Armstrong Flo-Direct AFD-1000 User manual
Keep this manual
with
heater for future
reference.
Armstrong
International
221
Armstrong Blvd., Three Rivers, Michigan, 49093
-
USA
Ph. (269) 279-3602 Toll Free (888)
HOT-HOSE
(468-4673)
Fax
(269) 279-3130
Flo-Direct
®
Complete Thermal
Exchange Gas
Fired Water Heater
Installation, Operation, and
Maintenance Manual
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.
Certified
to
5
U.S. patent
5,924,391
Armstrong
International
221
Armstrong Blvd., Three Rivers, Michigan, 49093
-
USA
Ph. (269) 279-3602 Toll Free (888)
HOT-HOSE
(468-4673)
Fax
(269) 279-3130
Contents
Safety
.....................................................
1
The Flo-Direct System
................................
2
Typical System
..................................................................
2
Specifications
.....................................................................
4
Heater...............................................................................
4
Materials of Construction .........................................
4
Operational Specifications .......................................
4
Technical Specifications...........................................
4
Dimensions...............................................................
5
Orientation ................................................................
6
Transfer Pump Assembly.................................................
8
Materials of Construction .........................................
8
Dimensions and Operational Specifications ............
8
Orientation ................................................................
8
Storage Tank....................................................................
9
Materialsof
Construction ........................................
9
General
Specifications..............................................
9
Specifications by Model ..................................
9
Orientation ...........................................................
10
Assembly and Installation....................
11
Unpacking ......................................................................... 11
Installing Large Heaters ................................................. 11
Installing Small Heaters ................................................. 13
Installing Exhaust Ducting ............................................ 15
Installing Intake Air Ducting.......................................... 16
Water Connections ......................................................... 17
Fuel Connection .............................................................. 18
Electrical Panels ...................................
19
Control Panel.................................................................... 19
Disconnect Panel ............................................................ 20
Heater Label................................................................... 20
Electrical Connections.................................................... 21
Top Plate
to
Upper
Canister .............................................
21
Upper
to Lower Canister..................................................
22
Transfer
Pump .................................................................
23
Storage Tank......................................................................
23
Main Power Connection ..................................................
24
Operation...............................................
25
Description of Operation................................................ 25
Sequencing of Operation............................................... 26
Pre-Startup Checklist...................................................... 27
Commissioning.....................................
28
Inspecting Installation..................................................... 28
Inspecting Water System............................................... 28
Commissioning................................................................ 28
Periodic Maintenance...........................
30
Maintenance
Schedule .................................... 30
High Temperature Switch Check.................................31
Troubleshooting ...................................
32
Troubleshooting
T
able.................................................32
PLC I/Os .......................................................................................... 33
Parts Lists .............................................
34
Top Plate ......................................................................................34
Water Train..................................................................................35
Control Box.................................................................................36
Disconnect Box.........................................................................37
Fuel
T
rain.........................................................................38
Lower Canister................................................................. 39
Storage Tank.........................................................................40
Appendix: Modulating Burner.............
41
Descriptions of the major modulation
components............................................................... 41
Operation .................................................................... 42
Limited Warranty and Remedy.........................
44
Notes...................................................................
45
Armstrong
International
IOM-706 V2.0
Flo-Direct Water
Heater
Page
1 of 45
Icon Legend
If
instructions are not
followed:
—
injury
or
death and property damage are
imminent
—
injury
or
death and property damage are
possible
—
potential property damage, expensive repairs, and/or voiding the warranty may
result
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.
Applicable codes must be followed
and
supersede any other instructions. Generally
applicable codes
in
the US
include:
•
NEC
•
NFPA
#86
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.
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.
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.
Armstrong
International
IOM-706 V2.0
Flo-Direct Water
Heater
T
ypical System
Page
2 of 45
The
Flo-Dir
ect
System
Armstrong's Flo-Direct water
heaters:
Are designed
for
industrial
applications
Use complete thermal exchange
technology
Come
in
sizes from
1 to
16 million
Btu/hr
Heat water up
to
185 °F
maximum
Typical System
Heater
T
ransfer
Pump
Storage
T
ank
Armstrong reserves the right
to
make design
or
specification changes without
notification.
Armstrong
International
IOM-706 V2.0
Flo-Direct Water
Heater
T
ypical System
Page
3 of 45
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.
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.
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)
For further information, visit
http://www
.armstronginternational.com/flo-direct
or
contact
Armstrong.
Note
: Armstrong provides separate IOMs
for
the burner, blower, and
for optional
components. Consult the appropriate document
for
more
information.
Armstrong
International
IOM-706 V2.0
Flo-Direct Water
Heater
Specifications
—
Heater
Page
4 of 45
Specifications
Heater
Materials of Construction
Component
Material
Canister
304 SS (10 ga.
≤
AFD-8000; 3/16 >
AFD-8000)
Canister
gasket
WARCO white (food grade buna
rubber)
Flame
tube
304 SS
Gas
piping
Malleable iron with standard yellow
finish
Water
piping
Copper with brass
or
bronze fittings OR welded SS
Spray
ring
304/316 SS
Pall
ring
304 SS
Operational
Specifications
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
120 °F
0
°C
to
49
°C
Outlet water
temperature
185 °F
85
°C
Water temperature
differential
10 °F
to
140 °F
5.6 °C
to
77.8
°C
NOx
emission
30–50
ppm
Thermal
efficiency
99.7%
Technical
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
Armstrong
International
IOM-706 V2.0
Flo-Direct Water
Heater
Specifications
—
Heater
Page
5 of 45
Dimensions
E
C
A
2
B
1
D
Model
Connections*
Dimensions
Weight
Btu/hr
kW
1
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 10¾ 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-4000
2
50
2
50 104 2642 80 2032 48 1214 40 1016
14
356 2000 907 4,200,000 1171
AFD-5000 2-1/2 65
2
50 127 3226
97
2464
65
1651 44 1118 16 406 2500 1136 5,300,000 1464
AFD-6000
3
80
2
50 132 3353 100 2540 70 1778 47 1194 18 457 2900 1316 6,300,000 1757
AFD-7000
3
80
2
50 139 3531 107 2718 77 1956 50 1270 18 457 3200 1455 7,400,000 2050
AFD-8000
3
80
2
50 139 3531 107 2718 77 1956 50 1270 18 457 3200 1455 8,400,000 2342
AFD-9000
3
80
2
50 169 4293 139 3531 107 2718 60 1524
20
508 5000 2273 9,500,000 2635
AFD-10000
3
80
2
50 181 4597 151 3835 119 3023 61 1549
20
508 5200 2405 10,500,000 2928
AFD-11000
4
100
3
80 181 4597 151 3835 119 3023 61 1549
22
559 5500 2495 11,600,000 3221
AFD-12000
4
100
3
80 181 4597 151 3835 119 3023 61 1549 22 559 5500 2495 12,600,000 3514
AFD-13000
4
100
3
80 192 4877 161 4089 129 3277 70 1778 24 610 7000 3175 13,700,000 3807
AFD-14000
4
100
3
80 192 4877 161 4089 129 3277 70 1778 24 610 7000 3175 14,700,000 4099
AFD-15000
4
100
3
80 192 4877 161 4089 129 3277 70 1778 24 610 7000 3175 15,800,000 4392
AFD-16000
4
100
3
80 216 5486 185 4699 153 3886 70 1778
24
610 7500 3402 16,000,000 4685
*Connections may be NPT, flanged,
or
use a sanitary ferrule as
required.
Armstrong
International
IOM-706 V2.0
Flo-Direct Water
Heater
Specifications
—
Heater
Page
6 of 45
Orientation
UV scanner
Top
Plate
Blower
Exhaust vent
Burner
actuator
Burner
Upper
Canister
Water
pressure
switch
Water flow
volume
adjust
valve
Water inlet
valve
Control
panel
See next page
for Fuel
T
rain
components
Disconnect
panel
Gas
inlet
(behind pipe)
W
ater
inlet
High
temp
shut-off switch
Lower
Canister
Level
switches
Hot water outlet
Drain plug
Anchoring
tab
Armstrong
International
IOM-706 V2.0
Flo-Direct Water
Heater
Specifications
—
Heater
Page
7 of 45
Fuel Train Components
Regulated
pressure
display
High gas
pressure
switch
Low gas
pressure
switch
Proof of Closure
(POC) switch
Dual blocking
valves
Visual display of
valve
state
(white =
closed
red =
open)
Regulator
Armstrong
International
IOM-706 V2.0
Flo-Direct Water
Heater
Specifications
—
T
ransfer Pump Assembly
Page
8 of 45
Transfer
Pump
Assembly
Materials of Construction
Component
Material
Piping
Type
L
hard copper/welded 304 OR 316 stainless
steel
Braided flex
hose
Stainless
steel
Pump
Stainless steel (TEFC
motor)
Bypass
valve
Bronze (110 VAC
solenoid/stainless steel motorized butterfly
valve)
Globe
valve
Bronze/stainless
steel
Stand
Carbon steel
(painted)
Dimensions and Operational
Specifications
Model
Maximum
Flow
Rate
Inlet
Connection
Outlet
Connection
Flow Control
V
alve
Bypass
V
alve
Pump
Power
GPM
m
3
/
h
r
in.
mm
in.
mm
in.
mm
in.
mm
HP
kW
TP-50 50 11.4 1-1/2 40 1-1/2
40
1
25
1
25
2
1.49
TP-90 90 20.4 1-1/2 40
2
50
1-1/2
40
1-1/2 40
3
2.24
TP-135 135 30.7
2
50 2-1/2
65
2
50
1-1/2 40
5
3.73
TP-200 200 45.4 2-1/2 65
3
80
2
50
2
50 7-1/2 5.59
TP-275 275 62.5 2-1/2 65
4
100 2-1/2
65
2
50
10
7.46
TP-350 350 79.5
3
80
4
100
3
80
2
50
10
7.46
Orientation
Water outlet
Bypass
Throttling
valve
Solenoid
valve
Pump
Water
inlet
Armstrong
International
IOM-706 V2.0
Flo-Direct Water
Heater
Specifications
—
Storage
T
ank
Page 9
of 45
Storage
T
ank
Materials of Construction
Component
Material
Structural
layer
Fiber-reinforced
plastic
Structural and liner
resin
Derakane
TM
441-400
Exterior layer
resin
Isophthalic
polyester
Tank
finish
Gel coat with UV
inhibitor
Color
Gray
(AT071)
Tank
fittings
Fiber-reinforced
plastic
V
ent
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
General
Specifications
Design
standard
ASTM
D49097-00
Maximum
pressure Atmospheric
V
acuum
None
Maximum
temperature
180 °F (82.2
°C)
Specific
gravity 1.2
Seismic
code/design None
Wind
load 0 mph/kph
Immersion heater
port
2" NPT
Sight glass
port
1" NPT
Insulation
thickness
2" (50
mm)
Specifications by
Model
Model
Nominal Storage
V
olume
No. Inlet
Connections
Piping Connections
Height
Diameter
Weight
(Empty)
Inlet
Outlet
Gal
m
3
in.
mm
in.
mm in. mm in. mm
lb
kg
RST
-1001
1000 3.785
1
2-1/2 NPT
65 2
NPT
50 96 2442 65 1651 1200 544
RST
-3001
3000 11.36
1
3
NPT
80 3
Flange
80 148 3759 87 2210 2000 907
RST
-5001
5000 18.93
1
4
Flange
100 4
Flange
100 152 3861 113 2870 2600 1179
RST
-5002
5000 18.93
2
4
Flange
100 4
Flange
100 152 3861 113 2870 2600 1179
Armstrong
International
IOM-706 V2.0
Flo-Direct Water
Heater
Specifications
—
Storage
T
ank
Page 10
of 45
Orientation
Screened vent
Water
inlet
Recirculation
return
Manway
Upper sight glass
mount (1"
NPT)
Float switch mount
for heater stop
Float switch mount
for heater
start
Thermometer
mount
Lower sight glass
mount (1"
NPT)
Float switch mount
for low water to
pump cutoff
(if used)
Outlet
Outlet for immersion
heater (2"
NPT)
Armstrong
International
IOM-706 V2.0
Flo-Direct Water
Heater
Page 11
of 45
Assembly
and
Installation
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.
Installing Large Heaters
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.
Note
: Long bolt
in
blower motor bracket
must
be reinstalled
in
that
hole.
Armstrong
International
IOM-706 V2.0
Flo-Direct Water
Heater
Page 12
of 45
4
Remove top plate
from
lower
canister.
Attach as shown
to
keep
plate
approximately level.
Note
: Top plates on largest
heaters have lifting
lugs.
5
Position top plate
on
top
of
upper canister
with holes
aligned.
Orient so union
in
fuel
line can be connected.
Note
: "Gas" and "fuel"
are
used interchangeably
in
this
document.
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.
Note
: This pattern
is for
heaters with 16
bolts.
24-bolt patterns should
be
tightened
similarly.
1 9
5
16
13
8
3
12
11
4
7
14
15
6
2
10
8
Attach canister sections
as
for
a small heater
below.
Armstrong
International
IOM-706 V2.0
Flo-Direct Water
Heater
Page 13
of 45
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
To transfer
pump
2
Wipe flange and gasket
to
remove any
dirt
or
debris and place gasket on flange
of
18" 48"
canister with holes aligned.
3
Move upper
canister
into position over
lower
canister using
lift lugs.
(sides and
back)
Wall
(front)
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
above
standpipe (see approval drawing
for actual
orientation).
If
slight indexing
is
required
to
align outlet, some rewiring may be
necessar
y
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.
Armstrong
International
IOM-706 V2.0
Flo-Direct Water
Heater
Page 14
of 45
7
Snug all bolts using pattern
shown
or similar.
1 9
5
16
13
8 3
12 11
4 7
14
15
6
2
10
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.
Armstrong
International
IOM-706 V2.0
Flo-Direct Water
Heater
Installing Exhaust Ducting
Page 15
of 45
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.
Cover
external
termination with
rain
guard and bird screen.
Exterior
opening
must be at least equal
to
cross section
of
exhaust
duct.
Provide
independent
support
for
duct. Do
not
rest weight on
heater.
Install horizontal
exhaust
duct sloping upward
to
drain
condensate
in
duct (1/4"
per
foot
is recommended).
Roof
Connect
exhaust
ducting using
either
CPVC
or
single
wall,
welded stainless steel.
Snap-together
ducting
is
not recommended.
Bird
screen
installation
is
recommended.
Duct must
be
same size
or
larger
than
heater's
exhaust
outlet.
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
R
TV
(clear
silicone).
Heater
stack
Armstrong
recommends
no
bend
sharper
than
45°.
Wall
Condensate
will drip
from end
of
horizontal
ducting. Install where
dripping
will
not be a
nuisance
or
ice a
hazard.
Armstrong
International
IOM-706 V2.0
Flo-Direct Water
Heater
Installing Intake Air Ducting
Page 16
of 45
Installing Intake
Air
Ducting
Note:
Do not
use manifold connected
to
other
appliances.
Do not
run heater under negative air
pressure.
Top must be solid
metal.
Typical enclosure
in
sheet metal box
with
screen.
Roof
Provide
independent
support
for duct.
Do not rest weight
on
heater.
Bird screen
required.
Wall
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
Armstrong
International
IOM-706 V2.0
Flo-Direct Water
Heater
W
ater Connections
Page 17
of 45
Water Connections
Warranty
is
void unless clean,
potable water
is used.
If
large pressure swings
occur, install
pressure
regulating valve
in inlet
water
line.
Note
: Incoming water must
not
contain any chloride compounds
above 100 ppm
or
salts. These
will
destroy 304 stainless
steel.
(Alternative metals are available.)
Line from
transfer
pump must be routed
to
top
of
storage
tank
to
prevent
backflow.
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.
Line from
transfer
pipe must be at least
as large as
transfer
pump
pipe.
Storage tank
Suction hose between
heater and
transfer
pump must be flexible
to
isolate
vibration.
Lower
canister
Transfer pump assembly
must
be installed on level
surface
and at
or
below heater level
to
maintain pump's
prime.
Armstrong
International
IOM-706 V2.0
Flo-Direct Water
Heater
Fuel Connection
Page 18
of 45
Fuel
Connection
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.
Note:
Do not put excess weight on heater
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.
3
With ball valve entering fuel
train
closed, purge air from fuel
line.
This manual suits for next models
16
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