Armstrong FLO-RITE-TEMP 8120, FLO-RITE-TEMP 415, FLO-RITE-TEMP 415DW, FLO-RITE-TEMP 535DW, FLO-RITE-TEMP 665DW Installation And Adjustment Instructions

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Bulletin No. AY-780-K
FLO-RITE-TEMP
INSTANTANEOUS WATER HEATER
INSTALLATION AND ADJUSTMENT INSTRUCTIONS
FOR SINGLE AND DOUBLE WALL UNITS
This bulletin should be used by experienced personnel as a guide to the installation of the
FLO-RITE-TEMP Instantaneous Water heater. Selection or installation of equipment should always
be accompanied by competent technical assistance. You are encouraged to contact Armstrong
Page 2
FLO-RITE-TEMP
INSTANTANEOUS WATER HEATER
INSTALLATION AND ADJUSTMENT INSTRUCTIONS
NOTICE
No water heater will work satisfactorily if improperly installed and operated. These instructions contain important information for the installation and adjustment of the FLO-RITE-TEMP Water Heaters. Read these instructions carefully before installing this unit. FAILURE TO ADHERE TO THESE INSTRUCTIONS COULD RESULT IN SERIOUS BODILY INJURY OR PROPERTY DAMAGE.
STEAM PIPING INSTALLATION OF A SINGLE UNIT
Single and Double Wall
Steam
In
Armstrong Pressure
Reducing Valve (If Req'd)
Armstrong
I.B. Trap
Armstrong Thermostatic
GP-2000
Air Vent
2-15 psig Steam
in the Shell
Vacuum Breaker
Pressure
Gauge
Gate
Valve
Safety Relief
Valve
Armstrong
I.B. Trap
NOTE: FLO-RITE TEMP is provided with (1) one Armstrong Steam Trap and Thermostatic Air Vent (shaded). All other items shown not included.
Fig. 2-1
NOTE: units may be piped in parallel for larger capacity requirements. See Fig. 15-1 for an example of parallel unit installation.
The unit includes the mixing valve mounted to the heat exchanger, channel iron and U-bolts mounted, thermostatic air vent installed on the heat exchanger, a water pressure pop off valve integral to the unit control valve and a separate Armstrong Inverted Bucket Steam Trap.
STEAM SIDE INSTALLATION
(Refer to Fig. 2-1)
1. Install the FLO-RITE-TEMP with adequate room to allow for tube bundle removal when cleaning is
required. See Table 12-1 for specific dimensions.
2. If 2-15 psig of steam is available a pressure reducing valve is NOT required. If a pressure reducing valve is
required, an Armstrong Inverted Bucket Steam Trap is recommended to drain condensate at the inlet of the pressure reducing valve.
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3. An Armstrong Y-strainer should be installed before the pressure reducing valve to reduce the chance of dirt fouling.
4. If an externally piloted pressure reducing valve is used, the control pipe should be pitched away from the PRV and installed at the pressure gauge on the shell of the heat exchanger.
5. A steam safety relief valve should be used prior to the heat exchanger if either or both of the following conditions exist. (1) If the maximum steam pressure could exceed the minimum water pressure in the tubes, or (2) The maximum steam pressure could exceed 150 psig (the maximum steam pressure rating of the shell).
IMPORTANT -Steam supply pipe size coming to the heat exchanger should NOT be smaller than the steam connection supplied on the heater, otherwise steam flow could be restricted. If a pressure reducing valve is used,
installation should be as close as possible to the Flo-Rite-Temp. Downstream piping from the Pressure Reducing Valve should be expanded immediately after the PRV to accomodate the expanded volume of steam.
6. To vent start-up air, an Armstrong Thermostatic Air Vent is included and installed on the top connection, opposite the trap drain connection of the heat exchanger. This discharge can be piped to drain or the floor if preferred.
7. Install a vacuum breaker in the piping between the heat exchanger drain connection and the steam trap. This will prevent improper draining of the heat exchanger caused by a possible vacuum forming when the steam is shut off.
8. Install a suitable steam pressure gauge in the 1/4" coupler located in the top mid section of the heat exchanger shell. This gauge will help diagnose pressure problems should they occur. This port may also be used for a PRV external control pipe if a PRV is required.
WATER PIPING INSTALLATION
(Follow same plumbing for DW units)
D
A
C
E
B
C
B
1. An 18 inch minimum thermal loop should be piped into the water inlet and outlet of the FLO-RITE-TEMP and should be located as close to the mixing valve as possible (See Fig. 3-1A). These loops will act as a thermal check valve or heat trap to prevent the conduction of heat through the water from the unit during inactive times.
F
A
Fig. 3-1
2. Isolation valves and hose connections added to both the inlet and outlet water supplies will allow for Clean-In-Place equipment to be utilized.
3. Use pipe unions on both the water inlet and outlet to allow ease of water heater mixing valve removal for maintenance and removal of the tube bundle for cleaning (See Fig. 3-1A).
4. For adjusting the unit, an isolation valve and hot water by-pass to drain should be installed close to the unit
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down stream from the thermal loops and prior to the recirculation loop (if one is used) (See Fig. 3-1B). This allows for quick and easy setting of the FLO-RITE-TEMP by one person. By isolating the unit from the hot water system, flow can be controlled to drain through the globe valve while monitoring outlet water temperature during low and high flow adjustments on the water heaters mixing valve.
Minimum line sizes to drain should be as follows: model 415 = 3/4", model 535 = 1", model 665 = 1-1/4", model 8120 = 2". Line
sizes smaller than these will not allow sufficient flow for making high flow settings on the mixing valve.
5. A water temperature gauge should be installed directly after the by-pass drain valve. This thermometer is only used for inital temperature adjustments of the Flo-Rite-Temp or troubleshooting the unit. (See Fig. 3-1B)
6. If a recirculation system is used with a FLO-RITE-TEMP, a small diverting valve must be piped into the loop return downstream of the recirculating pump (See Fig. 3-1C). This device is used to divert recirculated water back to the heater for reheating if the temperature of the water drops too low due to no hot water demand from the system plus piping radiation losses (See page 9 for operation explanation). Be sure to pipe
in unions and isolation valves to facilitate diverting valve removal required when element replacement is needed. A throttling type valve should be installed in a full return line size bypass around the diverting valve in order to balance the flow to the diverting valve. This is especially needed when recirculating pumps are large or oversized.
7. For a recirculated system, a small constant running pump should be piped in on the return side of the loop (See Fig.3-1D). This pump should be sized to move approximately 10% of the maximum rated gpm of the FLO-RITE-TEMP in the system with enough head to overcome the head encountered in the loop.
NOTE: A thermometer should be installed in
the outgoing loop to monitor system temperature
(Fig. 3-1E). A thermometer may also be
installed on the loop return to monitor temperature drop through the loop or to help troubleshoot the diverting valve (Fig. 3-1D). The thermometer referred to in point #4 and Fig. 3-1B should only be used to set the FLO-RITE-TEMP and never used to monitor system temperature.
NOTE: Expansion tanks should be used in on/ off demand applications where there is a short duration of time from high flow to no flow of water, i.e., a shut off time of 10 seconds or less. (See Fig. 3-1F)
OPTIONAL SAFETY EQUIPMENT
See Fig. 3-1E for location of each option within the system. All options would be installed downstream of the water heater in the outgoing recirculation loop, if one is present, or downstream of the hot water thermal loop if recirculation is not used but always before the first hot water take off from the system.
Option #1 A temperature relief valve set at roughly 15-30 degrees above that of the FLO-RITE-TEMP will help prevent any chance of overheated water reaching the faucets. (NOTE: Normally unit will fail closed and either no water or only cold water will flow from the unit.)
Option #2 A 3-way blending valve with a set point 10-30 degrees above that of the FLO-RITE­TEMP will help prevent the chance of overheated water reaching the faucets in the event of unit failure. Under normal operating conditions the hot water flows straight through the blending valve from Port B to Port A. But in the event of an overheated situation, the blending valve will open Port C to add sufficient cold water to maintain a constant temperature . (NOTE: The blending valve should be sized to handle the maximum flow of the system).
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Temperature
Relief Valve
Option #1
4
Loop or System
Thermometer
Hot Water from
Flo-Rite-Temp
Page 5
3-Way
Thermostatic
Valve
Loop or System
Thermometer
To Flo-Rite-Temp
Cold Water Supply
Option 3A
Temperature
Switch
Hot Water from
Flo-Rite-Temp
Option 3B
Pressure Switch
Loop or System
Thermometer
To steam
shut-off valve
Option #3Option #2
Hot Water Supply From
Flo-Rite-Temp
To Steam
Shut-Off Valve
!
Cold Water Supply to
Flo-Rite-Temp
Option #3 A temperature switch installed well downstream of the Flo-Rite-Temp outlet on a non-recirculated
system or just into the outgoing recirculated system loop on a recirculated system, with a set point 15-30
degrees above that of the FLO-RITE-TEMP will help prevent the chance of overheated water reaching the
faucets in the event of system problems. This switch can be used to turn off the steam supply to the heater in
the event of overheating. The most economical way to accomplish this is with a solenoid on the PRV. A full
ported motorized valve on the steam supply line may also be used. Option 3B. Along these same lines, a
pressure switch installed in the inlet water line would shut down the supply steam on the heat exchanger in the
event of water pressure loss, preventing thermal shock and water hammer to the unit.
Option #4 (Available only when a pressure reducing station is installed on the Flo-Rite-Temp). Using the
Model GP-2000W1P system, when piped as shown in the Option 4 drawing, will provide a safe dependable
shut down of the main steam valve when the water pressure fails or drops rapidly on the Flo-Rite-Temp.
Unlike a solenoid application, which shuts the steam down when the water pressure drops below a pre-set
point, the GP-2000W1P offers another benefit that it allows the system to keep producing hot water even
when the water pressure is below the set pressure. The GP-2000W1P Combination valve essentially lets the
steam pressure modulate below the water pressure by 2 or 3 pounds, allowing a water heater to supply hot
water even when water pressure is low.
Incoming cold water is piped into the hot water heater with a sample line piped to the W-1 Pilot of
GP-2000W1P. At the same time the cold water is supplying the water heater, its pressure it is also supplying
the W-1 Pilot. When the pressure of the incoming cold water decreases, the W-1 Pilot modulates down the
supply of steam to the pressure pilot controlling the main steam valve, acting as a non-electric self-controlled
shutdown device. Ultimately, this valve eliminates the use of any electricity and gives the customer safe
control of their hot water supply when water pressure loss or fluctuating water pressure conditions exist.
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Option #4
5
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IMPORTANT UNIT START-UP AND
SHUTDOWN PROCEDURES
Its important to remember that water pressure must ALWAYS be greater than steam pressure on the unit to avoid boiling the water in the tubes of the heat exchanger. When starting up a FLO-RITE-TEMP it is very important that the water supply is turned on to the unit before any steam is turned on. Once the unit is up and running, the inlet water valve should never be closed unless the steam is turned off first. When shutting down a unit you should always first shut off the steam and then allow water to run through the unit until it has cooled and completely condensed all remaining steam in the heat exchanger before closing off
the supply water to the unit.
ADJUSTING PROCEDURES
All models of FLO-RITE-TEMP’s have two settings which need to be made on initial start-up. One setting must be made at low flow while the other is made at high flows. IMPORTANT: Once the
low and high flow adjustments have been made, the unit generally need not be adjusted again unless your operating conditions change or a different set point is desired. A significant drop in temperature output or capacity is an indication of a bad diaphragm or that the tube bundle needs to be cleaned. Do not readjust the valve unless isolation of the unit from the system and running water to drain produces poor temperature control. If capacity is minimal, check the diaphragm or clean the bundle but do not readjust the control valve.
START-UP AND ADJUSTING
PROCEDURE FOR MODEL 415
1. Before turning on the steam to the FLO-RITE-
TEMP, begin by opening the water supply valve to the unit and checking for water leaks at the unit or any of the associated piping.
2. If the unit is connected to a system which has a
recirculation loop and pump, be sure the pump is turned off and the isolation valve on the leg of piping going from the diverting valve back to the inlet of the FLO-RITE-TEMP is closed (this is the isolation valve downstream of port “B” of the thermostatic diverting valve). (See Fig. 3-1)
3. Close the isolation valve on the hot water outlet of the unit and open full and close several times the throttling bypass valve to drain to purge all the air from the FLO-RITE-TEMP. (See Fig. 3-1B). This process also primes the units lower diaphragm area with water. Failure to do this
prior to initial adjustment can result in inaccurate settings and poor results.
4. Throttle the bypass valve to drain so that a constant 3 gpm of flow may pass to drain.
5. Slowly open steam valve or adjust the pressure reducing valve to allow 2 - 15 psig of steam pressure on the unit
(CAUTION: always make sure there is water pressure on the unit before adding steam. Failure to do this will cause severe hammering of the unit and possible damage).
6. Make sure that the steam trap draining the unit is functioning properly and allow the entire unit to come up to temperature for at least three to five minutes while passing the 3 gpm of water flow to drain before beginning the adjustment of the unit.
7. Locate the low and high flow adjustments on top of the mixing valve hidden under the hex bonnet (see Fig. 7-1). Before beginning adjustments, check to make sure the high flow adjustment is fully open. To do this start by pressing down on the high flow adjustment when water pressure is present on the unit and there is no water flow through the unit. This should only depress about 1/8". If it pushes in further, turn the adjustment stem counter clockwise to open. Check every turn until there is only 1/8" travel to the high flow stem when pushed down (Note: with water pressure on the unit the stem should pop back up after depressing it). If the high flow adjustment stem will not depress at all the valve is opened too far and you must turn the adjustment clockwise until there is 1/8" travel downward to the stem.
8. With the unit now isolated from the hot water system and all flow of water being directed to drain at 3 gpm, let the temperature stabilize.
9. Monitor the outlet temperature on the gauge located in the bypass to drain (see Fig. 3-1B). Place an adjustable wrench on the flats of the low flow adjustment (see Fig. 7-1).
Turning clockwise raises the discharge temperature and counter-clockwise lowers the discharge temperature. Make the appropriate adjustment to achieve the desired set point. For
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example if a set point of 140 °F is desired and the temperature reading is 155 °F, you must turn the low flow adjustment counter-clockwise to lower the set point temperature from 155 °F down to 140 °F.
(IMPORTANT - When making the low flow adjustment the high flow adjustment shaft SHOULD rotate with the low flow adjustment. If it does not do so, you will have to turn it by hand while making the low flow adjustment).
Allow the unit to stabilize to be sure that the unit will remain at the desired set point. The low flow is now adjusted and should not be readjusted.
10. To make the high flow adjustment, SLOWLY increase the flow of water through the unit to drain while monitoring the outlet thermometer. When the outlet temperature has dropped by approximately 10 °F below set point for a Model 415E, make your high flow adjustment while maintaining that flow.
11. Place a small screw driver or center punch through the hole in the high flow adjustment stem (see Fig. 7-1) and turn it in a clockwise direction. This will start to close the valve restricting the cooling water and cause the outlet water temperature of the unit to rise. Continue until the outlet temperature is back up to your required set point.
(IMPORTANT - When making the high flow adjustment the low flow adjustment SHOULD NOT rotate with the high flow adjustment. If it does, you will have to hold it stationary while making your high flow adjustment).
12. The unit is now adjusted.
(IMPORTANT - If for any reason you must readjust the unit, you will first have to return the high flow adjustment back to its full up position as stated in point # 7).
START-UP AND ADJUSTING PROCEDURE
FOR MODEL 535EP, 665SEP and 8120
High Flow Adjustment (HFT)
"
Low Flow Adjustment (LFT)
"
Top Of Mixing Valve
Fig. 7-1
Follow all the steps 1-6 as stated in the adjustment procedures of the model 415.
7. Locate the low flow temperature adjustment
(LFT) and the high flow temperature adjustment (HFT) on top of the mixing valve hidden under the hex bonnet (See Fig. 7-1). Before beginning adjustments, check to make sure the LFT is fully closed. To do this, turn the LFT clockwise until it stops. Also make sure the HFT is fully open. To do this start by pressing down on the HFT when water pressure is present on the unit and there is no water flow through the unit. The HFT should only depress about 1/8". If it pushes in further, turn the HFT stem counter clockwise to open. Check every turn until there is only 1/ 8" travel to the HFT when pushed down (Note: with water pressure on the unit the stem should pop back up after depressing it). If the HFT stem will not depress at all the valve is opened too far and you must turn the adjustment clockwise until there is 1/8" travel downward to the stem.
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8. With the unit now isolated from the hot water
system and all flow of water being directed to drain, slowly increase the water demand to approximately 3/4 of the maximum capacity according to the capacity chart on page 13. When starting a cold system, you should take at least 2 to 3 minutes to slowly increase to this demand. This will allow time for the steam piping feeding the unit to come up to temperature, pressure and purge itself of excess condensate.
the unit has been cleaned. Never attempt to re-adjust the unit with a dirty tube bundle ­always clean tube bundle first. The unit is now adjusted.
(IMPORTANT: If, for any reason, you must readjust the unit, you will first have to return the LFT adjustment to the fully closed position as stated in step 8).
9. Place a small screwdriver or center punch
through the hole in the HFT adjustment and slowly turn the HFT to change the temperature to the desired set point. Close (clockwise) the HFT to raise the outlet water temperature. Allow adequate time for the water temperature to stabilize. This could take several minutes if the piping is cold and the measurement point is far from the unit.
(IMPORTANT: When making the HFT adjustment, the LFT adjustment SHOULD NOT rotate with the HFT adjustment. If it does, you will have to hold it stationary while making your HFT adjustment).
10. Lower the water flow rate to 3 gpm. The
LFT adjustment is currently fully closed (see step 8). Slowly open (counterclockwise) the LFT to lower the outlet water temperature to the desired set point. Allow adequate time for the temperature to stabilize.This will take longer since the flow rate is so small.
CAUTION
When putting a heavy load on the heat exchanger, watch the steam pressure gauge. This pressure should not be permitted to fall below 2 psig. If it does and severe water hammer develops, reduce the load by closing some of the faucets or shut the system down. When steam pressure drops under heavy load and hammering occurs, not enough steam is getting to the unit. This can be a result of an undersized reducing valve, lack of boiler capacity or restrictive steam lines. Hammering can also be caused by a loss of water pressure where the water pressure in the unit falls below the pressure of steam. This condition is usually caused by improper shutdown of the unit or someone closing the inlet water valve with the steam pressure still on the unit.
(IMPORTANT: When making the LFT adjustment, the HFT adjustment shaft SHOULD rotate with the LFT adjustment. If it does not do so, you will have to turn it by hand while making the LFT adjustment).
11. Recheck the outlet water temperature at 3/4
of the maximum demand it will see. Adjust if necessary. Opening the HFT (counterclockwise) will lower the temperature and closing the HFT (clockwise) will raise the temperature. Note: You may want to fine tune the HFT adjustments during normal operation of the unit at heavy demand. If outlet temperature is slightly low, turn HFT clockwise to raise it. This should only be done during the initial service of the unit or when
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FLO-RITE-TEMP
Recirculation System Piping and Operation
Because of its relatively small size and compact­ness, the FLO-RITE-TEMP can easily be installed close to the point of water use eliminating the need for a recirculation system.
In applications where water heaters are located in basements or utility rooms and feed an entire building or wing a recirculation system or loop must be utilized to assure instantaneous hot water to all usage points.
The recirculation system is made up of several different components designed to work together to maintain the temperature of the water in the loop at times of low or no flow.
Recirculation pump - This is a constant GPM pump that runs continuously regardless of the hot water demand from the loop. Its function is to continually recirculate the water in the loop in order to maintain the temperature during low or no flow conditions. As a rule of thumb, the capacity of the pump should be approximately 10 to 15 percent of the maximum capacity of the FLO-RITE-TEMP and be able to overcome any head found in the loop. The recirculation pump however, may be larger than 15 percent. But when a larger pump is used, a full line size bypass with a globe valve must be piped to divert most of the flow around the thermostatic capsule.
Three-way Thermostatic Capsule - This device has a set point roughly 20 degrees below the set point of the FLO-RITE-TEMP and will maintain the temperature in the loop between the set point of the capsule and the set point of the FLO-RITE­TEMP. The capsule senses the temperature of the recirculated water and compares it with its pre-set temperature. If the temperature in the loop drops below the capsule's set point because of radiation loss from the piping and no hot water demand from the loop, then the capsule begins to divert some of the loop's flow to the inlet of the FLO-RITE-TEMP (ports A to B) for reheating. This diversion will bring the temperature of the loop back up to its required temperature. Once the temperature in the loop is over the capsule’s set point all flow from the recirculation pump now goes straight through the capsule (ports A to C) and the return water is fed back to the hot water supply line. To regulate flow to the capsule, a balancing/bypass line with globe valve is required.
This diverting recirculating system eliminates the need for aquastats and any electrical wiring. It is a self contained, self regulating system that controls the temperature of the water in the loop during low or no hot water demand situations. When there is a demand for hot water the temperature of the water introduced into the system is instantly controlled by the FLO-RITE-TEMP feed forward mode of operation.
Recirculation
Pump
Capsule Balance
Line
Globe Valve
Loop or System
Thermometer
Unit Setting Thermometer
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A
B
C
Bypass to drain
3-Way Thermostatic Capsule
Fig. 9-1
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FLO-RITE-TEMP-Accumulation System
For peak load conditions or to avoid large intermittent steam demands
The FLO-RITE-TEMP water heater accumula­tion system is designed to provide a specified volume of accumulated hot water for short duration peak loads or when steam is in short supply and a recovery time can be tolerated. During periods of low or no demand, the water in the accumulator tank is heated to the set point temperature by the FLO-RITE-TEMP water heater.
An accumulator or large storage tank is installed in series with the FLO-RITE-TEMP water heater. Cold water is piped to the inlet of the water heater and into the bottom of the accumulator tank. Hot water flows from the FLO-RITE-TEMP directly to the accumulator tank through a pump that is con­trolled by an aquastat. When the pump is off the flow goes to the accumulator via a bypass around the pump. This would occur when there is hot water demand and the temperature in the tank is at set point.
When the system is started the water in the accumulator tank is cold which causes the aquastat to turn the pump on. Water flows out of the bottom of the tank to the inlet of the FLO-RITE-TEMP. The water continues this cycle until the aquastat in the tank senses the appropriate temperature. At that time the pump shuts off and the water is ready for use. The globe valve on the bottom of the accumulator tank should be adjusted at full system demand so that a pressure differential of approximately 8 psi is read across the FLO-RITE-TEMP.
In operation, hot water is drawn off the top of the tank at the same time as cold water enters from the bottom and hot water from the FLO-RITE-TEMP enters the tank from the side. When the peak load stops and the aquastat senses the cooler water in the tank, the pump starts and the heating process begins another cycle.
A bypass line from the heater to the hot water demand is shown and is normally kept closed. When the accumulator tank requires maintenance this bypass allows the tank to be isolated, with hot water beingsupplied by the FLO-RITE-TEMP only.
Advantages of the accumulation system are:
! Accumulation tank temperatures are restored over
a period of time avoiding large intermittent steam demands.
! Providing the FLO-RITE-TEMP's safety features
to the entire system.
! Providing accurate hot water temperature control.
! Providing a back up alternative during tank
maintenance.
! To allow accumulator tanks to be relatively small
in size because hot water demand is supplemented by the FLO-RITE-TEMP.
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Fig. 10-1
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Flo-Rite-Temp Tempered Water Systems
For Safety Shower/Eye Wash Stations
The problem which faces many companies today is how to safely warm water to be used effectively in a drench shower or safety shower situation.
Storage tank units can run out of warm water causing people to go into possible shock due to cold water exposure or to end the shower before proper flushing has taken place. Also, because the water in the tank is only heated to a temperature range of 65 to 95 degrees F. there is the potential and risk of legionella bacteria forming inside of the tank. Lastly, tank systems are feedback systems which can cause severe overheating of the water when thermostatic elements fail causing personal injury.
The solution is to use the Armstrong Flo-Rite­Temp tankless instantaneous feedforward water heater in series with a self-contained fail safe thermo­static mixing valve.
How The System Works
The system, when piped as shown in the drawing, will provide a safe, continuous and depend­able source of accurately controlled warm water.
Incoming cold water is heated between 120 to 130 degrees F by the Flo-Rite-Temp. (The unit is set
to provide a constant supply of hot water at an adjusted set point within this temperature range,
O
usually the lowest set point of 120
degrees is used). The 120°F water can be piped to the Rada Z358 thermostatic mixing valve which will blend cold water with the 120°F water to make the tepid water for the safety shower/eye wash station. The Rada Z358 valve is equipped to allow cold water to the showerhead in the event of hot water failure.
The Rada Z358 Mixing Valve (see Bulletin ALIB-Z358-20) properly proportions the hot and cold incoming water to obtain a preset delivery tempera­ture to the drench shower head. Demand induced changes are sensed and automatically compensated for by the valve so that shower output temperature remains constant. A recirculation system may also be incorporated in this system and is especially recommended in applications where shower lines are exposed to the cold air or shower heads are a dis­tance from the heater.
Feedforward control in the water heater elimi­nates the danger of thermostatic element failure and overheating typical in storage tank feedback systems. Because there is no storage tank, there is no danger of legionella forming in the stored warm water. All water is heated instantaneously on the spot, there is no shortage of heated water or shower time limits.
Option 1: Water recirculation when heater is servicing a long run to the shower head, more than one shower
head, or piping is exposed to cold ambient temperatures
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Fig. 11-1
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Single Wall and Double Wall Profile
L
g
g
g
g
g
g
g
g
Model 415 and 535 Profile Shown (665 and 8120 valve shows that connections for water inlet and outlet are on opposite sides of the valve body).
Fig. 12-1
Table 12-1. Dimensions & Weights
Dimensions Connections
415
535
665
8120
415DW
535DW
665DW
8120DW
ABC D EFGHJ K
in mm54
in mm67- 1/2
in mm82
in mm85
in mm76- 1/8
in mm77- 3/8
in mm90- 5/8
in mm79- 7/8
1372
1715
2083
2159
1934
1965
2302
2029
4-1/2
114
5-1/4
133
5-3/4
146
5-3/4
146
4-1/2
114
5-1/4
133
5-3/4
146
5-3/4
146
7-1/2
190
8-5/8
219
10-3/8
264
11-3/4
299
7-1/2
190
8-5/8
219
10-3/8
264
11-3/4
298
7
178
9
229
10-3/8
264
12
305
7
178
9
229
10-3/8
264
12
305
4-1/2
3-1/2 893-1/2 897
114
5-9/16
4
141
102
6-5/8
4-3/4
168
121
8-5/8
6-1/8
219
156
4-1/2
3-3/8 863-3/4 9510-1/2
114
5-9/16
4
141
102
6-5/8
4-3/4
168
121
8-5/8
6
219
152
4-1/2
114
5-1/2
140
8-7/8
225
4-1/4
108
5
127
8-3/4
222
178
7-7/8
200
9-1/4
235
9-1/2
241
267
11-1/2
292
11-3/4
298
12-5/8
321
127
152
7-1/2
203
127
152
7-1/2
203
5
6
190
8
5
6
191
8
6-1/4
159
7-1/2
191
8-3/4
222
9-1/2
241
6-7/8
175
8-1/8
206
9-3/4
248
11-5/8
295
M1 2 3
50
7-1/2
1270
62
1575
74
1880
74
1880
75
1905
75
1905
87
2210
75
1905
12-3/8
12-3/8
1" NPT 253/4" N PT 202" NPT 50lb
190
9
1-1/2" NPT 401" NPT 252-1/2" NPT 65lb
229
11
2" NPT 501-1/4" NPT 323" NPT 80lb
280
3" NPT 802" NPT 504" 150# AN SI
314
7-1/2
1" NPT 253/4" N PT 202" NPT 50lb
190
9
1-1/2" NPT 401" NPT 252-1/2" NPT 65lb
229
11
2" NPT 501-1/4" NPT 323" NPT 80lb
280
3" NPT 802" NPT 504" 150# AN SI
314
100
100
k
k
k
lb
k
k
k
k
lb
k
Wt.Model
133
60 235 107 358 162 585 265 199
90 270 122 444 201 665 302
Table 12-2 Materials
Body Valve Valve Seats Diaphragm
(415) 303 Stainless Steel
Single WallDouble Wall
Bronze
with Teflon Inserts
(535/665/8120) Brass (665/8120) Brass
(415DW) 303 SS with
(415DW/535DW)
Teflon Inse rts
535DW/665DW/8120DW
(665DW/8120DW)
Brass
Note: ** There is an open vent to atmosphere between the tube sheets to detect tube failure.
Table 12-3. Specifications
Application Steam Supply Pr essure Water Supply Pressure Maximum Water Pr essure Dr op
Steam to Water 2 - 15 psig (0.14 - 1.0 bar) 20 - 125 psig ( 1.4 - 8.5 bar) 10 psig (0.7 bar )
October 31, 2002 @ 3:15 pm
(415/535) 303
Stainless Steel
303 SS
Brass
Viton® GF
Reinforced with
®
Nomex
Fiber
12
Heat Exchanger
Shell
Carbon Steel
ASME "U"
Stamped
Heat Exchanger
Tubes
5/8" 16 BWG
Admirality Brass
5/8" Copper Inner
Tube 3/4" I.D.
Grooved Copper
Outer Tube
Tube
Sheets**
Brass
Steam Side
Steel/Water
Side Brass
Tube Bundle
End Cap
Brass
N/A
Page 13
Table 13-1
4
5
5
2
5
2
5
5
3
3
4
2
5
5
3
3
4
FLO-RITE-TEMP
CAPACITIES AND STEAM LOADS
Standard
Inlet
Temp.
°F
40
5060140
*Units may be piped in parallel when desired capacities exceed that of a single unit. Notes: Minimum water temperature increase is 60°F (33°C). Consult factory if less than 60°F (33°C) increase in required or a set temperature of below 120°F (49°C) is required. See Armstrongs All Products Catalog 326 for proper pressure reducing valve selection.
Hot Water Capacities*
Set
Temp.
120
130
140
160
180
120
130
160
180
130
140
160
180
Steam Pressure
psig psig psig psig psig psig psig psig bar bar bar bar bar bar bar bar
°F
2 5 10 15 2 5 10 15 0.1
lb/hr lb/hr lb/hr lb/hr lb/hr lb/hr lb/hr lb/hr m
17 18 20 20 714767 839 901 3.8 4.1 4.5 4.5 323 347 379 407 415 37 40 43 45 1543 1657 1814 1946 8.4 9.1 9.8 10.2 697 749 820 880 535 69 74 80 80 2855 3067 3356 3601 15.7 16.8 18.2 18.2 1290 1386 1517 1628 665
142 145 14
15 16 17 18 681 734 807 868 3.4 3.6 3.8 4.1 308 332 365 392 415 32 34 37 39 1472 1587 1743 1876 7.3 7.7 8.4 8. 8 665 717 788 848 535 58 63 68 73 2723 2936 3226 3472 13.2 14.3 15.4 16.6 1230 1327 1458 1569 665
112 122 136 145 5040 5490 6120 6705 25.4 27.7 30.9 32.9 2286 2490 2776 3041 8120
12 13 15 16 646 700 773 83 27 29 32 34 1397 1513 1671 1804 6.1 6.6 7.3 7. 7 631 684 755 815 535 50 54 59 63 2585 2799 3091 3338 11.3 12.2 13.3 14.3 1168 1265 1397 1509 665 88 97 109 120 4400 4850 5450 6000 20.0 22.0 24.7 27.2 1996 2200 2472 2722 8120
9 10111257
20 22 24 26 1235 1355 1517 1652 4.5 5.0 5.5 5. 9 558 612 686 747 535 37 40 45 48 2286 2508 2806 3057 8.4 9.1 10.2 10.9 1033 1134 1268 1382 665 69 83 89 95 4140 4980 5340 5700 15.6 18.8 20.0 21.6 1878 2259 2422 2585 8120
7789486545623688 1.61.61.82.0220246282311415 14 16 18 20 1050 1178 1347 1487 3.2 3.6 4.1 4. 5 475 532 609 672 535 27 30 34 37 1942 2179 2492 2751 6.1 6.8 7.7 8. 4 878 985 1126 1243 665 43 47 52 59 3010 3290 3640 4130 9.7 10.7 11. 8 13.4 1365 1492 1651 1873 8120 19 20 20 20 69 41 44 45 45 1495 1609 1764 1896 9.3 10.0 10. 2 10.2 676 727 797 857 535 76 80 80 80 2767 2977 3264 3508 17.3 18.2 18.2 18.2 1251 1346 1475 1586 665
145 145 14
16 17 19 20 660 712 785 846 3.6 3.8 4.3 4.5 298 322 355 382 415 34 37 40 43 1425 1539 1695 1827 7.7 8.4 9.1 9. 8 644 696 766 826 535 64 68 75 80 2637 2848 3137 3381 14.5 15.4 17.0 18.2 1192 1287 1418 1528 665
127 138 14
13 14 16 17 626 679 752 81 29 31 34 37 1352 1467 1624 1756 6.6 7.0 7.7 8. 4 611 663 734 794 535 54 58 64 68 2502 2715 3005 3250 12.2 13.2 14.5 15.4 1131 1227 1358 1474 665 99 108 121 134 4455 4860 5445 6030 22.5 24.5 27.5 30.4 2021 2204 2470 2735 8120 10 11 12 13 55 21 23 25 28 1194 1313 1473 1607 4.7 5.2 5.7 6. 4 540 593 665 726 535 39 42 47 51 2210 2429 2725 2974 8.9 9.5 10.7 11.6 999 1098 1232 1344 665 76 90 95 102 4180 4950 5225 5610 17.2 20.4 21.6 23.1 1896 2245 2370 2545 8120
7 8 9 10 469 527 604 669 1.6 1.8 2.0 2.3 212 238 273 302 415 15 17 19 21 1013 1139 1306 1445 3.4 3.8 4.3 4. 7 458 515 590 653 535 28 31 35 39 1874 2108 2417 2673 6.4 7.0 7.9 8. 8 847 953 1092 1208 665 49 55 63 72 3185 3575 4095 4680 11.1 12.5 14.3 16.3 1445 1622 1857 2123 8120 18 19 20 20 638 690 762 82 38 41 45 45 1378 1491 1646 1777 8.7 9.3 10.2 10.2 623 674 744 803 535 70 76 80 80 2550 2760 3046 3288 15.9 17.3 18.2 18.2 1152 1247 1377 1486 665
145 145 14
15 16 17 19 60 32 34 38 40 1307 1421 1576 1708 7.3 7.7 3.6 9. 1 591 642 712 772 535 58 63 69 75 2418 2629 2917 3160 13.2 14.3 15.7 17.0 1093 1188 1318 1428 665
111 123 137 145 4440 4920 5480 6080 25.2 27.9 31.1 32.2 2014 2232 2486 2758 8120
10 11 13 14 53 22 24 27 30 1152 1270 1428 1561 5.0 5.5 6.1 6. 8 521 574 645 703 535 41 45 50 55 2132 2349 2642 2889 9.3 10.2 11. 3 12.5 964 1062 1194 1306 665 85 99 10
7 8 9 10 451 509 585 649 1.6 1.8 2.0 2.3 204 230 264 293 415 16 18 20 22 976 1100 1265 1402 3.6 4.1 4.5 5.0 441 497 572 634 535 29 33 37 41 1805 2036 2341 2594 6.6 7.5 8.4 9. 3 816 920 1058 1172 665 59 67 80 90 3540 4020 4800 5400 13.4 15.2 18.1 20.4 1606 1823 2177 2449 8120
St eam Capacities
Steam Pressure
145 5680 6160 6760 7160 32.2 32.9 32. 9 32.9 2576 2794 3066 3248 8120
627 702 76
745 816 877 4.3 4.5 4.5 4.5 313 337 369 396 415
145 5740 6090 6580 7035 32.2 32.2 32. 2 32.2 2603 2762 2985 3191 8120
145 5080 5520 6120 6760 28.8 31.3 32. 2 32.2 2304 2504 2776 3066 8120
608 682 74
145 5110 5565 6090 6510 32.2 32.2 32. 2 32.2 2318 2524 2762 2953 8120
658 729 790 3.4 3.6 3.8 4.3 273 297 330 357 415
588 661 72
115 4250 4950 5200 5750 19.3 22.5 23. 6 26.1 1928 2245 2359 2608 8120
Inlet
Temp.
°C
4
10
16
Set
Temp.
°C
49
54
60
71
82
49
54
60
71
82
54
60
71
82
Hot Water Capacities* Steam Capacities
Steam Pressure Steam Pressure
0. 35 0.7 1 0. 14 0.35 0. 7 1
3
/h m3/h m3/h m3/h kg/hr kg/hr kg/hr kg/hr
2.7 3.0 3.4 3.6 292 316 349 377 415
2.0 2.3 2.5 2.7 259 283 317 346 415
2.9 3.2 3.6 3.8 283 307 340 367 415
2.3 2.5 2.7 3.0 250 275 308 336 415
4.1 4.3 4.5 4.5 288 312 344 372 415
2.3 2.5 2.9 3.2 241 266 299 327 415
Standard
Model
October 31, 2002 @ 3:15 pm
13
Page 14
Table 14-1
Problem Causes S olutions
The steam is not turned on to the unit. Open steam valve to the unit.
Only cold water comes out of the unit.
O nl y warm water comes out of the unit.
Extreme hot water comes out of the unit.
No water comes out of the unit.
The unit hammers an d bang s during operation.
The water tubes in the heat exchanger are plugged. The differential pressure sensing diaphragm is ruptured. The mixing valve is not properly adjusted. Adjust the unit according to the instructions. The steam pressure is too low. Increase s team pressure (2 - 15 psig). Air has accumulated in the shell of the heat exchanger. The flow is above the rated capacity of the unit. The tubes in the heat exchanger are scaled. Remove the tube bundle and clean. The mixing valve is not properly adjusted. Adjust the unit according to the instructions. The steam pressure is too high. Decrease steam pressure (2 - 15 psig). Recirculated water is continually diverting through the Flo-Rite-Temp. The steam is superheated. Pipe to saturated steam. The mixing valve is not properly adjusted. Adjust the unit according to the instructions. The inlet valve on the water supply is closed. There is no demand for hot water. Wait till demand is present then re-check.
The shell of the heat exchanger is not properly drained.
The steam pressure has dropped or a vacuum has formed. The water pressure had dropped below that of the steam pressure and steam is forming inside of the water tubes.
TROUBLESHOOTING GUIDE
See Clean-In-Place operating instructions or remove tube bundle and clean.
Replace the diaphragm.
Install a thermostatic air vent on the s hell.
Make sure unit is sized properly.
Check diverting valve for a stuck or failed thermal capsule.
Open valve.
Make sure steam trap is working and properly installed. Make sure shell is sloped to drain. Do not elevate condensate if pressure is low. Increase pressure and install vacuum breaker at shell drain (Figure 1-1).
In s t all a pres s u re s witc h on wat e r in le t to s hut off steam on a drop in water pressure.
Control Valve - All maintenance on the valve should be done by a factory trained product specialist with the exception of replacing the pressure sensing diaphragm. To replace the diaphragm remove all nuts and bolts from the bottom cover. After removing the bottom cover, remove the split nut from the bottom of the valve shaft. You will need to hold the platter to prevent the assembly from spinning, or hold the stem with large a slotted screw driver in the slot at the bottom of the stem. After removing the nuts, slide the platter off, then the old diaphragm, being careful not to lose the brass washer above the diaphragm. To reassemble follow the reverse order. Make sure when tightening the cover bolts that you use a criss-cross pattern.
October 31, 2002 @ 3:15 pm
DISASSEMBLY
14
Page 15
Single Wall Heat Exchanger - To remove the tube bundle for cleaning. Simply unbolt the mixing valve from the shell and move it out of the way. The tube bundle can be pulled out from the valve end (see Table 12-1 for clearance dimensions). Once the tube bundle is out of the shell, unbolt the end cap on the floating head end and remove to provide straight through cleaning. Reassemble in the reverse order (On the Model 665 dual stem unit when reassembling the tube bundle, make sure that the "TOP" indicator stamped on the cover and both ends of the tube bundle line up and bundle is reinstalled in the shell with both "TOP" indicators facing up). New gaskets will be required for this procedure. (Order heat exchanger gasket kit for model number)
Armstrong
Pressure Reducing Valve
System Isolation
Valve
Steam In
I.B.
(If Req'd.)
GP-2000
Steam Pressure
Gauge
Safety Relief
Valve
Bypass to
Drain for
Setting
Setting
Thermometer
Heated
Water
Supply Water
NOTE: NOTE:
NOTE: Depending on capacity requirements a parallel water heater installation may also require (2) two PRVs in
NOTE: NOTE: parallel. proper reducing valve application.proper reducing valve application.
proper reducing valve application.
proper reducing valve application.proper reducing valve application.
Single wall installation shown - Double wall would be similar. See your Armstrong Representative forSingle wall installation shown - Double wall would be similar. See your Armstrong Representative for
Single wall installation shown - Double wall would be similar. See your Armstrong Representative for
Single wall installation shown - Double wall would be similar. See your Armstrong Representative forSingle wall installation shown - Double wall would be similar. See your Armstrong Representative for
System
Isolation
Valve
Bypass
to Drain
for Setting
Setting
Thermometer
Thermal
Loops
Thermal
Loops
Vacuum Breaker
2-15 Psig Steam
in The Shell
Armstrong
Trap
I.B.
Thermostatic
Air Vent
2-15 Psig Steam
in The Shell
I.B.
Armstrong
Trap
Steam
Pressure
Gauge
I.B.
Armstrong
Trap
October 31, 2002 @ 3:15 pm
Fig. 15-1
15
Page 16
Clean-In-Place Operating Instructions
)
D
Temp’s — hot water capacity, temperature, or an increased
When there is a noticeable drop in the Flo-Rite-
water pressure drop across the unit — tube bundle scale removal should be considered using the commercially available product called RITE-Qwik*.
Tube bundle scale removal can be accomplished as
follows:
Step 1 - Shut off steam supply valve #1 to the Flo-Rite­Temp. Step 2 - While the water pressure is still ON and the steam is OFF, run the Flo-Rite-Temp for (10) ten minutes or until the outside of the unit is cool to the touch. Step 3 - Shut the water inlet valve #4 OFF and water outlet valve #5 OFF; open cleaning connection outlet #7. Connect air hose with regulator to valve #9. Turn air on slowly to approximately 5 psi. Increase to maximum of 25 psi. Leave air pressure on until water stops coming out of connection #7. Turn air (valve #9) off. Open cleaning connection inlet #8 and remove the pop-off valve or inlet pipe plug #6 from the lower diaphragm cover of the control valve . Let the remaining water drain by gravity from the Flo-Rite-Temp. Step 4 - After all the water has been drained, reinstall the pop-off valve or pipe plug #6 into the lower diaphragm cover of the control valve. Step 5 - With hose valve closed connect return hose A of the Clean-in-Place to the outlet cleaning connection #7 of the Flo-Rite-Temp. Step 6 - With hose valve closed connect discharge hose B of the Clean-in-Place to the inlet cleaning connection #8 of the Flo-Rite-Temp. Step 7 - Start pump. Open ball valve of discharge hose B of the Clean-in-Place. Step 8 - Slowly open the ball valve on return hose A and watch for foaming in the tank. Step 9 - Clean-in-Place is now circulating cleaning solution through the Flo-Rite-Temp. Periodically check the solution to see if it has changed color or quit fizzing. If the cleaning
solution has stopped fizzing and has not changed color, the Flo-Rite-Temp is clean. You may save the remaining unspent solution for your next job. If the solution quits fizzing and the color has changed, add new cleaning solution. Continue circulating in the same manner as above. Do not exceed a
maximum circulation time of (3) three hours. Step 10 - Shut-off pump. Close discharge hose valve B on
Clean-in-Place. Open air (valve #9). Turn air on slowly to approximately 5 psi. Increase as Clean-in-Place fluid returns to tank. (Maximum air pressure 25 psi.) Step 11 - Leave air blow for approximately 3-5 minutes. This should return most of the fluid to the tank. Close both hose valves. Step 12 - Disconnect return hose A from the Flo-Rite-Temp outlet cleaning connection #7 and discharge hose B from the inlet cleaning connection #8. Also remove the pop-off valve or pipe plug #6 from the lower diaphragm cover of the control valve. Let the cleaning solution drain by gravity from the Flo-Rite-Temp. Step 13 - Close valve #2 going into the system and open valve #3 going to the drain. Step 14 - Open the water outlet valve #5 then open SLOWLY inlet water valve #4. Let the water run for (1) one minute before installing the pop-off valve or pipe plug #6 into the lower diaphragm cover of the control valve. Step 15 - After the pop-off valve or pipe plug #6 is installed, run water into the drain for (5) five minutes to flush out all of the cleaning solution. Throttle the outlet valve #3 open and closed to purge the air from under the diaphragm. Step 16 - After flushing the unit, close valve #3 and open the steam supply valve #1 SLOWLY and let the Flo-Rite-Temp heat up. Step 17 - Set the Flo-Rite-Temp as needed. (This step may not be necessary). Step 18 - Open valve #2 to the system and monitor the system until the temperature is back to normal. Step 19 - After use, flush the pump with water to remove the chemical to prevent seal deterioration.
Flo-Rite-Temp Clean-In-Place
35"
(889 mm)
Air Vent
Return
Hose
Air
ischarge
Hose
Drain
* RITE-QWIK is a non hazardous chemical cleaner which has
been proven effective for removing deposits without harming the FLO-RITE-TEMP internally.
Armstrong-Yoshitake, Inc.
221 Armstrong Blvd., P.O. Box 408, Three Rivers, Michigan 49093 - USA Ph: (616) 279-3600 Fax: (616) 273-8656
Bulletin No. AY-780-K 8/01 Printed in U.S.A.
Steam Traps \ Humidifiers \ Steam Coils \ Valves \ Air Vents \ Pumping Traps \ Water Heaters
www.armstrong-intl.com
47"
(1194 mm
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