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Installation & Operation Manual

13

Diagrams

Figure 13-1 Ladder Diagram

BOX DEPICTS

OPTIONAL ITEMS

LADDER DIAGRAM

LBL20149 REV D

INTEGRATED

CONTROL

X2-1

GAS VALVE

GAS VALVE

RELAY

X5-7

X5-16

X5-8

X5-15

1

2

4

5

TR2

X1-7

FLAME ROD

SPARK

ROD

BLOWER

CONNECTION

BOARD

INLET

SENSOR

OPERATING

SENSOR

FLUE

SENSOR

INTEGRATED

CONTROL

RUN-TIME

CONTACTS

RIBBON CABLE

X7

TANK

SENSOR

0-10V

+

-

CASCADE

A

B

SHIELD

SHIELD

13

6

2

1

SILENCIN

G

SWI

TCH

AL

A

R

M

BEL

L

S4

BMS

CN6

X6

CN6

X6

CN5-2

X4-6

CN5-9

X4-13

CN5-1

X4-7

CN5-8

X4-14

CN6

X6

CN6

X6

HIGH LIMIT

SENSOR

FLUE

SENSOR

X5-4

X5-12

X5-5

X5-13

X5-14

X5-6

0-10V

+

-

RATE

OUT

IN

MODBUS

A

B

SHIELD

SHIELD

CN6

X6

CN8-1

X6-1

CN8-2

X6-2

CN8-3

X6-3

X4-1

X9-2

X4-2

X9-1

X4-3

X9-3

PC INTERFACE

S2

S1a

S1b

S3a

S3b

16

17

19

20

21

22

23

24

25

26

27

28

29

30

3

4

1

2

ALARM

CONTACTS

CN6

X6

M
O
D

B
U
S

CN6

X6

CN6

X6

X2-2

NOTES:
1. Where possible, switches are shown without utilities (gas, water or
electricity) connected to the unit. As such, actual switch states may
vary from those shown on diagrams depending upon whether utilities
are connected or a fault condition is present.
2. See wiring diagram for additional notes.

LOW VOLTAGE
120 VAC

HIGH VOLTAGE

CN5-5

X4-3

HIGH VOLTAGE SPARK LEAD

CAUTION

X5-2

X5-11

X5-10

AIR PRESSURE

SWITCH

BLOCKED

DRAIN SWITCH

O-TEMP HEX SW

AW 286-801 ONLY

CN5-12

CN5-11

X4-10

X4-11

LOW GAS

PRESSURE

SWITCH

HIGH GAS

PRESSURE

SWITCH

LOUVER

RELAY COIL

24VAC

LOUVER

PROVING SWITCH

CN5-4 X4-4

CN5-3

X4-5

LWCO

TANK

THERMOSTAT

11

CN5-10 X4-12

CN5-14 X4-8

12

CN7-3

CN7-2

CN7-4

CN7-1

24 VAC

9

6

7

14

13

13

8

7

6

5

10

9

CONNECTION BOARD

120 VAC

24 VAC

120VAC

ON / OFF

SWITCH

X1-6

F2

3.15A

F1

5A

INTEGRATED CONTROL

JUNCTION BOX

X1-1

BUILDING

RECIRC PUMP

RELAY

DHW PUMP

RELAY

24V DC

SUPPLY

F3

.8A

X5-1

X5-9

AW 801

ONLY

X4-3

X1-3

X1-2

TERMINAL STRIP
120V SUPPLY "N"

3.5A

3

BLOWER

2

1

BUILDING

RECIRC

PUMP

DHW

PUMP

BUILDING

RECIRC PUMP

RELAY

DHW PUMP

RELAY

NEUTRAL GROUND

TERMINAL STRIP

120V SUPPLY "L"

L

IN

BUILDING

RECIRC PUMP

CONTACTS

DHW PUMP
CONTACTS

L

OUT

FLOW

SWITCH

JUNCTION BOX

72

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Summary of Contents for Knight 151

Page 1: ...T 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 Installation a...

Page 2: ...5 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 Wa...

Page 3: ...r The possible damage to a flooded appliance can be extensive and present numerous safety hazards Any appliance that has been under water must be replaced When calling or writing about the water heater Please have the water heater model and serial number from the water heater rating plate Consider piping and installation when determining water heater location Any claims for damage or shortage in s...

Page 4: ... 16 SMART SYSTEM Control Module The SMART SYSTEM Control responds to internal and external signals and controls the blower gas valve and pumps to meet the demand 17 Manual air vent Designed to remove trapped air from the heat exchanger coils 18 Air intake adapter Allows for the connection of the PVC air intake pipe to the water heater 19 High voltage junction box The junction box contains the conn...

Page 5: ...ar View Model 286 10 2 1 25 17 30 23 34 29 8 7 28 19 37 36 20 Left Side inside unit Model 286 The Armor Water Heater How it works continued Left Side inside unit Models 151 200 Models 151 200 23 8 10 13 14 15 18 20 12 25 30 29 34 9 36 21 16 19 2 1 3 26 17 7 28 39 11 6 15 31 22 32 33 18 9 13 14 40 ...

Page 6: ... Left Side inside unit Models 601 801 6 11 27 33 22 31 32 15 40 18 29 9 13 14 Models 400 501 17 30 2 35 3 21 19 4 8 7 28 36 20 34 23 25 Rear View Models 400 501 Left Side inside unit Models 400 501 11 27 22 15 33 32 31 18 29 9 13 14 6 40 16 21 3 5 10 2 23 20 7 34 28 8 1 36 19 4 Models 601 801 ...

Page 7: ...iven in this manual remains the same as the standard models A high altitude label as shown in FIG A is also affixed to the unit 4 The manual reset high limit provided with the Armor is listed to UL353 The auto reset high limit is listed to ANSI Z21 87 7 Maximum allowed working pressure is located on the rating plate NOTICE Figure A High Altitude Label Location UNIT EQUIPPED FOR HIGH ALTITUDE 3 000...

Page 8: ...er clearance minimums Clearances for service access 1 See FIG s 1 1 and 1 2 on page 9 for recommended service clearances If you do not provide the minimum clearances shown it may not be possible to service the water heater without removing it from the space Closet and alcove installations This appliance requires a special venting system If using PVC the vent connection to the appliance must be mad...

Page 9: ...ING AIR OPENING 0 RIGHT 12 LEFT 14 REAR 6 FRONT AREA OF EACH OPENING 645 SQ MM PER 1000 BTU PER HOUR INPUT WITH A MINIMUM O F64516 SQ MM RECOMMENDED SERVICE CLEARANCES FRONT 30 762 mm TOP 24 610 mm LEFT SIDE 24 610 mm REAR 24 610 mm Figure 1 1 Closet Installation Minimum Required Clearances WARNING WARNING For closet installations CPVC polypropylene or stainless steel vent material MUST BE used in...

Page 10: ...uel Gas Code ANSI Z223 1 and or CAN CGA B149 Installation Code Appliances located 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...

Page 11: ...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 3E and 3G for CAT IV positive pressure venting with flue producing condensate Supports Non combustible sup...

Page 12: ...stem 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 thermostat...

Page 13: ...ize Models 151 400 Table 2A The 501 801 Models do not require an orifice installation for propane operation but they will require a valve adjustment Models 151 286 1 Remove the top and front access covers from the unit no tools required for removal 2 Remove the three screws securing the gas valve to the venturi FIG 2 2 3 Locate the propane orifice disk from the conversion kit bag Verify that the s...

Page 14: ... left side of the unit in the lower left corner 9 Replace the top and front access covers DANGER Armor 400 Inspect the O ring when the blower is disassembled The O ring must be in good condition and must be installed Failure to comply will cause a gas leak resulting in severe personal injury or death Figure 2 4 Gas Valve Adjustment Model 501 Model 501 1 Remove the top access cover from the unit no...

Page 15: ...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 4 UseacombustionanalyzertoverifyCO2 iswithintherange of 9 6 10 5 If not adjust the screw counterclockwise incrementally to raise CO2 and clockwise to lower CO2 FIG 2 5 5 After adjustment is complete attach the propane conversion label in the conversion kit bag next to the water heater rating plate Attac...

Page 16: ...page 31 for more details Direct venting options Sidewall Vent Figure 3 2 PVC CPVC Concentric Sidewall Termination Models 151 601 Only See page 28 for more details Figure 3 4 PVC CPVC Concentric Vertical Termination Models 151 601 Only See page 33 for more details Figure 3 5 Vertical Vent Sidewall Air See page 20 for more details Direct venting options Vertical Vent ...

Page 17: ...unit for final connection 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 s 3 8 thru 3 11 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 Build...

Page 18: ...d to the ULC S636 standard for use in Canada Model Kit Number Equivalent Vent Length 151 200 CVK3003 3 feet 286 CVK3007 3 feet 400 CVK3007 5 feet 501 601 CVK3007 30 feet Table 3B Concentric Vent Kit Equivalent Vent Lengths Minimum Maximum allowable combustion air and vent piping lengths are as follows CombustionAir 12 equivalent feet minimum 100 equivalent feet maximum Vent 12 equivalent feet mini...

Page 19: ... Listed silicone sealant such as those manufactured by Dow Corning or General Electric b Do not install seams of vent pipe on the bottom of horizontal runs c Secure all joints with a minimum of three 3 sheet metal screws or pop rivets Apply Aluminum Foil Duct Tape or silicone sealant to all screws or rivets installed in the vent pipe d Ensure that the air inlet pipes are properly supported The PVC...

Page 20: ...ovided with properly sized openings to assure adequate combustion air Refer to the instructions provided with the room air kit There will be a noticeable increase in the noise level during normal operation from the inlet air opening Using the room air kit makes the unit vulnerable to combustion air contamination from within the building Please review Section 1 Prevent Combustion Air Contamination ...

Page 21: ...Vent Pipe and Fittings Item Material Standard Vent pipe PVC Schedule 40 80 ANSI ASTM D1785 PVC DWV ANSI ASTM D2665 CPVC Schedule 40 80 ANSI ASTM F441 Vent fittings PVC Schedule 40 ANSI ASTM D2466 PVC Schedule 80 ANSI ASTM D2467 CPVC Schedule 80 ANSI ASTM F439 Pipe Cement Primer PVC ANSI ASTM D2564 CPVC ANSI ASTM F493 NOTICE DO NOT USE CELLULAR FOAM CORE PIPE NOTE In Canada CPVC and PVC vent pipe f...

Page 22: ...es 3E and 3F 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 For Canadian installation polypropylene vent must be listed as a ULC S636 approved system NOTICE Installation of a polypropylene vent system should adhe...

Page 23: ... 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 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 ULC S636 approved system for Canada NOTICE Installation of a...

Page 24: ...use recirculation such as inside building corners near adjacent buildings or surfaces window wells stairwells alcoves courtyards or other recessed areas WARNING Sidewall vent and air inlet terminations must terminate in the same pressure 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 fini...

Page 25: ...uipment Never terminate above or below any of these within 4 feet horizontally 6 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 12 MIN 12 MIN 12 MIN Figure 4 3A Clearance to Gravity Air Inlets 12 305 MM MIN 15 381 MM MAX 12 305 MM MIN FROM BOILER VENT PIPE CONNECTION TO BOILER INTA...

Page 26: ...and wall Seal around the plate to the wall assuring no air gaps 6 Assemble the vent cap to the vent plate see FIG 4 5A 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 man...

Page 27: ...r 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 installations provide clearances required by CSA B149 1 Installation Code 3 The air inlet o...

Page 28: ... required combustion vent pipe materials are listed in Table 3D on page 19 of this manual Figure 4 7 Concentric Sidewall Termination Sidewall termination installation 1 Determine the best location for the termination kit see FIG 4 7 2 Reference the Determine Location Section on page 22 of this manual for general termination considerations 4 DIA SDR 26 PIPE 3 DIA SDR 26 PIPE RAIN CAP Y CONCENTRIC F...

Page 29: ...c fitting and pipe assembly through the structure s hole Do not allow insulation or other materials to accumulate inside the pipe assembly when installing through the hole 7 Install the rain cap and small diameter pipe assembly into the Y concentric fitting and large pipe assembly Ensure small diameter pipe is bottomed and cemented in the Y concentric fitting for CVK3003 installations and fastened...

Page 30: ...t that vent terminations be made as shown to avoid recirculation of flue gases VENT COMBUSTION AIR 12 MINIMUM Figure 4 14 Concentric Vent and Combustion Air Termination Figure 4 13 Concentric Vent Sidewall Attachment 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 concent...

Page 31: ...above 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 requi...

Page 32: ...pe 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 33: ... disassembly is desired for cleaning see FIG 4 12 page 29 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 injury or death 2 C...

Page 34: ...the concentric vent termination connections Multiventing vertical terminations When two 2 or more direct vent appliances are vented near each other each 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 tha...

Page 35: ...section to the 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 exis...

Page 36: ...wable pipe lengths Use only approved venting materials listed in the General Venting Section of this manual Figure 5 10 Existing Vent as a Chase FLUE EXHAUST FLUE OUTLET EXISTING CAP SEAL SEAL AIR INLET 5 Vertical direct venting For concept illustration only Individual installations may vary due to job site specific equipment ...

Page 37: ...ITCH PADDLE TEE WITH 1 FITTING ON TOP CLOSE NIPPLE TEE WITH 3 4 FITTING ON TOP For Example If using a 1 1 4 inch pipe size Models AWN151 AWN200 select paddle 1 6 Install the assembled flow switch into the 1 inch fitting of the tee installed in Step 4 see FIG 6 1 Flow switch adjustment Refer to Table 6A for the proper setting of the sensitivity screw For reference the position of the screw prior to...

Page 38: ...ater chemistry NOTICE The required temperature rise and the standard circulating pump are sized based on the heating of potable water with a hardness of 5 to 25 grains per gallon and a total dissolved solids not exceeding 350 ppm Consult the manufacturer when heating potable water exceeding these specifications Heating of high hardness and or high total dissolved solids water may require a larger ...

Page 39: ... 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 FLOW CHECK VALVE TYPICAL EXPANSION TANK THERMOMETER COLD WATER SUPPLY HOT WATER SUPPLY BUILDING RETURN DRAIN TEMPERATURE PRESSURE RELIEF VALVE TYPICAL FLOW SWITCH WATER H...

Page 40: ...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 Figure 6 5 Single Heater Single Tank 2 Temperature FLOW CHECK VALVE TYPICAL BALL VALVE TYPICAL EXPANSION TANK THERMOMETER TYPICAL COLD WATER SUPPLY 140 HOT WATER SUPPLY HIGH TEMPERATURE BUILDING RETURN DRAIN TEMPERATURE PRE...

Page 41: ...D Figure 6 6 Single Heater Double Tank NOTICE Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing required by local codes The piping will not support the weight of the water heater circulator pump Do not attempt to support the weight of the water heater circulator pump with the piping or its accessories Refe...

Page 42: ...2 1 2 2 1 2 3 3 4 286 2 2 1 2 2 1 2 3 3 4 4 400 2 1 2 3 3 1 2 4 4 5 5 501 3 3 1 2 4 5 5 5 6 601 3 3 1 2 4 5 5 5 6 701 3 4 5 5 6 6 6 801 3 4 5 6 6 6 6 NOTICE Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing required by local codes The piping will not support the weight of the water heater circulator pump D...

Page 43: ...g concept only the installer is responsible for all equipment and detailing required by local codes Model Number of Units 2 3 4 5 6 7 8 Required Pipe Sizes in NPT 151 1 1 2 2 2 2 2 1 2 3 3 200 1 1 2 2 2 1 2 2 1 2 3 3 4 286 2 2 1 2 2 1 2 3 3 4 4 400 2 1 2 3 3 1 2 4 4 5 5 501 3 3 1 2 4 5 5 5 6 601 3 3 1 2 4 5 5 5 6 701 3 4 5 5 6 6 6 801 3 4 5 6 6 6 6 The piping will not support the weight of the wat...

Page 44: ...eater 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 excess of 1 2 PSIG 3 5 kPa b The appliance must be isolated from the gas supply piping system by closing a manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less th...

Page 45: ...ches 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 requirements 1 Adjust propane ...

Page 46: ...in FIG s 7 6 thru 7 9 on page 47 4 Slowly turn on the gas supply at the field installed manual gas valve WARNING 5 Turn the power switch to the ON position 6 Adjust the temperature set point on the control panel of the SMART SYSTEM control module to call for heat 7 Observe the gas supply pressure as the burner fires at 100 of rated input Percent of burner input will be displayed on the control pan...

Page 47: ...OOSEN THE SET SCREW ONE 1 FULL TURN AND PLACE THE MANOMETER TUBING OVER THE PRESSURE TAP Figure 7 8 Inlet Gas Supply Check Model 501 DO NOT adjust 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 val...

Page 48: ... recommended as required by the code see FIG 8 1 3 The DHW water heater pump is shipped loose on all Armor models Wire the water heater pump as shown in FIG 8 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 8 1 5 Dry contacts are sized for 1 hp 120V 2 hp 240V or 15A 120V 25A 240V DOMESTIC HOT WAT...

Page 49: ...ystem to monitor the actual rate of the water heater ModBus When the optional ModBus interface module is installed the RS 485 ModBus 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 interface module Louver relay If louvers need to...

Page 50: ...sor must be installed The tank sensor should be wired to the low voltage connection board at the terminals marked for the tank sensor see FIG 8 3 The Leader control will use the water temperature at the tank sensor to control the operation of the Cascade Communication between the Leader water heater and the Member water heaters is accomplished by using shielded 2 wire twisted pair communication ca...

Page 51: ...tinued 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 8 3 Low Voltage Field Wiring Connections ...

Page 52: ...her authority PVC and CPVC pipe must comply with ASTM D1785 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 8 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...

Page 53: ...age to the valve causing potential severe personal injury death or substantial property damage PVC TEE ASSEMBLY FACTORY SUPPLIED TO FLOOR DRAIN 2 PVC CAP WITH BLOCKED DRAIN SWITCH RETAINING SCREW CONDENSATE FROM HEAT EXCHANGER Figure 10 1 Condensate Trap WARNING WARNING Propane water heaters only Your propane supplier mixes an odorant with the propane to make its presence detectable In some instan...

Page 54: ...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 around the water ...

Page 55: ...part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water OPERATING INSTRUCTIONS 1 STOP Read the safety information above on this label 2 Set the thermostat to lowest setting 3 Turn off all electric power to the appliance 4 This appliance is equipped with an ignitio...

Page 56: ...Installation Operation Manual 56 10 Start up Figure 10 3 Operating Instructions Models 400 801 ...

Page 57: ...alarm Open the manual shutoff valve and reset the control 9 Turn the main power off to the water heater and replace the flue temperature sensor into the flue pipe connection 10 Place the water heater back into normal operation You must replace the flue gas temperature sensor to prevent flue gas spillage into the room Failure to comply could result in severe personal injury death or substantial pro...

Page 58: ...key Please note that the brackets denote screen status NOTICE Please note that the brackets denote screen status NOTICE When installed in a Cascade system the individual controls must be programmed for cascade operation This is accomplished by accessing the control parameters Press the MENU key for at least five 5 seconds Input the Installer code as described in the Armor Service Manual Once the c...

Page 59: ...emperature 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 temperature exceeds 215 F the control will reduce t...

Page 60: ...et temperature can be set between 60 F and 190 F 11 Operating information 1 Turn ON the main power to the boiler by placing the ON OFF switch in the ON position 2 From the Status Screen press the NAVIGATION dial to access the Set Points Screen 3 Press the LEFT SELECT LIMITS key 4 Select the manual reset high limit MRHL by rotating the NAVIGATION dial counterclockwise then press the NAVIGATION dial...

Page 61: ...d temperature set point can be programmed into the control See page 57 of this manual to program the set point If the water temperature at the tank is less than the set point differential then the control will initiate a call for heat on the Cascade see the Armor Water Heater Service Manual for an explanation of the differential The Leader will energize the lead water heater on the Cascade For a n...

Page 62: ...ge cycle and try to light the burner again On the 501 and larger models the control will lock out if this second attempt also fails On the 400 and smaller models the control will perform a total of 4 attempts before locking out 6 If flame is detected it holds the firing rate steady for a few seconds to let the flame stabilize then it begins to modulate the firing rate based on a set point or some ...

Page 63: ...ol Panel Use the control panel FIG 11 1 to set temperatures operating conditions and monitor water heater operation 11 Operating information continued The information on the bottom of the display shows the functions of the two SELECT keys on either corner and the NAVIGATION dial in the center MENU Left SELECT Key SETPOINTS NAVIGATION Dial Pressing Down SHDN Right SELECT Key ...

Page 64: ...e unit has fired and is running at the displayed percentage POSTPURGE The call for heat has been satisfied and the unit runs the fan for an additional postpurge period to clear the combustion chamber and vent system of residual flue products SHUTDOWN The unit has been placed in the OFF position The controlled temperature has exceeded its set point and its offset BLOCKED The unit has detected a con...

Page 65: ... DHW PUMP The status of the DHW pump output BMS VOLTAGE The voltage received from a BMS system BLR PUMP OUTPUT The speed signal sent to a variable speed water heater pump in percent RATE OUTPUT A 0 10V signal indicating the firing rate of the water heater DHW RUN HOURS The total hours of operation in the DHW Mode DHW CYCLES The total burner cycles in the DHW Mode LAST 10 FAULTS NO The last 10 lock...

Page 66: ...cated by the cursor Pressing the NAVIGATION dial will display the Set Points Screen Turning the NAVIGATION dial will move the cursor up or down Turning the NAVIGATION dial will increase or decrease the current setting F RIGHT SELECT key function SHDN Press the RIGHT SELECT key to turn the water heater OFF ON Press the RIGHT SELECT key to turn the water heater ON NO Press the RIGHT SELECT key to ca...

Page 67: ...ctions Perform start up checkout and performance verification per Section 10 of this 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 compresse...

Page 68: ... manual and the Armor Water Heater Service Manual Inspect water heater interior 1 Remove the front access cover and inspect the interior of the water heater 2 Vacuum any sediment from inside the water heater and components Remove any obstructions Clean condensate trap 1 Inspect the condensate drain line condensate PVC fittings and condensate trap 2 Remove the PVC cap retaining screw from the PVC c...

Page 69: ... 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 precautions must be ...

Page 70: ...e extension s refractory cover and detailed instructions see Table 12B Heat Exchanger Cleaning Kits 1 Shut down water heater Follow the To Turn Off Gas to Appliance instructions for the water heater in Section 10 Startup Do not drain the water heater unless it will be exposed to freezing temperatures If using freeze prevention fluid in system do not drain 2 Allow time for the water heater to cool ...

Page 71: ...5 Rear Refractory Cover MSC20083 Nylon 4 Wheel Brush MSC20084 3mm Allen Wrench MSC20086 1 4 x 24 Drill Extension 501 801 KIT30064 CTN20005 Rear Refractory Cover MSC20083 Nylon 4 Wheel Brush MSC20085 1 4 x 12 Drill Extension MSC20086 1 4 x 24 Drill Extension Do NOT use a metal brush Only use the kit provided brush or an equivalent replacement nylon brush CAUTION 12 Maintenance continued Rope gasket...

Page 72: ...r electricity connected to the unit As such actual switch states may vary from those shown on diagrams depending upon whether utilities are connected or a fault condition is present 2 See wiring diagram for additional notes LOW VOLTAGE 120 VAC HIGH VOLTAGE CN5 5 X4 3 HIGH VOLTAGE SPARK LEAD CAUTION X5 2 X5 11 X5 10 AIR PRESSURE SWITCH BLOCKED DRAIN SWITCH O TEMP HEX SW AW 286 801 ONLY CN5 12 CN5 1...

Page 73: ...g same wire gauge AWG and rated for a minimum of 105 C Exceptions Replacement high vo ltage spark lead and ribbon cables must be purchased from the factory Use of a non approved spark lead or ribbon cables can lead to operational problems which could result in non repairable damage to the integrated controller or other components 3 Actual connector block locations may vary from those shown on diag...

Page 74: ...Notes Installation Operation Manual 74 ...

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

Page 76: ... pipe clearances from 1 to 1 4 ECR R04077 and changes made to Table 3A on page 19 Revision D ECO C08817 reflects the addition of the O temp switch additional information added to the humidity warning on page 8 and changes made to FIG 8 1 on page 48 Revision E ECO C09197 reflects updates made to the SMART SYSTEM control ECR R04523 Revision F ECO C09803 reflects the addition of the new Polypropylene...

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