AWII-I-O Rev G Installation & Operation Manual Models: 151 - 801 WARNING: If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life. -- This water heater MUST NOT be installed in any location where gasoline or flammable vapors are likely to be present. -- WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance. • Do not touch any electric switch; do not use any phone in your building.
Contents HAZARD DEFINITIONS .................................................... 2 PLEASE READ BEFORE PROCEEDING ........................ 3 THE ARMOR WATER HEATER -- HOW IT WORKS .... 4-6 RATINGS ........................................................................... 7 1. DETERMINE WATER HEATER LOCATION Provide Clearances ............................................................ 8 Provide Air Openings to Room ........................................ 10 Flooring and Foundation ........................
Installation & Operation Manual Please read before proceeding WARNING Installer – Read all instructions, including this manual and the Armor Water Heater Service Manual, before installing. Perform steps in the order given. Have this water heater serviced/inspected by a qualified service technician, at least annually. Failure to comply with the above could result in severe personal injury, death or substantial property damage.
Installation & Operation Manual The Armor Water Heater - How it works... 1. Stainless steel heat exchanger Allows water to flow through specially designed coils for maximum heat transfer, while providing protection against flue gas corrosion. The coils are encased in a jacket that contains the combustion process. 2. Combustion chamber access cover Allows access to the combustion side of the heat exchanger coils. 3. Blower The blower pulls in air and gas through the venturi (item 5).
Installation & Operation Manual The Armor Water Heater - How it works...
Installation & Operation Manual The Armor Water Heater - How it works...
Installation & Operation Manual Ratings HLW Model Number Note: Change “N” to “L” for L.P. gas models. CSA Input Modulation Btu/hr Water Content Gallons Water Connections Gas Connections (Note 2, 3) Vent/Air Size (Note 1) AWN151PM 30,000 - 150,000 1.3 1-1/4" 1/2" 3"/3" AWN200PM 40,000 - 199,999 1.7 1-1/4" 1/2" 3"/3" AWN286PM 57,000 - 285,000 2.4 2" 3/4" 4"/4" AWN400PM 80,000 - 399,999 3.4 2" 1" 4"/4" AWN501PM 100,000 - 500,000 4.
Installation & Operation Manual 1 Determine water heater location Installation must comply with: • Local, state, provincial, and national codes, laws, regulations, and ordinances. • National Fuel Gas Code, ANSI Z223.1 – latest edition. • National Electrical Code. • For Canada only: B149.1 Installation Code, CSA C22.1 Canadian Electrical Code Part 1 and any local codes. The Armor water heater gas manifold NOTICE and controls met safe lighting and other performance under tests specified in ANSI Z21.10.
Installation & Operation Manual 1 Determine water heater location (continued) Figure 1-1 Closet Installation - Minimum Required Clearances WARNING CLOSET INSTALLATION 1/4” MINIMUM CLEARANCE AROUND HOT WATER PIPES 1” MINIMUM CLEARANCE AROUND VENT PIPES 13" TOP For closet installations, CPVC, polypropylene or stainless steel vent material MUST BE used in a closet structure due to elevated temperatures. Failure to follow this warning could result in fire, personal injury, or death.
Installation & Operation Manual 1 Determine water heater location Provide air openings to room: Residential garage installation Armor water heater alone in equipment room Precautions 1. No air ventilation openings into the equipment room are needed when clearances around the Armor water heater are at least equal to the SERVICE clearances shown in FIG.’s 1-1 and 1-2. For spaces that do NOT supply this clearance, provide two openings as shown in FIG. 1-1.
Installation & Operation Manual 1 Determine water heater location Table 1A Corrosive Contaminants and Sources Products to avoid: Spray cans containing chloro/fluorocarbons Permanent wave solutions Chlorinated waxes/cleaners Chlorine-based swimming pool chemicals Calcium chloride used for thawing Sodium chloride used for water softening Refrigerant leaks Paint or varnish removers Hydrochloric acid/muriatic acid Cements and glues Antistatic fabric softeners used in clothes dryers Chlorine-type bleaches, de
Installation & Operation Manual 1 Determine water heater location When removing a water heater from existing common vent system: DANGER Do not install the Armor water heater into a common vent with any other appliance. This will cause flue gas spillage or appliance malfunction, resulting in possible severe personal injury, death, or substantial property damage.
Installation & Operation Manual 2 Prepare water heater Remove water heater from wood pallet 1. After removing the outer shipping carton from the water heater, remove the parts box. Table 2A LP Conversion Table LP Conversion Table Model LP Orifice Stamping 2. Remove the front door to access the lag bolts in front of the unit (FIG. 2-1). 151 150 200 210 / W150 3. To remove the water heater from the pallet (after removing the front door): a.
Installation & Operation Manual 2 Prepare water heater Model 400 Model 501 1. Remove the top and front access covers from the unit (no tools required for removal). 1. Remove the top access cover from the unit (no tools required for removal). 2. Remove the three screws securing the venturi to the blower. Note: When separating the venturi from the blower, take care not to damage the O-ring inside the blower (FIG. 2-3). 2. Turn the adjustment screw on the gas valve clockwise until it stops.
Installation & Operation Manual 2 Prepare water heater (continued) Models 601 - 801 Leveling the water heater 1. Remove the top access cover from the unit (no tools required for removal). 1. 2. Remove the cover on top of the gas valve (FIG. 2-5). 3. Turn the adjustment screw on top of the gas valve clockwise one and three quarter (1 3/4) turns on the 601 Model, one and a half (1 1/2) turns on the 701 Model, and one turn on the 801 Model (see FIG. 2-5). Set the water heater in place and check level.
Installation & Operation Manual 3 General venting Direct venting options - Sidewall Vent Figure 3-1 Two-Pipe Sidewall Termination - See page 24 for more details Figure 3-2 PVC/CPVC Concentric Sidewall Termination (Models 151 - 601 Only) - See page 28 for more details Direct venting options - Vertical Vent Figure 3-3 Two-Pipe Vertical Termination - See page 31 for more details 16 Figure 3-4 PVC/CPVC Concentric Figure 3-5 Vertical Vent, Sidewall Vertical Termination (Models 151 - Air - See page 20 fo
Installation & Operation Manual 3 General venting Install vent and combustion air piping DANGER WARNING The Armor water heater must be vented and supplied with combustion and ventilation air as described in this section. Ensure the vent and air piping and the combustion air supply comply with these instructions regarding vent system, air system, and combustion air quality. See also Section 1 of this manual.
Installation & Operation Manual 3 General venting Requirements for installation in Canada Minimum / Maximum allowable combustion air and vent piping lengths are as follows: 1. Installations must be made with a vent pipe system certified to ULC-S636. Combustion Air = 12 equivalent feet minimum / 100 equivalent feet maximum IPEX is an approved vent manufacturer in Canada supplying vent material listed to ULC-S636. Vent = 12 equivalent feet minimum / 100 equivalent feet maximum 2.
Installation & Operation Manual 3 General venting (continued) Air inlet pipe materials: The air inlet pipe(s) must be sealed. Choose acceptable combustion air inlet pipe materials from the following list: PVC, CPVC, Polypropylene or ABS Dryer Vent or Sealed Flexible Duct (not recommended for rooftop air inlet) Galvanized steel vent pipe with joints and seams sealed as specified in this section. Type “B” double-wall vent with joints and seams sealed as specified in this section.
Installation & Operation Manual 3 General venting Vent, air piping and termination: Air contamination The Armor water heater vent and air piping can be installed through the roof or through a sidewall. Follow the procedures in this manual for the method chosen. Refer to the information in this manual to determine acceptable vent and air piping length. Pool and laundry products and common household and hobby products often contain fluorine or chlorine compounds.
Installation & Operation Manual 3 General venting WARNING (continued) Insulation should not be used on PVC or CPVC venting materials. The use of insulation will cause increased vent wall temperatures, which could result in vent pipe failure. f. g. Table 3D PVC/CPVC Vent Pipe, and Fittings Approved PVC/CPVC Vent Pipe and Fittings Item Material While the cement is still wet, insert the pipe into the fitting, if possible twist the pipe a 1/4 turn as you insert it.
Installation & Operation Manual 3 General venting Polypropylene WARNING This product has been approved for use with polypropylene vent with the manufacturers listed in Table 3E. All terminations must comply with listed options in this manual and be a single-wall vent offering. For use of flex pipe, it is recommended to have the vent material in 32°F or higher ambient space before bending at installation.
Installation & Operation Manual 3 General venting (continued) Stainless steel vent NOTICE This product has been approved for use with stainless steel using the manufacturers listed in Table 3G. Use only the materials, vent systems, and terminations listed in Tables 3G and 3I. DO NOT mix vent systems of different types or manufacturers. Failure to comply could result in severe personal injury, death, or substantial property damage.
Installation & Operation Manual 4 Sidewall direct venting Vent/air termination – sidewall WARNING WARNING Follow instructions below when determining vent location to avoid possibility of severe personal injury, death, or substantial property damage. A gas vent extending through an exterior wall shall not terminate adjacent to a wall or below building extensions such as eaves, parapets, balconies, or decks.
Installation & Operation Manual 4 Sidewall direct venting (continued) Vent/air termination – sidewall Figure 4-1C Alternate PVC/CPVC/SS Vent Termination - Typical Stainless Steel Sidewall Termination of Air and Vent Models 151 - 801 w/Field Supplied Fittings BIRD SCREEN TO BOILER INTAKE AIR CONNECTION 12" (305 MM) MIN 15" (381 MM) MAX FROM BOILER VENT PIPE CONNECTION 12" (305 MM) MIN GRADE OR SNOW LINE NOTICE PVC/CPVC or ABS is acceptable air inlet pipe material.
Installation & Operation Manual 4 Sidewall direct venting 2. Figure 4-4A Clearance to Forced Air Inlets IF LESS THAN 10’ VENT / AIR TERMINATION 36" MIN. 3. FORCED AIR INLET 4. 5. 7' MIN. ABOVE ANY PUBLIC WALKWAY 6. Figure 4-4B Alternate Clearance to Forced Air Inlets w/ Field Supplied Fittings IF LESS THAN 10’ 7. 8. For Polypropylene Only: Install the vent and air intake sidewall adapters from Table 3F on page 20 into the vent plate.
Installation & Operation Manual 4 Sidewall direct venting (continued) Figure 4-5B Polypropylene Sidewall Termination Assembly Multiple vent/air terminations 1. When terminating multiple Armor water heaters terminate SIDEWALL ADAPTER each vent/air connection as described in this manual (AIR) WALL (FIG. 4-6A). PLATE SIDEWALL All vent pipes and air inlets must terminate WARNING RETAINING at the same height to avoid possibility of PLATE severe personal injury, death, or substantial property damage.
Installation & Operation Manual 4 Sidewall direct venting Sidewall termination – optional concentric vent: Models 151 - 601 Description and usage Lochinvar offers optional concentric combustion air and vent pipe termination kits (Factory Kit #CVK3003 for 3” diameter - Models 151 - 200 and #CVK3007 for 4” diameter - Models 286 - 601). Both combustion air and vent pipes must attach to the termination kit. The termination kits must terminate outside the structure and must be installed as shown below in FIG.
Installation & Operation Manual 4 Sidewall direct venting (continued) Sidewall termination – optional concentric vent: Models 151 - 601 Figure 4-10 Concentric Vent Dimensional Drawing Models 151 - 200 Figure 4-11 Concentric Vent Dimensional Drawing Models 286 - 501 "A" "C" DIA. "B" DIA. "D" 3" (76 MM) "E" "G" "H" DIA. "B" DIA.
Installation & Operation Manual 4 Sidewall direct venting Sidewall termination – optional concentric vent: Models 151 - 601 Figure 4-13 Concentric Vent Sidewall Attachment Note: CVK3003 shown for illustration purposes. CAUTION DO NOT use field-supplied couplings to extend pipes. Airflow restriction will occur and may cause intermittent operation. 9. Cement appliance combustion air and vent pipes to the concentric vent termination assembly. See FIG. 4-13 for proper pipe attachment. 10.
Installation & Operation Manual 5 Vertical direct venting Vent/air termination – vertical WARNING Follow instructions below when determining vent location to avoid possibility of severe personal injury, death or substantial property damage. Figure 5-1A PVC/CPVC Vertical Termination of Air and Vent Determine location Locate the vent/air terminations using the following guidelines: 1.
Installation & Operation Manual 5 Vertical direct venting Vent/air termination – vertical Prepare roof penetrations 1. 2. Air pipe penetration: a. Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter. Vent pipe penetration: a. Cut a hole for the vent pipe.
Installation & Operation Manual 5 Vertical direct venting (continued) Vertical termination – optional concentric vent: Models 151 - 601 Description and usage Lochinvar offers an optional concentric combustion air and vent pipe termination kit. Both combustion air and vent pipes must attach to the termination kit. The termination kit must terminate outside the structure and must be installed as shown in FIG. 5-4. Field supplied pipe and fittings are required to complete the installation.
Installation & Operation Manual 5 Vertical direct venting Vertical termination – optional concentric vent: Models 151 - 601 WARNING Do not operate the appliance with the rain cap removed or recirculation of combustion products may occur. Water may also collect inside the larger combustion air pipe and flow to the burner enclosure. Failure to follow this warning could result in product damage or improper operation, personal injury, or death. DO NOT use field-supplied couplings to extend pipes.
Installation & Operation Manual 5 Vertical direct venting (continued) Alternate vertical concentric venting This appliance may be installed with a concentric vent arrangement where the vent pipe is routed through an existing unused venting system; or by using the existing unused venting system as a chase for vent and combustion air routing. Figure 5-8 Concentric Vent Example 1 FLUE EXHAUST SEAL Concentric Venting Arrangement The venting is to be vertical through the roof.
Installation & Operation Manual 5 Vertical direct venting Existing vent as a chase Follow all existing termination and clearance requirements and allowable pipe lengths. Use only approved venting materials listed in the General Venting Section of this manual. Figure 5-10 Existing Vent as a Chase AIR INLET FLUE EXHAUST SEAL EXISTING CAP SEAL FLUE OUTLET *For concept illustration only. Individual installations may vary due to job site specific equipment.
Installation & Operation Manual 6 System piping System water piping methods Observe a minimum of 1/4 inch clearance around all un-insulated hot water pipes when openings around the pipes are not protected by non-combustible materials. General piping information Basic steps are listed below along with illustrations on the following pages (FIG.’s 6-4 thru 6-8), which will guide you through the installation of the Armor water heater. 1. Connect the cold water supply to the inlet side of the water heater.
Installation & Operation Manual 6 System piping Scalding This water heater can deliver scalding temperature water at any faucet in the system. Be careful whenever using hot water to avoid scalding injury. Certain appliances such as dishwashers and automatic clothes washers may require increased temperature water. By setting the thermostat on this water heater to obtain the increased temperature water required by these appliances, you may create the potential for scald injury.
Installation & Operation Manual 6 System piping (continued) Figure 6-4 Single Heater - Single Tank FLOW CHECK VALVE (TYPICAL) BUILDING RETURN COLD WATER SUPPLY MIXING VALVE EXPANSION TANK THERMOMETER HOT WATER SUPPLY WATER HEATER BALL VALVE (TYPICAL) UNION (TYPICAL) WATER HEATER CIRCULATOR TEMPERATURE & PRESSURE RELIEF VALVE (TYPICAL) STORAGE TANK FLOW SWITCH DRAIN CAUTION NOTICE Y-STRAINER [RECOMMENDED] The piping will not support the weight of the water heater circulator pump.
Installation & Operation Manual 6 System piping Figure 6-5 Single Heater - Single Tank (2 Temperature) FLOW CHECK VALVE (TYPICAL) 180° HOT WATER SUPPLY 140° HOT WATER SUPPLY LOW TEMPERATURE BUILDING RETURN COLD WATER SUPPLY THERMOMETER (TYPICAL) UNION (TYPICAL) MIXING VALVE TEMPERATURE & PRESSURE RELIEF VALVE (TYPICAL) NOTICE 40 HIGH TEMPERATURE BUILDING RETURN WATER HEATER CIRCULATOR STORAGE TANK EXPANSION TANK FLOW SWITCH DRAIN CAUTION BALL VALVE (TYPICAL) Y-STRAINER (RECOMMENDED)
Installation & Operation Manual 6 System piping (continued) Figure 6-6 Single Heater - Double Tank FLOW CHECK VALVE (TYPICAL) COLD WATER SUPPLY THERMOMETER MIXING VALVE BUILDING RETURN BALL VALVE (TYPICAL) EXPANSION TANK Y-STRAINER (RECOMMENDED) WATER HEATER CIRCULATOR HOT WATER SUPPLY FLOW SWITCH UNION (TYPICAL) TEMPERATURE & PRESSURE RELIEF VALVE (TYPICAL) WATER HEATER STORAGE TANK (TYPICAL) CAUTION NOTICE DRAIN (TYPICAL) The piping will not support the weight of the water heater circ
Installation & Operation Manual 6 System piping Figure 6-7 Double Heater - Single Tank Model 151 200 286 400 501 601 701 801 COLD WATER SUPPLY 2 Number of Units 3 4 5 6 7 Required Pipe Sizes in NPT 1 1/2" 2" 2" 2" 2 1/2" 1 1/2" 2" 2 1/2" 2 1/2" 3" 2" 2 1/2" 2 1/2" 3" 3" 2 1/2" 3" 3 1/2" 4" 4" 3" 3 1/2" 4" 5" 5" 3" 3 1/2" 4" 5" 5" 3" 4" 5" 5" 6" 3" 4" 5" 6" 6" WATER HEATER CIRCULATOR (TYPICAL) EXPANSION TANK 3" 3" 4" 5" 5" 5" 6" 6" 8 3" 4" 4" 5" 6" 6" 6" 6" WATER HEATER (TYPICAL) FLOW CHECK VAL
Installation & Operation Manual 6 System piping (continued) Figure 6-8 Double Heater - Double Tank Model 151 200 286 400 501 601 701 801 2 Number of Units 3 4 5 6 7 Required Pipe Sizes in NPT 1 1/2" 2" 2" 2" 2 1/2" 1 1/2" 2" 2 1/2" 2 1/2" 3" 2" 2 1/2" 2 1/2" 3" 3" 2 1/2" 3" 3 1/2" 4" 4" 3" 3 1/2" 4" 5" 5" 3" 3 1/2" 4" 5" 5" 3" 4" 5" 5" 6" 3" 4" 5" 6" 6" 3" 3" 4" 5" 5" 5" 6" 6" 8 3" 4" 4" 5" 6" 6" 6" 6" COLD WATER SUPPLY EXPANSION TANK FLOW CHECK VALVE (TYPICAL) BUILDING RETURN HOT WATER SUPPLY T
Installation & Operation Manual 7 Gas connections Connecting gas supply piping Figure 7-3 Gas Supply Piping - Model 501 UNION (FACTORY INSTALLED) 1. Remove the top access panel and refer to FIG.’s 7-1 thru 7-4 to pipe gas to the water heater. a. b. c. MANUAL SHUTOFF VALVE (FACTORY SUPPLIED) Install ground joint union for servicing, when required.
Installation & Operation Manual 7 Gas connections (continued) Do not check for gas leaks with an open WARNING flame – use the bubble test. Failure to use the bubble test or check for gas leaks can cause severe personal injury, death, or substantial property damage. 6. Use pipe sealing compound compatible with propane gases. Apply sparingly only to male threads of the pipe joints so that pipe dope does not block gas flow.
Installation & Operation Manual 7 Gas connections Table 7A Natural Gas Pipe Size Chart Nominal Iron Pipe Size (Inches) 1/2 3/4 1 1-1/4 1-1/2 2 2-1/2 3 4 Single Unit Natural Gas Pipe Capacity Chart Length of Pipe in Straight Feet for 1/2 PSI 10 20 30 40 50 175 120 97 82 N/A 369 256 205 174 155 697 477 384 328 292 1400 974 789 677 595 2150 1500 1210 1020 923 4100 2820 2260 1950 1720 6460 4460 3610 3100 2720 11200 7900 6400 5400 4870 23500 16100 13100 11100 10000 60 N/A 141 267 543 830 1560 2460 4410 9000
Installation & Operation Manual 7 Gas connections (continued) 17. Check burner performance by cycling the system while you observe burner response. The burner should ignite promptly. Flame pattern should be stable. Turn system off and allow burner to cool, then cycle burner again to ensure proper ignition and flame characteristics.
Installation & Operation Manual 8 Field wiring WARNING NOTICE ELECTRICAL SHOCK HAZARD – For your safety, turn off electrical power supply before making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death. Wiring must be N.E.C. Class 1. If original wiring as supplied with the water heater must be replaced, use only type 105°C wire or equivalent.
Installation & Operation Manual 8 Field wiring (continued) Tank thermostat Low gas pressure switch 1. Connect the tank thermostats (isolated contact only) to the tank thermostat contacts as shown in FIG. 8-3. 1. If a switch is provided to detect low gas pressure, remove the jumper wire from the terminals on the connection board and connect them to its normally open contacts (FIG. 8-3). Tank sensor 2.
Installation & Operation Manual 8 Field wiring Runtime contacts The SMART SYSTEM control closes a set of dry contacts whenever the burner is running. This is typically used by Building Management Systems to verify that the water heater is responding to a call for heat. Alarm contacts The SMART SYSTEM control closes another set of contacts whenever the water heater is locked out or the power is turned off.
NO COM LOW WATER CUTOFF TANK THERMOSTAT FLOW SWITCH BUILDING MANAGEMENT SYSTEM A B SHIELD TANK SENSOR Field wiring LOUVER PROVING SWITCH SHIELD B TO A NEXT HEATER 8 24VAC LOUVER RELAY COIL FROM B PREVIOUS A HEATER Installation & Operation Manual (continued) Figure 8-3 Low Voltage Field Wiring Connections 51
Installation & Operation Manual 9 Condensate disposal Condensate drain NOTICE 1. This water heater is a high efficiency appliance that produces condensate. 2. The side of the water heater has a 1/2 inch PVC union for connection of a 1/2 inch PVC pipe (FIG. 9-1). 3. Slope condensate tubing down and away from the water heater into a drain or condensate neutralizing filter. Condensate from the Armor water heater will be slightly acidic (typically with a pH from 3 to 5).
Installation & Operation Manual 10 Start-up Chlorine concentration less than 200 ppm WARNING 1. Do not fill the water heater or operate with water containing chlorine in excess of 200 ppm. 2. Filling with chlorinated fresh water should be acceptable since drinking water chlorine levels are much lower. 3. Do not use the water heater to directly heat swimming pool or spa water. 4. At initial fill and during water heater startup and testing, check system thoroughly for any leaks.
Installation & Operation Manual 10 Start-up Final checks before starting the water heater Read the Armor Water Heater Service Manual to familiarize yourself with SMART SYSTEM control module operation. Read this manual, pages 55 and 56 for proper steps to start the water heater. Verify the water heater and system are full of water and all system components are correctly set for operation. Verify the preparation procedures of Section 10, pages 53 and 54 have been completed.
Installation & Operation Manual 10 Start-up (continued) Figure 10-2 Operating Instructions - Models 151 - 286 FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury, or loss of life. A. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand. B.
Installation & Operation Manual 10 Start-up Figure 10-3 Operating Instructions - Models 400 - 801 56
Installation & Operation Manual 10 Start-up (continued) Check flame and combustion (continued) Set water heater operation 4. Place the water heater into the active position by pressing the RIGHT SELECT [ON] key (FIG. 11-1, page 63). Set tank set point temperature 5. Locate the pinhole button below the RESET button on the display board (FIG. 11-1). Insert a thin wire (such as a paper clip) into the hole and press the button once and hold for 5 seconds to place the water heater into Service Mode.
Installation & Operation Manual 10 Start-up Configuration of the cascade Set clock NOTICE Please note that the brackets ([]) denote screen status. The SMART SYSTEM control has a built-in clock that it uses for its night setback feature and for logging events. This clock must be set when the water heater is installed, and anytime the water heater has been powered off for more than 4 hours. Use the following procedure to set the clock: 1. Press and hold the LEFT SELECT [MENU] key for at least 5 seconds.
Installation & Operation Manual 11 Operating information General Protection features How the water heater operates Outlet temperature, flue temperature, and temperature rise limiting The Armor water heater uses an advanced stainless steel heat exchanger and electronic control module that allows fully condensing operation. The blower pulls in air and pushes flue products out of the water heater through the heat exchanger and flue piping.
Installation & Operation Manual 11 Operating information Monitor external limits Connections are provided on the connection board for external limits such as flow switch, gas pressure switches, and a louver proving switch. The SMART SYSTEM will shut off the burner and inhibit relighting whenever any of these external limits open. When the outlet temperature exceeds 200°F, the automatic high limit action occurs.
Installation & Operation Manual 11 Operating information (continued) Cascade Access modes When multiple water heaters are installed, they can be wired together in a cascade sequence. A maximum of eight water heaters can be controlled from a single control. In this application one water heater would be designated as the Leader control and all others would be designated as Member controls. The Leader control can be programmed to use Lead/Lag or Efficiency Optimization control methods.
Installation & Operation Manual 11 Operating information Sequence of operation OPERATION 1. The control will turn on the water heater pump (always ON except in Night Setback). The flow switch and/or LWCO must close. 2. The control turns on power to the louver relay. The louver proving switch, air pressure switch, and blocked drain switch must close. 3. The control starts the prepurge cycle. 4. The control starts the trial for ignition by firing the spark electrode and opening the gas valve. 5.
Installation & Operation Manual 11 Operating information (continued) Armor water heater control module Use the control panel (FIG. 11-1) to set temperatures, operating conditions, and monitor water heater operation.
Installation & Operation Manual 11 Operating information Figure 11-2 Status Display Screen Status Display Screens Section Display Description STANDBY The unit has not received a call for heat from a remote thermostat nor has it received a call for heat from a DHW thermostat. START A (Water heater Status Bar) The unit has begun a burn cycle and is checking all safety circuits. PREPURGE The unit has initiated a prepurge period on a call for heat.
Installation & Operation Manual 11 Operating information (continued) Status Display Screens (cont’d) Section Display TANK: The temperature read at the inlet to the heat exchanger. OUTLET TEMP: The temperature read at the outlet of the heat exchanger. FLUE TEMP: FLAME CURRENT: FAN SPEED: SYSTEM PUMP: DHW PUMP: BMS VOLTAGE: BLR PUMP OUTPUT: RATE OUTPUT: DHW RUN HOURS: DHW CYCLES: LAST 10 FAULTS NO: MENU D (LEFT SELECT key function) The temperature read by the tank sensor (if connected).
Installation & Operation Manual 11 Operating information Section Status Display Screens (cont’d) Display Description Turning the NAVIGATION dial will select the next or previous Status Screen. Pressing the NAVIGATION dial will show the next fault, NSB (Night Setback) trigger, or ramp delay setting. Pressing the NAVIGATION dial will select the setting indicated by the cursor. E (NAVIGATION Dial Function) Pressing the NAVIGATION dial will display the Set Points Screen.
Installation & Operation Manual 12 Maintenance Maintenance and annual startup Table 12A Service and Maintenance Schedules Service technician (see the following pages for instructions) Owner maintenance General: • Address reported problems • Inspect interior; clean and vacuum if necessary; Daily • Check water heater area • Check pressure/temperature gauge • Clean condensate trap and fill with fresh water ANNUAL START-UP • Check for leaks (water, gas, flue, condensate) • Verify flue and air lines i
Installation & Operation Manual 12 Maintenance WARNING Follow the service and maintenance procedures given throughout this manual and in component literature shipped with the water heater. Failure to perform the service and maintenance could result in damage to the water heater or system. Failure to follow the directions in this manual and component literature could result in severe personal injury, death, or substantial property damage.
Installation & Operation Manual 12 Maintenance WARNING (continued) Failure to inspect for the above conditions and have them repaired can result in severe personal injury or death. Check water system 1. Verify all system components are correctly installed and operational. 2. Check the cold fill pressure for the system. Verify it is correct (must be a minimum of 12 PSI). 3. Watch the system pressure as the water heater heats up (during testing) to ensure pressure does not rise too high.
Installation & Operation Manual 12 Maintenance Perform start-up and checks 1. Start water heater and perform checks and tests specified in Section 10 - Start-up. 2. Verify cold fill pressure is correct and that operating pressure does not go too high. Check burner flame 1. Inspect flame through observation window. 2. If the flame is unsatisfactory at either high fire or low fire, turn off water heater and allow water heater to cool down.
Installation & Operation Manual 12 Maintenance (continued) Table 12B Heat Exchanger Cleaning Kits Model Kit Part Number Number Component Description CTN20005 Rear Refractory Cover MSC20083* Nylon 4" Wheel Brush* 151 - 400 Check Delta T 1. Check Delta T. Reference Section 6 - System Piping on page 38 for more information regarding Delta T. Oiled bearing circulators 1. The circulator shipped with the Armor water heater is water-lubricated. No oiling is required.
Installation & Operation Manual 13 Diagrams Figure 13-1 Ladder Diagram JUNCTION BOX 120VAC NEUTRAL GROUND TERMINAL STRIP 120V SUPPLY "L" TERMINAL STRIP 120V SUPPLY "N" L IN L OUT INTEGRATED CONTROL ON / OFF SWITCH X1-1 F2 X1-6 1 2 BLOWER 3.15A 3 X1-2 BUILDING RECIRC PUMP CONTACTS F1 BUILDING RECIRC PUMP RELAY 5A BUILDING RECIRC PUMP RELAY BUILDING RECIRC PUMP X1-3 DHW PUMP DHW PUMP RELAY DHW PUMP RELAY F3 DHW PUMP CONTACTS .
Installation & Operation Manual 13 Diagrams (continued) Figure 13-2 Wiring Diagram LOW VOLTAGE 120 VAC HIGH VOLTAGE BOX DEPICTS OPTIONAL ITEMS BOX DEPICTS DUAL SENSOR SINGLE HOUSING INTEGRATED CONTROL CONNECTION BOARD JUNCTION BOX BELL JUMPER SILENCING SWITCH ALARM BELL COM ALARM CONTACTS RUN-TIME CONTACTS 24 VAC LOUVER RELAY COIL LOUVER PROVING SWITCH GAS PRESSURE SWITCH FLOW SWITCH TANK THERMOSTAT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 X-7 X1-3 OR/BK L N OR DHW PUMP OR NO X1-4 CN5-1 CN5
Installation & Operation Manual Notes 74
Installation & Operation Manual Notes 75
Revision Notes: Revision A (ECO #C06238) initial release. Revision B (ECO #C07442) new layout in InDesign, piping diagram on page 43 (ECR #R03671), and edits made to the Ratings Page (page 7).
