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Installation & Operation Manual

4  

Sidewall direct venting 

(continued)

VENT PIPING

GALVANIZED

THIMBLE

VENT CAP

AIR PIPING

WALL PLATE

VENT PLATE

VENT

AIR

CENTERLINE WIDTH

Figure 4-5A

 Sidewall Termination Assembly

2.  For Polypropylene Only:  Install the vent and air intake 
 

sidewall adapters from Table 3I into the vent plate.  Slide 

 

the sidewall retaining bracket down the sidewall adapters 

 

flush to the vent plate.

3.  For PVC/CPVC Only:  Install the vent and air intake 
 

piping through the wall into the vent plate openings.  Use 

 

RTV silicone sealant to seal the air pipe.  Use the cement/

 

primer listed in Table 3G to seal the vent pipe.

4.  Mount and secure the vent plate to the wall using 
 

stainless steel screws.  Seal around the plate to the wall 

 

assuring no air gaps.

5.  Seal all gaps between the pipes and wall. Seal around the 
 

plate to the wall assuring no air gaps.

6.  Assemble the vent cap to the vent plate.  Insert the 
 

stainless steel screws into the vent cap screw hole 

 

openings and securely attach the vent cap to the vent 

 plate.

7.  Seal all wall cavities.
8.  PVC/CPVC terminations are designed to accommodate 

any wall thickness of standard constructions per the 
directions found in this manual.

9.  Stainless steel terminations are designed to penetrate 

walls with a thickness up to 9.25 inches of standard 
construction.

27

Table 4D 

Sidewall Vent Centerline Dimensions

Prepare wall penetrations

1.  Use the factory supplied wall plate as a template to locate 
 

the vent and air intake holes and mounting holes.  

 

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.  For either combustible or 

 

noncombustible construction, size the vent pipe hole 

 

with at least a 1/2 inch clearance around the vent pipe 

 outer 

diameter:

 

• 5½ inch hole for 4 inch vent pipe

   

• 7½ inch hole (191 mm) hole for 6 inch (152 mm) 

   

   vent pipe

Drill 3/16" diameter holes for inserting the plastic anchors 
into the wall. 

SIDEWALL
ADAPTER
(AIR)

SIDEWALL
ADAPTER
(VENT)

WALL
PLATE

GALVANIZED
THIMBLE

SIDEWALL
RETAINING
PLATE

VENT
PLATE

VENT
CAP

IMG00085

Figure 4-5B

 Polypropylene Sidewall Termination Assembly

Model

Air

Vent Centerline 

Width

400 - 500

4"

4"

5 5/8"

650 - 800

4"

6"

7 3/4"

1000

6

"

6

"

7 3/4

"

Summary of Contents for Armor AWH0400L

Page 1: ...ter 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 Immediately call your gas supplier from a near by phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department ...

Page 2: ...ions 12 13 3 GENERAL VENTING Direct Venting Options 14 Install Vent and Combustion Air Piping 15 Requirements for Installation in Canada 16 Sizing 16 Min Max Combustion Air Vent Piping Lengths 16 Materials 17 Optional Room Air 18 PVC CPVC 18 Polypropylene 20 Stainless Steel Vent 21 4 SIDEWALL DIRECT VENTING Vent Air Termination Sidewall 22 31 Determine Location 22 27 Prepare Wall Penetrations 27 M...

Page 3: ...cation Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee Factory warranty shipped with unit does not apply to units improperly installed or improperly operated 3 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 ...

Page 4: ... of firing rates 13 Water outlet Water connection that supplies hot water to the tank 14 Water inlet Water connection that returns water from the tank to the heat exchanger 15 Gas connection pipe Threaded pipe connection This pipe should be connected to the incoming gas supply for the purpose of delivering gas to the water heater 16 SMART TOUCH Control Module The SMART TOUCH Control responds to in...

Page 5: ...00589238 00 9 11 13 14 15 17 19 21 28 30 31 22 Models 400 500 Rear View Models 400 500 Left Side inside unit Models 400 500 DIR 2000589256 00 9 11 13 14 15 17 19 21 28 30 31 22 2 33 1 4 DIR 2000589257 00 3 5 10 16 32 36 8 18 20 35 27 7 Models 650 1000 DIR 2000589239 00 DIR 2000589239 00 DIR 2000589239 00 8 18 1 4 33 34 2 3 5 10 24 32 35 27 7 16 20 ...

Page 6: ...eet elevation follow all applicable local codes and regulations 4 The manual reset high limit provided with the Armor is listed to UL353 or UL60730 2 9 The auto reset high limit is listed to ANSI Z21 87 6 Maximum allowed working pressure is located on the rating plate NOTICE Model Number Note Change N to L for L P gas models CSA Input Modulation MBtu hr Water Content Gallons Water Connection Gas C...

Page 7: ...ent system manufacturer s instructions 3 See FIG 1 1 and 1 2 for other clearance minimums Recommended clearances for service access Front Top Left Side Rear 24 Closet and alcove installations This appliance requires a special venting system If using PVC the vent connection to the appliance must be made with a CPVC pipe section The field provided vent fittings must be cemented to the CPVC pipe sect...

Page 8: ...DOOR 1 4 6MM MINIMUM CLEARANCE AROUND HOT WATER PIPES 1 25 MM MINIMUM CLEARANCE AROUND VENT PIPE DIR 2000589268 00 Figure 1 1 Closet Installation Minimum Required Clearances WARNING WARNING 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 o...

Page 9: ...ted in residential garages and in adjacent spaces that open to the garage and are not part of the living space of a dwelling shall be installed so that all burners and burner ignition devices are located not less than 18 inches 46 cm above the floor The appliance shall be located or protected so that it is not subject to physical damage by a moving vehicle Vent and air piping The Armor water heate...

Page 10: ...ed at the flue collar connection Size To ensure proper pipe size is in place see Table 3A Check to see that this size is used throughout the vent system Manufacturer For a stainless steel or polypropylene application you must use only the listed manufacturers and their type product listed in Tables 3H and 3J for CAT IV positive pressure venting with flue producing condensate Supports Non combustib...

Page 11: ...ng system are located and other spaces of the building Turn on clothes dryers and any appliance not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers d Place in operation the appliance being inspected Follow the lighting instructions Adjust therm...

Page 12: ...damaged For Models 650 1000 Disconnect the gas piping from the venturi by removing the four 4 bolts securing the pipe to the venturi 4 Remove the bolts connecting the venturi to the fan Remove the natural venturi from the unit FIG 2 2a and 2 2b 5 Install the LP venturi onto the fan taking note of the following a The UP arrow on the plastic housing is indeed pointing up b The connection for the gas...

Page 13: ...ER ALLEN WRENCH ADJUSTMENT SCREW Figure 2 4 Gas Valve Adjustment Models 650 1000 13 10 For Models 400 500 Remove the front panel from the unit no tools required for removal For Models 650 1000 Remove the top access cover from the unit no tools required for removal 11 For Models 650 1000 Remove the cover on top of the gas valve FIG 2 4 12 UseacombustionanalyzertoverifyCO2 iswithintherange of 9 4 10...

Page 14: ...589390 00 DIR 2000589393 00 Figure 3 3 Two Pipe Vertical Termination Direct venting options Sidewall Vent DIR 2000589389 00 Figure 3 2 PVC CPVC Concentric Sidewall Termination Figure 3 4 PVC CPVC Concentric Vertical Termination Figure 3 5 Vertical Vent Sidewall Air DIR 2000589392 00 Direct venting options Vertical Vent ...

Page 15: ...onnection Combustion air piping must be supported per guidelines listed in the National Mechanical Code Section 305 Table 305 4 or as local codes dictate 2 Vent Connector FIG 3 7 thru 3 10 Used to provide a passageway for conveying combustion gases to the outside A transition fitting is provided on the unit for final connection Vent piping must be supported per the National Building Code Section 3...

Page 16: ...ng The Armor water heater uses model specific combustion air intake and vent piping sizes as detailed in Table 3A below Increasing or decreasing combustion air or vent piping sizes is not authorized unless referenced in manual NOTICE When determining equivalent combustion air and vent length add 5 feet for each 90 elbow and 3 feet for each 45 elbow EXAMPLE 20 feet of PVC pipe 4 90 elbows 2 45 elbo...

Page 17: ...he air inlet pipe ensures that combustion air will be free of contaminants and supplied in proper volume Follow the polypropylene manufacturer s instructions when using polypropylene material as an inlet pipe When a sidewall or vertical rooftop combustion air supply system is disconnected for any reason the air inlet pipe must be resealed to ensure that combustion air will be free of contaminants ...

Page 18: ...ase review Section 1 Prevent Combustion Air Contamination to ensure proper installation Vent system and terminations must comply with the standard venting instructions set forth in this manual NOTICE Optional room air is intended for commercial applications Combustion air piping to the outside is recommended for residential applications WARNING When utilizing the single pipe method provisions for ...

Page 19: ...itting socket e Apply a second coat of cement to the pipe Table 3G PVC CPVC Vent Pipe and Fittings NOTE In Canada CPVC and PVC vent pipe fittings and cement primer must be ULC S636 certified WARNING Insulation shall 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 While the cement is still wet i...

Page 20: ...ent system See Table 3I for approved vent adapters Discard CPVC starter piece NOTICE Approved Polypropylene Vent Manufacturers Make Model Standard Centrotherm Eco Systems InnoFlue SW Flex UL 1738 ULC S636 Duravent M G Group PolyPro Single Wall PolyPro Flex ULC S636 Model Centrotherm InnoFlue SW Polypropylene Adapter Joint Connector Sidewall Retaining Bracket Sidewall Adapter Low Profile Wall Termi...

Page 21: ...erials vent systems and terminations listed in Tables 3J and 3K DO NOT mix vent systems of different types or manufacturers Failure to comply could result in severe personal injury death or substantial property damage WARNING Installations must comply with applicable national state and local codes Stainless steel vent systems must be listed as a UL 1738 approved system for the United States and a ...

Page 22: ...re zone f Do not terminate above any door or window Condensate can freeze causing ice formations g Locate or guard vent to prevent condensate damage to exterior finishes h Do not locate the terminations over public walkways i Do not locate the terminations near soffit vents crawl space vents or other areas where condensate or vapor could create a nuisance hazard or cause property damage j Do not l...

Page 23: ... Locate terminations so they are not likely to be damaged by foreign objects such as stones or balls or subject to buildup of leaves or sediment VENT AIR TERMINATION 4 MIN 12 MIN 12 MIN Figure 4 3A Clearance to Gravity Air Inlets 12 305 MM MIN 12 305 MM MIN FROM BOILER VENT PIPE CONNECTION TO BOILER INTAKE AIR CONNECTION BIRD SCREEN BIRD SCREEN GRADE OR SNOW LINE Figure 4 2 Alternate PVC CPVC SS P...

Page 24: ...W 9 in 23 cm for appliances 10 000 Btuh 3 kW and 50 000 Btuh 15 kW 12 in 30 cm for appliances 50 000 Btuh 15 kW and not exceeding 150 000 Btuh 30 kW C Clearance to permanently closed window D Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 ft 61 cm from the center line of the terminal E Clearance to unventilated soffit F Clearance to outside cor...

Page 25: ...n 10 ft 3 m horizontally L Clearance above paved sidewalk or paved driveway located on public property 7 ft 2 13 m 7 ft 2 13 m for mechanical draft systems Category I appliances Vents for Category II and IV appliances cannot be located above public walkways or other areas where condensate or vapor can cause a nuisance or hazard M Clearance under veranda porch deck or balcony 12 in 30 cm Clearance ...

Page 26: ... air supply inlet to building or the combustion air inlet to any other appliance 6 in 15 cm for appliances 10 000 Btuh 3kW 12 in 30 cm for appliances 10 000 Btuh 3 kW and 100 000 Btuh 30 kW 36 in 91 cm for appliances 100 000 Btuh 30 kW 4 ft 1 2 m below or to side of opening 1 ft 300 mm above opening K Clearance to a mechanical air supply inlet 6 ft 1 83 m 3 ft 91 cm above if within 10 ft 3 m horiz...

Page 27: ... Seal all wall cavities 8 PVC CPVC terminations are designed to accommodate any wall thickness of standard constructions per the directions found in this manual 9 Stainless steel terminations are designed to penetrate walls with a thickness up to 9 25 inches of standard construction 27 Table 4D Sidewall Vent Centerline Dimensions Prepare wall penetrations 1 Use the factory supplied wall plate as a...

Page 28: ...y of severe personal injury death or substantial property damage Multiple vent air terminations 1 When terminating multiple Armor water heaters terminate each vent air connection as described in this manual FIG 4 6A 2 Place wall penetrations to obtain minimum clearance of 12 inches between edge of air inlet and adjacent vent outlet as shown in FIG 4 6A for U S installations For Canadian installati...

Page 29: ...termination considerations 3 Cut one 1 hole 7 inch diameter into the structure to install the termination kit 4 Partially assemble the concentric vent termination kit Clean and cement using the procedures found in these instructions a Cement the Y concentric fitting to the larger kit pipe FIG 4 9 b Cement the rain cap to the smaller diameter kit pipe FIG 4 9 Instead of cementing the smaller pipe t...

Page 30: ...y needs to be extended to allow sidewall thickness requirement the two 2 pipes supplied in the kit may be replaced by using the same diameter field supplied SDR 26 PVC D2241 pipe and standard schedule 40 PVC Do not extend dimension D more than 60 inches see FIG 4 9 thru 4 11 If assembly depth needs to be reduced dimension D can be as short as possible NOTICE Figure 4 11 Concentric Vent Sidewall At...

Page 31: ...ion Operation Manual 31 4 Sidewall direct venting continued Sidewall termination optional concentric vent Models 400 500 VENT COMBUSTION AIR 12 MINIMUM Figure 4 12 Concentric Vent and Combustion Air Termination ...

Page 32: ...the air intake When the vent termination uses a rain cap as illustrated in FIG 5 1B maintain at least 36 914 mm above the air inlet The air inlet pipe and vent pipe can be located in any desired position on the roof but must always be no further than 2 feet 6 m apart and with the vent termination at least 1 foot for PVC and 3 feet for stainless steel above the air intake 6 Maintain the required di...

Page 33: ...e Multiple vent air terminations 1 When terminating multiple Armor water heaters terminate each vent air connection as described in this manual FIG 5 2 Terminate all vent pipes at the same height and all air pipes at the same height to avoid possibility of severe personal injury death or substantial property damage 2 Place roof penetrations to obtain minimum clearance of 12 inches between edge of ...

Page 34: ...nts together when field disassembly is desired for cleaning see FIG 4 12 When using the alternate screw assembly method drill a clearance hole in the rain cap and a pilot hole in the vent pipe for the screw size being used Failure to drill adequate holes may cause cracking of PVC components allowing combustion products to be recirculated Failure to follow this warning could result in personal inju...

Page 35: ...appliance must be individually vented see FIG 5 7 NEVER common vent or breach vent this appliance When two 2 or more direct vent appliances are vented near each other two 2 vent terminations may be installed as shown in FIG 5 7 It is important that vent terminations be made as shown to avoid recirculation of flue gases 12 MINIMUM 12 18 FOR CANADA MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LE...

Page 36: ...appropriate example Installation must comply with local requirements and with the National Fuel Gas Code The maximum allowable equivalent vent and air intake lengths for this venting arrangement are to be determined from the General Venting Section If an existing unused venting system is converted for use with this method of concentric venting the installer must ensure that the existing venting sy...

Page 37: ...gths Use only approved venting materials listed in the General Venting Section of this manual Figure 5 10 Existing Vent as a Chase DIR 2000589422 00 FLUE OUTLET SEAL CAP EXISTING SEAL FLUE EXHAUST AIR INLET 5 Vertical direct venting continued For concept illustration only Individual installations may vary due to job site specific equipment ...

Page 38: ...materials must be field supplied and supported per the vent manufacturer s instructions Combustion air supply must be free of contaminants see the Combustion and Ventilation Air Requirements section of this manual To prevent recirculation of the flue products into the combustion air inlet follow all instructions in this section WARNING Model DuraVent Z Flex Heat Fab Metal Fab Security Chimney Adap...

Page 39: ...oncrete brick block or other non combustible pad Do not locate unit so that high winds can deflect off of adjacent walls buildings or shrubbery causing recirculation Recirculation of flue products may cause operational problems bad combustion or damage to controls Multiple unit outdoor installations require 48 1 22 m clearance between each vent cap Locate outdoor cap at least 48 1 22m below and 48...

Page 40: ... tank on the system supply Consult the tank manufacturer s instruction for specific information relating to tank installation Size the expansion tank for the required system volume and capacity 6 Install a drain valve at the lowest point of the system 7 This appliance is supplied with a relief valve sized in accordance with ASME Boiler and Pressure Vessel Code Section IV Heating Boilers Pipe the d...

Page 41: ...2 5 to 12 gpg UP 43 110FN 79 15 25 F 12 to 15 gpg TP 50 80B 90 21 22 F Denotes standard pump supplied with unit Check recirculation pump size to verify it is sized for filter addition and upsize if necessary CAUTION Temperature and pressure relief valve Factory supplied on water heaters The temperature and pressure relief valve is sized to ASME specifications Storage tanks may require additional v...

Page 42: ... attempt to support the weight of the water heater circulator pump with the piping or its accessories Refer to the pump manufacturer s installation instructions Failure to comply could result in severe personal injury death or substantial property damage CAUTION DIR 2000589730 00 WATER HEATER STORAGE TANK HOT WATER SUPPLY COLD WATER SUPPLY BUILDING RETURN T CIRCULATION PUMP FLOW CHECK VALVE TEMPER...

Page 43: ...DIR 2000589731 00 CIRCULATION PUMP FLOW CHECK VALVE TEMPERATURE GAUGE T BUILDING RECIRCULATION FILTER STRAINER FILTER TEMPERATURE PRESSURE RELIEF VALVE BALL VALVE TYPICAL EXPANSION TANK MIXING VALVE UNION DRAIN PORT FLOW SWITCH PIPING WATER HEATER STORAGE TANK 140 HOT WATER SUPPLY 180 HOT WATER SUPPLY COLD WATER SUPPLY LOW TEMPERATURE BUILDING RETURN HIGH TEMPERATURE BUILDING RETURN T T Please not...

Page 44: ...rty damage CAUTION Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment The installer must follow all manufacturer s instructions for each system component The installer is responsible for compliance with local codes DIR 2000589732 00 CIRCULATION PUMP FLOW CHECK VALVE TEMPERATURE GAUGE T BUILDING RECIRCULATION FILTER STRAI...

Page 45: ... piping concept only the installer is responsible for all equipment The installer must follow all manufacturer s instructions for each system component The installer is responsible for compliance with local codes Model Number of Units 2 3 4 5 6 7 8 Required Pipe Sizes in NPT Based on 30 400 2 1 2 3 4 4 6 6 6 500 3 4 4 4 6 6 6 650 3 4 4 6 6 6 6 800 4 4 6 6 6 6 8 1000 4 6 6 6 8 8 8 DIR 2000589733 00...

Page 46: ...cept only the installer is responsible for all equipment The installer must follow all manufacturer s instructions for each system component The installer is responsible for compliance with local codes Model Number of Units 2 3 4 5 6 7 8 Required Pipe Sizes in NPT Based on 30 400 2 1 2 3 4 4 6 6 6 500 3 4 4 4 6 6 6 650 3 4 4 6 6 6 6 800 4 4 6 6 6 6 8 1000 4 6 6 6 8 8 8 DIR 2000589734 00 CIRCULATIO...

Page 47: ...PLY UNION FIELD SUPPLIED SEDIMENT TRAP DRIP LEG MANUAL SHUTOFF VALVE FACTORY SUPPLIED Figure 8 1 Gas Supply Piping 4 Purge all air from the gas supply piping 5 Before placing the water heater in operation check the water heater and its gas connection for leaks a The appliance must be disconnected from the gas supply piping system during any pressure testing of that system at a test pressure in exc...

Page 48: ...eater on Minimum 4 inches w c with gas flowing verify during water heater startup 2 Install 100 lockup gas pressure regulator in supply line if inlet pressure can exceed 14 inches w c at any time Adjust lockup regulator for 14 inches w c maximum Propane gas Pipe sizing for propane gas 1 Contact gas supplier to size pipes tanks and 100 lockup gas pressure regulator Propane supply pressure requireme...

Page 49: ...he control 11 Turn the power switch to the OFF position 12 Shut off the gas supply at the manual gas valve in the gas piping to the appliance 13 Remove the manometer from the pressure tap on top of the gas valve On Models 400 500 re tighten the set screw inside the pressure tap On Models 650 1000 remove the 1 8 3 mm field supplied fitting and reinstall the pipe plug removed in Step 3 Check inlet g...

Page 50: ...gas valve outlet pressure The gas valve is factory set for the correct outlet pressure This setting is suitable for natural gas and propane requiring no field adjustment Attempting to alter the gas valve outlet pressure could result in damage to the valve causing potential severe personal injury death or substantial property damage Failure to follow all precautions could result in fire explosion o...

Page 51: ...s shown in FIG 9 1 4 The Armor water heater is capable of controlling a building recirculation pump field supplied Wire the building recirculation pump as shown in FIG 9 1 5 Dry contacts are sized for 1 hp 120V or 2 hp 240V DOMESTIC HOT WATER PUMP 120V SUPPLY LINE GROUND NEUTRAL W G BK W G BK SERVICE SWITCH L1 G L2 N RECIRCULATION PUMP W G BK G L4 N L3 DOMESTIC HOT WATER PUMP W G BK G L6 N L4 N L5...

Page 52: ...e actual rate of the water heater ModBus BACnet When the optional ModBus BACnet interface module is installed the RS 485 ModBus BACnet cable is connected to these terminals Use shielded 2 wire twisted pair cable If desired the shield can be connected to ground by installing a jumper wire between terminals 1 and 3 on connector X5 on the optional ModBus BACnet interface module Louver relay If louver...

Page 53: ...r wires to Cascade terminal A on each of the low voltage connection boards and the other wire of the twisted pair to Cascade terminal B on each of the low voltage connection boards Connect the shield wires to one of the shield terminals on the low voltage connection boards FIG 9 3 If more than two water heaters are on the Cascade daisy chain the wiring from the Cascade terminals on the second wate...

Page 54: ...g 24VAC LOUVER RELAY COIL FLOW SWITCH TANK SENSOR BUILDING MANAGEMENT SYSTEM LOUVER PROVING SWITCH COM NO LOW WATER CUTOFF TANK THERMOSTAT SHIELD SHIELD TO NEXT HEATER A B A B FROM PREVIOUS HEATER A B Figure 9 3 Low Voltage Field Wiring Connections ...

Page 55: ...or D2845 Cement and primer must comply with ASME D2564 or F493 For Canada use CSA or ULC certified PVC or CPVC pipe fittings and cement 7 A condensate removal pump is required if the water heater is below the drain When installing a condensate pump select one approved for use with condensing water heaters and furnaces The pump should have an overflow switch to prevent property damage from condensa...

Page 56: ...ng check system thoroughly for any leaks Repair all leaks before proceeding further 3 When water hardness levels are less than 5 gpg or 85 5 mg l the following is recommended a Flush and clean existing water heating system prior to installation b Inspect and if necessary replace the anodes in any existing tanks c Install a Y strainer on the inlet of each water heater as detailed in Section 7 d Lim...

Page 57: ...acts as a seal against harmful flue gases escaping in case there is no condensate in the trap If this ball is not present flue gases may be able to pass through the trap when there is no condensate present resulting in an unsafe environment It is important to check and make sure the ball is located in the trap acting as a seal against flue gases 3 Connect the condensate trap to the condensate hose...

Page 58: ...al vents Air in the system will interfere with circulation and cause heat distribution problems and noise Check vent piping and air piping 1 Check for gastight seal at every connection seam of air piping and vent piping Venting system must be sealed gastight to prevent flue gas spillage and carbon monoxide emissions which will result in severe personal injury or death Check gas piping 1 Check arou...

Page 59: ...Installation Operation Manual 59 11 Start up continued Figure 11 2 Operating Instructions ...

Page 60: ... screen Enter the installer password 6 Select the Service Maintenance Screen The tabs will scroll up and down to reveal more options See FIG 11 3 7 Once the heat exchanger has modulated up to rate measure the combustion The values should be in the range listed in the Armor Service Manual CO levels should be less than 200 ppm for a properly installed unit If the combustion is not within range refer...

Page 61: ...an unprogrammed control The Door Menu button will become highlighted when there are changes that can be applied Figure 11 4 User Set Point Screen Installation Operation Manual 11 Start up continued Set clock The SMART TOUCH 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 appliance is installed and anytime the appliance ...

Page 62: ...e Cascade option as shown in FIG 11 5 4 Each unit must have a unique address set The leader has more options which are described in the Armor Service Manual 5 Once all the updates are complete press the Door Menu slider top left or the Setup button 6 Press the APPLY CHANGES button on the top of the screen NOTE The APPLY CHANGES button must be pressed to complete programming of the controls Failure...

Page 63: ...perature and temperature rise limiting The outlet temperature is monitored by the water heater outlet temperature sensor When the outlet temperature exceeds 185 F the unit will reduce the fan speed If the outlet water temperature exceeds 195 F the control will shut the unit down until it cools off The control module monitors the flue temperature by a sensor located in the flue exhaust If the flue ...

Page 64: ...nufacturer To enable this feature change the parameter to the desired time interval reference the Armor Service Manual for details regarding parameters Error logging The control will hold in memory the last 10 lockouts as well as the last 10 blockings The date and time of the occurrence will be recorded as well Only the 10 most current occurrences of each will be held in memory 12 Operating inform...

Page 65: ...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 Once the Leader water heater receives a call for heat from a tank sensor BMS or Modbus the control will determine what the set point will be A fixed temperature set point can be programmed into t...

Page 66: ...sparking ends the control will perform a postpurge then start another prepurge cycle and try to light the burner again On the 500 and larger models the control will lock out if this second attempt also fails On the 400 model the control will perform a total of 4 attempts before locking out Once the control has locked the unit out the RESET button will need to be pressed on the touch screen LCD 8 I...

Page 67: ...een and displays both factory installed and field installed sensor including Inlet Water Temperature Delta T Water Temperature Outlet Water Temperature Flue Temperature and HW Tank Temperature The Navigation Section is located down the left side of the screen There are five 5 sections located below the Lochinvar icon Home View Setup Information About and Settings The Home Section is the screen sho...

Page 68: ...manual Flame inspection stable uniform Flame signal at least 10 microamps at high fire Clean the heat exchanger if flue temperature is more than 54 F above return water temperature Check Delta T Temperature Rise If combustion or performance indicate need Clean heat exchanger Remove and clean burner using compressed air only Clean the blower wheel ANNUAL START UP Owner maintenance Daily Check water...

Page 69: ...ater 2 Vacuum any sediment from inside the water heater and components Remove any obstructions The condensate trap must be filled with water during all times of water heater operation to avoid flue gas emission from the condensate drain line Failure to fill the trap could result in severe personal injury or death WARNING WARNING WARNING WARNING Figure 13 1 Condensate Trap Clean condensate trap 1 I...

Page 70: ...ected could result in unsafe pressure buildup which can result in severe personal injury death or substantial property damage Following installation the valve lever must be operated AT LEAST ONCE A YEAR to ensure that waterways are clear Certain naturally occurring mineral deposits may adhere to the valve rendering it inoperative When manually operating the lever water will discharge and precautio...

Page 71: ... in the Service Manual Failure to comply could result in severe personal injury WARNING Cleaning heat exchanger For recommended materials including brush appropriate extension s refractory cover and detailed instructions see Table 13B Heat Exchanger Cleaning Kits 1 Shut down water heater Follow the To Turn Off Gas to Appliance instructions for the water heater in Section 11 Startup Do not drain th...

Page 72: ...e to the water heater drain and flush water heater thoroughly with clean water by using purging valves to allow water to flow through the water makeup line to the water heater 12 Perform start up and check out procedures in the Check Flame and Combustion Section 11 Startup on pages 57 and 60 of this manual 13 Replace the access cover and restore water heater to operation Table 13B Heat Exchanger C...

Page 73: ...2 CN8 3 X6 3 X4 1 X9 2 X4 2 X9 1 X4 3 X9 3 S2 S1a S1b S3a S3b 16 17 20 21 22 23 25 26 27 28 29 30 3 4 1 2 M O D B U S 19 24 9 5 6 7 8 X2 2 CN5 3 X4 5 3A 11 CN5 10 X4 12 CN5 14 X4 8 CN5 5 X4 3 LOW VOLTAGE 120 VAC HIGH VOLTAGE X5 2 X5 11 X5 10 AIR PRESSURE SWITCH BLOCKED DRAIN SWITCH CONNECTION BOARD 13 10 LWCO CN7 3 CN7 2 CN7 4 CN7 1 24 VAC TANK THERMOSTAT HIGH GAS PRESSURE SWITCH LOW GAS PRESSURE ...

Page 74: ...5 10 CN5 11 CN5 4 CN5 5 CN5 14 CN5 12 CN5 6 CN5 13 CN5 7 BK BK BK BK BK BK BK BK BK BK BK BK BK BK CN6 X6 X4 7 X4 14 X4 6 X4 13 X4 5 X4 12 X4 11 X4 4 X4 3 X4 8 X4 10 X4 2 X4 9 X4 1 CN9 BL Y OPTIONAL ETHERNET CABLE E GND J2 J9B J9A J12 J4 J8 OPTIONAL USB WIFI EXTENSION CABLE LCD DISPLAY 24V J3 J11 COMMUNICATION CONTROL BOARD WIFI DONGLE SHIELDED CABLE DAMPER RELAY FLUE DAMPER 3 2 1 M Notes 1 All wi...

Page 75: ...75 Notes Installation Operation Manual ...

Page 76: ...Revision Notes Revision A PCP 3000042688 CN 500030426 initial release Revision B PCP 3000043071 CN 500030823 reflects an update to the high altitude verbiage 100331786_2000588637_Rev B 12 20 ...

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