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Armstrong Flo-Direct Installation Manual

Complete thermal exchange gas fired water heater
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Installation Guide 706
®
Flo-Direct
Complete Thermal Exchange
Gas Fired Water Heater Product Manual
This Water Heater has been supplied for this application based upon information provided to Armstrong
at the time the order was accepted.
This Flo-Direct
Complete Thermal Exchange Gas Fired Water Heater has been designed, fabricated
®
and confi gured specifi cally for this installation and as such there may be customized components which
are not specifi cally addressed within this document.
Supplemental Product Manual's and Installation and Maintenance Guides specifi c 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.
Model Number ________________________________
Serial Number_________________________________
Ship Date_____________________________________

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Summary of Contents for Armstrong Flo-Direct

  • Page 1 Flo-Direct Complete Thermal Exchange Gas Fired Water Heater Product Manual This Water Heater has been supplied for this application based upon information provided to Armstrong at the time the order was accepted. This Flo-Direct Complete Thermal Exchange Gas Fired Water Heater has been designed, fabricated ®...
  • Page 2 Installation and service must be performed by a qualifi ed installer, service agency or the local gas supplier. Please read and save this installation and maintenance manual. This guide is to be left with the equipment owner. Customer Support: Armstrong Hot Water Group Phone: (269) 279-3602 Fax: (269) 279-3130 e-mail: hotwater@armstronginternational.com...

  • Page 3: Table Of Contents

    Armstrong Transfer Pump Operating Specifi cations ..................13 Armstrong Transfer Pump Standard Dimensions ....................13 Armstrong Storage/Supplemental Heater Tank Operating Specifi cations ............14 Armstrong Storage/Supplemental Heater Tank Standard Materials of Construction .........14 Armstrong Storage/Supplemental Heater Tank Standard Dimensions and Weights .........14 ®...
  • Page 4 No_____ 12. Type of Fuel: ____________________ 13. System Voltage: ____________________ 14. Control Voltage Transformer (circle one): Customer Supplied or Purchase from Armstrong 15. Electrical Disconnects (circle one): Customer Supplied or Purchase from Armstrong For Remote Storage: 1. Pump Bypass Material (cirlce one): Copper or 304L S.S. or Other: ____________________ 2.
  • Page 5 ® Complete Thermal Exchange Gas Fired Water Heater This product manual specifi cally addresses the following assembly components: • Flo-Direct ® CTE gas fi red water heater Models 1000, 1500, 2000, 3000, 4000, 5000, 6000, 7000, 8000, 9000, 10000, 11000, 12000, 13000, 14000 and 15000.
  • Page 6 Remote Storage Tank S5417 For the VFD Pump Assembly, reference Armstrong 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...
  • Page 7 30-60% when compared to steam/water heating systems. With a small footprint, 99.7% or greater heat transfer effi ciencies, remarkable dependability, ease of maintenance, and the ability to operate well with poor water quality Armstrong Flo-Direct ® CTE gas fi red water heaters are the product of choice for companies seeking to achieve Energy Conservation Measure (ECM) and Reduced Carbon Footprint objectives.
  • Page 8 (included) which delivers Small footprint because the burner heated water to application. is installed on top of the unit “out of the way” and not on the side. No side clearance required. Flo-Direct is U.S. Patent 5,924,391...
  • Page 9 Armstrong Flo-Direct ® CTE gas fi red water heaters, using CTE technology feature a 99.7% ef- fi ciency rating throughout each phase of its operation cycle. The sustained effi ciency of Flo-Direct ® CTE gas fi red water heaters are clearly the most energy effi cient method of hot water production on the market today.
  • Page 10 ® operation. As a result, if you have hard water entering the Flo-Direct CTE gas fi red water heater, you will have the same hard water coming out.

  • Page 11: Introduction

    CTE water heater Model/Assembly. For any installation, operational or maintenance detail not covered in this Product Manual please call Armstrong Toll Free at 1-888-HOT HOSE and reference this serial number. Supplemental Product Manual’s and Installation and Maintenance Guides specifi c to the peripheral components supplied on/with Flo-Direct ®...
  • Page 12 ® Flo-Direct Complete Thermal Exchange Gas Fired Water Heater ® Flo-Direct CTE Water Heater Operating Specifi cations Operating Specifi cations Gas Supply Pressure 2 - 6 psig / .14 - .41 bar Dynamic Water Supply Pressure Constant water pressure (+/-5 psi variation maximum) within a minimum of 30 psig/2 bar and a maximum of 100 psig/6.8 bar range is required for optimum performance.
  • Page 13 ® Flo-Direct Complete Thermal Exchange Gas Fired Water Heater Armstrong Flo-Direct ® CTE Transfer Pump Assembly Specifi cations Maximum Flow Rate Inet Connection Outlet Connection Flow Control Valve Bypass Valve Pump Power Model TP-50 11.4 1-1/2 1-1/2 1.49 TP-90 20.4...

  • Page 14: Armstrong Storage/Supplemental Heater Tank Standard Dimensions And Weights

    ® Flo-Direct Complete Thermal Exchange Gas Fired Water Heater Armstrong Supplemental Storage Tank Standard Dimensions and Weights Specifi cations Fiberglass Reinforced Nominal Piping Connections Number of Inlet Weight Plastic Nominal Tank Height Diameter Connections (Empty) Model No Inlet Outlet Storage Volume...

  • Page 15: Assembly & Installation

    ® Flo-Direct CTE water heaters are assembled and pressure and performance tested at the factory*. Flo-Direct CTE water heaters are typically delivered to the installation site with the upper canister, lower canister and top plate separated and if confi gured accordingly, the transfer pump assembly and storage tank as individual components indicated below.
  • Page 16 ® Flo-Direct Complete Thermal Exchange Gas Fired Water Heater Assembling the Upper Canister and Top Plate Figure 16-1. 1. Place the upper canister section on a fi rm level surface. 2. Align the interface gasket with the bolt holes on the upper canister fl...
  • Page 17 Warning: It is imperative that the transfer pump installation include either the fl exible hose as supplied by Armstrong OR a suitable equivalent which isolates vibration. The outlet from the transfer pump assembly should be piped to the top of the supplemental storage tank.
  • Page 18 • Connections for upper and lower fl oat switch assemblies * Note: For the purposes of this Product Manual it is presumed that a supplemental immersion heater is NOT included. For Immersion Heater installation and wiring detail call the Armstrong Technical Department at 1-888-HOT HOSE.
  • Page 19 Complete Thermal Exchange Gas Fired Water Heater Fuel Figure 19-1. ® While alternate fuel supplies can be used with Flo-Direct water heaters this product manual presumes natural gas ® supplied by a local utility. The Flo-Direct CTE gas fi red water heater includes an integral gas pressure regulator.
  • Page 20 ® Flo-Direct Complete Thermal Exchange Gas Fired Water Heater 1. Connect the upper and lower canister gas train sections Figure 20-1. at the union provided (Figure 20-1) 2. Connect the gas supply to the Fuel Train inlet using a standard union connection.
  • Page 21 ® Flo-Direct Complete Thermal Exchange Gas Fired Water Heater ® Flo-Direct CTE water heater are supplied as standard with the following components which will require on-site connection. Figure 21-1. Wiring Connections Top Plate Connections The conduit is identifi ed numerically 1-4 from left to right in Figure 21-1.
  • Page 22 ® Flo-Direct Complete Thermal Exchange Gas Fired Water Heater 2. Route the Top Plate Wiring Harness through conduit #3 and into the control box. 3. Tighten conduit fi ttings. 4. Connect the numerically identifi ed component wires to the corresponding numerically identifi ed terminals on the terminal strip (Figure 20-3).
  • Page 23 Mains Power Connection ® Important Note: Ensure that the mains power supply is adequately rated to meet the Flo-Direct instantaneous water heater power requirements. 1. Connect the 460 Volt 3 Phase motor power supply to the top terminals of both starters inside the control box as indicated in Figure 20-3.
  • Page 24 Complete Thermal Exchange Gas Fired Water Heater Power/Electrical Important Note: Ensure that the mains power supply is adequately rated to meet the Flo-Direct CTE instantaneous water heater power requirements. 1. Check the power supply wiring for installation accuracy and code compliance.
  • Page 25 CTE instantaneous water Gauge heater to the remote storage tank. To accomplish ® this is a series of level controls within the Flo-Direct CTE instantaneous water heater which are pro- gramed to open and close a by-pass on the transfer Thermometer pump assembly.
  • Page 26 fl oat switches installed within the remote storage tank. 1. Turn the Manual-Off-Auto Switch on the Control Box face panel to “Auto” (Figure 24-1). If the Lower Float Switch in the storage tank identifi es a low level condition it will signal for the Flo-Direct ®...

  • Page 27: Sequence Of Operation

    Controller are fi eld adjustable). 7. Eclipse Veri-Flame Controller terminals 3 and 4 energize allowing fuel to fl ow to the burner and the spark rod to spark. The main water valve then simultaneously opens and water fl ows into the Flo-Direct ®...

  • Page 28: Programmable Logic Controller (Plc)

    ® Flo-Direct Complete Thermal Exchange Gas Fired Water Heater Interlock System Figure 28-1. The low gas pressure, the high gas pressure and the high temperature switches require manual resetting if they are tripped. These switches are wired in series so that if any single switch trips then a fault condition exists...
  • Page 29 ® • Check the Low Gas Pressure Switch (fi g 19-2) by shutting off the fuel fl ow into the Flo-Direct CTE gas fi red water heater during operation.
  • Page 30 Discontinue operation of the Flo-Direct CTE gas fi red water heater and consult Armstrong toll free at 1-888-468-4673. Annually • Check that all electrical connections on the Flo-Direct CTE gas fi red water heater are secure. • Check/Tighten all nuts/bolts. • Visually inspect all accessible wetted parts for corrosion or mineral deposition.
  • Page 31 Flo-Direct ® Complete Thermal Exchange Gas Fired Water Heater Flo-Direct CTE Water Heater Componenet Identifi cation Diagrams Armstrong Flo Direct CTE Panel Spares Programmable Logic Controller (PLC) Allen Bradley 1762 0707070 4 Pole Double Throw Relay 0707100 Hour Meter 0705190...
  • Page 32 Flo-Direct ® Complete Thermal Exchange Gas Fired Water Heater Flo-Direct CTE Water Heater Componenet Identifi cation Diagrams Armstrong Flo Direct Gas Train Spares Gas Rated Ball Valve 1” NPT 0702100 1-1/2” NPT 0702105 2” NPT 0707110 3” NPT 0702115 Pressure Gauge, 0 - 15 psi...
  • Page 33 Flo-Direct ® Complete Thermal Exchange Gas Fired Water Heater Flo-Direct CTE Water Heater Componenet Identifi cation Diagrams Armstrong Flo Direct Water Train Spares Ball Valve 1” 6270002 1-1/2” 6270006 2” 6270008 2-1/2” 6270010 3” 6270012 4” (Gate Valve) 6270034 Weathermatic Valve 1”...
  • Page 34 All Components identifi ed by name in Water Heater Component Identifi cation Drawings with parts number cross referenced in a grid format which allows secondary cross reference to all models Grid Format Armstrong Flo Direct Spare Parts Listing Section Part...
  • Page 35 Flo-Direct ® Complete Thermal Exchange Gas Fired Water Heater ® Flo-Direct CTE Water Heater Troubleshooting Guide Fault Displays Clearing or Re-setting Turn the ‘Auto-Off-Manual’ switch on the face of the control box to the ‘Off’ position and Indicator Light #1 Actuator Fault then re-set to either ‘Manual’...
  • Page 36 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.
  • Page 37 Notes...
  • Page 38 Notes...
  • Page 39 Notes...
  • Page 40 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.