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Flo-Direct

®

Complete Thermal Exchange Gas Fired Water Heater

Fault Display Explanation

Indicator Light # 1 Actuator Fault

The unit tried to start without the actuator in the low fi re position. Check that the switch located on the burner arm
is in contact and closed.

Indicator Light # 2 Flame Safety Fault

Check the Eclipse Veri-Flame Controller inside the Control Box. The LED on the Veri-Flamewill display as follows:

• Flame Failure. A fl ame was not detected when the unit should have one.

Check the spark plug wiring. Check the UV scanner.

• Air Failure. Check the air fl ow switch and the blower overloads.

• System Error. Indicates a failure of the fuel valve Proof of Closure

(P.O.C.) switch. Check the adjustment of the P.O.C. switch, and also

check the valve for proper closure.

Indicator Light # 3 Low Gas Pressure

The incoming fuel pressure has dropped below the setpoint of the low
gas pressure switch. Check the upstream pressure regulators and
upstream shut-off valves.

Indicator Light # 4 High Gas Pressure

The regulator has allowed gas pressure through that is too high. Lower the regulator outlet pressure by turning
the regulator adjustment screw counter-clockwise

Indicator Light # 5 High Temperature Fault

Water fl ow into the unit is restricted, and there has been a failure of the water pressure switch to shut the unit
off. This is the most critical safety on the unit, and is a back-up to the water pressure switch. If water pressure is
within limits, then the nozzles are clogged. Remove the top plate and clear the nozzles. Also, replace the fi lter
screen in the “Y” strainer.

Indicator Light # 6 Tank Full Fault

The hand valve is adjusted so that the pump does not pump out all of the water collection in the lower section
(with the bypass off the water level rises). Once the third fl oat switch is triggered the bypass solenoid will open
and the pump will remove more water than is coming into the unit. The water level will fall until the second fl oat
switch is triggered. Then the bypass solenoid will shut off. This cycle repeats continuously.

Indicator Light # 7 Water Pressure Fault

The water pressure is too low. Check the fl ow control adjustment. Check the solenoid.

Figure 36-1.

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Содержание Flo-Direct

Страница 1: ... such there may be customized components which are not specifically addressed within this document Supplemental Product Manual s and Installation and Maintenance Guides specific to the peripheral components supplied on with Flo Direct Water Heaters are available online at http www armstronginternational com water heaters direct contact all models or by calling Armstrong Toll Free at 1 888 HOT HOSE...

Страница 2: ...ire department Installation and service must be performed by a qualified installer service agency or the local gas supplier Customer Support Armstrong Hot Water Group Phone 269 279 3602 Fax 269 279 3130 e mail hotwater armstronginternational com www armstronginternational com Flo Direct Complete Thermal Exchange Gas Fired Water Heater Warning If the information in this manual is not followed exact...

Страница 3: ... Supplemental Heater Tank Operating Speciﬁcations 14 Armstrong Storage Supplemental Heater Tank Standard Materials of Construction 14 Armstrong Storage Supplemental Heater Tank Standard Dimensions and Weights 14 Flo Direct Complete Thermal Exchange Gas Fired Water Heater On Site Commissioning 15 Assembly Installation 16 Utility Connection 18 Start Up and Tuning 24 Sequence of Operation 27 Programm...

Страница 4: ..._____PSI 9 Inlet Water Train Material cirlce one Copper or 304L S S or Other ____________________ 10 Ultra Low NOX Burner Yes _____ No_____ 11 Modulating Burner Yes _____ No_____ 12 Type of Fuel ____________________ 13 System Voltage ____________________ Product Technical Detail For Remote Storage 2 Dual Pump Yes_____ No_____ 14 Control Voltage Transformer circle one Customer Supplied or Purchase ...

Страница 5: ... Thermal Exchange Gas Fired Water Heater This product manual specifically addresses the following assembly components Flo Direct CTE gas ﬁred water heater Models 1000 1500 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 and 15000 Transfer Pump Assemblies for all models listed above Storage Tanks ...

Страница 6: ... installation and operation manual supplied separately Burner Assembly Installation and Maintenance Service and Spare Parts handled directly by MAXON Corporation Phone 765 284 3304 Fax 765 286 8394 Blower Assembly Installation and Maintenance Service and Spare Parts handled directly by Cincinnati Corporation Phone 513 573 0600 Fax 513 573 0640 S5417 Fan Blower Burner Assembly Flo Direct Remote Sto...

Страница 7: ...tives Primary Markets include Hot Water Food Process Industries Washdown Batch Production Vessel Filling Tank Cleaning Concrete Plants Pre Heated Water for batch production Space Heating Greenhouses Re Circulated HW for general space heating Light Manufacturing Warehouses Re Circulated HW for general space heating General Industry Boiler Make Up Water Customized Hot Water System Solutions are our ...

Страница 8: ...xibility in rotating for easiest utility hookups Allows for ease of internal inspection Level controls automatically control the transfer pump included which delivers heated water to application Standard Low Nox 30 50ppm high efficiency burner blower for low carbon monoxide and nitrous oxide emissions Complies with even the most stringent emission standards and is an ideal element for companies se...

Страница 9: ...r produces hotter outlet water temperatures The products of combustion are vented out of the top of the unit and this exhaust is typically within a few degrees of incoming water temperature The Result The Armstrong Flo Direct CTE gas ﬁred water heater produces potable hot water instantaneously There is no fuel consumed for warm up or idle time No energy is lost through steam conversion or within a...

Страница 10: ...ontact water heaters spray water directly on the ﬂame sometimes called ﬂame quenching Flo Direct using CTE technology avoids this process altogether According to the Industrial Heating Equipment Association s Combustion Technology Manual ﬂame quenching promotes incomplete com bustion and produces alcohols aldehyde formic acid higher order acids carbon monoxide as well as carbon dioxide and water v...

Страница 11: ...mponents supplied on with Flo Direct water heaters are available online at http www armstronginternational com water heaters direct contact all models Safety Warnings Flo Direct CTE water heaters are precision engineered and crafted with pride to deliver years of energy savings and superior performance provided 1 They are installed commissioned operated and maintained in accordance with the recomm...

Страница 12: ...ur 1 2 A B C D E in mm in mm in mm in mm in mm in mm in mm lb kg 1000 1 25 1 25 95 2413 71 1803 39 991 24 610 8 203 825 375 1 000 000 1500 1 25 1 25 97 2464 73 1854 41 1041 26 660 8 203 850 386 1 500 000 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 3000 1 1 2 40 1 1 2 40 100 2540 76 1930 44 1118 36 914 12 305 1600 725 3 000 000 4000 2 50 2 50 104 2642 80 203...

Страница 13: ... 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 5 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 Component Material Piping Type L hard copper Braided Flex Hose Stainless Steel Pump Stainless Steel TEFC Motor Bypass Valve Bronze 110 VAC Solenoid Globe Valve Bronze Stand Carbon Steel Armst...

Страница 14: ... 112 2845 2600 1179 Specifications 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 2 NPT Sight Glass Ports 2 1 NPT Insulation Thicknesss 2 50 mm Component Material Structural Layer Fiber Reinforced Plastic Structural and Liner Resin DERAKANE 441 400 Exter...

Страница 15: ... performance guarantees Utility connections should be performed by a licensed professional in accordance with prevailing local state and national codes and regulations Failure to perform the utility connections in accordance with this product manual and or prevailing local state and national codes and regulations voids all warranties and performance guarantees On Site Commissioning Assembly and In...

Страница 16: ...ower Canister 6 Place the lower canister section on a ﬁrm level surface 7 Align the interface gasket with the bolt holes on the lower canister ﬂange as indicated in Fig 16 2 Note Upper canister and lower canister are marked to indicate suggested indexing 8 Deploying the appropriate materials handling equipment place the upper canister atop the lower canister ensuring that the bolt holes and gasket...

Страница 17: ...bber boot to seal the extension to the exhaust outlet Models 2000 and larger have a flanged connection Transfer Pump Connect the Transfer Pump Figure 17 2 to the lower canister water outlet using the suction hose provided The throttling valve Figure 17 3 controls the pump back pressure The outlet from the transfer pump assembly should be piped to the top of the supplemental storage tank Note The p...

Страница 18: ...E Automatic Mode The unit is started when the water level in the storage tank falls below the lower float switch The unit stops when the water level reaches upper switch is made Manual Mode The unit will run continuously until manually switched off Utility Connections Water Flo Direct CTE water heaters are supplied as standard with a Water Train Figure 18 1 comprised of lead free soldered copper p...

Страница 19: ...s pressure is 6 PSIG OPTIMUM gas pressure is 4 5 5 PSIG Flo Direct CTE water heaters are supplied as standard with a gas train Figure 19 1 comprised of malleable iron with a yellow ﬁnish The fuel train is supplied pre piped and pressure tested The fuel train includes the following components Figure 19 2 A low gas pressure switch assembly A proof of valve closure switch assembly A high gas pressure...

Страница 20: ... 2 which contains the primary power supply and component wiring connection points A variety of power supply voltages and internal connection options are available For the purposes of reduced complexity this Product Manual presumes the optimum 460 Volt 3 Phase Power supply Note A 230 Volt Power Supply can also be used BUT the Motor connections must be adapted accordingly Consult Factory for further...

Страница 21: ...r this conduit and wiring is shipped attached to the center canister Connect threaded ring on UV scanner to nipple installed on burner ﬂame sensor port Figure 21 2 Conduit 3 Top Plate Switch Group consisting of Water Pressure Switch Air Pressure Switch Burner Damper Actuator Damper Position Switch Note that the wiring harness for the top plate switch group is attached to the top plate only 1 Ident...

Страница 22: ...ed beneath the motor starter Figure 20 3 3 Tighten conduit ﬁttings Lower Canister Connections High Temperature Switch Figure 22 1 1 Route wiring from conduit attached to high temperature switch through far left bottom conduit entry knock out on control box 2 Connect numerically identiﬁed component wires to the coresponding numerically identiﬁed terminals on the terminal strip See ﬁgure 20 3 3 Tigh...

Страница 23: ...20 Volt hot lead to the bottom of the 5 Amp fuse holder Connect AC common to the ACC terminal Connect earth ground to the ground terminal Figure 20 3 Start Up Check Utilities Water 1 Turn on the water supply and ensure that a minimum of 30 PSI at the required ﬂow rate is available 2 Check the water supply pipe work for installation accuracy and leaks Note A water inlet ﬂow control valve is supplie...

Страница 24: ...begin to flow The burner Figure 24 3 will then ignite and once a flame is established within the flame tube the spark ignitor will turn off automatically Note On initial start up a gas train line air purge may be required Purging the air line will require repeated attempts to start the unit To reset error codes turn the Manual Off Auto switch to the Off position and then repeat steps 1 and 2 Flo D...

Страница 25: ...er heater During operation the throttling valve Figure 25 1 on the transfer pump assembly must be adjusted so that water slowly rises in the lower canister of the Flo Direct CTE instantaneous water heater Once the water level in the lower canister rises to a point where the float switch 3 activates the by pass on the transfer pump assembly will open automatically to increase the flow rate and lowe...

Страница 26: ... ignitor Figure 24 3 and Water will begin to flow The Burner Figure 24 2 will then ignite and once a flame is established within the flame tube the spark ignitor will turn off automatically Note On initial start up a gas train line air purge may be required Purging the air line will require repeated at tempts to start the unit To reset error codes turn the Manual Off Auto switch to the Off positio...

Страница 27: ... will illuminate 4 The Eclipse Veri Flame Controller checks that the air pressure switch is open and that the fuel valve is closed If all of the above conditions are met then Wire 48 Terminal 8 on the Veri Flame Controller is energized starting the blower motor Figure 24 2 5 When the blower is started the Eclipse Veri Flame Controller looks for a signal from the air pressure switch Air flow pressu...

Страница 28: ...s are supplied with a pre programmed Programmable Logic Controller PLC Fig 28 2 Re programming of the PLC onsite is not required Re programming of the PLC onsite without written factory approval will void all warranties and factory service commitments The PLC has 10 inputs and 8 outputs Whenever an input or output is active a corresponding LED on the PLC will light The LED are numerically identifi...

Страница 29: ...s Pressure Switch fig 19 2 by shutting off the fuel flow into the Flo Direct CTE gas fired water heater during operation The low gas pressure fault light on the front of the control box will illuminate and the unit will shut off Check the high temperature switch Fig 22 1 by unscrewing the cover on the switch With the High Temperature Switch cover removed note the live 120 volt connection adjacent ...

Страница 30: ...er and the Eclipse Veri Flame controller should not keep the safety shutoff valves open after the end of the trial for ignition After that the Eclipse Veri Flame controller should have no indication of flame and it should de energize the safety shut off valves If the Eclipse Veri Flame controller does not respond as instructed above it failed the test and a hazard condition exists Discontinue oper...

Страница 31: ...sformer 0707080 5 Flame Safety Module Eclipse Veri Flame 0705070 6 Fuse Block DIN Rail Mount 036 500 940 7 Circuit Block IEC Single Feed DIN Rail Mount 036 500 950 8 Motor Start 5 Horsepower 0707520 7 5 Horsepower 0707510 10 Horsepower 0707500 15 Horsepower 0707530 20 Horsepower 0707540 25 Horsepower 0707550 30 Horsepower 0707560 9 Motor Overload 1 6 5A 0707630 3 2 16A 0707620 5 4 27A 0707625 9 45...

Страница 32: ... Spring AFD 1 000 TO AFD 4 000 Black 24 44 0702332 AFD 1 000 TO AFD 4 000 Yellow 12 28 0702320 AFD 5 000 TO AFD 10 000 Black 24 44 0702330 AFD 5 000 TO AFD 10 000 Yellow 12 28 0702331 AFD 11 000 TO AFD 15 000 Black 24 44 0702335 AFD 11 000 TO AFD 15 000 Yellow 12 28 0702336 5 Dual Blocking Valve Assembly AFD 1 000 TO AFD 4 000 0702120 AFD 5 000 TO AFD 10 000 0702130 AFD 11 000 TO AFD 15 000 080213...

Страница 33: ...s 1 Ball Valve 1 6270002 1 1 2 6270006 2 6270008 2 1 2 6270010 3 6270012 4 Gate Valve 6270034 2 Weathermatic Valve 1 0701400 1 1 2 0701410 2 0701420 2 1 2 0701430 3 0701440 4 Gate Valve 6270034 Weathermatic Valve Diaphragm Assembly 1 D8655 1 1 2 D8656 2 D8657 2 1 2 D8658 3 D8659 3 Solenoid SOL 7 110V 0705200 4 Pressure Gauge 0 110 psi 0705240 5 Water Pressure Switch 0705120 ...

Страница 34: ...5060 Modulating Actuator 0705064 Upper Canister Powers 535 Modulating Controller 0705130 RTD Temperature Sensor 3 0705000 AFD 1 000 Flange Gasket 0702000 AFD 1 500 Flange Gasket 0702003 AFD 2 000 Flange Gasket 0702006 AFD 3 000 Flange Gasket 0702010 AFD 4 000 Flange Gasket 0702015 AFD 5 000 Flange Gasket 0702020 AFD 6 000 Flange Gasket 0702025 AFD 7 000 8000 Flange Gasket 0702030 AFD 9 000 Flange ...

Страница 35: ...switch on the fuel train See figure 19 2 Indicator Light 5 High Temperature Fault Remove the cover of the high temperature switch on the lower canister figure 22 1 and push the re set button Danger The cause of this fault must be determined and corrected for safe operation Indicator Light 6 Tank Full Fault The unit will pump the lower cannister down to a level below the second float switch In Auto...

Страница 36: ...Gas Pressure The regulator has allowed gas pressure through that is too high Lower the regulator outlet pressure by turning the regulator adjustment screw counter clockwise Indicator Light 5 High Temperature Fault Water fl ow into the unit is restricted and there has been a failure of the water pressure switch to shut the unit off This is the most critical safety on the unit and is a back up to th...

Страница 37: ...37 Notes ...

Страница 38: ...38 Notes ...

Страница 39: ...39 Notes ...

Страница 40: ...ed by Armstrong however caused and whether such claim is based upon warranty contract negligence strict liability or any other basis or theory is limited to Armstrong s repair or replacement of the part or product excluding any labor or any other cost to remove or install said part or product or at Armstrong s option to repayment of the purchase price As a condition of enforcing any rights or reme...

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