2
Hazard definitions
The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or
to important information concerning the life of the product.
DANGER
WARNING
CAUTION
CAUTION
NOTICE
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious
injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury.
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not
avoided, may result in property damage.
NOTICE indicates special instructions on installation, operation, or maintenance that are important but not
related to personal injury or property damage.
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 ................................................. 10
Residential Garage Installation ........................................ 10
Vent and Air Piping .......................................................... 10
Prevent Combustion Air Contamination ........................... 10
Corrosive Contaminants and Sources ............................. 11
Using an Existing Vent System to Install a New Water
Heater ............................................................................... 11
Removing a Water Heater from Existing Common Vent . 12
2. PREPARE WATER HEATER
Remove Water Heater from Wood Pallet ........................ 13
Gas Conversions ......................................................... 13-15
Leveling the Water Heater .......................................... 15
3. GENERAL VENTING
Direct Venting Options ..................................................... 16
Install Vent and Combustion Air Piping ........................... 17
Requirements for Installation in Canada .......................... 18
Sizing ............................................................................... 18
Min./Max. Combustion Air & Vent Piping Lengths ............ 18
Materials ............................................................................ 19
Optional Room Air ............................................................ 20
PVC/CPVC ....................................................................... 21
Polypropylene ................................................................... 22
Stainless Steel Vent ......................................................... 23
4. SIDEWALL DIRECT VENTING
Vent/Air Termination - Sidewall ................................... 24-27
Determine Location ................................................ 24-26
Prepare Wall Penetrations .......................................... 26
Multiple Vent/Air Terminations ......................................... 27
Sidewall Termination - Optional Concentric Vent ....... 28-30
5. VERTICAL DIRECT VENTING
Vent/Air Termination - Vertical .................................... 31-32
Determine Location ..................................................... 29
Prepare Roof Penetrations ......................................... 31
Multiple Vent/Air Terminations .................................... 32
Vertical Termination - Optional Concentric Vent ... 33-34
Alternate Vertical Concentric Venting .................... 35-36
6. SYSTEM PIPING
System Water Piping Methods ......................................... 37
Flow Switch and Relief Valve Installation ........................ 37
Flow Switch Adjustment ................................................... 37
Scalding ............................................................................ 38
Water Chemistry............................................................... 38
Piping Components .......................................................... 38
7. GAS CONNECTIONS
Connecting Gas Supply Piping ........................................ 44
Natural Gas ...................................................................... 45
Pipe Sizing for Natural Gas ........................................ 45
Natural Gas Supply Pressure Requirements ............. 45
Propane Gas .................................................................... 45
Pipe Sizing for Propane Gas ...................................... 45
Propane Supply Pressure Requirements ................... 45
Check Inlet Gas Supply ................................................... 46
Gas Pressure ................................................................... 47
Gas Valve Replacement .................................................. 47
8. FIELD WIRING
Line Voltage Connections ................................................ 48
Low Voltage Connections ................................................ 48
Wiring of the Cascade ...................................................... 50
9. CONDENSATE DISPOSAL
Condensate Drain ............................................................ 52
10. STARTUP
............................................................. 53-58
11. OPERATING INFORMATION
General ............................................................................. 59
Cascade ........................................................................... 61
Sequence of Operation .................................................... 62
Armor Water Heater Control Module ............................... 63
Status Display Screens ............................................... 64-66
12. MAINTENANCE
Maintenance & Annual Startup ................................... 67-71
13. DIAGRAMS
Ladder Diagram ............................................................... 72
Wiring Diagram................................................................. 73
Revision Notes .................................................. Back Cover
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