seismic code/design None
Wind load 0 mph/kph
Immersion heater port 4" NPT
Sight glass port 1" NPT
Insulation thickness 2" (50 mm)
Component Material
Structural layer Fiber-reinforced plastic
Structural and liner resin DerakaneTM 441-400
Exterior layer resin Isophthalic polyester
Tank finish Gel coat with UV inhibitor
Color Gray (AT071)
Tank fittings Fiber-reinforced plastic
Vent Fiber-reinforced plastic
Manhole and cover Fiber-reinforced plastic
Manhole cover bolts Stainless steel
Manhole gasket EPDM
Hold down and lifting lugs Powder-coated carbon steel
Materials of Construction
General Specifications

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13
Orientation
Water inlet
Screened vent
Manway
Outlet
Outlet for immersion
heater (4" NPT)
Lower sight glass mount (1"
NPT)
(optional tank level sensor)
Float switch mount for low water
to pump cutoff (if used)
Thermometer mount
Float switch mount for
heater start
Upper sight glass
mount (1" NPT)
Float switch mount for heater stop
Recirculation return

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14
Assembly and Installation
Installing Large Heaters
Unpacking
Note:
• Obvious damage should be noted on delivery paperwork. Hidden damage must be reported to carrier within ten days.
• Cleaning heater using local plant standard is recommended prior to installation.
• Storage tanks are typically shipped directly from vendor.
Depending on heater size and mode of shipping, one of two scenarios may apply.
Small heaters (approximately AFD-5000 and under) when shipped with adequate height clearance in vehicle:
• Top plate and upper canister will be attached and upright.
• A fork lift will usually be adequate for moving. Use of a strap or chain is recommended.
Large heaters:
• Top plate will be bolted to lower canister.
• Upper canister will be on its side with top covered.
• A crane or hoist of some kind will be needed for moving. At least two, preferably four straps or chains will be needed.
1. Stand upper canister upright and position near final heater location.
Note: Remove cover and, if necessary, rearrange palls until they are approximately level and do not interfere with spray nozzles.
2. Wipe off flange and place gasket on it with holes aligned.
3. Remove cable ties from wiring and unbolt top plate from lower canister.

1
2
3
4
5
6
7
8
10
9
13
14
16
15
12 11
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15
Note: This pattern is for heaters
with 16 bolts. 24-bolt patterns
should be tightened similarly.
Attach as shown to keep plate approximately level.
Orient so union in fuel line can be connected.
Note: "Gas" and "fuel" are used interchangeably in this document.
Note: Top plates on largest heaters have lifting lugs.
Note: Long bolt in blower motor bracket must
be reinstalled in that hole.
4. Remove top plate from lower canister.
5. Position top plate on top of upper canister with holes aligned.
6. Install all bolts and start nuts. Liberal use of an anti-sieze compound is strongly recommended.
7. Tighten all bolts using pattern shown or similar.
8. Attach canister sections as for a small heater below.

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16
Installing Small Heaters
1. Place lower canister in final heater position:
• On level surface
• With adequate clearances
• With adequate support for operating weight
• With outlet facing transfer pump location
• Not near flammable or combustible materials
18" 48"
(sides
and back)
(front)
Wall
To transfer
pump
1
2
3
4
5
6
7
8
10
9
13
14
16
15
12 11
2. Wipe flange and gasket to remove any dirt or debris and place
gasket on flange of canister with holes aligned.
3. Move upper canister into position over lower canister using lift lugs.
4. Lower carefully until a few bolts can be inserted.
Tip: Using several tapered pry bars or long screwdrivers will aid in
aligning.
Note: Control panels are typically abovestandpipe (see approval
drawing for actual orientation). If slight indexing is required to align
outlet, some rewiring may be necessary between canister sections.
5. Lower upper canister completely, insert all bolts, and start
nuts. Liberal application of an anti-sieze compound is strongly
recommended.
6. Raise entire heater slightly above floor to allow self-aligning.
7. Snug all bolts using pattern shown or similar
8. Lower onto floor and tighten all bolts using pattern shown or
similar.
Note: Leakage is normal pending stress relief. Tighten applicable
bolts as required when leaks appear.
9. Armstrong recommends anchoring heater in place.
10. Repeat tightening sequence after several hours and after a few
days of operation or as leaks occur.

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17
Installing Exhaust Ducting
Note:
• Roof installation preferred.
• Flo-Direct heater is not naturally drafting; exhaust is under slight pressure.
• Insulation is not required because exhaust temperature is only a few degrees above incoming water temperature.
Install horizontal exhaust
duct sloping upward to drain
condensate in duct (1/4" per foot is
recommended).
Condensate will drip from end
of horizontal ducting. Install
where dripping will not be a
nuisance or ice a hazard.
Connect exhaust ducting
using either CPVC or single
wall, welded stainless steel.
Snap-together ducting is not
recommended.
Cover external termination with rain
guard and bird screen.
Models AFD-1000 and AFD-1500
require a rubber sewer connection
boot to connect. All other models
have a flange (shown). Joint
should be sealed with RTV (clear
silicone).
Exterior opening must
be at least equal to cross
section of exhaust duct.
Heater
stack
Roof
Wall
Provide independent support for
duct. Do not rest weight on heater.
Duct must be same
size or larger than
heater's exhaust
outlet. Armstrong recommends
no bend sharper than 45°.
Bird screen
installation is
recommended.

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18
Installing Intake Air Ducting
Using outside air is required.
Duct diameter must be at least
as large as intake diameter on
blower. 15% diameter increase
is recommended every 10 feet
removed from heater.
Material can be:
• CPVC
• Galvanized sheet metal
•Single wall stainless steel
Note:
Do not use manifold connected to other appliances.
Do not run heater under negative air pressure.
Typical enclosure in sheet
metal box with screen.
Provide independent
support for duct. Do not
rest weight on blower
inlet.
Roof
Wall
Top must be solid metal.
Bird screen required.
Flexible connector
required.

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19
Water Connections
Transfer pump assembly must
be installed on level surface
and at or below heater level to
maintain pump's prime.
Inlet water pipe must be at least as
large as heater's water inlet piping.
Maximum recommended water velocity
is 9 ft/sec in inlet piping.
Suction hose between heater
and transfer pump must be
flexible to isolate vibration.
Line from transfer pump must
be routed to top of storage
tank to prevent backflow.
If large pressure swings occur,
install pressure regulating
valve in inlet water line.
Lower canister
Storage tank
Note: Incoming water must not contain any chloride compounds above 100 ppm
or salts. These will destroy 304 stainless steel. (Alternative metals are available.)
Warranty is void unless clean, potable water is used.
Line from transfer pipe
must be at least as large as
transfer pump pipe. Check valve
recommended.

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20
Fuel Connection
Note: If codes require pressure test of fuel line, close ball valve entering
fuel train to heater. Failure to do so may damage fuel regulator.
1. Connect union in line between top plate and upper canister.
Note: Local codes may require routing regulator vent outside.
2. Connect gas supply (applicable codes may govern connection type). Provide adequate support.
3. With ball valve entering fuel train closed, purge air from fuel line.