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Installation & Operation

Manual

Models: 150 - 500

Starting Serial #H07H10046464

This manual must only be used by a
qualified heating installer / service
technician. Read all instructions,
including this manual and the
Armor Water Heater Service
Manual, before installing. Perform
steps in the order given. Failure to
comply could result in severe
personal injury, death, or substantial
property damage.



WARNING

Save this manual for future reference.

AW-I-O Rev I

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Содержание 150 - 500

Страница 1: ...ing installer service technician Read all instructions including this manual and the Armor Water Heater Service Manual before installing Perform steps in the order given Failure to comply could result...

Страница 2: ...stall Vent and Combustion Air Piping 15 Vent Piping Materials 15 Requirements for Installation in Canada 15 Air Intake Vent Connections 16 Air Inlet Pipe Materials 16 Min Max Combustion Air Vent Pipin...

Страница 3: ...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...

Страница 4: ...on the model 14 Water inlet NPT water connection that returns water from the system to the heat exchanger either 1 1 4 or 2 depending on the model 15 Gas connection pipe Threaded pipe connection eithe...

Страница 5: ...150 285 23 8 10 13 14 15 18 20 12 25 30 29 34 35 36 Left Side inside unit Models 150 285 1 3 4 2 27 7 28 26 21 19 16 17 5 Right Side inside unit Models 150 285 The Armor Water Heater How it works cont...

Страница 6: ...n Operation Manual 6 The Armor Water Heater How it works 15 18 Rear View Model 399 18 15 27 Rear View Model 500 Left Side inside unit Model 500 Left Side inside unit Model 399 Model 399 Model 500 27 4...

Страница 7: ...adjustments For high altitude models output ratings will be reduced by 2 for each 1 000 feet above sea level High altitude models have a different control module for altitude operation but the operati...

Страница 8: ...all the appliance outdoors or locate where the appliance will be exposed to freezing temperatures or to temperatures that exceed 100 F Failure to install the appliance indoors could result in severe p...

Страница 9: ...T SIDE 24 REAR 24 Figure 1 1 Closet Installation Minimum Required Clearances WARNING For closet installations CPVC material MUST BE used in a closet structure due to elevated temperatures Failure to f...

Страница 10: ...test edition of the National Fuel 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 o...

Страница 11: ...m are not in operation a Seal any unused openings in the common venting system b Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restrict...

Страница 12: ...size Models 150 399 Table 2A The 500 Model does not require an orifice installation for propane operation but it will require a valve adjustment Models 150 285 1 Remove the top and front access cover...

Страница 13: ...bag next to the water heater rating plate Attach the LP caution label in the conversion kit bag to the left side of the unit in the lower left corner 9 Replace the top and front access covers DANGER A...

Страница 14: ...Termination See page 24 for more details Figure 3 2 Sidewall Direct Venting Two Pipe Sidewall Termination See page 18 for more details Figure 3 3 Concentric Vertical Termination See page 26 for more...

Страница 15: ...ls primer and cement specified in this manual to make the vent connections Failure to follow this warning could result in fire personal injury or death WARNING NOTICE WARNING WARNING For closet and al...

Страница 16: ...UPPLIED WITH WATER HEATER MUST BE USED FOR VENT CONNECTION NOTE CPVC VENT PIPE AND VENT FITTINGS MUST BE USED IN CLOSET AND ALCOVE INSTALLATIONS VENT AIR Figure 3 6 Near Water Heater Venting Models 28...

Страница 17: ...ate air inlet and vent terminations to other areas Removing from existing vent Follow the instructions in Section 1 page 11 of this manual when removing a water heater from an existing vent system Ven...

Страница 18: ...lue products impinge on building surfaces or plants d Avoid possibility of accidental contact of flue products with people or pets e Do not locate the terminations where wind eddies could affect perfo...

Страница 19: ...er than 4 feet horizontally from any electric meter gas meter regulator relief valve or other equipment Never terminate above or below any of these within 4 feet horizontally 6 Locate terminations so...

Страница 20: ...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 manu...

Страница 21: ...quired combustion vent pipe materials are listed in Table 3A on page 15 of this manual Figure 4 6 Concentric Sidewall Termination Figure 4 5B Alternate Multiple Vent Terminations w Field Supplied Fitt...

Страница 22: ...ate Assembly 6 Install the Y concentric 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...

Страница 23: ...e made as shown to avoid recirculation of flue gases Dimension A in FIG 4 13 represents the distance between pipes or rain shields as touching or a 2 inch maximum separation Figure 4 13 Concentric Ven...

Страница 24: ...in a down turned 180 return pipe no further than 2 feet from the center of the vent pipe This placement avoids recirculation of flue products into the combustion air stream 4 The vent piping must term...

Страница 25: ...turned coupling as shown in FIG 5 1 The top of the coupling must be at least 1 foot above the air intake The air inlet pipe and vent pipe can be located in any desired position on the roof but must a...

Страница 26: ...secure the two 2 components together when field disassembly is desired for cleaning see FIG 4 11 page 22 When using the alternate screw assembly method drill a clearance hole in the rain cap and a pil...

Страница 27: ...ations 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 di...

Страница 28: ...3 turns RELIEF VALVE FLOW SWITCH PADDLE TEE WITH 1 FITTING ON TOP CLOSE NIPPLE TEE WITH 3 4 FITTING ON TOP 6 Install the assembled flow switch into the 1 inch fitting of the tee installed in Step 4 se...

Страница 29: ...5 to 25 grains per gallon and total dissolved solids not exceeding 350 ppm The required temperature rise and the standard circulating pump are sized based on the heating of potable water with a hardne...

Страница 30: ...TYPICAL COLD WATER SUPPLY 140 HOT WATER SUPPLY HIGH TEMPERATURE BUILDING RETURN DRAIN TEMPERATURE PRESSURE RELIEF VALVE TYPICAL FLOW SWITCH WATER HEATER CIRCULATOR STORAGE TANK WATER HEATER UNION TYPI...

Страница 31: ...YPICAL EXPANSION TANK THERMOMETER COLD WATER SUPPLY HOT WATER SUPPLY BUILDING RETURN DRAIN TEMPERATURE PRESSURE RELIEF VALVE TYPICAL FLOW SWITCH WATER HEATER CIRCULATOR STORAGE TANK WATER HEATER UNION...

Страница 32: ...ALVE TYPICAL EXPANSION TANK THERMOMETER COLD WATER SUPPLY HOT WATER SUPPLY BUILDING RETURN DRAIN TYPICAL TEMPERATURE PRESSURE RELIEF VALVE TYPICAL FLOW SWITCH WATER HEATER CIRCULATOR STORAGE TANK TYPI...

Страница 33: ...G RETURN DRAIN TEMPERATURE PRESSURE RELIEF VALVE WATER HEATER CIRCULATOR TYPICAL STORAGE TANK WATER HEATER TYPICAL UNION TYPICAL MIXING VALVE Figure 6 7 Double Heater Single Tank Model Number of Units...

Страница 34: ...ERATURE PRESSURE RELIEF VALVE TYPICAL FLOW SWITCH TYPICAL WATER HEATER CIRCULATOR TYPICAL STORAGE TANK TYPICAL WATER HEATER TYPICAL UNION TYPICAL MIXING VALVE Figure 6 8 Double Heater Double Tank Mode...

Страница 35: ...dels 285 399 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...

Страница 36: ...al gas supply pressure requirements 1 Pressure required at the gas valve inlet pressure port Maximum 14 inches w c with no flow lockup or with water heater on Minimum 4 inches w c with gas flowing ver...

Страница 37: ...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 Ob...

Страница 38: ...lter or measure 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...

Страница 39: ...comply with 1 National Electrical Code and any other national state provincial or local codes or regulations 2 In Canada CSA C22 1 Canadian Electrical Code Part 1 and any local codes Line voltage conn...

Страница 40: ...em to the terminals on the connection board FIG 8 3 Flow switch 1 A flow switch is used to guarantee flow through the water heater before allowing it to fire The flow switch must be installed in line...

Страница 41: ...Cascade system to work properly the tank sensor 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...

Страница 42: ...Installation Operation Manual 42 8 Field wiring Figure 8 3 Low Voltage Field Wiring Connections...

Страница 43: ...the authority having jurisdiction In the absence of other 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 U...

Страница 44: ...Attempting to alter or measure the gas valve outlet pressure could result in damage to the valve causing potential severe personal injury death or substantial property damage Figure 10 1 Condensate T...

Страница 45: ...ulation 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 g...

Страница 46: ...Installation Operation Manual 46 Figure 10 2 Operating Instructions Models 150 285 10 Start up...

Страница 47: ...Installation Operation Manual 47 10 Start up continued Figure 10 3 Operating Instructions Models 399 500...

Страница 48: ...e only The old setting will become active after the current heating cycle ends Table 10A Flue Products Chart 8 Once the combustion analysis is complete test the safety shutoff device by turning the ma...

Страница 49: ...n the Cascade designating the Leader control and the Member controls Set clock The SMART SYSTEM control has a built in clock that it uses for its night setback feature and for logging events This cloc...

Страница 50: ...tection features Outlet temperature flue temperature and temperature rise limiting The outlet temperature is monitored by the water heater outlet temperature sensor When the outlet temperature exceeds...

Страница 51: ...second water heater on the Cascade For a new startup this would be the first Member water heater The water heater will fire at its ignition speed and will then modulate its firing rate to maintain th...

Страница 52: ...equence will be as follows DAY SWITCHING ON SEQUENCE Day 1 L M1 M2 M3 M4 M5 M6 M7 Day 1 1 hour M1 M2 M3 M4 M5 M6 M7 L Day 1 2 hour M2 M3 M4 M5 M6 M7 L M1 Access modes User The user can adjust water ta...

Страница 53: ...is complete and the blocked drain switch and auto reset high limit are closed the control starts the 5 second trial for ignition by sending spark voltage to the spark electrode and opening the gas val...

Страница 54: ...Operation Manual 54 Armor water heater control module Figure 11 1 Control Panel Use the control panel FIG 11 1 to set temperatures operating conditions and monitor water heater operation 11 Operating...

Страница 55: ...t the displayed percentage Postpurge The call for heat has been satisfied and the unit runs the fan for an additional 10 seconds to clear the combustion chamber and vent system of residual flue produc...

Страница 56: ...M display to access Screen 4 4 FAN SPD RPM The control will display the actual fan motor RPM FLAME SIG uA The control will display the flame signal in dc microamps Press the Next arrow key on the SMAR...

Страница 57: ...MP On The Leader control has received a call for heat from a remote thermostat and has powered the water heater pump PMP Delay The tank call for heat has been satisfied and the water heater pump is ru...

Страница 58: ...osition Check wiring and connections 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 fir...

Страница 59: ...ed If they cannot be removed reinstall the air and vent lines per this manual and the Armor Water Heater Service Manual Inspect water heater interior 1 Remove the front access cover and inspect the in...

Страница 60: ...t 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...

Страница 61: ...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 dr...

Страница 62: ...CONTROL GROUND JUNCTION BOX INTEGRATED CONTROL 120 VAC LOW VOLTAGE HIGH VOLTAGE CAUTION HIGH VOLTAGE SPARK LEAD BLOWER TERMINAL STRIP TERMINAL STRIP CN3 9 CN3 7 CN3 8 CN3 6 CN3 4 CN3 3 CN3 1 CN3 10 DI...

Страница 63: ...EXTERNAL CONTROL AUTO RESET HI LIMIT CAUTION HIGH VOLTAGE SPARK LEAD CN5 3 CN5 4 CN5 2 24 VAC COM L N GND GND TR1 X8 120 VAC LOW VOLTAGE HIGH VOLTAGE X3 PC INTERFACE CN4 14 8 7 6 5 4 3 2 1 Notes 1 All...

Страница 64: ...s made to the ladder and wiring diagrams Revision G ECO C02545 reflects the addition of references to the safety shutoff testing and instructions sediment trap periodic cleaning of screens in vent ter...

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