Armstrong Flo-Direct 2.0 AFD-1000 Installation, Operation And Maintenance Manual Download Page 1

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Flo-Direct

2.0 Complete Thermal

Exchange Gas Fired Water Heater

Installation, Operation, and Maintenance Manual

Certified to

U.S. patent 5,924,391

706-EN V7.0

Please read and save

these instructions

Summary of Contents for Flo-Direct 2.0 AFD-1000

Page 1: ...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...

Page 2: ...ge 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...

Page 3: ...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 o...

Page 4: ...u 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 bypas...

Page 5: ...mate and subject to change without notice Visit armstronginternational com for up to date information 5 The Flo Direct System Armstrong s Flo Direct water heaters Are designed for industrial applicati...

Page 6: ...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...

Page 7: ...ed 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...

Page 8: ...nsions 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...

Page 9: ...com for up to date information 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 switch...

Page 10: ...rmance ratings are approximate and subject to change without notice Visit armstronginternational com for up to date information 10 Low gas pressure switch High gas pressure switch Proof of Closure POC...

Page 11: ...teel 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...

Page 12: ...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...

Page 13: ...ce Visit armstronginternational com for up to date information 13 Orientation Water inlet Screened vent Manway Outlet Outlet for immersion heater 4 NPT Lower sight glass mount 1 NPT optional tank leve...

Page 14: ...ne 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 lif...

Page 15: ...milarly 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 h...

Page 16: ...osition 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 typ...

Page 17: ...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 w...

Page 18: ...equired 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 wa...

Page 19: ...r 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...

Page 20: ...te information 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 bet...

Page 21: ...ings are approximate and subject to change without notice Visit armstronginternational com for up to date information 21 Electrical Panels Control Panel Spark generator LMV3 Controller Hour meter Fuse...

Page 22: ...and subject to change without notice Visit armstronginternational com for up to date information 22 Disconnect Panel Control transformer 3 phase to 120V Main fused disconnect Transfer Pump VFD Termin...

Page 23: ...schematic provided with your heater for exact details Remove all cable ties bubble wrap and tape from wiring 4 Reconnect spark rod wire to spark rod in burner 5 Reconnect threaded fitting to burner f...

Page 24: ...n wires and conduit for these connections may not be the correct length Rewire if necessary 1 Thread high temperature switch wiring into control panel 2 Reconnect conduit 3 Connect wires to correspond...

Page 25: ...nals on terminal block 1 Install float switches from Armstrong in tank oriented as shown For float orientation consult wiring diagram supplied with unit Main Power Connection Note If facility does not...

Page 26: ...ucing no undesirable gases Water is dispersed into upper canister and is broken into ever smaller droplets by passing down through palls Water is heated as combustion gases pass up through palls and o...

Page 27: ...and then the Spark rod will de energize Phase 42 A Flame Signal must be detected by the end of this Phase The HMI displays the Flame Signal ranging from 0 100 A Flame Failure occurs when the Flame Si...

Page 28: ...canister float switches High temperature switch Transfer pump Remote storage tank switches or field supplied relay coil in control panel Fuel line connected Adequately sized Adequately supported Press...

Page 29: ...1 Confirm all checks in start up checklist above 2 Check all field connections in control panels 3 Identify any additional wiring in panels 4 Confirm rotation of blower and pump motors 5 Confirm what...

Page 30: ...er pressure to obtain target output temperature if necessary 6 Adjust Low and High Speed on Transfer Pump Screen so the VFD cycles between the two speeds Level should fluctuate slowly between second a...

Page 31: ...window Check spark rod connection and wire Check the Siemens controller With heater running close ball valve in fuel train just upstream of burner Burner should go out The Siemens controller should F...

Page 32: ...ternational com for up to date information 32 High Temperature Switch Check 1 With heater on but not running unscrew cover on switch shown removed below 2 Compress spring to trip switch 3 Confirm that...

Page 33: ...losed Open all upstream valves Defective pressure regulator spring Replace spring Defective pressure regulator Replace regulator High Gas Pressure Transitory alarm or to confirm fault Press red reset...

Page 34: ...n Water Pressure Fault Flow control valve restricted Open flow control valve Shut off valve defective Repair or replace valve Restriction in inlet line Check filters and piping for obstructions Low sy...

Page 35: ...D17513 Flange Gasket WARCO White 1 Spark Rod 47232 D19194 10 AFD 1000 D7564 2 3 AFD Spark Plug Wire Kit Includes Pug End Connector Spark Plug Boot 15 Spark Plug Wire and Terminal Ring D89821 AFD 1500...

Page 36: ...nternational com for up to date information 36 Water Train Ref No Description Part No 1 Water Pressure Switch D16905 2 Pressure Gauge 0 110 psi D11554 Globe Valve Stainless Steel 3 1 D14596 1 1 2 D145...

Page 37: ...on 37 Control Panel Ref No Description Part No 1 HMI Panelview Plus 7 9 Inch D106961 2 Emergency Stop Button D106011 3 Ignition Transformer D19185 4 Siemens LMV3 D115428 5 Modbus Module D115434 6 PLC...

Page 38: ...use Cover Bus Indicating 15A D19614 5 30A D19762 17 1 2A D19615 60A D22629 20A D19616 100A D21900 25A D19617 6 Fuse Cover Bus Non Indicating D17413 30A D19618 Disconnect Handle 35A D19619 7 30A 60A D1...

Page 39: ...FD 5000 to AFD 10000 FRS 720 6 D14807 Gas Regulator Spring 4 AFD 1000 to AFD 4000 Yellow 12 28 w c D11555 AFD 1000 to AFD 4000 Black 24 44 w c D14809 AFD 5000 to AFD 10000 Yellow 12 28 w c D19189 AFD...

Page 40: ...5 100 D27358 5 Drain Plug 1 NPT 304 SS D16918 6 Plug NPT 304 SS D11018 7 Wiring Trough Drilled for Standpipe D17265 All 4 float switches swing downward Secured to float switches pumped only For pumpe...

Page 41: ...ange without notice Visit armstronginternational com for up to date information 41 Storage Tank Ref No Description Part No 1 Bushing CPVC 4 x 1 2 NPT D18785 2 Float Switch Polypropylene D16907 3 Therm...

Page 42: ...in detail on navigating though the HMI Depending on the options installed additional selections may be available The base selections are shown below NOTE BLUE denotes a user selection button or input...

Page 43: ...grees Air Actr Pos Position of the air actuator in degrees Outlet Temp Outlet water temperature in degrees Fahrenheit Basin Level Level of the lower basin corresponding with the float switches in the...

Page 44: ...ing in MANUAL mode When AUTO mode is selected the heater will switch to MODULATING mode To adjust your setpoint either degrees Fahrenheit in Modulating mode or Output position in Positioning mode You...

Page 45: ...nu Screen This screen is used to navigate through the HMI Each button will take you to its corresponding screen These screens will be explained in detail below Main Screen This button takes you to the...

Page 46: ...een displays all the PLC inputs outputs and VFD commands with an indicator denoting their status The indicator will be lit when the input output or command is on Pressing the BACK button will return y...

Page 47: ...Trending Screen The Trending screen records a 10 minute trend of the heaters Setpoint Outlet Water Temp and Burner Position Pressing the BACK button will return you to the MENU screen 47...

Page 48: ...emperature Fault Low Gas Pressure and High Gas Pressure require a manual reset of that component All active FSF will display an Error and Diagnostic Code at the bottom of the screen for more details o...

Page 49: ...s the status of the transfer pump See example below The water level in the lower basin is at the second float switch The transfer pump is running at LOW speed To adjust the speeds of the VFD press eit...

Page 50: ...to Armstrong i within 30 days of last day of the applicable warranty period or ii within 30 days of the date of the manifestation of the condition or occurrence giving rise to the claim whichever is...

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