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Flo-Direct
Certified to
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
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.
5
U.S. patent 5,924,391
Keep this manual with
heater for future reference.
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Table of Contents
Related Manuals for Armstrong Flo-Direct AFD-1000
Summary of Contents for Armstrong Flo-Direct AFD-1000
- Page 1 Certified to U.S. patent 5,924,391 Keep this manual with Armstrong International 221 Armstrong Blvd., Three Rivers, Michigan, 49093 - USA heater for future reference. Ph. (269) 279-3602 Toll Free (888) HOT-HOSE (468-4673) Fax (269) 279-3130...
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Page 2: Table Of Contents
Limited Warranty and Remedy ......Disconnect Panel ............20 Notes ..............Heater Label ..............20 Electrical Connections ............ 21 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... -
Page 3: Safety
Improper installation or operation may cause a fire or applicable codes in the US include: explosion resulting in property damage, personal • NEC injury, or death. Armstrong strongly recommends that • NFPA #86 a qualified installer be used. Service must be performed by a qualified person. -
Page 4: The Flo-Direct System
Armstrong reserves the right to make design or specification changes without notification. Armstrong International Typical System IOM-706 V2.0 Page 2 of 45 Flo-Direct Water Heater... - Page 5 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 Typical System IOM-706 V2.0 Page 3 of 45...
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Page 6: 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 Specifications — Heater IOM-706 V2.0... -
Page 7: Dimensions
3175 15,800,000 4392 AFD-16000 5486 4699 3886 1778 7500 3402 16,000,000 4685 *Connections may be NPT, flanged, or use a sanitary ferrule as required. Armstrong International Specifications — Heater IOM-706 V2.0 Page 5 of 45 Flo-Direct Water Heater... -
Page 8: Orientation
High temp shut-off switch Lower Level Canister switches Hot water outlet Anchoring tab Drain plug Armstrong International Specifications — Heater IOM-706 V2.0 Page 6 of 45 Flo-Direct Water Heater... - Page 9 Dual blocking valves Visual display of valve state (white = closed red = open) Regulator Armstrong International Specifications — Heater IOM-706 V2.0 Page 7 of 45 Flo-Direct Water Heater...
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Page 10: Transfer Pump Assembly
Water outlet Throttling valve Solenoid valve Pump Water inlet Armstrong International Specifications — Transfer Pump Assembly IOM-706 V2.0 Page 8 of 45 Flo-Direct Water Heater... -
Page 11: Storage Tank
2210 2000 RST-5001 5000 18.93 4 Flange 4 Flange 3861 2870 2600 1179 RST-5002 5000 18.93 4 Flange 4 Flange 3861 2870 2600 1179 Armstrong International Specifications — Storage Tank IOM-706 V2.0 Page 9 of 45 Flo-Direct Water Heater... -
Page 12: Orientation
Lower sight glass pump cutoff (if used) mount (1" NPT) Outlet Outlet for immersion heater (2" NPT) Armstrong International Specifications — Storage Tank IOM-706 V2.0 Page 10 of 45 Flo-Direct Water Heater... -
Page 13: Assembly And Installation
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 Page 11 of 45 Flo-Direct Water Heater... - Page 14 Note: This pattern is for heaters with 16 bolts. 24-bolt patterns should be tightened similarly. Attach canister sections as for a small heater below. Armstrong International IOM-706 V2.0 Page 12 of 45 Flo-Direct Water Heater...
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Page 15: Installing Small Heaters
Lower upper canister completely, insert all bolts, and start nuts. Liberal application of an anti-sieze compound is strongly recommended. Raise entire heater slightly above floor to allow self-aligning. Armstrong International IOM-706 V2.0 Page 13 of 45 Flo-Direct Water Heater... - Page 16 Note: Leakage is normal pending stress relief. Tighten applicable bolts as required when leaks appear. Armstrong recommends anchoring heater in place. Repeat tightening sequence after several hours and after a few days of operation or as leaks occur.
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Page 17: Installing Exhaust Ducting
AFD-1500 require a rubber Heater sewer connection boot to stack connect. All other models have a flange (shown). Joint should be sealed with RTV (clear silicone). Armstrong International Installing Exhaust Ducting IOM-706 V2.0 Page 15 of 45 Flo-Direct Water Heater... -
Page 18: Installing Intake Air Ducting
15% diameter increase Material can be: is recommended every 10 feet • CPVC removed from heater. • Galvanized sheet metal • Single wall stainless steel Armstrong International Installing Intake Air Ducting IOM-706 V2.0 Page 16 of 45 Flo-Direct Water Heater... -
Page 19: Water Connections
Lower canister Transfer pump assembly must be installed on level surface and at or below heater level to maintain pump's prime. Armstrong International Water Connections IOM-706 V2.0 Page 17 of 45 Flo-Direct Water Heater... -
Page 20: Fuel Connection
Failure to do so may damage fuel regulator. With ball valve entering fuel train closed, purge air from fuel line. Armstrong International Fuel Connection IOM-706 V2.0 Page 18 of 45 Flo-Direct Water Heater... -
Page 21: Electrical Panels
Terminal block Fuse 1 (5A) Control Panel Cover (non-modulating) Armstrong International Control Panel IOM-706 V2.0 Page 19 of 45 Flo-Direct Water Heater... -
Page 22: Disconnect Panel
Note: This is a sample label. All electrical work must conform to the specifications on this label as found on your heater. Armstrong International Heater Label IOM-706 V2.0 Page 20 of 45 Flo-Direct Water Heater... -
Page 23: Electrical Connections
Note: Wires are labeled. Confirm labeling of starter by checking for wire labeled 48A below it. Armstrong International Electrical Connections IOM-706 V2.0 Page 21 of 45 Flo-Direct Water Heater... -
Page 24: Upper To Lower Canister
Reconnect conduit. Connect wires to corresponding number locations in terminal block. Repeat for float switch wiring from standpipe. Armstrong International Electrical Connections IOM-706 V2.0 Page 22 of 45 Flo-Direct Water Heater... -
Page 25: Transfer Pump
If modulating burner, connect second wire for RTD to control panel. Storage Tank Install float switches from Armstrong in tank oriented as shown. Float #16 (cycle stop) -
Page 26: Main Power Connection
Main Power Connection Note: If facility does not have surge and lightning protection, Armstrong recommends both for heater. Connect supply voltage to top terminals of main fuse disconnect inside disconnect panel. Manually test each starter ("bump the starter") to check for correct motor... -
Page 27: Operation
Pump runs lower canister. continuously during heating cycle. Water level is controlled by four float switches in standpipe connected to bypass loop. Armstrong International IOM-706 V2.0 Page 25 of 45 Flo-Direct Water Heater... -
Page 28: Sequencing Of Operation
Note: PLC is preset. Re-progamming it without written permission will void the warranty and absolve Armstrong of all service commitments. If low gas pressure, high gas pressure, and high temperature switches are all closed (no fault conditions), power will be supplied to Veri-Flame controller (wire #47;... -
Page 29: Pre-Startup Checklist
• Float switches installed correctly • Float switches correctly wired to heater Main power supply properly connected • Three phase • Voltage as specified on nameplate and connections Armstrong International IOM-706 V2.0 Page 27 of 45 Flo-Direct Water Heater... -
Page 30: Commissioning
Note: Start-up process requires running heater in "MANUAL" mode, which overrides all automation and produces hot water continuously until heater is manually turned off. Never leave heater unattended in "MANUAL" mode. Armstrong International Commissioning IOM-706 V2.0 Page 28 of 45 Flo-Direct Water Heater... - Page 31 Run heater in "AUTOMATIC" mode to confirm proper operation in that mode. Allow heater to sit and cool for several hours, then check for cold start. Armstrong International Inspecting Installation IOM-706 V2.0 Page 29 of 45 Flo-Direct Water Heater...
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Page 32: Periodic Maintenance
Check all nuts and bolts. Annually Check float switches for proper operation. Check all fuel train connections and fittings. Check all water train connections and fittings. Armstrong International IOM-706 V2.0 Page 30 of 45 Flo-Direct Water Heater... -
Page 33: High Temperature Switch Check
Compress spring to trip switch. Confirm that heater shuts down and high temperature fault light comes on. If not, contact Armstrong. ... -
Page 34: Troubleshooting
Regulator pressure set too high Turn regulator adjustment screw CCW to reduce High Gas Pressure pressure. Defective pressure regulator spring Replace spring. Defective pressure regulator Replace regulator. Armstrong International Troubleshooting Table IOM-706 V2.0 Page 32 of 45 Flo-Direct Water Heater... -
Page 35: Plc I/Os
High Temperature Fault Water pressure switch failed and "dry fire" Check water pressure. If correct, replace pressure start-up attempted switch. If not, continue. Contact Armstrong! Nozzles clogged Remove top plate and clean nozzles. Do not operate heater! Transfer pump throttling valve out of Readjust valve. -
Page 36: Parts Lists
AFD-3000 & 4000 D27184 AFD-5000 to AFD-16000 D26712 For burner parts, contact MAXON Corp., 765-284-3304 (fax: 765-286-8394) For blower assembly parts, contact Cincinnati Corp., 513-573-0600 (fax: 513-573-0640) Armstrong International IOM-706 V2.0 Page 34 of 45 Flo-Direct Water Heater... -
Page 37: Water Train
4″ (flanged) D14601 Welded Stainless Steel Note: Weathermatic valve may be used on stainless steel train. Armstrong International IOM-706 V2.0 Page 35 of 45 Flo-Direct Water Heater... -
Page 38: Control Box
Programmable Logic Controller (PLC) AFD Program Loaded Allen Bradley Micrologix 1200 D19106 Allen Bradley Micrologix 1100 (Requires Output D22729 Module 1762-OW8) Allen Bradley PLC, Output Module, 1762-OW8 D22730 Armstrong International IOM-706 V2.0 Page 36 of 45 Flo-Direct Water Heater... -
Page 39: Disconnect Box
750VA 480 x 240 – 120 D17409 10 HP D7657 750VA 575/380 – 115 D13662 15 HP D7658 20 HP D7659 25 HP D7660 30 HP D7661 Armstrong International IOM-706 V2.0 Page 37 of 45 Flo-Direct Water Heater... -
Page 40: Fuel Train
AFD-1000 to AFD-4000 Armstrong International IOM-706 Page 38 of 45 Flo-Direct Water Heater ... -
Page 41: Lower Canister
AFD-1500 D7565 AFD-2000 D7566 AFD-3000 D7567 AFD-4000 D7568 AFD-5000 D7569 AFD-6000 D7570 AFD-7000 & 8000 D7571 AFD-9000 to AFD-12000 D7576 AFD-13000 to AFD-16000 D7579 Armstrong International IOM-706 V2.0 Page 39 of 45 Flo-Direct Water Heater... -
Page 42: Storage Tank
Bushing, CPVC 4″ x 1/2″ NPT D18785 Float Switch, Polypropylene D16907 Thermometer, Back Mount, 4″ Stem D8969 Plug, 2″ NPT, 304 SS D18789 Plug, 1″ NPT, 304 SS D16918 Armstrong International IOM-706 V2.0 Page 40 of 45 Flo-Direct Water Heater... -
Page 43: Appendix: Modulating Burner
Once the resistance is even, the “dry” contacts will open, leaving the actuator in the 50% position. Armstrong International IOM-706 V2.0... -
Page 44: Operation
Powers controller must be in "MANUAL" mode. Heater in "AUTO" mode Armstrong International IOM-706 V2.0 Page 42 of 45 Flo-Direct Water Heater... - Page 45 Powers Controller will not be released to go to high fire. For additional information please see the Powers Controller program listing, the electrical schematic, and the Powers Controller manual. Armstrong International IOM-706 V2.0 Page 43 of 45...
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Page 46: Limited Warranty And Remedy
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... -
Page 47: Notes
Notes Armstrong International IOM-706 V2.0 Page 45 of 45 Flo-Direct Water Heater...
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