Steam/Water Shell Tube Heat Exchanger

Steam/Water Shell Tube Heat Exchanger
IOM-785-C
Digital-FloTM
Digital Instantaneous
Steam/Water Shell & Tube 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 Shell & Tube Heat Exchanger has been designed, fabricated
and configured specifically for this installation and, as such, there may be customized components
which are not specifically addressed within this document.
Supplemental Product Manual’s and Installation and Maintenance Guides specific to the peripheral
components supplied on/with Digital Instantaneous Steam/Water Shell & Tube Heat Exchanger
are available online at: http://www.armstronginternational.com or by calling Armstrong Toll Free at
1-888-HOT-HOSE.
Model Number ________________________________
Serial Number_________________________________
Ship Date_____________________________________
Customer Support:
Armstrong Hot Water Group
Phone: (269) 279-3602
Fax: (269) 279-3130
E-mail: hotwater@armstronginternational.com
armstronginternational.com
Digital-FloTM Steam/Water Shell & Tube Heat Exchanger
The Digital-Flo Steam/Water Shell & Tube Heat Exchanger assembly covered by this IOM features installation,
commissioning, operation and general maintenance detail.
Each Digital-Flo Steam/Water Shell & Tube Heat Exchanger is serialized and the serial number is maintained on
file 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 1-888-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 Shell & Tube Heat Exchangers are available online at: http://www.
armstronginternational.com
Customer Support:
Armstrong Hot Water Group
Phone: (269) 279-3602
Fax: (269) 279-3130
e-mail: hotwater@armstronginternational.com
armstronginternational.com
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
2
Table of Contents
Safety Warnings...................................................................................................................................................5
Installation Details Form (IDF)..............................................................................................................................9
Installation Schematic........................................................................................................................................14
Operating Specifications....................................................................................................................................10
Standard Materials of Construction...............................................................................................................10-11
Standard Dimensions and Weights...................................................................................................................7-8
Installation ...................................................................................................................................................12-13
Commissioning..............................................................................................................................................14-29
Operation ........................................................................................................................................................35
Maintenance - Heat Exchanger..........................................................................................................................36
Maintenance - DRV80...................................................................................................................................37-44
Component Identification Guide.........................................................................................................................48
Spare Parts - DRV80 Only.................................................................................................................................44
Troubleshoot Guide.......................................................................................................................................45-46
Warranty Information..........................................................................................................................................50
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
3
Digital-FloTM Steam/Water Shell & Tube Heat Exchanger
Digital Controller
Outlet Temperature to
system +/- 2°F/1°C
ASSE 1017 CSA B125 and CE
certified
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
LED Display
Indicates
Set point °C or °F
Operating Temp °C or °F
IRDA Port for PC programming
Field programmable
Set point
High temperature alert
High temperature hot water shutoff
Thermal disinfection
316L Stainless steel construction
Battery back-up for
emergency shutdown
and default setting
retention
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
4
Digital-FloTM Steam/Water Shell & Tube Heat Exchanger
Safety Warnings
Digital-Flo Steam/Water Shell & Tube 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-fitting and general maintenance
guidelines.
2. Periodic attention is given, as necessary, to maintain the product, the accessory fittings & 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, qualified 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 fitter 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.
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
5
Digital-FloTM Steam/Water Shell & Tube Heat Exchanger
Digital Shell & Tube
Water Side
Model
Part Number
Steam Side
Connections @ 7.5 ft/sec
(2.3 m/s)
Flow @ 7.5 ft/sec
(2.3 m/s)
Connections
Hot/Cold
Recirc.
Capacity @ 90°F (50°C) Delta T
Typical @120°F (49°C) Setpoint
Steam Inlet
Condensate
Outlet
1” (25 mm)
Capacity @ 15 psi (1 bar)
D535
D21983
1.5” (40 mm)
1” (25 mm)
41.3 gpm (9.4 m3/hr)
2.5” (63.5 mm)
D535P
D21981
2” (50 mm)
1” (25 mm)
73.4 gpm (16.7 m3/hr)
2.5” (63.5 mm)
1” (25 mm)
3,495 lb/hr (1,585 kg/hr)
D665
D21979
2” (50 mm)
2” (50 mm)
73.4 gpm (16.7 m3/hr)
3” (80 mm)
1.25” (32 mm)
3,495 lb/hr (1,585 kg/hr)
D665P
D21722
3” (80 mm)
2” (50 mm)
165.2 gpm (37.5 m3/hr)
3” (80 mm)
1.25” (32 mm)
7,867 lb/hr (3,568 kg/hr)
D8120
D21977
3” (80 mm)
2” (50 mm)
165.2 gpm (37.5 m3/hr)
4” (102 mm)
2” (50 mm)
7,867 lb/hr (3,568 kg/hr)
D8120P
D21640
3” (80 mm)
2” (50 mm)
165.2 gpm (37.5 m3/hr)
4” (102 mm)
2” (50 mm)
7,867 lb/hr (3,568 kg/hr)
1,967 lb/hr (893 kg/hr)
Digital Shell & Tube Double Wall
Water Side
Model
Part Number
Connections @ 7.5 ft/sec
(2.3 m/s)
Hot/Cold
Recirc.
Steam Side
Flow @ 7.5 ft/sec
(2.3 m/s)
Connections
Capacity @ 90°F (50°C) Delta T
Typical @120°F (49°C) Setpoint
Steam Inlet
Condensate
Outlet
Capacity @ 15 psi (1 bar)
D535DW
D21984
1.5” (40 mm)
1” (25 mm)
41.3 gpm (9.4 m3/hr)
2.5” (63.5 mm)
1” (25 mm)
1,967 lb/hr (893 kg/hr)
D535DWP
D21982
2” (50 mm)
1” (25 mm)
73.4 gpm (16.7 m3/hr)
2.5” (63.5 mm)
1” (25 mm)
3,495 lb/hr (1,585 kg/hr)
D665DW
D21980
2” (50 mm)
2” (50 mm)
73.4 gpm (16.7 m3/hr)
3” (80 mm)
1.25” (32 mm)
3,495 lb/hr (1,585 kg/hr)
D665DWP
D22000
3” (80 mm)
2” (50 mm)
165.2 gpm (37.5 m3/hr)
3” (80 mm)
1.25” (32 mm)
7,867 lb/hr (3,568 kg/hr)
D8120DW
D21978
3” (80 mm)
2” (50 mm)
165.2 gpm (37.5 m3/hr)
4” (102 mm)
2” (50 mm)
7,867 lb/hr (3,568 kg/hr)
D8120DWP
D21975
3” (80 mm)
2” (50 mm)
165.2 gpm (37.5 m3/hr)
4” (102 mm)
2” (50 mm)
7,867 lb/hr (3,568 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.
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
6
Digital-FloTM Steam/Water Shell & Tube Heat Exchanger
Dimensions and Weight
Dimensions
in (mm)
Model
A
Weight
B
C
D
E
D535
20.0 (508)
34.0 (864)
45.0 (1143)
66.9 (1699)
81.0 (2057)
804 lbs (365 kgs)
D535DW
20.0 (508)
46.5 (1181
45.0 (1143)
76.5 (1944)
82.0 (2083)
1080 lbs (490 kgs)
D535P
20.0 (508)
67.0 (1702)
45.0 (1143)
66.9 (1699)
85.6 (2174)
1234 lbs (560 kgs)
D535DWP
20.0 (508)
67.0 (1702)
45.0 (1143)
76.6 (1944)
87.6 (2224)
1317 lbs (597 kgs)
D665
30.0 (762)
34.0 (864)
57.0 (1448)
79.9 (2030)
103.3 (2624)
1094 lbs (496 kgs)
D665DW
30.0 (762)
34.0 (864)
57.0 (1448)
88.7 (2252)
99.6 (2530)
1373 lbs (623 kgs)
D665P
30.0 (762)
64.0 (1626)
57.0 (1448)
79.9 (2030)
110.5 (2806)
1835 lbs (832 kgs)
D665DWP
30.0 (762)
64.0 (1626)
57.0 (1448)
88.7 (2252)
104.1 (2645)
1892 lbs (858 kgs)
D8120
34.0 (864)
34.0 (864)
57.0 (1448)
83.0 (2108)
132.6 (3368)
1507 lbs (684 kgs)
D8120DW
34.0 (864)
34.0 (864)
57.0 (1448)
77.3 (1963)
132.6 (3368)
1550 lbs (703 kgs)
D8120P
34.0 (864)
58.0 (1473)
57.0 (1448)
83.0 (2108)
123.4 (3135)
3011 lbs (1366 kgs)
D8120DWP
34.0 (864)
58.0 (1473)
57.0 (1448)
80.2 (2035)
129.2 (3281)
3050 lbs (1383 kgs)
Standard Components
•
•
•
•
Thermometers
DRV80 Digital Recirculating Valve
Steam Trap
Automatic Hot Water Safety Shut Off Valve
•
•
•
•
Check Valves
Inlet Strainer(s)
Isolation Valves
Air Vent
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
7
Digital-FloTM Steam/Water Shell & Tube Heat Exchanger
H
Shell & Tube Heat Exchanger Dimensions and Weights
Dimensions
Model
A
B
C
D
E
F
L
1
2
3
Weight
D535
in
mm
67-1/4
1,708
5-9/16
141
4-1/2
114
4
102
7-7/8
200
6-3/4
171
62
1,575
1-1/2 NPT
40
1 NPT
25
2-1/2 NPT
65
lb
kg
169
77
D665
in
mm
80-1/4
2,038
6-5/8
168
5-1/2
140
4-3/4
121
9-1/4
235
6-7/8
175
74
1,880
2 NPT
25
1-1/4 NPT
32
3 NPT
80
lb
kg
239
108
D8120
in
mm
83-1/2
2,121
8-5/8
219
8-7/8
225
6-1/8
156
9-1/2
241
7-7/8
200
74
1,880
3 NPT
80
2 NPT
25
4 150# ANSI
100
lb
kg
440
200
Shell & Tube Heat Exchanger Double Wall Dimensions and Weights
Dimensions
Model
A
B
C
D
E
F
H
1
2
3
Weight
D535 DW
in
mm
70-3/4
1949
5-9/16
141
4-1/2
114
4
102
11-1/2
292
7.5
191
75
1905
1-1/2 NPT
40
1 NPT
25
2-1/2 NPT
65
lb
kg
204
192
D665 DW
in
mm
88-3/4
2254
6-5/8
168
5-1/2
140
4-3/4
121
11-3/4
298
7-1/8
181
87
2210
2 NPT
25
1-1/4 NPT
32
3 NPT
80
lb
kg
325
147
D8120 DW
in
mm
77-3/4
1975
8-5/8
219
8-7/8
225
6-1/8
156
12-5/8
321
8-3/8
213
75
1905
3 NPT
80
2 NPT
25
4 150# ANSI
100
lb
kg
520
236
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
8
Digital-FloTM Steam/Water Shell & Tube 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 e-mail confirmation
2. Indicates that AHWG supports you by endorsing the application
3. Initiates the warranty
4. Delivers a complete, AHWG supported performance guarantee to the final user of the product
5. Drives the relevant point of specification/influence, point of installation and point of order financial allocation if appropriate
Section 1, Ordering Processing/Tracking Detail:
Point of Order (Sold To): ____________________________________________________________________________
(eg: ABC Mechanical)
City: _______________________ State: _______________________ Rep Firm: _______________________
Point of Installation:___________________________________________________________________________________
(eg: Mercy Hospital)
City: _______________________ State: _______________________ Rep Firm: _______________________
Point of Specification: ______________________________________________________________________________
(eg: DEF Consulting Engineers)
City: _______________________ State: _______________________ Rep Firm: _______________________
Other Influence: ____________________________________________________________________________
(eg: point of installation recommended product to point of specifiation)
Section 2, Product Technical Detail:
1. Cold Water Temperature (EWT): ________°F
2. DRV80 Set Point: ________°F
3. Steam Pressure Available: ________PSIG
Pre-piped PRV Station required:
Y _____
4. Incoming Water Pressure: ________PSIG
5. Maximum Simultaneous Demand: ________GPM
6. Pump Size in GPM: ________GPM
PACKAGE REFERENCE INFORMATION
Reference Drawing # ___________________
(Drawing Included With Quotation If Provided)
Package Model # ___________________
List any non standard variations: _________________________________________________________
__________________________________________________________________________________________
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
9
N _____
Digital-FloTM Steam/Water Shell & Tube Heat Exchanger
Operating Specifications - Digital-Flo
Operating Specifications
Steam Supply Pressure
2-15 psig (.14-1 bar)
Water Supply Pressure
20-150 PSI (1.4-10 bar)
Minimum Inlet Supply Water Temperature
34°F (1°C)
Set Point Range (DRV80)
81-158°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
50-60 Hz
Power Supply - Safety Solenoid
120 V AC
Materials of Construction - Digital-Flo - Single Wall
Component
Material - Standard
Material Option(s)
Heat Exchanger Shell
Carbon Steel ASTM - SA - 106B
ASME “U” stamped
Stainless Steel
Heat Exchanger Tube Bundle
5/8”16BWG Admiralty Brass
Stainless Steel
Heat Exchanger Tube Sheets
Brass
Stainless Steel
Heat Exchanger Tube Bundle End Cap
Brass
Stainless Steel
Integral Supply Pipe Work
Brass
Carbon Steel, Stainless Steel
Integral Valves and Fittings
Brass/Bronze
Carbon Steel, Stainless Steel
Condensate/Steam Piping
Cast Iron/Carbon Steel
Stainless Steel
PRV Station (option)
SG Iron/Carbon Steel
N/A
Low Surface Temperature
Assembly (Modulating Steam)
SG Iron/Carbon Steel
N/A
DRV80
316L Stainless Steel
N/A
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
10
Digital-FloTM Steam/Water Shell & Tube Heat Exchanger
Materials of Construction - Digital-Flo - Double Wall
Component
Material - Standard
Material Option(s)
Heat Exchanger Shell
Carbon Steel ASTM - SA - 106B
ASME “U” stamped
N/A
Heat Exchanger Tube Bundle
5/8” Copper Inner Tube - 3/4”
Grooved Copper Outer Tube
N/A
Heat Exchanger Tube Sheets
Steam Side - Carbon Steel
Water Side - Brass
N/A
Integral Supply Pipe Work
Brass
Carbon Steel, Stainless Steel
Integral Valve and Fittings
Brass/Bronze
Carbon Steel, Stainless Steel
Condensate/Steam Piping
Cast Iron/Carbon Steel
Stainless Steel
PRV Station (option)
SG Iron/Carbon Steel
N/A
Low Surface Temperature
Assembly (Modulating Steam)
SG Iron/Carbon Steel
N/A
DRV80
316L Stainless Steel
N/A
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
11
Digital-FloTM Steam/Water Shell & Tube Heat Exchanger
Installation
Commissioning must be carried out in accordance with these instructions by designated, qualified and competent
personnel.
Electrical
Digital-Flo requires electrical power to be supplied to the DRV80 and the safety solenoid 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.
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.
Plumbing
A licensed plumber or pipe fitter familiar with local code requirements should be engaged to install Digital-Flo and
should be on hand to oversee commissioning.
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 floor if necessary.
Note: The clearance distance required to access/remove the internal tube bundle on page 8 letter
indication H.
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 fitted 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 fitted to all circuits per generally accepted piping practices.
12
Digital-FloTM Steam/Water Shell & Tube Heat Exchanger
Commissioning Digital-Flo
Commissioning must be carried out in accordance with these instructions by designated, qualified and competent
personnel.
1. Check all plumbing, piping and electrical connections to ensure the installation meets specification 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.
Note: Hot Water safety solenoid is controlled by a relay output on DRV80. Relay will open the normally closed
tsolenoid valve AFTER it has gone through it full start up sequence providing no errors or faults are present. Make
sure “enable relay on alarm” is disbled in DRV80 programming.
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 25-27.
10. 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”.
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
13
Digital-FloTM Steam/Water Shell & Tube 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
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
14
Commissioning the System
Commissioning must be carried out in accordance with these instructions by designated, qualified 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 flow 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 specified 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 28.
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.
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
15
Adjusting Temperature
Important: The DRV80 is supplied to the job site preprogrammed to an outlet temperature set point specified 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.
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
16
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 confirm.
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 https://armstronginternational.com/resource-library and search
for “DRV80 Laptop”.
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
17
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 confirm 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 flow 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”.
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
18
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 first 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
confirm 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.
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
19
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.
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
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.
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
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.
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
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. Make sure “active relay on alarm” is unchecked.
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.
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
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.
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.
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
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 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
26
DRV80 Display Alerts
Temp High
Setpoint
127˚F
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”).
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
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 fitting.
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 0 - 100°C. The input signal is only active when the DRV80 is configured to “Ext. 4-20 mA”. These settings can only be altered when the DRV80 is switched to its “Offline” 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 1 - 100°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 fitting.
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.
2.
3.
4.
5.
6.
7.
Power failure.
Start up sequence.
Outlet temperature causing an alarm signal.
Outlet temperature causing an error signal.
Internal fault on PCB.
Battery failure.
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 BrainScan™. Available by contacting Armstrong technical support.
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
28
DRV80 using Building Automation System (BAS) (continued)
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
29
DRV80 connected to generic BAS
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
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 flow 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.
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
31
ºC
ºC
5.12 17 6.72 27
5.28 18 6.88 28
5.44 19 7.04 29
7
8
9
ºC
32
ºC
15.2 80
mA
16.8
mA
16 85
17.6
104
ºF
10.4
mA
122
ºF
12
mA
140
ºF
13.6
mA
158
ºF
15.2
176
ºF
20
100
mA
19.84
19.68
19.52
99
98
97
19.2
19.36
16.8
mA
194
ºF
18.4
mA
131
12.8
149
14.4
167
16
185
17.6
203
19.2
212
20
11.84 138.2 13.44 156.2 15.04 174.2 16.64 192.2 18.24 210.2 19.84
48.2 5.44 66.2 7.04 84.2 8.64 102.2 10.24 120.2
11.52 134.6 13.12 152.6 14.72 170.6 16.32 188.6 17.92 206.6 19.52
11.36 132.8 12.96 150.8 14.56 168.8 16.16 186.8 17.76 204.8 19.36
11.2
11.04 129.2 12.64 147.2 14.24 165.2 15.84 183.2 17.44 201.2 19.04
11.68 136.4 13.28 154.4 14.88 172.4 16.48 190.4 18.08 208.4 19.68
114.8
113
111.2
118.4
9.76
9.6
9.44
9.28 109.4 10.88 127.4 12.48 145.4 14.08 163.4 15.68 181.4 17.28 199.4 18.88
9.12 107.6 10.72 125.6 12.32 143.6 13.92 161.6 15.52 179.6 17.12 197.6 18.72
8.96 105.8 10.56 123.8 12.16 141.8 13.76 159.8 15.36 177.8 16.96 195.8 18.56
8.8
mA
11.84 59 13.44 69 15.04 79 16.64 89 18.24
11.68 58 13.28 68 14.88 78 16.48 88 18.08
11.52 57 13.12 67 14.72 77 16.32 87 17.92
95
96
19.04
18.88
18.72
18.56
116.6
98.6
44.6 5.12 62.6 6.72 80.6 8.32
14.4 75
94
93
92
91
18.4
mA
9.92
96.8
42.8 4.96 60.8 6.56 78.8 8.16
12.8 65
11.36 56 12.96 66 14.56 76 16.16 86 17.76
11.2 55
11.04 54 12.64 64 14.24 74 15.84 84 17.44
ºC
90
46.4 5.28 64.4 6.88 82.4 8.48 100.4 10.08
95
77
93.2
6.4
8
59
39.2 4.64 57.2 6.24 75.2 7.84
4.8
91.4
37.4 4.48 55.4 6.08 73.4 7.68
41
89.6
ºF
87.8
68
mA
35.6 4.32 53.6 5.92 71.6 7.52
5.6
9.92 47
9.76 46
9.6 45
9.44 44
8.64 39 10.24 49
ºF
ºC
13.6 70
mA
9.28 43 10.88 53 12.48 63 14.08 73 15.68 83 17.28
33.8 4.16 51.8 5.76 69.8 7.36
50
mA
ºC
12 60
mA
9.12 42 10.72 52 12.32 62 13.92 72 15.52 82 17.12
86
4
32
ºF
ºC
10.4 50
mA
8.96 41 10.56 51 12.16 61 13.76 71 15.36 81 16.96
7.2
mA
ºF
ºC
8.8 40
mA
8.48 38 10.08 48
8.32 37
8.16 36
8 35
7.84 34
7.68 33
7.52 32
7.36 31
7.2 30
mA
Chart 1.2 DRV80 mA chart (ºF)
4.96 16 6.56 26
6
6.4 25
4.64 14 6.24 24
4
4.8 15
4.48 13 6.08 23
3
5
4.32 12 5.92 22
2
5.6 20
mA
4.16 11 5.76 21
4 10
mA
1
0
ºC
Chart 1.1 DRV80 mA chart (ºC).
Operational Check
Use Charts 1.1 and 1.2 to check the temperature output from the DRV80 against the current input from the BAS.
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
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 34-1
Isolate electricity to DRV80. Remove
all 8 cover screws, make sure cover
is constantly supported.
Figure 34-2.
Caution heavy parts.
Carefully remove cover and
disconnect display cable.
Figure 34-3.
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 34-4.
Remove blanking plugs as required
and connect 3/8” Liquitight conduit
fittings (not supplied) as shown using
a suitable spanner.
Figure 34-5.
Fit 3/8” Liquitight conduit tube (not
supplied) and feed the wires through
as required. Do not overtighten the
conduit fittings.
Figure 34-6.
Reconnect display cover and
carefully refit cover. Loosely refit
screws to locate cover correctly.
Tighten all screws to secure cover.
Restore electricity to DRV80.
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
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.
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
34
Maintenance - Heat Exchanger
Time Interval: as needed based upon water quality.
Performance: Check temperatures and flow rates against commissioning data. If there is a noticeable reduction
in heat exchanger capacity, temperature or an elevated pressure drop across the exchanger, scaling is a
possibility.
Scale remediation options are: Tube Bundle removal and manual individual tube cleaning (single wall only) and/
or chemical clean in place.
1. Single wall manual individual tube cleaning – Extract the tube bundle form the heat exchanger shell by
removing the two pass cap.
The tube bundle has a floating end cap which can be removed to allow cleaning rod access from either end.
Chemical cleaning agents and descalents might expedite the cleaning process.
2. Chemical Clean in Place – Armstrong offers a suitable cleaning agent called Rite-Quik™. Rite Quik is a non
hazardous chemical cleaner which has been proven effective for removing deposits without harming the
Digital-Flo internally.
Rite-Quick can be applied to the heat exchanger in place by using an Armstrong portable Clean in Place
product Model # 0600000.
Model # 0600000 Clean in Place
Clean-In-Place
35"
(889 mm)
Air Vent
Return
Hose
Discharge
Hose
47"
(1194 mm)
Drain
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
35
Maintenance - Heat Exchanger
Tube bundle scale removal can be accomplished as follows:
1.
2.
3.
4.
Isolate the steam supply from the Digital-Flo.
Isolate the inlet water supply, outlet hot water supply and condensate drainage connection from the
Digital-Flo.
Isolate the DRV 80 from the Heat Exchanger.
Remove the 1” plug from the inlet cleaning connection provided on the Digital-Flo and replace with a close
nipple.
5. Connect a garden hose to the close nipple.
6. Confirm that the steam supply is off and open the inlet water supply.
7. Run cold water through the heat exchanger and out the garden hose to drain (10) ten minutes or until the
outside of the heat exchanger is cool to the touch.
8. Close the inlet water supply.
9. Allow the residual water in the Digital-Flo to drain.
10. Close the Hot Water outlet isolation valve as close to the Digital-Flo as available.
11. Remove the 1” plug from the inlet cleaning connection provided on the Digital-Flo and replace with a close
nipple.
12. Connect (thread) the union ball valve provided on the end of the Armstrong Clean in Place Model 0600000
(CIP) discharge hose to the nipple just installed on the cleaning connection inlet. Ensure that the ball valve is
closed.
13. Connect (thread) the union ball valve provided on the end of the CIP return hose to the nipple just installed on
the cleaning connection outlet. Ensure that the ball valve is closed.
14. Start the pump on the CIP.
15. Open the ball valve on the discharge hose at the cleaning connection inlet on the Digital-Flo.
16. SLOWLY open the ball valve on the return hose at the cleaning connection outlet on the Digital-Flo and watch
for fizzing/foaming in the CIP tank.
17. The CIP is now circulating Rite Quik cleaning agent through the Digital-Flo.
18. When the Rite Quik cleaning agent has stopped fizzing the cleaning process is complete.
Note: Maximum Rite-Quik circulation time is 3 hours
19. Shut off pump and close the ball valve on the discharge hose at the cleaning connection inlet on the DigitalFlo
20. Drain the residual Rite Quik from the Digital-Flo to the tank.
21. Close the ball valve on the return hose at the cleaning connection outlet on the Digital-Flo.
22. Disconnect the return hose at the ball valve provided at the CIP tank inlet.
23. Open the cold water inlet isolation valve so that fresh water flows through the Digital-Flo and out the return
hose (disconnected from CIP) to drain.
24. Flush for 15 minutes.
25. Close the cold water inlet isolation valve and fully disconnect the CIP from the Digital-Flo.
26. Remove the close nipples the inlet and outlet cleaning connections provided on the Digital-Flo and replace
the 1” plugs.
27. Open the cold water inlet isolation valve.
28. Open the Hot Water outlet isolation valve.
29. Re-engage the DRV80
30. Commission the Digital-Flo
Note: Test the Rite Quik cleaning solution in the tank to see if it is still active. This is best accomplished by
dropping a calcium tablet (Tums) into the solution. If the solution “fizzes” the Rite Quick may be stored for future
use. If the solution remains inactive it should be disposed of properly.
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
36
Maintenance - Digital Re-Circulating Valve
Time Interval: Minimum once per year.
Performance: Check temperatures and flow 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 five (5) years..
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
37
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!
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
38
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
0V
D8413 (us) *
D33169 (eu)
+12V
•
•
•
•
*Directly affects digital water temperature control.
Contact Armstrong for technical advice prior to fitting.
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
39
Servicing and Maintenance (continued)
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
40
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.
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
41
Servicing and Maintenance (continued)
• DO
NOT DAMAGE MOTOR PCB.
D8405 *
D8407
D8406
REPLACE
SEAL ONLY IF
NECESSARY.
D8404 *
D8410
D8411
affects digital water temperature control.
* Directly
Contact Armstrong for technical advice prior to fitting.
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
42
Spare Parts
D8972
D8417
x2
D8411
D8410
D8407
D8404
D8405
D8406
D8415
D8414 (us)
D33170 (eu)
D8412
D8406
D8409
D8413 (us)
D33169 (eu)
D8408
x3
D8418
D8406
D8408
D8415
D8416
D8406
x4
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).
D8406
D8404
D8405
D8406
D8407
D8408
D8409
D8410
D8411
D8412
D8413
D8414
D8415
D8416
D8417
D8418
D8972
D33169
D33170
43
Troubleshoot Guide
Problem
1. Unable to bring Digital-Flo to
temperature.
2. Water from Digital-Flo
is too hot.
3. System temperature
rises during periods of
no system demand.
4. System temperature fluctuates
more than +/= 5°F.
Cause
Solution
1. System fault.
a. Steam isolation valve is not open - check.
b. Steam pressure is too low - rectify.
c. Air has accumulated in the shell of the heat exchanger - rectify.
d. The tubes in the heat exchanger are scaled – service – see item 7a-1.
e. The flow rate is higher than the rated capacity of the heat exchanger - rectify.
f. High temperature shut off valve closed - check.
g. Steam trap isolation valves closed - check.
h. Steam trap is blocked - check that the condensate temperature after the steam
trap is at steam temperature. If no condensate exits the steam trap, disassemble
and check for blockage.
i. Back pressure in the condensate line may be too high. - disconnect the pipework
after the steam trap, 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.
j. If the “Low Surface Temperature” option is fitted 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.
k. Check that re-circulation line is hot. If it is cool then a check valve may not be
working correctly. A failed check valve cause the cold water to bypass the heat
exchanger – check – rectify.
2. DRV80 fault.
a. Check DRV80 display for error message.
b. Ensure the high temperature alert setting in the DRV80 is set at least 10°C
higher than the desired hot water temperature.
1. System fault.
a. Steam pressure is too high – rectify.
b. Steam is superheated - rectify.
2. DRV80 fault
a. Check DRV80 display for error message.
1. System fault.
a. Flow rate is less than 10GPM – check flow rate, check for air locks, closed
valves, pump failure etc.
b. Return temperature less than 2°F below DRV80 set point - rectify.
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. A higher temperature circuit (kitchen, laundry etc) is manifolded into the return
line – rectify.
2. DRV80 fault.
a. Refer to DRV80 display error messages.
1. System fault.
a. Maintained supply pressures are unequal. Ensure that pressures are balanced.
Check for blocked filters, closed valves, air locks etc.
b. Supply temperatures. Check for reasonable temperature differential between set
point and hot and cold inlet supply temperatures to DRV80.
c. Check the steam pressure before the high limit valve or before the pressure
reducing valve (if fitted). If the steam pressure is decreasing under normal
conditions there may be insufficient steam available to meet the higher hot water
demands.
2. DRV80 fault.
a. Spool sticking. Clean and descale spool. Renew separator seal and lubricate
assembly.
b. Refer to DRV80 display error messages.
c. Poor calibration. Refer to DRV80 “Valve Calibration” screen.
d. The demand from the hot water system is greater than the designed capacity of
the heater - rectify.
e. Steam supply line is undersized – rectify.
If the “Low Surface Temperature” option is fitted ensure that the steam control
valve is fully functional. Refer to the control valve/actuator IOM for more
information.
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
44
Troubleshoot Guide
Problem
5. DRV80 display shows any of
the following:
Cause
Solution
1. System fault.
a. Water supply problem. Check supply temperature between PHE and DRV80.
b. Perform hard reset: Turn power to DRV80 off for 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.
3. Process error.
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 finish times.
• Use Dump Valve to speed up Cool Down time.
b. Early abort of disinfection process.
6. Constant difference between
system temperature
and DRV80 display.
1. System fault.
a. Outlet thermometer inaccurate - replace.
2. DRV80 fault
a. Thermistor problem – refer to thermistor error message.
7. Reduced heater capacity.
1. Digital-Flo 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 .
8. Unable to adjust system
temperature.
1. System fault.
a. Pump flow rate to low. Reset circuit flow rate. Check for blocked filters, closed
valves, air locks, pump failure, etc .
b. Return temperature less than 2F below DRV80 set point. Ensure minimum temp
drop around circuit of 2F.
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 filters, closed valves, air locks etc.
g. Supply temperatures. Check for reasonable temperature differential between set
point and hot and cold inlet supply temperatures to DRV80.
2. DRV80 fault.
a. Refer to DRV80 display error messages.
9. No display on DRV80
and/or no control.
1. 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.
10. High pitched noise
from DRV80.
1. System fault.
a. Maintained supply pressures are unequal. Ensure that pressures are balanced.
Check for blocked filters, closed valves, air locks etc.
b. Supply temperatures. Check for reasonable temperature differential between set
point and hot and cold inlet supply temperatures to DRV80.
2. DRV80 fault.
a. Motor is worn – replace
b. Refer to DRV80 display error messages.
1. System fault.
a. Steam pressure has dropped and a vacuum has formed inside the heat
exchanger - rectify.
b. Water pressure has dropped below the steam pressure and steam is forming
inside the tubes - rectify.
2. Digital-Flo fault.
a. The shell of the heat exchanger is not properly drained – rectify – see item 1a 8
& 9.
12. Water leaking from DRV80.
1. DRV80 fault.
a. Check all seals for wear and/or damage. Clean, lubricate or replace.
b. Body casting failure – replace DRV80.
13. Water/Moisture visible
in DRV80 cover.
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.
11. Digital-Flo “bangs” and
“hammers” during operation.
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
45
Component Identification Guide
D535
Item
Description
A
D665
D8120
Part
Number
Connection
Size
Part
Number
Connection
Size
Part
Number
Connection
Size
Tube Bundle
D9189
D32971
SW
DW
D9200
D32972
SW
DW
D10208
D32973
SW
DW
B
Trap
C5318-43
1” (25 mm)
D502468
1” (25 mm)
C6126
2” (50 mm)
C
Pressure Relief Valve
D8312
N/A
D8312
N/A
D8312
N/A
D
HW Safety Shut Off Valve
D28826
1.5” (40 mm)
D28827
1.5” (40 mm)
D28829
1.5” (40 mm)
E
Ball Valve
D9341
1.5” (40 mm)
D10275
2” (50 mm)
D15147
3” (80 mm)
F
Gate Valve
D8967
1.5” (40 mm)
D7343
2” (50 mm)
D7345
3” (80 mm)
G
Thermometer
D8969
4” (102 mm)
D8969
4” (102 mm)
D8746
6” (153 mm)
H
Thermowell
D8970
4” (102 mm)
D8970
4” (102 mm)
D8747
6” (153 mm)
I
Terminator (Bell/Strainer Combo) Valve
D10769
1.5” (40 mm)
D10292
2” (50 mm)
D17889
3” (80 mm)
K
Swing Check Valve
D8964
1.5” (40 mm)
D7349
2” (50 mm)
D7351
3” (80 mm)
M
DRV80
D6774
3” (80 mm)
D6774
3” (80 mm)
D6774
3” (80 mm)
N
Air Vent
D8309
.75” (19 mm)
D8309
.75” (19 mm)
D8309
.75” (19 mm)
O
Swing Check Valve
D7347
1” (25 mm)
D7349
2” (50 mm)
D7349
2” (50 mm)
P
Terminator Valve
D10763
1” (25 mm)
D10292
2” (50 mm)
D10292
2” (50 mm)
Q
Spring Check Valve
D10779
1” (25 mm)
D10779
1” (25 mm)
D10779
1” (25 mm)
R
Thermometer
D8931
2.5” (63.5 mm)
D8969
4” (102 mm)
D8969
4” (102 mm)
S
Thermowell
D8933
2.5” (63.5 mm)
D8970
4” (102 mm)
D8970
4” (102 mm)
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
46
Component Identification Guide
D535P
Item
Description
A
D665P
D8120P
Part
Number
Connection
Size
Part
Number
Connection
Size
Part
Number
Connection
Size
Tube Bundle
D9189
D32971
SW
DW
D9200
D32972
SW
DW
D10208
D32973
SW
DW
B
Trap
C5318-43
1” (25 mm)
D502468
1.25” (32 mm)
C6126
2” (50 mm)
C
Pressure Relief Valve
D8312
N/A
D8312
N/A
D8312
N/A
D
HW Safety Shut Off Valve
D28827
2” (50 mm)
D28829
3” (80 mm)
D28829
3” (80 mm)
E
Ball Valve
D9341
1.5” (40 mm)
D10275
2” (50 mm)
D15147
3” (80 mm)
F
Gate Valve
D7343
2” (50 mm)
D15147
3” (80 mm)
D15147
3” (80 mm)
G
Thermometer
D8969
4” (102 mm)
D8746
6” (153 mm)
D8746
6” (153 mm)
H
Thermowell
D8970
4” (102 mm)
D8747
6” (153 mm)
D8747
6” (153 mm)
I
Terminator (Ball/Strainer Combo) Valve
D10292
2” (50 mm)
D17889
3” (80 mm)
D17889
3” (80 mm)
K
Swing Check Valve
D7349
2” (50 mm)
D7351
3” (80 mm)
D7351
3” (80 mm)
M
DRV80
D6774
3” (80 mm)
D6774
3” (80 mm)
D6774
3” (80 mm)
N
Air Vent
D8309
.75” (19 mm)
D8309
.75” (19 mm)
D8309
.75” (19 mm)
O
Swing Check Valve
D7347
1” (25 mm)
D7349
2” (50 mm)
D7349
2” (50 mm)
P
Terminator Valve
D10763
1” (25 mm)
D10292
2” (50 mm)
D10292
2” (50 mm)
Q
Spring Check Valve
D10779
1” (25 mm)
D10779
1” (25 mm)
D10779
1” (25 mm)
R
Thermometer
D8931
2.5” (63.5”)
D8969
4” (102 mm)
D8969
4” (102 mm)
S
Thermowell
D8933
2.5” (63.5”)
D8970
4” (102 mm)
D8970
4” (102 mm)
T
Ball Valve
D10275
2” (50 mm)
D15147
3” (80 mm)
D15147
3” (80 mm)
Armstrong has technical support personnel available from 8:00 a.m. to 5:00 p.m. EST. Call Toll Free 1-888-468-4673.
47
Notes
48
Notes
49
Notes
50
Notes
51
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 CONSEQUENTIAL 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-785-C
2/13
Armstrong Hot Water Group
221 Armstrong Blvd., Three Rivers, Michigan 49093 - USA Ph: (269) 279-3602 Fax: (269) 279-3130
armstronginternational.com
Toll Free:52
(888) HOT-HOSE
Printed in U.S.A.
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