Installation & Operation Manual
4
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). Air
and gas mix inside the blower and are pushed into the burner, where
they burn inside the combustion chamber.
4. Gas
valve
The gas valve senses the negative pressure created by the blower,
allowing gas to flow only if the gas valve is powered and combustion
air is flowing.
5. Venturi
The venturi controls air and gas flow into the burner.
6. Flue gas (limit rated)
This sensor monitors the flue gas exit temperature. The control
module will modulate and shut down the water heater if the flue gas
temperature gets too hot. This protects the flue pipe from
overheating.
7. Water heater outlet temperature sensor (housed with the
high limit sensor)
This sensor monitors water heater outlet water temperature
(system supply). If selected as the controlling sensor, the control
module adjusts water heater firing rate so the outlet temperature is
correct.
8. Water heater inlet temperature sensor
This sensor monitors return water temperature (system return). If
selected as the controlling sensor, the control module adjusts the
water heater firing rate so the inlet temperature is correct.
9. Flow
Switch
The flow switch is a safety device that ensures flow through the
heat exchanger during operation. This appliance is low mass
and should never be operated without flow. The flow switch makes
contact when flow is detected and allows the unit to operate. If flow
is discontinued during operation for any reason the flow switch will
break the control circuit and the unit will shut down.
10. Electronic LCD display
The electronic display consists of 4 buttons, a navigation dial and a
multiple line liquid crystal display.
11. Flue pipe adapter
Allows for the connection of the PVC vent pipe system to the
water
heater.
12. Burner (not shown)
Made with metal fiber and stainless steel construction, the burner
uses pre-mixed air and gas and provides a wide range of firing rates.
13. Water outlet
NPT water connection that supplies hot water to the tank.
14. Water inlet
NPT 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 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 connection points for the line
voltage power and the pump.
20. Water heater drain port
Location from which the heat exchanger can be drained.
21. Low voltage connection board
The connection board is used to connect external low voltage
devices.
22. Low voltage wiring connections (knockouts)
Conduit connection points for the low voltage connection
board.
23. Condensate drain connection
Connects the condensate drain line to a 1/2" PVC union.
24. Access cover - front (not shown)
Provides access to the gas train and the heat exchanger.
25. Ignition electrode
Provides direct spark for igniting the burner.
26. Flame inspection window
The quartz glass window provides a view of the burner surface
and
flame.
27. Gas shutoff valve
Manual valve used to isolate the gas valve from the gas supply.
28. High limit sensor (housed with the outlet temperature
sensor)
Device that monitors the outlet water temperature. If the
temperature exceeds its setting, the integrated control will
break the control circuit, shutting the water heater down.
29. Relief valve
Protects the heat exchanger from over pressure and temperature
conditions. The relief valve is set at 150 PSI.
30. Flame sensor
Used by the control module to detect the presence of burner
flame.
31. Line voltage wiring connections (knockouts)
Conduit connection points for the high voltage junction box.
32. Top panel
Removable panel to gain access to the internal components.
33. Power switch
Turns 120 VAC ON/OFF to the water heater.
34. Leveling legs
Used to allow the heat exchanger to be leveled. This is needed
for the proper draining of the condensate from the combustion
chamber.
35.
Air shroud (501 Model Only)
The air shroud directs air and gas flow into the burner.
36. Air pressure switch
The air pressure switch detects blocked inlet or outlet
conditions.
37. Pump relay (not shown)
The pump relay is used to control the circulation pump.
38.
Transformer
The transformer provides 24V power to the integrated control.
39. Gas shutoff switch
An electrical switch designed to cut power to the gas valve to
prevent releasing any gas.
40. Over-temp switch (Models 286 - 801) (located
underneath access cover)
An electrical switch designed to shut down water heater
operation in the event the outer back of the heat exchanger,
directly above the flue connection exceeds 604°F (318°C).
This is a one time switch and could warrant a heat exchanger
replacement. Check the integrity of the rear refractory at the
back of the upper coil if the switch opens.
