Lochinvar ARMOR 151 User Manual

Page 1

 WARNING: If the information in this

manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

-- 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

AWII-I-O Rev C

Installation & Operation Manual

Models: 151 - 801

• 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 and service must be performed by a qualified installer, service agency, or the gas supplier.

 WARNING

Save this manual for future reference.

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.

Page 2

Contents

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 ................................................ 16-17

Install Vent and Combustion Air Piping ........................... 18

PVC/CPVC Vent Piping Materials ............................... 18

Requirements for Installation in Canada .......................... 18

Installing Vent or Air Piping .............................................. 18

PVC/CPVC Air Intake/Vent Connections ......................... 19

Air Inlet Pipe Materials ..................................................... 20

Stainless Steel Vent ......................................................... 20

Stainless Steel Air Intake/Vent Connections .................... 21

Min./Max. Combustion Air & Vent Piping Lengths ........... 22

Vent and Air Piping .......................................................... 22

Optional Room Air ............................................................ 23

4. SIDEWALL DIRECT VENTING

Vent/Air Termination - Sidewall ................................... 24-27

Determine Location ................................................ 24-26

Prepare Wall Penetrations ..................................... 26-27

Termination and Fittings ............................................. 27

Multiple Vent/Air Terminations .................................... 27

Sidewall Termination - Optional Concentric Vent ....... 28-30

5. VERTICAL DIRECT VENTING

Vent/Air Termination - Vertical .................................... 31-32

Determine Location ......................................................... 31

Prepare Roof Penetrations ......................................... 32

Termination and Fittings ............................................. 32

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

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.

Page 3

Please read before proceeding

Installation & Operation Manual

 WARNING

NOTICE

Installer – Read all instructions, including this manual and the Armor Water Heater Service Manual, before installing. Perform steps in the order given.

Have this water heater serviced/inspected by a qualified service technician, at least annually.

Failure to comply with the above could result in severe personal injury, death or substantial property damage.

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 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.

When servicing the water heater –

• To avoid electric shock, disconnect electrical supply before performing maintenance.

• To avoid severe burns, allow the water heater to cool before performing maintenance.

Water heater operation –

• Do not block flow of combustion or ventilation air to the water heater.

• Should overheating occur or gas supply fail to shut off, do not turn off or disconnect electrical supply to circulator. Instead, shut off the gas supply at a location external to the appliance.

• Do not use this water heater if any part has been under water. 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.

 WARNING

Failure to adhere to the guidelines on this page can result in severe personal injury, death, or substantial property damage.

If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

-- 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 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 and service must be performed by a qualified installer, service agency, or the gas supplier.

Page 4

Installation & Operation Manual

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.

Page 5

Installation & Operation Manual

The Armor Water Heater - How it works... (continued)

Models 151 - 200

Rear View - Models 151 - 200

2 1

Left Side (inside unit) - Models 151 - 200

2 1

Rear View - Model 286

Left Side (inside unit) - Model 286

Page 6

Installation & Operation Manual

The Armor Water Heater - How it works...

Models 400 - 501

Rear View - Models 400 - 501

Left Side (inside unit) - Models 400 - 501

Models 601 - 801

Rear View - Models 601 - 801

Left Side (inside unit) - Models 601 - 801

Page 7

Ratings

Installation & Operation Manual

Model Number

Note: Change “N” to “L” for L.P. gas

models.

AWN151PM 30,000 - 150,000 1.3 1-1/4" 1/2" 3"/3"

AWN200PM 40,000 - 199,999 1.7 1-1/4" 1/2" 3"/3"

AWN286PM 57,000 - 285,000 2.4 2" 3/4" 4"/4" AWN400PM 80,000 - 399,999 3.4 2" 1" 4"/4" AWN501PM 100,000 - 500,000 4.2 2" 1" 4"/4" AWN601PM 120,000 - 600,000 4.2 2" 1" 4"/4" AWN701PM 140,000 - 700,000 5.0 2" 1" 6"/4" AWN801PM 160,000 - 800,000 5.7 2" 1" 6"/4"

NOTICE

Maximum allowed working pressure is located on the rating plate.

Input Modulation Btu/hr

CSA

Water Content

Gallons

(Note 2, 3) (Note 1)

Water

Connections

Gas

Connections

Notes:

1. Armor water heaters require special gas venting. Use only the vent materials and methods specified in the Armor Installation and Operation Manual.

2. Standard Armor water heaters are equipped to operate from sea level to 4,500 feet only with no adjustments. The water heater will de-rate by 4% for each 1,000 feet above sea level up to 4,500 feet.

Vent/Air Size

UNIT EQUIPPED FOR

HIGH ALTITUDE

3,000 FT TO 12,000 FT

3. High altitude Armor water heaters are equipped to operate from 3,000 to 12,000 feet only with no field adjustments. The water heater will de-rate by 2% for each 1,000 feet above 3,000 feet. High altitude models are manufactured with a different control module for altitude operation, but the operation given 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 and ANSI Z21.87.

Figure A High Altitude Label Location

Page 8

1 Determine water heater location

Installation & Operation Manual

Installation must comply with:

• Local, state, provincial, and national codes, laws, regulations, and ordinances.

• National Fuel Gas Code, ANSI Z223.1 – latest edition.

• National Electrical Code.

• For Canada only: B149.1 Installation Code, CSA C22.1 Canadian Electrical Code Part 1 and any local codes.

NOTICE

The Armor water heater gas manifold and controls met safe lighting and other performance under tests specified in ANSI Z21.10.3 – latest edition.

Before locating the water heater, check:

1. Check for nearby connection to:

• Water piping

• Venting connections

• Gas supply piping

• Electrical power

2. Locate the appliance so that if water connections should

leak, water damage will not occur. When such locations cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the appliance. The pan must not restrict combustion air flow. Under no circumstances is the manufacturer to be held responsible for water damage in connection with this appliance, or any of its components.

3. Check area around the water heater. Remove any

combustible materials, gasoline and other flammable liquids.

 WARNING

4. The Armor water heater must be installed so that gas control

system components are protected from dripping or spraying water or rain during operation or service.

Failure to keep water heater area clear and free of combustible materials, gasoline, and other flammable liquids and vapors can result in severe personal injury, death, or substantial property damage.

 WARNING

This appliance requires a special venting system. If using PVC the vent connection to the appliance must be made with the starter CPVC pipe section provided with the appliance. The field provided vent fittings must be cemented to the CPVC pipe section. Use only the vent materials, 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.

Closet and alcove installations

A closet is any room the water heater is installed in which is less than 86 cubic feet for AWN151 models, 106 cubic feet for AWN200 models, 120 cubic feet for AWN286 models, 165 cubic feet for AWN400 models, 191 cubic feet for AWN501 models, 223 cubic feet for AWN601 models, 247 cubic feet for AWN701 models and 278 cubic feet for AWN801 models.

An alcove is any room which meets the criteria for a closet with the exception that it does not have a door.

Example: Room dimensions = 4 feet long, 5 feet wide, and 9 foot ceiling = 4 x 5 x 9 = 180 cubic feet.

 WARNING

For closet and alcove installations as shown in FIG.’s 1-1 and 1-2, CPVC vent material must be used inside the structure. The ventilating air openings shown in FIG.’s 1-1 and 1-2 are required for this arrangement. Failure to follow this warning could result in fire, personal injury, or death.

Provide clearances:

Clearances from combustible materials

1. Hot water pipes—at least 1/4" from combustible materials.

2. Vent pipe – at least 1" from combustible materials.

3. See FIG.’s 1-1 and 1-2 on page 9 for other clearance minimums.

5. If a new water heater will replace an existing water heater, check for and correct system problems, such as:

• System leaks causing oxygen corrosion or heat exchanger cracks from hard water deposits.

 WARNING

This appliance is certified as an indoor appliance. Do not install 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 personal injury, death, or substantial property damage.

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.

Page 9

Installation & Operation Manual

1 Determine water heater location (continued)

Figure 1-1 Closet Installation - Minimum Required Clearances

1/4” MINIMUM CLEARANCE

ROUND HOT WATER PIPES

1” MINIMUM CLEARANCE

ROUND VENT PIPES

12” LEFT

14” REAR

CLOSET INSTALLATION

6” FRONT

 WARNING

For closet installations, CPVC or stainless steel vent material MUST BE used in a closet structure due to elevated temperatures. Failure to

13" TOP

* AREA OF EACH OPENING: 645 SQ. MM PER 1000 BTU PER HOUR INPUT WITH A MINIMUM O F64516 SQ. MM

follow this warning could result in fire, personal injury, or death.

VENTILATING AIR OPENING

CLOSED DOOR

VENTILATING AIR OPENING

0” RIGHT

Figure 1-2 Alcove Installation - Minimum Required Clearances

For alcove installations, CPVC or stainless steel vent material MUST BE used in an alcove structure due to elevated temperatures. Failure to follow this warning could result in

1/4” MINIMUM CLEARANCE

ROUND HOT WATER PIPES

1” MINIMUM CLEARANCE

ROUND VENT PIPES

ALCOVE INSTALLATION

 WARNING

12"

TOP

fire, personal injury, or death.

OPEN

FRONT

12”

LEFT

14”

REAR

18"

FRONT

RIGHT

Page 10

1 Determine water heater location

Installation & Operation Manual

Provide air openings to room:

Armor water heater alone in equipment room

1. No air ventilation openings into the equipment room are needed when clearances around the Armor water heater are at least equal to the SERVICE clearances shown in FIG.’s 1-1 and 1-2. For spaces that do NOT supply this clearance, provide two openings as shown in FIG. 1-1. Each opening must provide one square inch free area per 1,000 Btu/hr of water heater input.

Armor water heater in same space with other gas or oil-fired appliances

1. Follow the National Fuel Gas Code (U.S.) or CSA B149.1 (Canada) to size/verify size of the combustion/ventilation air openings into the space.

 WARNING

2. Size openings only on the basis of the other appliances in the space. No additional air opening free area is needed for the Armor water heater because it takes its combustion air from outside (direct vent installation).

The space must be provided with combustion/ ventilation air openings correctly sized for all other appliances located in the same space as the Armor water heater.

Do not install the water heater in an attic.

Failure to comply with the above warnings could result in severe personal injury, death, or substantial property damage.

Residential garage installation

Precautions

Take the following precautions when installing the appliance in a residential garage. If the appliance is located in a residential garage, it should be installed in compliance with the latest 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 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 heater requires a special vent system, designed for pressurized venting.

The water heater is to be used for either direct vent installation or for installation using indoor combustion air. When room air is considered, see the General Venting Section. Note prevention of combustion air contamination below when considering vent/ air termination.

Vent and air must terminate near one another and may be vented vertically through the roof or out a side wall, unless otherwise specified. You may use any of the vent/air piping methods covered in this manual. Do not attempt to install the Armor water heater using any other means.

Flooring and foundation

Flooring

The Armor water heater is approved for installation on combustible flooring, but must never be installed on carpeting.

 WARNING

If flooding is possible, elevate the water heater sufficiently to prevent water from reaching the water heater.

Do not install the water heater on carpeting even if foundation is used. Fire can result, causing severe personal injury, death, or substantial property damage.

Be sure to locate the water heater such that the vent and air piping can be routed through the building and properly terminated. The vent/air piping lengths, routing and termination method must all comply with the methods and limits given in this manual.

Prevent combustion air contamination

Install air inlet piping for the Armor water heater as described in this manual. Do not terminate vent/air in locations that can allow contamination of combustion air. Refer to Table 1A, page 11 for products and areas which may cause contaminated combustion air.

 WARNING

You must pipe combustion air to the water heater air intake. Ensure that the combustion air will not contain any of the contaminants in Table 1A, page 11. Contaminated combustion air will damage the water heater, resulting in possible severe personal injury, death or substantial property damage. Do not pipe combustion air near a swimming pool, for example. Also avoid areas subject to exhaust fumes from laundry facilities. These areas will always contain contaminants.

Page 11

Installation & Operation Manual

1 Determine water heater location (continued)

When using an existing vent system to install a new water heater:

 WARNING

Check the following venting components before installing:

• Material - For materials listed for use with this appliance, see Section 3 - General Venting, Table 3A. For stainless steel venting, an adapter of the same manufacturer (Table 3B) must be used at the flue collar connection.

• Size - To ensure proper pipe size is in place, see Table 3D. Check to see that this size is used throughout the vent system.

• Manufacturer - For a stainless steel application, you must use only the listed manufacturers and their type product listed in Table 3A for CAT IV positive pressure venting with flue producing condensate.

• Supports - Non-combustible supports must be in place allowing a minimum 1/4" rise per foot. The supports should adequately prevent sagging and vertical slippage, by distributing the vent system weight. For additional information, consult the vent manufacturer’s instructions for installation.

Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

Table 1A Corrosive Contaminants and Sources

Products to avoid:

Spray cans containing chloro/fluorocarbons

Permanent wave solutions

Chlorinated waxes/cleaners

Chlorine-based swimming pool chemicals

Calcium chloride used for thawing

Sodium chloride used for water softening

Refrigerant leaks

Paint or varnish removers

Hydrochloric acid/muriatic acid

Cements and glues

Antistatic fabric softeners used in clothes dryers

Chlorine-type bleaches, detergents, and cleaning solvents found in household laundry rooms

Adhesives used to fasten building products and other similar products

Areas likely to have contaminants

• Terminations - Carefully review Sections 3 through 5 to ensure requirements for the location of the vent and air terminations are met and orientation of these fit the appropriate image from the Horizontal or Vertical options listed in the General Venting Section. For stainless steel vent, only use terminations listed in Table 3B for the manufacturer of the installed vent.

• Seal - With prior requirements met, the system should be tested to the procedure listed in parts (c) through (f) of the Removal of an Existing Water Heater Section on page 12.

With stainless steel vent, seal and connect all pipe and components as specified by the vent manufacturer used; with PVC/CPVC vent, see the Installing Vent or Air Piping Section on page 18.

 WARNING

If any of these conditions are not met, the existing system must be updated or replaced for that concern. Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

Dry cleaning/laundry areas and establishments

Swimming pools

Metal fabrication plants

Beauty shops

Refrigeration repair shops

Photo processing plants

Auto body shops

Plastic manufacturing plants

Furniture refinishing areas and establishments

New building construction

Remodeling areas

Garages with workshops

Page 12

Installation & Operation Manual

1 Determine water heater location

When removing a water heater from existing common vent system:

 DANGER

 WARNING

At the time of removal of an existing water heater, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.

a. Seal any unused openings in the common venting system.

Do not install the Armor water heater into a common vent with any other appliance. This will cause flue gas spillage or appliance malfunction, resulting in possible severe personal injury, death, or substantial property damage.

Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

g. Any improper operation of the common venting system

should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code, ANSI Z223.1/NFPA and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code.

b. Visually inspect the venting system for proper size and

horizontal pitch and determine there is no blockage or restriction, leakage, corrosion, or other deficiencies, which could cause an unsafe condition.

c. Test vent system – Insofar as is practical, close all building

doors and windows and all doors between the space in which the appliances remaining connected to the common venting 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 thermostat so appliance will operate continuously.

e. Test for spillage at the draft hood relief opening after

5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar, or pipe.

f. After it has been determined that each appliance

remaining connected to the common venting system properly vents when tested as outlined herein, return doors, windows, exhaust fans, fireplace dampers, and any other gas-burning appliance to their previous conditions of use.

Page 13

2 Prepare water heater

Installation & Operation Manual

Remove water heater from wood pallet

1. After removing the outer shipping carton from the water heater, remove the parts box.

2. Remove the front door to access the lag bolts in front of the unit (FIG. 2-1).

3. To remove the water heater from the pallet (after removing the front door):

a. Remove the two lag bolts from the wood pallet inside the water heater (FIG. 2-1). b. Detach the water heater from the lag bolts in the rear of the unit, see FIG. 2-1.

NOTICE

Figure 2-1 Water heater Mounted on Shipping Pallet

Do not drop the water heater or bump the jacket on the floor or pallet. Damage to the water heater can result.

Table 2A LP Conversion Table

LP Conversion Table

Model LP Orifice Stamping

151 150

200 210 / W150

286 285

400 8.0

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 stamping on the orifice disk matches the water heater size (151 – 286) (see Table 2A above).

Place the orifice into the black rubber grommet in the side

of the gas valve and secure in the valve (FIG. 2-2).

4. Reposition the gas valve against the venturi and replace the screws (FIG. 2-2) securing the valve to the venturi.

Gas conversions

 WARNING

For a water heater already installed, you must turn off gas supply, turn off power and allow the water heater to cool before proceeding. You must also completely test the water heater after conversion to verify performance as described under Startup, Section 10 of this manual. Failure to comply could result in severe personal injury, death, or substantial property damage.

For Models 151 - 400 you must install a propane orifice to operate the Armor water heater on propane gas. Verify when installing that the orifice size marking matches water heater size (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.

5. After installation is complete, attach the propane conversion label (in the conversion kit 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.

6. Replace the top and front access covers.

 WARNING

Figure 2-2 Installing Propane Orifice - Models 151 - 286

After converting to LP, check combustion per the Start-up procedure in Section 10 of this manual. Failure to check and verify combustion could result in severe personal injury, death, or substantial property damage.

Page 14

2 Prepare water heater

Model 400

Installation & Operation Manual

Model 501

1. Remove the top and front access covers from the unit (no tools required for removal).

2. Remove the three screws securing the venturi to the blower.

Note: When separating the venturi from the blower,

take care not to damage the O-ring inside the blower (FIG. 2-3).

3. Remove the four screws securing the gas valve to the venturi (FIG. 2-3).

4. Locate the propane orifice disk from the conversion kit bag. Verify that the stamping on the orifice disk matches the water heater size (see Table 2A on page 13).

5. Remove the existing orifice from the O-ring in the side of the gas valve and replace it with the orifice from the kit. Position and secure the orifice in the valve as shown in FIG. 2-3.

6. Reposition the gas valve against the venturi and replace the screws (FIG. 2-3) securing the valve to the venturi.

7. Inspect the O-ring inside the blower. Handle the O-ring with care, do not damage. Reposition the venturi against the blower and replace the screws securing the venturi to the blower (FIG. 2-3).

8. After installation is complete, attach the propane conversion label (in the conversion kit 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.

 WARNING

 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.

1. Remove the top access cover from the unit (no tools required for removal).

2. Turn the adjustment screw on the gas valve clockwise until it stops. Then turn the adjustment screw counterclockwise four and three quarter (4 3/4) turns (see FIG. 2-4).

3. Use a combustion analyzer to verify CO2 is within the range of 9.6 – 10.5%. If not, adjust the screw

counterclockwise incrementally to raise CO2 and clockwise to lower CO2 (FIG. 2-4).

4. After adjustment is complete, attach the propane conversion label (in the conversion kit 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.

5. Replace the top access cover.

 WARNING

Figure 2-4 Gas Valve Adjustment - Model 501

Figure 2-3 Installing Propane Orifice - Model 400

Page 15

2 Prepare water heater (continued)

Installation & Operation Manual

Models 601 - 801

1. Remove the top access cover from the unit (no tools required for removal).

2. Remove the cover on top of the gas valve (FIG. 2-5).

3. Turn the adjustment screw on top of the gas valve clockwise one and three quarter (1 3/4) turns on the 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. Use a combustion analyzer to verify CO2 is within the range 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. Attach the LP caution label (in the conversion kit bag) to the left side of the unit in the lower left corner.

6. Replace the gas valve cover along with the top access cover.

 WARNING

Leveling the water heater

1. Set the water heater in place and check level. a) Adjust legs if necessary to level the water heater, see FIG. 2-6 below.

Figure 2-6 Leveling Legs on the Water Heater

Figure 2-5 Gas Valve Adjustment - Models 601 - 801

COVER

ALLEN WRENCH

ADJUSTMENT SCREW

Page 16

3 General venting

Direct venting options - Sidewall Vent

Installation & Operation Manual

Figure 3-1 PVC/CPVC Two-Pipe Sidewall Termination

- See page 24 for more details

Figure 3-2 Stainless Steel Two-Pipe Sidewall Termination - See page 25 for more details

Figure 3-3 PVC/CPVC Concentric Sidewall Termination

(Models 151 - 601 Only) - See page 28 for more details

Page 17

3 General venting (continued)

Direct venting options - Vertical Vent

Installation & Operation Manual

Figure 3-4 PVC/CPVC Two-Pipe Vertical Termination - See page 31 for more details

Figure 3-5 Stainless Steel TwoPipe Vertical Termination - See page 31 for more details

Figure 3-6 PVC/CPVC Concentric Vertical Termination (Models 151 601 Only) - See page 33 for more details

Direct venting options - Vertical Vent, Sidewall Air

Figure 3-7 PVC/CPVC Vertical Vent, Sidewall Air

NOTICE

Stainless steel vent/air design and terminations will vary slightly by manufacturer.

Figure 3-8 Stainless Steel Vertical Vent, Sidewall Air

Page 18

3 General venting

Install vent and combustion air piping

Installation & Operation Manual

 DANGER

The Armor water heater must be vented and supplied with combustion and ventilation air as described in this section. Ensure the vent and air piping and the combustion air supply comply with these instructions regarding vent system, air system, and combustion air quality. See also Section 1 of this manual.

Inspect finished vent and air piping thoroughly to ensure all are airtight and comply with the instructions provided and with all requirements of applicable codes.

Failure to provide a properly installed vent and air system will cause severe personal injury or death.

PVC/CPVC Vent piping materials

 WARNING

NOTICE

 WARNING

NOTICE

 WARNING

Use only the materials listed in Table 3A (page 19) for vent pipe, and fittings. Failure to comply could result in severe personal injury, death, or substantial property damage.

Installation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations.

For closet and alcove installations, CPVC or stainless steel material MUST BE used in a closet/alcove structure. Failure to follow this warning could result in fire, personal injury, or death.

All PVC vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of a 1/4 inch per foot back to the water heater (to allow drainage of condensate).

This appliance requires a special venting system. The vent connection to the appliance must be made with the starter CPVC pipe section provided with the appliance if PVC/CPVC vent is to be used. For stainless steel venting use an adapter from Table 3B (page 21) that corresponds with the intended vent manufacturer to be used and discard the CPVC starter piece. The field provided vent fittings must be cemented to the CPVC pipe section using an “All Purpose Cement” suitable for PVC and CPVC pipe. Use only the vent materials, 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

Insulation should 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.

Requirements for installation in Canada

1. Installations must be made with a vent pipe system certified to ULC-S636.

IPEX is an approved vent manufacturer in Canada supplying vent material listed to ULC-S636.

2. The first three (3) feet of plastic vent pipe from the appliance flue outlet must be readily accessible for visual inspection.

3. The components of the certified vent system must not be interchanged with other vent systems or unlisted pipe/fittings. For concentric vent installations, the inner vent tube must be replaced with field supplied certified vent material to comply with this requirement.

4. The 3" Concentric Vent Kit available from Lochinvar (see Section 4 – Sidewall Termination – Optional Concentric Vent) and the 3" Concentric Vent Kit available from IPEX are both approved for use on the Armor water heater. Both kits are listed to the ULC-S636 standard for use in Canada.

 CAUTION

Installing vent or air piping

NOTICE

1. Work from the water heater to vent or air termination. Do not exceed the lengths given in this manual for the air or vent piping.

2. Cut pipe to the required lengths and deburr the inside and outside of the pipe ends.

3. Chamfer outside of each pipe end to ensure even cement distribution when joining.

4. Clean all pipe ends and fittings using a clean dry rag. (Moisture will retard curing and dirt or grease will prevent adhesion.)

5. Dry fit vent or air piping to ensure proper fit up before assembling any joint. The pipe should go a third to two-thirds into the fitting to ensure proper sealing after cement is applied.

Improper installation of PVC or CPVC systems may result in injury or death.

Use only cleaners, primers, and solvents that are approved for the materials which are joined together.

Page 19

Installation & Operation Manual

3 General venting (continued)

6. Priming and Cementing:

a. Handle fittings and pipes carefully to prevent contamination of surfaces. b. Apply a liberal even coat of primer to the fitting socket. c. Apply a liberal even coat of primer to the pipe end to approximately 1/2" beyond the socket depth. d. Apply a second primer coat to the fitting socket. e. While primer is still wet, apply an even coat of approved cement to the pipe equal to the depth of the fitting socket.

Table 3A Vent Pipe, and Fittings

All vent pipe materials and fittings must comply with the following:

Item Material

PVC Plastic Pipe, Schedules 40, 80, & 120 ANSI/ASTM D1785

PVC Plastic Pipe Fittings, Schedule 40 ANSI/ASTM D2466

Vent pipe and

fittings

ProTech Systems (Simpson Dura-Vent Co.) FasNSeal Vent / FasNSeal Flex* Vent Z-Flex (Nova Flex Group) Z-Vent Heat Fab (Selkirk Corporation) Saf-T Vent

PVC Plastic Pipe Fittings, Schedule 80 ANSI/ASTM D2467

PVC - DWV Pipe and Fittings ANSI/ASTM D2665

CPVC Plastic Pipe, Schedule 40 & 80 ANSI/ASTM F441

CPVC Plastic Pipe Fittings, Schedule 80 ANSI/ASTM F439

AL29-4C UL1738 ULC-S636

NOTICE: DO NOT USE CELLULAR (FOAM) CORE PIPE

Approved Stainless Steel Vent Manufacturers

Make Model

*Use of FasNSeal Flex smooth inner wall vent is to be used in vertical or near vertical sections only, taking precaution to ensure no sagging occurs of the vent system. Connect to the FasNSeal rigid vent using specially designed adapters and sealing method, see manufacturer’s instructions.

PVC/CPVC Air intake/vent connections

1. Combustion Air Intake Connector (FIG.’s 3-9 thru 3-11) - Used to provide combustion air directly to the unit from

outdoors. A fitting is provided on the 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 3-9 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 Building Code, Section 305, Table 305.4 or as local codes dictate.

f. While primer is still wet, apply an even coat of approved cement to the fitting socket. g. Apply a second coat of cement to the pipe. h. While the cement is still wet, insert the pipe into the fitting, if possible twist the pipe a 1/4 turn as you insert it. NOTE: If voids are present, sufficient cement was not applied and joint could be defective. i. Wipe excess cement from the joint removing ring or beads as it will needlessly soften the pipe.

Standards for installation in:

United States Canada

CPVC and PVC venting must be ULC-S636

Certified. IPEX is an approved manufacturer

in Canada supplying vent material listed to

ULC-S636.

Figure 3-9 Near Water Heater PVC/CPVC Venting Models 151 - 200

AIR

VENT

3” CPVC PIPE SUPPLIED WITH WATER HEATER MUST BE USED FOR VENT CONNECTION

NOTE: CPVC VENT PIPE AND VENT FITTINGS MUST BE USED IN CLOSET AND ALCOVE INSTALLATIONS.

Figure 3-10 Near Water Heater PVC/CPVC Venting Models 286 - 601

AIR

VENT

4" CPVC PIPE SUPPLIED WITH WATER HEATER MUST BE USED FOR VENT CONNECTION

NOTE: CPVC VENT PIPE AND VENT FITTINGS MUST BE USED IN CLOSET AND ALCOVE INSTALLATIONS.

Page 20

3 General venting

Figure 3-11 Near Water Heater PVC/CPVC Venting Models 701 - 801

6” COUPLING

(FIELD SUPPLIED)

6” CPVC

STARTER

PIECE

(FACTORY SUPPLIED)

Air inlet pipe materials:

The air inlet pipe(s) must be sealed. Choose acceptable combustion air inlet pipe materials from the following list:

PVC, CPVC or ABS Dryer Vent or Sealed Flexible Duct (not recommended for rooftop air inlet) Galvanized steel vent pipe with joints and seams sealed as specified in this section. Type “B” double-wall vent with joints and seams sealed as specified in this section. AL29-4C, stainless steel material to be sealed to specification of its manufacturer.

*Plastic pipe may require an adapter (not provided) to transition between the air inlet connection on the appliance and the plastic air inlet pipe.

 WARNING

NOTICE

Sealing of Type “B” double-wall vent material or galvanized vent pipe material used for air inlet piping on a sidewall or vertical rooftop Combustion Air Supply System:

a. Seal all joints and seams of the air inlet pipe using either Aluminum Foil Duct Tape meeting UL Standard 723 or 181A-P or a high quality UL 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.

VENT

AIR

THE 6” STAINLESS STEEL ADAPTER SUPPLIED WITH THE BOILER MUST BE USED FOR VENT CONNECTION TO PVC/CPVC. THE 6” CPVC STARTER PIECE MUST BE USED FOR PVC ONLY.

Using vent or air intake materials other than those specified, failure to properly seal all seams and joints or failure to follow vent pipe manufacturer’s instructions can result in personal injury, death or property damage. Mixing of venting materials will void the warranty and certification of the appliance.

The use of double-wall vent or insulated material for the combustion air inlet pipe is recommended in cold climates to prevent the condensation of airborne moisture in the incoming combustion air.

Installation & Operation Manual

c. Secure all joints with a minimum of three 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, CPVC, or ABS air inlet pipe should be cleaned and sealed with the pipe manufacturer’s recommended solvents and standard commercial pipe cement for the material used. The PVC, CPVC, ABS, Dryer Vent or Flex Duct air inlet pipe should use a silicone sealant to ensure a proper seal at the appliance connection and the air inlet cap connection. Dryer vent or flex duct should use a screw type clamp to seal the vent to the appliance air inlet and the air inlet cap. Proper sealing of the air inlet pipe ensures that combustion air will be free of contaminants and supplied in proper volume.

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 and supplied in proper volume.

 DANGER

Stainless steel vent

This product has been approved for use with stainless steel using the manufacturers listed in Table 3A.

 WARNING

NOTICE

Failure to properly seal all joints and seams as required in the air inlet piping may result in flue gas recirculation, spillage of flue products and carbon monoxide emissions causing severe personal injury or death.

Use only the materials, vent systems, and terminations listed in Table 3B. DO NOT mix vent systems of different types or manufacturers, unless listed in this manual. Failure to comply could result in severe personal injury, death, or substantial property damage.

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.

Installation of a stainless steel vent system should adhere to the stainless steel vent manufacturer’s installation instructions supplied with the vent system.

The installer must use a specific vent starter adapter at the flue collar connection, supplied by the vent manufacturer to adapt to its vent system. See Table 3B for approved vent adapters. Discard CPVC starter piece.

Page 21

Installation & Operation Manual

3 General venting (continued)

Table 3B Approved Stainless Steel Terminations and Adapters

ProTech Heat Fab Z Flex

FasNSeal Saf-T Vent Z-Vent

Model

**Adapter

151 - 200

286-601

701-801

300715

F303759 F303759

(Intake

Only)

* = This adapter must be used in addition to the water heater adapter for Saf-T vent pipe as shown in FIG. 3-12, unless approved vent other than standard diameter is used. Consult a Heat Fab representative for questions. **The stainless steel venting option is only available in 3" vent diameters.

Flue

Termination

FSBS3

FSRC3(R.C)

FSBS4

FSRC4(R.C)

FSBS6

Intake

Air

**Adapter

Termination

303889 KB80210 9353BUREZ-1*

FSAIH04

303888

FSAIH04

303888

KB285600 9454BUREZ-1*

Intermediate

Adapter

Flue

Termination

9392

5300CI

9492

5400CI

Intake

Air

**Adapter

Termination

9314TERM 2SVSLA03

9414TERM 2SVSLA04

Flue

Termination

2SVSTP03

2SVSRCX03

2SVSTP04

2SVSRCX04

Intake Air

Termination

2SVSTEX0390

2SVSTEX0490

Table 3C Stainless Steel Vent Termination Kit(s)

Model Kit Number

701 - 801 KIT3137

Stainless steel air intake/vent connections

1. Combustion Air Intake Connector (FIG.’s 3-12 thru

3-14) - Used to provide combustion air directly to the unit from outdoors. A fitting is provided on the 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 3-12 thru 3-14) - 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 305, Table 305.4 or as local codes dictate.

Figure 3-12 Near Water Heater Stainless Steel Venting Models 151 - 200

VENT

3" S.S. ADAPTER

3" S.S. INTERMEDIATE (FOR SAF-T VENT ONLY)

Page 22

(

)

3 General venting

Figure 3-13 Near Water Heater Stainless Steel Venting Models 286 - 601

VENT

Installation & Operation Manual

Minimum / Maximum allowable combustion air and vent piping lengths are as follows:

Combustion Air = 12 equivalent feet minimum / 100 equivalent feet maximum

Vent = 12 equivalent feet minimum / 100 equivalent feet maximum

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° elbows + (1) concentric vent kit (CVK3003) = 49 equivalent feet of piping.

4" S.S. ADAPTER

4" S.S. INTERMEDIATE

FOR SAF-T VENT ONLY

Figure 3-14 Near Water Heater Stainless Steel Venting Models 701 - 801

NOTICE

Table 3E Concentric Vent Kit Equivalent Vent Lengths

Model Kit Number

151 - 200 CVK3003 3 feet

286 CVK3007 3 feet 400 CVK3007 5 feet

501 - 601 CVK3007 30 feet

The appliance output rating will reduce by up to 1.5% for each 25 feet of vent length.

Equivalent Vent

Length

Removing from existing vent

Follow the instructions in Section 1, page 12 of this manual when removing a water heater from an existing vent system.

Vent and air piping

Vent and air system:

NOTICE

Installation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations.

You must also install air piping from outside to the water heater

The Armor water heater uses model specific combustion air intake and vent piping sizes as detailed in Table 3D below.

Table 3D Air Intake/Vent Piping Sizes

Model Air Intake Vent

151 - 200 3 inches 3 inches 286 - 601 4 inches 4 inches 701 - 801 4 inches 6 inches

NOTICE

Increasing or decreasing combustion air or vent piping is not authorized.

air intake adapter. The resultant installation is direct vent (sealed combustion).

You may use any of the vent/air piping methods covered in this manual. Do not attempt to install the Armor water heater using any other means.

 WARNING

DO NOT mix components from different systems. The vent system could fail, causing leakage of flue products into the living space. Use only approved stainless steel, PVC or CPVC pipe and fittings. For PVC/CPVC use with primer and cement specifically designed for the material used.

Page 23

3 General venting (continued)

Installation & Operation Manual

Vent, air piping and termination:

The Armor water heater vent and air piping can be installed through the roof or through a sidewall. Follow the procedures in this manual for the method chosen. Refer to the information in this manual to determine acceptable vent and air piping length.

Optional room air

NOTICE

Commercial applications utilizing the Armor water heater may be installed with a single pipe carrying the flue products to the outside while using combustion air from the equipment room. In order to use the room air venting option the following conditions and considerations must be followed.

• The unit MUST be installed with the appropriate

room air kit (Table 3F).

• The equipment room MUST be provided 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, to ensure proper installation.

• Vent system and terminations must comply with the

standard venting instructions set forth in this manual.

 WARNING

Optional room air is intended for commercial applications. Combustion air piping to the outside is recommended for residential applications.

When utilizing the single pipe method, provisions for combustion and ventilation air must be in accordance with Air for Combustion and Ventilation, of the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment, or applicable provisions of the local building codes.

Table 3F Optional Room Air Kit

Model Kit Number Description

151 - 200 KIT30052 Room Air Kit 286 - 801 KIT30053 Room Air Kit 400 - 801 KIT30054 Room Air Filter Kit

Air contamination

Pool and laundry products and common household and hobby products often contain fluorine or chlorine compounds. When these chemicals pass through the water heater, they can form strong acids. The acid can eat through the water heater wall, causing serious damage and presenting a possible threat of flue gas spillage or appliance water leakage into the building.

Please read the information given in Table 1A, page 11, listing contaminants and areas likely to contain them. If contaminating chemicals will be present near the location of the water heater combustion air inlet, have your installer pipe the water heater combustion air and vent to another location, per this manual.

 WARNING

If the water heater combustion air inlet is located in a laundry room or pool facility, for example, these areas will always contain hazardous contaminants.

To prevent the potential of severe personal injury or death, check for areas and products listed in Table 1A, page 11 before installing the water heater or air inlet piping.

If contaminants are found, you MUST:

• Remove contaminants permanently. —OR—

• Relocate air inlet and vent terminations to other areas.

Page 24

4 Sidewall direct venting

Vent/air termination – sidewall

 WARNING

Follow instructions below when determining vent location to avoid possibility of severe personal injury, death, or substantial property damage.

A gas vent extending through an exterior wall shall not terminate adjacent to a wall or below building extensions such as eaves, parapets, balconies, or decks. Failure to comply could result in severe personal injury, death, or substantial property damage.

Do not connect any other appliance to the vent pipe or multiple water heaters to a common vent pipe. Failure to comply could result in severe personal injury, death, or substantial property damage.

Installation & Operation Manual

Figure 4-1A Sidewall Termination of Air and Vent

TO BOILER

INTAKE AIR

CONNECTION

FROM BOILER

VENT PIPE

CONNECTION

POSSIBLE ORIENTATIONS

VENT / AIR

TERMINATION

GRADE OR

SNOW LINE

Table 4A Sidewall Vent Kits

12"

MIN

OVER

HANG

12" MIN

NOTICE

Installation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations.

Determine location

Locate the vent/air terminations using the following guidelines:

1. The total length of piping for vent or air must not exceed the limits given in the General Venting Section on page 22 of this manual.

2. You must consider the surroundings when terminating

the vent and air:

a. Position the vent termination where vapors will not damage nearby shrubs, plants or air conditioning equipment or be objectionable. b. The flue products will form a noticeable plume as they condense in cold air. Avoid areas where the plume could obstruct window views. c. Prevailing winds could cause freezing of condensate and water/ice buildup where flue 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 performance or cause recirculation, such as inside building corners, near adjacent buildings or surfaces, window wells, stairwells, alcoves, courtyards, or other recessed areas.

Model Kit Number Vent Size

151 - 200 KIT30045 3 inch vent 286 - 601 KIT30046 4 inch vent 701 - 801 KIT30048 6 inch vent

If using the alternate sidewall termination:

3. The air piping must terminate in a down-turned elbow as shown in FIG. 4-1B. This arrangement avoids recirculation of flue products into the combustion air stream.

4. The vent piping must terminate in an elbow pointed outward or away from the air inlet, as shown in FIG. 4-1B.

 WARNING

Figure 4-1B Alternate PVC/CPVC Sidewall Termination of Air and Vent w/Field Supplied Fittings

FROM BOILER

VENT PIPE

CONNECTION

Do not exceed the maximum lengths of the outside vent piping shown in FIG. 4-1B. Excessive length exposed to the outside could cause freezing of condensate in the vent pipe, resulting in potential water heater shutdown.

TO BOILER INTAKE AIR

CONNECTION

BIRD SCREEN

12” MIN

15” MAX

 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 finishes.

TERMINATION

PLATE

BIRD

SCREEN

GRADE OR

SNOW LINE

12”

MIN

Page 25

4 Sidewall direct venting (continued)

Installation & Operation Manual

Vent/air termination – sidewall

Figure 4-1C Alternate Stainless Steel Vent Termination

- Typical Stainless Steel Sidewall Termination of Air and Vent Models 286 - 601 w/Field Supplied Fittings, Utilizing FasNSeal’s Hood Intake. Available Through FasNSeal Only

12" (305 MM) MIN

12" MIN

BIRD SCREEN

12" (305 MM) MIN

15" (381 MM) MAX

12" MIN

15" MAX

TO BOILER INTAKE AIR

CONNECTION

FROM BOILER

VENT PIPE

CONNECTION

GRADE OR SNOW LINE

Figure 4-1D Alternate PVC/CPVC/SS Vent Termination

- Typical Stainless Steel Sidewall Termination of Air and Vent Models 151 - 601 w/Field Supplied Fittings, Utilizing 90° Elbow Intake

TO BOILER INTAKE AIR

CONNECTION

FROM BOILER

VENT PIPE

CONNECTION

BIRD SCREEN

GRADE OR SNOW LINE

Figure 4-2B Alternate Stainless Steel Sidewall Termination Models 701 - 801 w/Field Supplied Fittings

TO BOILER INTAKE

NOTICE

AIR CONNECTION

FROM BOILER VENT PIPE CONNECTION

GRADE OR SNOW LINE

PVC/CPVC or ABS is acceptable air inlet pipe material.

12" (305 MM) MIN 15" (381 MM) MAX

12" (305 MM) MIN

5. Maintain clearances as shown in FIG.’s 4-1A thru 4-3B, pages 24 thru 26. Also maintain the following:

a. Vent must terminate:

• At least 6 feet from adjacent walls.

• No closer than 12 inches below roof overhang.

• At least 7 feet above any public walkway.

• At least 3 feet above any forced air intake within 10 feet.

• No closer than 12 inches below or horizontally from any door or window or any other gravity air inlet. b. Air inlet must terminate at least 12 inches above grade or snow line; at least 12 inches below the vent termination; and the vent pipe must not extend more than 24 inches vertically outside the building as shown in FIG. 4-1B. c. Do not terminate closer 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 they are not likely to be damaged by foreign objects, such as stones or balls, or subject to buildup of leaves or sediment.

Figure 4-2A Alternate PVC/CPVC Sidewall Termination Models 151 - 801 w/Field Supplied Fittings

BIRD SCREEN

12" (305 MM) MIN

15" (381 MM) MAX

BIRD SCREEN

FROM BOILER

VENT PIPE

CONNECTION

TO BOILER INTAKE AIR

CONNECTION

GRADE OR SNOW LINE

12" (305 MM) MIN

Figure 4-3A Clearance to Gravity Air Inlets

12"

MIN.

VENT / AIR

TERMINATION

12"

MIN.

12"

MIN.

Page 26

4 Sidewall direct venting

Installation & Operation Manual

Figure 4-3B Alternate Clearance to Gravity Air Inlets w/ Field Supplied Fittings

12”

MIN.

BIRD

SCREEN

(TYPICAL)

12”

MIN.

12”

MIN.

Figure 4-4A Clearance to Forced Air Inlets

IF LESS

THAN 10’

VENT / AIR

TERMINATION

36"

MIN.

FORCED AIR

INLET

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:

• 4½ inch hole for 3 inch vent pipe

• 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.

2. Install the vent and air intake piping through the wall into the vent plate openings. Seal all gaps between the pipes and wall. Use RTV silicone sealant to seal the air pipe. Use the cement/primer listed in Table 3A on page 19 to seal the vent pipe.

3. Mount and secure the vent plate to the wall using stainless steel screws. Seal around the plate to the wall assuring no air gaps.

4. 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.

5. Seal all wall cavities.

7' MIN. ABOVE ANY

PUBLIC WALKWAY

Figure 4-4B Alternate Clearance to Forced Air Inlets w/ Field Supplied Fittings

IF LESS THAN 10’

36”

MIN.

FORCED AIR

INLET

BIRD

SCREEN

7’ MIN. ABOVE ANY

PUBLIC WALKWAY

(TYPICAL)

Figure 4-5A Sidewall Termination Assembly

VENT

AIR

CENTERLINE WIDTH

VENT CAP

VENT PIPING

WALL PLATE

GALVANIZED

AIR PIPING

VENT PLATE

THIMBLE

Table 4B Sidewall Vent Centerline Dimensions

Model Air Vent Centerline Width

151 - 200 3" 3" 5 5/8" 286 - 601 4" 4" 5 5/8" 701 - 801 4" 6" 7 3/4"

Page 27

4 Sidewall direct venting (continued)

Prepare wall penetrations (Alternate Field Supplied Option)

1. 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.

2. 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:

• 4½ inch hole for 3 inch vent pipe

• 5½ inch hole for 4 inch vent pipe

• 7½ inch hole (191 mm) hole for 6 inch (152 mm) vent pipe b. Insert a galvanized metal thimble in the vent pipe hole as shown in FIG. 4-5B.

3. Use a sidewall termination plate as a template for correct

location of hole centers.

4. Follow all local codes for isolation of vent pipe when

passing through floors or walls.

5. Seal exterior openings thoroughly with exterior caulk.

Figure 4-5B A Typical Sidewall Termination Assembly

- Models 151 - 801 PVC/CPVC or Stainless Steel

SIDEWALL

TERMINATION PLATE

VENT

PIPING

GALVANIZED THIMBLE (WHEN REQUIRED BY LOCAL CODES)

ELBOW

AIR PIPING

6. Stainless steel terminations are designed to penetrate walls with a thickness up to 9.25 inches of standard construction.

Multiple vent/air terminations

1. When terminating multiple Armor water heaters terminate

each vent/air connection as described in this manual (FIG. 4-6A).

 WARNING

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 of a Armor water heater is part of a direct vent

connection. It is not classified as a forced air intake with regard to spacing from adjacent water heater vents.

Figure 4-6A Multiple Vent Terminations (must also comply with Figure 4-1A)

VENT

Installation & Operation Manual

All vent pipes and air inlets must terminate at the same height to avoid possibility of severe personal injury, death, or substantial property damage.

12" MIN. BETWEEN EDGE OF AIR

INLET AND ADJACENT VENT OUTLET

AIR

BIRD SCREEN

ELBOW

BIRD SCREEN

Termination and fittings

1. Prepare the vent termination elbow and the air termination elbow (FIG. 4-5B) by inserting bird screens. Bird screens can be obtained locally.

2. When completed, the air termination coupling must be oriented at least 12 inches (305 mm) below the vent termination and at least 12 inches (305 mm) above grade or snow line as shown in FIG. 4-1A, page 24.

3. Maintain the required dimensions of the finished termination piping as shown in FIG. 4-1A, page 24.

4. Do not extend exposed vent pipe outside of building more than shown in this document. Condensate could freeze and block vent pipe.

5. PVC/CPVC terminations are designed to accommodate any wall thickness of standard constructions per the directions found in this manual.

VENT / AIR

TERMINATION

Figure 4-6B Alternate Multiple Vent Terminations w/Field Supplied Fittings (must also comply with Figure 4-1B)

Page 28

Installation & Operation Manual

4 Sidewall direct venting

Sidewall termination – optional concentric vent: Models 151 - 601

Description and usage

Lochinvar offers optional concentric combustion air and vent pipe termination kits (Factory Kit #CVK3003 for 3” diameter - Models 151 - 200 and #CVK3007 for 4” diameter

- Models 286 - 601). Both combustion air and vent pipes must attach to the termination kit. The termination kits must terminate outside the structure and must be installed as shown below in FIG. 4-7.

Field supplied pipe and fittings are required to complete the installation.

The required combustion vent pipe materials are listed in Table 3A, on page 19 of this manual.

Figure 4-7 Concentric Sidewall Termination

c. Prevailing winds could cause freezing of condensate and water/ice buildup where flue products impinge on building surfaces or plants. d. Avoid possibility of accidental contact of flue products with people or pets. e. Do not terminate above any door or window. Condensate can freeze, causing ice formations. f. Locate or guard vent to prevent condensate damage to exterior finishes.

Figure 4-8 Kit Contents_CVK3003 - Models 151 - 200

RAIN CAP

4" DIA.

SDR-26 PIPE

"Y" CONCENTRIC FITTING

3" DIA. SDR-26 PIPE

Sidewall termination installation

1. Determine the best location for the termination kit (see FIG. 4-7).

2. The total length of piping for vent or air must not exceed the limits given in the General Venting Section on page 22 of this manual.

3. You must consider the surroundings when terminating

the vent and air:

Figure 4-9 Kit Contents_CVK3007 - Models 286 - 601

RAIN CAP

6" (152 MM) TO 4" (102 MM) REDUCER

6" (152 MM) DIA.

4" (102 MM) DIA.

"Y" CONCENTRIC FITTING

6" (152 MM) DIA.

"FLEXIBLE" PIPE COUPLING

4. Cut one (1) hole (5 inch diameter for #CVK3003 installations or 7 inch diameter for #CVK3007 installations) into the structure to install the termination kit.

5. 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.’s 4-8 and 4-9). b. Cement the rain cap to the smaller diameter kit pipe (FIG.’s 4-8 and 4-9).

Page 29

Installation & Operation Manual

4 Sidewall direct venting (continued)

Sidewall termination – optional concentric vent: Models 151 - 601

Figure 4-10 Concentric Vent Dimensional Drawing Models 151 - 200

NOTICE

Instead of cementing the smaller pipe to the rain cap, a field-supplied stainless steel screw may be used to secure the two (2) components together when field disassembly is desired for cleaning (see FIG. 4-12).

 WARNING

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.

 WARNING

Do not operate the appliance with the rain cap removed or recirculation of combustion products may occur. Water may also collect inside the larger combustion air pipe and flow to the burner enclosure. Failure to follow this warning could result in product damage or improper operation, personal injury, or death.

Figure 4-12 Rain Cap to Vent Pipe Alternate Assembly

Figure 4-11 Concentric Vent Dimensional Drawing -

Models 286 - 501

"A"

(152 MM)

"B" DIA.

"G"

(76 MM)

(537 MM)

"H" DIA.

(254 MM) (194 MM)

"D"

"E"

"F"

(168 MM)

(76 MM)

"C" DIA.

"B" DIA. PVC VENT / EXHAUST

ABC D E F GH

60" 4" 6" 21 1/8" 10" 7 5/8" 3" 6 5/8"

(1524 MM)

(102 MM)

6. Install the Y concentric fitting and pipe assembly through the structure’s hole.

NOTICE

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 tightly into the rubber adapter for #CVK3007 installations.

8. Secure the assembly to the structure as shown in FIG. 4-13 using field-supplied metal strapping or equivalent support material.

NOTICE

Ensure termination location clearance dimensions are as shown in FIG. 4-7.

If assembly 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 for CVK3003 and standard schedule 40 PVC for CVK3007. Do not extend dimension D* more than 60 inches (see FIG.’s 4-10 and 4-11).

NOTICE

If assembly depth needs to be reduced, dimension D can be as short as possible.

Page 30

Installation & Operation Manual

4 Sidewall direct venting

Sidewall termination – optional concentric vent: Models 151 - 601

Figure 4-13 Concentric Vent Sidewall Attachment

Note: CVK3003 shown for illustration purposes.

CAUTION

9. Cement appliance combustion air and vent pipes to the concentric vent termination assembly. See FIG. 4-13 for proper pipe attachment.

10. Operate the appliance one (1) heat cycle to ensure combustion air and vent pipes are properly connected to the concentric vent termination connections.

DO NOT use field-supplied couplings to extend pipes. Airflow restriction will occur and may cause intermittent operation.

Multiventing sidewall terminations

When two (2) or more direct vent appliances are vented near each other, each appliance must be individually vented (see FIG. 4-14). 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. 4-14. It is important that vent terminations be made as shown to avoid recirculation of flue gases.

12" MINIMUM

VENT

COMBUSTION AIR

Figure 4-14 Concentric Vent and Combustion Air Termination

Page 31

5 Vertical direct venting

Vent/air termination – vertical

Installation & Operation Manual

 WARNING

Follow instructions below when determining vent location to avoid possibility of severe personal injury, death or substantial property damage.

 WARNING

Do not connect any other appliance to the vent pipe or multiple water heaters to a common vent pipe. Failure to comply could result in severe personal injury, death, or substantial property damage.

NOTICE

Installation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations.

Determine location

Locate the vent/air terminations using the following guidelines:

1. The total length of piping for vent or air must not exceed the limits given in the General Venting Section on page 22 of this manual.

 WARNING

Rooftop vent and air inlet terminations must terminate in the same pressure zone, unless vertical vent sidewall air is set up as shown in the General Venting - Vertical Vent, Sidewall Air Section.

Figure 5-1A PVC/CPVC Vertical Termination of Air and Vent

2. The vent must terminate at least 3 feet above the highest

place in which the vent penetrates the roof and at least 2 feet above any part of a building within 10 horizontal feet.

3. The air piping must terminate 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 terminate in an up-turned coupling

as shown in FIG. 5-1A. The top of the coupling must be at least 1 foot 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 apart and with the vent termination at least 1 foot above the air intake.

Figure 5-1B Stainless Steel Vertical Termination of Air and Vent

ALTERNATE INTAKE LOCATIONS: INTAKE PIPES MAY BE LOCATED ANYWHERE WITHIN 24” (610 MM) OF VENT PIPE

BIRD SCREEN

(TYPICAL)

6" (152 MM) MINIMUM

ABOVE ROOF /

SNOW LINE

VENT OUTLET

36” (914 MM) MINIMUM

ABOVE AIR INLET

VENT

COM,BUSTION AIR

5. 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.

Page 32

5 Vertical direct venting

Vent/air termination – vertical

Installation & Operation Manual

Prepare roof penetrations

1. 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.

• 4½ inch hole for 3 inch vent pipe

• 5½ inch hole for 4 inch vent pipe

• 7½ inch hole for 6 inch vent pipe b. Insert a galvanized metal thimble in the vent pipe hole.

3. Space the air and vent holes to provide the minimum

spacing shown in FIG. 5-1A, page 31.

4. Follow all local codes for isolation of vent pipe when

passing through floors, ceilings, and roofs.

5. Provide flashing and sealing boots sized for the vent

pipe and air pipe.

Termination and fittings

1. Prepare the vent termination coupling and the air

termination elbow (FIG.’s 5-1A and 5-1B) by inserting bird screens. Bird screens should be obtained locally.

Multiple vent/air terminations

1. When terminating multiple Armor water heaters, terminate each vent/air connection as described in this manual (FIG. 5-2).

 WARNING

2. Place roof penetrations to obtain minimum clearance of 12 inches between edge of air intake elbow and adjacent vent pipe of another water heater for U.S. installations (see FIG. 5-2). For Canadian installations, provide clearances required by CSA B149.1 Installation Code.

3. The air inlet of an Armor water heater is part of a direct vent connection. It is not classified as a forced air intake with regard to spacing from adjacent water heater vents.

Figure 5-2 Vertical Terminations with Multiple Water Heaters

VENT

AIR

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.

12” MINIMUM VERTICALLY FROM VENT OUTLET TO

VENT

AIR

ANY AIR INLET

12” MINIMUM FROM EDGE OF AIR INTAKE PIPE TO ADJACENT VENT PIPE FROM ANOTHER WATER HEATER

2. The air piping must terminate in a down-turned 180° return bend as shown in FIG.’s 5-1A and 5-1B. Locate the air inlet 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.

3. The vent piping must terminate in an up-turned coupling as shown in FIG. 5-1A. The top of the coupling must be at least 1 foot 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 apart and with the vent termination at least 1 foot above the air intake.

4. Maintain the required dimensions of the finished termination piping as shown in FIG.’s 5-1A and 5-1B.

5. Do not extend exposed vent pipe outside of building more than shown in this document. Condensate could freeze and block vent pipe.

Figure 5-3 Alternate Vertical Terminations with Multiple

Water Heaters

Page 33

Installation & Operation Manual

5 Vertical direct venting (continued)

Vertical termination – optional concentric vent: Models 151 - 601

Description and usage

Lochinvar offers an optional concentric combustion air and vent pipe termination kit. Both combustion air and vent pipes must attach to the termination kit. The termination kit must terminate outside the structure and must be installed as shown in FIG. 5-4.

Field supplied pipe and fittings are required to complete the installation.

The required combustion vent pipe and fittings are listed in Table 3A, on page 19 of this manual.

Vertical termination installation

1. See Section 5, Vertical Direct Venting - Determine Location (where applicable).

Figure 5-4 Concentric Vertical Termination

2. Cut one (1) hole (5 inch diameter for #CVK3003 installations or 7 inch diameter for #CVK3007 installations) into the structure to install the termination kit.

3. Partially assemble the concentric vent termination kit. Clean and cement following the cleaning procedures in these instructions.

a. Cement the Y concentric fitting to the larger

diameter kit pipe (see FIG.’s 4-8 and 4-9, page 28).

b. Cement rain cap to the smaller diameter kit pipe (see

FIG.’s 4-8 and 4-9, page 28).

c. Do not attach a U-Bend to the rain cap. Doing so

could cause recirculation (see FIG. 5-5).

NOTICE

 WARNING

Instead of cementing the smaller pipe to the rain cap, a field supplied stainless steel screw may be used to secure the two (2) components together when field disassembly is desired for cleaning (see FIG. 4-12, page

29).

Figure 5-5 Do Not Install U-Bend to Rain Cap

Page 34

Installation & Operation Manual

5 Vertical direct venting

Vertical termination – optional concentric vent: Models 151 - 601

 WARNING

4. Install the Y concentric fitting pipe assembly up through the structure’s hole and field supplied roof boot/flashing.

NOTICE

Do not allow insulation or other materials to accumulate inside the pipe assembly when installing through the hole.

5. Secure the assembly to the roof structure as shown below in FIG. 5-6 using field supplied metal strapping or equivalent support material.

Figure 5-6 Concentric Vent Roof Installation

Note: CVK3003 shown for illustration purposes.

CAUTION

DO NOT use field-supplied couplings to extend pipes. Airflow restriction will occur.

6. Install the rain cap and the small diameter pipe assembly into the roof penetration assembly. Ensure the small diameter pipe is cemented and bottomed in the Y concentric fitting for #CVK3003 installations and fastened tightly into the rubber adapter for #CVK3007 installations.

7. Cement the appliance combustion air and vent pipes to the concentric vent termination assembly. See FIG. 5-6 for proper pipe attachment.

8. Operate the appliance through one (1) heat cycle to ensure combustion air and vent pipes are properly connected to 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 that vent terminations be made as shown to avoid recirculation of flue gases.

NOTICE

Ensure termination height is above the roof surface or anticipated snow level (12 inches in U.S.A. or 18 inches in Canada) as shown in FIG. 5-4, page 33.

If assembly is too short to meet height requirement, the two (2) pipes supplied in the kit may be replaced by using the same diameter, field supplied SDR-26 PVC (D2241) pipe for CVK3003 and standard schedule 40 PVC for CVK3007. Do not extend dimension D* more than 60 inches (see FIG.’s 4-10 and 4-11, page 29).

Figure 5-7 Concentric Vent and Combustion Air Vertical Termination

12”

MINIMUM

COMBUSTION AIR (TYPICAL)

12” (18” FOR CANADA) MINIMUM CLEARANCE

ABOVE HIGHEST ANTICIPATED SNOW LEVEL. MAXIMUM OF

24” ABOVE ROOF.

Page 35

5 Vertical direct venting (continued)

Alternate vertical concentric venting

Installation & Operation Manual

This appliance may be installed with a concentric vent arrangement where the vent pipe is routed through an existing unused venting system; or by using the existing unused venting system as a chase for vent and combustion air routing.

Concentric Venting Arrangement

The venting is to be vertical through the roof. The annular space between the O.D. of the vent pipe and the I.D. of the existing unused venting system is utilized for the combustion air source.

The minimum size of the existing vent system required to achieve enough annular space for combustion air can be found in Table 5A below.

The upper and lower termination as well as any other unsealed joints in the existing vent system must be sealed to ensure that all combustion air is drawn from under the vent cap as shown in FIG.’s 5-8 and 5-9.

Approved venting materials must be used as specified in Table 3A on page 19.

Follow all vent / air termination and clearance requirements per this 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.

Figure 5-8 Concentric Vent Example 1

FLUE EXHAUST

SEAL

COMBUSTION AIR

IR INLET

W/ SCREEN

12"

MIN.

SEAL

FLUE OUTLET

*For concept illustration only. Individual installations

may vary due to job site specific equipment.

Figure 5-9 Concentric Vent Example 2

SEAL

FLUE EXHAUST

EXISTING

SEALED CAP

If an existing unused venting system is converted for use

COMBUSTION AIR

with this method of concentric venting, the installer must ensure that the existing venting system is clean and free from particulate contamination that will harm this appliance and

IR INLET

W/ SCREEN

cause increased nuisance calls or maintenance. See Table 1A on page 11 for a list of corrosive contaminants and sources.

are shown for illustrative purposes in FIG.’s 5-8 and 5-9.

Two example scenarios of a concentric venting arrangement

SEAL

EXISTING

Table 5A Alternate Vertical Concentric Vent / Chase Sizes

Model

Vent / Air Inlet Size

SEAL

Minimum Existing

Vent / Chase Size

SEALED CAP

151 - 200 3" 5" 286 - 601 4" 7"

FLUE OUTLET

701 - 801 6" 10"

Page 36

5 Vertical direct venting

Existing vent as a chase

Follow all existing termination and clearance requirements and allowable pipe lengths. Use only approved venting materials listed in the General Venting Section of this manual.

Figure 5-10 Existing Vent as a Chase

Installation & Operation Manual

AIR INLET

CAP

*For concept illustration only. Individual installations

may vary due to job site specific equipment.

FLUE EXHAUST

SEAL

EXISTING

SEAL

FLUE OUTLET

Page 37

6 System piping

System water piping methods

Observe a minimum of 1 inch clearance around all un-insulated hot water pipes when openings around the pipes are not protected by non-combustible materials.

General piping information

Basic steps are listed below along with illustrations on the following pages (FIG.’s 6-4 thru 6-8), which will guide you through the installation of the Armor water heater.

1. Connect the cold water supply to the inlet side of the water heater.

2. Connect the hot water supply to the outlet side of the water heater.

3. Install a backflow preventer on the cold feed make-up water line.

4. Install the factory supplied pump as shown in FIG.’s 6-4 thru 6-8.

5. Install an expansion 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 discharge of the safety relief valve to a suitable drain to prevent injury in the event of pressure relief. Pipe the discharge to a drain. Provide piping that is the same size as the safety relief valve outlet. Never block the outlet of the safety relief valve.

 WARNING

See the *piping illustrations included in this section, FIG.’s 6-4 thru 6-8 for suggested guidelines in piping the Armor water heater.

NOTICE

Flow switch and relief valve installation

Basic steps are listed below to guide you through the installation of the flow switch and relief valve provided with the unit.

1. Install the tee with the 3/4 inch fitting positioned vertically

and on the top as shown in FIG. 6-1.

2. Install the relief valve into the 3/4 inch fitting of the tee

installed in Step 1 (FIG. 6-1).

3. Install the close nipple on the downstream side of the

temperature and pressure relief valve tee (FIG. 6-1).

4. Install the tee with the 1 inch fitting positioned vertically

and on the top (FIG. 6-1).

5. Attach the paddle to the flow switch per the manufacturer’s

instructions. Reference Table 6A to select the correct paddle for the pipe size used (consult the manufacturer’s instructions for a detailed explanation).

The relief valve, tee and other necessary fittings are shipped in the install kit with the water heater and are to be field installed.

*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.

Installation & Operation Manual

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).

NOTICE

Figure 6-1 Flow Switch and Relief Valve Installation

TEE WITH 1” FITTING ON TOP

Flow switch adjustment

Refer to Table 6A for the proper setting of the sensitivity screw. For reference, the position of the screw prior to setting should be turned clockwise with a Phillips driver until it stops (FIG. 6-2). Proceed to turn the screw counterclockwise the amount of turns listed in Table 6A based on the model.

Consult the manufacturer’s instructions for wiring the flow switch to your system.

Table 6A Paddle Size / Sensitivity Screw Adjustment

MODEL PADDLE SIZE

Note: Paddles are included with the flow switch.

151 #1 9 turns 200 #1 6 turns 286 #3 8¾ turns 400 #1 8 turns 501 #1 7½ turns 601 #1 7 turns 701 #1 6½ turns 801 #1 5½ turns

NOTICE

Figure 6-2 Flow Switch Adjustment

Be sure to install flow switch so that the arrow on the flow switch is pointing in the direction of the flow (see FIG. 6-2).

RELIEF VALVE

FLOW SWITCH

PADDLE

CLOSE NIPPLE

TEE WITH 3/4” FITTING ON TOP

SENSITIVITY SCREW

ADJUSTMENT

Turn the sensitivity screw clockwise to increase the flow rate required to activate the switch. Turn the sensitivity screw counterclockwise to decrease the flow rate required to activate the switch.

NORMALLY OPEN

SENSITIVITY ADJUSTMENT

GROUND

COMMON

NORMALLY CLOSED

Page 38

6 System piping

Scalding

This water heater can deliver scalding temperature water at any faucet in the system. Be careful whenever using hot water to avoid scalding injury. Certain appliances such as dishwashers and automatic clothes washers may require increased temperature water. By setting the thermostat on this water heater to obtain the increased temperature water required by these appliances, you may create the potential for scald injury. To protect against injury, you should install a mixing valve in the water system. This valve will reduce point of discharge temperature by mixing cold and hot water in branch supply lines. Such valves are available from the local plumbing supplier.

Figure 6-3 Scald Warning Label Located on the Appliance

The following chart (Table 6B) details the relationship of water temperature and time with regard to scald injury and may be used as a guide in determining the safest water temperature for your applications.

Table 6B Approximate Time / Temperature Scald Chart

APPROXIMATE TIME / TEMPERATURE

RELATIONSHIPS IN SCALDS

120°F More than 5 minutes 125°F 1 1/2 to 2 minutes 130°F About 30 seconds 135°F About 10 seconds 140°F Less than 5 seconds 145°F Less than 3 seconds 150°F About 1 1/2 seconds 155°F About 1 second

Water 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 circulating pump, and a revised temperature rise specification based on the water chemistry of the water to be heated.

Water temperature rise and maximum flow data is based on heating potable water with a hardness of 5 to 25 grains per gallon and total dissolved solids not exceeding 350 ppm.

Table 6C Water Heater Pump Applications / Recommended Temperature Rise

Model

151 1-1/4" E8 -- 16 16.6 18°F 200 1-1/4" E8 -- 21 11.8 18°F 286 2" E17 -- 30 17.1 18°F 400 2" E24 -- 39 21 18°F 501 2" E22 -- 53 26 18°F 601 2" E22 -- 53 26 22°F 701 2" -- TP 40-160 63 32 22°F 801 2" -- TP 40-160 67 31 24°F

NOTICE

Installation & Operation Manual

Water with a hardness of less than 5 grains per gallon will usually have a pH which can be aggressive and corrosive causing non-warrantable damage to the pump, and associated piping. Corrosion due to water chemistry generally shows up first in the hot water system because heated water increases the rate of corrosive chemical reactions.

Piping components

Water heater system piping:

Water heater system piping MUST be sized per the pipe requirements listed in Table 6C. Reducing the pipe size can restrict the flow rate through the water heater, causing inadvertent high limit shutdowns and poor system performance.

Check valves:

Field supplied. Check valves are recommended for installation as shown in FIG.’s 6-4 thru 6-8.

Water heater isolation valves:

Field supplied. Full port ball valves are required. Failure to use full port ball valves could result in a restricted flow rate through the water heater.

Anti-scald mixing valve:

Field supplied. An anti-scald mixing valve is recommended when storing domestic hot water above 115°F.

Unions:

Field supplied. Recommended for unit serviceability.

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 valves depending on local codes.

Tank sensor:

Lochinvar supplies a tank sensor. The tank sensor must be installed in the tapping provided in the lower 25% of the storage tank to achieve proper operation. As shipped from the factory, the tank sensor is in the literature package shipped with the unit. Placing the sensor in the tapping provided on the storage tank will improve temperature response and prevent short cycles of operation.

Water Heater Pump Applications

*Pipe

Armstrong Grundfos

Size

Pump sizing and flow requirements are based on 45 feet of piping, 4 - 90° elbows, and 2 - fully ported ball valves.

Flow Rate

(GPM)

Loss

(FT/HD)

Temp.

Rise

Page 39

6 System piping (continued)

Figure 6-4 Single Heater - Single Tank (2 Temperature)

FLOW CHECK

VALVE (TYPICAL)

Installation & Operation Manual

TEMPERATURE

LOW

BUILDING

RETURN

SUPPLY

140° HOT WATER SUPPLY

COLD

WATER

180° HOT

WATER

SUPPLY

EXPANSION

TANK

THERMOMETER

MIXING VALVE

STORAGE TANK

(TYPICAL)

DRAIN

UNION (TYPICAL)

TEMPERATURE & PRESSURE RELIEF VALVE (TYPICAL)

BALL VALVE

(TYPICAL)

WATER

HEATER

CIRCULATOR

FLOW

SWITCH

Y-STRAINER (RECOMMENDED)

HIGH TEMPERATURE BUILDING RETURN

WATER HEATER

 CAUTION

NOTICE

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. Refer to the pump manufacturer’s installation instructions. Failure to comply could result in severe personal injury, death, or substantial property damage.

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.

Page 40

6 System piping

Figure 6-5 Single Heater - Single Tank

Installation & Operation Manual

COLD WATER

THERMOMETER

HOT WATER

SUPPLY

UNION

(TYPICAL)

TEMPERATURE

& PRESSURE

RELIEF VALVE

(TYPICAL)

SUPPLY

MIXING VALVE

FLOW CHECK

VALVE (TYPICAL)

BUILDING RETURN

EXPANSION TANK

WATER

HEATER

BALL VALVE (TYPICAL)

WATER

HEATER

CIRCULATOR

STORAGE

TANK

 CAUTION

NOTICE

FLOW

SWITCH

Y-STRAINER

DRAIN

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.

[RECOMMENDED]

Page 41

6 System piping (continued)

Figure 6-6 Single Heater - Double Tank

Installation & Operation Manual

HOT WATER

(TYPICAL)

TEMPERATURE

& PRESSURE

RELIEF VALVE

(TYPICAL)

THERMOMETER

SUPPLY

UNION

COLD WATER

SUPPLY

MIXING VALVE

FLOW CHECK VALVE (TYPICAL)

BUILDING RETURN

BALL VALVE (TYPICAL)

EXPANSION TANK

Y-STRAINER (RECOMMENDED)

WATER HEATER CIRCULATOR

FLOW SWITCH

STORAGE TANK

 CAUTION

NOTICE

(TYPICAL)

DRAIN

(TYPICAL)

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.

WATER HEATER

Page 42

6 System piping

Figure 6-7 Double Heater - Single Tank

Installation & Operation Manual

Number of Units

Model

2345678

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"

COLD WATER

SUPPLY

FLOW CHECK

VALVE (TYPICAL)

BUILDING

RETURN

HOT WATER

SUPPLY

THERMOMETER

TEMPERATURE

& PRESSURE

RELIEF VALVE

EXPANSION

TANK

MIXING VALVE

WATER HEATER CIRCULATOR (TYPICAL)

WATER HEATER (TYPICAL)

UNION (TYPICAL)

BALL VALVE (TYPICAL)

Y-STRAINER (RECOMMENDED)

STORAGE

 CAUTION

NOTICE

TANK

DRAIN

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.

Page 43

6 System piping (continued)

Figure 6-8 Double Heater - Double Tank

COLD WATER

SUPPLY

EXPANSION

TANK

FLOW CHECK

VALVE (TYPICAL)

BUILDING

RETURN

HOT WATER

SUPPLY

THERMOMETER

MIXING VALVE

UNION

(TYPICAL)

Installation & Operation Manual

Number of Units

Model

2345678

Required Pipe Sizes in NPT

WATER HEATER (TYPICAL)

FLOW SWITCH (TYPICAL)

WATER HEATER CIRCULATOR (TYPICAL)

BALL VALVE (TYPICAL)

Y-STRAINER (RECOMMENDED)

TEMPERATURE

& PRESSURE

RELIEF VALVE

(TYPICAL)

STORAGE TANK

(TYPICAL)

 CAUTION

NOTICE

DRAIN

(TYPICAL)

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.

Page 44

7 Gas connections

Installation & Operation Manual

Connecting gas supply piping

1. Remove the top access panel and refer to FIG.’s 7-1 thru 7-4 to pipe gas to the water heater.

a. Install ground joint union for servicing, when

required.

b. On Models 151 - 400 install a manual shutoff valve in

the gas supply piping outside water heater jacket when required by local codes or utility requirements.

c. In Canada – When using manual main shutoff

valves, it must be identified by the installer.

2. Install sediment trap / drip leg.

Figure 7-1 Gas Supply Piping - Models 151 - 200

UNION

GAS SUPPLY

Figure 7-3 Gas Supply Piping - Model 501

(FACTORY INSTALLED)

SHUTOFF VALVE

(FACTORY SUPPLIED)

GAS SUPPLY

SEDIMENT TRAP/

DRIP LEG

UNION

MANUAL

Figure 7-4 Gas Supply Piping - Models 601 - 801

(FACTORY INSTALLED)

SHUTOFF VALVE

(FACTORY SUPPLIED)

GAS SUPPLY

UNION

MANUAL

DRIP LEG

MANUAL

SHUT OFF

VALV E

Figure 7-2 Gas Supply Piping - Models 286 - 400

SEDIMENT TRAP / DRIP LEG

SEDIMENT TRAP/

DRIP LEG

3. Support piping with hangers, not by the water heater or its accessories.

 WARNING

The gas valve and blower will not support the weight of the piping. Do not attempt to support the weight of the piping with the water heater or its accessories. Failure to comply could result in severe personal injury, death, or substantial property damage.

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 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 than 1/2 PSIG (3.5 kPa).

c. The appliance and its gas connection must be leak tested before placing it in operation.

Page 45

7 Gas connections (continued)

Installation & Operation Manual

 WARNING

6. Use pipe sealing compound compatible with propane gases. Apply sparingly only to male threads of the pipe joints so that pipe dope does not block gas flow.

 WARNING

Figure 7-5 Inlet Pipe with Backup Wrench

Do not check for gas leaks with an open flame – use the bubble test. Failure to use the bubble test or check for gas leaks can cause severe personal injury, death, or substantial property damage.

Failure to apply pipe sealing compound as detailed in this manual can result in severe personal injury, death, or substantial property damage.

Armor water heaters are typically shipped ready to fire on natural gas. Check the water heater rating plate to determine which fuel the water heater is set for. If set to natural gas, it may be converted to LP by installing an orifice or by making a gas valve adjustment (see pages 13 thru

15). In order to operate on LP gas, an orifice MUST BE installed or a gas valve adjustment MUST BE made. Failure to comply could result in severe personal injury, death, or substantial property damage.

Use two wrenches when tightening gas piping at water heater (FIG. 7-5), using one wrench to prevent the water heater gas line connection from turning. Failure to support the water heater gas connection pipe to prevent it from turning could damage gas line components.

Natural gas:

Pipe sizing for natural gas

1. Refer to Table 7A for pipe length and diameter. Based on rated water heater input (divide by 1,000 to obtain cubic feet per hour).

a. Table 7A is only for natural gas with specific gravity

0.60 inches, with a pressure drop through the gas piping of 0.50 inches w.c.

b. For additional gas pipe sizing information, refer to

ANSI Z223.1 (or B149.1 for Canadian installations).

Natural 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 (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:

 WARNING

Pipe sizing for propane gas

Armor water heaters are typically shipped ready to fire on natural gas. Check water heater rating plate to determine which fuel the water heater is set for. If set to natural gas, it may be converted to LP by installing an orifice or by making a gas valve adjustment (see pages 13 thru 15). In order to operate on LP gas, an orifice MUST BE installed or a gas valve adjustment MUST BE made. Failure to comply could result in severe personal injury, death, or substantial property damage.

NOTICE

Maximum inlet gas pressure must not exceed the value specified. Minimum value listed is for the purposes of input adjustment.

1. Contact gas supplier to size pipes, tanks, and 100% lockup gas pressure regulator.

Propane supply pressure requirements

1. Adjust propane supply regulator provided by the gas supplier for 14 inches w.c. maximum pressure.

2. Pressure required at gas valve inlet pressure port:

• Maximum 14 inches w.c. with no flow (lockup) or with water heater on.

• Minimum 8 inches w.c. with gas flowing (verify during water heater startup).

 WARNING

Ensure that the high gas pressure regulator is at least 6 - 10 feet upstream of the appliance.

Page 46

7 Gas connections

Table 7A Natural Gas Pipe Size Chart

Installation & Operation Manual

Nominal

Iron Pipe

Size (Inches)

1/2 3/4

1 1-1/4 1-1/2

2 2-1/2

 WARNING

10 175 120 97 82 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 369 697

1400 2150 4100

6460 11200 23500

256 477

974 1500 2820 4460 7900

16100

205 384

789 1210 2260 3610 6400

13100

174 328

677 1020 1950 3100 5400

11100

Natural Gas Pipe Capacity Chart

Length of Pipe in Straight Feet for 1/2 PSI

155 292 595

923 1720 2720 4870

10000

141 267 543

830 1560 2460 4410 9000

1440 2310 4000 8300

an orifice or by making a gas valve adjustment (see pages 13 thru 15). In order to operate on LP gas, an orifice MUST BE installed or a gas valve adjustment MUST BE made. Failure to comply could result in severe personal injury, death, or substantial property damage.

Check inlet gas supply

NOTICE

 WARNING

The gas piping must be sized for the proper flow and length of pipe, to avoid excessive pressure drop. Both the gas meter and the gas regulator must be properly sized for the total gas load.

If you experience a pressure drop greater than 1 inch w.c., the meter, regulator, or gas line is undersized or in need of service. Perform the steps below when checking inlet gas supply:

1. Turn the main power switch to the “OFF” position.

2. Shut off gas supply at the manual gas valve in the gas piping to the appliance.

3. On Models 151 - 501 loosen the set screw one (1) full turn from inside the pressure tap on top of the gas valve. On Models 601 - 801 remove the 1/8" (3 mm) pipe plug on the inlet flange to the valve and install a suitable 1/8" (3 mm) fitting (field supplied) for the manometer tubing. Place the tubing of the manometer over the tap once the set screw is loosened or the 1/8" (3 mm) fitting is installed (depending on model) as shown 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.

CSA or UL listed flexible gas connections are acceptable, but you must exercise caution to ensure that the line has adequate capacity to allow your water heater to fire at full rate. Consult with local codes for proper installation or service procedures.

DO NOT adjust or attempt to measure 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 or measure the gas valve outlet pressure could result in damage to the valve, causing potential severe personal injury, death, or substantial property damage.

Single Unit

128 246 502 769

121 236 472

707 1330 2100 3800 7690

113 210 441

666 1250 2000 3540 7380

100

106 200 410

636 1180 1900 3330 6870

125

95 179 369 564

1100 1700 3000 6150

150

86 164 333 513 974

1540 2720 5640

175

79 149 308 472 871

1400 2500 5130

200

74 138 287 441 820

1300 2340 4720

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 panel.

8. Ensure inlet pressure is within specified range. Minimum and maximum gas supply pressures are specified in this section of the manual.

9. If gas supply pressure is within normal range and no adjustments are needed, proceed on to Step 11.

10. If the gas pressure is out of range, contact the gas utility, gas supplier, qualified installer or service agency to determine the necessary steps to provide proper gas pressure to the 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 151 - 501 re-tighten the set screw inside the pressure tap. On Models 601 - 801 remove the 1/8" (3 mm) field supplied fitting and reinstall the pipe plug removed in Step 3.

 WARNING

When re-tightening the set screw, be sure to tighten securely to prevent gas leaks.

Do not check for gas leaks with an open flame -- use the bubble test. Failure to use the bubble test or check for gas leaks can cause severe personal injury, death, or substantial property damage.

14. Turn on the gas supply at the manual gas valve.

15. Turn the power switch to the “ON” position.

16. Adjust the temperature set point on the control panel of the SMART SYSTEM control module to the desired water temperature so the appliance will call for heat.

Page 47

7 Gas connections (continued)

17. Check burner performance by cycling the system while you observe burner response. The burner should ignite promptly. Flame pattern should be stable. Turn system off and allow burner to cool, then cycle burner again to ensure proper ignition and flame characteristics.

Figure 7-6 Inlet Gas Supply Check - Models 151 - 286

LOOSEN THE SET SCREW ONE (1) FULL TURN AND PLACE THE MANOMETER TUBING OVER THE PRESSURE TAP

Installation & Operation Manual

Figure 7-9 Inlet Gas Supply Check - Models 601 - 801

REMOVE THE 1/8” (3 MM) PIPE PLUG ON THE INLET FLANGE TO THE VALVE AND INSTALL A SUITABLE 1/8” (3 MM) FITTING (FIELD SUPPLIED) FOR THE MANOMETER TUBING.

DETAIL

Figure 7-7 Inlet Gas Supply Check - Model 400

LOOSEN THE SET SCREW ONE (1) FULL TURN AND PLACE THE MANOMETER TUBING OVER THE PRESSURE TAP

DETAIL

Figure 7-8 Inlet Gas Supply Check - Model 501

LOOSEN THE SET SCREW ONE (1) FULL TURN AND PLACE THE MANOMETER TUBING OVER THE PRESSURE TAP

DETAIL

Gas pressure

The gas pressure must remain between 4 inches w.c. (natural), 8 inches w.c. (LP) minimum and 14 inches w.c. (natural and LP) maximum during stand-by (static) mode and while in operating (dynamic) mode. If an in-line regulator is used, it must be a minimum of 10 feet from the Armor water heater. It is very important that the gas line is properly purged by the gas supplier or utility company. Failure to properly purge the lines or improper line sizing, will result in ignition failure.

The problem is especially noticeable in NEW LP installations and also in empty tank situations. This can also occur when a utility company shuts off service to an area to provide maintenance to their lines.

Gas valve replacement

The gas valve MUST NOT be replaced with a conventional gas valve under any circumstances. As an additional safety feature, this gas valve has a flanged connection to the venturi and blower.

 WARNING

Failure to follow all precautions could result in fire, explosion, or death!

Page 48

8 Field wiring

Installation & Operation Manual

 WARNING

ELECTRICAL SHOCK HAZARD – For your safety, turn off electrical power supply before making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death.

NOTICE

Wiring must be N.E.C. Class 1.

If original wiring as supplied with the water heater must be replaced, use only type 105°C wire or equivalent.

The water heater must be electrically grounded as required by National Electrical Code ANSI/NFPA 70 – latest edition.

 CAUTION

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.

Figure 8-1 Line Voltage Field Wiring Connections

DOMESTIC

HOT WATER

PUMP

RECIRCULATION

PUMP

W G

SERVICE

SWITCH

L2/N

L4/N

120V SUPPLY

GROUND

LINE

NEUTRA

Installation must 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 connections

1. Connect 120 VAC power wiring to the line voltage terminal strip in the junction box, as shown in FIG. 8-1.

2. Provide and install a fused disconnect or service switch (15 amp 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.

Low voltage connections

1. Route all low voltage wires through the knockouts in the rear of the water heater, as shown in FIG. 8-2.

2. Connect low voltage wiring to low voltage connection board as shown in FIG. 8-3 on page 51 of this manual and the water heater wiring diagram.

Figure 8-2 Routing Field Wiring (Models 151 - 286)

LOW VOLTAGE WIRING KNOCKOUTS

LOW VOLTAGE CONNECTION BOARD

LINE VOLTAGE WIRING KNOCKOUTS

Page 49

8 Field wiring (continued)

Installation & Operation Manual

Tank thermostat

1. Connect the tank thermostats (isolated contact only) to the tank thermostat contacts as shown in FIG. 8-3.

Tank sensor

1. By installing a tank sensor, the SMART SYSTEM control can perform the tank thermostat function. The SMART SYSTEM control automatically detects the presence of this sensor and generates a DHW call for heat when the tank temperature drops 6°F (3°C) below the tank set point and finishes the call for heat when the tank temperature reaches 3°F (1.5°C) above the tank set point.

2. The tank sensor TST20015 is the only sensor suitable for use with the SMART SYSTEM control. Connect the sensor leads to the Tank Sensor terminals on the Low Voltage Connection Board (FIG. 8-3). Consult the tank manufacturer for application and performance when

used with any other indirect tank.

Louver relay

If louvers need to operate when the water heater fires, they can be controlled by this output. Connect these terminals to a 24 VAC relay coil, which is wired to operate the louvers (FIG. 8-3).

Louver proving switch

When the operation of the louvers needs to be verified before the water heater fires, remove the jumper wire from these terminals and connect them to the normally open contacts on its proving switch (FIG. 8-3).

Low gas pressure switch

1. If a switch is provided to detect low gas pressure, remove the jumper wire from the terminals on the connection board and connect them to its normally open contacts (FIG. 8-3).

2. If both a high and low gas pressure switch are used, connect their respective contacts in series, and connect them to the terminals on the connection board (FIG. 8-3).

NOTICE

See Section 7 - Gas Connections for a detailed explanation regarding high and low gas pressure switch operation.

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 at the water heater outlet.

2. Connect these terminals to the normally open contacts on the flow switch (FIG. 8-3).

Rate output

This output provides a 0 - 10V signal that is proportional to the firing rate of the water heater. This may be used by a BMS system 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.

High gas pressure switch

If a switch is provided to detect excessive gas pressure, remove the jumper wire from the terminals on the connection board, and then connect them to its normally closed contacts (FIG. 8-3).

Water heater Building Management System (BMS)

1. An external control may be connected to control either the firing rate or the set point of the water heater. If the external control uses a set of contacts to enable the water heater, connect the contacts to the Tank Thermostat terminals. Otherwise, the SMART SYSTEM control will be enabled by the 0-10V signal.

2. Make sure the ground terminal is connected to the ground output terminal of the external control, and the 0 - 10 VDC terminal is connected to the 0 - 10 VDC terminal of the external control.

Page 50

8 Field wiring

Runtime contacts

The SMART SYSTEM control closes a set of dry contacts whenever the burner is running. This is typically used by Building Management Systems to verify that the water heater is responding to a call for heat.

Alarm contacts

The SMART SYSTEM control closes another set of contacts whenever the water heater is locked out or the power is turned off. This can be used to turn on an alarm, or signal a Building Management System that the water heater is down.

Wiring of the cascade

When wiring the water heaters for Cascade operation, select one water heater as the Leader water heater. The remaining water heaters will be designated as Members. See page 58 “Configuration of the Cascade” for a detailed explanation of this procedure.

Installation & Operation Manual

Connect the tank sensor to the Leader water heater. For the 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 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 cable. Connect one of the twisted pair 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. 8-3). If more than two water heaters are on the Cascade, daisy chain the wiring from the Cascade terminals on the second water heater to the Cascade terminals on the third water heater, then from the third to the forth, and so on. The connections between heaters can be made in any order, regardless of the addresses of the water heaters. Try to keep each cable as short as possible.

Page 51

8 Field wiring (continued)

Figure 8-3 Low Voltage Field Wiring Connections

HEATER

TAN K SENS OR

Installation & Operation Manual

FROM

HEATER

SHIELD SHIELD

BUILDING

SYSTEM

MANAGEMENT

COM

RELAY COIL

24VAC LOUVER

LOUVER PROVING SWITCH

FLOW SWITCH

TAN K THERMOSTAT

LOW WATER CUTOFF

Page 52

9 Condensate disposal

Installation & Operation Manual

Condensate drain

1. This water heater is a high efficiency appliance that produces condensate.

2. The side of the water heater has a 1/2 inch PVC union for connection of a 1/2 inch PVC pipe (FIG. 9-1).

3. Slope condensate tubing down and away from the water heater into a drain or condensate neutralizing filter. Condensate from the Armor water heater will be slightly acidic (typically with a pH from 3 to 5). Install a neutralizing filter if required by local codes.

A Neutralizer Kit (FIG. 9-1) is available from the factory

(KIT3087 for Models 151 - 501 and KIT3046 for Models 601 - 801).

4. Install the 1/2 inch PVC tee assembly (shipped with the unit) as shown in FIG. 9-1.

5. Leave the top of the 1/2 inch tee OPEN. This is needed as a vacuum break.

6. Do not expose condensate line to freezing temperatures.

7. Use only plastic tubing or piping as a condensate drain line (FIG. 9-1).

NOTICE

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 an overflow switch to prevent property damage from condensate spillage. The switch should be wired in series with the blocked drain switch inside the water heater (see FIG. 10-1 on page 53).

Use materials approved by 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 ULC certified PVC or CPVC pipe, fittings, and cement.

To allow for proper drainage on large horizontal runs, a second line vent may be required and tubing size may need to increase to 1 inch.

The condensate line must remain unobstructed, allowing free flow of condensate. If condensate is allowed to freeze in the line or if the line is obstructed in any other manner, condensate can exit from the water heater tee, resulting in potential water damage to property.

Figure 9-1 Condensate Disposal

1/2” PVC TEE ASSEMBLY

(FACTORY SUPPLIED)

1/2” PVC UNION

(FACTORY SUPPLIED)

NEUTRALIZER KIT

FLOOR DRAIN OR DRAIN PAN

NOTE: KIT3087 shown for illustration purposes.

Page 53

10 Start-up

)

Installation & Operation Manual

Chlorine concentration less than 200 ppm

1. Do not fill the water heater or operate with water containing chlorine in excess of 200 ppm.

2. Filling with chlorinated fresh water should be acceptable since drinking water chlorine levels are much lower.

3. Do not use the water heater to directly heat swimming pool or spa water.

4. At initial fill and during water heater startup and testing, check system thoroughly for any leaks. Repair all leaks before proceeding further.

Check for gas leaks

 WARNING

Before starting the water heater, and during initial operation, smell near the floor and around the water heater for gas odorant or any unusual odor. Remove the top access panel and smell the interior of the water heater enclosure. Do not proceed with startup if there is any indication of a gas leak. Use an approved leak detection solution. Repair any leaks at once.

DO NOT adjust or attempt to measure 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 or measure the gas valve outlet pressure could result in damage to the valve, causing potential severe personal injury, death, or substantial property damage.

 WARNING

Propane water heaters only – Your propane supplier mixes an odorant with the propane to make its presence detectable. In some instances, the odorant can fade, and the gas may no longer have an odor. Before startup (and periodically thereafter), have the propane supplier verify the correct odorant level in the gas.

Inspect/fill condensate system

Inspect/check condensate lines and fittings

1. Inspect the condensate drain line, condensate PVC fittings and condensate trap.

Fill condensate trap with water

1. Remove the PVC cap retaining screw from the PVC cap (FIG. 10-1).

2. Remove the 2 inch PVC cap with the switch located at the top of the trap (FIG. 10-1).

3. Fill with fresh water until the water begins to pour out of the drain.

4. Replace the cap. Press the cap onto the trap until the cap makes contact with the drain.

5. Replace the retaining screw.

 WARNING

The condensate trap (FIG. 10-1) 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.

Figure 10-1 Condensate Trap

RETAINING

SCREW

CONDENSATE FROM

HEAT EXCHANGER

2” PVC CAP WITH

BLOCKED DRAIN SWITCH

PVC TEE ASSEMBLY

(FACTORY SUPPLIED

TO FLOOR

DRAIN

Page 54

10 Start-up

Installation & Operation Manual

Final checks before starting the water heater

 Read the Armor Water Heater Service Manual to

familiarize yourself with SMART SYSTEM control module operation. Read this manual, pages 55 and 56 for proper steps to start the water heater.

 Verify the water heater and system are full of water and

all system components are correctly set for operation.

 Verify the preparation procedures of Section 10, pages 53

and 54 have been completed.

 Fill the vent condensate trap with water (removing the

retaining screw in order to remove the 2 inch PVC cap with the switch located at the top of the trap). Replace the cap. Press the cap onto the trap until the cap makes contact with the drain. Replace the retaining screw.

 Verify electrical connections are correct and securely

attached.

 Inspect vent piping and air piping for signs of deterioration

from corrosion, physical damage or sagging. Verify air piping and vent piping are intact and correctly installed per this manual.

Start the water heater

1. Read and follow the Operating instructions in FIG.’s 10-2 and 10-3, pages 55 and 56.

If water heater does not start correctly

1. Check for loose connections, blown fuse or service switch off?

2. Is water heater water temperature above 200°F?

3. Is tank thermostat or tank set point set below room temperature?

4. Is gas turned on at meter or water heater?

5. Is incoming gas pressure less than 4 inches w.c.?

If none of the above corrects the problem, refer to the Troubleshooting Section of the Armor Water Heater Service Manual.

Check system and water heater

 Check water piping

1. Check system piping for leaks. If found, shut down the water heater and repair immediately. (See WARNINGS on pages 53 and 54 (startup) regarding failure to repair leaks.)

2. Check Delta T. Reference Section 6 - System Piping on page 38 for more information regarding Delta T.

3. Vent any remaining air from the system using manual 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.

 WARNING

 Check gas piping

1. Check around the water heater for gas odor following the procedure on page 44 of this manual (Connecting Gas Supply Piping).

 WARNING

 Propane water heaters – verify conversion

1. Verify propane conversion has been completed per the Propane Conversion instructions.

 WARNING

Venting system must be sealed gastight to prevent flue gas spillage and carbon monoxide emissions, which will result in severe personal injury or death.

If you discover evidence of any gas leak, shut down the water heater at once. Find the leak source with a bubble test and repair immediately. Do not start the water heater again until corrected. Failure to comply could result in severe personal injury, death, or substantial property damage.

Check flame and combustion

1. Turn the main power off to the water heater by placing the “On/Off” switch in the OFF position.

2. Remove the flue temperature sensor from the flue pipe connection. Note: Combustion measurements will be made at this point.

3. Turn the main power on to the water heater by placing the “On/Off” switch in the ON position.

Page 55

10 Start-up (continued)

Figure 10-2 Operating Instructions - Models 151 - 286

FOR YOUR SAFETY READ BEFORE OPERATING

Installation & Operation Manual

WARNING:

If you do not follow these instructions exactly, a fire or explosion

may result causing property damage, personal injury, or loss of life.

A. This appliance does not have a pilot. It is

equipped with an ignition device which automatically lights the burner. Do not try

to l ight the burner by hand.

B. BEFORE OPERATING smell all around

the appliance area for gas. Be sure to sm ell n ext t o the floor be c a use s om e ga s is heavie r than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electric switch; do not use an y phon e in you r build ing.

• Immedia tely ca ll your gas su pp lier f rom a neighbor’s phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fir e de pa rtm ent.

C. Use only your hand to move the gas control

switch. Never use tools. If the switch will not move by hand, don’t try to repair it, call a

qualified service technician. Force or attempted repair may r esult in a fire or explosio n.

D. Do not use this appliance if any part has been

under water. Immediately call a qualified servi ce tech ni cian to inspe ct the applia nce an d 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 ignition device which automatically lights the

burner. Do not try to light the burner by hand.

5. Remove front door.

6. Move switch to the “OFF” position.

7. Wait five (5) minutes to clear out any gas. If yo u then sme ll gas, STOP! F ollow “B” in the safety information above this label. If you don’t smell gas, go to next step.

8. Move the switch to the “ON” position.

9. In stall fr on t door.

10. Turn on all electric power to appliance.

11. Set thermostat to desired setting.

12. If the appliance will not operate, follow the inst ru ctio ns “To Tur n O f f Gas To Ap pl iance” an d

call your service technician or gas supplier.

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat to lowest setting.

2. Turn off all electric power to the appliance if service is to be performed.

3. Remove front door.

4. Move the switch to the “OFF” position.

5. In stall fr on t door.

LBL 2339

REV

Page 56

10 Start-up

Figure 10-3 Operating Instructions - Models 400 - 801

Installation & Operation Manual

Page 57

10 Start-up (continued)

Installation & Operation Manual

Check flame and combustion (continued)

4. Place the water heater into the active position by pressing the RIGHT SELECT [ON] key (FIG. 11-1, page 63).

5. Locate the pinhole button below the RESET button on the display board (FIG. 11-1). Insert a thin wire (such as a paper clip) into the hole and press the button once and hold for 5 seconds to place the water heater into Service Mode. In Service Mode the water heater will fire at ignition speed and will then modulate up to full fire.

6. Insert the probe from a combustion analyzer into the hole left by the removal of the flue temperature sensor.

7. Once the water heater has modulated up to full fire, measure the combustion. The values should be in the range listed in Table 10A below. The CO levels should be less than 150 ppm for a properly installed unit.

If the combustion is not within the specified range,

reference the Troubleshooting Section of the Armor Water Heater Service Manual for possible causes and corrective actions.

Table 10A Flue Products Chart

Natural Gas Propane

8.0% - 10% 3.0% - 6.5% 9.0% - 11% 4.1% - 6.9%

8. Once the combustion analysis is complete, test the safety

shutoff device by turning the manual shutoff valve to the OFF position and ensuring that the water heater shuts down and registers an alarm. Open the manual shutoff valve, reset the control, and return to Service Mode.

Set water heater operation

Set tank set point temperature

NOTICE

The NAVIGATION dial may be used during normal operation to adjust the tank set point temperature.

1. From the Status Screen press the NAVIGATION dial.

2. Press the NAVIGATION dial then rotate the NAVIGATION dial to adjust the temperature.

3. Once the desired temperature is displayed, press the RIGHT SELECT [SAVE] key.

4. Press the RIGHT SELECT [HOME] key to upload the changes.

5. If the RIGHT SELECT [SAVE] key is not pressed, the new settings will be discarded.

Verify WHR circulator mode

When the tank thermostat or tank sensor calls for heat, the SMART SYSTEM control will turn on the water heater pump. When the DHW call for heat ends, the water heater pump will continue to run for a period of time. This pump delay is set at the factory to 60 seconds. If a shorter or longer delay is desired, the appropriate parameter in the control must be changed. See the Armor Water Heater Service Manual for a detailed explanation of this procedure.

Please note that the brackets ([]) denote screen status.

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.

 WARNING

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 property damage.

Page 58

10 Start-up

Installation & Operation Manual

Set clock

NOTICE

The SMART SYSTEM 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 water heater is installed, and anytime the water heater has been powered off for more than 4 hours. Use the following procedure to set the clock:

1. Press and hold the LEFT SELECT [MENU] key for at least 5 seconds.

2. The display changes to read [PASSWORD], with four (4) zeros below it.

3. Press the RIGHT SELECT [SAVE] key.

4. The display will then show a menu with the time and date and temperature unit.

5. Press the NAVIGATION dial twice.

6. Turn the NAVIGATION dial to adjust the hours. Press the NAVIGATION dial.

7. Turn the NAVIGATION dial to adjust the minutes. Press the NAVIGATION dial.

8. Turn the NAVIGATION dial to adjust the month. Press the NAVIGATION dial.

Please note that the brackets ([]) denote screen status.

Configuration of the cascade

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 control parameters have been accessed, use the NAVIGATION dial to select the Control Mode parameters. Press the NAVIGATION dial to access these parameters.

Rotate the NAVIGATION dial to select the parameter “Cascade Address”. Press the NAVIGATION dial to access this parameter. Each appliance in the Cascade system must be programmed with its own address. The water heater designated as the Leader will have an address of 0. The remaining water heaters in the Cascade will be Members and have addresses from 1 - 7. Rotate the NAVIGATION dial to select the appropriate address. Press the RIGHT SELECT [SAVE] key. If installing the water heaters in an existing system, the new water heaters should be programmed as the Leader and/or the higher number addresses.

Press the RIGHT SELECT [HOME] key to upload the address into the control. Repeat this procedure for all water heaters in the Cascade, designating the Leader control and the Member controls.

Please note that the brackets ([]) denote screen status.

9. Turn the NAVIGATION dial to adjust the date. Press the NAVIGATION dial.

10. Turn the NAVIGATION dial to adjust the year. Press the RIGHT SELECT [SAVE] key.

11. Press the RIGHT SELECT [HOME] key.

NOTICE

The internal clock does not adjust for Daylight Savings Time and therefore, will require a manual adjustment.

Note: A tank sensor must be installed when operating Armor water heaters in Cascade.

Page 59

11 Operating information

Installation & Operation Manual

General

How the water heater operates

The Armor water heater uses an advanced stainless steel heat exchanger and electronic control module that allows fully condensing operation. The blower pulls in air and pushes flue products out of the water heater through the heat exchanger and flue piping. The control module regulates blower speed to control the water heater firing rate. The gas valve senses the amount of air flowing into the water heater and allows only the right amount of gas to flow.

Control inputs and outputs

Tank thermostat / tank sensor

Either of these inputs will tell the water heater to provide heat to the water tank. If a tank sensor is connected, the SMART SYSTEM control will ignore the tank thermostat.

0 - 10VDC input (set point or power)

The Armor water heater can be controlled by a Building Management System (BMS) using a 0 - 10 VDC signal. The control can be configured by the installer to use this signal to either control set point or firing rate. This signal can be sent to the heater through ModBus as well.

Protection 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 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 the maximum fan speed. If the flue temperature exceeds 240°F the control will shut the unit down. The unit will restart automatically once the flue temperature drops 25°F and the minimum off time has expired.

The control monitors the temperature difference between the inlet and the outlet sensor. On Models 151 - 501 if this difference is between 25 - 30°F the control will reduce the fan speed. If the temperature difference exceeds 30°F the control will shut the unit down.

On Models 601 - 801 if the temperature difference is between 30 - 35°F the control will reduce the maximum fan speed. If the temperature difference exceeds 35°F the control will shut the unit down.

Temperature control

Modulation

The Armor water heater is capable of modulating its firing rate from a minimum of 20% to a maximum of 100%. The firing rate is dictated by the hot water draw and various other temperature limitations.

Night setback

The controller may be programmed to reduce the DHW set point during certain times each week. Seven different start and stop times may be programmed for the DHW setback.

Flame current support

To prevent nuisance shutdowns when the water heater is firing at minimum rates, the control will increase fan speed when the flame signal drops too low.

The unit will restart automatically once the temperature difference has dropped below 25°F (Models 151 - 501) or 30°F (Models 601 - 801) and the minimum off time has expired.

Freeze protection

DO NOT install the water heater in a room likely to freeze.

The following integral feature of the SMART SYSTEM control module provides some protection for the water heater.

• The SMART SYSTEM control module provides freeze-up protection as follows when the water heater water temperature drops below 45°F:

• Below 45°F, the water heater pump operates constantly.

• Below 37°F, the water heater turns on.

• The water heater and pump will turn off if water heater water temperature rises above 45°F.

 CAUTION

This feature of the SMART SYSTEM control module does not eliminate the possibility of freezing. The installation must still use recognized design, installation and maintenance practice to prevent freeze potential for the water heater.

Page 60

11 Operating information

Monitor external limits

Connections are provided on the connection board for external limits such as flow switch, gas pressure switches, and a louver proving switch. The SMART SYSTEM will shut off the burner and inhibit relighting whenever any of these external limits open.

Installation & Operation Manual

When the outlet temperature exceeds 200°F, the automatic high limit action occurs. The water heater shuts down until the outlet water temperature cools below 190°F, and a 60 second timer has expired. If the outlet temperature continues to increase, the manual reset high limit action will occur at 210°F.

High limit test procedure

Runtime and alarm outputs

The water heater provides dry contacts for indicating when the water heater is running, and when it is unable to operate.

Runtime and cycle counting

The control uses a timer to monitor the total hours of burner operation. The timer monitors the time the water heater is firing.

The control uses two (2) ignition counters to monitor the amount of water heater cycles. The first counter counts all ignitions of the control. The second counter counts only ignition attempts that have failed.

Service reminder

The control can be programmed for service reminder notification. This notification will become active when either a set amount of time has expired, or a set amount of running hours or cycles has expired (all adjustable by the installer). The display will show a Maintenance Required screen. The service reminder notification can be reset or disabled by the installer.

The time dependent feature has been disabled by the manufacturer. To enable this feature change parameter I1 to the desired time range, 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.

Water heater temperature regulation

Operating temperature (target)

The SMART SYSTEM control module senses water temperature and regulates water heater firing and firing rate to achieve a target temperature. The target temperature can be set between 60°F and 190°F.

High limit operations

The Armor water heater is equipped with a fixed automatic reset hight limit and an adjustable manual reset high limit. The automatic reset high limit has a set point of 200°F and the manual reset high limit has a maximum set point of 210°F.

NOTICE

1. Turn ON the main power to the water heater by placing the ON/OFF switch in the ON position.

2. If water heater status reads [SHUTDOWN] place the water heater into the active position by pressing the RIGHT SELECT [ON] key.

3. Locate the pinhole (SERVICE button) below the RESET button on the display board. Insert a thin wire (such as a paper clip) into the hole and press the button once, hold for five (5) seconds to place the water heater into Service Mode. In Service Mode the water heater will fire at ignition speed and will then modulate up to full fire.

4. From the Status Screen, press the NAVIGATION dial to access the Set Points Screen.

5. Press the LEFT SELECT [LIMITS] key.

6. Select the manual reset high limit (MRHL) by pressing the NAVIGATION dial.

7. Decrease the set point of the MRHL below the outlet temperature by turning the NAVIGATION dial counterclockwise.

8. Press the RIGHT SELECT [SAVE] key.

9. Press the RIGHT SELECT [HOME] key.

10. The new parameters will upload to the control and the MRHL will function causing water heater shutdown and [LOCKOUT] to be displayed.

11. Press the RESET button to clear the lockout.

12. Repeat Steps 4, 5 and 6.

13. Set the MRHL to the appropriate set point by turning the NAVIGATION dial clockwise.

14. Repeat Steps 8 and 9.

Low water cutoff protection

1. The SMART SYSTEM control module uses temperature sensing of both supply and return areas of the heat exchanger. If the flow rate is too low or the outlet temperature too high, the control module modulates and shuts the water heater down. This ensures water heater shutdown in the event of low water or low flow conditions.

2. Some codes and jurisdiction may accept these integral features of the control in lieu of requiring an additional limit control or low water cutoff. Consult local jurisdiction to determine. A low water cutoff is available from the factory (WTR20009).

Please note that the brackets ([]) denote screen status.

Page 61

11 Operating information (continued)

Cascade

Access modes

Installation & Operation Manual

When multiple water heaters are installed, they can be wired together in a cascade sequence. A maximum of eight water heaters can be controlled from a single control. In this application one water heater would be designated as the Leader control and all others would be designated as Member controls. If installing the water heaters in an existing system, the new water heater should be programmed as the Leader and/or the higher number addresses. 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 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 new startup this will be the Leader water heater.

Sequence of the cascade

To equalize the runtime of all water heaters on the Cascade, the firing sequence will automatically be changed at set intervals.

User

The user can adjust tank target temperatures by pressing the NAVIGATION dial when “SETPOINTS” is flashing at the bottom of the display. The date and time, and the temperature units can also be changed (see page 58).

Installer

Most parameters are available only to the installer, accessible by entering the installer password, see the Armor Water Heater Service Manual.

Saving parameters (reference the Parameter Table in

the Armor Water Heater Service Manual)

NOTICE

To save parameters and exit programming:

Press the RIGHT SELECT [SAVE] key and then press the RIGHT SELECT [HOME] key.

To enter a parameter and continue programming:

Press the RIGHT SELECT [SAVE] key 1 time to return to the parameter listings; press again to return to the menu listings. Remember to press the RIGHT SELECT [HOME] key when finished programming in order to save the changes made.

Please note that the brackets ([]) denote screen status.

For the first 24 hours after initializing the Cascade, the sequence will be changed every hour. After that the sequence will be changed once every 24 hours. The switching on/off sequence 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

Night Setback operation with cascade

Night Setback operation of the water heaters within the Cascade is available. Programming of the Night Setback will be done through the Leader water heater. Refer to the Armor Water Heater Service manual for information regarding Night Setback.

See the Armor Water Heater Service Manual for a detailed description of parameters and access modes.

Page 62

11 Operating information

Sequence of operation

OPERATION DISPLAY

1. The control will turn on the water heater pump (always ON except in Night Setback). The flow switch and/or LWCO must close.

2. The control turns on power to the louver relay. The louver proving switch, air pressure switch, and blocked drain switch must close.

3. The control starts a 15 second prepurge cycle.

Installation & Operation Manual

4. The control starts a 4 second trial for ignition by firing the spark electrode and opening the gas valve.

5. If flame is not detected within 1 second after the sparking ends, the control will perform a 10 second post-purge, then start another prepurge 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 5 seconds to let the flame stabilize, then it begins to modulate the firing rate based on a set point or some other command (such as a 0-10V BMS signal).

7. Once the call for heat is satisfied, the control will turn off the burner. The blower will continue to run during a 10 second postpurge.

8. The water heater pump will continue to run for its respective pump delay time before turning off. A 60 second anti-cycle period will start, which will delay any new call for heat until it times out.

9. In Standby, ready to start a new cycle.

Page 63

Installation & Operation Manual

11 Operating information (continued)

Armor water heater control module

Use the control panel (FIG. 11-1) to set temperatures, operating conditions, and monitor water heater operation.

Figure 11-1 Control Panel

NAVIGATION DIAL

RESET KEY

(PRESS OR TURN)

LEFT SELECT KEY

(SOFT KEY)

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

RIGHT SELECT KEY

(SOFT KEY)

Page 64

11 Operating information

Figure 11-2 Status Display Screen

Installation & Operation Manual

Status Display Screens

Section Display Description

The unit has not received a call for heat from a remote thermostat nor has it received a call for heat from a DHW thermostat.

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 products.

The controlled temperature has exceeded its set point and its offset.

The unit has detected a condition that has temporarily interrupted the current call for heat.

(Water heater

Status Bar)

STANDBY

START The unit has begun a burn cycle and is checking all safety circuits.

PREPURGE The unit has initiated a 10 second purge period on a call for heat.

IGNITION The unit has begun a 4 second spark period to ignite the main burner.

The unit has fired and is running at the displayed percentage.

POSTPURGE

SHUTDOWN The unit has been placed in the OFF position.

BLOCKED

(Call for Heat

Indicators)

The tank thermostat or sensor has a call for heat.

The unit is being controlled by a 0 - 10V BMS signal.

The member unit is supplying heat while in Cascade Mode.

Page 65

11 Operating information (continued)

Status Display Screens (cont’d)

Section Display Description

TANK: The temperature read by the tank sensor (if connected).

INLET TEMP: The temperature read at the inlet to the heat exchanger.

OUTLET TEMP: The temperature read at the outlet of the heat exchanger.

Installation & Operation Manual

(Operational

Information)

DELTA T:

FLUE TEMP: The temperature read by the flue sensor.

FLAME CURRENT: The current measured by the flame sense circuit.

FAN SPEED: The speed of the combustion blower.

SYSTEM PUMP: The status of the recirculation pump output.

DHW PUMP: The status of the DHW pump output.

BMS VOLTAGE: The voltage received from a BMS system.

BLR PUMP OUTPUT:

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.

The temperature difference between the inlet and the outlet of the heat exchanger.

The speed signal sent to a variable speed water heater pump in percent.

(LEFT SELECT

key function)

LAST 10 FAULTS NO:* The last 10 lockouts.

EXIT Press the LEFT SELECT key to exit the current screen or setting.

YES

LIMITS

HOME

Press and hold the LEFT SELECT key for 5 seconds to enter the Menu Screen.

Press the LEFT SELECT key to confirm that the water heater needs to shutdown.

Press the LEFT SELECT key to enter the screen that allows you to adjust the limit settings.

Press the LEFT SELECT key to return to the Status Screen and upload parameter changes.

Page 66

11 Operating information

Status Display Screens (cont’d)

Section Display Description

Turning the NAVIGATION dial will select the next or previous Status Screen.

Pressing the NAVIGATION dial will show the next fault, NSB (Night Setback) trigger, or ramp delay setting.

Installation & Operation Manual

(NAVIGATION

Dial Function)

(RIGHT SELECT

key function)

Pressing the NAVIGATION dial will select the setting indicated 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.

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 cancel the shutdown operation.

SAVE Press the RIGHT SELECT key to save the current change.

HOME

Press the RIGHT SELECT key to return to the Status Screen and upload parameter changes.

Page 67

12 Maintenance

Maintenance and annual startup

Table 12A Service and Maintenance Schedules

Installation & Operation Manual

Service technician

(see the following pages for instructions)

General:

• Address reported problems

• Inspect interior; clean and vacuum if necessary;

• Clean condensate trap and fill with fresh water

• Check for leaks (water, gas, flue, condensate)

• Verify flue and air lines in good condition and sealed tight

• Check system water pressure/system piping/expansion tank

• Check control settings

• Check ignition and flame sense electrodes (sand off any deposits; clean and reposition)

• Check wiring and connections

ANNUAL START-UP

• 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)

Owner maintenance

Daily

Monthly

• Check water heater area

• Check pressure/temperature gauge

• Check vent piping

• Check air piping

• Check air and vent termination screens

• Check relief valve

• Check condensate drain system

• Check automatic air vents

• 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

Every

6 months

• Check water heater piping (gas and water) for leaks

• Operate relief valve

Page 68

12 Maintenance

 WARNING

Follow the service and maintenance procedures given throughout this manual and in component literature shipped with the water heater. Failure to perform the service and maintenance could result in damage to the water heater or system. Failure to follow the directions in this manual and component literature could result in severe personal injury, death, or substantial property damage.

Installation & Operation Manual

 WARNING

The water heater should be inspected annually only by a qualified service technician. In addition, the maintenance and care of the water heater designated in Table 12A and explained on the following pages must be performed to assure maximum water heater efficiency and reliability. Failure to service and maintain the water heater and system could result in equipment failure.

 WARNING

Electrical shock hazard – Turn off power to the water heater before any service operation on the water heater except as noted otherwise in this instruction manual. Failure to turn off electrical power could result in electrical shock, causing severe personal injury or death.

Address reported problems

1. Inspect any problems reported by the owner and correct before proceeding.

Inspect water heater area

1. Verify that water heater area is free of any combustible materials, gasoline and other flammable vapors and liquids.

2. Verify that air intake area is free of any of the contaminants listed in Section 1 - Determine Water Heater Location. If any of these are present in the water heater intake air vicinity, they must be removed. 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 interior of the water heater.

2. Vacuum any sediment from inside the water heater and components. Remove any obstructions.

Clean condensate trap

Figure 12-1 Condensate Trap

RETAINING

SCREW

2” PVC CAP WITH

BLOCKED DRAIN SWITCH

CONDENSATE FROM

HEAT EXCHANGER

 WARNING

The condensate trap must be filled with water during all times of water heater operation to

TO FLOOR

DRAIN

avoid flue gas emission from the condensate drain line. Failure to fill the trap could result in severe personal injury or death.

Check all piping for leaks

 WARNING

Eliminate all system or water heater leaks. Leaking water may cause severe property damage.

PVC TEE ASSEMBLY

(FACTORY SUPPLIED)

1. Inspect the condensate drain line, condensate PVC fittings, and condensate trap.

2. Remove the PVC cap retaining screw from the PVC cap (FIG. 12-1).

3. Remove the 2 inch PVC cap with the switch located at the top of the trap (FIG. 12-1).

4. Remove any sediment in the trap.

5. Fill with fresh water until the water begins to pour out of the drain.

6. Replace the cap. Press the cap onto the trap until the cap makes contact with the drain.

7. Replace the retaining screw.

1. Inspect all water and gas piping and verify to be leak free.

2. Look for signs of leaking lines and correct any problems found.

3. Check gas line using the procedure found in Section 7 - Gas Connections.

Flue vent system and air piping

1. Visually inspect the entire flue gas venting system and air

piping for blockage, deterioration or leakage. Repair any joints that show signs of leakage. Verify that air inlet pipe is connected and properly sealed.

2. Verify that water heater vent discharge and air intake are

clean and free of obstructions.

Page 69

12 Maintenance (continued)

Installation & Operation Manual

 WARNING

Failure to inspect for the above conditions and have them repaired can result in severe personal injury or death.

Check water system

1. Verify all system components are correctly installed and operational.

2. Check the cold fill pressure for the system. Verify it is correct (must be a minimum of 12 PSI).

3. Watch the system pressure as the water heater heats up (during testing) to ensure pressure does not rise too high. Excessive pressure rise indicates expansion tank sizing or performance problem.

4. Inspect automatic air vents and air separators. Remove air vent caps and briefly push valve to flush vent. Replace caps. Make sure vents do not leak. Replace any leaking vents.

Check expansion tank

1. Expansion tanks provide space for water to move in and out as the heating system water expands due to temperature increase or contracts as the water cools. Tanks may be open, closed or diaphragm or bladder type. See Section 6 - System Piping for suggested best location of expansion tanks and air eliminators.

Check water heater relief valve

1. Inspect the relief valve and lift the lever to verify flow. Before operating any relief valve, ensure that it is piped with its discharge in a safe area to avoid severe scald potential. Read Section 6 - System Piping before proceeding further.

 WARNING

Safety relief valves should be re-inspected AT LEAST ONCE EVERY THREE YEARS, by a licensed plumbing contractor or authorized inspection agency, to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally. Certain naturally occurring conditions may corrode the valve or its components over time, rendering the valve inoperative. Such conditions are not detectable unless the valve and its components are physically removed and inspected. This inspection must only be conducted by a plumbing contractor or authorized inspection agency – not by the owner. Failure to re-inspect the water heater relief valve as directed could result in unsafe pressure buildup, which can result in severe personal injury, death, or substantial property damage.

 WARNING

2. After following the above warning directions, if the relief valve weeps or will not seat properly, replace the relief valve. Ensure that the reason for relief valve weeping is the valve and not over-pressurization of the system due to expansion tank waterlogging or undersizing.

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 taken to avoid contact with hot water and to avoid water damage. Before operating lever, check to see that a discharge line is connected to this valve directing the flow of hot water from the valve to a proper place of disposal. Otherwise severe personal injury may result. If no water flows, valve is inoperative. Shut down the water heater until a new relief valve has been installed.

Inspect ignition and flame sense electrodes

1. Remove the ignition and flame sense electrodes from the water heater heat exchanger access cover.

2. Remove any deposits accumulated on the ignition/flame sense electrode using sandpaper. If the electrodes cannot be cleaned satisfactorily, replace with new ones.

3. Replace ignition/flame sense electrode, making sure gasket is in good condition and correctly positioned.

Check ignition ground wiring

1. Inspect water heater ground wire from the heat exchanger access cover to ground terminal strip.

2. Verify all wiring is in good condition and securely attached.

3. Check ground continuity of wiring using continuity meter.

4. Replace ground wires if ground continuity is not satisfactory.

Check all water heater wiring

1. Inspect all water heater wiring, making sure wires are in good condition and securely attached.

Check control settings

1. Set the SMART SYSTEM control module display to Parameter Mode and check all settings. See Section 1 of the Armor Service Manual. Adjust settings if necessary. See Section 1 of the Armor Service Manual for adjustment procedures.

2. Check settings of external limit controls (if any) and adjust if necessary.

Page 70

12 Maintenance

Perform start-up and checks

1. Start water heater and perform checks and tests specified in Section 10 - Start-up.

2. Verify cold fill pressure is correct and that operating pressure does not go too high.

Check burner flame

1. Inspect flame through observation window.

2. If the flame is unsatisfactory at either high fire or low fire, turn off water heater and allow water heater to cool down. Remove the burner and clean it thoroughly using a vacuum cleaner or compressed air. Do not use compressed air to clean burner if performed inside a building.

3. Remove the burner, reference FIG. 12-2 below.

4. When replacing the burner, ensure gasket is in good condition and positioned correctly (FIG. 12-2).

Figure 12-2 Burner Assembly

Installation & Operation Manual

3. Remind the owner to follow the proper shutdown procedure and to schedule an annual start-up.

Cleaning heat exchanger

For recommended materials; including brush, appropriate 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 to room temperature

if it has been firing.

3. Remove the nuts securing the heat exchanger access cover

to the heat exchanger and set aside.

4. Remove the heat exchanger access cover, burner, and

gas/air arm assembly.

Check flame signal

1. At high fire the flame signal shown on the display should be at least 10 microamps.

2. A lower flame signal may indicate a fouled or damaged flame sense electrode. If cleaning the flame sense electrode does not improve, ground wiring is in good condition, and ground continuity is satisfactory, replace the flame sense electrode.

3. See Section 3 - Troubleshooting in the Armor Service Manual for other procedures to deal with low flame signal.

Review with owner

1. Emphasize the need to perform the maintenance schedule specified in this manual.

2. Remind the owner of the need to call a licensed contractor should the water heater or system exhibit any unusual behavior.

 WARNING

5. Remove the condensate hose from the heat exchanger end. Connect a field supplied 3/4" diameter hose to a drain pan. Using field supplied means, cover the refractory in the back of the combustion chamber of the heat exchanger.

6. Use a vacuum cleaner to remove any accumulation on the water heater heating surfaces. Do not use any solvent.

7. Brush the heat exchanger while dry using a nylon bristle brush. Caution: DO NOT use a metal brush. Re-vacuum the heat exchanger.

8. Finish cleaning using a clean cloth dampened with warm water. Rinse out debris with a low pressure water supply.

9. Allow the heat exchanger to thoroughly dry.

10. Remove the field supplied rear refractory cover from the back of the combustion chamber of the heat exchanger and reassemble.

11. Close isolation valves on piping to isolate water heater from system. Attach a hose 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 make-up line to the water heater.

12. Perform start-up and check-out procedures in the Check Flame and Combustion - Section 10 - Startup on pages 54 and 57 of this manual.

13. Replace the access cover and restore water heater to operation.

The water heater contains ceramic fiber materials. Use care when handling these materials per instructions in the Service Manual. Failure to comply could result in severe personal injury.

Page 71

12 Maintenance (continued)

Installation & Operation Manual

Table 12B Heat Exchanger Cleaning Kits

Model

151 - 400 KIT30063

501 - 801 KIT30064

 CAUTION

Kit

Number

* Do NOT use a metal brush. Only use the kit provided brush or an equivalent

Part

Number

CTN20005 Rear Refractory Cover

MSC20083* Nylon 4" Wheel Brush*

MSC20084 3mm Allen Wrench

MSC20086

CTN20005 Rear Refractory Cover

MSC20083* Nylon 4" Wheel Brush*

MSC20085

MSC20086

Component Description

1/4" x 24" Drill

1/4" x 12" Drill

1/4" x 24" Drill

replacement nylon brush.

Extension

Check Delta T

1. Check Delta T. Reference Section 6 - System Piping on page 38 for more information regarding Delta T.

Oiled bearing circulators

1. The circulator shipped with the Armor water heater is water-lubricated. No oiling is required.

2. Check other circulators in the system. Oil any circulators requiring oil, following circulator manufacturer’s instructions. Over-oiling will damage the circulator.

Figure 12-3 Rope Gasket - Heat Exchanger Door

ROPE GASKET

CAUTION: IF GASKET IS DAMAGED

DO NOT REUSE, THE HEAT EXCHANGER DOOR

MUST BE REPLACED.

NOTICE

Rope gasket is intended for sealing combustion (see FIG. 12-3). If gasket is damaged DO NOT reuse, the heat exchanger door must be replaced. Consult factory for replacement heat exchanger door (kit WTR3080 and WTR3086).

Page 72

13 Diagrams

Figure 13-1 Ladder Diagram

Installation & Operation Manual

120VAC

TERMINAL STRIP 120V SUPPLY "L"

ON / OFF SWITCH

X1-6

X4-3

CN5-5

X5-9

3.5A

AW 801 ONLY

CN7-1

CN7-3

CONNECTION BOARD

JUNCTION BOX

INTEGRATED CON TROL

3.15A

RECIRC PUMP

.8A

24V DC

SUPPLY

120 VAC

24 VAC

LWCO

BUILDING

RELAY

DHW PUMP

RELAY

CN7-4

CN7-2

RIBBON CABLE

GROUND

NEUTRAL

TERMINAL STRIP 120V SUPPLY "N"

BLOWER

INTEGRATED

CN5-14 X4-8

CN5-10

CN5-12

CN5-11

CN5-3

CN5-4 X4-4

CONTROL

X4-12

X4-10

X4-11

X4-5

BUILDING

RECIRC

PUMP

DHW

PUMP

TERMINAL

CONNECTION BOARD

FLOW

SWITCH

TANK

THERMOSTAT

HIGH GAS

PRESSURE

SWITCH

LOUVER

RELAY COIL

24VAC

LOUVER

PROVING SWITCH

GND

SYSTEM

PUMP "N"

GND

DHW

PUMP "N"

STRIP

SYSTEM

X1-1

PUMP "L"

X1-2

DHW

PUMP "L"

X1-3

TERMINAL

STRIP

X5-1

LOW GAS

PRESSURE

SWITCH

INTEGRATED

CONTROL

PC INTERFACE

ALARM

BELL

SWITCH

SILENCING

TANK

SENSOR

SHIELD

CASCADE

SHIELD

BMS

RATE

OUT

SHIELD

MODBUS

SHIELD

ALARM

CONTACTS

RUN-TIME

CONTACTS

0-10V

INLET

SENSOR

S1a

OPERATING

SENSOR

S1b

HIGH LIMIT

SENSOR

S3a

FLUE

SENSOR

S3b

FLUE

SENSOR

CONNECTION

BOARD

CN8-1

CN8-2

CN8-3 X6-3

X5-6

X5-4

X5-12

X5-5

X5-13

X5-14

CN5-1

X4-7

X4-14

CN5-8

CN5-2

X4-6

CN5-9

X4-13

CN3-9

X4-9

CN3-6

X4-6

CN6

M O

X4-1

X9-2

X6-1

X6-2

X4-2

X9-1

B U

X4-3

X9-3

NOTES:

1. Where possibl e, switches are shown w ithout 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 addit ional notes.

BLOCKED

DRAIN SWITCH

AIR PRESSURE

SWITCH

GAS VALVE

BLOWER

SPARK

ROD

HIGH VOLTAGE SPARK LEADCAUTION

X5-2

X5-10

X5-11

X2-2

X2-1

TR2

X1-7

FLAME ROD

GAS VALVE

RELAY

X5-7

X5-16

X5-8

X5-15

BOX DEPICTS

OPTIONAL ITEMS

LOW VOLTAGE 120 VAC HIGH VOLTAGE

LADDER DIAGRAM

LBL20149 REV B

Page 73

13 Diagrams (continued)

Figure 13-2 Wiring Diagram

Installation & Operation Manual

ALARM BELL

SILENCI NG SWITCH

CONTACT S

24 VAC LO UVER

BELL JUMPER

RELAY COIL

PROVING SWIT CH

GAS PRESSURE

THERMOSTAT

ALARM

RUN-TIME

LOUVER

SWITCH

FLOW

SWITCH

TANK

CONNECTION BOARD

1 2 3 4 5 6 7 8 9

11 12 13 14

LOW VOLTAGE 120 VAC HIGH VOLTAGE

CN5-1 CN5-8 CN5-2 CN5-9

CN5-3 CN5-10 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

INTEGR ATED

CONTROL

X-7

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

BOX DEPICTS

OPTIONAL ITEMS

BOX DEPICTS

DUAL SENSOR

SINGLE HOUSI NG

COM

X1-3

OR/BK

X1-4

COM

PR/W

X1-2

X1-6

X1-5

X1-8

X1-1

ON/OFF SWITC H

1 2G3

JUNCTION

BOX

L N

TRANSFORMER

3.5A

AW 801

ONLY

GND

DHW PUMP

BUILDING RECIRC. PUMP

120V SUPPLY

TANK

SENSOR

SHIELD

CASCADE

SHIELD

15 16 17 18 19 20 21 22

CN6

BMS

0-10V

RATE

0-10V

OUT

SHIELD

OPTION

LOW

WATER

SHIELD

JUMPER

SHIELD

24 VAC

COM

MODBUS

CUT-OFF

GROUNDING

Notes:

1. All wiring must be installed in accordance with:

2. If any original equipment wire as supplied with minimum of 105°C. Exceptions: Replacement high vo or ribbon cables can lead to operational problem s w

3. Actual connector block locations may vary from those shown on diagrams. Refer to actual components diagrams to troubleshoot unit.

23 24

25 26 27 28 29 30

CN7-1 CN7-2 CN7-3 CN7-4

MODBUS BOARD

X5-1 X5-2

local, state, provincial and national code requir the appliance must be replaced, it must be replaced

ltage spark lead and ribbon cables must be purchased from the factory. Use of a non-approved spark le

hich could result in non-repairable damage to the integrated controller or other components.

MTR-01

CN8-1

CN8-2

CN8-3

X6-3

X6-2

X6-1

X6-4

X4-1

X4-2 X4-3

X4-4

X1-1

X1-2

X1-3

ements per either N.E.C. in USA or C.S.A. in Canada

with wire having same wire gauge (AWG) and rated for a

BLOWER

123 4

X9-1

X9-2

X9-3

X9-4

X5-7

X5-16

X5-8

X5-15

X5-9

X5-1

X5-2

X5-10

X5-11

X5-4

X5-12

X5-6

X5-5

X5-13

X5-14

X2-2

X2-1

X1-7

TR2

O/BK

R/BK

P/BK

W/BK

W/R

-T

GAS VALVE @24VAC

FLAME SENSOR

SPARK

ROD

CAUTION

HIGH VOLTAGE SPARK LEAD

OPERATING SENSO R S1a

HIGH LIMIT SENSOR S1b

INLET SENSOR S2

FLUE SENSOR S3a

FLUE SENSOR S3b

for proper connect or block locations when using

BLOCKED DRAIN SWITCH AIR PRESSURE SWITCH

WIRING DIAGRAM

LBL20134 REV B

Page 74

Notes

Installation & Operation Manual

Page 75

Notes

Installation & Operation Manual

Page 76

Revision Notes: Revision A (ECO #C06238) initial release.

Revision B (ECO #C07442) new layout in InDesign, piping diagram on page 43 (ECR #R03671), and edits made to the Ratings Page (page 7).

Revision C (ECO #C07575) changes made (mixing valves) to the piping diagrams on pages 39 - 43, changes made to the gas supply piping images on page 44 (ECR R03740), the addition of the rope gasket notice on page 71 (ECR R03940), change water pipe clearances from 1" to 1/4" (ECR R04077), and changes made to Table 3A on page 19.

AWII-I-O Rev C

4/11

Lochinvar ARMOR 151 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual