Lochinvar ArmorX2 1, ArmorX2 1.5, ArmorX2 1.3 User Manual

AWX2-SER Rev A

Service Manual

Models: 1.0, 1.3, and 1.5

 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 X2 Installation and
Operation Manual, before
installing. Perform steps in
the order given. Failure to
comply could result in severe
personal injury, death, or
substantial property damage.

Contents

CONTENTS ........................................................................ 2

Hazard Definitions .............................................................. 2

PLEASE READ BEFORE PROCEEDING ......................... 2

Handling Ceramic Fiber Materials ...................................... 3

When servicing water heater ........................................ 3

Water heater operation ................................................ 3

Heater water ................................................................. 3

Freeze protection fluids ................................................ 3

WHAT IS IN THIS MANUAL .............................................. 4

1. SERVICE

The Armor X2 Water Heater Display ................................. 5

Control Inputs ............................................................... 6

Control Outputs ............................................................. 7

General Operation ........................................................ 8

Sequence of Operation ...................................................... 9

Parameter Table.......................................................... 10-11

Viewable and Changeable Control Parameters .......... 12-31

2. MAINTENANCE

Maintenance and Annual Startup ................................ 32-36

3. TROUBLESHOOTING

Alarm Screen.................................................................... 37

Before Troubleshooting .................................................... 38

Check Control Module Fuses .......................................... 38

Table 3A - Troubleshooting Chart - No Display ......... 39

Checking Temperature Sensors ...................................... 40

Table 3D - Troubleshooting Chart - Noisy System ..... 41

Table 3E - Troubleshooting Chart - Fault Messages 42-48

Combustion Analysis Procedure ...................................... 49

Table 3F - Troubleshooting Chart - Combustion Levels 49

Table 3G - Flue Products ........................................... 49

Gas Valve Adjustment Procedure .................................... 50

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.

Please read before proceeding

 WARNING

Installer – Read all instructions,
including this manual and the Armor
X2 Installation and Operation Manual,
before installing. Perform steps in the
order given.

User – This manual is for use only by
a qualified heating installer/service
technician.

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.

NOTICE

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 (see
the Armor X2 Installation and Operation
Manual).

Any claims for damage or shortage
in shipment must be filed immediately
against the transportation company by the
consignee.

2

Please read before proceeding

Service Manual

 WARNING

Installer – Read all instructions,
including this manual and the Armor X2
Water Heater Installation and Operation
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.

Handling ceramic fiber materials

REMOVAL OF COMBUSTION CHAMBER LINING

 WARNING

The combustion chamber insulation in this appliance
contains ceramic fiber material. Ceramic fibers can
be converted to cristobalite in very high temperature
applications. The International Agency for Research
on Cancer (IARC) has concluded, “Crystalline silica
in the form of quartz or cristobalite from occupational
sources is carcinogenic to humans (Group 1)”. Normal
operating temperatures in this appliance are below the
level to convert ceramic fibers to cristobalite. Abnormal
operating conditions would have to be created to convert
the ceramic fibers in this appliance to cristobalite.

The ceramic fiber material used in this appliance is
an irritant; when handling or replacing the ceramic
materials it is advisable that the installer follow these
safety guidelines.

Avoid breathing dust and contact with skin and eyes.

• Use NIOSH certified dust respirator (N95).
This type of respirator is based on the OSHA
requirements for cristobalite at the time this
document was written. Other types of
respirators may be needed depending on the job
site conditions. Current NIOSH recommendations
can be found on the NIOSH website at
http://www.cdc.gov/niosh/homepage.html.
NIOSH approved respirators, manufacturers, and
phone numbers are also listed on this website.

NOTICE

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 (see the Armor
X2 Water Heater Installation and Operation
Manual).

Any claims for damage or shortage in
shipment must be filed immediately against the
transportation company by the consignee.

When servicing 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.

• Wear long-sleeved, loose fitting clothing, gloves,
and eye protection.

Apply enough water to the combustion chamber
lining to prevent airborne dust.

 Remove the combustion chamber lining from the
water heater and place it in a plastic bag for disposal.

 Wash potentially contaminated clothes separately
from other clothing. Rinse clothes washer thoroughly.

NIOSH stated First Aid.

 Eye: Irrigate immediately.
 Breathing: Fresh air.

3

What is in this manual?

Service Manual

Service

The Armor X2 water heater display

• Display panel readout, buttons and their functions

Control module inputs

• Control module inputs and options

Control module outputs

• Control module outputs and options

General

• How the water heater operates

• How the control module operates

• Access modes -- user and installer

• Sequence of operation -- Water Heating

Control panel menu access

• Accessing programming mode and locating menus
(See separate guide covering the PC interface.)

Control panel parameter access

• Accessing and changing parameters from the display panel

Quick start information -- parameter table

• An index of available adjustments and readouts, where to
access them and where to find detailed information.

Armor X2 water heater operation

• Setup

• Service / Setup

• Setpoint

• Night Setback

• Cascade

• Pumps

• BMS

Maintenance

• Service and maintenance schedules

• Address reported problems

• Inspect water heater area and water heater interior

• Clean condensate trap

• Check all piping for leaks

• Check air openings

• Flue vent system and air piping

• Check water system

• Check water heater relief valve

• Inspect ignition electrode

• Check ignition ground wiring

• Check all water heater wiring

• Check control settings

• Perform start-up and checks

• Check burner flame

• Check flame signal

• Check flue gas temperature

• General maintenance

• Review with owner

• Cleaning the water heater heat exchanger

• Oiled bearing circulators

Troubleshooting

• Troubleshooting table - No display

• Checking temperature sensors

• Sensor tables

• Troubleshooting table - Fault messages displayed on the
water heater interface

• Combustion analysis procedure

• Gas valve adjustment procedure

4

1 Service

The Armor X2 display

Service Manual

5

1 Service

Control inputs

LOW VOLTAGE

CONNECTION

BOARD

SEQUENCER / BUILDING

MANAGEMENT SYSTEM

Service Manual

SECONDARY

SMART CONTROL

MODULE

PRIMARY

SMART CONTROL

MODULE

HW TANK SENSOR

ENABLE

HEAT EXCHANGER SWITCH

TOUCH DISPLAY

O-TEMP

BLOCKED DRAIN SWITCH

FLOW SWITCH

TOUCH PANEL

INTERFACE

HEAT EXCHANGER SWITCH

O-TEMP

PRIMARY/SECONDARY INLET

TEMPERATURE SENSOR

PRIMARY/SECONDARY OUTLET

TEMPERATURE SENSOR

FLOW SW ITCH

PRIMARY/SECONDARY

FLUE GAS SENSOR

PRIMARY/SECONDARY

HIGH LIMIT SENSOR

PRIMARY/SECONDARY

FLAME SENSOR

PC INTERFACE

MODBUS COMMUNICATION

BOARD

IMG00166

6

E

1 Service (continued)

Control outputs

Service Manual

SECONDARY

LOW VOLTAGE

CONNECTION

BOARD

ALARM BELL

RUN TIME CONTACTS

PRIMARY

SMART TOUCH

CONTROL MODULE

SMART TOUCH

CONTROL MODUL

SEQUENCER / BUILDING

MANAGEMENT SYSTEM

TOUCH DISPLAY

PC INTERFACE

HEAT EXCHANGER 1 /
HEAT EXCHANGER 2
HW PUMP

TOUCH PANEL

INTERFACE

IGNITOR

BLOWER

GAS VALVE

7

1 Service

General Operation

Service Manual

How the water heater operates

The Armor X2 uses two (2) advanced stainless steel heat
exchangers and two (2) electronic control modules that allow
fully condensing operation. The blowers pull in gas and
air and push flue products out of the water heater through
the heat exchangers and flue piping. The control modules
regulate blower speeds to control total water heater firing
rate. The gas valves sense the amount of air flowing into the
water heater and allow only the right amount of gas to flow.

Sequence of operation

Table 1A shows control module normal sequences of
operation for each individual control module. Additionally,
the control modules are programmed to synchronize their
combined modulation rates in order to maximize total water
heater efficiency.

Access modes

User

The user can view all of the settings on the LCD screen. By
entering the user password (0704), the user can adjust the
User Set Point, Outdoor Shutdown, Night Setback, Boost,
HW Water Heater Output Set Point, Backlight Time, and
Backlight Brightness settings.

Installer

Most parameters are available only to the installer, accessible
only by entering the installer access code (5309).

8

Service Manual

1 Service (continued)

Sequence of operation

Table 1A Sequence of operation

Note: This unit is equipped with two (2) independent, but synchronized combustion systems. One of the heat exchanger
combustion systems will fire first. If the demand cannot be met by one (1) combustion system the same sequence of operation
will be followed to bring the second heat exchanger combustion system online.

Upon a call for heat, the control turns on the appropriate pumps.

1.

The control confirms that the flow switch contacts are closed.

2.

The control starts the blower and closes the louver contacts to begin the Pre-Purge cycle.

3.

The control confirms that the blower comes up to the desired speed, the flap valve opens, and the air pressure switch,

4.

gas pressure switch (optional), louver proving switch (optional), and blocked drain switch contacts close.

5.

6.

7.

8.

9.

10.

11.

Once the Pre-Purge cycle is complete, the control lowers the blower speed, initiates sparking of the ignition electrode,
and opens the gas valve.

After a short wait, the control stops sparking and checks for the presence of flame current through the spark and
flame sense electrodes.

If the control does not detect flame current, the control will try again. If no flame current is detected on the second
try, the control will lockout indefinitely until the RESET button on the touch screen LCD is pressed.

If the control detects flame current, the control will hold the blower speed constant for a few seconds to allow the
flame to stabilize, then begin modulating the firing rate in order to maintain the controlling sensor to the desired set
point temperature.

If the first heat exchanger in the water heater is unable to maintain the desired set point temperature, the second
heat exchanger in the water heater will be started, using much of the same sequences as described above. Once both
heat exchangers are firing, the controls will work in synchronization to maintain the desired set point temperature.
If the heat load should decrease sufficiently, the second heat exchanger will be shut down, much like the sequences
described below.

Once a call for heat is satisified, the control will turn off the gas valve and begin the Post-Purge cycle. The pumps that
are running will begin their respective Pump Delay cycles.

At the end of the Post-Purge cycle, the louver contacts will open.

12.

13.

The control verifies that the blower stops running and the flap valve closes.

At the end of the Pump Delay cycle(s), the pump(s) will be turned off.

9

Service Manual

1 Service

Parameter table

Table 1B This table lists the parameters and where to access them

MENU DESCRIPTION

Service/Setup 17 Yes Yes Yes Yes
Night Setback 17 Yes Yes Yes Yes

SETUP

Set points 17 Yes Yes Yes Yes
Cascade 17 Yes Yes Yes Yes
BMS 17 Yes Yes Yes Yes

Demand Conf 18 Yes No Yes No
Serv Not Time 18 No No Yes Yes
Serv Not Run H 18 No No Yes Yes
Serv Not Cycl 18 No No Yes Yes
Max Serv T 19 Yes No Yes No

Temp Unit 19 No No Yes Yes

User Passwd 19 No No Yes Yes

PARAMETERS

SERVICE / SETUP

LCD Backlight 19 No No Yes Yes

LCD Bright 19 No No Yes Yes

SEE

PAGE

USER ACCESS INSTALLER ACCESS

DISPLAY MODIFY DISPLAY MODIFY

SET POINT

PARAMETERS

HW Pump D 19 No No Yes Yes

Tank setp 20 No No Yes Yes

Tank on df 20 No No Yes Yes

Tank off df 20 Yes Yes Yes Yes

NSB setp 20 No No Yes Yes

Drop in Inlet
Anti-C t 20 No No Yes Yes

Tank Off Diff 20 Yes Yes Yes Yes

20 No No Yes Yes

10

Service Manual

1 Service (continued)

Table 1B (continued from previous page) This table lists the parameters and where to access them

Date and time 21 Yes Yes Yes Yes

NIGHT

SETBACK

CASCADE

BMS

On Timer and Off Timer 21 No No Yes Yes

Casc Address 22 Yes Yes Yes Yes
Casc off df 22 No No Yes Yes
Casc off/on df 22 No No Yes Yes
Max Outl temp 22 No No Yes Yes

BMS Type 23 No No Yes Yes

ModBus Timeout 23 No No Yes Yes

BMS Setp min V 23 No No Yes Yes

BMS Setp max V 23 No No Yes Yes

BMS V min Setp 23 No No Yes Yes

BMS V max Setp 23 No No Yes Yes

BMS V Heat 23 No No Yes Yes

Dropin BMS End 23 No No Yes Yes

BMS mod@minV 24 No No Yes Yes

BMS mod@maxV 24 No No Yes Yes

BMS V @min mod 24 No No Yes Yes

BMS V @max mod 24 No No Yes Yes

11

Service Manual

1 Service

Viewable and changeable control parameters

Status Screen:

When the ON/OFF switch is turned to the ON position,
the first screen visible on the LCD display will be the Status
Screen. This screen displays the current status of the Armor
X2 water heater. The following items can be viewed or
interacted with on the Status Screen:

On/Off button - Pressing this button allows the water heater
to be placed in either Manual Shutdown Mode or Standby
Mode.

Status - This line shows the current operating status of the
Armor X2 water heater. Displayed items are as follows:

• Manual Shutdown - The water heater will not
respond to a hot water call.

• Standby - The water heater has not received a hot water
call.

• HW Storage - The water heater has received a hot water
call.

• HW Pump Delay - The water heater has satisfied a hot
water call and the hot water pumps
are running for a fixed time to remove any residual
heat.

• BMS - The water heater has received a call for heat from
a 0-10 VDC BMS control.

• Service Set Point Met - While in Service Mode, the
water temperature at either the outlet sensor or the
system sensor has exceeded 185°F.

• Anti-Cycle Delay - The water heater has satisfied a call for
heat, but has received another call for heat before the anti­ cycling time parameter has elapsed.

• Cascade ComError - A communication error has occurred
between the Control Module 1 and Control Module 2 or
between the Leader and Member water heaters.

12

1 Service (continued)

Service Manual

Configuration - This line shows the current configuration of
the two control modules inside the unit.

Outlet Water Temperature - This is a calculated temperature
based on the readings of the outlet temperatures of the two
(2) heat exchangers.

Inlet Water Temperature - This is a calculated temperature
based on the inlet temperature readings from the two (2) heat
exchangers.

Hot Water Tank Temperature - This is the temperature as
measured by the tank sensor in the hot water storage tank.

Time - The time is displayed in the upper right-hand corner of
the display. It is displayed in a 24 hour format. Reference the
Night Setback parameters on page 21 for information regarding
adjusting the date and time.

Details button - Pressing this button brings up the Details
Screen. This screen shows the status of the various safeties,
inputs, and outputs to each control module. Reference the
Details Screen section on page 14 for more information
regarding this screen.

Main button - Pressing this button brings up the Main Screen.
From this screen navigation to eight (8) other screens is
possible. Reference the Main Screen section on page 16 of this
manual for more information regarding this screen.

13

1 Service

Details Screen:

Service Manual

The Details Screen is accessed by pressing the DETAIL button
on the Status Screen. This screen shows the status of the
various safeties, inputs and outputs to each control module.
Selection of the control module to be viewed is accomplished
by pressing the SELECT button. The control module being
displayed is shown in the module box.

Displayed items are as follows:

• HW Thermostat - Is ON when a Hot Water call has been
received from a tank thermostat. Is OFF when a Hot
Water call has not been received from a tank thermostat.

• Gas Pressure Switches - Is ON when the high and low gas
pressure switches are closed. If OFF when either the high
or low gas pressure switches are open.

• Louver Proving Switch - Is ON when a remote proving
safety switch is closed. Is OFF when a remote proving
safety switch is open.

• Manual Reset High Limit - Is ON when the manual reset
high limit is closed. Is OFF when the manual reset high
limit is open.

• Air Pressure Switch - Is ON when the combustion air
blower is energized and the flap valve switch is closed.
Is OFF when the flap valve switch is open.

• Flow Switch / Low Water Cutoff - Is ON when the low
water cutoff contacts are closed or if an optional flow
switch is used and it is closed as well. Is OFF when the
low water cutoff contacts are open or if an optional flow
switch is open.

• Blocked Drain Switch - Is ON when the blocked drain
switch on the condensate trap is closed. Is OFF when the
blocked drain switch on the condensate trap is open.

• Auto Reset High Limit - An auto reset high limit is not used
in the standard configuration of the Armor X2 water
heater. If OFF is shown then a wiring problem exists.

• HW Pump - Is ON when a Hot Water Generation call has
been received from a tank thermostat or a tank sensor and
the hot water generation pump is energized. Is OFF when
the hot water generation pump is de-energized.

• Gas Valve - Is ON when the gas valve is energized. Is OFF
when the gas valve is de-energized.

• Alarm - Is ON when a fault has been detected and the
alarm contacts are closed. Is OFF when the alarm
contacts are open.

• Blower Power - Is ON when the combustion air blower is
energized. Is OFF when the combustion air blower is de­ energized.

• Run Time Contacts - Is ON when the burner is energized.
Is OFF when the burner is de-energized.

• 0-10Vdc - Shows the voltage signal being delivered from a
remote Building Management System (BMS).

14

1 Service (continued)

Service Manual

A blank message box is located on the Details Screen. This
box will display various messages detailing the status of the
control module. If a message is present in this box, the
DETAILS button on the Status Screen will contain a yellow
triangle with an exclamation mark (!) inside.

Displayed items are as follows:

• Delta T Shutdown - The temperature rise between the
inlet and outlet temperatures has exceeded 35°F.
Reference page 48 for more information regarding this
shutdown.

• Outlet Temp Shutdown - The outlet temperature has
exceeded 195°F. Reference page 48 for more information
regarding this shutdown.

• Flue Temp Shutdown - The flue temperature has
exceeded 240°F. Reference page 48 for more information
regarding this shutdown.

• Voltage too Low - The 120 VAC input to the control has
dropped below 80 VAC. Reference page 47 for more
information regarding this fault message.

• Connect Tank Sensor - Tank sensor is not detected by
Control Module 1. For proper operation of the Armor X2
water heater the tank sensor must be connected.

• Manual Shutdown - The water heater has been shutdown
with the ON/OFF button on the Status Screen.

Time - The time is displayed in the upper right-hand corner of
the display. It is displayed in a 24 hour format. Reference the
night setback parameters on page 22 for information regarding
adjusting the date and time.

Status button - Pressing this button displays the Status Screen.
This screen shows the current status of the Armor X2 water
heater. Reference pages 12 - 13 for more information regarding
this screen.

Main button - Pressing this button displays the Main Screen.
From this screen, navigation to eight (8) additional screens is
possible. Refer to Main Screen on page 16 for more information
regarding this screen.

15

1 Service

Main Screen:

Service Manual

The Main Screen allows navigation to eight (8) additional
screens which are used to set temperatures, operating
conditions, and monitor water heater operation. These
screens are as follows:

• Setup - Allows access to five (5) other screens for the
adjustment of the control parameters.

• Cascade - Shows the status of multiple heaters connected
together in a cascade arrangement.

• Temps - Shows the temperatures measured by the
individual sensors connected to the heater.

• Burners - Shows the status of the two (2) independent
burner systems used in the heater.

• Building - Shows the information from a Building
Integration System using Modbus Protocols.

• Graphs - Allows the selection of items to be graphed on a
chart.

• History - Shows the operating and fault history of the
two (2) control modules.

• Service Mode - Allows the installer to control the fan
speed of the individual control modules for the purposes
of combustion analysis. Service Mode will override all
other heat demands, however, all safeties will continue to
function.

Navigation to the Main Screen can be accomplished by pressing
the MAIN button at the bottom of the page.

Reference pages 17 - 31 of this manual for more information
regarding the eight (8) accessible screens.

Time - The time is displayed in the upper right-hand corner of
the display. It is displayed in a 24 hour format. Reference the
night setback parameters on page 21 for information regarding
adjusting the date and time.

Status button - Pressing this button displays the Status Screen.
This screen shows the current status of the Armor X2 water
heater. Reference pages 12 - 13 for more information regarding
this screen.

16

1 Service (continued)

Service Manual

CAUTION

Before changing parameters, note the settings so that the unit can be returned to its original operating
parameters.

Setup Screen:

The Setup Screen allows access to five (5) other screens for
adjusting control parameters.

These screens are as follows:

• Service / Setup - Allows access to change service
notification parameters, LCD backlight parameters, and
temperature units.

• Setpoints - Allows access to change the HW set point
and ON/OFF differentials.

• Cascade - Allows access to change the cascade parameters.

• Night Setback - Allows access to change the date and time
and ON/OFF times for night setback.

• BMS - Allows access to change the 0 - 10Vdc BMS
parameters.

To change a parameter, press one of the five screen buttons.
A list of parameters and their corresponding location are
located on pages 10 and 11, Table 1B. Once a Screen button
is pressed a list of adjustable parameters will appear.

Select the parameter to be adjusted by pressing the SELECT
button next to the parameter. The first time the parameters
are accessed, you will be required to enter the service
password. The service password is 5309. Using the keypad,
enter the password and then press the OK button. If the
password is not entered correctly, the screen will revert to the
Parameter List Screen and you will not be able to adjust the
parameters. If a digit has been entered incorrectly, press the
left arrow key on the keypad to back up one digit.

If the password has been entered correctly, the Parameter
Change Screen will appear. The Parameter Change Screen will
display the parameter being changed, the previous setting of the
parameter, and adjustment buttons.

To adjust the parameter, press the + or - buttons to change the
value being displayed. Once the parameter has been adjusted
to the desired setting, press the APPLY button to change the
parameter and return to the Parameter List Screen. If no change
is necessary, press the BACK button to return to the Parameter
List Screen. Once all the necessary adjustments have been
made, press the BACK button to return to the Setup Screen.
Repeat this procedure to adjust the parameters in other screens.

Press the SAVE button to program all changes made to the
control parameters and return to the Status Screen. Leaving the
Setup Screen without pressing the SAVE button will erase the
changes made to the control parameters and revert them back
to their previous settings.

Time - The time is displayed in the upper right-hand corner of
the display. It is displayed in a 24 hour format. Reference the
night setback parameters on page 21 for information regarding
adjusting the date and time.

Main button - Pressing this button brings up the Main Screen.
From this screen navigation to eight (8) other screens is
possible. Reference the Main Screen section on page 16 of this
manual for more information regarding this screen.

Save button - Pressing this button will save all changes made to
the control parameters.

Status button - Pressing this button displays the Status Screen.
This screen shows the current status of the Armor X2 water
heater. Reference pages 12 - 13 for more information regarding
this screen.

17

1 Service

Service/Setup Parameters Screen:

Service Manual

The Service / Setup Screen allows access to 10 parameters.
Those parameters are as follows:

• Demand Configuration - Sets the configuration of the
control modules inside the water heater. The
configuration selections are:

Demand Configuration 1: Cascade Set Point Thermostat
based - the control modulates the water heater based on the
user set point and the temperature of the tank sensor.
Demand Configuration 2: Cascade BMS Thermostat
based - a 0 - 10Vdc signal is provided to the water heater
to control either the set point or the modulation of the
water heater.
Demand Configuration 3: Cascade BMS Voltage based - a
0 - 10Vdc signal is provided to the water heater to control
either set point or modulation. A minimum voltage signal is
required to initiate a call for heat.
Demand Configuration 4: Cascade Set Point Modbus
Thermostat based - the control modulates the water
heater based on the tank set point and the temperature of the
tank sensor. An enable signal is provided by writing
to the holding registers on the Modbus communication
board.
Demand Configuration 5: Cascade Modbus BMS
Thermostat based - a 0 - 10V dc signal is provided to the
water heater to control either the set point or the modulation
of the water heater. An enable signal and an equivalent 0 ­ 10V signal is provided by writing to the holding registers on
the Modbus communication board.

Demand Configuration 6: Cascade Modbus BMS Voltage
based on a 0 - 10V dc signal is provided to the water heater to
control either set point or modulation. An equivalent 0 ­10V dc signal is provided by writing to the holding registers
on the Modbus communication board.

When any of these BMS configurations are selected, additional
parameters for BMS operation will have to be adjusted. Reference
the BMS parameters on pages 23 and 24 for information
regarding adjusting these parameters. There are three (3) other
configuration selections that are possible, however, they must
NOT be used on the Armor X2 water heater.

This parameter can only be changed by the installer. The default
configuration is Cascade Set Point Thermostat based.

• Service Notification Time - When the water heater
determines that a scheduled service is due based on days of
installation, the Service Needed screen will appear. This
parameter can only be changed by the installer. The
adjustment range for this parameter is 0 months to 36
months. The default time is 12 months.

• Service Notification Running Hours - When the water
heater determines that a scheduled service is due based on the
hours of actual operation. This parameter can only be
changed by the installer. The adjustment range for this
parameter is 0 hours to 100,000 hours. The default time is
10,000 hours.

• Service Notification Cycles - When the water heater
determines that a scheduled service is due based on the
number of water heater cycles, the Service Needed screen will
appear. This parameter can only be changed by the
installer. The range for this parameter is 0 cycles to 100,000
cycles. The default is 10,000 cycles.

18

1 Service (continued)

Service Manual

• Maximum Service Time - Service Mode allows the
installer to control the fan speed of the individual control
modules for the purposes of combustion analysis.

Service Mode will override all other heat demands,
however, all safeties will remain intact. Maximum
service time sets the length of time the water heater
will stay in Service Mode if no buttons are pressed before
reverting back to its original state. This parameter
can only be changed by the installer. The time range of
this parameter is 0 to 40 minutes. The default value is 20
minutes.

• Temperature Units - The control can be configured to
display temperatures in either °C or °F. The default is °F.

• User Password - Allows the user to access and change a
limited number of control parameters. The access code
can be changed by the user or the installer to a code of
their choosing. The default code is 0704.

• LCD Backlight - Sets the length of time the LCD Screen
will stay on after a button has been pressed. This
parameter can be changed by the user or the installer.
The time range for this parameter is 30 seconds to ON.
With a setting of ON, the LCD Screen will be on
continuously. The default time is 15 minutes.

Reference page 17 for information regarding changing
parameters.

Time - The time is displayed in the upper right-hand corner of
the display. It is displayed in a 24 hour format. Reference the
night setback parameters on page 21 for information regarding
adjusting the date and time.

Back button - Pressing this button will back the screen up to
the previous screen.

• LCD Brightness - Controls the brightness of the screen.
This parameter can be changed by the user or the
installer. The range for this parameter is 10% to 100%.
The default percentage is 50%.

• HW Pump D - Controls the length of time the HW pump
continues to run after the burner turns off.

19

1 Service

Set Point Parameters Screen:

Service Manual

The Set Point Screen allows access to 6 parameters. Those
parameters are as follows:

• Hot Water Tank Set Point - The hot water tank
set point sets the target temperature of the water in the
tank. This parameter can be changed by the user or the
installer. The temperature range of this parameter is 60°
to 185°F. The default value is 125°F.

• Hot Water Tank On Differential - Sets how many degrees
below the Hot Water Tank Set Point the hot water tank
temperature must drop before the water heater will turn
on. This parameter can only be changed by the installer.
The temperature range for this parameter is 0° to 100°F.
The default value is 5°F.

• Night Setback Set Point - Once the internal clock has
been set correctly, the night setback feature can be used to
program a lower water temperature set point. This
parameter can be changed by the user or the installer.
The temperature range for this parameter is 32° to 140°F.
This feature is turned off with a setting of 32°F. The
default value is 32°F.

• Drop in Inlet Temperature for Ending Anti-cycling - The
control will bypass the anti-cycling time if the inlet water
temperature drops too quickly. The control will use the
inlet water temperature at Heat Exchanger 1 when it shuts
off as the starting point. If the temperature drops below the
temperature parameter the control will abort anti-cycling
and allow the water heater to fire. This parameter can only be
changed by the installer. The temperature range of this
parameter is 0° to 86°F. The default value is 10°F.

• Anti-cycling Time - Once a call for heat has been satisfied, a
set amount of time must elapse before the control will
respond to a new call for heat. The control will block the
new call for heat and Anti-cycling will be shown in the
water heater status display until the time has elapsed or
the inlet water temperature drops below the parameter
drop in inlet temperature for ending anti-cycling. This
parameter can only be changed by the installer. The time
range for this parameter is 0 minutes to 40 minutes. The
default value is 1 minute.

• Hot Water Tank Off Differential - Sets how many degrees
above the Hot Water Tank Set Point the hot water tank
temperature must rise before the water heater will turn
off. This parameter can only be changed by the installer.
The temperature range for this parameter is 0° to 100°F.
The default value is 5°F.

Reference page 17 for information regarding changing
parameters.

Time - The time is displayed in the upper right-hand corner of
the display. It is displayed in a 24 hour format. Reference the
night setback parameters on page 21 for information regarding
adjusting the date and time.

Back button - Pressing this button will back the screen up to
the previous screen.

20

1 Service (continued)

Night Setback Parameters Screen:

Service Manual

The Night Setback Screen allows access to 15 parameters.
Those parameters are as follows:

• Date and Time - The control uses an internal clock for the
night setback feature and for logging of events. For these
features to work correctly, the clock must be set when the
heater is first installed or any time the heater has been
powered off for more than 30 days.

To set the clock, press the SELECT button in the upper right­hand corner of the display. The date and time are displayed
as “Day dd/mm/yy hh:mm”. Day = day of the week (1 =
Monday, 2 = Tuesday, etc.), dd = date, mm = month, yy =
year, hh = hour, mm = minutes (24 hours time; 2:30 PM =
14:30). Using the keypad, adjust the date and time by working
from left to right. If a digit has been entered incorrectly, press
the left arrow key on the keypad to back the digit up. If a
change is not necessary, press the BACK button to return to
the Parameter List Screen. Once the correct date and time
have been entered press the OK button on the display to
program the date and time into memory and return to the
Parameter List Screen.

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

Example: Monday ON: 22:30, Tuesday OFF: 6:45. If you wish
to skip a day and no night setback is necessary, program the on
and off times the same and set them prior to 12:00 (noon). If
you wish to keep night setback active throughout an entire day,
program the on and off times the same and set them after 12:00
(noon). The default times for each day will be on at 18:00 and
off at 8:00.

To adjust the on and off times, select the parameter to be
adjusted by pressing the SELECT button next to the parameter.
Using the keypad, adjust the time by working from left to right.
If a digit has been entered incorrectly, press the left arrow key
on the keypad to back the digit up. If no change is necessary,
press the BACK button to return to the Parameter List Screen.
Once the correct time has been entered press the OK button on
the display to program the time into memory and return to the
Parameter List Screen.

Reference page 21 for information regarding NSB Set Point
Temp programming.

Apply button - If changes have been made to the date and time
or to one of the on or off timers, the APPLY button must be
pressed to program the changes into the control module and
return to the Setup Screen.

• On Timer and Off Timer - If the parameter night setback
set point is set to anything other than 32°F, the night
setback feature becomes active. This will require on and
off times to be programmed for the days that reduced
temperatures are required. Each day of the week
(Monday through Sunday) will have an on and off time.

Back button - Pressing this button will back the screen up to the
previous screen.

21

1 Service

Cascade Parameters Screen:

Service Manual

Cascade Operation

When multiple water heaters are installed, they can be wired
together in a cascade sequence. A maximum of eight (8)
heaters can be controlled from a single control. In this
application one heater would be designated as the Leader and
all others would be designated as Members. The designated
Leader water heater determines the total output needed from
the group based on the set point and the tank sensor reading.
Reference the Wiring of the Cascade section in the Armor
X2 Installation and Operation Manual for more information
regarding the cascade feature.

The Cascade Screen allows access to four (4) parameters.
Those parameters are as follows:

• Cascade Address - The heater designated as the Leader
should be programmed with address 0-1. All Member
heaters require addresses from 2-3 through 14-15. The
address must be different for each member. The
addresses can be in any order, regardless of the order in
which the water heaters are wired together. This
parameter can only be changed by the installer. The
default address is 0-1.

• Cascade Off Differential - Sets how many degrees above
set point the temperature has to go before the lead water
heater will shut off. This parameter can only be changed
by the installer. The temperature range of this parameter
is 0° to 72°F. The default value is 10°F.

• Cascade Off/On Differential - Sets how many degrees
below the turn off temperature (set point + Cascade Off
Differential) the temperature has to go before the lead
water heater will turn on. This parameter can only be
changed by the installer. The temperature range of this
parameter is 0° to 72°F. The default value is 20°F.

• Maximum Outlet Temperature - Sets the set point that
individual heater will attempt to achieve in a cascade.
When a heater is commanded to fire by the Leader, it will
attempt to achieve this temperature at its outlet. The
Leader will control the modulation of the last heater to fire
in order to hold the temperature at the tank
sensor to the user set point. If any of the water heater
outlet temperatures reach the Maximum Outlet
Temperature setting, the water heater will then modulate
down on its own in order to keep its outlet temperature
within the Maximum Outlet Temperature setting.
Therefore, this parameter can be used to limit the
outlet temperatures of all the heaters in a cascade.

Reference page 17 for information regarding changing
parameters.

Time - The time is displayed in the upper right-hand corner of
the display. It is displayed in a 24 hour format. Reference the
night setback parameters on page 21 for information regarding
adjusting the date and time.

Back button - Pressing this button will back the screen up to the
previous screen.

22

1 Service (continued)

0 - 10Vdc BMS Parameters Screen:

Service Manual

0-10Vdc Operation

When the Demand Configuration parameter (see page 18)
is set to either Cascade BMS Thermostat Based, Cascade
BMS Voltage Based, Cascade Modbus BMS Thermostat
Based, or Cascade Modbus BMS Voltage Based; a 0 - 10Vdc
signal can be supplied to the terminal strip connection or
through Modbus communications to control a single unit or
a multiple unit cascade.

The BMS Screen allows access to 12 parameters. Those
parameters are:

• BMS Type - When the unit or cascade is controlled by the
0-10Vdc BMS input, the voltage signal can control either
the modulation rate or set point. This parameter can only
be changed by the installer. The default method of
control is modulation rate.

• ModBus Time - When the tank temperature reading is
provided through the ModBus control, it should be
refreshed on a regular basis. This setting defines the
maximum time it must be refreshed. If the time expires,
the control will revert to its local reading.

• BMS Set Point at Minimum Voltage - Determines the set
point used by the unit or cascade when the BMS voltage
is at or below the setting of the BMS Voltage Minimum
Set Point parameter. This parameter is only active when
the BMS Type is set to Set Point. This parameter can only
be changed by the installer. The temperature range of this
parameter is 32° to 179°F. The default value is 70°F.

• BMS Set Point at Maximum Voltage - Determines the set
point used by the unit or cascade when the BMS voltage
is at or above the setting of the BMS Voltage Maximum
Set Point parameter. This parameter is only active when
the BMS Type is set to Set Point. This parameter can only
be changed by the installer. The temperature range of this
parameter is 70° to 190°F. The default value is 179°F.

• BMS Voltage at Minimum Set Point - Determines the
voltage at which the external signal begins to increase the
set point. Below this voltage, the set point will be at the
setting of the BMS Set Point Minimum Voltage
parameter. This parameter is only active when the BMS
Type is set to Set Point. This parameter can only be
changed by the installer. The range of this parameter is 0
to 10V. The default value is 2V.

• BMS Voltage at Maximum Set Point - Determines the
voltage at which the external signal forces the set point to
the setting of the BMS Set Point Maximum Voltage
parameter. This parameter is only active when the BMS
Type is set to Set Point. This parameter can only be changed
by the installer. The range of this parameter is 2V to 10V.
The default value is 10V.

• BMS Voltage at Start Call for Heat - When the Demand
Configuration parameter (see page 18) is set to Cascade
BMS Voltage Based, this parameter determines the BMS
input voltage at which the unit or cascade is enabled. The
unit or cascade will become enabled when the BMS input
voltage rises up to or above this value. This parameter can
only be changed by the installer. The range of this
parameter is 0 to 10V. The default value is 2V.

• Drop in BMS Voltage to End Call for Heat - When the
Demand Configuration parameter (see page 18) is set to
Cascade BMS Voltage Based, this parameter determines the
BMS input voltage at which the unit or cascade is disabled.
The unit or cascade will become disabled when the BMS
input voltage drops down to or below the BMS voltage at
start call for heat minus this value. This parameter can only
be changed by the installer. The range of this parameter is
0 to 10V. The default value is 1V.

23

1 Service

Service Manual

• BMS Modulation at Minimum Voltage - Determines the
modulation rate of the unit or cascade when the BMS
input voltage is at or below the setting of the BMS Voltage
at Minimum Modulation parameter. This parameter is
only active when the BMS Type is set to modulation rate.
This parameter can only be changed by the installer. The
range of this parameter is 0% to 100%. The default value
is 14.5%.

• BMS Modulation at Maximum Voltage - Determines the
modulation rate of the unit or cascade when the BMS
input voltage is at or above the setting of the BMS Voltage
at Maximum Modulation parameter. This parameter is
only active when the BMS Type is set to modulation rate.
This parameter can only be changed by the installer. The
range of this parameter is 14.5% to 100%. The default
value is 100%.

• BMS Voltage at Minimum Modulation - Determines the
voltage at which the external signal begins to increase the
modulation rate (power). Below this voltage, the
modulation rate (power) will be at the setting of the BMS
Modulation at Minimum Voltage parameter. This
parameter is only active when the BMS Type is set to
modulation rate (power). This parameter can only be
changed by the installer. The range of this parameter is
0V to 10V. The default value is 2V.

Reference page 17 for information regarding changing
parameters.

Time - The time is displayed in the upper right-hand corner of
the display. It is displayed in a 24 hour format. Reference the
night setback parameters on page 21 for information regarding
adjusting the date and time.

Back button - Pressing this button will back the screen up to the
previous screen.

• BMS Voltage at Maximum Modulation - Determines the
voltage at which the external signal forces the modulation
rate (power) to the setting of the BMS Modulation at
Maximum Voltage parameter. This parameter is only
active when the BMS Type is set to modulation rate
(power). This parameter can only be changed by the
installer. The range of this parameter is 2V to 10V. The
default value is 10V.

24

1 Service (continued)

Cascade Screen:

Service Manual

The Cascade Screen provides the status of the cascade system.
Items that can be viewed on the Cascade Screen are as follows:

Water Heater Power Level Indicators - For each water heater
present in the cascade a power level indicator will be present
above its corresponding number. The level will rise and fall
indicating the approximate power level of the water heater.
The display box underneath each number will display “HW”
when that water heater is providing heat for a Hot Water
Generation call.

On Timer and Off Timer - The ON and OFF timers are
used to force each water heater in the cascade to have a
minimum on and off time to prevent short cycling.

Block Switch On Timer - Whenever a water heater is
commanded to start, the block switch on timer is started.
This provides a delay between the first ignition system and
the second ignition system inside the water heater. Once the
second ignition system is started, the timer is reset and the
next water heater is prevented from starting until the timer
times out. This process is repeated for each water heater in
the cascade.

Demand - Shows the status of the cascade. Displayed
items are:

No Demand - the Cascade leader has not received a
call for heat.

 Hot Water Demand - the Cascade leader has received a
call for heat.

 Set Point Met - the tank temperature has met the
User Set Point + the Off Differential.


 Pump Delay - the cascade has satisfied a hot

water call and the hot water pump is running for a fixed
time.

Set Point - This is the set point of the cascade system. The heater
designated as the Leader will use this set point to determine the
power level required to bring the tank temperature to this point.
A default value of 50°F (10°C) is displayed when the Call for
Heat is inactive.

Time - The time is displayed in the upper right-hand corner of
the display. It is displayed in a 24 hour format. Reference the
night setback parameters on page 21 for information regarding
adjusting the date and time.

Status button - Pressing this button displays the Status Screen.
This screens shows the current status of the Armor X2 water
heater. Reference the Status Screen on page 12 for more
information regarding this screen.

Main button - Pressing this button displays the Main Screen.
From this screen, navigation to eight (8) other screens is
possible. Reference the Main Screen on page 16 for more
information regarding this screen.

25

1 Service

Service Manual

1

On

34

80

55

The Building Screen displays information that is specific to the Building Automation System and is being transmitted through
the Modbus communication link:

Modbus Address - This is the address of a specific Armor
X2 water heater. This address is set by dip switches on the
Modbus communication board. The value displayed here
should be the same as the value of the dip switches. The
Building Automation System should use this address to
communicate with the water heater.

Boiler Enable - This displays the enable status that has been
transmitted to the water heater by the Building Automation
System.

Boiler State - This displays the state code of the water heater.
Please reference the Armor X2 Modbus Instruction Manual
for a full definition of each code.

Boiler Command - This displays the value written to register
40003 of the Modbus communication board by the Building
Automation System. The value is displayed as the percent of
firing rate, 80 = 80% firing rate.

Effective Setpoint - This displays the value written to register
40003 of the Modbus communication board by the Building
Automation System. The value is displayed as the effective
setpoint in degrees (°F or °C).

Note: The water heater can be configured to operate off the
water heater command or the effective setpoint. The water
heater configuration determines which value is meaningful.

Time - The time is displayed in the upper right-hand corner of
the display. It is displayed in a 24 hour format. Reference the
night setback parameters on page 21 for information regarding
adjusting the date and time.

Status button - Pressing this button displays the Status Screen.
this screen shows the current status of the Armor X2 water
heater. Reference page 12 for more information regarding this
screen.

26

Main button - Pressing this button displays the Main Screen.
From this screen, navigation to eight (8) other screens is
possible. Reference the Main Screen on page 16 for more
information regarding this screen.

1 Service (continued)

Temps Screen:

Service Manual

The Temps Screen displays the various temperatures as
measured by sensors connected to each control module.
Items that can be viewed on the Temps Screen are as follows:

• Inlet 1-2 - This is the water temperature as measured by
the sensor located in the inlet of each heat exchanger.

• Outlet 1-2 - This is the water temperature as measured by
the sensor located in the outlet of each heat exchanger.

• Flue 1-2 - This is the temperature as measured by the
sensor located in the flue connection on each heat
exchanger.

• Set Point - The temperature is the tank set point for a Hot
Water call.

• Tank Sensor - Temperature sensed in the tank by the tank
sensor.

Time - The time is displayed in the upper right-hand corner of
the display. It is displayed in a 24 hour format. Reference the
night setback parameters on page 21 for information regarding
adjusting the date and time.

Status button - Pressing this button displays the Status Screen.
this screen shows the current status of the Armor X2 water
heater. Reference page 12 for more information regarding this
screen.

Main button - Pressing this button displays the Main Screen.
From this screen, navigation to eight (8) other screens is
possible. Reference the Main Screen on page 16 for more
information regarding this screen.

27

1 Service

Burners Screen:

Service Manual

This screen provides the status of the combustion air blowers
and flame signals. Items that can be viewed on the Burners
Screen are as follows:

• Blower Power Level Indicator - Two (2) blowers are
depicted on the display. The top blower corresponds with
Heat Exchanger 1 or Top heat exchanger. The lower
blower corresponds with Heat Exchanger 2 or Bottom
heat exchanger. Beside each blower is a power level
indicator. The level will increase and decrease indicating
the approximate power level of the blower. The display
box underneath each indicator level will display the firing
rate of each control module.

• RPM’s - Each blower will display the rpm that the
control module is requiring of the blower.

• Flame Signal - The flame signal for each control module
will be displayed in dc microamps.

Time - The time is displayed in the upper right-hand corner of
the display. It is displayed in a 24 hour format. Reference the
night setback parameters on page 21 for information regarding
adjusting the date and time.

Status button - Pressing this button displays the Status Screen.
this screen shows the current status of the Armor X2 water
heater. Reference page 12 for more information regarding this
screen.

Main button - Pressing this button displays the Main Screen.
From this screen, navigation to eight (8) other screens is
possible. Reference the Main Screen on page 16 for more
information regarding this screen.

28

1 Service (continued)

Graph Select Screen:

Service Manual

The Graphs Screen consists of two (2) different screens. The
first screen is the Parameter Selection Screen. By pressing the
box beside the desired item, a check will appear in the selected
box and the control will graph the status of that item. A
maximum of five (5) items can be graphed at one time.

The second screen is accessed by pressing the NEXT button.
Once the items to be graphed are selected, press the NEXT
button to view the graph. Each item graphed will have a
different color line to represent it. The items selected will
be shown in a display bar with their Min and Max ranges
listed below them. Press the BACK button to return to the
Parameter Selection Screen.

Time - The time is displayed in the upper right-hand corner of
the display. It is displayed in a 24 hour format. Reference the
night setback parameters on page 21 for information regarding
adjusting the date and time.

Status button - Pressing this button displays the Status Screen.
this screen shows the current status of the Armor X2 water
heater. Reference page 12 for more information regarding this
screen.

Main button - Pressing this button displays the Main Screen.
From this screen, navigation to eight (8) other screens is
possible. Reference the Main Screen on page 16 for more
information regarding this screen.

29

1 Service

History Screen:

Service Manual

The History Screen shows the status of various counters
and faults for each control module. Selection of the control
module to be viewed is accomplished by pressing the SELECT
button. The control module being displayed is shown in the
module box. Items that can be viewed on the History Screen
are as follows:

• Successful Ignitions - Shows the number of times the
control has successfully ignited.

• Hours > 50% - Shows the number of hours the
control has operated at greater than 50%.

• Hours < 50% - Shows the number of hours the
control has operated at less than 50%.

• Total Ignitions - Shows the total number of times the
control has attempted to ignite.

• Last 10 Faults - Shows the last 10 faults of the control
module by date and time.

Time - The time is displayed in the upper right-hand corner of
the display. It is displayed in a 24 hour format. Reference the
night setback parameters on page 21 for information regarding
adjusting the date and time.

Status button - Pressing this button displays the Status Screen.
this screen shows the current status of the Armor X2 water
heater. Reference page 12 for more information regarding this
screen.

Main button - Pressing this button displays the Main Screen.
From this screen, navigation to eight (8) other screens is
possible. Reference the Main Screen on page 16 for more
information regarding this screen.

30

1 Service (continued)

Service Mode Screen:

Service Manual

The Service Mode Screen allows the individual control
modules to override all other heat demands and operate at
a full fire condition for the purpose of combustion analysis.
Selection of the control module to be placed into Service
Mode is accomplished by pressing the SELECT button. The
control module being placed into Service Mode is shown in
the module box.

To place the unit into Service Mode, press the ON/OFF button
until ON is displayed. The control module will override all
other heat demands, however, all safeties will be active. If no
buttons are pressed, the control module will automatically
revert back to its original state after the Max Service Time
delay has expired. The default setting for the Max Service
Time is 20 minutes. To take the control module out of Service
Mode, press the ON/OFF button until OFF is displayed.

Items that can be viewed and interacted with on the Service
Mode Screen are as follows:

• Blower Power Level Indicator - A blower is depicted on
the display with a power level indicator beside it. The
level will increase and decrease indicating the
approximate power level of the blower. The display box
underneath the indicator level will display the firing rate
of the control module.

Time - The time is displayed in the upper right-hand corner of
the display. It is displayed in a 24 hour format. Reference the
night setback parameters on page 21 for information regarding
adjusting the date and time.

Status button - Pressing this button displays the Status Screen.
this screen shows the current status of the Armor X2 water
heater. Reference page 12 for more information regarding this
screen.

Main button - Pressing this button displays the Main Screen.
From this screen, navigation to eight (8) other screens is
possible. Reference the Main Screen on page 16 for more
information regarding this screen.

• RPM’s - The blower motor rpm that the control module
is requiring of the blower.

• Plus and Minus Buttons - By pressing the plus or minus
button the rpm of the blower motor can be increased or
decreased.

• Flame Signal - The flame signal for the control module
will be displayed in dc microamps.

31

Service Manual

2 Maintenance

Maintenance and annual startup

Table 2A Service and Maintenance Schedules

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

• Perform start-up checkout and
performance verification per Section 9

ANNUAL START-UP

in the Armor X2 Installation and
Operation Manual.

Owner maintenance

• Check water heater area

Daily

Monthly

• 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

• 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 (30°C)
above return water temperature.

• Test low water flow conditions.

If combustion or performance
indicate need:

• Clean heat exchanger

• Remove and clean burner using
compressed air only

• Clean the blower wheel

32

Every

6 months

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

• Operate relief valve

2 Maintenance (continued)

Service Manual

 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.

 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 2A 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.

Figure 2-1 Condensate Trap

PVC TEE ASSEMBLY

(FACTORY SUPPLIED)

2” PVC CAP WITH

BLOCKED DRAIN SWITCH

RETAINING

SCREW

CONDENSATE FROM

HEAT EXCHANGER

2. Verify that air intake area is free of any of the contaminants
listed in Section 1 of the Armor X2 Installation and
Operation Manual. 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 X2 Installation and
Operation Manual.

Inspect water heater interior

1. Remove the front access cover and inspect the interior of
the water heater.

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

Clean condensate trap

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

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

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

4. Remove any sediment in the trap.

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

TO FLOOR

DRAIN

 WARNING

The condensate trap 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.

Check all piping for leaks

 WARNING

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 of the Armor X2 Installation and
Operation Manual.

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

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

7. Replace the retaining screw.

33

2 Maintenance

Service Manual

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.

 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. 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.

Check expansion tank

1. Expansion tanks provide space for water to move in and

out as the water expands due to temperature increase or
contracts as the water cools. Tanks may be diaphragm or
bladder type. See Section 6 - System Piping of the Armor
X2 Water Heater Installation and Operation Manual for
suggested best location of expansion tanks.

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 of the Armor
X2 Installation and Operation Manual before proceeding
further.

 WARNING

 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.

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.

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.

34

)

2 Maintenance (continued)

Service Manual

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

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. 2-2.

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

Figure 2-2 Burner Assembly

DOOR FIBER

BURNER DOOR

BURNER DOOR

HEX NUT (6)

BURNER

AIR/GAS GASKET

FLAPPER VALVE

SCREW (5X)

FLAPPER VALVE

FLAME SENSE

SCREW (2X)

IGNITER

FLAME SENSE

IGNITER GASKET

FLAME SENSE

GASKET

IGNITER SCREW (2X

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

Check control settings

1. Go to the Setup Screen and check all settings. See Section
1 of this manual. Adjust settings if necessary. See Section
1 of this manual for adjustment procedures.

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

Perform start-up and checks

1. Start water heater and perform checks and tests specified

in Section 9 - Start-up of the Armor X2 Installation and
Operation Manual.

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 this manual for other
procedures to deal with low flame signal.

Review with owner

1. Review the Armor X2 Installation and Operation Manual
with the owner.

2. Emphasize the need to perform the maintenance schedule
specified in the Armor X2 Installation and Operation
Manual (and in this manual as well).

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

35

2 Maintenance

Service Manual

Cleaning water heater heat
exchanger

For recommended materials; including brush, appropriate
extension(s), refractory cover, and detailed instructions
see Table 2B - Heat Exchanger Cleaning Kits.

1. Shut down water heater:

• Follow the “To Turn Off Gas to Appliance” instructions
for the heater in the Armor X2 Installation and
Operation Manual.

• Do not drain the heater unless it will be exposed to
freezing temperatures.

2. Allow time for the 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.

 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 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 of the Armor
X2 Installation and Operation 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 on page
3 of this manual. Failure to comply
could result in severe personal injury.

Table 2B Heat Exchanger Cleaning Kits

Model

Number

AW 1.0 - 1.5 KIT30064

 CAUTION

Kit

Number

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

Part

Number

MSC20083* Nylon 4” Wheel Brush*

MSC20085 1/4” x 12” Drill Extension

MSC20086 1/4” x 24” Drill Extension

Component
Description

Check Delta T

1. Check the Delta T using Table 2C as a reference.

Table 2C Water Heater Pump Applications / Recommended
Temperature Rise

Water Heater Pump Applications

*Pipe

Model

1.0 2" 3" Armstrong E22 100 26 22°F

1.3 2" 3" Grundfos TP 40-160 125 32 22°F

1.5 2" 3" Grundfos TP 40-160 130 31 24°F

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

**Note: This appliance is shipped with two pumps to meet the fl ow
requirements listed above.

Size

Inlet Outlet

Pump

Make

Pump

Model

**Flow

Rate

(GPM)

Loss

(FT/
HD)

Temp.

Rise

Oiled bearing circulators

1. The circulator shipped with the Armor water heater is water­lubricated. 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.

36

3 Troubleshooting

Alarm Screen:

Service Manual

If a fault occurs which requires a Manual Reset, the unit
will go into a lockout condition and the Alarm Screen will
be activated. The screen will switch between a black or red
background every 5 seconds with the text “Alarm Unit Needs
Servicing” shown on the display.

A message box shows the alarm status of the two (2) control
modules. Mod1 is for Control Module 1 and Mod2 is for
Control Module 2. A description of the alarm will be beside
the control module with the fault. If a control module does
not have a fault, “No Alarm Present” will be in the text.

It is possible for one control module to be in alarm while the
other continues to function. However, it will not be possible
to view any other screens until the control module is reset.

Reset button - The RESET button must be pressed to reset an
alarm. Once the button is pressed, the Reset Confirmation
Screen appears. You are asked if you wish to reset the control
module. If so, press the YES button. If you do not wish to reset
the control module press the NO button. If neither button is
pressed within 20 seconds, the screen will return to the Alarm
Screen.

Once the condition has been corrected and the alarm is reset,
the Status Screen will be displayed.

37

3 Troubleshooting

Service Manual

 WARNING

 WARNING

Label all wires prior to disconnection when
servicing controls. Wiring errors can
cause improper and dangerous operation.
Always disconnect power to the water
heater before servicing. Failure to comply
could result in severe personal injury,
death, or substantial property damage.

Never jumper (bypass) any device except
for momentary testing as outlined in the
Troubleshooting chart. Severe personal
injury, death, or substantial property
damage can result.

Before troubleshooting:

1. Have the following items:
a. Voltmeter that can check 120 VAC, 24 VAC, and
12 VDC.
b. Continuity checker.
c. Contact thermometer.

2. Check for 120 VAC (minimum 102 VAC to maximum

132 VAC) to water heater.

3. Make sure all external limit controls are installed and

operating.

Figure 3-1 Control Module Fuses

F3 - 1.25 AMP FUSE

MAIN BOARD

F4 - 3.15 AMP FUSE

BLOWER

F5 - 5 AMP FUSE

PUMPS

F2 - 3.15 AMP FUSE

24V SUPPLY

4. Remove the two (2) nuts on the control module cover.

5. Inspect fuses F2, F3, F4, and F5, see FIG 3-1 below.

6. The water heater is shipped with six (6) spare fuses in
a plastic bag located under the low water cutoff on the
control module.

Check the following:

1. Wire connectors to control module are securely plugged
in at the control module and originating control.

2. Gas pressures:

• Maximum: 14 inches w.c. (3.5 kPa) natural,
14 inches w.c. (3.2 kPa) LP with no flow (lockup)
or with water heater on

• Minimum: 4 inches (5 inches on 1.0 models only) w.c.
(1.0 kPa) natural, 8 inches w.c. (2.0 kPa) LP with gas
flowing (verify during water heater startup)

Check control module fuses

NOTICE

1. Turn OFF the power to the water heater at the external

line switch.

2. Remove the front access cover.

ALWAYS check control module fuses
before replacing control module or any
major components (blower, etc.). If one
of these fuses is blown, it can prevent the
control module or other components from
operating.

7. If necessary, replace open fuse (F3 is 1.25 amps, F2 and F4
are 3.15 amps, and F5 is 5 amps).

Note: Fuses F2 - F5 are all slow blow fuses.

 WARNING

8. Re-install the control module cover using the nuts
removed in Step 4.

Note: If the spark wire was unplugged, reattach it to the

control.

9. Re-install the control panel using the two (2) screws
removed in Step 3. Re-install the front access cover after
fuse inspection.

10. Restore power to the water heater at the external line
switch and verify water heater operation (Section 9 ­Start-up in the Armor X2 Installation and Operation
Manual) after completing water heater service.

Do not jumper fuse or replace with any
fuse except as specified. Failure to comply
could result in severe personal injury,
death, or substantial property damage.

3. Remove the two (2) screws securing the control panel to
the unit to gain access to the control module.

38

Service Manual

3 Troubleshooting (continued)

Table 3A Troubleshooting Chart - No Display

FAULT CAUSE CORRECTIVE ACTION

- No 120 VAC supplied to unit. • Check external line switch, fuse, or breaker.

• Check position of ON/OFF switch. Turn switch to the
ON position.

• Check 120 VAC through the ON/OFF switch.

• Check wiring harness connection between display
board and main control board. Connect
harness at both points.

No Display

- No voltage through the switch. • Replace switch.

- Bad display board. • Replace board.

No Burner

Operation

Unit Does

Not Modulate

Above 50%

- Bad main control board. • Replace the main control board.

- Blown fuse. • Replace fuse F3 on the main control board, see
page 38 of this manual.

- Main control board temperature set point

satisfied.

- Remote thermostat satisfied. • Review remote thermostat setting.

- Unit locked out on fault. • Consult display for specific fault. Refer to fault

- Water heater controlled by BMS.

- Flue sensor open.

• Review temperature setting.

descriptions on page 42 of this manual for corrective
actions.

• Check BMS parameter settings.

• Verify that the flue sensor is located in the flue outlet.

• Check wiring connections at the flue sensor.

• Check the resistance of the flue sensor and compare
to Table 3C on page 40 of this manual.

39

Service Manual

3 Troubleshooting

Checking temperature sensors

The water heater temperature sensors (inlet water, outlet water, system water, and flue) are all resistance type devices. The
following tables show the correct values for the sensors at various temperatures. Use an ohmmeter to read the resistance of the
sensor at a known temperature. If the resistance of the sensor does not closely match its corresponding table, replace the sensor.

Table 3B - Inlet/Outlet and Tank Sensor Resistance vs. Temperature

Temperature Resistance Temperature Resistance

50 18,780 158 1,990

68 12,263 176 1,458

86 8,194 194 1,084

104 5,592 212 817

122 3,893 -- --

140 2,760 -- --

Table 3C - Flue Temperature Sensor Resistance vs. Temperature

Temperature Resistance Temperature Resistance

68 14,773 176 1,707

86 9,804 194 1,266

104 6,652 212 952

122 4,607 230 726

140 3,252 248 560

158 2,337 -- --

40

Service Manual

3 Troubleshooting (continued)

Table 3D Troubleshooting Chart - Noisy System

FAULT CAUSE CORRECTIVE ACTION

Noisy

Operation

- Supply gas problem. Natural gas pressures
should be between 4 inches w.c. (1.0 kPa)
and 14 inches w.c. (3.5 kPa). LP gas
pressures should be between 8 inches w.c.
(2.0 kPa) and 14 inches w.c. (3.2 kPa).

- Gas/air mixture problem.

- Dirty/damaged burner.

- Low water flow through the heat exchanger.

- Air in the piping system. • Properly purge all air from the piping system.

• Refer to Section 7 - Gas Connections of the Armor X2
Installation and Operation Manual for detailed
information concerning the gas supply.

• Refer to the Gas Valve Adjustment Procedure on
page 50 of this manual for the proper gas valve setting.
Verify that the vent/air intake lengths do not exceed the
maximum listed in the General Venting section of the
Armor X2 Installation and Operation Manual.

• Refer to page 35 in this manual for the burner removal
and inspection procedure. Clean or replace the burner
as necessary.

• Refer to Section 6 - System Piping of the
Armor X2 Installation and Operation Manual for
minimum flow rates. Verify that the water heater is piped
in a primary/secondary fashion and that the water heater
and system pump are running on a call for heat.

No Pump

Operation -

HW Pump

Relief Valve

Opening

- Low system water pressure.

- Blown fuse.

- Faulty pump. • Replace pump.

- Internal fault on control board. • Replace main control board.

- Faulty pump relay. • Replace relay.

- System pressure exceeds relief valve
setting.

- Outlet temperature exceeds relief valve
settings.

• Verify system pressure is a minimum of 12 psi
(82.7 kPa).

• Replace fuse F5 on the control board, see page 38 of
this manual.

• Lower the system pressure below the 150 psi
(1034.2 kPa) rating of the supplied relief valve.

• Improperly sized expansion tank.

• Check temperature settings of the main control board.

41

Service Manual

3 Troubleshooting

Table 3E Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface

FAULT DESCRIPTION CORRECTIVE ACTION

• Check water heater pump operation on a call for heat.

Flow Switch/

LWCO

(will require a manual

reset once condition has

been corrected. Press
the RESET button on

the display to reset.)

Condensate

Drain Blocked

(will require a manual

reset once condition has

been corrected. Press
the RESET button on

the display to reset.)

Either the flow switch or the optional AUX
switch is not making.

Blown fuse.

The blocked drain switch has detected
excessive condensate build up inside the
unit.

• Check for closed valves or obstructions in the water
heater piping.

• Verify system is full of water and all air has been
purged from the system.

• Check for loose or misplaced jumpers if flow switch is
not installed.

• Replace fuse F2 on the control board, see page 38 of
this manual.

• Check condensate tube from unit to floor drain for
proper installation and obstructions.

• Inspect condensate trap for blockage. Clean if
necessary.

• Check for loose wiring connection at wire harness
plug.

• Bad blocked drain switch. Replace switch.

Flame out of

Sequence

(will require a manual

reset once the condition

has been corrected.

Press the RESET button

on the display to reset.)

Gas Valve /
Connection

(will require a manual

reset once the condition

has been corrected.

Press the RESET button

on the display to reset.)

Burner Did Not

Light

(will require a manual

reset once the condition

has been corrected.

Press the RESET button

on the display to reset.)

The flame detector circuit is seeing a flame
signal while no flame is present.

The main control board did not detect the
gas valve.

The unit has failed to prove main burner
ignition. It will require a manual reset before
attempting to fire again.

• Check supply voltage for proper polarity.

• Check external wiring for voltage feedback.

• Check the flame rod and make sure it is clean.

• Check the internal wiring for bad connections.

• Replace main control board.

• Check wiring harness connection at the gas valve and
at the main control board.

• Replace the gas valve wire harness.

• Replace the gas valve.

• Replace the main control board.

• Inspect spark electrode and associated wiring for
damage and connection. Reference page 35 of this
manual for removal and cleaning procedures.
Replace if necessary.

• Check for proper electrical grounding of the unit.

• Check incoming supply gas pressure. Natural gas
pressures should be between 4 - 14 inches w.c.
(1.0 - 3.5 kPa) and LP gas pressures should be
between 8 - 14 inches w.c. (2.0 - 3.2 kPa). Refer
to Section 7 - Gas Connections of the Armor X2
Installation and Operation Manual for detailed
information concerning the gas supply.

• Verify that the tube from the gas valve to the
air inlet is connected and is not damaged.

• Verify that the vent/air intake pipes are correctly
installed and that there are no obstructions.

42

• Check for 24 VAC to the gas valve at the 2-pin
connection on the side of the main control board
during the ignition attempt. If no voltage is present,
replace the main control board.

Service Manual

3 Troubleshooting (continued)

Table 3E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface

FAULT DESCRIPTION CORRECTIVE ACTION

• If 24 VAC is present at the main control board, check
the wiring between the main control board and the gas
valve. Replace the wiring if necessary. Do not
disconnect the wiring from the gas valve and attempt
to measure voltage at that point. The main control
board can detect if the gas valve is not connected and
will display the Gas Valve / Connection fault.

• If 24 VAC is present, check the outlet of the valve to

Burner Did Not

Light (cont’d)

(will require a manual

reset once the condition

has been corrected.

Press the RESET button

on the display to reset.)

The unit has failed to prove main burner
ignition. It will require a manual reset before
attempting to fire again.

ensure the valve is flowing gas. With a manometer
connected to the outlet tap of the gas valve, when the
unit is in the prepurge period, there should be a
negative pressure present. When the valve is
energized a change in pressure should occur. If the
pressure change does not occur, the gas valve is not
opening. Replace the gas valve.

• Inspect flame sensor and associated wiring.
Reference page 35 of this manual for removal and
cleaning procedures. Replace if necessary.

Flame Lost

While Running

(will require a manual

reset once the condition

has been corrected.

Press the RESET button

on the display to reset.)

The unit was running and lost the flame
signal. This condition occurred twice .

• Inspect the burner. Reference page 35 of this manual
for removal and cleaning procedures. Replace if
necessary.

• Replace the main control board.

• Inspect spark electrode and associated wiring for
damage and connection. Reference page 35 of this
manual for removal and cleaning procedures.
Replace if necessary.

• Check for proper electrical grounding of unit.

• Check incoming supply gas pressure. Natural gas
pressures should be between 4 - 1 4 inches w.c.
(1.0 - 3.5 kPa) and LP gas pressures should be
between 8 - 14 inches w.c. (2.0 - 3.2 kPa).
Refer to Section 7 - Gas Connections of the Armor X2
Installation and Operation Manual for detailed
information concerning the gas supply.

• Verify that the tube from the gas valve to the air
inlet is connected and is not damaged.

• Verify that the vent/air intake pipes are installed
correctly and there are no obstructions.

• Check for 24 VAC to the gas valve at the 2-pin
connection on the side of the main control board
during the ignition attempt. If no voltage is present,
replace the main control board.

43

Service Manual

3 Troubleshooting

Table 3E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface

FAULT DESCRIPTION CORRECTIVE ACTION

• If 24 VAC is present at the main control board, check
the wiring between the main control board and the gas
valve. Replace the wiring if necessary. Do not
disconnect the wiring from the gas valve and attempt
to measure voltage at that point. The main control
board can detect if the gas valve is not connected and

Flame Lost

While Running

(cont’d)

(will require a

manual reset once the

condition has been

corrected. Press the

RESET button on the

display to reset.)

The unit was running and lost the flame
signal. This condition occurred twice .

will display the Gas Valve / Connection fault.

• If 24 VAC is present, check the outlet of the valve to
ensure the valve is flowing gas. With a manometer
connected to the outlet tap of the gas valve, when the
unit is in the prepurge period, there should be a
negative pressure present. When the valve is
energized a change in pressure should occur. If the
pressure change does not occur, the gas valve is not
opening. Replace the gas valve.

• Inspect flame sensor and associated wiring.
Reference page 35 of this manual for removal and
cleaning procedures. Replace if necessary.

• Inspect the burner. Reference page 35 of this manual
for removal and cleaning procedures. Replace if
necessary.

• Replace the main control board.

Manual Reset

High Limit

(will require a

manual reset once the

condition has been

corrected. Press the

RESET button on the

display to reset.)

44

The outlet water temperature has exceeded
the setting of the high limit.

• Verify that the system is full of water and that all air
has been properly purged from the system.

• Verify that the water heater is piped properly into the
heating system. Refer to Section 6 - System Piping
of the Armor X2 Installation and Operation Manual
for the proper piping methods for the Armor X2.

• Check voltage to water heater pump motor on a call for
heat. If voltage is not present, check wiring back to
the pump relay.

• Replace the pump relay if necessary.

• If 120 VAC is present on a call for heat and the water
heater pump is not operating, replace the pump.

• If the high limit has tripped, check setting of the
device.

• Check resistance of water sensors and compare to
Table 3B on page 40 of this manual. Replace sensor
if necessary.

• Replace high limit.

Service Manual

3 Troubleshooting (continued)

Table 3E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface

FAULT DESCRIPTION CORRECTIVE ACTION

Automatic Reset High Limit:

• Verify that the system is full of water and that all air
has been properly purged from the system.

• Verify that the water heater is piped properly into the
heating system. Refer to Section 6 - System Piping
of the Armor X2 Installation and Operation Manual for
the proper piping methods for the Armor X2.

• Check voltage to water heater pump motor on a call
for heat. If voltage is not present, check wiring back
to the pump relay.

Automatic Reset
High Limit / HEX-

Temp SW

(will require a manual

reset once the condition

has been corrected. Press

the RESET button on the

display to reset.)

Either the auto-reset high limit, or the
O-temp heat exchanger switch has opened.

• Replace the pump relay if necessary.

• If 120 VAC is present on a call for heat and the water
heater pump is not operating, replace the pump.

• Check resistance of water sensors and compare to
Table 3B on page 40 of this manual. Replace sensor
if necessary.

• Replace outlet sensor.

Blower RPM’s

Too Low

(will require a manual

reset once the condition

has been corrected. Press

the RESET button on the

display to reset.)

The actual fan rpm is 30% lower than what
is being called for. Reference the Burners
Screen information on page 28 of this
manual.

Blown fuse.

HEX Temp SW:

• Check continuity across two contacts. Wires should
be connected at both poles of normally closed switch.

• Inspect the rear of the inner combustion chamber
at the burner level, for refractory breakdown/missing.
Replace the refractory if no damage to the heat
exchanger as a result of the burner, otherwise,
replace the heat exchanger.

• Faulty O-temp heat exchanger switch. Replace
switch.

• Vent/air intake lengths exceed the maximum allowed
lengths. Refer to Section 3 - General Venting of the
Armor X2 Installation and Operation Manual for
proper lengths.

• Check for obstruction or blockage in the vent/air
intake pipes or at terminations.

• Check the wiring connections at the fan and at the
main control board.

• Replace the fan.

• Replace the main control board.

• Replace fuse F4 on the control board, see page 38 of
this manual.

45

Service Manual

3 Troubleshooting

Table 3E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface

FAULT DESCRIPTION CORRECTIVE ACTION

• Vent/air intake lengths exceed the maximum allowed
lengths. Refer to Section 3 - General Venting of the

Blower RPM’s

Too High

(will require a manual

reset once the condition

has been corrected. Press

the RESET button on the

display to reset.)

The actual fan rpm is 30% higher than what
is being called for.

Armor X2 Installation and Operation Manual for
proper lengths.

• Check for obstruction or blockage in the vent/air
intake pipes or at terminations.

• Check the wiring connections at the fan and at the
main control board.

• Replace the fan.

• Replace the main control board.

Sensor Open

(will require a manual

reset once the condition

has been corrected. Press

the RESET button on the

display to reset.)

Sensor Shorted

(will require a manual

reset once the condition

has been corrected. Press

the RESET button on the

display to reset.)

Flue Sensor

Open / Removed

(will require a manual

reset once the condition

has been corrected. Press

the RESET button on the

display to reset.)

Flue Sensor

Shorted

(will require a manual

reset once the condition

has been corrected. Press

the RESET button on the

display to reset.)

Either the inlet water or outlet water
temperature sensor has been disconnected.

Either the inlet water or outlet water
temperature sensor has been shorted.

The flue sensor has been disconnected or
removed from the flue.

The flue sensor has been shorted.

• Check the sensors and their associated wiring.
Repair or replace the sensor or wiring if damaged.

• Measure the resistance of the sensors and compare
the resistance to the tables on page 40 of this
manual.

• Replace the sensor if necessary.

• Check the sensors and their associated wiring.
Repair or replace the sensor or wiring if damaged.

• Measure the resistance of the sensors and compare
the resistance to the tables on page 40 of this
manual.

• Replace the sensor if necessary.

• Check the sensor and its associated wiring. Repair
or replace the sensor or wiring if damaged.

• Measure the resistance of the sensors and compare
the resistance to the tables on page 40 of this
manual.

• Replace the sensor in flue.

• Replace the sensor if necessary.

• Check the sensor and its associated wiring. Repair
or replace the sensor or wiring if damaged.

• Measure the resistance of the sensors and compare
the resistance to the tables on page 40 of this
manual.

• Replace the sensor if necessary.

Louver Proving

Switch

(will require a manual

reset once the condition

has been corrected. Press

the RESET button on the

display to reset.)

46

An optional remote proving switch is not
making.

• Check function of remote devices.

• Check for loose or misplaced jumper if proving switch
is not installed.

Service Manual

3 Troubleshooting (continued)

Table 3E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface

FAULT DESCRIPTION CORRECTIVE ACTION

Air Flow Too

Low

(will require a manual

reset once the condition

has been corrected.

Press the RESET button

on the display to reset.)

Air pressure switch contacts are open.

Flap valve contacts are in an open position.

• Check the wiring connections to switch. Wires should
be connected to the common and normally closed
terminals.

• Vent/air intake lengths exceed the maximum allowed
lengths. Refer to Section 3 - General Venting of the
Armor X2 Installation and Operation Manual for
proper lengths.

• Check for obstruction or blockage in the vent/air
intake pipes or at terminations.

• Check reference hoses connected to the air pressure
switch for blockage or obstruction.

• Inspect the burner. Reference page 35 of this manual
for removal and cleaning procedures. Replace if
necessary.

• Inspect the heat exchanger. Reference page 36 of
this manual for removal and cleaning procedures.
Replace if necessary.

• Faulty air pressure switch. Replace switch.

• Check the wiring connections to the flap valve switch.
Replace or repair wiring if necessary.

• Check for obstruction in the vent / air intake pipes or
at terminations.

• Verify combustion air blower is operating. Replace if
necessary.

Flap Valve

Stuck Open

Too Many

Resets - Try Later

Voltage Too

Low

Flap valve contacts are in a closed position.

Too many manual resets have occurred
during a 15 minute period.

120 VAC input to the main control board has
dropped below 80 VAC.

• Replace flap valve switch.

• Check wiring connections to the flap valve switch.
Replace or repair wiring if necessary.

• Check flap valve for obstruction or blockage.

• Replace flap valve switch.

• Wait 15 minutes and try again.

• Turn power off to unit, wait 30 seconds and then turn
power back on.

• Check 120 VAC supply to the transformer.

• Check wiring connections at the low voltage terminal
strip.

• Check the wire size/length to remote devices.

• Replace the main control board.

47

Service Manual

3 Troubleshooting

Table 3E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface

FAULT DESCRIPTION CORRECTIVE ACTION

Internal Fault

Writing to

Memos

CRC Parameters

No Error Stored

Flue Temp

Shutdown

Delta T

Shutdown

Outlet Temp

Shutdown

The main control board has detected an
internal fault.

The main control board has detected an
internal fault.

The main control board has detected an
internal fault.

The main control board has detected an
internal fault.

The stack temperature has exceeded the
set parameters for the water heater.

The temperature rise across the heat
exchanger has exceeded the set parameters
for the water heater.

Outlet water temperature has exceeded the
maximum outlet water temperature.

• Replace the main control board.

• Replace the main control board.

• Replace the main control board.

• Press the RESET button on the SMART
TOUCH display panel.

• Inspect the heat exchanger. Reference page 36 of
this manual for the procedure on how to clean the
flue side of the heat exchanger.

• Inspect the flue sensor and associated wiring.
Measure the resistance of the flue sensor and
compare to Table 3C on page 40 of this manual.
Replace the sensor if necessary.

• Verify that the vent/air intake pipes are properly
installed and that there are no obstructions.

• Replace the main control board.

• Verify that the system is full of water and that all air
has been properly purged from the system.

• Verify that the heater is piped properly into the heating
system. Refer to Section 6 - System Piping of the
Armor X2 Installation and Operation Manual
for the proper piping methods for the Armor X2 water
heater.

• Check for voltage to the water heater pump motor
on a call for heat. If voltage is not present, check
the wiring back to the pump relay. Replace the pump
relay if necessary.

• If 120 VAC is present on a call for heat and the water
heater pump is not operating, replace the pump.

• Verify that the water heater pump is set to the proper
speed or that the pump is the proper size. Reference
Section 6 - System Piping of the Armor X2 Water
Heater Installation and Operation Manual for water
heater pump specifications.

• Verify that the system is full of water and that all air
has been properly purged from the system.

• Verify that the water heater is piped properly into the
heating system. Refer to Section 6 - System Piping
of the Armor X2 Installation and Operation Manual
for the proper piping methods for the Armor X2 water
heater.

• Check for voltage to the water heater pump motor on
a call for heat. If voltage is not present, check wiring
back to the pump relay. Replace the pump relay if
necessary.

• If 120 VAC is present on a call for heat and the heater
pump is not operating, replace the pump.

48

3 Troubleshooting (continued)

Service Manual

Combustion Analysis Procedure

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 sensors from the flue pipe
connections. 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.

4. Navigate to the Service Mode Screen from the Status
Screen by pressing the MAIN button and then the
SERVICE MODE button.

5. On the Service Screen place Heat Exchanger 1 into

operation by selecting Heat Exchanger 1 with the SELECT
button and turning the heat exchanger on by pressing the
ON/OFF button (OFF indicates that the heat exchanger
is off and ON indicates that the heat exchanger should be
firing).

6. Insert the probe from a combustion analyzer into the

hole left by the removal of the flue temperature sensor.

Note: Heat Exchanger 1 is the top heat exchanger; please

ensure the probe is in the top flue sensor location.

7. Once the heat exchanger has modulated up to full fire

measure the combustion. The values should be in the
range listed in Table 3H above. CO levels should be
less than 200 ppm for a properly installed unit. If the
combustion is not within range reference the chart below
for possible causes and corrective actions.

Table 3H Flue Products

Natural Gas Propane

CO

2

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

O

2

CO

2

O

2

8. Once the Heat Exchanger 1 analysis is complete, test the
safety shutoff device by turning the manual shutoff valve
to the OFF position and ensuring that Heat Exchanger
1 shuts down and registers an alarm. Open the manual
shutoff valve, reset the control, and return to Service
Mode.

9. Repeat the same procedure for Heat Exchanger 2
by selecting Heat Exchanger 2 while on the Service
Mode Screen. Be certain to insert the probe from the
combustion analyzer into the Heat Exchanger 2 flue
temperature sensor location.

10. Turn the main power off to the water heater and replace
the flue temperature sensor into the flue pipe connection.

11. 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.

Table 3G Troubleshooting Chart - Combustion Levels

POSSIBLE CAUSE CORRECTIVE ACTION

• Refer to Section 3 - General Venting of the Armor X2 Installation and Operation Manual

Vent/Air Intake Length

or Obstruction

Gas Supply Pressure

Dirty/Damaged Burner

Gas Valve Adjustment

for the proper venting and air intake methods for the Armor X2 water heater.

• Check for obstructions at the vent/air intake terminals.

• Refer to Section 7 - Gas Connections of the Armor X2 Installation and Operation
Manual for the proper gas supply for the Armor X2 water heater.

• Refer to page 35 of this manual for burner removal and cleaning procedures.

• Replace burner if necessary.

• Refer to page 50 of this manual for the gas valve adjustment procedure.

49

3 Troubleshooting

Service Manual

Gas valve adjustment procedure

If adjustment of the gas valve is deemed necessary, use the
following procedures: (Note: The procedures below are
model specific.)

CAUTION

Model 1.0

Locate the throttle adjustment screw on top of the gas valve,
see FIG. 3-2. Using a screwdriver, turn the screw a 1/4 turn

counterclockwise to increase CO2 levels or a 1/4 turn
clockwise to decrease CO2 levels. After one adjustment on

the valve, follow the Combustion Analysis Procedure on
page 49 of this manual to measure the combustion.

If combustion is still not within the specified range,
repeat the procedure. This procedure SHOULD NOT
be performed more than four (4) times. If after four (4)
adjustments and the combustion is still not within the
specified range, revisit the possible causes in Table 3F on
page 49 or replace the gas valve.

Under normal operating conditions this
valve should not need adjusting.

Models 1.3 - 1.5

Locate the throttle adjustment screw on top of the gas valve,
see FIG. 3-3. Using an Allen wrench, turn the screw a 1/4
turn counterclockwise to increase CO
clockwise to decrease CO2 levels. After one adjustment on
the valve, follow the Combustion Analysis Procedure on page
49 of this manual to measure the combustion.

If combustion is still not within the specified range, repeat
the procedure. This procedure SHOULD NOT be performed
more than four (4) times. If after four (4) adjustments and
the combustion is still not within the specified range, revisit
the possible causes in Table 3F on page 49 or replace the gas
valve.

Figure 3-3 Gas Valve Adjustment: Models 1.3 - 1.5

levels or a 1/4 turn

2

Figure 3-2 Gas Valve Adjustment: Model 1.0

THROTTLE ADJUSTMENT SCREW

THROTTLE ADJUSTMENT

SCREW (REMOVE BLUE COVER)

50

Notes

51

Revision Notes: Revision A (ECO #C09645) initial release.

AWX2-SER Rev A

1/12