Digital-Flo TM Digital Instantaneous Steam/Water Plate & Frame Heat Exchanger Product Manual

Transcription

1 IOM-786-B Digital-Flo TM Digital Instantaneous Steam/Water Plate & Frame Heat Exchanger 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 Digital Instantaneous Steam/Water Plate & Frame Heat Exchanger 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 Digital Instantaneous Steam/Water Shell & Tube Heat Exchanger are available online at: or by calling Armstrong Toll Free at HOT-HOSE. Model Number Serial Number Ship Date Customer Support: Armstrong Hot Water Group Phone: (269) Fax: (269) hotwater@armstronginternational.com armstronginternational.com

2 Digital-Flo TM Steam/Water Plate & Frame Heat Exchanger The Digital-Flo Steam/Water Plate & Frame Heat Exchanger assembly covered by this IOM features installation, commissioning, operation and general maintenance detail. Each Digital-Flo Steam/Water Plate & Frame Heat Exchanger is serialized and the serial number is maintained on fi le in the Technical Department at Armstrong. For any installation, operational or maintenance detail not covered in this Product Manual please call Armstrong Toll Free at HOT HOSE and reference this serial number. Supplemental Product Manual s and Installation and Maintenance Guides specific to the peripheral components supplied on/with Digital-Flo Steam/Water Plate & Frame Heat Exchangers are available online at: armstronginternational.com Customer Support: Armstrong Hot Water Group Phone: (269) Fax: (269) hotwater@armstronginternational.com armstronginternational.com 2

3 Table of Contents Safety Warnings...5 Installation Details Form (IDF)...8 Installation Schematic...12 Operating Specifi cations...10 Standard Materials of Construction Standard Dimensions and Weights Installation Commissioning Operation...33 Maintenance - Heat Exchanger...34 Maintenance - DRV Component Identifi cation Guide...44 Spare Parts - DRV80 Only...41 Troubleshoot Guide Warranty Information

4 Digital-Flo TM Steam/Water Shell & Tube Heat Exchanger ASSE 1017 CSA B125 and CE certified Digital Controller Outlet Temperature to system +/- 2 F/1 C Self diagnostics. Digital valve runs internal component check and reports out of specification performance on display 4-20mA Connection Port Integral relay for auxiliary connection (alarm, solenoid) Hot water shutoff upon power failure Port to port travel in 2.6 seconds Serial data port for BAS Module (BrainScan ) connectivity. Transmits/receives all field programmable and LED display features IRDA Port for PC programming LED Display Indicates Set point C or F Operating Temp C or F Field programmable Set point High temperature alert High temperature hot water shutoff Thermal disinfection Battery back-up for emergency shutdown and default setting retention 316L Stainless steel construction Single integral digital control valve (DRV80) REPLACES: - Steam Control Valve - PID Controller - High Temperature Limit Thermostat - High Temperature Limit Controller - Cold Water Injection Valve - Internal Circulating Pump - Compressed Air Requirement 4

5 Digital-Flo TM Steam/Water Plate & Frame Heat Exchanger Safety Warnings Digital-Flo Steam/Water Plate & Frame Heat Exchangers are precision engineered and crafted with pride to deliver years of superior performance and customer satisfaction provided: 1. They are installed, commissioned, operated and maintained in accordance with the recommendations provided in this Product Guide and generally accepted plumbing, pipe-fi tting and general maintenance guidelines. 2. Periodic attention is given, as necessary, to maintain the product, the accessory fi ttings & components and the overall plumbing/distribution system is operated in good functional order. General Safety 1. This product is designed and constructed to withstand the forces encountered during normal use. 2. Use of the product for any purpose other than its intended use could cause damage to the product and may cause an injury or fatality. 3. Installation or maintenance must be carried out in accordance with the instructions provided in this product manual by designated, qualifi ed and competent personnel. 4. A licensed electrician familiar with local code requirements should be engaged to perform all electrical work. 5. A licensed plumber or pipe fi tter familiar with local code requirements should be engaged to perform installation and should be on hand to oversee commissioning. 6. When installing, commissioning or servicing this product: Always ensure that all primary steam and condensate return lines and secondary water lines are isolated. Ensure any residual internal pressure in the system or connecting pipe work is carefully relieved. Always allow hot parts to cool before commencing work, to avoid the risk of burns. Always wear appropriate safety clothing before carrying out any installation or maintenance work. 5

6 Digital-Flo TM Steam/Water Plate & Frame Heat Exchanger Digital Plate & Frame Steam to Water Model Part Number Certifi ed Drawing 7.5 ft/sec (2.3 m/s) Hot/Cold Recirc. Secondary Side 7.5 ft/sec (2.3 m/s) 90 F (50 C) Delta T F (49 C) Setpoint Steam Inlet Connections Primary Side Condensate Outlet 15 psi (1 bar) D1S D27593 CD (25 mm) 1 (25 mm) 18.4 gpm (4.2 m3/hr) 2.5 (63.5 mm) 1 (25 mm) 973 lb/hr (441 kg/hr) D2S D27594 CD (40 mm) 1 (25 mm) 41.3 gpm (9.4 m3/hr) 3 (80 mm) 1.5 (40 mm) 2,185 lb/hr (991 kg/hr) D3S D27595 CD (50 mm) 2 (50 mm) 73.4 gpm (16.7 m3/hr) 3 (80 mm) 1.5 (40 mm) 3,883 lb/hr (1,761 kg/hr) D4S D27596 CD (80 mm) 2 (50 mm) gpm (37.5 m3/hr) 6 (153 mm) 2 (50 mm) 8,741 lb/hr (3,965 kg/hr) Digital Plate & Frame Steam to Water Double Wall Model Part Number Certifi ed Drawing 7.5 ft/sec (2.3 m/s) Hot/Cold Recirc. Secondary Side 7.5 ft/sec (2.3 m/s) 90 F (50 C) Delta T F (49 C) Setpoint Steam Inlet Connections Primary Side Condensate Outlet 15 psi (1 bar) D1S DW D27603 CD (25 mm) 1 (25 mm) 18.4 gpm (4.2 m3/hr) 2.5 (63.5 mm) 1 (25 mm) 973 lb/hr (441 kg/hr) D2S DW D27604 CD (40 mm) 1 (25 mm) 41.3 gpm (9.4 m3/hr) 3 (80 mm) 1.5 (40 mm) 2,185 lb/hr (991 kg/hr) D3S DW D27605 CD (50 mm) 2 (50 mm) 73.4 gpm (16.7 m3/hr) 3 (80 mm) 1.5 (40 mm) 3,883 lb/hr (1,761 kg/hr)) D4S DW D27606 CD (80 mm) 2 (50 mm) gpm (37.5 m3/hr) 6 (153 mm) 2 (50 mm) 8,741 lb/hr (3,965 kg/hr) Maximum Allowable Steam Pressure = 15.0 psi (1 bar), Maximum Allowable Water Pressure = 150 psi (10 bar), Maximum Allowable Setpoint = 158 F (70 C) *Consult factory for pressure drop information. 6

7 Digital-Flo TM Steam/Water Plate & Frame Heat Exchanger Dimensions and Weight Model Dimensions in (mm) Weight A B C D E D1S* 66.0 (1676) 50.7 (1288) 62.8 (1595) 62.8 (1595) 24.0 (610) Consult Factory D2S* 66.0 (1676) 50.7 (1288) 62.8 (1595) 69.0 (1752) 24.0 (610) Consult Factory D3S* 66.0 (1676) 50.7 (1288) 62.8 (1595) 77.0 (1956) 24.0 (610) Consult Factory D4S* 78.0 (1981) 50.7 (1288) 63.5 (1613) 87.0 (2210) 24.0 (610) Consult Factory *Consult factory for Double Wall (DW) dimensional changes. Standard Components Thermometers DRV80 Digital Recirculating Valve Steam Trap Automatic Steam Safety Shut Off Valve Check Valves Inlet Strainer(s) Isolation Valves 7

8 Digital-Flo TM Steam/Water Plate & Frame Heat Exchanger Digital-Flo Installation Details Form (IDF) We are unable to enter purchase orders into the system or guarantee delivery dates without a technically accurate and fully completed IDF. The review and acceptance of the information on the IDF by Armstrong: 1. Approves the order for processing which triggers an confi rmation 2. Indicates that AHWG supports you by endorsing the application 3. Initiates the warranty 4. Delivers a complete, AHWG supported performance guarantee to the fi nal user of the product 5. Drives the relevant point of specifi cation/infl uence, point of installation and point of order fi nancial allocation if appropriate Section 1, Ordering Processing/Tracking Detail: Point of Order (Sold To): City: State: Rep Firm: Point of Installation: City: State: Rep Firm: Point of Specification: City: State: Rep Firm: Other Influence: Section 2, Product Technical Detail: Constant Steam Pressure Low Surface Temperature (Modulating Steam) 1. Primary Side Steam Pressure: PSI 2. Incoming Water Pressure: PSI 3. DRV80 Set Point: F 4. Secondary Side Pump Flow Rate: GPM 5. Pre-piped PRV Station: Y N (eg: ABC Mechanical) (eg: Mercy Hospital) (eg: DEF Consulting Engineers) (eg: point of installation recommended product to point of specifi ation) PACKAGE REFERENCE INFORMATION Reference Drawing # (Drawing Included With Quotation If Provided) Package Model # List any non standard variations: 8

9 Digital-Flo TM Steam/Water Plate & Frame Heat Exchanger Operating Specifications - Digital-Flo Operating Specifi cations Steam Supply Pressure 2-15 psig (.14-1 bar) Water Supply Pressure PSI ( bar) Minimum Inlet Supply Water Temperature 34 F (1 C) Set Point Range (DRV80) F (27-70 C) Minimum System Recirculation Flow 10 GPM (38 LPM) Minimum System Draw Off 0 GPM Minimum Distance to First Outlet 50 ft (15 m) Minimum Recirculation Loop Temperature Loss 2 F (1 C) Supply Fuse/Circuit Breaker (DRV80) 3 amp Protection Rating (DRV80) IPX4 Signal Cable Fittings (DRV80) 3/8 Light Tight Conduit Fitting Battery (DRV80) 2 x CR - P2 6V Power Supply (DRV80) 120/240 V AC Hz Power Supply - Safety Solenoid 120 V AC Materials of Construction - Primary Side Component PFX Plates PFX Frame Gasket Condensate/Steam Piping PRV Station (Option) Control Valve Material 316 Stainless Steel Carbon Steel Painted Acrylic EPDM Cast Iron/Carbon Steel SG Iron/Carbon Steel SG Iron Materials of Construction - Secondary Side Component DRV80 Pipework Fittings 316L Stainless Steel Copper Brass/Bronze Material 9

10 Digital-Flo TM Steam/Water Plate & Frame Heat Exchanger Installation Commissioning must be carried out in accordance with these instructions by designated, qualifi ed and competent personnel. Electrical Digital-Flo requires electrical power to be supplied to the DRV80 and the Hot Water shut off valve. DRV80 is suitably rated (US NEMA 5) 12V DC electrical device which is supplied with a smart transformer capable of receiving 110V or 220V service. The electrical cable from the DRV80 transformer terminates in a two pronged plug suitable for insertion into a typical receptacle/outlet. A fused set of circuit blocks is provided in an enclosure to power the safety solenoid valve. Digital-Flo requires a secondary side circulating pump which is not supplied as standard by Armstrong. If the Digital-Flo low surface temperature option is selected an optional Sauter valve will need to be powered/ wired. A licensed electrician familiar with local code requirements should be engaged to install an outlet(s) with suitable amperage and circuit protection to power both the DRV80 and the safety solenoid valve. Installation 1. Before any installation or maintenance procedure, always ensure that all primary steam and condensate return lines and secondary water lines are isolated. 2. Ensure any residual internal pressure in the system or connecting pipework is carefully relieved. 3. Allow hot parts to cool before commencing work, to avoid the risk of burns. 4. Always wear appropriate safety clothing before carrying out any installation or maintenance work. 5. Place Digital-Flo in its desired location ensuring that there is adequate space left for service and maintenance access. Secure stand to fl oor if necessary. 6. Connect an appropriately sized inlet steam supply pipe to the inlet of the heat exchanger shell. Note: The steam supply must be controlled such that the maximum operating conditions are not exceeded (see page 10). A pressure reducing valve should be used to achieve these conditions where necessary. In addition where the steam pressure might exceed the maximum rating of Digital-Flo a suitably sized safety relief valve should be fi tted to the incoming steam supply. 7. Connect the condensate return to the integral steam trap outlet (tagged accordingly). Note: Satisfactory condensate removal is important to achieving optimum heater performance. As such an integral steam trap is supplied. Under certain conditions, constant pressure steam installations aid condensate removal prior to system stall point without the requirement for ancillary equipment. Constant pressure steam systems which require condensate lift in excess of the inlet pressure available and low surface temperature models will require the use of a mechanical or electric pumping trap. Note: Digital-Flo is supplied with an enable/disable high temperature limit protection for the secondary circuit. 8. Connect inlet cold water supply (tagged accordingly). 9. Connect outlet (to system) (tagged accordingly). 10. Connect recirculation return pipework (tagged accordingly). Note: A system side recirculation pump must be maintained at all times installed on the inlet to the unit. Note: Balance valves should be fi tted to all circuits per generally accepted piping practices. 10

11 Digital-Flo TM Steam/Water Plate & Frame Heat Exchanger Commissioning Digital-Flo Commissioning must be carried out in accordance with these instructions by designated, qualifi ed and competent personnel. 1. Check all plumbing, piping and electrical connections to ensure the installation meets specifi cation and generally accepted trade practices. 2. Ensure that the inlet steam supply valve to Digital-Flo is closed. 3. Ensure that all mixed water outlets on the system are closed. 4. Open condensate drain valve. 5. Vent air from system. 6. Flood the system by opening the appropriate isolation valves. 7. Turn the power to the DRV80 and the hot water outlet safety solenoid valve ON. tnote: Hot Water safety solenoid is controlled by a relay output on DRV80. Relay will open the normally closed solenoid valve AFTER it has gone through it full start up sequence providing no errors or faults are present. 8. Start re-circulating pump. 9. Check for water circulation through Digital-Flo. Note: DRV80 is supplied factory preset to system temperature based upon information previously supplied to Armstrong. Note: DRV80 is factory preset with a high limit default 18 F/10 C above DRV80 set point. To adjust DRV80 set point, high limit default or to enable/disable other integral valve features refer to pages Slowly open the inlet steam supply valve to Digital-Flo. 11. Adjust Steam Pressure Reducing Valve (if installed) 12. Check the LED display on the DRV80. The display will indicate the secondary side delivery temperature and the system setpoint. Note: At system start up the display on the DRV80 may read a temp low. 11

12 Digital-Flo TM Steam/Water Plate & Frame Heat Exchanger Installation Schematic Steam Inlet F&T Trap Condensate Outlet Mixed Water Outlet Recirculation Return The Brain DRV80 Cold Water Inlet SYMBOL KEY Isolation Valve Check Valve Strainer Flow Indicator Shower Expansion Tank Seperator Pressure Reducing Valve Solenoid Valve Pump Condensate Trap 12

13 Commissioning the System Commissioning must be carried out in accordance with these instructions by designated, qualifi ed and competent personnel. Commissioning: 1. Ensure that the system is powered and the display on the DRV80 is illuminated. Note: At system start up the display on the DRV80 may read an error message. This will correct itself automatically during commissioning.* 2. Flood the system by sequentially opening the inlet cold water isolation valve(s), the outlet fl ow isolation valve(s) and the inlet hot isolation valve(s). Ensure that the hot and cold inlet supplies are at their designated pressures and temperatures. 3. Ensure that all mixed water outlets are closed and turn on the circulating pump. 4. The display on the DRV80 will initially indicate the outlet water temperature and the default outlet water temperature set point which was programmed at the factory per installation details which were specifi ed at the time of order. * If an error message appears in the LCD and does not correct itself automatically during commissioning, see DRV80 Display Errors on Page 29. Temp. 119 F Setpoint 120 F Current Outlet Temperature Current Setpoint Temp. 119 F Setpoint 120 F Display as seen during normal operating mode The following sections show temperature values in F. This is region dependant setting and can be altered within the DRV80 Control Software. 13

14 Adjusting Temperature Important: The DRV80 is supplied to the job site preprogrammed to an outlet temperature set point specifi ed to Armstrong at the time the order was placed. In addition, Armstrong has enabled two levels of out of temperature range alerts. The alert presets can be adjusted by using the control software. Out of Temperature Range Alert Level 1 preset: +/- 5 F from set point = DRV80 will display Temp High or Temp Low only. Out of Temperature Range Alert Level 2 preset: +/- 10 F from set point = DRV80 will display Error Temp and shut off inlet hot water supply. The following example shows how the above settings affect the DRV80 s operation: Note! The Setpoint value does not need to be the same as the Default value. Both Setpoint and Default are adjustable within the Max. and Min. range only. Important! The software will not allow an Error Temp. value to be set lower than the Max. value plus the Above value. There are three options for on site temperature adjustment: 1. Temperature Adjustment using a Laptop Computer with software and a USB port adapter (supplied with valve). 2. Temperature Adjustment using a Building Automation System (BAS) or local area computer network (LAN) with a direct 12 to 30vdc, 4-20mA connection to the DRV80. This is termed Remote Setpoint Adjustment. 3. Temperature Adjustment using a Web Browser via the integral serial port and BrainScan supplied by Armstrong.* * This option is detailed in a separate Installation, Operation and Maintenance (IOM) Guide for BrainScan. Available by contacting Armstrong technical support. 14

15 Temperature Adjust Using Laptop or PC System Requirements Operating System: Windows XP or Windows Vista. Minimum Screen Resolution: 1024 x 768 (Recommended 1280 x 1024 or higher.) Wireless Connection to DRV80 1. Connect the IrDA Wireless Adapter to an available USB port on a laptop or PC. 2. The IrDA Wireless Adapter needs to be within range of the DRV80 and pointing toward the black IrDA sensor on the front, below the LCD Display. 3. When the Adapter is in range, an icon will appear on the Windows Taskbar to confi rm. 4. When transferring data to and from the DRV80, the icon changes to confirm button. Software Installation 1. Insert the CD-ROM. The CD should run automatically. If the CD does not start automatically, then please use the support instructions on the CD wallet. 2. Select the Control Software button from the menu and follow the on-screen instructions. 3. The Rada Icon will automatically be placed on the desktop. Double-click the icon to launch the software. 4. If the icon does not appear, locate and double click on the Rada icon in C:\Program Files\Kohler Mira\ Rada Digital. The Control Software can be downloaded at and search for DRV80 Laptop. 15

16 DRV80 Control Screen On launching an initial session, it is good practice to establish the DRV80 s current settings before making a change. Point the IrDA Infrared Adapter at the valve until the icon appears on the taskbar to confi rm a connection is established (see page 21), then press Read. The box above the Read and Write buttons shows the progress of the transfer. The DRV80 s current settings are now displayed. To transfer data from the screen to the valve, press Write. Press Online/Offline to change the DRV80 s control state. Online - the DRV80 is controlling the temperature of the blend circuit within the programmed parameters. Offline - the valve is switched to full cold fl ow and all temperature control functions and alarms are suspended. Switching the DRV80 Offline makes the blend circuit safe when writing changes to the valve. The current settings can be save to a recipe file (*.rcp) by choosing File, Save. 16

17 Options Switch Offline to make changes to Options. The Address of the DRV80 as used by the BrainScan can be set to Standard or Alternate. This allows the use of two DRV80s on one serial line, such as DMC2 or DMC3 recirculation systems. Set the fi rst DRV80 to Standard and the second DRV80 to Alternate. The Write button must be pressed after this option is changed. Important Note: This function will only work with DRV80 version 9 and onwards. This can be found under Valve Information on the DRV80 Control Screen. The Offset enables the system to correct for temperature loss and mixing conditions by creating a temperature offset to the valve. The offset temperature is subtracted from the setpoint temperature, this allows the valve to produce water at the correct temperature at the required point in the circuit. The offset is limited to ± 9 F (± 5 C). The Write button must be pressed after this option is changed. Important Note: This function will only work with DRV80 Version 9 and onwards. This can be found under Valve Information on the DRV80 Control Screen. The temperature conversion units can be changed from F to C. If the setpoint is required to be controlled via external software, switch the setpoint source to Ext. 4-20mA. Refer to section DRV80 using Building Automation System (BAS) for further details (page 35). Note! After changing the temperature display units or the setpoint source, the valve must be unplugged (powered off/ on electrically) to complete the change. Press Read to confi rm the settings. The Disinfection Timeout is the maximum number of minutes the temperature error messages are disabled to allow for disinfection and cool down before automatically switching back to normal operation. The Disinfection Enable box must be checked before the disinfection mode can be armed and triggered. Caution! All temperature error messages could remain disabled after disinfection has been completed. During Disinfection Timeout, the temperature within the blend circuit is not thermostatically controlled until the Cool Down button is pressed. 17

18 Disinfection Switch Online to perform Disinfection Cycle. The disinfection mode must first be enabled under Options before it can be armed and triggered. Due to the scalding temperature, the disinfection process must be supervised. The DRV80 should be monitored whilst in disinfection mode and no one should be allowed to approach within 3 metres of any affected outlets. Press Arm to make ready. The green box will confi rm the operation. Press Trigger while the box is green to start the disinfection cycle. The box will turn from green to red to confi rm the operation. 18

19 Disinfection (continued) Water fl ow commences when the nine second countdown reaches zero and the display on the DRV80 changes to confi rm the disinfection mode. Press Abort at any time to stop the cycle. Note! Pressing Abort could cause a temperature error to be displayed. Full Hot 160 F Disinfection Press Cool Down as per the on screen instructions. The display on the DRV80 changes to confi rm the cool down mode. After the cool down period has been initiated, the blend circuit takes time to return to normal temperature. This must be considered when setting the Disinfection Timeout value under Options. At the end of the Disinfection Timeout period, the DRV80 will return to it s normal operating mode. Temp 119 F Cooling Down 19

20 Commission, Calibration and Servicing Switch Online to make changes to Engineer. Altering the Calibration No. will affect the performance of the DRV80. The Calibration No. must match the value printed on the valve body. Enter a name for the location of the DRV80 (maximum 16 characters). Press Commission and the location will be stored along with the date and time. The location will now appear at the top of the window every time the Read button is pressed.. Press Serviced to record the time and date from the Laptop or PC. 20

21 Altering Absolute Setpoint Range and Alarms Switch Offline to make changes to Setpoints. 1. Alter values to their required settings. 2. Turn DRV80 Offline by pressing Valve Online/ Offline. 3. Transfer the settings to DRV80 by pressing Write. 4. Turn DRV80 back Online by pressing Valve Online/ Offline. 5. Press Read to confirm the settings have transferred to the DRV80. Altering Local Setpoint Value Switch Online to make changes to Temperatures. 1. Alter the Setpoint to the required value. 2. Transfer the settings to DRV80 by pressing Set. (Valve does not have to be Offline.) 3. Alter the Setpoint back to the Default value by pressing Reset to Default. 4. The Setpoint value is shown on the DRV80. Setpoint - Explained The setpoint is the required outlet water temperature supplied to the blend circuit. This area controls the range in which the setpoint can be adjusted to, but not the current setpoint itself (valve display). The Default value is the setpoint the valve will return to should the power be lost and the DRV80 reset. The Default is adjustable, but cannot be more than the Max. (maximum) value or less than the Min. (minimum) value. 21

22 Alarms - Explained The DRV80 does not contain an audible alarm, however, the error relay may be used to send an alarm signal from the DRV80 if the blend temperature falls outside either the Above or Below tolerance values of the setpoint. If the blend temperature exceeds the Error Temp. value, the DRV80 activates the error relay and closes down to full cold. For more details on the error relay connection see section DRV80 using Building Automation System (BAS) in the Installation and Maintenance Guide. Example 1: Note! The Setpoint value does not need to be the same as the Default value. Both Setpoint and Default are adjustable within the Max. and Min. range only. 22

23 Example 2: Important! The software will not allow an Error Temp. value to be set lower than the Max. value plus the Above value. 23

24 Temperatures The current inlet and outlet temperatures are displayed. The setpoint is the current blend temperature the DRV80 is instructed to control to. Pressing Reset to Default will alter to match the Default value in the Setpoints area. Switch valve to the on state and press Read to show the current settings. Press Set to transfer the setpoint to the valve. The display appears on the DRV80 indicating the normal operating mode. 24

25 Error Messages - PC Display Connection was lost during data transfer. Make sure IrDA adapter remains in the range of DRV80 (see IrDA symbols below). If the error persists, make sure the IrDA adapter is in range and cycle the power to DRV80 off/on once to reset. Connection was not established before data transfer. Make sure IrDA adapter is in range of DRV80 (see IrDA symbols below). If the error persists, make sure the IrDA adapter is in range and cycle the power to DRV80 off/on to reset. Connection was not established before data transfer. Make sure IrDA adapter is in range of DRV80 (see IrDA symbols below). The Enable Disinfection box has not been checked and transferred to DRV80 prior to initiating a disinfection cycle. Check Enabled Disinfection box and press Write. IrDA Symbols (Windows Tasker) DRV80 is in range of IrDA adapter. If symbol is not displayed when IrDA is at close range, check USB connection (remove and reconnect IrDA) or cycle power to DRV80 off/on once. Data is being transferred to/from DRV80. If symbol is not displayed, check IrDA adapter is in range of DRV80. Armstrong has technical support personnel available from 25

26 DRV80 Display Alerts Temp High 127 F Setpoint 120 F Outlet temperature exceeds the alarm range. This condition causes an alarm signal to be activated. Temp Low Setpoint 100 F 120 F Outlet temperature is below the alarm range. This condition causes an alarm signal to be activated. Emergency Setpoint 85 F 120 F Maintenance to the DRV80 internal motor is required. DRV80 continues to operate safely, but with reduced performance. DRV80 Display Errors Temp Error PCB 120 F Reset the DRV80. If the error persists, replace the PCB. Temp 120 F Error Motor Reset the DRV80. If the error persists, replace the Motor. Temp 120 F Error Thermistor Reset the DRV80. If the error persists, check the Thermistor connections or replace the Thermistors. Temp High 120 F Error Temp Outlet temperature exceeds the Error Temp value. This condition causes the DRV80 to switch to full cold. Temp 120 F Error Battery Reset the DRV80. If the error persists, replace the battery (see Fitting the Cable Conduit and Changing the Battery ). 26

27 DRV80 using Building Automation System (BAS) DRV80 contains three integral connection points for component/system integration. 1. Building Automation System The DRV80 can be adjusted remotely when linked via its integral 12 to 30vdc, 4-20mA connection to a Building Automation System (BAS) or Local Area Computer Network (LAN). Two signal connections can be made via a 3/8 Liquitight connector conduit fi tting. The connections are: Remote Setpoint Adjustment. The ability to change the setpoint on the DRV80 via a Building Automation System (BAS) or Local Area Computer Network (LAN). This is an opto-isolated input intended for connection to a 12 to 30vdc, 4-20mA self powered transmitter with a maximum output of 12V. The connection is used to determine the DRV80 s setpoint and is scaled at 4-20 ma for C. The input signal is only active when the DRV80 is confi gured to Ext ma. These settings can only be altered when the DRV80 is switched to its Offl ine state. Actual Outlet Temperature Reading. The ability to link the computer signal from the DRV80 outlet temperature thermistor to a Building Automation System (BAS) or Local Area Computer Network (LAN). This is an opto-isolated signal intended for connection to a 4-20 ma self powered indicator with a maximum output of 12V. The signal sends the DRV80 s outlet temperature and is scaled at 4-20 ma for C. 2. Error Relay Connection The DRV80 can be connected to a downstream audible alarm, a solenoid valve or another ancillary device via a direct connection to its error relay via a liquitight connector conduit fi tting. This provides a connection to a set of single pole changeover relay contacts fused at 2 Amps. When the DRV80 is operating normally, the relay is energized and therefore the contacts are closed. The relay is de-energized and the contacts are open under the following circumstances: 1. Power failure. 2. Start up sequence. 3. Outlet temperature causing an alarm signal. 4. Outlet temperature causing an error signal. 5. Internal fault on PCB. 6. Battery failure. 7. Thermistor failure. 3. Serial Line Connection* The DRV80 provides an RS485 serial interface for connection to BrainScan. Note: BrainScan is not specifically addressed by this Installation Manual. * Serial Line Connection is detailed in a separate Installation, Operation and Maintenance (IOM) Guide for Brain- Scan. Available by contacting Armstrong technical support. 27

28 DRV80 using Building Automation System (BAS) (continued) 28

29 DRV80 connected to generic BAS 29

30 Testing DRV80/BAS connections using two multimeters Current Loop Check Set Multimeters to ma dc current range. Fault Diagnosis for BAS Possible causes for BAS indicating an incorrect fl ow value: BAS analog input terminals resistance is too high causing current to be limited to the analog input giving a lower reading than expected on the BAS display. BAS signal scaling is incorrect. Consult BAS engineer. 30

31 Operational Check Use Charts 1.1 and 1.2 to check the temperature output from the DRV80 against the current input from the BAS. Chart 1.1 DRV80 ma chart (ºC). ºC ma ºC ma ºC ma ºC ma ºC ma ºC ma ºC ma ºC ma ºC ma ºC ma Chart 1.2 DRV80 ma chart (ºF) ºF ma ºF ma ºF ma ºF ma ºF ma ºF ma ºF ma ºF ma ºF ma ºF ma

32 Fitting the Cable Conduit and Changing the Battery Battery replacement and conduit connection must be carried out in accordance with these instructions by designated and competent personnel. Figure 22-1 Isolate electricity to DRV80. Remove all 8 cover screws, make sure cover is constantly supported. Figure Caution heavy parts. Carefully remove cover and disconnect display cable. Figure If required, pull batteries from housing and replace with new batteries of same type. Do not mix old and new batteries. Do not use rechargeable batteries. Figure Remove blanking plugs as required and connect 3/8 Liquitight conduit fi ttings (not supplied) as shown using a suitable spanner. Figure Fit 3/8 Liquitight conduit tube (not supplied) and feed the wires through as required. Do not overtighten the conduit fi ttings. Figure Reconnect display cover and carefully refi t cover. Loosely refi t screws to locate cover correctly. Tighten all screws to secure cover. Restore electricity to DRV80. 32

33 Operation Digital-Flo employs digital technology to monitor inlet hot supply, inlet cold/system return water temperature. In constant pressure steam supply systems this eliminates the requirement for a steam control valve. Digital-Flo is supplied pre-piped and pressure tested with an integral digital re-circulating valve (The Brain Model DRV80). Inlet (2) and outlet (2) thermistors integral to The Brain and the time proven water temperature control accuracy eliminate the requirement for the external temperature sensors, programmers and controllers typically associated with steam heat exchangers. A low surface temperature option is available which requires a secondary controller for applications where higher mineral content water portends a scaling concern. 33

34 Maintenance - Plate & Frame Heat Exchanger Module A separate IOM is available for specific Plate & Frame Module supplied with your Digital-Flo Model Note serial number on PHE and refer to IOM guide for specific PHE module supplied with heater. Please call Armstrong Technical Support at HOT-HOSE. Performance: Check temperatures and fl ow rates against commissioning data. Plate Pack: Check tightening dimension and look for signs of leakage. Nozzles: Check in general condition, and for signs of leakage. Frame: Wipe clean all painted parts and check surfaces for signs of damage - touch up if required. Bolts & Bars: Check for ruse, and clean. Lightly coat threaded parts with molybdenum grease, or a corrosion inhibitor (ensure that not grease etc falls onto the plate gaskets). Gaskets: Check and replace when required. Rollers: If fi tted to the follower frame plate, lubricate bearings with light machine oil. Spare Parts: Note serial number on PHE and refer to IOM guide for specifi c PHE module supplied with heater. 34

35 Maintenance - Digital Re-Circulating Valve Time Interval: Minimum once per year. Performance: Check temperatures and fl ow rates against commissioning data. Batteries: Batteries are supplied to ensure the valve switches to a Safe Mode in the event of a primary power supply failure. Battery life is variable depending on usage. A battery error message appears on the valve display when they require changing. Where primary power supply failure occurs regularly or the valve 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 maximum of fi ve (5) years. 35

36 Servicing and Maintenance (continued) WARNING - ISOLATE POWER AND WATER SUPPLIES BEFORE REMOVING COVER! CAUTION - HEAVY EQUIPMENT! DISASSEMBLE WITH CARE. A MINIMUM OF 2 PEOPLE REQUIRED TO SAFELY REMOVE APPLIANCE FROM PIPEWORK. DO NOT DAMAGE ELECTRONIC CONNECTIONS WHEN REMOVING COVER. DO NOT TRAP ANY WIRES WHEN REFITTING COVER. CAUTION - PARTS ARE EASILY DAMAGED! REASSEMBLE WITH CARE! 36

37 Servicing and Maintenance (continued) ONLY USE 2 X CR - P2 6V BATTERIES (NOT INCLUDED IN SPARE PARTS). DISCONNECT ALL WIRES BEFORE REMOVING PBC. USE GREASE PROVIDED ON REPLACEMENT SEALS. CHECK PCB FOR SIGNS OF RUST. SEE SECTION FAULT DIAGNOSTICS - PROBLEM 9. D8414 (us) D33170 (eu) Blue Wire = Cold Inlet D8418 D8406 D8408 D8409 D8412 D8413 (us)* D33169 (eu) *Directly affects digital water temperature control. Contact Armstrong for technical advice prior to fi tting. +12V 0V 37

38 Servicing and Maintenance (continued) 38

39 Servicing and Maintenance (continued) REMOVE SEALS USING NONMETALLIC TOOLS TO PREVENT SEAL GROOVE DAMAGE CLEAN ALL GROOVES BEFORE REASSEMBLY. USE GREASE PROVIDED WHEN REASSEMBLING SEALS. 39

40 Servicing and Maintenance (continued) DO NOT DAMAGE MOTOR PCB. D8405 * D8407 D8406 REPLACE SEAL ONLY IF NECESSARY. D8404 * D8410 D8411 * Directly affects digital 40

41 Spare Parts - DRV80 D8404 D8405 D8406 D8407 D8408 D8409 D8410 D8411 D8412 D8413 D8414 D8415 D8416 D8417 D8418 D8972 D33169 D33170 Drive Mechanism. Spool Assembly. Screw and Seal Pack. Seal Housing. Thermistor Loom. Thermistor Retainers. Stepper Motor. Stepper Motor Loom. Battery Holder. PCB (US compatible). PSU (US compatible). Cover Seals. Display Window Assembly. LCD Display. Grommet Spare. Data Cable Spare. PCB (EU compatible). PSU (EU compatible). D8405 D8404 D8410 D8414 (us) D33170 (eu) D8406 D8407 D8415 D8411 D8412 D8418 D8406 D8406 D8408 x3 D8406 D8408 D8972 x2 D8416 D8415 x4 D8406 D8409 D8413 (us) D33169 (eu) D

42 Troubleshoot Guide Problem Cause Solution 1. Unable to bring Secondary Side to temperature. 2. Secondary Side system temperature rises during periods of no system demand. 3. Secondary Side system temperature fl uctuates more than +/- 5 F. 4. DRV80 display shows any of the following. 1. Primary side system fault. a. Check the steam system valve. b. Check the high temperature shut off valve is open. Spindle should be in the down position. c. Ensure the high temperature trip setting in the DRV80 is set at least 10 C higher than the desired hot water temperature. d. Check steam trap isolation valves are open. e. Check that the condensate temperature after the steam trap is at steam temperature. If not, the steam trap may be blocked or the back pressure in the condensate line may be too high. Disconnect the pipework after the steam traps, running the condensate to drain, and see if the hot water comes up to temperature. If not, investigate potential problems on the condensate system or install a pump trap to overcome the higher back pressure. It no condensate exits the steam trap, disassemble and check for blockage. f. If the Low Surface Temperature option is fi tted ensure the set point in the Econotrol panel (normally 90 C) is set higher than the hot water temperature set point on the DRV80. Please consult the LST/Econotrol IOM. 2. Secondary Side system fault. a. Check that the Secondary Side re-circulation line is hot. If it cool, then the non return valve may not be working correctly. A failed NRV may cause the cold water to bypass heat exchanger. 1. Secondary Side system fault. a. Flow rate is less than 10 GPM - reset fl ow rate, check for air locks, closed valves, pump failure, etc. b. Return temperature less than 2 F below DRV80 set point. Ensure minimum temp drop around circuit of 2 F. c. Check valve problem. Make sure placement of check valve is correct. Refer to installation schematics. Ensure that check vales are fully functional. d. Water pressure. Ensure maintained supply pressures are balanced. Ensure that there is mixed return to water heater. e. Flow problem. Ensure maintained supply pressures are balanced. Ensure that there is mixed return to water heater. 2. DRV80 fault a. Refer to DRV80 display error messages. 1. Secondary Side system fault. a. Maintained supply pressures are unequal. Ensure that pressures are balanced. Check for blocked fi lters, closed valves, air locks, etc. b. Supply temperatures. Check for reasonable temperature differential between set point and hot and cold inlet supply temperatures to DRV DRV80 fault. a. Spool sticking. Clean and descale pool. Renew separator seal and lubricate assembly. b. Refer to DRV80 display error messages. c. Poor calibration. Refer to DRV80 Valve Calibration screen. 3. Primary side system fault. a. Check the steam pressure before the high limit valve or before the pressure reducing valve (if fi tted). If the steam pressure is decreasing under normal conditions, there may be insuffi cient steam available to meet the higher hot water demands. If the Low Surface Temperature option is fi tted ensure the control valve is set 30 second travel time. Refer to the actuator IOM for more information. b. The demand from the hot water system is greater than the designed capacity of the PHE. Take measures to reduce Secondary Side hot water demand. 1. System fault. a. Water supply problem. Check supply temperature between PHE and DRV80. b. Perform hard set: Turn power to DRV80 off 10 seconds and restart. 2. DRV80 fault. a. Spool sticking. Clean and descale spool. Renew separator seal and lubricate assembly. b. Refer to DRV80 display error messages. a. System does not fully return to normal temperature within the Disinfection Timeout period. Check the following: Disinfection Timeout value (Valve Setup: screen). Cool down start and fi nish times. Use Dump Valve to speed up Cool Down time. b. Early abort of disinfection process. 42

43 Troubleshoot Guide Problem Cause Solution 5. Constant difference between Secondary Side system temperature and DRV80 display. 1. Secondary Side system fault. a. Outlet thermometer inaccurate - replace. 2. DRV80 fault. a. Thermistor problem - refer to thermistor error message. 6. Reduced heater capacity. 1. PHE fault. a. Heat exchanger may be becoming blocked due to scaling. Clean the heat exchanger using a suitable de-scaling fluid via the CIP connections. If the heat exchanger has become completely blocked then dismantle and clean the heat exchanger as per the relevant IOM. 7. Unable to adjust Secondary Side system temperature. 8. No display on DRV80 and/or no control. 1. Digital-Flo fault. a. Pump fl ow rate to low. Reset circuit flow rate. Check for blocked fi lters, closed valves, air locks, pump failure, etc. b. Return temperature less than 2 F below DRV80 set point. Ensure minimum temp drop around circuit of 2 F. c. Check valve problem. Make sure placement of check valve is correct. Refer to installation schematics. Ensure that check valves are fully functional. d. Water Pressure. Ensure maintained supply pressures are balanced. Ensure that there is mixed return to water heater. e. Flow problem. Check for air locks, blocked filters, closed valves etc. f. Maintained supply pressures are unequal. Ensure that pressures are balanced. Check for blocked fi lters, closed valves, air locks etc. g. Supply temperatures. Check for reasonable temperature differential between set point and hot and cold inlet supply temperatures to DRV DRV80 fault. a. Refer to DRV80 display error messages. 1. Secondary Side system fault. a. No power to DRV80 - Check electrical supply. 2. DRV80 fault. a. Internal power connection or display connection is loose or not made. Check and reconnect. b. DRV80 power transformer has failed replace. c. Internal fuse failure replace fuse and investigate cause. d. PCB failure - replace. 9. High pitched noise from DRV Secondary Side system fault. a. Maintained supply pressures are unequal. Ensure that pressures are balanced. Check for blocked fi lters, closed valves, air locks etc. b. Supply temperatures. Check for reasonable temperature differential between set point and hot and cold inlet supply temperatures to DRV DRV80 fault. a. Motor is worn replace b. Refer to DRV80 display error messages. 10. Water leaking from DRV DRV80 fault. a. Check all seals for wear and/or damage. Clean, lubricate or replace. b. Body casting failure - replace DRV Water/moisture visible in DRV80 cover. 12. Water leaking from plate & frame module. 1. DRV80 fault. a. Water left in DRV80 during previous maintenance, interior of cover must be kept dry, as moisture will condense and corrode PCB. b. Check thermistor seals for wear and/or damage. Clean, lubricate or replace. 1. PHE fault. a. Note serial number on PHE and refer to IOM guide for specifi c PHE module supplied with heater. 43

44 Component Identification Guide Item A Description Plate & Frame HX Part Number D28017 D28027 D1S D2S D3S D4S Connection Size SW DW Part Number D28018 D28028 Connection Size SW DW Part Number D28019 D28029 Connection Size SW DW Part Number D28020 D28030 Connection Size B Trap D (25 mm) D (40 mm) (40 mm) C (50 mm) C Pressure Relief Valve D8312 N/A D8312 N/A D8312 N/A D8312 N/A D Steam Shut Off Valve D (63.5 mm) D (80 mm) D (80 mm) D (153 mm) E Ball/Butterfly Valve D (25 mm) D (40 mm) D (50 mm) D (80 mm) F Gate Valve D (25 mm) D (40 mm) D (50 mm) D (80 mm) G Thermometer D (63.5 mm) D (102 mm) D (102 mm) D (153 mm) H Thermowell D (63.5 mm) D (102 mm) D (102 mm) D (153 mm) I Terminator (Ball/Strainer Combo) Valve D (25 mm) D (40 mm) D (50 mm) D (80 mm) J Spring Check Valve D (25 mm) D (40 mm) D (50 mm) D (80 mm) K Swing Check Valve D (25 mm) D (40 mm) D (50 mm) D (80 mm) L Actuator D28688 N/A D28688 N/A D28688 N/A D28688 N/A M DRV80 D (50 mm) D677 3 (80 mm) D (80 mm) D (80 mm) N Controller Panel D29952 N/A D29952 N/A D29952 N/A D29952 N/A O Swing Check Valve D (25 mm) D (25 mm) D (50 mm) D (50 mm) P Terminator Valve D (25 mm) D (25 mm) D (50 mm) D (50 mm) Q Swing/Spring Check Valve D (25 mm) D (25 mm) D (25 mm) D (25 mm) R Thermometer D (63.5 mm) D (102 mm) D (102 mm) D (102 mm) S Thermowell D (63.5 mm) D (102 mm) D (102 mm) D (102 mm) SW DW 44

45 Notes 45

46 Armstrong Hot Water Group Warranty Armstrong Hot Water Group, Inc. ( Armstrong ) warrants to the original user of those products supplied by it and used in the service and in the manner for which they are intended, that such products shall be free from defects in material and workmanship for a period of one (1) year from the date of installation, but not longer than 15 months from the date of shipment from the factory [unless a Special Warranty Period applies, as listed below]. This warranty does not extend to any product that has been subject to misuse, neglect, or alteration after shipment from the Armstrong factory. Except as may be expressly provided in a written agreement between Armstrong and the user, which is signed by both parties, Armstrong DOES NOT MAKE ANY OTHER REPRESENTATIONS OR WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTY OF MERCHANTABILITY OR ANY IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE. The sole and exclusive remedy with respect to the above limited warranty or with respect to any other claim relating to the products or to defects or any condition or use of the products supplied 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 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. IN NO EVENT SHALL ARMSTRONG BE LIABLE FOR SPECIAL, DIRECT, INDIRECT, INCIDENTAL OR CONSE- QUENTIAL DAMAGES, INCLUDING, BUT NOT LIMITED TO, LOSS OF USE OR PROFITS OR INTERRUPTION OF BUSINESS. The Limited Warranty and Remedy terms herein apply notwithstanding any contrary terms in any purchase order or form submitted or issued by any user, purchaser, or third party and all such contrary terms shall be deemed rejected by Armstrong. Special Warranty Periods are as follows: Flo-Direct Gas Fired Water Heater The stainless steel structure and stainless steel internals shall have a 10-year guarantee against failure caused by materials or workmanship provided by Armstrong. All external componenets shall have a 2-year guarantee against failure caused by materials or workmanship provided by Armstrong. IOM-786-B 6/11 Armstrong Hot Water Group 221 Armstrong Blvd., Three Rivers, Michigan USA Ph: (269) Fax: (269) armstronginternational.com Toll Free: 46 (888) HOT-HOSE Printed in U.S.A.