Lochinvar AW1000, AW1300, AW1500 Installation Manual

 WARNING: If the information in this

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

-- This water heater MUST NOT be installed in any location where gasoline or flammable vapors are likely to be present.

-- WHAT TO DO IF YOU SMELL GAS

AWX2-I-O Rev B

Installation & Operation

Manual

Models: 1000 - 1500

• Do not try to light any appliance.

• Do not touch any electric switch; do not use any phone in your building.

• Immediately call your gas supplier from a near by phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

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

 WARNING

Save this manual for future reference.

This manual must only be used by a qualified heating installer / service technician. Read all instructions, including this manual and the Armor X2 Water Heater Service Manual, before installing. Perform steps in the order given. Failure to comply could result in severe personal injury, death, or substantial property damage.

Contents

HAZARD DEFINITIONS................................................................. 2

PLEASE READ BEFORE PROCEEDING .............................. 3

THE ARMOR X2 WATER HEATER -- HOW IT WORKS 4-5

RATINGS ............................................................................................ 6

1. DETERMINE WATER HEATER LOCATION

Provide Clearances .............................................................................. 7

Provide Air Openings to Room ......................................................... 9

Flooring and Foundation................................................................... 9

Vent and Air Piping ............................................................................ 9

Prevent Combustion Air Contamination ........................................ 9

Corrosive Contaminants and Sources ............................................ 10

Using an Existing Vent System to Install a New Water

Heater .................................................................................................. 10

Removing a Water Heater from Existing Common Vent ........... 11

Combustion and Ventilation Air Requirements ..................... 12-13

2. PREPARE WATER HEATER

Remove Water Heater from Wood Pallet ...................................... 14

3. GENERAL VENTING

Direct Venting Options .................................................................... 15

Install Vent and Combustion Air Piping ....................................... 16

Requirements for Installation in Canada ....................................... 17

Sizing .................................................................................................. 17

Materials ............................................................................................... 18

Optional Room Air ............................................................................ 19

PVC/CPVC ......................................................................................... 20

Polypropylene ..................................................................................... 21

Stainless Steel Vent ............................................................................ 22

4. SIDEWALL DIRECT VENTING

Vent/Air Termination - Sidewall .............................................. 23-26

Determine Location ............................................................... 23-25

Prepare Wall Penetrations .................................................... 25-26

Multiple Vent/Air Terminations ..................................................... 26

5. VERTICAL DIRECT VENTING

Vent/Air Termination - Vertical ............................................... 27-28

Determine Location ..................................................................... 27

Prepare Roof Penetrations .......................................................... 27

Multiple Vent/Air Terminations ............................................... 28

6. SYSTEM PIPING

System Water Piping Methods ........................................................ 29

General Piping Information ............................................................. 29

Scalding ............................................................................................... 29

Water Chemistry ................................................................................ 30

Piping Components ........................................................................... 30

7. GAS CONNECTIONS

Connecting Gas Supply Piping ........................................................ 36

Natural Gas ......................................................................................... 37

Pipe Sizing for Natural Gas ........................................................ 37

Natural Gas Supply Pressure Requirements ............................ 37

Propane Gas ........................................................................................ 37

Pipe Sizing for Propane Gas ....................................................... 37

Propane Supply Pressure Requirements ................................... 37

Check Inlet Gas Supply ............................................................... 38-39

Gas Pressure ....................................................................................... 39

Gas Valve Replacement .................................................................... 39

8. FIELD WIRING

Line Voltage Connections ................................................................ 40

Low Voltage Connections ................................................................ 41

Wiring of the Cascade ....................................................................... 41

9. CONDENSATE DISPOSAL

Condensate Drain .............................................................................. 44

10. STARTUP ............................................................................ 45-49

11. OPERATING INFORMATION

General ................................................................................................ 50

Cascade ................................................................................................ 52

Sequence of Operation ...................................................................... 53

Armor X2 Water Heater Control Module ..................................... 54

Status Screen .......................................................................... 54-55

Main Menu Screen ...................................................................... 56

12. MAINTENANCE

Maintenance & Annual Startup ................................................. 57-62

13. DIAGRAMS

Ladder Diagram ........................................................................... 63-64

Wiring Diagram ................................................................................. 65

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

Installation & Operation Manual

 WARNING

NOTICE

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

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

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

When calling or writing about the water heater – Please have the water heater model and serial number from the water heater rating plate.

Consider piping and installation when determining water heater location.

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

Factory warranty (shipped with unit) does not apply to units improperly installed or improperly operated.

When servicing the water heater –

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

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

Water heater operation –

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

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

• Do not use this water heater if any part has been under water. The possible damage to a flooded appliance can be extensive and present numerous safety hazards. Any appliance that has been under water must be replaced.

 WARNING

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

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

-- This water heater MUST NOT be installed in any location where gasoline or flammable vapors are likely to be present.

-- WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electric switch; do not use any phone in your building.

• Immediately call your gas supplier from a near by phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

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

Installation & Operation Manual

The Armor X2 Water Heater - How it works...

1. Access cover - front

Provides access to the gas train and the heat exchanger.

2. Air intake adapter

Allows for the connection of the PVC air intake pipe to the water heater.

3. Air pressure switches

The air pressure switches detect blocked flue/vent conditions.

4. Air shrouds (1.0 Model only)

The air shrouds control air and gas flow into the burners.

5. Automatic air vents

Designed to remove trapped air from the heat exchanger coils.

6. Blowers

The blowers pull in air and gas through the venturis (item

36). Air and gas mix inside the blowers and are pushed into the burners, where they burn inside the combustion chamber.

7. Water heater drain port

Location from which the heat exchangers can be drained.

8. Water heater inlet temperature sensors

These sensors monitor inlet water temperature.

9. Water heater outlet temperature sensors

These sensors monitor water heater outlet water temperature.

10. Burners (not shown)

Made with metal fiber and stainless steel construction, the burners use pre-mixed air and gas and provide a wide range of firing rates.

11. Condensate drain connection

Connects the condensate drain line to a 1/2" PVC union.

12. Control modules

The control modules respond to internal and external signals and control the blowers, gas valves, and pumps to meet the heating demand.

13. Electronic display

Digital controls with touch screen technology and full color display.

14. Flame inspection windows

The quartz glass windows provide a view of the burner surfaces and flames.

15. Flame sensors

Used by the control module to detect the presence of burner flame.

16. Flap valves

Prevents recirculation of flue products when only one burner is running.

17. Flue gas sensors

These sensors monitor the flue gas exit temperature. The control modules will modulate and shut down the water heater if the flue gas temperature gets too hot. This protects the flue pipe from overheating.

18. Flue pipe adapter

Allows for the connection of the PVC vent pipe system to the water heater.

19. Gas connection pipe

Threaded 1½" pipe connection. This pipe should be connected to the incoming gas supply for the purpose of delivering gas to the water heater.

20. Gas shutoff valves (inside unit)

Manual valves used to isolate the gas valves from the burners.

21. Gas shutoff valve (outside unit)

Manual valve used to isolate the gas valve from the gas supply.

22. Gas valves

The gas valves sense the negative pressure created by the blowers, allowing gas to flow only if the gas valves are powered and combustion air is flowing.

23. Heat exchanger access covers

Allows access to the combustion side of the heat exchanger coils.

24. High limits

Devices used to monitor the outlet water temperature. If the temperature exceeds its setting, they will break the control circuit, shutting the water heater down.

25. Ignition electrodes

Provides direct spark for igniting the burners.

26. Line voltage junction box

The junction box contains the connection points for the line voltage power and all pumps.

27. Line voltage wiring connections (knockouts)

Conduit connection points for the high voltage junction box.

28. Low voltage connection board

The connection board is used to connect external low voltage devices.

29. Low voltage wiring connections (knockouts)

Conduit connection points for the low voltage connection board.

30. Power switch

Turns 120 VAC ON/OFF to the heater.

31. Pump relay board

The pump relay board is used to control the HW pumps.

32. Relief valve

Protects the heat exchangers from an over pressure condition. The relief valve will be set at 150 PSI and 210°F.

33. Stainless steel heat exchangers

Allows system water to flow through specially designed coils for maximum heat transfer, while providing protection against flue gas corrosion. The coils are encased in a jacket that contains the combustion process.

34. Temperature and pressure gauge

Monitors the outlet temperature of the water heater as well as the system water pressure.

35. Top panel

Removable panel to gain access to the internal components.

36. Venturis

The venturis control air and gas flow into the burners.

37. Water inlets

Two 2" NPT water connections that return water from the system to the heat exchangers.

38. Water outlets

A 3" NPT stainless steel water connection that supplies hot water to the system.

39. O-temp switch (located underneath access cover)

An electrical switch designed to shut down water heater operation in the event the outer back of the heat exchanger, directly above the flue connection does not exceed 604°F (318°C). This is a one time switch and could warrant a heat exchanger replacement. Check the integrity of the rear refractory at the back of the upper coil if the switch opens.

40. Flow switch The flow switch is a safety device that ensures flow through the

heat exchanger during operation. This appliance is low mass and should never be operated without flow. The flow switch makes contact when flow is detected and allows the unit to operate. If flow is discontinued during operation for any reason the flow switch will break the control circuit and the unit will shut down.

41. Limiting thermostat The limiting thermostat is used to prevent the outlet water of the

heat exchangers from exceeding 190°F.

Installation & Operation Manual

The Armor X2 Water Heater - How it works... (continued)

Models 1.0 - 1.3 - 1.5

IMG00133

IMG00134

Front View

1.0 MODEL ONLY

34 16

Rear View

IMG00135A

Left Side (inside unit)

IMG00135

Right Side (inside unit)

IMG00136

Ratings

HLW

Installation & Operation Manual

Model Number

Note: Change “N” to “L” for

L.P. gas models.

AWN1000 100,000 - 1,000,000 8.4 2" 3" 1 1/2" 6"

AWN1300 130,000 - 1,300,000 10.0 2" 3" 1 1/2" 6"

AWN1500 150,000 - 1,500,000 11.4 2" 3" 1 1/2" 6"

NOTICE

Maximum allowed working pressure is located on the rating plate.

Input Modulation Btu/hr

CSA

(Note 2, 3) (Note 1)

Notes:

1. Armor X2 water heaters require special gas venting. Use only the vent materials and methods specified in the Armor X2 Installation and Operation Manual.

2. Standard Armor X2 water heaters are equipped to operate from sea level to 4,500 feet only with no adjustments. The water heater will de-rate by 4% for each 1,000 feet above sea level up to 4,500 feet.

3. High altitude Armor X2 water heaters are equipped to operate from 3,000 to 12,000 feet only with no field adjustments. The water heater will de-rate by 2% for each 1,000 feet above 3,000 feet. High altitude models are manufactured with a different control module for altitude operation, but the operation given in this manual remains the same as the standard water heaters. A high altitude label (as shown in FIG. A) is also affixed to the unit.

4. The manual reset high limit provided with the Armor X2 is listed to UL353.

Water

Content

Gallons

Water Connections

Gas Connections

Inlet Outlet

Figure A High Altitude Label Location

Vent/Air Size

UNIT EQUIPPED FOR

HIGH ALTITUDE

3,000 FT. TO 12,000 FT.

1 Determine water heater location

Installation & Operation Manual

Installation must comply with:

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

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

• National Electrical Code.

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

NOTICE

The Armor X2 water heater gas manifold and controls met safe lighting and other performance under tests specified in ANSI Z21.10.3 – latest edition.

Before locating the water heater, check:

1. Check for nearby connection to:

• Water piping

• Venting connections

• Gas supply piping

• Electrical power

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

3. Check area around the water heater. Remove any combustible materials, gasoline and other flammable liquids.

 WARNING

4. The Armor X2 water heater must be installed so that gas

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

5. If a new water heater will replace an existing water heater,

check for and correct system problems, such as:

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

 WARNING

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

This appliance is certified as an indoor appliance. Do not install the appliance outdoors or locate where the appliance will be exposed to freezing temperatures or to temperatures that exceed 100°F.

Do not install the appliance where the relative humidity may exceed 93%. Do not install the appliance where condensation may form on the inside or outside of the appliance, or where condensation may fall onto the appliance.

Failure to install the appliance indoors could result in severe personal injury, death, or substantial property damage.

 WARNING

This appliance requires a special venting system. Use only the vent materials, primer and cement specified in this manual to make the vent connections. Failure to follow this warning could result in fire, personal injury, or death.

Closet and alcove installations

A closet is any room the water heater is installed in which is less than 778 cubic feet for AW1000 models, 847 cubic feet for AW1300 models, and 914 cubic feet for AW1500 models.

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

Example: Room dimensions = 9 feet long, 9 feet wide, and 9 foot ceiling = 9 x 9 x 9 = 729 cubic feet. This would be considered a closet for a Armor X2 water heater.

 WARNING

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

Provide clearances:

Clearances from combustible materials

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

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

3. See FIG.’s 1-1 and 1-2 on page 8 for other clearance minimums.

Clearances for service access

1. See FIG.’s 1-1 and 1-2 on page 8 for recommended

service clearances. If you do not provide the minimum clearances shown, it may not be possible to service the water heater without removing it from the space.

1 Determine water heater location

Installation & Operation Manual

Figure 1-1 Closet Installation - Minimum Required Clearances

1/4” (6 MM) MINIMUM CLEARANCE

ROUND HOT WATER PIPES

1” (25 MM) MINIMUM CLEARANCE

ROUND VENT PIPES

LEFT

24" (610 MM)

REAR

RECOMMENDED SERVICE CLEARANCES:

Front - 30" (762 mm) Top - 24" (610 mm) Left Side - 24" (610 mm) Rear - 24" (610 mm)

 WARNING

For closet installations, CPVC, polypropylene or stainless steel vent material MUST BE used in a closet structure due to elevated temperatures. Failure to follow this warning could result in fire, personal injury, or death.

4" (330 MM)

TOP

VENTILATING*

AIR OPENING

CLOSED DOOR

VENTILATING* AIR OPENING

6" (152 MM)

RIGHT

6" (152 MM)

FRONT

*AREA OF EACH OPENING: 1 SQ. INCH PER 1000 BTU PER HOUR INPUT WITH A MINIMUM OF 100 SQ. INCHES

Figure 1-2 Alcove Installation - Minimum Required Clearances

1/4” (6 MM) MINIMUM CLEARANCE

ROUND HOT WATER PIPES

1” (25 MM) MINIMUM CLEARANCE

ROUND VENT PIPES

 WARNING

For alcove installations, CPVC, polypropylene or stainless steel vent material MUST BE used in an alcove structure due to elevated

LEFT

24" (610 MM)

REAR

RECOMMENDED SERVICE CLEARANCES:

Front - 30" (762 mm) Top - 24" (610 mm)

6" (152.40 MM)

FRONT

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

13" (330 MM)

TOP

OPEN FRONT

RIGHT

Left Side - 24" (610 mm) Rear - 24" (610 mm)

Installation & Operation Manual

1 Determine water heater location (continued)

Provide air openings to room:

The Armor X2 alone in boiler room

1. No air ventilation openings into the boiler room are needed when clearances around the Armor X2 are at least equal to the SERVICE clearances shown in FIG.’s 1-1 and 1-2. For spaces that do NOT supply this clearance, provide two openings as shown in FIG. 1-1. Each opening must provide one square inch free area per 1,000 Btu/hr of water heater input.

2. Combustion air openings are required when using the Room Air Option on page 19 of this manual.

The Armor X2 in same space with other gas or oilfired appliances

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

 WARNING

2. Size openings only on the basis of the other appliances in

the space. No additional air opening free area is needed for the Armor X2 because it takes its combustion air from outside (direct vent installation).

The space must be provided with combustion/ventilation air openings correctly sized for all other appliances located in the same space as the Armor X2.

Do not install the water heater in an attic.

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

Flooring and foundation

Flooring

The Armor X2 is approved for installation on combustible flooring, but must never be installed on carpeting.

 WARNING

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

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

Vent and air piping

The Armor X2 requires a special vent system, designed for pressurized venting.

The water heater is to be used for either direct vent installation or for installation using indoor combustion air. When room air is considered, see Section 5, Vertical Direct Venting. Note prevention of combustion air contamination below when considering vent/air termination.

Vent and air must terminate near one another and may be vented vertically through the roof or out a side wall, unless otherwise specified. You may use any of the vent/air piping methods covered in this manual. Do not attempt to install the Armor X2 using any other means.

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

Prevent combustion air contamination

Install air inlet piping for the Armor X2 as described in this manual. Do not terminate vent/air in locations that can allow contamination of combustion air. Refer to Table 1A, page 10 for products and areas which may cause contaminated combustion air.

 WARNING

Ensure that the combustion air will not contain any of the contaminants in Table 1A, page 10. Contaminated combustion air will damage the water heater, resulting in possible severe personal injury, death or substantial property damage. Do not pipe combustion air near a swimming pool, for example. Also, avoid areas subject to exhaust fumes from laundry facilities. These areas will always contain contaminants.

1 Determine water heater location

Installation & Operation Manual

Table 1A Corrosive Contaminants and Sources

Products to avoid:

Spray cans containing chloro/fluorocarbons

Permanent wave solutions

Chlorinated waxes/cleaners

Chlorine-based swimming pool chemicals

Calcium chloride used for thawing

Sodium chloride used for water softening

Refrigerant leaks

Paint or varnish removers

Hydrochloric acid/muriatic acid

Cements and glues

Antistatic fabric softeners used in clothes dryers

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

Adhesives used to fasten building products and other similar products

Areas likely to have contaminants

Dry cleaning/laundry areas and establishments

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

 WARNING

Check the following venting components before installing:

• Material - For materials listed for use with this appliance, see Section 3 - General Venting. For polypropylene or stainless steel venting, an adapter of the same

manufacturer must be used at the flue collar connection.

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

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

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

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

Swimming pools

Metal fabrication plants

Beauty shops

Refrigeration repair shops

Photo processing plants

Auto body shops

Plastic manufacturing plants

Furniture refinishing areas and establishments

New building construction

Remodeling areas

Garages with workshops

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

• Seal - With prior requirements met, the system should be tested to the procedure listed in parts (c) through (f) of the Removal of an Existing Water Heater Section on page 11.

With polypropylene and stainless steel vent, seal and connect all pipe and components as specified by the vent manufacturer used; with PVC/CPVC vent, see the Installing Vent or Air Piping Section on page 20.

 WARNING

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

Installation & Operation Manual

1 Determine water heater location (continued)

When removing a water heater from existing common vent system:

 DANGER

Do not install the Armor X2 into a common vent with any other appliance. This will cause flue gas spillage or appliance malfunction, resulting in possible severe personal injury, death, or substantial property damage.

 WARNING

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

a. Seal any unused openings in the common venting system. b. Visually inspect the venting system for proper size and

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

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

doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.

d. Place in operation the appliance being inspected. Follow

the lighting instructions. Adjust thermostat so appliance will operate continuously.

e. Test for spillage at the draft hood relief opening after 5

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

f. After it has been determined that each appliance

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

g. Any improper operation of the common venting system

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

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

1 Determine water heater location

Combustion and ventilation air requirements for appliances drawing air from the equipment room

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

The equipment room MUST be provided with properly sized openings to assure adequate combustion air and proper ventilation.

Figure 1-4_Combustion Air Through Ducts

2. If combustion and ventilation air is taken from the outdoors using a duct to deliver the air to the equipment room, each of the two openings should be sized based on a minimum free area of one square inch per 2000 Btu/hr (11 cm2 per kW) of input (see FIG. 1-4).

Installation & Operation Manual

Figure 1-3_Combustion Air Direct from Outside

1. If air is taken directly from outside the building with no duct, provide two permanent openings to the equipment room (see FIG. 1-3):

(a) Combustion air opening, with a minimum free area of one square inch per 4000 Btu/hr input

(5.5 cm

per kW). This opening must be located

within 12" (30 cm) of the bottom of the enclosure.

(b) Ventilation air opening, with a minimum free area of one square inch per 4000 Btu/hr input (5.5 cm

per kW). This opening must be located

within 12" (30 cm) of the top of the enclosure.

IF NECESSARY

FOR TIGHT

CONSTRUCTION

Figure 1-5_Combustion Air from Interior Space

3. If air is taken from another interior space, each of the two openings specified above should have a net free area of one square inch for each 1000 Btu/hr (22 cm2 per kW) of input, but not less than 100 square inches (645 cm2) (see FIG. 1-5).

1 Determine water heater location (continued)

Where two openings are provided, one must be within 12" (30cm) of the ceiling and one must be within 12" (30cm) of the floor of the equipment room. Each opening must have net free area as specified in the chart below (Table 1B). Single openings shall commence within 12" (30cm) of the ceiling.

Under no circumstances should the equipment room ever be under negative pressure. Particular care should be taken where exhaust fans, attic fans, clothes dryers, compressors, air handling units, etc., may take away air from the unit.

Figure 1-6_Combustion Air from Outside - Single Opening

4. If a single combustion air opening is provided to bring combustion air in directly from the outdoors, the opening must be sized based on a minimum free area of one square inch per 3000 Btu/hr (7 cm2 per kW). This opening must be located within 12" (30 cm) of the top of the enclosure (see FIG. 1-6).

Combustion air requirements are based on the latest edition of the National Fuel Gas Code, ANSI Z223.1; in Canada refer to the latest edition of CGA Standard CAN B149.1. Check all local code requirements for combustion air.

All dimensions based on net free area in square inches. Metal louvers or screens reduce the free area of a combustion air opening a minimum of approximately 25%. Check with louver manufacturers for exact net free area of louvers.

 CAUTION

The combustion air supply must be completely free of any flammable vapors that may ignite or chemical fumes which may be corrosive to the appliance. Common corrosive chemical fumes which must be avoided are fluorocarbons and other halogenated compounds, most commonly present as refrigerants or solvents, such as Freon, trichlorethylene, perchlorethylene, chlorine, etc. These chemicals, when burned, form acids which quickly attack the stainless steel heat exchanger, headers, flue collectors, and the vent system.

The result is improper combustion and a non-warrantable, premature appliance failure.

EXHAUST FANS: Any fan or equipment which exhausts air from the equipment room may deplete the combustion air supply and/or cause a downdraft in the venting system. Spillage of flue products from the venting system into an occupied living space can cause a very hazardous condition that must be corrected immediately.

Installation & Operation Manual

TABLE - 1B

MINIMUM RECOMMENDED COMBUSTION

AIR SUPPLY TO EQUIPMENT ROOM

FIG. 1-3 FIG. 1-4 FIG. 1-5 FIG. 1-6

Model

Number

1000

1300

1500

*Outside Air from

2 Openings Directly from

Outdoors

Top

Opening, in

250

(1613 cm2)

325

(2097 cm2)

375

(2420 cm2)

Bottom

Opening, in

250

(1613 cm2)

325

(2097 cm2)

375

(2420 cm2)

*Outside Air from

2 Ducts Delivered from

Outdoors

Top

Opening, in

Bottom

500

(3226 cm2)

650

(4194 cm2)

750

(4839 cm2)

500

650

750

**Inside Air from

2 Ducts Delivered from

Interior Space

Top

Opening, in

1000

(6452 cm2)

1300

(8388 cm2)

1500

(9678 cm2)

Bottom

Opening, in

1000

(6452 cm2)

1300

(8388 cm2)

1500

(9678 cm2)

*Outside Air from 1 Opening Directly from Outdoors, in

333

(2149 cm2)

433

(2794 cm2)

500

(3226 cm2)

*Outside air openings shall directly communicate with the outdoors. When combustion air is drawn from the outside through a duct, the net free area of each of the two openings must have twice (2 times) the free area required for Outside Air/2 Openings. The above requirements are for the appliance only; additional gas fired appliances in the equipment room will require an increase in the net free area to supply adequate combustion air for all appliances.

**Combined interior space must be 50 cubic feet per 1,000 Btu/hr input. Buildings MUST NOT be of *“Tight Construction”. For buildings of *“Tight Construction”, provide air openings into the building from outside.

*No combustion air openings are needed when the appliance is installed in a space with a volume NO LESS than 50 cubic feet per 1,000 Btu/hr of all installed gas fired appliances. Buildings MUST NOT be of *“Tight Construction”.

*”Tight Construction” is defined as a building with less than 0.40 ACH (air changes per hour).

2 Prepare water heater

Remove water heater from wood pallet

1. After removing the outer shipping carton from the water heater, remove the parts package (packaged parts inside the jacket of the water heater).

2. To remove the water heater from the pallet:

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

NOTICE

Figure 2-1 Water heater Mounted on Shipping Pallet

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

Installation & Operation Manual

LAG BOLTS

(QTY. 3)

REAR

LAG BOLTS

(QTY. 3)

FRON

Maintain minimum specified clearances for adequate operation. All installations must allow sufficient space for servicing the vent connections, water pipe connections, piping and other auxiliary equipment, as well as the appliance. The clearance labels on each appliance note the same service and combustible clearance requirements as shown in this manual.

Multiple appliances may be installed in a modular water heater installation. Multiple appliances may be installed side by side with no clearance between adjacent appliances because this appliance is approved for zero clearance from combustible surfaces and no service access is required from the sides.

Consult the Venting section of this manual for specific installation instructions for the appropriate type of venting system that you will be using.

3 General venting

Direct venting options - Sidewall Vent

Installation & Operation Manual

Figure 3-1 Two-Pipe Sidewall Termination - See page 23 for more details

Direct venting options - Vertical Vent

Figure 3-2 Two-Pipe Vertical Termination - See page 27 for more details

Figure 3-3 Vertical Vent, Sidewall Air - See page 19 for more details

3 General venting

Install vent and combustion air piping

Installation & Operation Manual

 DANGER

 WARNING

NOTICE

 WARNING

The Armor X2 water heater must be vented and supplied with combustion and ventilation air as described in this section. Ensure the vent and air piping and the combustion air supply comply with these instructions regarding vent system, air system, and combustion air quality. See also Section 1 of this manual.

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

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

This appliance requires a special venting system. Use only approved stainless steel,

PVC, CPVC or polypropylene pipe and fittings listed in Tables 3C, 3E, and 3F for vent pipe, and fittings. Failure to comply could result in severe personal injury, death, or substantial property damage.

DO NOT mix components from different systems. The vent system could fail, causing leakage of flue products into the

living space. Mixing of venting materials will void the warranty and certification of the appliance.

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

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

The Armor X2 water heater vent and air piping can be installed through the roof or through a sidewall. Follow the procedures in this manual for the method chosen. Refer to the information in this manual to determine acceptable vent and air piping length.

You may use any of the vent/air piping methods covered in this manual. Do not attempt to install the Armor X2 water heater using any other means.

You must also install air piping from outside to the water heater air intake adapter unless following the Optional Room Air instructions on page 19 of this manual. The resultant installation is direct vent (sealed combustion).

Air intake/vent connections

1. Combustion Air Intake Connector (FIG. 3-4) - Used to provide combustion air directly to the unit from outdoors. A fitting is provided with the unit for final connection. Combustion air piping must be supported per guidelines listed in the National Mechanical Code, Section 305, Table

305.4 or as local codes dictate.

2. Vent Connector (FIG.'s 3-5 thru 3-8) - Used to provide a passageway for conveying combustion gases to the outside. A transition fitting is provided on the unit for final connection. Vent piping must be supported per the National Building Code, Section 305, Table 305.4 or as local codes dictate.

Figure 3-4 Near Water Heater Air Piping

AIR

 CAUTION

NOTICE

 WARNING

Improper installation of venting systems may result in injury or death.

Follow the instructions in Section 1, page 11 of this manual when removing a water heater from an existing vent system.

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

3 General venting (continued)

Installation & Operation Manual

Requirements for installation in Canada

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

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

3. The components of the certified vent system must not be interchanged with other vent systems or unlisted pipe/fittings.

Table 3A Air Intake/Vent Piping Sizes

Model

AW 1000 6" 12' 100' 6" 12' 100' 1.25%*

AW 1300 6" 12' 50' 6" 12' 50' 2.90%

AW 1300 7" 12' 100' 7" 12' 100' 0.95%

AW 1500 6" 12' 50' 6" 12' 50' 3.30%

AW 1500 7" 12' 100' 7" 12' 100' 1.65%

*LP models will derate by 1.5% per 25 feet of vent pipe.

Note: When using a 7" vent or air pipe, a field supplied increaser is required.

Air Intake

Diameter

Air Intake

Min. Length

Air Intake

Max. Length

Sizing

The Armor X2 water heater uses model specific combustion air intake and vent piping sizes as detailed in Table 3A below.

When determining equivalent combustion air and vent length, add 5 feet for each 90° elbow and 3 feet for each 45° elbow.

EXAMPLE: 20 feet of PVC pipe + (4) 90° elbows + (2) 45° elbows + (1) concentric vent kit (CVK3003) = 49 equivalent feet of piping.

Vent

Diameter

Vent

Min. Length

Vent

Max. Length

De-Rate per

25 feet of Vent

Input

NOTICE

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

3 General venting

Materials

Air inlet pipe materials:

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

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

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

 WARNING

NOTICE

Using air intake materials other than those specified can result in personal injury, death or property damage.

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

Installation & Operation Manual

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

When a sidewall or vertical rooftop combustion air supply system is disconnected for any reason, the air inlet pipe must be resealed to ensure that combustion air will be free of contaminants and supplied in proper volume.

 DANGER

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

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

a. Seal all joints and seams of the air inlet pipe using either Aluminum Foil Duct Tape meeting UL Standard 723 or 181A-P or a high quality UL Listed silicone sealant such as those manufactured by Dow Corning or General Electric.

b. Do not install seams of vent pipe on the bottom of horizontal runs.

c. Secure all joints with a minimum of three (3) sheet metal screws or pop rivets. Apply Aluminum Foil Duct Tape or silicone sealant to all screws or rivets installed in the vent pipe.

d. Ensure that the air inlet pipes are properly supported.

3 General venting (continued)

Optional room air

Applications utilizing the Armor X2 water heater may be installed with a single pipe carrying the flue products to the outside while using combustion air from the equipment room. In order to use the room air venting option the following conditions and considerations must be followed.

• The unit MUST be installed with the appropriate room air kit (Table 3B).

• The equipment room MUST be provided with properly sized openings to assure adequate combustion air. Please refer to instructions provided with the room air kit.

• There will be a noticeable increase in the noise level during normal operation from the inlet air opening.

• Using the room air kit makes the unit vulnerable to combustion air contamination from within the building. Please review Section 1, Prevent Combustion Air Contamination, to ensure proper installation.

• Vent system and terminations must comply with the standard venting instructions set forth in this manual.

 WARNING

Figure 3-5 Room Air Installation

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

NOTICE

FOR DIRECT VENT SYSTEMS REMOVE AIR INLET COVER AND INSTALL RUBBER COUPLING FOR PVC / CPVC VENT SYSTEMS OR STAINLESS STEEL ADAPTER FOR STAINLESS STEEL VENT SYSTEMS

Installation & Operation Manual

Table 3B Room Air Minimum / Maximum Allowable Air / Vent Lengths

Model

AW 1000 6" 12’ 100’ 0.63%*

AW 1300 6" 12’ 100’ 1.45%

AW 1500 6" 12’ 100’ 1.65%

*LP models will derate by .9% per 25 feet of vent pipe.

Air contamination

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

Please read the information given in Table 1A, page 10, listing contaminants and areas likely to contain them. If contaminating chemicals will be present near the location of the water heater combustion air inlet, have your installer pipe the water heater combustion air and vent to another location, per this manual.

 WARNING

Vent

Diameter

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

To prevent the potential of severe personal injury or death, check for areas and products listed in Table 1A, page 10 before installing the water heater or air inlet piping.

If contaminants are found, you MUST:

Vent Min.

Length

• Remove contaminants permanently.

• Relocate air inlet and vent terminations

Vent Max.

Length

—OR—

to other areas.

Input

De-Rate per

25 feet of

Vent

3 General venting

Installation & Operation Manual

PVC/CPVC

This product has been approved for use with the PVC/CPVC vent materials listed in Table 3C.

Installing vent and air piping

 WARNING

NOTICE

 WARNING

Table 3C PVC/CPVC Vent Pipe, and Fittings

For all installations, the first ten (10) equivalent feet of vent must be CPVC or stainless steel (see FIG. 3-6). The field provided vent fittings must be cemented to the CPVC pipe section using an “All Purpose Cement” suitable for PVC and CPVC pipe. Use only the vent materials, primer, and cement specified in Table 3C to make the vent connections. Failure to follow this warning could result in fire, personal injury, or death.

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

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

Insulation should not be used on PVC or CPVC venting materials. The use of insulation will cause increased vent wall temperatures, which could result in vent pipe failure.

For all installations, the first ten (10) equivalent feet of vent must be CPVC or stainless steel (see FIG. 3-6). Failure to follow this warning could result in fire, personal inury, or death.

Approved PVC/CPVC Vent Pipe and Fittings

Item Material Standard

PVC Schedule 40, 80 ANSI/ASTM D1785

Vent pipe

Vent fittings

Pipe Cement /

Primer

NOTICE: DO NOT USE CELLULAR (FOAM) CORE PIPE

PVC - DWV ANSI/ASTM D2665

CPVC Schedule 40, 80 ANSI/ASTM F441

PVC Schedule 40 ANSI/ASTM D2466

PVC Schedule 80 ANSI/ASTM D2467

CPVC Schedule 80 ANSI/ASTM F439

PVC ANSI/ASTM D2564

CPVC ANSI/ASTM F493

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

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

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

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

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

6. Priming and Cementing: a. Handle fittings and pipes carefully to prevent contamination of surfaces.

b. Apply a liberal even coat of primer to the fitting socket and to the pipe end to approximately 1/2" beyond the socket depth.

c. Apply a second primer coat to the fitting socket.

d. While primer is still wet, apply an even coat of approved cement to the pipe equal to the depth of the fitting socket along with an even coat of approved cement to the fitting socket.

e. Apply a second coat of cement to the pipe. f. While the cement is still wet, insert the pipe into

the fitting, if possible twist the pipe a 1/4 turn as you insert it. NOTE: If voids are present, sufficient cement was not applied and joint could be defective.

g. Wipe excess cement from the joint removing ring or beads as it will needlessly soften the pipe.

Figure 3-6 Near Water Heater PVC/CPVC Venting

CPVC ELBOW

CPVC PIPE

NOTE: In Canada, CPVC and PVC vent pipe, ﬁ ttings and cement/ primer must be ULC-S636 certiﬁ ed.

3 General venting (continued)

Installation & Operation Manual

Polypropylene

This product has been approved for use with polypropylene vent with the manufacturers listed in Table 3D.

All terminations must comply with listed options in this manual and be a single-wall vent offering.

For use of flex pipe, it is recommended to have the vent material in 32°F or higher ambient space before bending at installation. No bends should be made to greater than 45° and ONLY installed in vertical or near vertical installations.

For support and special connections required, see the manufacturer's instructions. All vent is to conform to standard diameter and equivalent length requirements established.

Table 3D Polypropylene Vent Pipe and Fittings

Approved Polypropylene Vent Manufacturers

Make Model

Centrotherm Eco Systems

Duravent (M & G Group)

NOTICE

PolyPro Single-Wall / PolyPro Flex

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

InnoFlue SW/Flex

 WARNING

NOTICE

Figure 3-7 Near Water Heater Polypropylene Venting

Use only the adapters and vent system listed in Tables 3E and 3F. DO NOT mix vent systems of different types or manufacturers. Failure to comply could result in severe personal injury, death, or substantial property damage.

Installations must comply with applicable national, state, and local codes. For Canadian installation, polypropylene vent must be listed as a ULC-S636 approved system.

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

NOTICE

 WARNING

Table 3E Approved PolypropyleneTerminations

Model

1000 -1500

* These parts are only needed if the sidewall termination assembly is used (see FIG. 4-4B on page 25).

All vent connections MUST be secured by the vent manufacturer's joint connector (FIG. 3-7).

Insulation should not be used on polypropylene venting materials. The use of insulation will cause increased vent wall temperatures, which could result in vent pipe failure.

Centrotherm InnoFlue SW

Polypropylene

Adapter

ISAAL0606 Not Required IATP0606 ISTAGL0606 FSA-6PVCM-6PPS N/A 6PPK-HLK

Joint

Connector

Sidewall Retaining

Bracket*

POLYPROPYLENE

DAPTER

Sidewall

Adapter*

Duravent Polypro

Polypropylene

Adapter

Joint

Connector

IMG00024

Sidewall Adapter*

+ 47 hidden pages