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
OAW-I-O Rev D
Outdoor Armor W a ter
Heater Installation &
Operation Manual
Models: 151 - 801
• Do not try to light any appliance.
• Do not touch any electric switch; do not
use any phone in your building.
• Immediately call your gas supplier from
a near by phone. Follow the gas supplier’s
instructions.
• If you cannot reach your gas supplier, call
the fire department.
• Installation and service must be performed
by a qualified installer, service agency, or
the gas supplier.
WARNING
Save this manual for future reference.
This manual must only be used by
a qualified heating installer / service
technician. Read all instructions,
including this manual and the
Outdoor Armor Water Heater
Service Manual, before installing.
Perform steps in the order given.
Failure to comply could result in
severe personal injury, death, or
substantial property damage.
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
2
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious
injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury.
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not
avoided, may result in property damage.
NOTICE indicates special instructions on installation, operation, or maintenance that are important but not
related to personal injury or property damage.
Page 3
Outdoor Armor Water Heater Installation & Operation Manual
Please read before proceeding
WARNING
NOTICE
Installer – Read all instructions, including
this manual and the Outdoor Armor Water
Heater Service Manual, before installing.
Perform steps in the order given.
Have this water heater serviced/inspected
by a qualified service technician, at least
annually.
Failure to comply with the above could
result in severe personal injury, death or
substantial property damage.
When calling or writing about the water
heater – Please have the water heater
model and serial number from the water
heater rating plate.
Consider piping and installation when
determining water heater location.
Any claims for damage or shortage in
shipment must be filed immediately
against the transportation company by the
consignee.
Factory warranty (shipped with unit) does
not apply to units improperly installed or
improperly operated.
When servicing the water heater –
• To avoid electric shock, disconnect electrical supply
before performing maintenance.
• To avoid severe burns, allow the water heater to cool
before performing maintenance.
Water heater operation –
• Do not block flow of combustion or ventilation air to
the water heater.
• Should overheating occur or gas supply fail to shut off,
do not turn off or disconnect electrical supply to
circulator. Instead, shut off the gas supply at a location
external to the appliance.
• Do not use this water heater if any part has been under
water. The possible damage to a flooded appliance can
be extensive and present numerous safety hazards. Any
appliance that has been under water must be replaced.
WARNING
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 near the
water heater.
• Do not touch any electric switch.
• Immediately call your gas supplier.
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.
3
Page 4
Outdoor Armor Water Heater Installation & Operation Manual
The Outdoor Armor Water Heater - How it works...
1. Stainless steel heat exchanger
Allows water to flow through specially designed coils for maximum
heat transfer, while providing protection against flue gas corrosion.
The coils are encased in a jacket that contains the combustion
process.
2. Combustion chamber access cover
Allows access to the combustion side of the heat exchanger coils.
3. Blower
The blower pulls in air and gas through the venturi (item 5). Air
and gas mix inside the blower and are pushed into the burner, where
they burn inside the combustion chamber.
4. Gas valve
The gas valve senses the negative pressure created by the blower,
allowing gas to flow only if the gas valve is powered and combustion
air is flowing.
5. Venturi
The venturi controls air and gas flow into the burner.
6. Flue gas sensor (limit rated - not shown)
This sensor monitors the flue gas exit temperature. The control
module will modulate and shut down the water heater if the flue gas
temperature gets too hot. This protects the flue pipe from
overheating.
7. Water heater outlet temperature sensor (housed with the
high limit sensor)
This sensor monitors water heater outlet water
temperature.
8. Water heater inlet temperature sensor
This sensor monitors return water temperature. If
the tank sensor is not connected, the control module will adjust the
water heater firing rate so the inlet temperature is correct.
9. Flow switch
The flow switch is a safety device that ensures flow through the
heat exchanger during operation. This appliance is low mass
and should never be operated without flow. The flow switch makes
contact when flow is detected and allows the unit to operate. If flow
is discontinued during operation for any reason the flow switch will
break the control circuit and the unit will shut down.
10. Electronic LCD display
The electronic display consists of 4 buttons, a navigation dial and a
multiple line liquid crystal display.
11. Burner (not shown)
Made with metal fiber and stainless steel construction, the burner
uses pre-mixed air and gas and provides a wide range of firing rates.
12. Water outlet
NPT water connection that supplies hot water to the tank.
13. Water inlet
NPT water connection that returns water from the tank to the heat
exchanger.
14. Gas connection pipe
Threaded pipe connection. This pipe should be connected to the
incoming gas supply for the purpose of delivering gas to the water
heater.
15. SMART SYSTEM Control Module
The SMART SYSTEM Control responds to internal and external
signals and controls the blower, gas valve, and pumps to meet the
demand.
16. Manual air vent
Designed to remove trapped air from the heat exchanger coils.
17. High voltage junction box
The junction box contains the connection points for the line
voltage power and the pump.
18. Water heater drain port
Location from which the heat exchanger can be drained.
19. Low voltage connection board
The connection board is used to connect external low voltage
devices.
20. Low voltage wiring connections (plugs)
Conduit connection points for the low voltage connection
board.
21. Condensate drain connection
Connects the condensate drain line to a 1/2" PVC union.
22. Access cover - front (not shown)
Provides access to the gas train and the heat exchanger.
23. Ignition electrode
Provides direct spark for igniting the burner.
24. Flame inspection window
The quartz glass window provides a view of the burner surface
and flame.
25. Gas shutoff valve
Manual valve used to isolate the gas valve from the gas supply.
26. High limit sensor (housed with the outlet temperature
sensor)
Device that monitors the outlet water temperature. If the
temperature exceeds its setting, the integrated control will
break the control circuit, shutting the water heater down.
27. Relief valve
Protects the heat exchanger from over pressure and temperature
conditions. The relief valve is set at 150 PSI / 210°F.
28. Flame sensor
Used by the control module to detect the presence of burner
flame.
29. Line voltage wiring connections (plugs)
Conduit connection points for the high voltage junction box.
30. Top panel
Removable panel to gain access to the internal components.
31. Power switch
Turns 120 VAC ON/OFF to the water heater.
32. Leveling legs
Used to allow the heat exchanger to be leveled. This is needed
for the proper draining of the condensate from the combustion
chamber.
33.Air shroud (501 Model Only - not shown)
The air shroud directs air and gas flow into the burner.
34. Air pressure switch
The air pressure switch detects blocked inlet or outlet
conditions.
35. Pump relay (not shown)
The pump relay is used to control the circulation pump.
36. Transformer (not shown)
The transformer provides 24V power to the integrated control.
37. Gas shutoff switch (Models 151 - 286 Only - not shown)
An electrical switch designed to cut power to the gas valve to
prevent releasing any gas.
An electrical switch designed to shut down water heater
operation in the event the outer back of the heat exchanger,
directly above the flue connection exceeds 604°F (318°C).
This is a one time switch and could warrant a heat exchanger
replacement. Check the integrity of the rear refractory at the
back of the upper coil if the switch opens.
39. Vent / air cover
On Models 400 - 801 it functions as a vent cover only. Covers
the over-temp switch and the flue collar with flue sensor.
40. Air intake
Provides combustion air to the appliance.
41. Air intake cover (Models 400 - 801 Only)
Provides protection from outdoor elements.
42. Flue pipe assembly
Factory supplied components for a complete venting system.
4
Page 5
Outdoor Armor Water Heater Installation & Operation Manual
The Outdoor Armor Water Heater - How it works... (continued)
Models 151 - 200
42
29
20
30
17
15
19
42
IMG00284
Rear View - Models 151 - 200
29
20
30
39
13
21
14
27
9
12
40
8
13
9
27
12
7
26
32
1
21
IMG00287
Left Side (inside unit) - Models 151 - 200
34
34
10
31
16
24
23
28
2
18
17
15
19
IMG00359
39
Rear View - Model 286
13
14
9
12
40
7
26
8
27
18
1
21
Left Side (inside unit) - Model 286
10
31
2
24
23
16
28
IMG00360
5
Page 6
Outdoor Armor Water Heater Installation & Operation Manual
The Outdoor Armor Water Heater - How it works...
Models 400 - 501
15
29
20
42
39
IMG00395
Rear View - Models 400 - 501
13
30
14
27
41
25
12
19
34
5
3
17
16
9
4
8
7
26
32
18
1
21
IMG00396
23
28
2
Left Side (inside unit) - Models 400 - 501
Models 601 - 801
30
20
42
39
29
14
13
25
IMG00288
41
27
9
12
26
17
15
19
3
4
7
8
32
1
18
24
21
IMG00289
5
10
31
2
34
Rear View - Models 601 - 801
6
Left Side (inside unit) - Models 601 - 801
Page 7
Ratings
Outdoor Armor Water Heater Installation & Operation Manual
Maximum allowed working pressure is located on the rating plate.
Input Modulation Btu/hr
CSA
(Note 2)
Water Content
Gallons
Water
Connections
Notes:
1. Outdoor Armor water heaters are supplied with
special gas venting materials. Use only the method of
installation specified in the Outdoor Armor Installation
and Operation Manual.
Gas
Connections
2. Standard outdoor Armor water heaters are equipped
to operate from sea level to 4,500 feet only with no
adjustments. The water heater will de-rate by 4% for
each 1,000 feet above sea level up to 4,500 feet.
3. The manual reset high limit provided with the outdoor
water heater is listed to UL353. The auto reset high
limit is listed to ANSI Z21.87.
7
Page 8
Outdoor Armor Water Heater Installation & Operation Manual
1 Determine water heater location
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.
NOTICE
WARNING
CAUTION
WARNING
Tabe 1A - Ambient Temperature
ModelKit Number
OK 151/211
OA 151/200
OK/OA 286KIT30124
OK/OA
501 - 801
The outdoor Armor water heater gas
manifold and controls met safe lighting and
other performance under tests specified in
ANSI Z21.10.3 – latest edition.
Outdoor models must be installed outdoors
only and must use the outdoor vent kit
assembly supplied by the manufacturer.
Personal injury or product damage may
result if any other cap is used or if an outdoor
model is used indoors. All covers, doors
and jacket panels must be properly installed
to ensure proper operation and prevent a
hazardous situation.
This product contains a condensate
management and disposal system that
may be subject to freezing if exposed to
sustained temperatures below 32°F.
Precautions should be taken to protect the
condensate trap and drain lines during
extended periods of outdoor temperatures
below 32°F. Consult the manufacturer
(and see Table 1A below) for an optional
condensate trap kit recommended for areas
which may experience temperatures below
32°F. Note: This condensate option is only
available for Models OA 151 - 286 and
501 - 801.
Model OA 400 is NOT suitable for installation
in areas which may experience temperatures
below 32°F.
Requirements
Minimum Allowable
Ambient Temperature
KIT30123
KIT30125
10°F (OK/OA 501)
5°F (OK/OA 601 - 801)
5°F
5°F
Before locating the water heater, check:
1. Check for nearby connection to:
• Water piping
• Gas supply piping
• Electrical power
8
2. - Keep venting areas free of obstructions.
- Keep area clean and free of combustible and flammable
materials.
- To avoid a blocked air inlet or blocked flue condition,
keep the outdoor air inlet and flue outlet clear of leaves,
debris, etc.
CAUTION
CAUTION
WARNING
CAUTION
Do not install outdoor models directly on
the ground. You must install the outdoor
unit on a concrete, brick, block or pressuretreated wood platform.
Do not locate unit so that high winds can
deflect off of adjacent walls, buildings
or shrubbery causing recirculation.
Recirculation of flue products may cause
operational problems, bad combustion or
damage to controls. Locate unit at least
3 feet (0.91m) from any wall or vertical
surface to prevent wind conditions from
affecting performance.
The outdoor unit must not be installed in
an area that is enclosed by walls or a fence
that will block free wind movement around
the unit. Free movement of wind around
the outdoor unit is required to carry away
the flue products and provide combustion
air. The flue outlet/combustion air inlet
of an outdoor unit must not be installed
closer than 10 feet from an inside corner of
an L-shaped structure. Walls or enclosed
fencing may cause eddy currents which
can recirculate the flue products into the
combustion air inlet. Recirculation of flue
products may cause operational problems,
bad combustion or non-warrantable
damage to controls.
- Do not install the outdoor unit under a
deck.
- Do not install an outdoor unit in a well,
stairwell, alcove, courtyard or other
recessed area.
- Do not install outdoor units on stack
frames.
Failure to comply with the above could
result in severe personal injury, death or
substantial property damage.
- Do not install outdoor units in locations
where rain from building runoff drains
will spill onto the unit.
- Do not locate the outdoor unit so that
water from sprinklers may spray directly
onto it. Water may damage controls or
other electrical components.
Page 9
Outdoor Armor Water Heater Installation & Operation Manual
1 Determine water heater location (continued)
3. Check area around the water heater. Remove any
combustible materials, gasoline and other flammable
liquids.
WARNING
4. If a new water heater will replace an existing water heater,
check for and correct system leaks causing oxygen corrosion
or heat exchanger cracks from hard water deposits.
Failure to keep the 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.
Provide clearances:
Clearances from combustible materials
1. Hot water pipes—at least 1/4" (6mm) from combustible
materials.
2. Vent pipes—minimum of 14" (356mm) from the rear and
0" on the right side from combustible materials.
Clearances for service access
1. If you do not provide the minimum clearances, it may
not be possible to service the water heater without
removing it from the space.
Recommended service clearances:
Front - 30" (762mm)
Top - 24" (610mm)
Left side - 24" (610mm)
Rear - 24" (610mm)
Outdoor vent / air intake location
WARNING
To prevent recirculation of the flue products into the combustion
air inlet, follow all instructions in this section.
Flue gas condensate can condense on exterior walls or on the
vent. Some discoloration to exterior building or unit surfaces
can be expected. Adjacent brick or masonry surfaces should be
protected with a rust resistant sheet metal plate.
Maintain a minimum of 24" (610mm) clearance to the side of
the air inlet.
Locate the outdoor vent termination at least 48" (1.22m) below
and 48" (1.22m) horizontally from any window, door, walkway
or gravity air intake.
Locate outdoor unit at least 10 feet (3.05m) away from any
forced air inlet.
Multiple outdoor unit installations require 24" (.61m) clearance
between each vent termination.
Clearances around outdoor installations can change with time.
Do not allow the growth of trees, shrubs or other plants to
obstruct the proper operation of the outdoor vent system.
The flue products discharged from the flue
outlet on the outdoor vent may be very
hot. Avoid touching or other direct contact
with the flue gases or the vent termination
assembly. These components are hot and
direct contact can result in burns.
Flooring and foundation
Flooring
The outdoor Armor water heater is approved for installation on
combustible flooring.
WARNING
Under no circumstances is the manufacturer to be held
responsible for water damage in connection with this appliance,
or any of its components. 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.
Prevent combustion air contamination
Do not install in locations that can allow contamination of
combustion air. Refer to Table 1B for products and areas
which may cause contaminated combustion air.
Table 1B 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
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
9
Page 10
Outdoor Armor Water Heater Installation & Operation Manual
2 Prepare water heater
Remove water heater from wood pallet
1. After removing the outer shipping carton from the water
heater, remove the installation kit.
2. Remove the front door to access the lag bolts in front of
the unit (FIG. 2-1).
3. To remove the water heater from the pallet (after
removing the front door):
a. Remove the two lag bolts from the wood pallet
inside the water heater (FIG. 2-1).
b. Detach the water heater from the lag bolts in the rear
of the unit, see FIG. 2-1.
NOTICE
Do not drop the water heater or bump the
jacket on the floor or pallet. Damage to
the water heater can result.
Figure 2-1 Water heater Mounted on Shipping Pallet
The outdoor water heater is shipped with all the necessary
vent components. All components must be installed prior to
operation. Basic steps are listed below to guide you through
the installation of the flue pipe assembly provided with the
unit.
1. Locate all venting components from the installation kit
and carton.
2. Before connecting the vent pipe sections or components,
verify the gasket is seated evenly inside the groove in the
female end of the elbow and flue adapter.
3. Remove the factory provided screws from the vent/air
cover and use them to install the wall strap.
4. Insert the elbow into the flue adapter.
CAUTION
5. Slide the flue pipe through the wall strap and insert it into
the elbow.
6. Install the bird screen into the top of the vent.
10
Do not use grease or other lubricant
on the vent seals. Only water may be
used for this purpose. Grease or other
lubricant can make the seal brittle or it
can result in tears in the surface of the
seal, this will result in flue gas leakage.
FLUE PIPE
ELBOW
NOTE: VERIFY GASKETS ARE
SEATED EVENLY INSIDE
THE GROOVE.
The outdoor water heater is shipped with all the necessary
vent components. All components must be installed prior to
operation. Basic steps are listed below to guide you through the
installation of the flue pipe assembly provided with the unit.
1. Locate all venting components from the installation kit and
carton.
2. Before connecting the vent pipe sections or components,
verify the gasket is seated evenly inside the groove in the
female end of all pieces.
3. Remove the vent cover from the back of the unit.
4. Insert the elbow into the flue adapter and tighten the clamp
using a 5/16" nut driver.
5. Re-install the vent cover on the back of the unit.
6. Remove the provided screws from the vent cover and use
them to install the wall strap.
CAUTION
7. Slide the flue pipe through the wall strap and insert it into
the elbow, tighten clamp.
8. Install the bird screen into the top of the vent and tighten
the clamp.
NOTE: VERIFY GASKETS ARE SEATED
EVENLY INSIDE THE GROOVE.
VENT TERMINATION
FLUE PIPE
WALL STRAP
WALL STRAP
SCREWS
Do not use grease or other lubricant
on the vent seals. Only water may be
used for this purpose. Grease or other
lubricant can make the seal brittle or it
can result in tears in the surface of the
seal, this will result in flue gas leakage.
ELBOW
CLAMP
VENT COVER
IMG00445
Page 11
Outdoor Armor Water Heater Installation & Operation Manual
2 Prepare water heater (continued)
Gas conversions
WARNING
Table 2A LP Conversion Table
Models 151 - 286
1. Remove the top and front access covers from the unit
(Phillips screwdriver required for removal).
2. Remove the three screws securing the gas valve to the
venturi (FIG. 2-4).
3. Locate the propane orifice disk from the conversion kit bag.
Verify that the stamping on the orifice disk matches the
water heater size (151 – 286) (see Table 2A above).
Place the orifice into the black rubber grommet in the side
of the gas valve and secure in the valve (FIG. 2-4).
4. Reposition the gas valve against the venturi and replace the
screws (FIG. 2-4) securing the valve to the venturi.
5. After installation is complete, attach the propane conversion
label (in the conversion kit bag) next to the water heater
rating plate. Attach the LP caution label (in the conversion
kit bag) to the left side of the unit in the lower left corner.
6. Replace the top and front access covers.
WARNING
For a water heater already installed, you
must turn off gas supply, turn off power
and allow the water heater to cool before
proceeding. You must also completely test
the water heater after conversion to verify
performance as described under Start-up,
Section 10 of this manual. Failure to comply
could result in severe personal injury, death,
or substantial property damage.
For Models 151 - 400 you must install a
propane orifice to operate the outdoor water
heater on propane gas. Verify when installing
that the orifice size marking matches water
heater size (Models 151 – 400, Table 2A).
The 501 - 801 Models do not require an
orifice installation for propane operation,
but they will require a valve adjustment.
LP Conversion Table
ModelLP Orifice Stamping
151150
200210 / W150
286285
4008.0
After converting to LP, check combustion
per the Start-up procedure in Section 10
of this manual. Failure to check and verify
combustion could result in severe personal
injury, death, or substantial property damage.
1. Remove the top and front access covers from the unit
(Phillips screwdriver required for removal).
2. Remove the three screws securing the venturi to the
blower.
Note: When separating the venturi from the blower,
take care not to damage the O-ring inside the blower
(FIG. 2-5 on page 12).
3. Remove the four screws securing the gas valve to the
venturi (FIG. 2-5).
4. Locate the propane orifice disk from the conversion kit
bag. Verify that the stamping on the orifice disk matches
the water heater size (see Table 2A).
5. Remove the existing orifice from the O-ring in the side of
the gas valve and replace it with the orifice from the kit.
Position and secure the orifice in the valve as shown in
FIG. 2-5.
6. Reposition the gas valve against the venturi and replace
the screws (FIG. 2-5) securing the valve to the venturi.
7. Inspect the O-ring inside the blower. Handle the O-ring
with care, do not damage. Reposition the venturi against
the blower and replace the screws securing the venturi to
the blower (FIG. 2-5).
8. After installation is complete, attach the propane
conversion label (in the conversion kit bag) next to the
water heater rating plate. Attach the LP caution label (in
the conversion kit bag) to the left side of the unit in the
lower left corner.
9. Replace the top and front access covers.
WARNING
DANGER
After converting to LP, check combustion
per the Start-up procedure in Section 7 of
this manual. Failure to check and verify
combustion could result in severe personal
injury, death, or substantial property
damage.
Armor 400: Inspect the O-ring when
the blower is disassembled. The O-ring
must be in good condition and must be
installed. Failure to comply will cause a
gas leak, resulting in severe personal injury
or death.
11
Page 12
Outdoor Armor Water Heater Installation & Operation Manual
2 Prepare water heater
Figure 2-5 Installing Propane Orifice - Model 400
Model 501
1. Remove the top access cover from the unit (Phillips
screwdriver required for removal).
2. Turn the adjustment screw on the gas valve clockwise
until it stops. Then turn the adjustment screw
counterclockwise four and three quarter (4 3/4) turns
(see FIG. 2-6).
3. Use a combustion analyzer to verify CO2 is within
the range of 9.6 – 10.5%. If not, adjust the screw
counterclockwise incrementally to raise CO2 and
clockwise to lower CO2 (FIG. 2-6).
4. After adjustment is complete, attach the propane
conversion label (in the conversion kit bag) next to the
water heater rating plate. Attach the LP caution label (in
the conversion kit bag) to the left side of the unit in the
lower left corner.
5. Replace the top access cover.
WARNING
After converting to LP, check combustion
per the Start-up procedure in Section
10 of this manual. Failure to check and
verify combustion could result in severe
personal injury, death, or substantial
property damage.
4. Use a combustion analyzer to verify CO2 is within the range
of 9.6 – 10.5%. If not, adjust the screw counterclockwise
incrementally to raise CO2 and clockwise to lower CO2
(FIG. 2-7).
5. After adjustment is complete, attach the propane conversion
label (in the conversion kit bag) next to the water heater
rating plate. Attach the LP caution label (in the conversion
kit bag) to the left side of the unit in the lower left corner.
6. Replace the gas valve cover along with the top access cover.
WARNING
Figure 2-7 Gas Valve Adjustment - Models 601 - 801
COVER
ALLEN WRENCH
After converting to LP, check combustion
per the Start-up procedure in Section
10 of this manual. Failure to check and
verify combustion could result in severe
personal injury, death, or substantial
property damage.
ADJUSTMENT SCREW
Figure 2-6 Gas Valve Adjustment - Model 501
Models 601 - 801
1. Remove the top access cover from the unit (Phillips
screwdriver required for removal).
2. Remove the cover on top of the gas valve (FIG. 2-7).
3. Turn the adjustment screw on top of the gas valve
clockwise one and three quarter (1 3/4) turns on the 601
Model, one and a half (1 1/2) turns on the 701 Model, and
one turn on the 801 Model (see FIG. 2-7).
12
Leveling the water heater
1. Set the water heater in place and check level.
a) Adjust legs if necessary to level the water heater,
see FIG. 2-8 below.
Figure 2-8 Leveling Legs on the Water Heater
Page 13
Outdoor Armor Water Heater Installation & Operation Manual
3 System piping
System water piping methods
Observe a minimum of 1/4 inch clearance around all
un-insulated hot water pipes when openings around the pipes
are not protected by non-combustible materials.
General piping information
Basic steps are listed below along with illustrations on the
following pages (FIG.’s 3-6 thru 3-10), which will guide you
through the installation of the outdoor water heater.
1. Connect the cold water supply to the inlet side of the water
heater.
2. Connect the hot water supply to the outlet side of the water
heater.
3. Install a backflow preventer on the cold feed make-up water
line.
4. Install the factory supplied pump as shown in FIG.’s 3-6
thru 3-10. If pump is installed outdoors use pump cover,
reference the Pump Cover Installation section on this page.
5. Install an expansion tank on the system supply. Consult the
tank manufacturer’s instruction for specific information
relating to tank installation. Size the expansion tank for the
required system volume and capacity.
6. Install a drain valve at the lowest point of the system.
7. This appliance is supplied with a relief valve sized in
accordance with ASME Boiler and Pressure Vessel Code,
Section IV (“Heating Boilers”). Pipe the discharge of the
safety relief valve to a suitable drain to prevent injury in
the event of pressure relief. Pipe the discharge to a drain.
Provide piping that is the same size as the safety relief valve
outlet. Never block the outlet of the safety relief valve.
Pump cover installation reference FIG.’s 3-1 and 3-2 for
pump cover installation)
If the water heater was purchased with a pump, please follow
the instructions below to install the pump and outdoor cover
assembly. If a field supplied pump is used, ensure that it
is installed per the manufacturer’s specification in regard
to indoor or outdoor location. An outdoor rated pump is
recommended.
1. Locate the pump, pump cover assembly, flange kit and
additional mounting nuts.
2. Before installing the pump, ensure the intended piping
location allows room for the sheet metal cover assembly
without interference.
3. Install the pump with the provided flanges and hardware.
4. Mount the pump cover base sheet metal aligning the holes
for the piping and the bolts.
5. Using additional nuts, secure the sheet metal to the pump
bolts.
6. Install the sheet metal top on the base with the provided
screws (10x).
The relief valve, tee and other necessary
fittings are shipped in the install kit with the
water heater and are to be field installed.
See the *piping illustrations included in this section, FIG.’s 3-6
thru 3-10 for suggested guidelines in piping the outdoor water
heater.
NOTICE
*Please note that these illustrations are meant
to show system piping concept only, the
installer is responsible for all equipment and
detailing required by local codes.
Flow switch and relief valve installation
Basic steps are listed below to guide you through the installation
of the flow switch and relief valve provided with the unit.
1. Install the tee with the 3/4 inch fitting positioned vertically
and on the top as shown in FIG. 3-3.
2. Install the relief valve into the 3/4 inch fitting of the tee
installed in Step 1 (FIG. 3-3).
3. Install the close nipple on the downstream side of the
temperature and pressure relief valve tee (FIG. 3-3).
4. Install the tee with the 1 inch fitting positioned vertically
and on the top (FIG. 3-3).
13
Page 14
3 System piping
5. Attach the paddle to the flow switch per the manufacturer’s
instructions. Reference Table 3A to select the
correct paddle for the pipe size used (consult the
manufacturer’s instructions for a detailed explanation).
For Example: If using a 1 1/4 inch pipe size (Models
OAN151 - OAN200) select paddle #1.
6. Install the assembled flow switch into the 1 inch fitting of
the tee installed in Step 4 (see FIG. 3-3).
NOTICE
Figure 3-3 Flow Switch and Relief Valve Installation
Be sure to install flow switch so that the arrow
on the flow switch is pointing in the direction
of the flow (see FIG. 3-4).
Installation & Operation Manual
NOTICE
Figure 3-4 Flow Switch Adjustment
GROUND
Turn the sensitivity screw clockwise to increase
the flow rate required to activate the switch.
Turn the sensitivity screw counterclockwise to
decrease the flow rate required to activate the
switch.
NORMALLY
OPEN
SENSITIVITY
ADJUSTMENT
RELIEF VALVE
CLOSE NIPPLE
FLOW
SWITCH
TEE WITH 1"
FITTING ON TOP
CLOSE NIPPLE
TEE WITH 3/4"
FITTING ON TOP
COUPLING
6" NIPPLE
(400-701 ONLY)
IMG00424
Flow switch adjustment
Refer to Table 3A for the proper setting of the sensitivity screw.
For reference, the position of the screw prior to setting should
be turned clockwise with a Phillips driver until it stops (FIG.
3-4). Proceed to turn the screw counterclockwise the amount
of turns listed in Table 3A based on the model.
Consult the manufacturer’s instructions for wiring the flow
switch to your system.
COMMON
NORMALLY
CLOSED
Scalding
This water heater can deliver scalding temperature water at any
faucet in the system. Be careful whenever using hot water to avoid
scalding injury. Certain appliances such as dishwashers and
automatic clothes washers may require increased temperature
water. By setting the thermostat on this water heater to obtain
the increased temperature water required by these appliances,
you may create the potential for scald injury. To protect against
injury, you should install a mixing valve in the water system.
This valve will reduce point of discharge temperature by mixing
cold and hot water in branch supply lines. Such valves are
available from the local plumbing supplier.
Figure 3-5 Scald Warning Label Located on the Appliance
The following chart (Table 3B) details the relationship of water
temperature and time with regard to scald injury and may be
used as a guide in determining the safest water temperature for
your applications.
Table 3B Approximate Time / Temperature Scald Chart
APPROXIMATE TIME / TEMPERATURE
RELATIONSHIPS IN SCALDS
120°FMore than 5 minutes
125°F1 1/2 to 2 minutes
130°FAbout 30 seconds
135°FAbout 10 seconds
140°FLess than 5 seconds
145°FLess than 3 seconds
150°FAbout 1 1/2 seconds
155°FAbout 1 second
Water chemistry
NOTICE
Heating of high hardness and/or high total dissolved solids
water may require a larger circulating pump, and a revised
temperature rise specification based on the water chemistry of
the water to be heated.
Water with a hardness of less than 5 grains per gallon will
usually have a pH which can be aggressive and corrosive
causing non-warrantable damage to the pump, and associated
piping. Corrosion due to water chemistry generally shows up
first in the hot water system because heated water increases
the rate of corrosive chemical reactions.
The required temperature rise and the
standard circulating pump are sized based
on the heating of potable water with a
hardness of 5 to 25 grains per gallon and
a total dissolved solids not exceeding 350
ppm. Consult the manufacturer when
heating potable water exceeding these
specifications.
Table 3C Water Heater Pump Applications / Recommended
Temperature Rise
Piping components
Water heater system piping:
Water heater system piping MUST be sized per the pipe
requirements listed in FIG.’s 3-9 and 3-10. Reducing the pipe
size can restrict the flow rate through the water heater, causing
inadvertent high limit shutdowns and poor system performance.
Check valves:
Field supplied. Check valves are recommended for installation
as shown in FIG.’s 3-6 thru 3-10.
Water heater isolation valves:
Field supplied. Full port ball valves are required. Failure to use
full port ball valves could result in a restricted flow rate through
the water heater.
Anti-scald mixing valve:
Field supplied. An anti-scald mixing valve is recommended
when storing domestic hot water above 115°F.
Unions:
Field supplied. Recommended for unit serviceability.
Temperature and pressure relief valve:
Factory supplied on water heaters. The temperature and pressure
relief valve is sized to ASME specifications. Storage tanks may
require additional valves depending on local codes.
Tank sensor:
Lochinvar supplies a tank sensor. The tank sensor must be
installed in the tapping provided in the lower 25% of the storage
tank to achieve proper operation. As shipped from the factory,
the tank sensor is in the literature package shipped with the unit.
Placing the sensor in the tapping provided on the storage tank
will improve temperature response and prevent short cycles of
operation.
Pump sizing and flow requirements are based on 45 feet of
piping, 4 - 90° elbows, and 2 - fully ported ball valves.
Flow Rate
(GPM)
Loss
(FT/HD)
Temp.
Rise
15
Page 16
3 System piping
Figure 3-6 Single Heater - Single Tank
Installation & Operation Manual
FLOW CHECK
VALVE (TYPICAL)
COLD WATER
SUPPLY
MIXING VALVE
THERMOMETER
HOT WATER
SUPPLY
UNION
(TYPICAL)
TEMPERATURE
& PRESSURE
RELIEF VALVE
BUILDING
RETURN
BALL VALVE
(TYPICAL)
WATER
HEATER
CIRCULATOR
WATER
HEATER
FLOW SW ITCH
STORAGE
TANK
IMG00302
DRAIN
CAUTION
NOTICE
The piping will not support the weight of the water heater circulator pump. Do not attempt to support
the weight of the water heater circulator pump with the piping or its accessories. Refer to the pump
manufacturer’s installation instructions. Failure to comply could result in severe personal injury, death, or
substantial property damage.
Please note that these illustrations are meant to show system piping concept only, the installer is responsible
for all equipment and detailing required by local codes.
Indoor tank shown for illustration purposes.
16
Y-STRAINER
(RECOMMENDED)
Page 17
3 System piping (continued)
Figure 3-7 Single Heater - Single Tank (2 Temperature)
FLOW CHECK
VALVE (TYPICAL)
Installation & Operation Manual
TEMPERATURE
LOW
BUILDING
RETURN
SUPPLY
140° HOT
WATER
SUPPLY
COLD
WATER
180° HOT
WATER
SUPPLY
EXPANSION
TANK
THERMOMETER
MIXING
VALVE
STORAGE
TANK
(TYPICAL)
DRAIN
UNION
(TYPICAL)
TEMPERATURE
& PRESSURE
RELIEF VALVE
(TYPICAL)
BALL VALVE
(TYPICAL)
FLOW
SWITCH
Y-STRAINER
(RECOMMENDED)
HIGH TEMPERATURE
BUILDING RETURN
WATER HEATER
CIRCULATOR
IMG00361
WATER
HEATER
CAUTION
The piping will not support the weight of the water heater circulator pump. Do not attempt to support
the weight of the water heater circulator pump with the piping or its accessories. Refer to the pump
manufacturer’s installation instructions. Failure to comply could result in severe personal injury, death, or
substantial property damage.
NOTICE
Please note that these illustrations are meant to show system piping concept only, the installer is responsible
for all equipment and detailing required by local codes.
Indoor tank shown for illustration purposes.
17
Page 18
3 System piping
Figure 3-8 Single Heater - Double Tank
BALL VALVE
(TYPICAL)
FLOW CHECK
VALVE (TYPICAL)
COLD WATER
SUPPLY
MIXING VALVE
Outdoor Armor Water Heater Installation & Operation Manual
BUILDING
RETURN
EXPANSION TANK
WATER HEATER
CIRCULATOR
THERMOMETER
HOT WATER
SUPPLY
UNION
(TYPICAL)
TEMPERATURE
& PRESSURE
RELIEF VALVE
(TYPICAL)
IMG00309
STORAGE TANK
(TYPICAL)
FLOW SWITCH
WATER HEATER
Y-STRAINER
(RECOMMENDED)
DRAIN
(TYPICAL)
CAUTION
The piping will not support the weight of the water heater circulator pump. Do not attempt to support
the weight of the water heater circulator pump with the piping or its accessories. Refer to the pump
manufacturer’s installation instructions. Failure to comply could result in severe personal injury, death, or
substantial property damage.
NOTICE
Please note that these illustrations are meant to show system piping concept only, the installer is responsible
for all equipment and detailing required by local codes.
Indoor tank shown for illustration purposes.
18
Page 19
Outdoor Armor Water Heater Installation & Operation Manual
The piping will not support the weight of the water heater circulator pump. Do not attempt to support
the weight of the water heater circulator pump with the piping or its accessories. Refer to the pump
manufacturer’s installation instructions. Failure to comply could result in severe personal injury, death, or
substantial property damage.
NOTICE
Please note that these illustrations are meant to show system piping concept only, the installer is responsible
for all equipment and detailing required by local codes.
Indoor tank shown for illustration purposes.
19
Page 20
3 System piping
Figure 3-10 Double Heater - Double Tank
COLD WATER
SUPPLY
Outdoor Armor Water Heater Installation & Operation Manual
The piping will not support the weight of the water heater circulator pump. Do not attempt to support
the weight of the water heater circulator pump with the piping or its accessories. Refer to the pump
manufacturer’s installation instructions. Failure to comply could result in severe personal injury, death, or
substantial property damage.
NOTICE
20
Please note that these illustrations are meant to show system piping concept only, the installer is responsible
for all equipment and detailing required by local codes.
Indoor tank shown for illustration purposes.
Page 21
4 Gas connections
Outdoor Armor Water Heater Installation & Operation Manual
Connecting gas supply piping
1. Remove the top access panel and refer to FIG.’s 4-1 thru 4-4
to pipe gas to the water heater.
a. Install ground joint union for servicing, when
required.
b. On Models 151 - 400 install a manual shutoff valve in
the gas supply piping outside water heater jacket when
required by local codes or utility requirements.
2. Install sediment trap / drip leg.
Figure 4-1 Gas Supply Piping - Models 151 - 200
UNION
GAS SUPPLY
DRIP LEG
Figure 4-3 Gas Supply Piping - Model 501
UNION
GAS SUPPLY
SEDIMENT TRAP/
DRIP LEG
MANUAL
SHUTOFF VALVE
(FACTORY SUPPLIED)
(FACTORY INSTALLED)
IMG00398
Figure 4-4 Gas Supply Piping - Models 601 - 801
GAS SUPPLY
MANUAL
SHUT OFF
VALVE
(FIELD SUPPLIED)
Figure 4-2 Gas Supply Piping - Models 286 - 400
UNION
GAS SUPPLY
SEDIMENT TRAP /
DRIP LEG
MANUAL
SHUTOFF VALVE
(FIELD SUPPLIED)
IMG00290
IMG00397
MANUAL SHUTOFF VALVE
(FACTORY SUPPLIED)
SEDIMENT TRAP/
DRIP LEG
IMG00296
3. Support piping with hangers, not by the water heater or its
accessories.
WARNING
The gas valve and blower will not support
the weight of the piping. Do not attempt
to support the weight of the piping with
the water heater or its accessories. Failure
to comply could result in severe personal
injury, death, or substantial property
damage.
4. Purge all air from the gas supply piping.
5. Before placing the water heater in operation, check the
water heater and its gas connection for leaks.
a. The appliance must be disconnected from the gas
supply piping system during any pressure testing of
that system at a test pressure in excess of 1/2 PSIG
(3.5 kPa).
b. The appliance must be isolated from the gas supply
piping system by closing a manual shutoff valve
during any pressure testing of the gas supply piping
system at test pressures equal to or less than 1/2 PSIG
(3.5 kPa).
c. The appliance and its gas connection must be leak
tested before placing it in operation.
21
Page 22
4 Gas connections
Outdoor Armor Water Heater Installation & Operation Manual
WARNING
6. Use pipe sealing compound compatible with propane
gases. Apply sparingly only to male threads of the pipe
joints so that pipe dope does not block gas flow.
WARNING
WARNING
WARNING
Figure 4-5 Inlet Pipe with Backup Wrench
Do not check for gas leaks with an open
flame – use the bubble test. Failure to use
the bubble test or check for gas leaks can
cause severe personal injury, death, or
substantial property damage.
Failure to apply pipe sealing compound as
detailed in this manual can result in severe
personal injury, death, or substantial
property damage.
Outdoor Armor water heaters are typically
shipped ready to fire on natural gas. Check
the water heater rating plate to determine
which fuel the water heater is set for. If
set to natural gas, it may be converted to
LP by installing an orifice or by making
a gas valve adjustment (see pages 11 and
12). In order to operate on LP gas, an
orifice MUST BE installed or a gas valve
adjustment MUST BE made. Failure to
comply could result in severe personal
injury, death, or substantial property
damage.
Use two wrenches when tightening gas
piping at water heater (FIG. 4-5), using
one wrench to prevent the water heater
gas line connection from turning. Failure
to support the water heater gas connection
pipe to prevent it from turning could
damage gas line components.
Natural gas:
Pipe sizing for natural gas
1. Refer to Table 4A for pipe length and diameter. Based on
rated water heater input (divide by 1,000 to obtain cubic
feet per hour).
a. Table 4A is only for natural gas with specific gravity
0.60 inches, with a pressure drop through the gas
piping of 0.50 inches w.c.
b. For additional gas pipe sizing information, refer to
ANSI Z223.1 (or B149.1 for Canadian installations).
Natural gas supply pressure requirements
1. Pressure required at the gas valve inlet pressure port:
• Maximum 14 inches w.c. with no flow (lockup) or
with water heater on.
• Minimum 4 inches w.c. with gas flowing (verify during
water heater startup).
2. Install 100% lockup gas pressure regulator in supply line if
inlet pressure can exceed 14 inches w.c. at any time. Adjust
lockup regulator for 14 inches w.c. maximum.
Propane gas:
WARNING
Pipe sizing for propane gas
Outdoor Armor water heaters are typically
shipped ready to fire on natural gas. Check
water heater rating plate to determine which
fuel the water heater is set for. If set to
natural gas, it may be converted to LP by
installing an orifice or by making a gas valve
adjustment (see pages 11 and 12). In order
to operate on LP gas, an orifice MUST BE
installed or a gas valve adjustment MUST
BE made. Failure to comply could result in
severe personal injury, death, or substantial
property damage.
USE BACKUP WRENCH TO
PREVENT PIPE FROM ROTATING
IMG00297
NOTICE
Maximum inlet gas pressure must not
exceed the value specified. Minimum
value listed is for the purposes of input
adjustment.
22
1. Contact gas supplier to size pipes, tanks, and 100% lockup
gas pressure regulator.
Propane supply pressure requirements
1. Adjust propane supply regulator provided by the gas
supplier for 14 inches w.c. maximum pressure.
2. Pressure required at gas valve inlet pressure port:
• Maximum 14 inches w.c. with no flow (lockup) or with
water heater on.
• Minimum 8 inches w.c. with gas flowing (verify during
water heater startup).
WARNING
Ensure that the high gas pressure regulator
is at least 6 - 10 feet upstream of the
appliance.
Page 23
Outdoor Armor Water Heater Installation & Operation Manual
Outdoor Armor water heaters are typically shipped ready to fire on natural gas. Check the water heater rating
plate to determine which fuel the water heater is set for. If set to natural gas, it may be converted to LP by
installing an orifice or by making a gas valve adjustment (see pages 11 and 12). In order to operate on LP gas,
an orifice MUST BE installed or a gas valve adjustment MUST BE made. Failure to comply could result in severe
personal injury, death, or substantial property damage.
Check inlet gas supply
NOTICE
WARNING
The gas piping must be sized for the proper flow and length of
pipe, to avoid excessive pressure drop. Both the gas meter and
the gas regulator must be properly sized for the total gas load.
If you experience a pressure drop greater than 1 inch w.c., the
meter, regulator, or gas line is undersized or in need of service.
Perform the steps below when checking inlet gas supply:
1. Turn the main power switch to the “OFF” position.
2. Shut off gas supply at the manual gas valve in the gas
piping to the appliance.
3. On Models 151 - 501 loosen the set screw one (1) full
turn from inside the pressure tap on top of the gas valve.
On Models 601 - 801 remove the 1/8" (3 mm) pipe plug
on the inlet flange to the valve and install a suitable 1/8"
(3 mm) fitting (field supplied) for the manometer tubing.
Place the tubing of the manometer over the tap once the
set screw is loosened or the 1/8" (3 mm) fitting is installed
(depending on model) as shown in FIG.’s 4-6 thru 4-9 on
page 24.
4. Slowly turn on the gas supply at the field installed
manual gas valve.
CSA or UL listed flexible gas connections are
acceptable, but you must exercise caution to
ensure that the line has adequate capacity
to allow your water heater to fire at full
rate. Consult with local codes for proper
installation or service procedures.
DO NOT adjust or attempt to measure
gas valve outlet pressure. The gas valve is
factory-set for the correct outlet pressure.
This setting is suitable for natural gas and
propane, requiring no field adjustment.
Attempting to alter or measure the gas valve
outlet pressure could result in damage to
the valve, causing potential severe personal
injury, death, or substantial property damage.
Single Unit
Natural Gas Pipe Capacity Chart
Length of Pipe in Straight Feet for 1/2 PSI
50
155
292
595
923
1720
2720
4870
10000
60
141
267
543
830
1560
2460
4410
9000
70
128
246
502
769
1440
2310
4000
8300
80
121
236
472
707
1330
2100
3800
7690
90
113
210
441
666
1250
2000
3540
7380
100
106
200
410
636
1180
1900
3330
6870
5. Turn the power switch to the “ON” position.
6. Adjust the temperature set point on the control panel of
the SMART SYSTEM control module to call for heat.
7. Observe the gas supply pressure as the burner fires at
100% of rated input. Percent of burner input will be
displayed on the control panel.
8. Ensure inlet pressure is within specified range.
Minimum and maximum gas supply pressures are
specified in this section of the manual.
9. If gas supply pressure is within normal range and no
adjustments are needed, proceed on to Step 11.
10. If the gas pressure is out of range, contact the gas utility,
gas supplier, qualified installer or service agency to
determine the necessary steps to provide proper gas
pressure to the control.
11. Turn the power switch to the “OFF” position.
12. Shut off the gas supply at the manual gas valve in the gas
piping to the appliance.
13. Remove the manometer from the pressure tap on top of
the gas valve. On Models 151 - 501 re-tighten the set
screw inside the pressure tap. On Models 601 - 801
remove the 1/8" (3 mm) field supplied fitting and
reinstall the pipe plug removed in Step 3.
WARNING
When re-tightening the set screw, be sure to
tighten securely to prevent gas leaks.
Do not check for gas leaks with an open
flame -- use the bubble test. Failure to
use the bubble test or check for gas leaks
can cause severe personal injury, death, or
substantial property damage.
14. Turn on the gas supply at the manual gas valve.
15. Turn the power switch to the “ON” position.
16. Adjust the temperature set point on the control panel of
the SMART SYSTEM control module to the desired
water temperature so the appliance will call for heat.
125
95
179
369
564
1100
1700
3000
6150
150
86
164
333
513
974
1540
2720
5640
175
79
149
308
472
871
1400
2500
5130
200
74
138
287
441
820
1300
2340
4720
23
Page 24
Outdoor Armor Water Heater Installation & Operation Manual
4 Gas connections
17. Check burner performance by cycling the system while
you observe burner response. The burner should ignite
promptly. Flame pattern should be stable. Turn system
off and allow burner to cool, then cycle burner again to
ensure proper ignition and flame characteristics.
REMOVE THE 1/8” (3MM) PIPE PLUG ON
THE INLET FLANGE TO THE VALVE AND
INSTALL A SUITABLE 1/8” (3MM) FITTING
(FIELD SUPPLIED) FOR THE MANOMETER
TUBING.
DETAIL
IMG00403
Gas pressure
The gas pressure must remain between 4 inches w.c. (natural),
8 inches w.c. (LP) minimum and 14 inches w.c. (natural and
LP) maximum during stand-by (static) mode and while in
operating (dynamic) mode. If an in-line regulator is used, it
must be a minimum of 10 feet from the outdoor water heater. It
is very important that the gas line is properly purged by the gas
supplier or utility company. Failure to properly purge the lines
or improper line sizing, will result in ignition failure.
IMG00401
Figure 4-8 Inlet Gas Supply Check - Model 501
LOOSEN THE SET SCREW ONE (1) FULL TURN AND
PLACE THE MANOMETER TUBING OVER THE
PRESSURE TAP
DETAIL
IMG00402
DETAIL
The problem is especially noticeable in NEW LP installations
and also in empty tank situations. This can also occur when
a utility company shuts off service to an area to provide
maintenance to their lines.
Gas valve replacement
The gas valve MUST NOT be replaced with a conventional gas
valve under any circumstances. As an additional safety feature,
this gas valve has a flanged connection to the venturi and blower.
WARNING
WARNING
Failure to follow all precautions could result
in fire, explosion, or death!
DO NOT adjust gas valve outlet pressure.
The gas valve is factory-set for the correct
outlet pressure. This setting is suitable
for natural gas and propane, requiring
no field adjustment. Attempting to alter
the gas valve outlet pressure could result
in damage to the valve, causing potential
severe personal injury, death, or substantial
property damage.
24
Page 25
5 Field wiring
L
Outdoor Armor Water Heater Installation & Operation Manual
WARNING
ELECTRICAL SHOCK HAZARD – For
your safety, turn off electrical power supply
before making any electrical connections
to avoid possible electric shock hazard.
Failure to do so can cause severe personal
injury or death.
NOTICE
Wiring must be N.E.C. Class 1.
If original wiring as supplied with the
water heater must be replaced, use only
type 105°C wire or equivalent.
The water heater must be electrically
grounded as required by National
Electrical Code ANSI/NFPA 70 – latest
edition.
All wiring exterior to the appliance must
be enclosed in approved conduit.
CAUTION
Label all wires prior to disconnection
when servicing controls. Wiring errors can
cause improper and dangerous operation.
Figure 5-1 Line Voltage Field Wiring Connections
120V SUPPLY
GROUND
LINE
BK
RECIRCULATION
PUMP
BK
W
G
SERVICE
SWITCH
L2/N
G
L1
NEUTRA
WG
Installation must comply with:
1. National Electrical Code and any other national, state,
provincial, or local codes, or regulations.
Line voltage connections
1. Connect 120 VAC power wiring to the line voltage
terminal strip in the junction box, as shown in FIG. 5-1.
2. Provide and install a fused disconnect or service switch
(15 amp recommended) as required by the code (see
FIG. 5-1).
3. The DHW (water heater) pump is shipped loose on all
Armor models. Wire the water heater pump as shown in
FIG. 5-1.
4. The outdoor water heater is capable of controlling a
building recirculation pump (field supplied). Wire the
building recirculation pump as shown in FIG. 5-1.
5. Dry contacts are sized for 1 hp/120V, 2 hp/240V or
15A/120V, 25A/240V.
Low voltage connections
1. Route all low voltage wires through the knockouts in the
rear of the water heater, as shown in FIG. 5-2.
2. Connect low voltage wiring to low voltage connection
board as shown in FIG. 5-3 on page 28 of this manual and
the water heater wiring diagram.
DOMESTIC
HOT WATER
PUMP
BK
Figure 5-2 Routing Field Wiring (Models 151 - 286)
G
L4/N
W
G
L3
LOW VOLTAGE
CONNECTION BOARD
LOW VOLTAGE
WIRING
KNOCKOUT
PLUGS
IMG00298
LINE VOLTAGE
JUNCTION BOX
LINE VOLTAGE
WIRING KNOCKOUT PLUGS
25
Page 26
5 Field wiring
Outdoor Armor Water Heater Installation & Operation Manual
Tank thermostat
1. Connect the tank thermostats (isolated contact only) to
the tank thermostat contacts as shown in FIG. 5-3.
Tank sensor
1. By installing a tank sensor, the SMART SYSTEM control
can perform the tank thermostat function. The SMART
SYSTEM control automatically detects the presence of
this sensor and generates a DHW call for heat when
the tank temperature drops below the programmed
differential and finishes the call for heat when the tank
temperature reaches above the programmed offset.
2. The tank sensor TST20015 is the only sensor suitable
for use with the SMART SYSTEM control. Connect the
sensor leads to the Tank Sensor terminals on the Low
Voltage Connection Board (FIG. 5-3).
High gas pressure switch
If a switch is provided to detect excessive gas pressure, remove
the jumper wire from the terminals on the connection board,
and then connect them to its normally closed contacts
(FIG. 5-3).
Flow switch
1. A flow switch is used to guarantee flow through the water
heater before allowing it to fire. The flow switch must be
installed at the water heater outlet.
2. Connect these terminals to the normally open contacts on
the flow switch (FIG. 5-3).
Rate output
This output provides a 0 - 10V signal that is proportional to
the firing rate of the water heater. This may be used by a BMS
system to monitor the actual rate of the water heater.
ModBus
When the optional ModBus interface module is installed, the
RS-485 ModBus cable is connected to these terminals. Use
shielded, 2-wire twisted pair cable. If desired, the shield can
be connected to ground by installing a jumper wire between
terminals 1 and 3 on connector X5 on the optional ModBus
interface module.
Water heater Building Management
System (BMS)
Low gas pressure switch
1. If a switch is provided to detect low gas pressure, remove
the jumper wire from the terminals on the connection
board and connect them to its normally open contacts
(FIG. 5-3).
2. If both a high and low gas pressure switch are used,
connect their respective contacts in series, and connect
them to the terminals on the connection board (FIG.
5-3).
NOTICE
See Section 4 - Gas Connections for a
detailed explanation regarding high and
low gas pressure switch operation.
1. An external control may be connected to control either the
firing rate or the set point of the water heater. If the external
control uses a set of contacts to enable the water heater,
connect the contacts to the Tank Thermostat terminals.
Otherwise, the SMART SYSTEM control will be enabled by
the 0-10V signal.
2. Make sure the (-) terminal is connected to the (-) or
common output terminal of the external control, and the
(+) terminal is connected to the (+) or 0 - 10 VDC terminal
of the external control. Make sure the (-) voltage is not
below ground.
26
Page 27
Outdoor Armor Water Heater Installation & Operation Manual
5 Field wiring (continued)
Runtime contacts
The SMART SYSTEM control closes a set of dry contacts
whenever the burner is running. This is typically used by
Building Management Systems to verify that the water
heater is responding to a call for heat.
Alarm contacts
The SMART SYSTEM control closes another set of contacts
whenever the water heater is locked out or the power is
turned off. This can be used to turn on an alarm, or signal
a Building Management System that the water heater is
down.
Wiring of the cascade
When wiring the water heaters for Cascade operation, select
one water heater as the Leader water heater. The remaining
water heaters will be designated as Members. See page 35
“Configuration of the Cascade” for a detailed explanation
of this procedure.
Connect the tank sensor to the Leader water heater. For the
Cascade system to work properly the tank sensor must be
installed. The tank sensor should be wired to the low voltage
connection board at the terminals marked for the tank
sensor (see FIG. 5-3). The Leader control will use the water
temperature at the tank sensor to control the operation of
the Cascade.
Communication between the Leader water heater and the
Member water heaters is accomplished by using shielded,
2-wire twisted pair communication cable. Connect one of
the twisted pair wires to Cascade terminal A on each of
the Low Voltage Connection boards, and the other wire of
the twisted pair to Cascade terminal B on each of the Low
Voltage Connection Boards. Connect the shield wires to
one of the shield terminals on the Low Voltage Connection
Boards (FIG. 5-3). If more than two water heaters are on the
Cascade, daisy chain the wiring from the Cascade terminals
on the second water heater to the Cascade terminals on the
third water heater, then from the third to the forth, and so
on. The connections between heaters can be made in any
order, regardless of the addresses of the water heaters. Try
to keep each cable as short as possible.
27
Page 28
Outdoor Armor Water Heater Installation & Operation Manual
5 Field wiring
Figure 5-3 Low Voltage Field Wiring Connections
TO
NEXT
HEATER
B
A
TANK SENSOR
IMG00423
B
A
B
A
FROM
HEATER
PREVIOUS
SHIELDSHIELD
BUILDING
SYSTEM
MANAGEMENT
28
COM
FLOW SWITCH
NO
TANK THERMOSTAT
LOW WATER CUTOFF
Page 29
Outdoor Armor Water Heater Installation & Operation Manual
6 Condensate disposal
Condensate drain
1. This water heater is a high efficiency appliance that
produces condensate.
2. The side of the water heater has a 1/2 inch PVC union
for connection of a 1/2 inch PVC pipe (FIG. 6-1).
3. Slope condensate tubing down and away from the water
heater into a drain or condensate neutralizing filter.
Condensate from the outdoor water heater will be
slightly acidic (typically with a pH from 3 to 5). Install
a neutralizing filter if required by local codes.
A Neutralizer Kit (FIG. 6-1) is available from the factory
(KIT3087 for Models 151 - 501 and KIT3046 for Models
601 - 801).
4. Install the 1/2 inch PVC tee assembly (shipped with the
unit) as shown in FIG. 6-1.
5. Leave the top of the 1/2 inch tee OPEN. This is needed
as a vacuum break.
6. Do not expose condensate line to freezing temperatures.
Precautions should be taken to protect the condensate
management and disposal system during extended
periods of outdoor temperatures below 32°F.
NOTICE
NOTICE
8. A condensate removal pump is required if the water heater
is below the drain. When installing a condensate pump,
select one approved for use with condensing water heaters
and furnaces. The pump should have an overflow switch
to prevent property damage from condensate spillage. The
switch should be wired in series with the blocked drain
switch inside the water heater (see FIG. 7-1 on page 30).
Use materials approved by the authority
having jurisdiction. In the absence of other
authority, PVC and CPVC pipe must comply
with ASTM D1785 or D2845. Cement and
primer must comply with ASME D2564 or
F493.
To allow for proper drainage on large
horizontal runs, a second line vent may
be required and tubing size may need to
increase to 1 inch.
The condensate line must remain
unobstructed, allowing free flow of
condensate. If condensate is allowed to
freeze in the line or if the line is obstructed
in any other manner, condensate can exit
from the water heater tee, resulting in
potential water damage to property.
7. Use only plastic tubing or piping as a condensate drain
line (FIG. 6-1).
Figure 6-1 Condensate Disposal
1/2" PVC TEE ASSEMBLY
(FACTORY SUPPLIED)
FLOOR DRAIN OR
DRAIN PAN
IMG00300
1/2" PVC UNION
(FACTORY SUPPLIED)
NEUTRALIZER KIT
KIT3087 shown for illustration purposes.
29
Page 30
7 Start-up
)
Outdoor Armor Water Heater Installation & Operation Manual
Chlorine concentration less than 200 ppm
1. Do not fill the water heater or operate with water
containing chlorine in excess of 200 ppm.
2. Filling with chlorinated fresh water should be acceptable
since drinking water chlorine levels are much lower.
3. Do not use the water heater to directly heat swimming
pool or spa water.
4. At initial fill and during water heater startup and testing,
check system thoroughly for any leaks. Repair all leaks
before proceeding further.
Check for gas leaks
WARNING
WARNING
Before starting the water heater, and
during initial operation, smell near
the floor and around the water heater
for gas odorant or any unusual odor.
Remove the top access panel and smell
the interior of the water heater enclosure.
Do not proceed with startup if there is any
indication of a gas leak. Use an approved
leak detection solution. Repair any leaks
at once.
DO NOT adjust gas valve outlet pressure.
The gas valve is factory set for the correct
outlet pressure. This setting is suitable
for natural gas and propane, requiring
no field adjustment. Attempting to
alter the gas valve outlet pressure could
result in damage to the valve, causing
potential severe personal injury, death, or
substantial property damage.
WARNING
Propane water heaters only – Your propane
supplier mixes an odorant with the propane
to make its presence detectable. In some
instances, the odorant can fade, and the gas
may no longer have an odor. Before startup
(and periodically thereafter), have the
propane supplier verify the correct odorant
level in the gas.
Inspect/fill condensate system
Inspect/check condensate lines and fittings
1. Inspect the condensate drain line, condensate PVC fittings
and condensate trap.
Fill condensate trap with water
1. Remove the PVC cap retaining screw from the PVC cap
(FIG. 7-1).
2. Remove the 2 inch PVC cap with the switch located at the
top of the trap (FIG. 7-1).
3. Fill with fresh water until the water begins to pour out of
the drain.
4. Replace the cap. Press the cap onto the trap until the cap
makes contact with the drain.
5. Replace the retaining screw.
WARNING
The condensate trap (FIG. 7-1) must be filled
with water during all times of water heater
operation to avoid flue gas emission from
the condensate drain line. Failure to fill the
trap could result in severe personal injury or
death.
Figure 7-1 Condensate Trap
RETAINING
SCREW
CONDENSATE FROM
HEAT EXCHANGER
30
2” PVC CAP WITH
BLOCKED DRAIN SWITCH
PVC TEE ASSEMBLY
(FACTORY SUPPLIED
TO FLOOR
DRAIN
Page 31
7 Start-up (continued)
Outdoor Armor Water Heater Installation & Operation Manual
Final checks before starting the water
heater
Read the Outdoor Armor Water Heater Service Manual
to familiarize yourself with SMART SYSTEM control
module operation. Read this manual, pages 32 and 33 for
proper steps to start the water heater.
Verify the water heater and system are full of water and
all system components are correctly set for operation.
Verify the preparation procedures of Section 7, pages 30
and 31 have been completed.
Fill the vent condensate trap with water (removing the
retaining screw in order to remove the 2 inch PVC cap
with the switch located at the top of the trap). Replace
the cap. Press the cap onto the trap until the cap makes
contact with the drain. Replace the retaining screw.
Verify electrical connections are correct and securely
attached.
Start the water heater
1. Read and follow the Operating instructions in FIG.’s 7-2
and 7-3, pages 32 and 33.
If water heater does not start correctly
1. Check for loose connections, blown fuse or service switch
off?
2. Is water heater water temperature above 200°F?
3. Is tank thermostat or tank set point set below tank
temperature?
4. Is gas turned on at meter or water heater?
5. Is incoming gas pressure less than 4 inches w.c.?
If none of the above corrects the problem, refer to the
TroubleshootingSection of the Outdoor Armor Water Heater
Service Manual.
Check system and water heater
Check water piping
1. Check system piping for leaks. If found, shut down the
water heater and repair immediately. (See WARNINGS
on pages 30 and 31 (startup) regarding failure to repair
leaks.)
2. Check Delta T. Reference Section 3 - System Piping on
page 15 for more information regarding Delta T.
3. Vent any remaining air from the system using manual
vents. Air in the system will interfere with circulation and
cause heat distribution problems and noise.
Check vent piping and air piping
1. Check for gastight seal at every connection, seam of air
piping, and vent piping.
WARNING
Check gas piping
1. Check around the water heater for gas odor following
the procedure on page 21 of this manual (Connecting Gas Supply Piping).
WARNING
Propane water heaters – verify conversion
1. Verify propane conversion has been completed per the
Propane Conversion instructions.
WARNING
WARNING
Venting system must be sealed gastight
to prevent flue gas spillage and carbon
monoxide emissions, which will result in
severe personal injury or death.
If you discover evidence of any gas leak,
shut down the water heater at once. Find
the leak source with a bubble test and repair
immediately. Do not start the water heater
again until corrected. Failure to comply
could result in severe personal injury, death,
or substantial property damage.
DO NOT adjust gas valve outlet pressure.
The gas valve is factory-set for the correct
outlet pressure. This setting is suitable
for natural gas and propane, requiring
no field adjustment. Attempting to alter
the gas valve outlet pressure could result
in damage to the valve, causing potential
severe personal injury, death, or substantial
property damage.
Outdoor Armor water heaters are typically
shipped ready to fire on natural gas. Check
water heater rating plate to determine which
fuel the water heater is set for. If set to
natural gas, it may be converted to LP by
installing an orifice or by making a gas valve
adjustment (see pages 11 and 12). In order
to operate on LP gas, an orifice MUST BE
installed or a gas valve adjustment MUST
BE made. Failure to comply could result in
severe personal injury, death, or substantial
property damage.
Check flame and combustion
1. Turn the main power off to the water heater by placing the
“On/Off” switch in the OFF position.
2. Remove the flue temperature sensor from the flue pipe
connection. Note: Combustion measurements will be
made at this point.
3. Turn the main power on to the water heater by placing the
“On/Off” switch in the ON position.
31
Page 32
Outdoor Armor Water Heater Installation & Operation Manual
If you do not follow these instructions exactly, a fire or explosion
may result causing property damage, personal injury, or loss of life.
A. This appliance does not have a pilot. It is
equipped with an ignition device which
automatically lights the burner. Do not try
to l ight the burner by hand.
B. BEFORE OPERATING smell all around
the appliance area for gas. Be sure to
sm ell next t o the floo r be ca us e som e ga s
is heavier tha n air and will settle on the
floor.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electric switch; do
not use an y phon e in you r bu ild in g.
• Im me dia t ely ca ll your g as su pp lie r from a
neighbor’s phone. Follow the gas supplier’s
instructions.
• If you cannot reach your gas supplier, call
the fir e depa rtm en t.
C. Use only your hand to move the gas contr ol
switch. Never use tools. If the switch will not
move by hand, don’t try to repair it, call a
qualified service technician. Force or attempted
repair may r esult in a fire or explosion.
D. Do not use this appliance if any part has been
under water. Immediately call a qualified
servi ce techni cian to in spe ct the appliance and
to replace any part of the control system and
any gas control which has been under water.
OPERATING INSTRUCTIONS
1. STOP! Read the safety information
above on this label.
2. Set the thermostat to lowest setting.
3. Turn off all electric power to the
appliance.
4. This appliance is equipped with an ignition
device which automatically lights the
burner. Do not try to light the burner by
hand.
5. Remove front door.
6. Move switch to the “OFF” position.
7. Wait five (5) minutes to clear out any gas.
If you then smell gas, STOP! Follow “B”
in the safety information above this label.
If you don’t smell gas, go to next step.
8. Move the s witch to the “ON” position.
9. In stall fr on t d oo r.
10. Turn on all electric power to appliance.
11. Set thermostat to desired setting.
12. If the appliance will not operate, follow the
inst ru c t io ns “To Tur n O f f Gas To Ap pl ian ce” an d
call your service technician or gas supplier.
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to lowest setting.
2. Turn off all electric power to the appliance
if service is to be performed.
3. Remove front door.
32
4. Move the switch to the “OFF” position.
5. In stall fr on t d oo r.
LBL 2339
REV
C
Page 33
Outdoor Armor Water Heater Installation & Operation Manual
Outdoor Armor Water Heater Installation & Operation Manual
Check flame and combustion (continued)
4. Place the water heater into the active position by pressing
the RIGHT SELECT [ON] key (FIG. 8-1, page 40).
5. Locate the pinhole button below the RESET button on
the display board (FIG. 8-1). Insert a thin wire (such as
a paper clip) into the hole and press the button once and
hold for 5 seconds to place the water heater into Service
Mode. In Service Mode the water heater will fire at
ignition speed and will then modulate up to full fire.
6. Insert the probe from a combustion analyzer into the flue
outlet.
7. Once the water heater has modulated up to full fire,
measure the combustion. The values should be in the
range listed in Table 7A below. The CO levels should be
less than 150 ppm for a properly installed unit.
If the combustion is not within the specified range,
reference the Troubleshooting Section of the Outdoor
Armor Water Heater Service Manual for possible causes
and corrective actions.
Table 7A Flue Products Chart
Natural GasPropane
CO
2
8.0% - 10%3.0% - 6.5%9.0% - 11%4.1% - 6.9%
8. Once the combustion analysis is complete, test the safety
shutoff device by turning the manual shutoff valve to the
OFF position and ensuring that the water heater shuts
down and registers an alarm. Open the manual shutoff
valve and reset the control.
O
2
CO
2
O
2
Set water heater operation
Set tank set point temperature
NOTICE
The NAVIGATION dial may be used during normal operation
to adjust the tank set point temperature.
1. From the Status Screen press the NAVIGATION dial.
2. Press the NAVIGATION dial then rotate the NAVIGATION
dial to adjust the temperature.
3. Once the desired temperature is displayed, press the
RIGHT SELECT [SAVE] key.
4. Press the RIGHT SELECT [HOME] key to upload the
changes.
5. If the RIGHT SELECT [SAVE] key is not pressed, the
new settings will be discarded.
Verify WHR circulator mode
When the tank thermostat or tank sensor calls for heat, the
SMART SYSTEM control will turn on the water heater pump.
When the DHW call for heat ends, the water heater pump will
continue to run for a period of time. This pump delay is set at
the factory to 60 seconds. If a shorter or longer delay is desired,
the appropriate parameter in the control must be changed. See
the Outdoor Armor Water Heater Service Manual for a detailed
explanation of this procedure.
Please note that the brackets ([]) denote
screen status.
9. Turn the main power off to the water heater.
10. Place the water heater back into normal operation.
34
Page 35
7 Start-up (continued)
Outdoor Armor Water Heater Installation & Operation Manual
Set clock
NOTICE
The SMART SYSTEM control has a built-in clock that it
uses for its night setback feature and for logging events. This
clock must be set when the water heater is installed, and
anytime the water heater has been powered off for more than
4 hours. Use the following procedure to set the clock:
1. Press and hold the LEFT SELECT [MENU] key for at
least 5 seconds.
2. The display changes to read [PASSWORD],
with four (4) zeros below it.
3. Press the RIGHT SELECT [SAVE] key.
4. The display will then show a menu with the time and
date and temperature unit.
5. Press the NAVIGATION dial twice.
6. Turn the NAVIGATION dial to adjust the hours. Press
the NAVIGATION dial.
Please note that the brackets ([]) denote
screen status.
Configuration of the cascade
NOTICE
When installed in a Cascade system, the individual controls
must be programmed for cascade operation. This is
accomplished by accessing the control parameters.
Press the [MENU] key for at least five (5) seconds. Input
the Installer code as described in the Outdoor Armor Service
Manual. Once the control parameters have been accessed,
use the NAVIGATION dial to select the Control Mode
parameters. Press the NAVIGATION dial to access these
parameters.
Rotate the NAVIGATION dial to select the parameter
“Cascade Address”. Press the NAVIGATION dial to access
this parameter. Each appliance in the Cascade system must
be programmed with its own address. The water heater
designated as the Leader will have an address of 0. The
remaining water heaters in the Cascade will be Members and
have addresses from 1 - 7. Rotate the NAVIGATION dial
to select the appropriate address. Press the RIGHT SELECT
[SAVE] key.
Please note that the brackets ([]) denote
screen status.
7. Turn the NAVIGATION dial to adjust the minutes. Press
the NAVIGATION dial.
8. Turn the NAVIGATION dial to adjust the month. Press
the NAVIGATION dial.
9. Turn the NAVIGATION dial to adjust the date. Press the
NAVIGATION dial.
10. Turn the NAVIGATION dial to adjust the year. Press the
RIGHT SELECT [SAVE] key.
11. Press the RIGHT SELECT [HOME] key.
NOTICE
The clock is automatically updated whenever a PC is
connected and the Win Pro-Installer program is started.
The internal clock does not adjust for
Daylight Savings Time and therefore,
will require a manual adjustment.
Press the RIGHT SELECT [HOME] key to upload the
address into the control. Repeat this procedure for all water
heaters in the Cascade, designating the Leader control and the
Member controls.
Note: A tank sensor must be installed when operating
outdoor water heaters in Cascade.
35
Page 36
Outdoor Armor Water Heater Installation & Operation Manual
8 Operating information
General
How the water heater operates
The outdoor water heater uses an advanced stainless steel heat
exchanger and electronic control module that allows fully
condensing operation. The blower pulls in air and pushes flue
products out of the water heater through the heat exchanger
and flue piping. The control module regulates blower speed
to control the water heater firing rate. The gas valve senses the
amount of air flowing into the water heater and allows only the
right amount of gas to flow.
Control inputs and outputs
Tank thermostat / tank sensor
Either of these inputs will tell the water heater to provide heat
to the water tank. If a tank sensor is connected, the SMART
SYSTEM control will ignore the tank thermostat.
0 - 10VDC input (set point or power)
The outdoor water heater can be controlled by a Building
Management System (BMS) using a 0 - 10 VDC signal. The
control can be configured by the installer to use this signal to
either control set point or firing rate. This signal can be sent to
the heater through ModBus as well.
Protection features
Outlet temperature, flue temperature, and temperature
rise limiting
The outlet temperature is monitored by the water heater outlet
temperature sensor. When the outlet temperature exceeds
185°F, the unit will reduce the fan speed. If the outlet water
temperature exceeds 195°F the control will shut the unit down
until it cools off.
The control module monitors the flue temperature by a sensor
located in the flue exhaust. If the flue temperature exceeds
215°F the control will reduce the maximum fan speed. If
the flue temperature exceeds 240°F the control will shut the
unit down. The unit will restart automatically once the flue
temperature drops 25°F and the minimum off time has expired.
The control monitors the temperature difference between
the inlet and the outlet sensor. On Models 151 - 501 if this
difference is between 25 - 30°F the control will reduce the fan
speed. If the temperature difference exceeds 30°F the control
will shut the unit down.
On Models 601 - 801 if the temperature difference is between
30 - 35°F the control will reduce the maximum fan speed. If
the temperature difference exceeds 35°F the control will shut
the unit down.
Temperature control
Modulation
The outdoor water heater is capable of modulating its firing
rate from a minimum of 20% to a maximum of 100%. The
firing rate is dictated by the hot water draw and various other
temperature limitations.
Night setback
The controller may be programmed to reduce the DHW set
point during certain times each week. Seven different start and
stop times may be programmed for the DHW setback.
Flame current support
To prevent nuisance shutdowns when the water heater is firing
at minimum rates, the control will increase fan speed when the
flame signal drops too low.
The unit will restart automatically once the temperature
difference has dropped below 25°F (Models 151 - 501) or 30°F
(Models 601 - 801) and the minimum off time has expired.
Freeze protection
DO NOT install the water heater in a location likely to freeze.
The following integral feature of the SMART SYSTEM control
module provides some protection for the water heater.
• The SMART SYSTEM control module provides
freeze-up protection as follows when the water heater
water temperature drops below 45°F:
• Below 45°F, the water heater pump operates constantly.
• Below 37°F, the water heater turns on.
• The water heater and pump will turn off if water
heater water temperature rises above 45°F.
CAUTION
This feature of the SMART SYSTEM control
module does not eliminate the possibility
of freezing. The installation must still
use recognized design, installation and
maintenance practice to prevent freeze
potential for the water heater.
36
Page 37
8 Operating information (continued)
Monitor external limits
Connections are provided on the connection board for
external limits such as a flow switch and gas pressure
switches. The SMART SYSTEM will shut off the burner
and inhibit relighting whenever any of these external limits
open.
Runtime and alarm outputs
The water heater provides dry contacts for indicating
when the water heater is running, and when it is unable to
operate.
Runtime and cycle counting
The control uses a timer to monitor the total hours of
burner operation. The timer monitors the time the water
heater is firing.
The control uses two (2) ignition counters to monitor the
amount of water heater cycles. The first counter counts all
ignitions of the control. The second counter counts only
ignition attempts that have failed.
Service reminder
The control can be programmed for service reminder
notification. This notification will become active when
either a set amount of time has expired, or a set amount of
running hours or cycles has expired (all adjustable by the
installer). The display will show a Maintenance Required
screen. The installer’s name and phone number can be
programmed into the control. This information will appear
on the Maintenance Required screen. The service reminder
notification can be reset or disabled by the installer.
The time dependent feature has been disabled by the
manufacturer. To enable this feature change the parameter
to the desired time interval, reference the Outdoor Armor
Service Manual for details regarding parameters.
Error logging
The control will hold in memory the last 10 lockouts as
well as the last 10 blockings. The date and time of the
occurrence will be recorded as well. Only the 10 most
current occurrences of each will be held in memory.
Water heater temperature regulation
Operating temperature (target)
The SMART SYSTEM control module senses water
temperature and regulates water heater firing and firing rate
to achieve a target temperature. The target temperature can
be set between 60°F and 190°F.
High limit operations
The outdoor water heater is equipped with a fixed automatic
reset high limit and an adjustable manual reset high limit.
The automatic reset high limit has a set point of 200°F and
the manual reset high limit has a maximum set point of
210°F.
Outdoor Armor Water Heater Installation & Operation Manual
When the outlet temperature exceeds 200°F, the automatic high
limit action occurs. The water heater shuts down until the outlet
water temperature cools below 190°F, and a 60 second timer has
expired. If the outlet temperature continues to increase, the
manual reset high limit action will occur at 210°F.
High limit test procedure
NOTICE
1. Turn ON the main power to the water heater by placing the
ON/OFF switch in the ON position.
2. From the Status Screen, press the NAVIGATION dial to
access the Set Points Screen.
3. Press the LEFT SELECT (LIMITS) key.
4. Select the manual reset high limit (MRHL) by rotating
the NAVIGATION dial counterclockwise, then press
the NAVIGATION dial.
5. Decrease the set point of the MRHL to below the current
outlet temperature (or to its minimum setting, whichever
is higher) by turning the NAVIGATION dial
counterclockwise.
6. Press the RIGHT SELECT [SAVE] key.
7. Press the RIGHT SELECT [HOME] key. The new
parameter will upload to the control.
8. If the current outlet temperature is above the new MRHL
set point, the MRHL will function causing water heater
lockout. If this occurs, skip to Step 11.
9. If the current outlet temperature is below the new MRHL
set point, locate the pinhole (SERVICE button) below the
RESET button on the display board. Insert a thin probe
(such as a paper clip) into the hole and press the button
continuously for five (5) seconds to place the water heater
into Service Mode. In Service Mode, the water heater will
fire at ignition speed and will then modulate up to full fire.
10. Once the outlet temperature rises up to the MRHL set
point, the MRHL will function, causing the water heater to
shut down and lock out.
11. Repeat Steps 2, 3 and 4.
12. Set the MRHL to the appropriate set point by turning the
NAVIGATION dial clockwise.
13. Repeat Steps 6 and 7.
14. Press the RESET button to clear the lockout.
15. If needed, press the RIGHT SELECT [STOP] key to exit
Service Mode.
Low water cutoff protection
1. The SMART SYSTEM control module uses temperature
sensing of both supply and return areas of the heat exchanger.
If the flow rate is too low or the outlet temperature too
high, the control module modulates and shuts the water
heater down. This ensures water heater shutdown in the
event of low water or low flow conditions.
2. Some codes and jurisdiction may accept these integral
features of the control in lieu of requiring an additional
limit control or low water cutoff. Consult local jurisdiction
to determine. A low water cutoff is available from the
factory (WTR30024).
Please note that the brackets ([]) denote
screen status.
37
Page 38
Outdoor Armor Water Heater Installation & Operation Manual
8 Operating information
Cascade
Access modes
When multiple water heaters are installed, they can be
wired together in a cascade sequence. A maximum of eight
water heaters can be controlled from a single control. In
this application one water heater would be designated as the
Leader control and all others would be designated as Member
controls. The Leader control can be programmed to use
Lead/Lag or Efficiency Optimization control methods.
Once the Leader water heater receives a call for heat from
a tank sensor, BMS or ModBus, the control will determine
what the set point will be. A fixed temperature set point can
be programmed into the control. See page 34 of this manual
to program the set point.
If the water temperature at the tank is less than the set point
- differential, then the control will initiate a call for heat on
the Cascade (see the Outdoor Armor Water Heater Service
Manual for an explanation of the differential). The Leader
will energize the lead water heater on the Cascade. For a new
startup this will be the Leader water heater.
Sequence of the cascade
To equalize the runtime of all water heaters on the Cascade,
the firing sequence will automatically be changed at set
intervals.
For the first 24 hours after initializing the Cascade, the
sequence will be changed every hour. After that the sequence
will be changed once every 24 hours. The switching on/off
sequence will be as follows:
TIMESWITCHING ON SEQUENCE
User
The user can adjust tank target temperatures by pressing the
NAVIGATION dial when “SETPOINTS” is flashing at the
bottom of the display. The date and time, and the temperature
units can also be changed (see page 35).
Installer
Most parameters are available only to the installer, accessible by
entering the installer password, see the Outdoor Armor Water
Heater Service Manual.
Saving parameters (reference the Parameter Table in
the Outdoor Armor Water Heater Service Manual)
NOTICE
To save parameters and exit programming:
Press the RIGHT SELECT [SAVE] key and then press the
RIGHT SELECT [HOME] key.
To enter a parameter and continue programming:
Press the RIGHT SELECT [SAVE] key 1 time to return to the
parameter listings; press again to return to the menu listings.
Remember to press the RIGHT SELECT [HOME] key when
finished programming in order to save the changes made.
See the Outdoor Armor Water Heater Service Manual for a
detailed description of parameters and access modes.
Please note that the brackets ([]) denote
screen status.
StartL-M1-M2-M3-M4-M5-M6-M7
+ 1 hourM1-M2-M3-M4-M5-M6-M7-L
+ 2 hoursM2-M3-M4-M5-M6-M7-L-M1
If a water heater locks out, it will automatically be given the
lowest priority for the rest of that 24 hour period.
Night Setback operation with cascade
Night Setback operation of the water heaters within the
Cascade is available. Programming of the Night Setback
will be done through the Leader water heater. Refer to the
Outdoor Armor Water Heater Service manual for information
regarding Night Setback.
38
Page 39
Outdoor Armor Water Heater Installation & Operation Manual
8 Operating information (continued)
Sequence of operation
OPERATIONDISPLAY
1. The control will turn on the water heater pump (always ON except
in Night Setback). The flow switch and/or LWCO must close.
2. Air pressure switch and blocked drain switch must close.
3. The control starts a 15 second prepurge cycle.
4. The control starts a 4 second trial for ignition by firing the spark
electrode and opening the gas valve.
5. If flame is not detected within 1 second after the sparking ends,
the control will perform a 10 second post-purge, then start
another prepurge cycle and try to light the burner again. On the
501 and larger models, the control will lock out if this second
attempt also fails. On the 400 and smaller models, the control
will perform a total of 4 attempts before locking out.
6. If flame is detected, it holds the firing rate steady for 5 seconds
to let the flame stabilize, then it begins to modulate the firing rate
based on a set point or some other command (such as a 0-10V
BMS signal).
7. Once the call for heat is satisfied, the control will turn off the
burner. The blower will continue to run during a 10 second
postpurge.
8. The water heater pump will continue to run for its respective
pump delay time before turning off. A 60 second anti-cycle period
will start, which will delay any new call for heat until it times out.
9. In Standby, ready to start a new cycle.
39
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Outdoor Armor Water Heater Installation & Operation Manual
8 Operating information
Outdoor Armor water heater control module
Use the control panel (FIG. 8-1) to set temperatures, operating conditions, and monitor water heater operation.
Figure 8-1 Control Panel
The information on the bottom of the display shows the functions of the two SELECT keys (on either corner), and the
NAVIGATION dial (in the center):
MENU = Left SELECT Key
SETPOINTS = NAVIGATION Dial - Pressing Down
SHDN = Right SELECT Key
40
Page 41
Outdoor Armor Water Heater Installation & Operation Manual
8 Operating information (continued)
Figure 8-2 Status Display Screen
Status Display Screens
SectionDisplayDescription
The unit has not received a call for heat from a remote thermostat nor
has it received a call for heat from a DHW thermostat.
The call for heat has been satisfied and the unit runs the fan for an
additional 10 seconds to clear the combustion chamber and vent
system of residual flue products.
The controlled temperature has exceeded its set point and its offset.
The unit has detected a condition that has temporarily interrupted
the current call for heat.
A
(Water heater
Status Bar)
STANDBY
START The unit has begun a burn cycle and is checking all safety circuits.
PREPURGEThe unit has initiated a 10 second purge period on a call for heat.
IGNITIONThe unit has begun a 4 second spark period to ignite the main burner.
The unit has fired and is running at the displayed percentage.
%
POSTPURGE
SHUTDOWNThe unit has been placed in the OFF position.
BLOCKED
B
(Call for Heat
Indicators)
The tank thermostat or sensor has a call for heat.
The unit is being controlled by a 0 - 10V BMS signal.
The member unit is supplying heat while in Cascade Mode.
41
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Outdoor Armor Water Heater Installation & Operation Manual
8 Operating information
Status Display Screens (cont’d)
SectionDisplayDescription
TANK: The temperature read by the tank sensor (if connected).
INLET TEMP:The temperature read at the inlet to the heat exchanger.
OUTLET TEMP:The temperature read at the outlet of the heat exchanger.
C
(Operational
Information)
DELTA T:
FLUE TEMP:The temperature read by the flue sensor.
FLAME CURRENT:The current measured by the flame sense circuit.
FAN SPEED:The speed of the combustion blower.
SYSTEM PUMP:The status of the recirculation pump output.
DHW PUMP:The status of the DHW pump output.
BMS VOLTAGE:The voltage received from a BMS system.
RATE OUTPUT:A 0 - 10V signal indicating the firing rate of the water heater.
DHW RUN HOURS:The total hours of operation in the DHW Mode.
DHW CYCLES:The total burner cycles in the DHW Mode.
LAST 10 FAULTS NO:The last 10 lockouts.
The temperature difference between the inlet and the outlet of the
heat exchanger.
D
(LEFT SELECT
key function)
42
MENU
EXITPress the LEFT SELECT key to exit the current screen or setting.
YES
LIMITS
HOME
Press and hold the LEFT SELECT key for 5 seconds to enter the Menu
Screen.
Press the LEFT SELECT key to confirm that the water heater needs
to shutdown.
Press the LEFT SELECT key to enter the screen that allows you to
adjust the limit settings.
Press the LEFT SELECT key to return to the Status Screen and upload
parameter changes.
Page 43
Outdoor Armor Water Heater Installation & Operation Manual
8 Operating information (continued)
Status Display Screens (cont’d)
SectionDisplayDescription
Turning the NAVIGATION dial will select the next or previous Status
Screen.
Pressing the NAVIGATION dial will show the next fault, NSB (Night
Setback) trigger, or ramp delay setting.
E
(NAVIGATION
Dial Function)
F
(RIGHT SELECT
key function)
Pressing the NAVIGATION dial will select the setting indicated by
the cursor.
Pressing the NAVIGATION dial will display the Set Points Screen.
Turning the NAVIGATION dial will move the cursor up or down.
Turning the NAVIGATION dial will increase or decrease the current
setting.
SHDNPress the RIGHT SELECT key to turn the water heater OFF.
ONPress the RIGHT SELECT key to turn the water heater ON.
NOPress the RIGHT SELECT key to cancel the shutdown operation.
SAVEPress the RIGHT SELECT key to save the current change.
HOME
Press the RIGHT SELECT key to return to the Status Screen and
upload parameter changes.
43
Page 44
Outdoor Armor Water Heater Installation & Operation Manual
9 Maintenance
Maintenance and annual startup
Table 9A 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)
ANNUAL START-UP
• Check wiring and connections
• Perform start-up checkout and
performance verification per Section 7
of this manual.
• Flame inspection (stable, uniform)
• Flame signal (at least 10 microamps at
high fire)
• Clean the heat exchanger if flue
temperature is more than 54°F above
return water temperature.
• Check Delta T (Temperature Rise)
Owner maintenance
Daily
Monthly
• Check water heater area
• Check pressure/temperature
gauge
• Check air and vent termination
screens
• Check relief valve
• Check condensate drain system
• Check automatic air vents
• Check Delta T (Temperature
Rise)
If combustion or performance
indicate need:
• Clean heat exchanger
• Remove and clean burner using
compressed air only
• Clean the blower wheel
44
Every
6 months
• Check water heater piping (gas
and water) for leaks
• Operate relief valve
Page 45
Outdoor Armor Water Heater Installation & Operation Manual
9 Maintenance (continued)
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 9A and explained on the following pages must
be performed to assure maximum water heater efficiency and reliability. Failure to service and maintain the
water heater and system could result in equipment failure.
WARNING
Electrical shock hazard – Turn off power to the water heater before any service operation on the water heater
except as noted otherwise in this instruction manual. Failure to turn off electrical power could result in
electrical shock, causing severe personal injury or death.
Address reported problems
1. Inspect any problems reported by the owner and
correct before proceeding.
Inspect water heater area
1. Verify that water heater area is free of any combustible
materials, gasoline and other flammable vapors and
liquids.
2. Verify that air opening area is free of any of the
contaminants listed in Section 1 - Determine Water Heater Location. If any of these are present in the water
heater intake air vicinity, they must be removed.
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. 9-1).
Figure 9-1 Condensate Trap
RETAINING
SCREW
2” PVC CAP WITH
BLOCKED DRAIN SWITCH
PVC TEE ASSEMBLY
(FACTORY SUPPLIED)
CONDENSATE FROM
HEAT EXCHANGER
WARNING
The condensate trap must be filled with water
during all times of water heater operation to
TO FLOOR
DRAIN
avoid flue gas emission from the condensate
drain line. Failure to fill the trap could result
in severe personal injury or death.
Check all piping for leaks
WARNING
1. Inspect all water and gas piping and verify to be leak free.
Eliminate all system or water heater leaks.
Leaking water may cause severe property
damage.
3. Remove the 2 inch PVC cap with the switch located at
the top of the trap (FIG. 9-1).
4. Remove any sediment in the trap.
5. Fill with fresh water until the water begins to pour out
of the drain.
6. Replace the cap. Press the cap onto the trap until the
cap makes contact with the drain.
7. Replace the retaining screw.
2. Look for signs of leaking lines and correct any problems
found.
3. Check gas line using the procedure found in Section 4 - Gas
Connections.
Flue vent system and air piping
1. Visually inspect the entire flue gas venting system and air
piping for blockage, deterioration or leakage. Repair any
joints that show signs of leakage. Verify that the air inlet
pipe internal to the appliance is connected and properly
sealed.
2. Verify that water heater vent discharge and air intake are
clean and free of obstructions.
45
Page 46
9 Maintenance
Outdoor Armor Water Heater Installation & Operation Manual
WARNING
Failure to inspect for the above conditions
and have them repaired can result in
severe personal injury or death.
Check water system
1. Verify all system components are correctly installed and
operational.
2. Check the cold fill pressure for the system. Verify it is
correct (must be a minimum of 12 PSI).
3. Watch the system pressure as the water heater heats up
(during testing) to ensure pressure does not rise too high.
Excessive pressure rise indicates expansion tank sizing or
performance problem.
4. Inspect automatic air vents and air separators. Remove
air vent caps and briefly push valve to flush vent. Replace
caps. Make sure vents do not leak. Replace any leaking
vents.
Check expansion tank
1. Expansion tanks provide space for water to move in
and out as the heating system water expands due to
temperature increase or contracts as the water cools.
Tanks may be open, closed or diaphragm or bladder type.
See Section 3 - System Piping for suggested best location of
expansion tanks and air eliminators.
Check water heater relief valve
1. Inspect the relief valve and lift the lever to verify flow.
Before operating any relief valve, ensure that it is
piped with its discharge in a safe area to avoid severe
scald potential. Read Section 3 - System Piping before
proceeding further.
WARNING
46
Safety relief valves should be re-inspected
AT LEAST ONCE EVERY THREE YEARS,
by a licensed plumbing contractor or
authorized inspection agency, to ensure
that the product has not been affected by
corrosive water conditions and to ensure
that the valve and discharge line have not
been altered or tampered with illegally.
Certain naturally occurring conditions
may corrode the valve or its components
over time, rendering the valve inoperative.
Such conditions are not detectable unless
the valve and its components are physically
removed and inspected. This inspection
must only be conducted by a plumbing
contractor or authorized inspection agency
– not by the owner. Failure to re-inspect
the water heater relief valve as directed
could result in unsafe pressure buildup,
which can result in severe personal injury,
death, or substantial property damage.
WARNING
2. After following the above warning directions, if the relief
valve weeps or will not seat properly, replace the relief valve.
Ensure that the reason for relief valve weeping is the valve
and not over-pressurization of the system due to expansion
tank waterlogging or undersizing.
Following installation, the valve lever must
be operated AT LEAST ONCE A YEAR to
ensure that waterways are clear. Certain
naturally occurring mineral deposits may
adhere to the valve, rendering it inoperative.
When manually operating the lever, water
will discharge and precautions must be taken
to avoid contact with hot water and to avoid
water damage. Before operating lever, check
to see that a discharge line is connected to
this valve directing the flow of hot water
from the valve to a proper place of disposal.
Otherwise severe personal injury may result.
If no water flows, valve is inoperative. Shut
down the water heater until a new relief
valve has been installed.
Inspect ignition and flame sense
electrodes
1. Remove the ignition and flame sense electrodes from the
water heater heat exchanger access cover.
2. Remove any deposits accumulated on the ignition/flame
sense electrode using sandpaper. If the electrodes cannot
be cleaned satisfactorily, replace with new ones.
3. Replace ignition/flame sense electrode, making sure gasket
is in good condition and correctly positioned.
Check ignition ground wiring
1. Inspect water heater ground wire from the heat exchanger
access cover to ground terminal strip.
2. Verify all wiring is in good condition and securely attached.
3. Check ground continuity of wiring using continuity meter.
4. Replace ground wires if ground continuity is not satisfactory.
Check all water heater wiring
1. Inspect all water heater wiring, making sure wires are in
good condition and securely attached.
Check control settings
1. Set the SMART SYSTEM control module display to
Parameter Mode and check all settings. See Section 1 of
the Outdoor Armor Service Manual. Adjust settings if
necessary. See Section 1 of the Outdoor Armor Service
Manual for adjustment procedures.
2. Check settings of external limit controls (if any) and adjust
if necessary.
Page 47
Outdoor Armor Water Heater Installation & Operation Manual
9 Maintenance (continued)
Perform start-up and checks
1. Start water heater and perform checks and tests specified
in Section 7 - Start-up.
2. Verify cold fill pressure is correct and that operating
pressure does not go too high.
Check burner flame
1. Inspect flame through observation window.
2. If the flame is unsatisfactory at either high fire or low
fire, turn off water heater and allow water heater to
cool down. Remove the burner and clean it thoroughly
using a vacuum cleaner or compressed air. Do not use
compressed air to clean burner if performed inside a
building.
3. Remove the burner, reference FIG. 9-2 below.
4. When replacing the burner, ensure gasket is in good
condition and positioned correctly (FIG. 9-2).
Figure 9-2 Burner Assembly
3. Remind the owner to follow the proper shutdown procedure
and to schedule an annual start-up.
Cleaning heat exchanger
For recommended materials; including brush, appropriate
extension(s), refractory cover, and detailed instructions see
Table 9B - Heat Exchanger Cleaning Kits.
1. Shut down water heater:
• Follow the “To Turn Off Gas to Appliance” instructions
for the water heater in Section 7 - Startup.
2. Allow time for the water heater to cool to ambient
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
The water heater contains ceramic fiber
materials. Use care when handling these
materials per instructions in the Service
Manual. Failure to comply could result in
severe personal injury.
AIR / GAS ARM
INSULATION
HEAT EXCHANGER
ACCESS COVER
BURNER
GASKET
SCREWS
(QTY. 5)
IMG00447
Check flame signal
1. At high fire the flame signal shown on the display should
be at least 10 microamps.
2. A lower flame signal may indicate a fouled or damaged
flame sense electrode. If cleaning the flame sense electrode
does not improve, ground wiring is in good condition,
and ground continuity is satisfactory, replace the flame
sense electrode.
3. See Section 3 - Troubleshooting in the Outdoor Armor
Service Manual for other procedures to deal with low
flame signal.
Review with owner
1. Emphasize the need to perform the maintenance schedule
specified in this manual.
2. Remind the owner of the need to call a licensed contractor
should the water heater or system exhibit any unusual
behavior.
5. Remove the condensate hose from the heat exchanger end.
Connect a field supplied 3/4" diameter hose to a drain pan.
Using field supplied means, cover the refractory in the back
of the combustion chamber of the heat exchanger.
6. Use a vacuum cleaner to remove any accumulation on the
water heater heating surfaces. Do not use any solvent.
7. Brush the heat exchanger while dry using a nylon bristle
brush. Caution: DO NOT use a metal brush. Re-vacuum
the heat exchanger.
8. Finish cleaning using a clean cloth dampened with warm
water. Rinse out debris with a low pressure water supply.
9. Allow the heat exchanger to thoroughly dry.
10. Remove the field supplied rear refractory cover from the
back of the combustion chamber of the heat exchanger and
reassemble.
11. Close isolation valves on piping to isolate water heater from
system. Attach a hose to the water heater drain and flush
water heater thoroughly with clean water by using purging
valves to allow water to flow through the water make-up
line to the water heater.
12. Perform start-up and check-out procedures in the Check
Flame and Combustion - Section 7 - Startup on pages 31 and
34 of this manual.
13. Replace the access cover and restore water heater to
operation.
47
Page 48
9 Maintenance
Outdoor Armor Water Heater Installation & Operation Manual
Table 9B Heat Exchanger Cleaning Kits
Model
151 - 400 KIT30063
501 - 801 KIT30064
CAUTION
Kit
Number
* Do NOT use a metal brush. Only use
the kit provided brush or an equivalent
Part
Number
CTN20005 Rear Refractory Cover
MSC20083* Nylon 4" Wheel Brush*
MSC200843mm Allen Wrench
MSC20086
CTN20005 Rear Refractory Cover
MSC20083* Nylon 4" Wheel Brush*
MSC20085
MSC20086
Component
Description
1/4" x 24" Drill
1/4" x 12" Drill
1/4" x 24" Drill
replacement nylon brush.
Extension
Extension
Extension
Check Delta T
1. Check Delta T. Reference Section 3 -System Piping on
page 15 for more information regarding Delta T.
Oiled bearing circulators
1. The circulator shipped with the outdoor water heater is
water-lubricated. No oiling is required.
2. Check other circulators in the system. Oil any circulators
requiring oil, following circulator manufacturer’s
instructions. Over-oiling will damage the circulator.
Figure 9-3 Rope Gasket - Heat Exchanger Door
ROPE GASKET
CAUTION: IF GASKET IS DAMAGED
DO NOT REUSE, THE HEAT EXCHANGER DOOR
MUST BE REPLACED.
NOTICE
Rope gasket is intended for sealing
combustion (see FIG. 9-3). If gasket
is damaged DO NOT reuse, the heat
exchanger door must be replaced. Consult
factory for replacement heat exchanger
door (kit WTR3080 and WTR3086).
48
Page 49
10 Diagrams
Figure 10-1 Ladder Diagram
Outdoor Armor Water Heater Installation & Operation Manual
120VAC
AW MODELS ONLY
ON / OFF
SWITCH
TERMINAL STRIP
120V SUPPLY "L"
X1-6
X4-3
X4-3
CN5-5
X5-9
3.5A
AW 801
ONLY
JUNCTION BOX
INTEGRATED CONTROL
F2
3.15A
F1
5A
RECIRC PUMP
F3
.8A
24V DC
SUPPLY
120 VAC
24 VAC
11
13
13
LOW GAS
PRESSURE
9
9
BUILDING
RELAY
DHW PUMP
RELAY
SWITCH
THERMOSTAT
SWITCH
X5-1
FLOW
TANK
HIGH GAS
PRESSURE
SWITCH
RELAY COIL
PROVING SWITCH
X1-1
X1-2
X1-3
CONNECTION BOARD
LOUVER
24VAC
LOUVER
TERMINAL STRIP
120V SUPPLY "N"
BLOWER
3
BUILDING
RECIRC PUMP
RELAY
DHW PUMP
RELAY
12
14
10
5
6
6
7
7
8
INTEGRATED
CONTROL
GROUND
NEUTRAL
L
IN
21
CN7-4
CN7-1
LWCO
24 VAC
BUILDING
RECIRC PUMP
CONTACTS
DHW PUMP
CONTACTS
JUNCTION BOX
CN7-3
CN7-2
CN5-14 X4-8
CN5-10
CN5-12
CN5-11
CN5-3
CN5-4
BUILDING
X4-12
X4-10
X4-11
X4-5
X4-4
RECIRC
PUMP
DHW
PUMP
INTEGRATED
CONTROL
L
OUT
PC INTERFACE
ALARM
BELL
SWITCH
SILENCING
CONTACTS
CONTACTS
TANK
SENSOR
SHIELD
CASCADE
SHIELD
BMS
IN
RATE
OUT
SHIELD
MODBUS
SHIELD
1
2
6
13
ALARM
RUN-TIME
A
B
+
-
+
-
A
B
0-10V
0-10V
RIBBON CABLE
S2
INLET
SENSOR
S1a
OPERATING
SENSOR
S1b
HIGH LIMIT
SENSOR
S3a
FLUE
SENSOR
S3b
FLUE
SENSOR
CONNECTION
BOARD
1
2
3
4
S4
16
17
19
20
21
22
23
24
25
26
27
28
29
30
CN6
CN6
CN8-1
CN8-2
CN8-3 X6-3
CN5-1
CN5-8
CN5-2
CN5-9
CN6
CN6
CN6
CN6
CN6
CN6
M
O
X6-1
D
X6-2
B
U
S
X7
X5-6
X5-4
X5-12
X5-5
X5-13
X5-14
X4-7
X4-14
X4-6
X4-13
X6
X6
X6
X6
X6
X6
X6
X6
X4-1
X9-2
X4-2
X9-1
X4-3
X9-3
AW 286-801 ONLY
O-TEMP HEX SW
AIR PRESSURE
GAS VALVE
BLOWER
SPARK
ROD
DRAIN SWITCH
SWITCH
HIGH VOLTAGE SPARK LEADCAUTION
NOTES:
1. Where possible, switches are shown without utilities (gas, water or
electricity) connected to the unit. As such, actual switch states may
vary from those shown on diagrams depending upon whether utilities
are connected or a f ault condition is present.
2. See wiring diagram for additional notes.
BLOCKED
X5-2
X5-10
X5-11
X2-2
X2-1
1
2
4
5
TR2
X1-7
FLAME ROD
GAS VALVE
RELAY
X5-7
X5-16
X5-8
X5-15
BOX DEPICTS
OPTIONAL ITEMS
LOW VOLTAGE
120 VAC
HIGH VOLTAGE
LADDER DIAGRAM
LBL20341 REV A
49
Page 50
10 Diagrams
Figure 10-2 Wiring Diagram
Outdoor Armor Water Heater Installation & Operation Manual
1. All wiring must be installed in accordance with: local, state,
2. If any original equipment wire as supplied with the appliance
minimum of 105°C. Exceptions: Replacement high voltage spark lead and ribbon cables must be purchased from the factory. Use
or ribbon cables can lead to operational problems which could result in non-repairable damage to the integrated controller or other components.
3. Actual connector block locations may vary from those shown on diagrams. Refer to actual components for proper connector block locations when using
diagrams to troubleshoot unit.
15
16
17
18
19
20
21
22
X5-1
X5-2
CN6
23
24
25
26
27
28
29
30
CN7-1
CN7-2
CN7-3
CN7-4
MODBUS BOARD
MTR-01
provincial and national code requirements per either N.E.C. in USA or C.S.A. in Canada.
must be replaced, it must be replaced with wire having same wire gauge (AWG) and rated for a
CN8-1
CN8-2
CN8-3
BL
R
G
X6-3
X6-2
X6-1
X6-4
X4-1
X4-2
X4-3
X4-4
X1-1
X1-2
X1-3
X6
O
X9-1
GY
X9-2
X9-3
G
X9-4
BK
W
G
X5-7
X5-16
X5-8
X5-15
X5-9
X5-1
X5-2
X5-10
X5-11
X5-4
X5-12
X5-6
X5-5
X5-13
X5-14
X2-2
X2-1
X1-7
TR2
BLOWER
1 2 3 4
5
R
T
W
BK
Y
BL
O
BLOCKED DRAIN SWITCH
P
O/BK
R/BK
GY
P/BK
W/BK
PR
Y
BK
Y
W/R
AIR PRESSURE SWITCH
-T
-T
-T
-T
-T
GAS VALVE
@24VAC
FLAME SENSOR
SPARK
ROD
CAUTION
HIGH VOLTAGE SPARK LEAD
of a non-approved spark lead
OPERATING SENSOR S1a
HIGH LIMIT SENSOR S1b
INLET SENSOR S2
FLUE SENSOR S3a
FLUE SENSOR S3b
AW 286-801 ONLY
O-TEMP HEX SW
G
WIRING DIAGRAM
LBL20342 REV A
50
Page 51
Notes
OUTDOOR CONDENSING WATER HEATER
Installation & Operation Manual
51
Page 52
Revision Notes: Revision A (ECO #C10942)
initial release.
Revision B (ECO #C11235) reflects updates
made to the freezing conditions warnings.
Revision C (ECO C12102) reflects the addition
of condensate kit option information for areas
that may reach below 32°F as well as a warning
not to install OA 400 in these areas and Table
1A on page 8.
Revision D (ECO #C12692) reflects changes
made to the wiring and ladder diagrams to match
the diagrams used on the Armor Wall Mount
(pages 49 and 50).
OAW-I-O Rev D
04/13
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