Armstrong Digital-Flo DFS1540, Users Installation Operation & Maintenance Manual

Page 1: ...Digital Flo Semi Instantaneous Steam to Water Shell and Tube Water Heater Installation Operation Maintenance Manual 789 EN Please read and save these instructions ...

Page 2: ...le of Contents Safety 3 General Description 4 Typical Piping Layout 5 Specifications 6 8 Dimensions 9 Precautions 10 Installation Requirements 11 16 Commissioning 17 18 Safety Shutoff Valve 19 Periodic Maintenance 20 23 Preventative Maintenance and Fitting Spare Parts 24 Troubleshooting 25 33 Spare Parts 34 37 Steam Trap Assemblies 38 39 Limited Warranty and Remedy 40 ...

Page 3: ...ted during normal use 2 Inappropriate use of this product could cause damage to the product and other property It may also result in personal injury or in extreme cases death 3 Installation or maintenance must be carried out in accordance with the instructions provided in this product manual by designated qualified and competent personnel 4 Installation shall comply with all applicable federal sta...

Page 4: ...oring measuring and reporting directly to office PC s or mobile apps DFSI is precision engineered and crafted with pride to deliver years of superior performance and customer satisfaction provided 1 Installation commissioning operation and maintenance are in accordance with the recommendations provided in this product installation and operation manual IOM in addition to generally accepted plumbing...

Page 5: ...5 Designs materials weights and performance ratings are approximate and subject to change without notice Visit armstronginternational com for up to date information Typical Piping Layout ...

Page 6: ...n Loop Temperature Loss 2 F 1 C General Specifications Control Circuit Fuse 3 A 5A w SAGE Enclosure Protection Rating Electrical Enclosure Nema 12 DRV Nema 3S Signal Cable Fittings DRV 3 8 liquid tight conduit fitting Battery DRV Qty 2 type CR P2 6V rating Power Supply Requirements 120 240 VAC 50 60 Hz 1 Ph Insulation Jacket Aspen Aerogel Pyrogel R Value 12 5 Component Material Heat Exchanger Shel...

Page 7: ...al Stand Height HT6 HT6 6 Taller Optional HT12 HT12 12 Taller Optional HT18 HT18 18 Taller Optional HT24 HT24 24 Taller Optional Insulation Jacket RF Removable Fiberglass Optional SS Stainless Steel Casing Optional Component Material Heat Exchanger Shell 316 Stainless Steel ASME U Stamped Heat Exchanger Tube Bundle 5 8 Double Wall Copper Heat Exchanger Tube Sheets 304 Stainless Steel Integral Supp...

Page 8: ...odel Water Side Connections 7 5ft sec 2 3m s Steam Side Connections Hot Cold Recirc HX Capacity 100ºF 55ºC Delta T Max Package Capacity at 120ºF 49ºC Blend Outlet Steam Condensate Inlet Outlet Capacity 15psi 1bar DFS15DW40 1 5 40mm 1 25mm 14gpm 53lpm 18gpm 68 1lpm 2 50mm 737lb hr 334kg hr DFS35DW40 1 5 40mm 1 25mm 27gpm 102lpm 35gpm 132 5lpm 3 80mm 1421lb hr 645kg hr DFS50DW50 2 50mm 1 5 40mm 46gp...

Page 9: ...DFS5050 26 1 663mm 88 4 2245mm 56 7 1440mm 54 6 1387mm 18 8 477mm SW xxx lbs xxx kgs DW xxx lbs xxx kgs DFS9080 29 6 752mm 91 5 2324mm 57 6 1463mm 65 4 1662mm 4 4 113mm SW xxx lbs xxx kgs DW xxx lbs xxx kgs F G H I J DFS1540 21 3 542mm 80 8 2052mm 42 8 1087mm SW 21 1 536mm DW 20 3 515mm 35 899mm DFS3540 22 8 578mm 81 4 2067mm 45 3 1150mm SW 19 2 488mm DW 18 4 467mm 35 899mm DFS5050 25 5 646mm 82 6...

Page 10: ... or install effective electrical surge and lightning protection to protect this equipment Water Treatment Requirements The end user shall be responsible for providing effective water treatment systems suitable to his application The heater design does not incorporate a water quality control system Since the DFSI design incorporates a steam to water shell tube type heat exchanger minimizing scaling...

Page 11: ...red mounting location ensuring that there is adequate free space from adjacent walls and other obstructions for service and maintenance access If movement or tipping of the water heater could occur secure the heater stand or base to the floor 6 Connect an appropriately sized boiler steam supply line to the heat exchanger steam connection Note In the event the tube bundle must be extracted from the...

Page 12: ...uires external electrical power to operate the DRV and the hot water safety shutoff valve A licensed electrician or electrical contractor should run electrical current from a 120 240 VAC 50 60 Hz 1 Ph power source to the DFSI control cabinet An electrical schematic for a DFSI control system w a single DRV mixing valve and a single HW shutoff valve appears in Figure 1 below Figure 1 Electrical Sche...

Page 13: ...ional com for up to date information Installation Requirements continued An electrical schematic for a DFSI control system when equipped w a single DRV mixing valve a single HW shutoff valve and the optional SAGE feature appears in Figure 2 below Figure 2 Electrical Schematic for a Standard DFSI w a Single DRV and the SAGE Option ...

Page 14: ...notice Visit armstronginternational com for up to date information Installation Requirements continued An electrical schematic for a DFSI control system when equipped with two DRV mixing valves and two HW shutoff valves appears in Figure 3 below Figure 3 Electrical Schematic for a DFSI with Two DRV s ...

Page 15: ...Visit armstronginternational com for up to date information Installation Requirements continued An electrical schematic for a DFSI control system when equipped with two DRV mixing valves two HW shutoff valves and SAGE appears in Figure 4 below Figure 4 Electrical Schematic for a DFSI with Two DRV s and SAGE ...

Page 16: ...the OFF position 7 The display of the DRV should deactivate and the safety shutoff valve should power closed Confirm that the safety shutoff valve position indicator returns to the CLOSED position WARNING The manual selector switch DOES NOT completely de energize the DRV and it DOES NOT de energize the safety shutoff valve The control panel must be de energized following standard lock out tag out ...

Page 17: ... water volume and pressure is supplied to the DFSI BEFORE introducing steam into the heat exchanger Only designated qualified and competent personnel shall conduct commissioning in accordance with these instructions 1 Perform a visual overview and confirmation that the DFSI is installed per our installation schematics located in our IOM s a Confirm all water supply lines are connected correctly an...

Page 18: ... open fixtures and confirm presence of continuous recirculation 11 Monitor DRV outlet and confirm it is maintaining set point a New systems may take some time for the recirculation return temperature to rise to an appropriate level Note The setpoint of the DRV is preset based on information provided to Armstrong To adjust the DRV setpoints high limit error temp or to enable disable other integral ...

Page 19: ... will not actuate to the open position in the presence of battery power only The system will return to normal when power is restored In the event of a DRV error listed above the DRV and the safety shutoff valve via the closed DRV relay are configured to close the hot water inlet via the building power source In response to a DRV error the DRV relay remains closed until personnel have had an opport...

Page 20: ...red Quarterly Wipe down assembly Check for damaged components Touch up paint as required As required Descale system frequency depends on water quality As required If excessive leakage is found replace worn or damaged plumbing parts and heat exchanger gaskets as required Critical Preventive Maintenance Batteries Replace DRV battery every 12 months or more frequently if frequent power interruptions ...

Page 21: ... d Disconnect all steam condensate piping e Loosen remove the heat exchanger bolts nuts holding the head cover to the shell f With the tube bundle now supported by only the strap or chain fall slowly lower the tube bundle one may choose to further support the tube bundle weight by use of a heavy duty floor jack or equipment mover g If the tube bundle won t lower turn it slightly using the removal ...

Page 22: ...ipple supplied on union end of the CIP hose l Connect the CIP hose from the pump discharge outlet to the close pipe nipple installed on the hot water outlet Verify ball valve is closed m Connect the CIP hose from the tank inlet to the close pipe nipple installed on the cold water inlet Verify ball valve is closed and leave tank fill opening uncapped to allow venting n Connect the Armstrong CIP uni...

Page 23: ...er Used solution may be hazardous as a result of the pre existing contaminants present in the equipment being cleaned Dispose of material in accordance with the Local State Provincial and Federal regulations for your location c After draining and properly storing or disposing of contents in the CIP unit tank close the tank drain and fill the CIP tank with fresh water d Connect a CIP hose to the pu...

Page 24: ...ry error message appears on the DRV display when they require replacing Where primary power supply failure occurs regularly or the DRV is installed within a supply system where safety is critical the batteries must be changed at least every 12 months as part of an annual maintenance routine In noncritical systems or where battery usage is low longer replacement cycles may be considered up to a max...

Page 25: ...nvasive procedure close the steam inlet following lockout tagout procedures and allow the heat exchanger to cool Always close steam inlet before closing water inlet De energize the DFSI electrical control panel following lockout tagout procedures Stop recirculation pump s close cold water inlet and relieve water pressure before breaking any couplings and joints Note For problems exclusive to the D...

Page 26: ...DRV Troubleshooting Guide in the following section Heat exchanger fault a Vent trapped air gases from heat exchanger shell b Clean scaled or fouled heat exchanger tubes Water from DFSI is too hot System fault a Reduce steam pressure b Steam is superheated reduce superheating DRV fault DRV Troubleshoot Guides See DRV Troubleshooting Guide in the following section System tem perature rises during pe...

Page 27: ...losed valves d Blowdown strainers then remove and thoroughly clean all strainer screens e Confirm return temperature is at least 2 F below DRV set point f Check the steam pressure at the heat exchanger shell If the steam pres sure is decreasing under normal conditions there may be insufficient steam available to meet the hot water demands DRV fault See DRV Troubleshooting Guide in the following se...

Page 28: ... there may be insufficient steam available to meet the hot water demands DRV fault See DRV Troubleshooting Guide in the following section No display on DRV and or no control System fault a Confirm uninterrupted power to DFSI control panel b Check status of DRV power switches on the DFSI control panel DRV fault See DRV Troubleshooting Guide in the following section DFSI bangs and hammers during ope...

Page 29: ... ok Is the motor operational i e is it able to turn drive gears Is the valve PSU opera tional and ok Reset the valve by powering down then powering back on Replace GDA Check strength of magnets inside rotor if not sufficient replace rotor Close door fully against valve body Ensure all wires are not pinched plugs are connected if needed replace cable loom Remove valve internals and thoroughly clean...

Page 30: ...l and ok Is the valve PCB operational and ok Is the valve PSU operational and ok Issue addressed or Contact Factory 269 279 3602 Reset the valve by powering down then powering back on Reset the valve by powering down then powering back on If has BrainScan replace Ele Housing Ensure all wires are not pinched plugs are connected if needed replace cable loom Ensure all wires are not pinched plugs are...

Page 31: ...ls characters ok Is the valve PCB operational and ok Issue addressed or Contact Factory 269 279 3602 Is the valve PSU operational and ok Reset the valve by powering down then powering back on Reset the valve by powering down then powering back on Replace Batteries Adjust brightness via POT adjustment screw on PCB Ensure all wires are not pinched plugs are connected Replace display keep original to...

Page 32: ... increase pump size Equalize pressures Check Yes Yes No No No No No Yes Yes Yes Does the recirculation pump run continuously without an Aquastat Is there adequate supply water temperatures hot cold supply Are the valve internals free of debris and clean Are the O Rings Seals in good condition not preventing the spool travel Remove aquastat recirculation pump should run continu ously Reduce size of...

Page 33: ... the valve installed piped according to installation instructions Are the checkvalves installed holding correctly Is the valve installed in a single temperature loop system i e no high temp kitchen loops Issue addressed or Contact Factory 269 279 3602 Install strainers on ALL supply lines remove basket not just blow down to clean Re pipe to ensure installed per instructions Replace checkvalves Ens...

Page 34: ...0 DFS90 D82031 Aluminum Cover Standard Part No DFS15 D80896 DFS35 D80897 DFS50 D80898 DFS90 D80899 Stainless Steel Cover Replaces Aluminum Part No DFS15 D80904 DFS35 D80905 DFS50 D80906 DFS90 D80907 Removeable Fiberglass Part No DFS15 D80900 DFS35 D80901 DFS50 D80902 DFS90 D80903 Single Wall Tube Bundle Heat Exchanger Gasket Kit Double Wall Tube Bundle with Heat Exchanger Gasket Kit Heat Exchanger...

Page 35: ...al Kit D45792 DRV50 DRV80 DRV50 DRV80 O Ring Seal Kit D51825 DRV40 50 80 USB to DRV RS485 Programming Cable D48023 Size Description Part Number 25 25 NPT BRZ 150 LF FULL PORT D65344 5 5 NPT BRZ 150 LF FULL PORT D65345 5 5 NPT BRZ 150 LF FULL PORT LOCKING D69333 75 75 NPT BRZ 150 LF FULL PORT D65346 75 75 NPT BRZ 150 LF FULL PORT LOCKING D69351 1 1 NPT BRZ 150 LF FULL PORT D65347 1 1 NPT BRZ 150 LF...

Page 36: ... LF D40164 2 BALL VALVE ELE ACT 2 NPT BRZ LF D40165 3 BTFL VALVE ELE ACT 3 LUG E501S D40168 Size Actuator Only Part No 1 ACTUATOR ELEC VB030 013 W ADAPTER D70878 1 5 ACTUATOR ELEC VB030 013 W ADAPTER D70878 2 ACTUATOR ELEC VB030 013 W ADAPTER D70878 3 ACTUATOR ELEC VB030 013 W ADAPTER D70878 Size Valve Only Part No 1 VALVE BALL 1 NPT LF LESS ACTR D70727 1 5 VALVE BALL 1 1 2 NPT LF LESS ACTR D70729...

Page 37: ...9 Thermometer 5 NPT X 9 D44955 9 Thermowell 75 NPT X 9 SS D44903 Size Description Part Number 1 5 NPT Strainer 1 5 NPT BRS LF WATTS D38922 1 5 NPT Strainer Replacement Screen D76663 1 5 NPT Replacement Screen Gasket D76661 Size Description Part Number 2 NPT Strainer 2 NPT BRS LF D30036 2 NPT Strainer Replacement Screen D76662 2 NPT Replacement Screen Gasket D76660 Size Description Part Number 3 FL...

Page 38: ...onginternational com for up to date information Steam Trap Assemblies DFS15 DFS15 F T Condensate Trap Assembly DFS35 DFS35 F T Condensate Trap Assembly STRAINER CA9SC 1 25 NPT 1 2NPT B5480 4 STRAINER CA9SC 1 5 NPT 1 2NPT C4425 5 GATE VALVE 1 25NPT D37024 GATE VALVE 1 5NPT D8967 30A5 1 25NPT D509998 30A6 1 5NPT D505635 ...

Page 39: ...com for up to date information Steam Trap Assemblies continued DFS50 DFS50 F T Condensate Trap Assembly Needed if You Service a DFSI Tube Bundle DFS90 DFS90 F T Condensate Trap Assembly STRAINER CA9SC 2 NPT 1 2NPT C4426 5 GATE VALVE 2NPT D7343 30A8 2NPT D505477 STRAINER CA9SC 2NPT 1 2NPT C4426 5 GATE VALVE 2NPT D7343 30JD8 2NPT D500514 ...

Page 40: ...arranty 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 remedies relating to Armstrong products notice of any warranty or other c...

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Page 44: ... Printed in U S A 4 12 19 2016 Armstrong International Inc Digital Flo Semi Instantaneous Steam to Water Shell and Tube Water Heater Installation Operation Maintenance Manual Designs materials weights and performance ratings are approximate and subject to change without notice Visit armstronginternational com for up to date information ...