Subscribe to Our Youtube Channel
Related Manuals for Armstrong Flo-Direct 2.0 AFD-1000
Summary of Contents for Armstrong 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 Please read and save these instructions 706-EN V7.0...
-
Page 2: Table Of Contents
Table of Contents Safety Transfer Pump ....................................... Storage Tank ............Icon Legend: ........................Main Power Connection ........Warnings and Cautions ................. Operation ........The Flo-Direct® System ....... Description of Operation Typical System ..................................... Sequence of Operation Specifications ...................................... -
Page 3: Safety
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. —... -
Page 4: Warnings And Cautions
• Improper installation or operation may cause a a neighbor's phone. Follow the gas fire or explosion resulting in property damage, supplier's instructions. personal injury, or death. Armstrong strongly If you cannot reach your gas supplier, call the fire recommends that a qualified installer be used. department. -
Page 5: The Flo-Direct® System
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 Designs, materials, weights and performance ratings are approximate and subject to change without notice. - Page 6 • System assessment and optimization • Energy conservation measures (ECM) Note: Armstrong provides separate IOMs for the burner, blower, and for optional components. Consult the appropriate document for more information. Designs, materials, weights and performance ratings are approximate and subject to change without notice. Visit armstronginternational.com for up-to-date information.
-
Page 7: Specifications
Specifications Heater Materials of Construction Component Material 304 SS (10 ga. ≤ AFD-9000; 3/16 > AFD-9000) Canister 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... -
Page 8: Dimensions
Dimensions ® Flo-Direct Dimensions and Weights Connections Dimensions Weight Model btu/hr AFD-1000 2413 1803 1,000,000 AFD-1500 2464 1854 1041 1,500,000 AFD-2000 1-1/2 1-1/2 2540 1930 1118 10-3/4 1500 2,000,000 AFD-3000 1-1/2 2540 1930 1118 1600 3,000,000 AFD-5000 2-1/2 3226 2464 1651 1118 2500... -
Page 9: Orientation
Orientation UV scanner Blower Actuator Exhaust vent Blower Fuel actuator Top Plate Burner Water pressure switch See next page Control panel for Fuel Train components Upper Water flow volume Canister adjust valve Disconnect panel Water inlet valve Gas inlet (behind pipe) Water inlet High temp shut-off switch... -
Page 10: Fuel Train Components
Fuel Train Components Regulated pressure display High gas pressure switch Proof of Closure (POC) switch Low gas pressure switch Dual blocking valves Visual display of valve state (white = closed red = open) Regulator Designs, materials, weights and performance ratings are approximate and subject to change without notice. Visit armstronginternational.com for up-to-date information. North America •... -
Page 11: Transfer Pump Assembly
Transfer Pump Assembly Materials of Construction 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) Dimensions and Operational Specifications Maximum Inlet Outlet Flow Control Pump Flow Rate Connection... -
Page 12: Storage Tank
Storage Tank Materials of Construction Component Material Structural layer Fiber-reinforced plastic Structural and liner resin Derakane 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... -
Page 13: Orientation
Orientation Screened vent Water inlet Manway Recirculation return Upper sight glass mount (1" NPT) Float switch mount for heater stop Float switch mount for heater start Thermometer mount Float switch mount for low water Lower sight glass mount (1" to pump cutoff (if used) NPT) (optional tank level sensor) Outlet... -
Page 14: Assembly And Installation
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. - Page 15 Note: Long bolt in blower motor bracket must be reinstalled in that hole. Attach as shown to keep plate approximately level. Note: Top plates on largest heaters have lifting lugs. 4. Remove top plate from lower canister. Orient so union in fuel line can be connected. Note: "Gas"...
-
Page 16: Installing Small Heaters
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. -
Page 17: Installing Exhaust Ducting
Duct must be same size or larger than heater's exhaust outlet. Condensate will drip from end Armstrong recommends of horizontal ducting. Install no bend sharper than 45°. where dripping will not be a nuisance or ice a hazard. Models AFD-1000 and AFD-1500... -
Page 18: Installing Intake Air Ducting
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 blower Using outside air is required... -
Page 19: Water Connections
Water Connections Warranty is void unless clean, potable water is used. Note: Incoming water must not contain any chloride compounds above 100 ppm If large pressure swings occur, or salts. These will destroy 304 stainless steel. (Alternative metals are available.) install pressure regulating valve in inlet water line. -
Page 20: Fuel Connection
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: If codes require pressure test of fuel line, close ball valve entering fuel train to heater. -
Page 21: Electrical Panels
Electrical Panels Control Panel LMV3 Controller Spark generator Fuse 2 (3A—PLC) Hour meter Hour meter Power supply - 24 VDC Programmable logic controller (PLC) Ethernet switch Control relay Fuse 1 (5A) Terminal block Control Panel Cover Designs, materials, weights and performance ratings are approximate and subject to change without notice. Visit armstronginternational.com for up-to-date information. North America •... -
Page 22: Disconnect Panel
Disconnect Panel Main fused disconnect Control transformer (3 phase to 120V) Grounding lug Transfer Pump VFD Terminal block Grounding lug Heater Label Note: This is a sample label. All electrical work must conform to the specifications on this label as found on your heater. Designs, materials, weights and performance ratings are approximate and subject to change without notice. -
Page 23: Electrical Connections
Electrical Connections Note: Consult wiring schematic provided with your heater for exact details. Remove all cable ties, bubble wrap, and tape from wiring. Top Plate to Upper Canister Reconnect threaded fitting to burner flame sensor port. Reconnect spark rod wire to spark rod in burner. -
Page 24: Upper To Lower Canister
Upper to Lower Canister Note: Depending on how canister sections were oriented during installation, wires and conduit for these connections may not be the correct length. Rewire if necessary. Repeat for outlet temp sensor Thread high temperature switch wiring into control panel. Reconnect conduit. -
Page 25: Storage Tank
Main Power Connection Note: If facility does not have surge and lightning protection, Armstrong recommends both for heater. 1. Connect supply voltage to top terminals of main fuse disconnect inside disconnect panel. 2. Manually test each starter ("bump the starter") to check for correct motor rotation, as indicated on motor housing. -
Page 26: Operation
Operation Description of Operation Very efficient heat exchange keeps exhaust within a few degrees of incoming water temperature. Water is dispersed into upper canister and is Air and gas combine in burner broken into ever smaller and enter dry flame tube, which droplets by passing enables complete combustion down through palls. -
Page 27: Sequence Of Operation
Sequence of Operation Notes: • The description in this section assumes that the AFD is in automatic mode and not in a Fault Condition. • The numbers in parenthesis refer to the operating phase of the LMV3 Flame Safety. 1. The AFD is in Standby (Phase 12). When the PLC receives the Auto Start Input, it will then send a run command to the LMV3 and the start-up sequence will begin. -
Page 28: Pre-Start-Up Checklist
Pre-Start-Up Checklist Note: This section to be performed by installer. Consult other information, such as schematics, as necessary. … Heater in permanent location on level surface sufficient for load and anchored … Heater assembled … Transfer pump (if used) in place with flexible water pipe connected …... -
Page 29: Commissioning
Commissioning Inspecting Installation 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 fuel is supplied and note label on fuel train. Inspecting Water System 1. -
Page 30: Commissioning
Commissioning 1. Turn on fuel. - Check for leaks in piping - Verify that gas pressure is between 2 and 6 psi 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"... -
Page 31: Periodic Maintenance
• Burner should go out • The Siemens controller should Fault • This should shut down the AFD. If results are not as described, a hazard condition exists. Shut down heater and contact Armstrong. Check all electrical connections. Check all nuts and bolts. -
Page 32: 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. Press reset button and replace cover. Caution: Wiring is live! Avoid touching connections! Designs, materials, weights and performance ratings are approximate and subject to change without notice. Visit armstronginternational.com for up-to-date information. -
Page 33: Troubleshooting
High Temperature Fault Water pressure switch failed and "dry fire" start-up Check water pressure. If correct, replace pressure switch. If not, attempted continue. Contact Armstrong! Remove top plate and clean nozzles. Nozzles clogged Do not operate heater! Transfer pump inoperable Check and repair or replace. -
Page 34: Plc I/Os
Problem Probable Cause Correction Flow control valve restricted Open flow control valve. Shut-off valve defective Repair or replace valve. Water Pressure Fault Restriction in inlet line Check filters and piping for obstructions. Correct system pressure. Low system pressure Press "FAULT RESET" on HMI. Reference Fault Code to Allen Bradley Power Flex 520 Series Manual VFD Fault VFD for Transfer pump has Faulted... -
Page 35: Parts Lists
Parts Lists Top Plate Note: Some wiring in this drawing has been removed for clarity. Ref No. Description Part No. Ref No. Description Part No. — Spark Plug Wire, 7 mm, SCS7-100 D17513 Flange Gasket – WARCO White Spark Rod, #47232 D19194 AFD-1000 D7564... -
Page 36: Water Train
Water Train Ref No. Description Part No. Water Pressure Switch D16905 Pressure Gauge; 0-110 psi D11554 Globe Valve, Stainless Steel 1" D14596 1-1/2" D14597 2" D14598 2-1/2" (flanged) D14599 3" (flanged) D14600 4" (flanged) D14601 Actuacted Valve Assembly 1-1/2" D53299 2"... -
Page 37: Control Panel
Control Panel Ref No. Description Part No. HMI Panelview Plus 7 9 Inch D106961 Emergency Stop Button D106011 Ignition Transformer D19185 Siemens LMV3 D115428 D115434 Modbus Module PLC Micrologix 1400 D60067 PLC Analog Module 2 IN 2 OUT D90858 Relay Base 14 Blade D16886 Relay 4PDT 120VAC Coil D16903... -
Page 38: Disconnect Panel
Disconnect Panel Ref No. Description Part No. Ref No. Description Part No. Fuse, Low Peak, Class J Motor Overload D19610 1.6–5A D17910 D17885 3.2–16A D7663 D19611 5.4–27A D7664 D19612 9–45A D7665 D19613 Fuse Cover, Bus, Indicating D19614 D19762 17 1/2A D19615 D22629 D19616... -
Page 39: Fuel Train
Fuel Train Ref No. Description Part No. Gas Rated Ball Valve AFD-1000 and AFD-1500 (1" NPT) D15432 AFD-2000 and AFD-3000 (1-1/2" NPT) D15433 AFD-4000 to AFD-10000 (2" NPT) D15434 Pressure Gauge, 0–15 psi D14800 Gas Pressure Regulator AFD-1000 to AFD-4000 (FRI 710/6) D14806 AFD-5000 to AFD-5000 to AFD-10000 (FRS 720/6) -
Page 40: Lower Canister
Lower Canister Note: This drawing is a composite. Not all parts are present in every heater configuration. All 4 float switches swing downward Gravity drain Secured to float switches (pumped only) For pumped units only Outlet temp sensor Ref No. Description Part No. -
Page 41: Storage Tank
Storage Tank Float switch* Float switch* Float switch* *For float orientation, consult wiring diagram supplied with unit. Ref No. Description Part No. 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"... -
Page 42: Appendix: Hmi Interface
Appendix: HMI Interface This water heater package includes an HMI (Human-Machine Interface) terminal with displays and controls for heater status and operation, along with related system information. This section will explain 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: Setpoint And Mode Screen
Each status and selection of this screen is explained below. COMBUSTION AIR STATUS Blower On: The combustion air blower has been energized. Air On: The combustion air proving switch has been made. BURNER AND FUEL STATUS Spark On: The burner spark igniter has been energized. Fuel On: The main fuel valves have been energized. - Page 44 Setpoint and Mode The setpoint and mode are changed from this screen. By pressing the SETPOINT button (picture below) a secondary screen will appear. From here you can select to run in MODULATING or POSITIONING mode simply by pressing the MOD/POS button.
-
Page 45: Menu Screen
Menu Screen Below is a picture of the Menu 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 main screen that was explained above. - Page 46 I/O List The I/O List screen 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 you to the MENU screen.
-
Page 47: Trending Screen
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. -
Page 48: Transfer Pump Screen
Alarms The Alarms screen tracks all active and non-active alarms. Active alarms are indicated by a # symbol. As an example, in the picture below. This heater has 3 active alarms, an FSF (Flame Safety Fault) Special Position Undefined, Transfer Pump VFD Fault, and an E-Stop Tripped. The FAULT RESET button appears when non-critical faults are active, such as (FSF, Water Pressure, or High Basin). - Page 49 Transfer Pump The Transfer Pump screen allows you to set the LOW and HIGH speed of the VFD. This screen also displays 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 either the LOW or HIGH speed button to enter your desired speed.
-
Page 50: Limited Warranty And Remedy
As a condition of enforcing any rights or remedies relating to Armstrong products, notice of any warranty or other claim relating to the products must be given in writing 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 earlier.
Need help?
Do you have a question about the Flo-Direct 2.0 AFD-1000 and is the answer not in the manual?
Questions and answers