Europe - Middle East - Africa - Installation and Maintenance
Contents
1. Armstrong Operating Manual Hot Water Package Digital Flo Steam to Water This bulletin should be used by experienced personnel as a guide to the start up and maintenance of the supplied package Selection or installation of equipment should always be accompanied by competent technical assistance We encourage you to contact Armstrong or your local Representative if further information is required Read carefully the Start up and maintenance Instructions of the components before any starting or shut off of the supplied package Digital Flo Steam to Water Armstrong Start up should be done by experienced personnel Installation of equipment should always be accompanied by competent technical assistance Electrical connection should be done by authorized and qualified personnel only Installation of equipment should always be accompanied by competent technical assistance Read carefully the Start up and maintenance Instructions of the components before any starting or shut off of the supplied package Equipment under pressure Operating temperature above 100 C Let system cool down before any handling THE STEAM SHOULD NOT BE STARTED IF NO FLUID IS RUNNING ON THE COLD SIDE OF THE HEAT EXCHANGER WATER SIDE On pre piped packaged units inspect and tighten all threaded fittings such as unions etc that may have loosened during shipment Digital Flo Steam to Water Armstrong Safet2. Warranty These OMs are based on the technological and product specific parameters of the supplied package system The manufacturer does however reserve the right to add information to these OMs The manufacturer offers guarantees and warranties only according to its General Terms and Conditions of Sale and Delivery Warranty claims as well as liability claims in case of personal and or property damage will be rejected if caused by one or more of the following circumstances The package system was used for purposes other than those for which it was intended not operated in accordance with the instructions given in this OM operated after safety devices had been disabled was operated with unacceptable operating materials was operated after constructional and or functional changes had been made without consulting the manufacturer in advance was equipped with spare parts neither delivered nor approved of by the manufacturer was improperly installed commissioned operated repaired and or serviced was not regularly serviced was damaged by Acts of God disasters or through foreign objects i See back cover for more information on warranty period Safety Armstrong i a Intended use NOTE Always use spare parts and equipment recommended by ARMSTRONG INTERNATIONAL SA Contact your Representative or Armstrong International SA for more details if required The Special Heat Exchanger Package
3. Dispose of waste remainders and packing separately as specified by valid local regulations NOTE ARMSTRONG INTERNATIONAL SA will not accept returned packaging materials free of charge 1 6 Storage Store the package system in working position clean dry dust free and protected against direct sunlight Properly cover the package system If you plan to store the system for a long period of time agree the precisely defined storage conditions in writing Do not remove or damage the package system s packaging and conservation materials during storage Ensure that transport locks inside packing are not removed Transport locks may only be removed by authorized personnel during assembly Avoid high temperature differences and condensation Minimum storage temperature 0 C Maximum storage temperature 40 C Maximum air humidity 50 CAUTION Never stack loads onto the packaging This may damage the packaging and the contents Packaging Storage and Transport Armstrong Transport CAUTION The package system is equipped with sensitive electronic components Ensure that the installation is transported without being knocked or pushed Ensure that all piping is unpressurized before transporting the package system Please pay attention to the shipping list instructions Ensure that the package system cannot slide when being transported e g by truck These transport instructions are only valid
4. flow on secondary side before starting increase of pressure If available the safety devices of the thermo processing equipment should be connected to the package control to ensure that starting and operating the package is only possible when conditions are safe All safety devices must always be in perfect and operative condition The qualified staff must regularly check the safety devices to ensure that they are fully functional Do not deactivate any of the safety devices on the package system All safety devices must be in full working order before starting the package system for the first time Do not start up the package system if any safety device is defective Stop the package system if a safety device fails during operation and restart it only after the safety device has been repaired Wait until the package system has been shut down and secured before removing any safety devices Safety Armstrong Electrical Engineering MANDATORY regulation to switch off the package system Go to the control unit and switch off the main supply secure the main supply against unintentional or unauthorized switch on with one or more padlocks Only skilled electricians may access the electrical components of the package system for maintenance purposes Check the operability of the protective systems after finishing the maintenance work Always use original fuses with the specified amperage Packaging Storag
5. followed at all times WARNING High Voltage This pictogram is used to warn against electric shock hazard Only qualified electricians may work on the system s electrical equipment Make sure that all national and local safety requirements are observed WARNING Suspended Loads This pictogram is used to warn against possibly dangerous situations involving falling loads which could lead to serious injury or death Only qualified staff may work on the package system Make sure that all national and local safety requirements are observed WARNING Toxic Substances This pictogram is used to warn against the danger of toxic substances Only qualified staff may work on the package system Make sure that all national and local safety requirements are observed WARNING Hot Surfaces This pictogram is used to warn against the danger of hot surfaces Only qualified staff may work on the package system Make sure that all national and local safety requirements are WARNING Fire This pictogram is used to warn against possibly dangerous situations involving fire which could lead to serious injury or death Only qualified staff may work on the package system Make sure that all national and local safety requirements are observed WARNING Explosion Hazard This pictogram is used to warn against possibly dangerous situations where an explosion could lead to serious injury or death Only qualified staff may work on the package system Make sure
6. in their original packing Make sure that surfaces and seals are not misshapen or damaged while being transported Ensure that all moving parts are secured in place while being transported Transport locks may only be removed by authorized personnel during assembly Forklift trucks are used to transport the package system to its installation location Take individual maximum loads into account when choosing suitable transport and hoisting equipment The transport and hoisting equipment must be provided by the customer Check the shipment as to its completeness transport damage and the stability of screwed connections Check the package system for external damage as soon as it arrives on site Immediately report damages Report any transport damages immediately after receiving the package system to the shipping department of ARMSTRONG ARMSTRONG INTERNATIONAL SA Parc Industriel des Hauts Sarts Deuxieme Avenue 4 B 4040 Herstal Phone 32 4 240 90 90 Telefax 32 2 240 40 33 eMail info armstronginternational eu Internet www armstronginternational com IV Operation Armstrong The Digital Flo Steam to Water skid is composed of the following main components On the Water Side of the Plate Heat Exchanger Digital Mixing Valve could be a DRV40 or DRV80 depending on the size Isolation valves on cold water inlet mixed water outlet return and mixing valve hot inlet Strainers on cold water inlet return and mixing
7. inlet Gradually open closed shut off valve between pump and exchanger vi Vent system again if necessary Hot steam Side Open all isolation valves on the condensate side Isolation valves on steam side have to be opened SLOWLY Slowly open the main steam isolation valve until you have steam at the inlet to the control valve Allow pressures and temperatures to equalize before fully opening the steam isolation valve Set the control valve order to have 1 barg steam entering into the heat exchanger this will reduce water hammer of any condensate in the steam line and the pressure thermal shock of the exchanger IMPORTANT Equipment under pressure Operating temperature above 100 C Let system cool down before any handling To avoid flashing of the water on the secondary side water pressure should always be p gt greater than steam pressure 19 IV Operation Armstrong 2 Check for proper operation a Check for pressure pulses in the system caused by the pumps or control valves If found stop operation and rectify Continuous pressure pulses will result in fatigue failure of the HE Visually check the unit for leakage Ensure that the steam trap is working correctly this will prevent water clogging inside the heat exchanger d Cold leakage is caused by a sudden change in temperature The sealing properties of certain elastomers are temporarily reduced wh
8. is exclusively designed for heating water with steam Always observe the limit values and operating conditions specified in chapter V d Operating Conditions page 23 ll b Incorrect Use CAUTION Incorrect use of either the entire package system or parts of it may lead to fatal or lethal injury of persons and severe damage to the package system or environment Never use the package system for the production of products or for process technology methods other than specified The manufacturer cannot be held liable for any damage or injury occurring as a result of the installation and use of parts purchased from other manufacturers i e of parts which are not approved of by the manufacturer as either accessory or spare part il c Residual Risks It is impossible to exclude all residual risks even if the package system 15 used correctly These residual risks do not arise from the package system itself but are in general caused by inattentiveness or incorrect operation Strictly adhere to the general statutory and operational safety regulations all approved technical rules regarding safe and professional work all safety instructions contained in this Operating Manual Safety instructions in suppliers documentation especially regarding troubleshooting and maintenance work carried out on this package system the information given on the safety marks of the package system the rules on accident prevention the instru
9. mixed water temperature based on the setpoint see component specific documentation for more information 3 When water temperature failure occurs too high temperature the Digital Mixing Valve integrated relay will trip out The automatic steam shut off closes and the Reset Alarm Mixing Valve light button is ON See specific component documentation for more information on possible failure on the Digital Mixing Valve 4 When problem has been fixed press on the Reset Alarm Mixing Valve light button The Digital Mixing Valve will switch off for a few second and then restart automatically The automatic Steam shut off valve will open IMPORTANT Equipment under pressure Operating temperature above 100 C Let system cool down before any handling IV Operation Armstrong IV c Start Up Operation THE STEAM SHOULD NOT BE STARTED IF NO FLUID IS RUNNING ON THE COLD SIDE OF THE HEAT EXCHANGER WATER SIDE 1 Before Start up this section consider components that should be installed by the user Ensure that both the steam isolation and control valves are fully closed Ensure that the heat exchanger is fully drained of condensate Start cold circuit first then the steam side Cold Circuit Fully vent the system Close shut off valve fitted between pump and exchanger Fully open valve fitted into outlet line from the exchanger IV Start the circulation pump normally placed by the
10. valve hot inlet Check valve on cold water inlet and return CIP connections on cold inlet and hot outlet of the heat exchanger Temperature gauges on cold water inlet and return On the Steam Side of the Plate Heat Exchanger Electric ON OFF valve on the steam inlet Strainer isolation valve and steam trap on the condensate side The skid is also equipped with a control panel IV a Control Panel Layout IMPORTANT Equipment under pressure Operating temperature above 100 C Let system cool down before any handling IV Operation Armstrong 1 Lights a Power ON Type Information Indication Healthy Supply Color White b Solenoid Valve ON Type Information Indication Steam Isolation Valve is open Color Green 2 Light Button a Reset Alarm Mixing Valve Type Information Reset Indication High Temp Alarm Color Red IMPORTANT Equipment under pressure Operating temperature above 100 C Let system cool down before any handling IV Operation Armstrong IV b Control Philosophy 1 The control panel on the skid is supplied with power as and when the system has to operate 2 When the panel is supplied with power the system operates as follows a When system is operational with no fault signal the automatic steam shut off valve is open b The Digital Mixing Valve has fully integrated actuator controller and temperature probes and will control on its own the
11. Mixing Valve fault relay DRV ALARM MVFR 4 9 40 41 40 41 BRAIN VALVE FAULT SIGNAL TO BMS 1 SIGNAL OUT to BMS a Mixing Valve Failed teminals 40 41 Volt free contact Electrical connection should be done by authorized and qualified personnel only Installation of equipment should always be accompanied by competent technical assistance 24 IONS ical Connect Electr gt ical drawings Vi c Electr ONJJIM 3273521 12 A8LINIDTL Way 29 Ara 21 2 21 21 Ade SLIHA A389 20 5 NOV W NADYA ASI A0EZ an0109 08918915 CHHILIWS VS WO 7HOS 1 N0SZ 2813502399 WILS EN IATA TONO 01043705 AVS ND 3NIYA Gonos 4OL3 N03 OB Aa oN 11793 INKIN 0 13534 11793 JAWA WADI avd JAWA 13534 Lines JAWA BANI SN HALIWS gt ND JAWA Tumo 100927105 1 1 wavy 0891 SATA OBO NISE E AINN SMa 01 Tots INA ONDON OFAN 705 519370 ZHOS 1T AGE 25 IONS ical Connect Electr gt Vi c Electrical draw
12. al connections Power supply Connections Electrical drawing How to read this operating Manual Armstrong Definitions Operating Company The operating company is either the owner of the hot water package or has rented it The operating company integrates the hot water package in the installation used for industrial purposes Qualified Staff Qualified staff carries out their work and recognize potential risks due to their professional training In addition they are familiar with relevant rules accident prevention regulations and special circumstances within a company Qualified staff installs and services the hot water package system Operators The operators receive on the job training and know about possible dangers that may arise from incorrect use They are familiar with all required protective gear and personal protection measures all applicable rules all accident prevention regulations and all operating conditions How to read this operating Manual Armstrong l b Explanation of Pictograms and Notes Never remove warning signs or have them blocked from view The risks which the warning signs refer to are described in the text next to the pictogram gt e gt CAUTION This pictogram marks safety instructions which must be observed to avoid danger to the system and Its operation All signs on the system must be readable and the information on the signs must be
13. ctions on environmental protection Safety Armstrong ll d Requirements Of the Operating Company The operating company is required to ensure that any work on the package system is carried out by persons who have been trained and are familiar with basic occupational safety and accident prevention regulations provide necessary personal safety gear for the operator regularly check the safety devices and the protective gear provided be certain that the operator has read and understood the Operating Manual OM especially the safety and warning notices Of the Operators Operators are required to observe the basic occupational safety and accident prevention regulations read this OM especially the safety and warning notices and to ask about anything that is unclear report damage to the package system immediately and in case of danger shut the package system down immediately ll e Safety Devices The package system is equipped with safety devices according to applicable European Directives However the integration of the package system into thermo processing equipment can lead to dangers which can only be recognized and avoided with a proper knowledge of all design based and functional details of the thermo processing equipment Due to these circumstances ARMSTRONG INTERNATIONAL SA cannot specify every possible safety relevant measure Here are some examples of possible dangers excess temperature no
14. e and Transport Armstrong A WARNING Suspended Loads Never step under a suspended load Use only approved hoisting equipment such as for example handling chains which comply with DIN EN 818 handling ropes which comply with DIN 3088 hoisting belts which comply with DIN 61360 or hoisting straps which comply with DIN EN 1492 1 CAUTION Ensure that the installation is transported without being knocked or pushed Observe all signs on the packaging Additional transport locking devices were installed by the manufacturer for transport purposes Remove these transport locking devices only just before assembly Remove these transport interlocks before commissioning MANDATORY use of safety gloves Remove nails sticking out of the wooden boxes immediately after opening NOTE When transporting the package system observe the transport regulations of ARMSTRONG INTERNATIONAL SA see chapter Transport page 15 General and local safety and accident prevention regulations must be explained to all staff and must be followed during unpacking storing and transportation work The regulations must be stored close to the package system for future reference Packaging Storage and Transport Armstrong Packaging Unless specifically agreed otherwise packaging complies with the packaging guidelines Each packing unit is strapped to a pallet clad with edge protectors and put into a tailored crate or box
15. e hot water system and must be accessible for operators It is the responsibility of the company operating the hot water system to keep an equipment history record of the integrated hot water system which is to include commissioning records with final settings maintenance and inspection reports as well as reports on modified settings and replacement of parts We advise to systematically add the above records to this instruction manual and keep the resulting binder hardcopy or folder electronic accessible for operators and service technicians Digital Flo Steam to Water Armstrong Contents Page I How to read this operating 6 la Definitions eee 6 Explanation of Pictograms andNotes GB 7 l c Warranty 9 Safety 22 000 10 Intended use 10 Incorrect use eee 10 Residual risks ee 10 Requirements eee 11 ll e Safety Devices eee 11 Electrical Engineering sss 20222 12 Packaging storage 13 Packaging ss 222 2 000 14 II b 14 Transport 1 15 IV Operation ss IIIWU PjPjr jj jj 9S Sh 9 16 Control Panellayoutt ee 16 Control Philoisodhy Cc a 18 Start up Operation 2 222 20022 19 Mechanical connections 21 V a Rear view 21 V b Topview a 22 Connections Position eee 23 Operating Conditions se 23 Armstrong Contents Digital Flo Steam to Water VI Electric
16. en the temperature changes suddenly No action is required as the gaskets should re seal after the temperature has stabilized Demountable plate heat exchangers can always leak We advise you to take this into account while installing Preferably you should install a drip tray underneath the heat exchanger skid to prevent leakages onto the floor and or harm to electrical equipment Short circuit moisture damage Read carefully the Start up and maintenance Instructions of the components before any starting or shut off of the supplied package IMPORTANT Equipment under pressure Operating temperature above 100 C Let system cool down before any handling To avoid flashing of the water on the secondary side water pressure should always be greater than steam pressure A 20 V Mechanical Connections V a Rear View i For exact position and rating of the connections please refer to the supplied drawing Return Water fot a N I m 1 H L CU pf Cold Water IN E En P UH s toe A ar L mt ae N 4 B Mixed Water OUT Steam IN Supplied skid might differ from this image 21 V Mechanical Connections Armstrong V b Top View i For exact position and rating of the connections please refer to the supplied draw
17. ing Return IN Condensate OUT 2 Supplied skid might differ from this image 22 V Mechanical Connections Armstrong V c Connections Position i For exact position and rating of the connections please refer to the supplied drawing ll d Operating Conditions 1 SIDE1 Fluid saturated Steam Maximum Allowable Pressure 4 barg Max Temperature 142 C Max Operating Pressure 1 barg 2 SIDE 2 Fluid Water Maximum Temperature OUT 70 C Max Pressure 10 barg Max Temperature 100 C Min Flow 19 l min for unit with DRV40 38 l min for unit with DRV80 IMPORTANT Equipment under pressure Operating temperature above 100 C Let system cool down before any handling To avoid flashing of the water on the secondary side water pressure should always be greater than steam pressure A VI Electrical Connections Armstrong Electrical connection should be done by authorized and qualified personnel only Installation of equipment should always be accompanied by competent technical assistance Power Supply The electrical panel should be supplied with 230V 1ph 50Hz Tolerance 10V Terminals L1 N1 PE Connections The electrical panel is supplied fully pre wired All components supplied on the package are already connected to the panel There is one Volt Free signal available for BMS This signal give the information coming from
18. ings LIYHS MOLY OSI 330 4GIT ZADN3Y 2 INIANNAL AJLI LOTS 40 09x52 aul 62 ISNA S O ISNA 5 t sorta sz IVd GNA TNL ISNA 57 1 ITINWNOLAM 5 3573 SE i 9sverol9z SITNIM ONLLNNOW 1YH JOL 95 fav us opceco sz AINNNUIM STNG 60 57 Wal z 1990 2 sanaaa Gusog st ONI 3908 52 67 dy zpod 95099020 SWN ay LZ 3208 lt lt 7 AYS STP sroaco tZ Ha Se t od 911990 2 ONI TWNINAGL St d We 962110 64 ITINWOLIM 5 31 97 3009 6 vs sschro si 3TIINHIS S8IWIL NOJL SIDYINI NO 1 1 1 21 5359 Der 43d GNH3S 7109 POACEZ AYIIN Oder 61 25 1102 NOLIFLNOD INIA T 25 LHI NOLINAHSNA QILYNIWNATT dae T 2 430 1QNHIS NOLINAHSNd 1319 113 Prema raz z1 ITIBNHIS SIHSIT ANY dd 4 SY30 70H 483931 amp e zazj 1 SSUIGNHIS SIHOIT 137 20 0 2 EWAd raz 01 4ITIBNHIS SN3T LHD 10718 keona vaz ITI3NHIS IHSIT LOTId 431 9 iwaa rd
19. itten agreement between Armstrong and the user which is signed by both parties Armstrong DOES NOT MAKE ANY OTHER REPRESENTATIONS OR WARRANTIES EXPRESS 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 within 30 days of the date of the manifestation of the condition or occurrence giving rise to the claim whichever is earlier INNO 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 app
20. ly 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 The Brain DRV40 shall have a 5 year guarantee against failure caused by materials or workmanship provided by Armstrong The Brain DRV80 shall have a 5 year guarantee against failure caused by materials or workmanship provided by Armstrong ARMSTRONG INTERNATIONAL S A Parc Industriel des Hauts Sarts 2 Avenue 4 B 4040 Herstal BELGIUM Tel 32 0 4 240 90 90 Fax 32 0 4 240 40 33 ARMSTRONG INTERNATIONAL ITALIANA S r l Via S Botticelli 80 10154 Torino ITALY Tel 39 011 20 00 35 Fax 39 011 24 25 744 ARMSTRONG INTERNATIONAL S A Manchester Business Park 3000 Aviator Way Manchester M22 5TG UNITED KINGDOM Tel 44 0 161 266 2279 Fax 44 0 161 266 1001 ARMSTRONG SERVICE FRANCE BP 102 route du Hoc 76700 Gonfreville FRANCE Tel 33 02 35 53 68 35 Fax 33 02 35 53 68 37 OM L37097 rev 1 june 2013 27
21. that all national and local safety requirements are observed How to read this operating Manual Armstrong WARNING Crushing Hazard This pictogram is used to warn against possibly dangerous situations where moving parts can lead to serious crushing injuries or death Only qualified staff may work on the package system Make sure that all national and local safety requirements are observed MANDATORY Use of Safety Gloves This pictogram is used to warn against possibly dangerous situations which can only be avoided by wearing safety gloves MANDATORY Use of Protective Clothing This pictogram is used to warn against possibly hazardous situations which could lead to moderate physical injuries making the use of protective clothing mandatory MANDATORY Use of Ear Protection This pictogram is used to warn against possibly hazardous situations which could lead to ear damage MANDATORY Regulation to Switch OFF the Package System Switch off the package system at the control unit Secure the main switch against unintentional or unauthorized switch on with one or more padlocks PROHIBITED This pictogram is used to warn against smoking and or open fire near a package system NOTE This pictogram is used to highlight special information on key functions or special user tips which will help you make full use of all the functions the package system has to offer How to read this Operating Manual Armstrong
22. y Information This instruction manual has been written for the standard Digital Flo Steam to Water Heat Exchanger Package Some options might differ the supplied Package Refer to the components IOM for more detailed information It is required that all workers on the hot water system have read and understood these instructions In case of conflicting instructions the components instructions provided with the hot water system override the instructions of this user manual provided for the hot water system Local codes and or regulations as well as plant specific health and safety requirements shall also be respected If any of the instructions described this user manual provided by ARMSTRONG INTERNATIONAL SA are in conflict with the local codes and regulations please contact your local Representative or ARMSTRONG INTERNATIONAL SA before initial start up of the equipment For explanations on pictograms and notes please refer to chapter l b Explanation of Pictograms and Notes page 7 All personnel involved in the installation integration commissioning maintenance repair inspection and operation of this hot water system shall ensure that all the necessary health and safety requirements are fulfilled before commencing the work They should wear the appropriate personal protective equipment PPE together with if applicable required site specific equipment This instruction manual must be stored in a place near th
23. z YZLIBNHIS SN3ZT 18911 10714 1 ewAg raz 43TIBNHIS 3VADEZ GIN 1 1 2 NBAS ZUIBNHIS 92 1 1 2 8042 2482 71775 25 MOLYTOSI 21 02 10 422 ONJINNOK TWA SeNsOION3 JeNSOTINI 220909598 1 ANDAV1 TIYA WNIWS3SL 319144298 TOSIND Pia DILA IHAA RO 13 IN ADH TT NADAMA ONIM LO 4813r313L 29 Ara Ave et 21 AGE 29 Adve STr S80 109 1371 15 INDAYT GN e 709100 ao SLEW LE 0 SNOILIGWNOD 26 Armstrong International SA Warranty Armstrong International SA 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 wr
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