Lochinvar ARMOR 151 - 801 User's Manual
Contents
1. Table 3F continued from previous page Troubleshooting Chart Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION The unit was running and lost the flame signal This condition occurred four 4 straight times e Inspect spark electrode and associated wiring for damage and connection Reference page 22 of this manual for removal and cleaning procedures Replace If necessary Exception Models 501 801 will lock out after one retry for ignition It will require a manual reset before attempting to fire again Check for proper electrical grounding of unit Check incoming supply gas pressure Natural gas pressures should be between 4 14 inches w c and LP gas pressures should be between 8 14 inches w c Refer to Section 7 Gas Connections of the Armor Water Heater Installation and Operation Manual for detailed information concerning the gas supply Verify that the plastic hose from the gas valve to the air inlet is connected and is not damaged Verify that the vent air intake pipes are installed correctly and there are no obstructions Check for 24 VAC to the gas valve at the 2 pin connection on the side of the main control board during the ignition attempt If no voltage is present replace the main control board No Flame Running will reguire a manual reset once the condition If 24 VAC is present at the main control board check has been corrected the wiring between2. Display panel menu access Table 1B Use this procedure to access menus from the display panel BUTTON STATUS OPERATION DISPLAY STANDBY K SHDN Select Press the RIGHT SELECT soft key SHDN TANK 128 F 1259 MEHU JSETPOIHT SHDN 10 Press the LEFT SELECT soft key YES Press and hold the LEFT SELECT soft key MENU for five 5 seconds Rotate the NAVIGATION dial clockwise until 5 is displayed first digit on the left Press the NAVIGATION dial to select the next digit Rotate the NAVIGATION dial clockwise until 3 is shown in the display Press the NAVIGATION dial 2 times to move to the last digit Rotate the NAVIGATION dial counterclockwise until 9 is displayed Press the RIGHT SELECT soft key SAVE Rotate the NAVIGATION dial counterclockwise to select a category STANDBY SHUT COMM STANDBY TANK 128 F 1253 MEHU SETPOIHT SHOH SHUTDOWN PASSWORD O000 EAIT HEST SHUTDOWN PASSWORD 2000 SAVE EAIT SHUTDOWN PASSWORD 2300 HEST SAVE EAIT SHUTDOWN PASSWORD 22093 HEST SAVE EMIT SHUTDOWN gt GENERAL DATA LOGGING FUMCT IONS DHL SETTINGS HOME 47 SCROLL HEAT SHWE Service Manual CONDENSING WATER HEATER 1 Service continued Display panel parameter access jassa Table 1C This is a typical example of accessing a parameter shown for parameter DHW Settings TANK MIN Setpt BUTTON STATUS OPERATION DISPLAY This example sh
3. Using a screwdriver turn the screw 1 8 turn counterclockwise to increase CO levels or 1 8 turn clockwise to decrease CO levels After one adjustment on the valve follow the Combustion Analysis Procedure on page 36 of this manual to measure the combustion If combustion is still not within the specified range repeat the procedure This procedure SHOULD NOT be performed more than four 4 times If after four 4 adjustments and the combustion is still not within the specified range revisit the possible causes in Table 3H on page 36 or replace the gas valve Figure 3 3 Gas Valve Adjustment Model 400 THROTTLE ADJUSTMENT SCREW mu 37 mu 3 Troubleshooting Model 501 Locate the throttle adjustment screw on top of the gas valve see FIG 3 4 Using a screwdriver turn the screw a 1 4 turn counterclockwise to increase CO levels or a 1 4 turn clockwise to decrease CO levels After one adjustment on the valve follow the Combustion Analysis Procedure on page 36 of this manual to measure the combustion If combustion is still not within the specified range repeat the procedure This procedure SHOULD NOT be performed more than four 4 times If after four 4 adjustments and the combustion is still not within the specified range revisit the possible causes in Table 3H on page 36 or replace the gas valve Figure 3 4 Gas Valve Adjustment Model 501 THROTTLE ADJUSTMENT SCREW RMOR CONDENSING WATER HEATER Figure
4. i 2 26 GRMOR Service Manual 3 Troubleshooting continued Table 3E Troubleshooting Chart Noisy System CORRECTIVE ACTION Supply gas problem Natural gas pressures should be between 4 inches w c and 14 inches w c LP gas pressures should be between 8 inches w c and 14 inches w c e Refer to Section 7 Gas Connections of the Armor Water Heater Installation and Operation Manual for detailed information concerning the gas supply e Refer to the Gas Valve Adjustment Procedure on pages 37 38 of this manual for the proper gas valve setting Verify that the vent air intake lengths do not exceed the maximum listed in the General Venting section of the Armor Water Heater Installation and Operation Manual Gas air mixture problem Noisy Operation e Refer to page 22 in this manual for the burner removal and inspection procedure Clean or replace the burner as necessary Dirty damaged burner e Refer to Section 6 System Piping of the Armor Water Heater Installation and Operation Manual for minimum flow rates Low water flow through the heat exchanger Air in the piping system e Properly purge all air from the piping system Low system water pressure e Verify system pressure is a minimum of 12 PSI Blown fuse e Replace fuse F1 on the control board see page 24 of l this manual No Pump Faulty pump e Replace pump Operation Faulty pump relay e Replace pump relay e Replace main contr
5. occurring conditions may corrode the valve or its components over time rendering the valve inoperative Such conditions are not detectable unless the valve and its components are physically removed and inspected This inspection must only be conducted by a plumbing contractor or authorized inspection agency not by the owner Failure to re inspect the water heater relief valve as directed could result in unsafe pressure buildup which can result in severe personal injury death or substantial property damage Following installation the valve lever must A WARNING 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 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 wa
6. 3 5 Gas Valve Adjustment Models 601 801 Service Manual Models 601 801 Locate the throttle adjustment screw on top of the gas valve see FIG 3 4 Using an Allen wrench turn the screw a 1 4 turn counterclockwise to increase CO levels or a 1 4 turn clockwise to decrease CO levels After one adjustment on the valve follow the Combustion Analysis Procedure on page 36 of this manual to measure the combustion If combustion is still not within the specified range repeat the procedure This procedure SHOULD NOT be performed more than four 4 times If after four 4 adjustments and the combustion is still not within the specified range revisit the possible causes in Table 3H on page 36 or replace the gas valve i THROTTLE ADJUSTMENT SCREW REMOVE BLUE CAP Notes 39 Lochinvar High Efficiency Water Heaters Boilers and Pool Heaters 300 Maddox Simpson Parkway Lebanon TN 37090 615 889 8900 Fax 615 547 1000 www Lochinvar com Revision Notes Revision A ECO C06238 initial release AWII SER Rev A 8 10
7. H Avoid breathing dust and contact with skin and eyes e Use NIOSH certified dust respirator N95 This type of respirator is based on the OSHA reguirements for cristobalite at the time this document was written Other types of respirators may be needed depending on the job site conditions Current NIOSH recommendations can be found on the NIOSH website at http www cdc gov niosh homepage html NIOSH approved respirators manufacturers and phone numbers are also listed on this website e Wear long sleeved loose fitting clothing gloves and eye protection H Apply enough water to the combustion chamber lining to prevent airborne dust H Remove the combustion chamber lining from the water heater and place it in a plastic bag for disposal H Wash potentially contaminated clothes separately from other clothing Rinse clothes washer thoroughly NIOSH stated First Aid H Eye Irrigate immediately H Breathing Fresh air number from the water heater rating plate Consider piping and installation when determining water heater location see the Armor Water Heater Installation and Operation Manual Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee When servicing water heater e To avoid electric shock disconnect electrical supply before performing maintenance e To avoid severe burns allow the water heater to cool before performing mai
8. RETAINING SCREW 2 PVC CAP WITH BLOCKED DRAIN SWITCH PVC TEE ASSEMBLY 3 SUPPLIED CONDENSATE FROM S TO FLOOR HEAT EXCHANGER a A WARNING The condensate trap must be filled with water during all times of water heater operation to avoid flue gas emission from the condensate drain line Failure to fill the trap could result in severe personal injury or death Check all piping for leaks A WARNING Eliminate all system or water heater leaks Leaking water may cause severe property damage 1 Inspectall water and gas piping and verity to be leak free 2 Look for signs of leaking lines and correct any problems found 3 Check gas line using the procedure found in Section 7 Gas Connections of the Armor Water Heater Installation and Operation Manual 2 Maintenance continued Flue vent system and air piping l Visually inspect the entire flue gas venting system and air piping for blockage deterioration or leakage Repair any joints that show signs of leakage Verify that air inlet pipe is connected and properly sealed Verify that water heater vent discharge and air intake are clean and free of obstructions A WARNING Failure to inspect for the above conditions and have them repaired can result in severe personal injury or death Check water system l Verify all system components are correctly installed and operational Verify system pressure is at least 12 PSI Watch th
9. could result in electrical shock causing severe personal injury or death Address reported problems 1 Inspect any problems reported by the owner and correct before proceeding Inspect water heater area 1 Verify that water heater area is free of any combustible materials gasoline and other flammable vapors and liquids 2 Verify that air intake area is free of any of the contaminants listed in Section 1 of the Armor Water Heater Installation and Operation Manual If any of these are present in the water heater intake air vicinity they must be removed If they cannot be removed reinstall the air and vent lines per this manual and the Armor Water Heater Installation and Operation Manual Inspect water heater interior 1 Remove the front access cover and inspect the interior of the water heater 2 Vacuum any sediment from inside the water heater and components Remove any obstructions Clean condensate trap 1 Inspect the condensate drain line condensate PVC fittings and condensate trap 2 Remove the PVC cap retaining screw from the PVC cap FIG 2 1 3 Remove the 2 inch PVC cap with the switch located at the top of the trap FIG 2 1 4 Remove any sediment in the trap 5 Fill with fresh water until the water begins to pour out of the drain 6 Replace the cap Press the cap onto the trap until the cap makes contact with the drain 7 Replace the retaining screw 20 Figure 2 1 Condensate Trap
10. lol del internal fault The main control detected Replace the main control board ULE ILLE internal fault The main control detected Replace the main control board fed tom ETETA tee internal fault The main control detected Replace the main control board PAI KS 1123 M internal fault Restore the default parameters Replace the main control board Replace the display board Fatal Error The main control detected Parameters internal fault m 35 m GRMOR Service Manual 3 Troubleshooting Combustion Analysis Procedure Table 3G Flue Products 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 co o connection Note Combustion measurements will be 8 0 10 3 0 6 5 9 0 11 4 1 6 9 made at this point 3 Turn the main power on to the water heater by placing the 8 Once the combustion analysis is complete test the safety On Off switch in the ON position shutoff device by turning the manual shutoff valve to the OFF position and ensuring that the water heater shuts down 4 Place the water heater into the active position by pressing and registers an alarm Open the manual shutoff valve the RIGHT SELECT ON key see page 5 reset the control and return to Service Mode 5 Locate the pinhole button below the RESET button on the 9 Turn the main power off to the water heater and replace th
11. more than 54 F above return water temperature e Check air vents eCheck Delta T Temperature Rise e Check Delta T Temperature Rise If combustion or performance indicate need e Clean heat exchanger Every 6 months e Check water heater piping gas and water for leaks e Remove and clean burner using compressed air only e Operate relief valve e Clean the blower wheel 2 Maintenance CONDENSING WATER HEATER Service Manual Follow the service and maintenance procedures given throughout this manual and in component literature A WARNING 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 A WARNING The water heater should be inspected annually only by a qualified service technician In addition the maintenance and care of the water heater designated in Table 2A and explained on the following pages must be performed to assure maximum water heater efficiency and reliability Failure to service and maintain the A WARNING Electrical shock hazard Turn off power to the water heater before any service operation on the water heater water heater and system could result in equipment failure except as noted otherwise in this instruction manual Failure to turn off electrical power
12. the modulation percentage represented by the Volts at Maximum parameter H3 is set by parameter H5 The minimum value is the Power at Minimum Volts setting H4 and the maximum is 100 The default value is 100 Set Point at Minimum Volts When programmed for BMS control through the 0 10V BMS input or through ModBus and the BMS Type is programmed as SETPOINT the set point represented by the Volts at Minimum parameter H2 is set by parameter H6 The minimum value is 32 F 0 C and the maximum is the Set Point at Maximum Volts setting H7 The default value is 70 F 21 C 17 1 Service Set Point at Maximum Volts When programmed for BMS control through the 0 10V BMS input or through ModBus and the BMS Type is programmed as SETPOINT the set point represented by the Volts at Maximum parameter H4 is set by parameter H7 The minimum value is the Set Point at Minimum Volts setting H6 and the maximum is 190 F 88 C The default value is 180 F 82 C On Volts When programmed for BMS control through the 0 10V BMS input or through ModBus and the BMS Thermostat Input is set to INACTIVE parameter H8 determines the 0 10V BMS input voltage at which the water heater is enabled The minimum value is 0 5V and the maximum is 10 0V The default value is 2 0V Off Differential Volts When programmed for BMS control through the 0 10V BMS input or through ModBus and the BMS Thermostat Input is set to INACTIVE parameter H9 de
13. the time has elapsed or the water temperature drops below parameter E2 This parameter can be changed by the installer by accessing parameter E1 The time range for this parameter is 0 minutes to 10 minutes The default value is 1 minute Anti Cycling Override Differential The control will bypass the anti cycling time if the water temperature drops too quickly The control will use the water temperature the water heater was at when it shut off as the starting point If the temperature drops below the temperature parameter the control will abort anti cycling and allow the water heater to fire This parameter can be changed by the installer by accessing parameter E2 The temperature range of this parameter is 0 F 0 C to 54 F 30 C The default value is 10 F 6 C 15 1 Service F Control modes BMS Thermostat Input Active Inactive When controlling the water heater through the 0 10V BMS input or through ModBus the water heater can be enabled one of two ways With parameter F1 set to ACTIVE the water heater will be enabled by closing the Tank Thermostat input With parameter F1 set to INACTIVE the water heater will be enabled by the voltage level on the 0 10V input in the case of 0 10V BMS control or the 0 10V input value received through ModBus The default value is INACTIVE BMS Active Inactive The set point or modulation of the water heater may be controlled through the 0 10V BMS input or through M
14. 0 Startup of the Installation and Operation Manual 13 Replace the access cover and restore water heater to operation Table 2B Heat Exchanger Cleaning Kits Part Number CTN20005 MSC20083 KIT30063 MSC20084 Component Description Rear Refractory Cover Nylon 4 Wheel Brush 3mm Allen Wrench 151 400 MSC20086 1 4 x 24 Drill Extension CTN20005 Rear Refractory Cover MSC20083 Nylon 4 Wheel Brush KIT30064 MSC20085 1 4 x 12 Drill Extension MSC20086 1 4 x 24 Drill Extension Do NOT use a metal brush Only use the kit provided brush or an equivalent replacement nylon brush 2 Allow time for the water heater to cool to room Check Delta T temperature if 1t has been firing 1 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 The water heater contains ceramic fiber materials Use care when handling these materials per the instructions on page 3 of this manual Failure to comply could result in severe personal injury 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 L 6 Use a vacuum cleaner to remove any accumulation on the water heater heating surfaces Do not use any 2 solvent
15. 0 higher than what intake pipes or at terminations is being called for e Check the wiring connections at the fan and at the main control board e Replace the fan e Replace the main control board Either the inlet water or outlet water temperature sensor has been disconnected e Check the sensors and their associated wiring Repair or replace the sensor or wiring if damaged e Measure the resistance of the sensors and compare the resistance to the tables on page 26 of this manual e Replace the sensor if necessary GRMOR Service Manual 3 Troubleshooting continued Table 3F continued from previous page Troubleshooting Chart Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION ST ET M OJAT Either the inlet water or outlet water Check the sensors and their associated wiring OLA KS UKI EINEINN temperature sensor has been shorted Repair or replace the sensor or wiring if damaged reset once the condition has been corrected Press e Measure the resistance of the sensors and compare the RESET button on the the resistance to the tables on page 26 of this SMART SYSTEM display manual to reset e Replace the sensor if necessary BT CTT An optional remote proving switch is not Check function of remote devices ALAT ETSO TAE EIUEIN making reset once the condition e Check for loose or misplaced jumper if auxiliary has been corrected Press proving switch is
16. 6 Control Outputs 0 0 cee eee eee eee 7 Table 3G lt Flue Products 062 44 lt 26 ea akan 36 General Operation 0 0 cece eee eee eee 8 Table 3H Troubleshooting Chart Combustion Levels 36 Sequence of Operation 00 0 eee eee 9 Gas Valve Adjustment Procedure 37 38 Display Panel Menu Access 00005 10 Revision Notes 000 0c eee eaes Back Cover Display Panel Parameter Access 11 Parameter Table 0 0 00 c cece eee 12 13 Viewable and Changeable Control Parameters 14 18 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 A DANGER DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury A WARNING 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 A CAUTION ine CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not CAUTION avoided may result in property damage NOTICE NOTICE indicates special instructions on installation operation or maintenance that are important but not related to
17. 8 Flue Sensor open e Verify that the flue sensor is located in the flue outlet Modulate Above 50 e Check wiring connections at the flue sensor e Check the resistance of the flue sensor and compare to Table 3D on page 26 of this manual mu 25 mu GRMOR Service Manual 3 Troubleshooting Checking temperature sensors The water heater temperature sensors inlet water outlet water system water and flue are all resistance type devices The following tables show the correct values for the sensors at various temperatures Use an ohmmeter to read the resistance of the sensor at a known temperature If the resistance of the sensor does not closely match its corresponding table replace the sensor It is important to note that the flue and outlet water sensors have two temperature sensing devices in one housing These devices are designated as Sla S1b outlet sensor and S3a S3b flue sensor Please reference the wiring diagram in the Armor Water Heater Installation and Operation Manual for correct terminal location Table 3B Inlet System Sensor Resistance vs Temperature sm o mm 1 gt gt Table 3C Outlet Water Sensor Resistance vs Temperature Temperature Resistance Temperature Resistance e oo w a e so m m s 194 o s 1609 a 186 m 2 e Tooo o wlml Llmwlsal 1 Table 3D Flue Sensor Resistance vs Temperature 8 674 7 16 E 10 4 943
18. AWII SER Rev A CONDENSING WATER HEATER Service Manual Models 151 801 This manual must only be used by a qualified heating installer service technician Read all instructions including this manual and the Armor Water Heater Installation and Operation Manual before installing Perform steps in the order given Failure to comply could result in severe personal injury death or substantial property damage High Efficiency Water Heaters Boilers and Pool Heaters Save this manual for future reference CONTENTS 223 Soe e staia eee see detec s HIRSSI S 2 2 MAINTENANCE Hazard Definitions lon 2 Maintenance and Annual Startup 19 23 PLEASE READ BEFORE PROCEEDING 3 3 TROUBLESHOOTING Handling Ceramic Fiber Materials 3 Before TrOUDIESMOOUNG aises sass ieg ee ee eee eae 24 When servicing water heater 3 Check Control Module Fuses 005 24 Water heater operation 0 000 0 ee eee 3 Table 3A Troubleshooting Chart No Display 25 WHAT IS IN THIS MANUAL 4 Checking Temperature Sensors 05 26 1 SERVICE Table 3E Troubleshooting Chart Noisy System 27 The Armor Water Heater Display 5 Table 3F Troubleshooting Chart Fault Messages 28 35 Control Inputs a2fche cca Sue EEE SSE 6 Combustion Analysis Procedure 45 3
19. Check the Delta T using Table 2C as a reference Table 2C Water Heater Pump Applications Recommended Temperature Rise Water Heater Pump Applications Pipe polis Amst Temp Flow Rate Loss GPM FT HD Rise iv ier 67 PAE E22 E22 2 5 18 F 3 5 5 6 TP 40 160 TP 40 160 Oiled bearing circulators The circulator shipped with the Armor water heater is water lubricated No oiling is reguired Check other circulators in the system Oil any circulators requiring oil following circulator manufacturer s instructions Over oiling will damage the circulator 23 3 Troubleshooting A WARNING Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Always disconnect power to the water heater before servicing Failure to comply could result in severe personal injury death or substantial property damage Never jumper bypass any device except for momentary testing as outlined in the Troubleshooting chart Severe personal injury death or substantial property damage can result Before troubleshooting 1 Have the following items a Voltmeter that can check 120 VAC 24 VAC and 12 VDC b Continuity checker c Contact thermometer 2 Check for 120 VAC minimum 102 VAC to maximum 132 VAC to water heater 3 Make sure thermostat is calling for heat and contacts including appropriate zone controls are closed Check f
20. IGHITION The control starts a 4 second trial for ignition by firing the spark electrode and opening the gas valve THHE 1197 Plea MEHL S7SCREEMH SHOH If flame is not detected within 1 second after the sparking ends POST PURGE 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 TAHKE 119 F125 7 attempt also fails On the 400 and smaller models the control will perform a total of 4 attempts before locking out MEHL S2SCEEEN SHOH H Le If flame is detected it holds the firing rate steady for 5 seconds 427 6 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 TAHKE 119 Feizsa BMS signal MEHU sa SCREEH SHOH Once the call for heat is satisfied the control will turn off the burner The blower will continue to run during a 10 second TAHE ize FE1253 postpurge MEHL g1 SCEEEH SHOH BLOCKED AHTI CYCLIHG TAHE 128 FC125 3 The water heater pump will continue to run for its respective pump delay time before turning off A60 second anti cycle period will start which will delay any new call for heat until it times out MEHU st SCREEHM SHEH STANDBY In Standby ready to start a new cycle TAHE 128 F C1253 MEHU JSETPOIMNT SHOH Service Manual CONDENSING WATER HEATER 1 Service
21. T button on the SMART SYSTEM display to reset Fan High OR Fan Speed High will require a manual reset once the condition has been corrected Press the RESET button on the SMART SYSTEM display to reset Sensor Open will require a manual reset once the condition has been corrected Press the RESET button on the SMART SYSTEM display to reset mu 32 FAULT DESCRIPTION CORRECTIVE ACTION e Vent air intake lengths exceed the maximum allowed lengths Refer to Section 3 General Venting of the Armor Water Heater Installation and Operation Manual for proper lengths The actual fan RPM is 30 lower than what is being called for e Check for obstruction or blockage in the ventair intake pipes or at terminations e Check the wiring connections at the fan and at the main control board e Replace the fan e Replace the main control board e Replace fuse F4 on the control board see page 24 of Blown fuse this manual The main control board did not detect the e Check wiring harness connection at the gas valve and gas valve at the main control board e Replace the gas valve wire harness e Replace the gas valve e Replace the main control board e Vent air intake lengths exceed the maximum allowed lengths Refer to Section 3 General Venting of the Armor Water Heater Installation and Operation Manual for proper lengths e Check for obstruction or blockage in the ventair The actual fan RPM is 3
22. al Air pressure switch contacts are open H 29 MI ARMOR Service Manual 3 Troubleshooting continued Table 3F continued from previous page Troubleshooting Chart Fault Messages Displayed on Water Heater Interface FAUT DESCRIPTION CORRECTIVE ACTION The main control board has received a call The control board will release the call for heat after a for heat too quickly after the previous call for set time period heat has ended Anti cycling The control board will release the call for heat if the outlet temperature drops too quickly The unit has failed to prove main burner Inspect spark electrode and associated wiring for ignition after four 4 attempts damage and connection Reference page 22 of this manual for removal and cleaning procedures Exception Models 501 801 will lock out Replace if necessary after one retry for ignition It will require a l l l manual reset before attempting to fire again Check for proper electrical grounding of the unit Check incoming supply gas pressure Natural gas pressures should be between 4 14 inches w c and LP gas pressures should be between 8 14 inches w c Refer to Section 7 Gas Connections of the Armor Water Heater Installation and Operation Manual for detailed information concerning the gas supply Verify that the plastic hose from the gas valve to the air inlet is connected and is not damaged Verify that the vent air intake pipes are correctl
23. antial property damage 7 Install control module cover and top access cover after fuse inspection 8 Restore power to the water heater at the external line switch and verify water heater operation Section 10 Start up in the Armor Water Heater Installation and Operation Manual after completing water heater service GRuMOR Service Manual 3 Troubleshooting continued Table 3A Troubleshooting Chart No Display a ee EN No 120 VAC supplied to unit e Check external line switch fuse or breaker e Check position of ON OFF switch Turn switch to the ON position e Check 120 VAC through the ON OFF switch e Check wiring harness connection between display board and main control board Connect harness at both points No Display No voltage through the switch e Replace switch Bad display board e Replace board Bad main control board e Replace the main control board Blown fuse e Replace fuse F3 on the main control board see page 24 of this manual Main control board temperature set point Review temperature setting satisfied No Burner Remote thermostat satisfied e Review remote thermostat setting Operation e Consult display for specific fault Refer to fault Unit locked out on fault descriptions on pages 28 35 of this manual for corrective actions e Check BMS parameter settings Optional PC software Water heater controlled by BMS required UTE 4
24. cedure until the entire message is entered If you make a mistake and wish to back up one character select the back arrow lt character and press the NAVIGATION dial 4 When finished press the RIGHT SELECT SAVE key to return to the previous menu GRMOR Service Manual 2 Maintenance Maintenance and annual startup Table 2A Service and Maintenance Schedules Service technician see the following pages for instructions Owner maintenance General e Check water heater area e Address reported problems e Check pressure temperature e Inspect interior clean and vacuum if gauge necessary e Clean condensate trap and fill with fresh water e Check for leaks water gas flue condensate e Verify flue and air lines in good condition and sealed tight e Check system water pressure system piping expansion tank e Check control settings e Check ignition and flame sense electrodes e Check vent piping sand off any deposits clean and reposition e Check air piping e Check wiring and connections aB H lt H N l lt lt Monthly e Check air and vent termination e Perform Start up checkout and screens performance verification per Section 10 in the Armor Installation and Operation Manual e Check relief valve e Flame inspection stable uniform e Check condensate drain system e Flame signal at least 10 microamps at high fire eClean the heat exchanger if flue temperature is
25. d that all air has been properly purged from the system Verify that the water heater is piped properly into the heating system Refer to Section 6 System Piping of the Armor Water Heater Installation and Operation Manual for the proper piping methods for the Armor water heater Service Blk While the unit is in Service Mode the outlet temperature has exceeded 185 F Check 120 VAC to the water heater pump motor on a call for heat If voltage is not present check the wiring back to the main control board Replace the main control board if necessary If 120 VAC is present on a call for heat and the water heater pump is not operating replace the pump Verify that the water heater pump is set to the proper speed or that the water heater pump is the proper size Reference Section 6 System Piping of the Armor Water Heater Installation and Operation Manual for water heater pump specifications mu 34 ORMOR Service Manual 3 Troubleshooting continued Table 3F continued from previous page Troubleshooting Chart Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION 120 VAC input to the main control board has e Check 120 VAC supply to the transformer dropped below 80 VAC e Check wiring connections at the low voltage terminal Low 24 VAC strip Check the wire size length to remote devices Replace the transformer The main control detected Replace the main control board ELM
26. e display board see page 5 Insert a thin wire such as a flue temperature sensor into the flue pipe connection 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 asiasi E Sas femme and will then modulate up to full fire A WARNING P 8 E sensor to prevent flue gas spillage into the 10 Place the water heater back into normal operation 6 Insert the probe from a combustion analyzer into the hole room Failure to comply could result in left by the removal of the flue temperature sensor severe personal injury death or substantial property damage 7 Once the water heater has modulated up to full fire measure the combustion The values should be in the range listed in Table 3G above 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 chart below for possible causes and corrective actions Table 3H Troubleshooting Chart Combustion Levels POSSIBLE CAUSE CORRECTIVE ACTION e Refer to Section 3 General Venting of the Armor Water Heater Installation and Operation Vent Air Intake Length Manual for the proper venting and air intake methods for the Armor water heater or Obstruction e Check for obstructions at the vent air intake terminals Gas Supply Pressure e Refer to Section 7 Gas Connections of the Armor Wat
27. e 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 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 Expansion tanks provide space for water to move in and out as the water expands due to temperature increase or contracts as the water cools Tanks may be diaphragm or bladder type See Section 6 System Piping of the Armor Water Heater Installation and Operation Manual for suggested best location of expansion tanks and air eliminators Check water heater relief valve Inspect the relief valve and lift the lever to verify flow Before operating any relief valve ensure that it is piped with its discharge in a safe area to avoid severe scald potential Read Section 6 System Piping of the Armor Water Heater Installation and Operation Manual before proceeding further CONDENSING WATER HEATER Service Manual Safety relief valves should be re inspected AT amp WARNING 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
28. er Heater Installation and Operation Manual for the proper gas supply for the Armor water heater e Refer to page 22 of this manual for burner removal and cleaning procedures Dirty Damaged Burner e Replace burner if necessary Gas Valve Adjustment Refer to pages 37 38 of this manual for the gas valve adjustment procedure 36 3 Troubleshooting continued Gas valve adjustment procedure If adjustment of the gas valve is deemed necessary use the following procedures Note The procedures in this section are model specific Models 151 286 Locate the throttle adjustment screw on the side of the venturi valve FIG 3 2 Using a screwdriver turn the screw a 1 4 turn clockwise to decrease CO levels or a 1 4 turn counterclockwise to increase CO levels After performing one adjustment on the valve follow the Combustion Analysis Procedure on page 36 of this manual to measure the combustion If combustion is still not within the specified range repeat the procedure This procedure SHOULD NOT be performed more than four 4 times If after four 4 adjustments and the combustion is still not within the specified range revisit the possible causes in Table 3H on page 36 or replace the gas valve Figure 3 2 Gas Valve Adjustment Models 151 286 THROTTLE ADJUSTMENT SCREW RMOR CONDENSING WATER HEATER Service Manual Model 400 Locate the throttle adjustment screw on the top of the gas valve see FIG 3 3
29. eratures 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 Installer Most parameters are available only to the installer accessible by entering the installer password 5309 Saving parameters reference the Parameter Table Table 1D on pages 12 and 13 of this manual NOTICE Please note that the brackets denote screen status 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 CONDENSING WATER HEATER Service Manual GRMOR Service Manual 41 Service continued Table 1A Seguence of operation OPERATION DISPLAY START A Thecontrol will turn on the water heater pump always ON except in Night Setback The flow switch and or LWCO must close TAHE 119 FG1252 MEHU SSSCEEEN SHOH The control turns on power to the louver relay The louver proving switch air pressure switch and blocked drain switch TAHE 19 F ies must close MENU et SlREEH SHOH PRE PURGE The control starts a 15 second prepurge cycle TAHE 119 F 1253 MEHI yISCEEEH SHOH
30. et Point When programmed for BMS control through the 0 10V BMS input or through ModBus the 0 10V signal can be interpreted as either a modulation command or a set point When parameter HI is set to POWER the 0 10V signal will control the modulation When set to SETPOINT the 0 10V signal will control the tank set point The default setting is SETPOINT Volts at Minimum When programmed for BMS control through the 0 10V BMS input or through ModBus parameter H2 should be set to the minimum voltage signal sent to the SMART SYSTEM control The range of this parameter is 0 0V to the Volts at Minimum value parameter H3 The default setting is 2 0V Volts at Maximum When programmed for BMS control through the 0 10V BMS input or through ModBus parameter H3 should be set to the maximum voltage signal sent to the SMART SYSTEM control The range of this parameter is the Minimum value parameter H2 to 10 0V The default value is 10 0V Rate at Minimum Volts When programmed for BMS control through the 0 10V BMS input or through ModBus and the BMS Type is programmed as POWER the modulation percentage represented by the Volts at Minimum parameter H2 is set by parameter H4 The minimum value is 0 and the maximum is the Power at Maximum Volts setting H5 The default value is 20 Rate at Maximum Volts When programmed for BMS control through the 0 10V BMS input or through ModBus and the BMS Type is programmed as POWER
31. ether This parameter is adjustable by the installer by accessing parameter F5 The tank sensor must be connected to the Leader water heater The default address is 1 If installing the water heaters in an existing system with existing Armor water heaters with old style controls the new water heaters should be programmed as the Leader and or the higher number addresses Cascade Type L L EFF There are two 2 options for the way a Cascade divides the load between its heaters The first is Lead Lag designated at L Lin the menu This method will modulate the last two 2 water heaters only When the last water heater reaches 100 and the calculated load is still increasing it will start the next water heater at 20 and reduce the previous water heater to 80 When the calculated load is decreasing and the last water heater gets down to 20 fire it will hold it there and start lowering the firing rate on the next to last water heater When the next to last water heater reaches 20 it will turn the last water heater off and raise the rate of the next to last water heater to 40 thus eliminating the sudden drop in total output of the Cascade The other Cascade divider method is Efficiency Optimization designated as EFF in the menu This method is used as the name implies when it is desired to have the most efficient system When the first water heater reaches a certain rate default 90 it lowers its rate to 45 and turns on the n
32. ext water heater at 45 The two 2 water heaters then modulate at the same rate As the calculated load increases further and both water heaters ramp up to 90 it lowers the rate of the first two 2 water heaters to 60 and brings the next water heater on at 60 The three 3 water heaters then modulate together As the calculated load decreases the water heaters will reach a lower threshold default 30 at which time the last water heater the third in our example will turn off and the Cascade will increase the rates of the remaining water heaters to provide the equivalent total output as before 3 x 30 2 45 in our example 1 Service continued Maximum Cascade Outlet Set Point This parameter determines the set point used by the individual water heaters in a Cascade When a water heater is commanded to fire by the Leader water heater it will attempt to achieve this temperature at its outlet The Leader water heater will limit the modulation of the water heater in order to hold the temperature at the tank sensor to the user set point If any of the water heater outlet temperatures reach the maximum cascade outlet set point the water heater will then modulate down on its own in order to keep its outlet temperature within the maximum cascade outlet set point Therefore this parameter can be used to limit the outlet temperatures of all the water heaters in a Cascade This parameter is adjustable by the installer by access
33. ification LOMUONHP Service Manual CONDENSING WATER HEATER Maintenance e Service and maintenance schedules e Address reported problems Inspect water heater area and water heater interior e Clean condensate trap e Check all piping for leaks e Check air openings Flue vent system and air piping e Check water system e Check water heater relief valve Inspect ignition electrode e Check ignition ground wiring e Check all water heater wiring e Check control settings Perform start up and checks e Check burner flame e Check flame signal e Check flue gas temperature General maintenance e Review with owner e Cleaning the water heater heat exchanger e Oiled bearing circulators Troubleshooting e Troubleshooting table No display e Checking temperature sensors e Sensor tables Troubleshooting table Fault messages displayed on the water heater interface e Combustion analysis procedure Gas valve adjustment procedure ARMOR Service Manual 1 Service The Armor water heater display NAVIGATION DIAL PRESS OR TURN RESET KEY SCROLL i J Select LEFT SELECT KEY RIGHT SELECT KEY SOFT KEY SOFT KEY The information on the bottom of the display shows the functions of the two SELECT keys on either corner and the NAVIGATION dial in the center MENU Left SELECT Key SETPOINTS NAVIGATION Dial Pressing Down SHDN Right SELECT Key GRMOR Service Manual 1 Service Cont
34. ing parameter F7 The default maximum cascade set point is 185 F 85 C Minimum On Off Time In order to prevent units in a Cascade from short cycling this parameter defines the minimum ON and OFF time for each unit The installer can adjust this time by accessing parameter F8 The minimum setting is 0 seconds and the maximum setting is 10 minutes The default is 30 seconds Minimum Next On Time In order to reduce the risk of temperature overshoot with a Cascade this parameter defines the minimum time delay from starting one unit until the next unit may be started The installer can adjust this time delay by accessing parameter F9 The minimum setting is 0 minutes and the maximum setting is 10 minutes The default is 60 seconds Boiler Size Not used G Circulation pumps DHW Pump Delay The DHW pump delay parameter sets the length of time the pump if connected will run after a DHW demand has been satisfied This parameter is adjustable by the installer by accessing parameter Gl The time range for this parameter is 0 minutes to 40 minutes The default time is 30 seconds DHW Pump Anti Seize Delay If the water heater pump does not run for 24 hours it will be turned on briefly to prevent it from seizing The length of time it runs is determined by parameter G2 The range of this setting is 0 seconds to 40 minutes The default setting is 20 seconds CONDENSING WATER HEATER Service Manual H BMS BMS Type Power S
35. l air has been properly purged from the system Verify that the water heater is piped properly into the heating system Refer to Section 6 System Piping of the Armor Water Heater Installation and Operation Manual for the proper piping methods for the Armor water heater Manual Reset High Limit will require a manual ajameeeaulaeeucnses The outlet water temperature has exceeded EIS R the fixed setting of the manual reset high the RESET button on the limit SMART SYSTEM display Check 120 VAC to water heater pump motor on a call for heat If voltage is not present check wiring back to the main control board Replace the main control board if necessary If 120 VAC is present on a call for heat and the water heater pump is not operating replace the pump to reset If the manual reset high limit has tripped check setting of the device Check resistance of water sensors and compare to Table 3C on page 26 of this manual Replace sensor If necessary e Replace high limit Service Manual RMOR CONDENSING WATER HEATER 3 Troubleshooting Table 3F continued from previous page Troubleshooting Chart Fault Messages Displayed on Water Heater Interface Fan Low OR Fan Speed Low will require a manual reset once the condition has been corrected Press the RESET button on the SMART SYSTEM display to reset GV Relay Fail will require a manual reset once the condition has been corrected Press the RESE
36. lace fuse F2 on the control board see page 24 of this manual e Check condensate tube from unit to floor drain for e Verify system is full of water and all air has been purged from the system Blocked Drain SW proper installation and obstructions will reguire a manual a e Inspect condensate trap for blockage Clean if BS SOTO The blocked drain switch has detected necessary eain azan 6xcessive condensate build up inside the the RESET button on MNT e Check for loose wiring connection at wire harness the SMART SYSTEM plug display to reset e Bad blocked drain switch Replace switch e Check the wiring connections to switch Wires should be connected to the common and normally closed terminals e Air intake lengths exceed the maximum allowed lengths Refer to Section 3 General Venting of the APS Armor Water Heater Installation and Operation Manual for proper lengths e Check for obstruction or blockage in the air A AINON intake pipes or at terminations has been corrected e Check reference hoses connected to the air pressure Press the RESET button switch for blockage or obstruction on the SMART SYSTEM e Inspect the burner Reference page 22 of this manual display to reset for removal and cleaning procedures Replace if necessary e Inspect the heat exchanger Reference page 23 of this manual for removal and cleaning procedures Replace if necessary e Faulty air pressure switch Replace switch will reguire a manu
37. lay Yes Yes KN Anti Cycling Time Yes Yes 2 Anti Cycling Override Differential Yes Yes On On ANTI DATA CYCLING LOGGING GRMOR Service Manual 1 Service continued Parameter table Table 1D continued from previous page This table lists SMART SYSTEM control module parameters and where to access them Installer Access Modify See Description P n BMS Tstat Input Active Inactive o femmes e we we we Po SERVICE NOTIFICATION an P uoan fonn EN ESEESE w O O z Q DHW Pump Delay Yes j O lt gt gt Sia 2 DHW Pump Anti Seize Delay 17 Yes O 13 CONDENSING WATER HEATER 1 Service Service Manual Viewable and changeable control parameters CAUTION Before changing parameters note the settings so that the unit can be returned to its original operating parameters A General Date and Time The control uses an internal clock for the night setback feature and for logging of events For these features to work correctly the clock must be set when the water heater is first installed or anytime the water heater has been powered off for more than four 4 hours To set the clock parameter Al must be accessed The internal clock does not adjust for NOTICE Daylight Savings Time and therefore will require a manual adjustment Software Version The software version allows the user to view the software version in use by the control This software controls
38. not installed the RESET button on the SMART SYSTEM display to reset The stack temperature has exceeded the set Inspect the heat exchanger Reference page 23 of parameters for the water heater this manual for the procedure on how to clean the flue side of the heat exchanger e Inspect the flue sensor and associated wiring Measure the resistance of the flue sensor and compare to Table 3D on page 26 of this manual Flue Temp High Replace the sensor if necessary e Verify that the vent air intake pipes are properly installed and that there are no obstructions e Replace the main control board Scaling has reduced water flow e Deliming may be required e Verify that the system is full of water and that all air has been properly purged from the system e Verify that the water heater is piped properly into the heating system Refer to Section 6 System Piping of the Armor Water Heater Installation and Operation Manual for the proper piping methods for the Armor water heater e Check for 120 VAC to the water heater pump motor on The temperature rise across the heat a call for heat If voltage is not present check the exchanger has exceeded the set parameters wiring back to the main control board Replace the for the water heater main control board if necessary Delta T High e If 120 VAC is present on a call for heat and the water heater pump is not operating replace the pump e Verify that the water heater pump i
39. ntenance Water heater operation Do not block flow of combustion or ventilation air to the water heater e 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 What is in this manual Service The Armor water heater display Display panel readout buttons and their functions Control module inputs e Control module inputs and options Control module outputs e Control module outputs and options General e How the water heater operates e How the control module operates e Access modes user and installer e Sequence of operation Water Heating Control panel menu access e Accessing programming mode and locating menus See separate guide covering the PC interface Control panel parameter access e Accessing and changing parameters from the display panel Quick start information parameter table e An index of available adjustments and readouts where to access them and where to find detailed information Armor water heater operation General Data Logging Functions DHW Settings Anti Cycling Control Modes Circulation Pumps BMS Service Not
40. odBus When parameter F2 is set to INACTIVE the 0 10V input will be ignored When set to ACTIVE the set point or modulation will be controlled by the voltage on the 0 10V input in the case of 0 10V BMS control or the 0 10V input value received through ModBus The default value is INACTIVE ModBus Active Inactive When BMS is set to ACTIVE see BMS Active Inactive and the water heater is being controlled through ModBus set parameter F3 to ACTIVE Otherwise set the ModBus parameter to INACTIVE Note that the water heater can still be monitored by ModBus with this parameter set to INACTIVE The default value is INACTIVE ModBus T O Timeout The ModBus T O is the amount of time the unit controls will wait to receive a communication string from the BMS controller before reverting back to its own internal parameters This is used to prevent unwanted operation should ModBus communication be lost Therefore the ModBus commands need to be refreshed within this time period This parameter is adjustable by the installer by accessing parameter F4 The default value is 10 seconds 16 CONDENSING WATER HEATER Service Manual Cascade Address The water heater designated as the Leader needs to be programmed with address 0 All the Member water heaters require addresses from 1 to 7 and the addresses must be different for each Member The addresses can be in any order regardless of the order in which the units are wired tog
41. ol board Internal fault on control board e Lower the system pressure below the 150 PSI rating of the supplied relief valve AISNEN System pressure exceeds relief valve Opening setting GRMOR Service Manual 3 Troubleshooting Table 3F Troubleshooting Chart Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION Either the manual reset low gas pressure Reset the pressure switches switch or the manual reset high gas pressure switch tripped e Measure the supply gas pressure to determine cause Gas Pressure SW of failure Natural gas pressures should be between will reguire a manual 4 14 inches w c reset once the condition has been corrected Press the RESET button on the SMART SYSTEM display to reset e Correct the supply gas pressure if necessary e Refer to Section 7 Gas Connections of the Armor Water Heater Installation and Operation Manual for detailed information concerning the gas supply e Check for a loose or misplaced jumper if pressure switches are not installed The flow switch is not making e Check water heater pump operation on a call for heat e Check for closed valves or obstructions in the water Flow Switch heater piping will reguire a manual reset once condition has been corrected Press the RESET button on e Check for loose or misplaced jumpers if flow switch is the SMART SYSTEM not installed display to reset Blown fuse e Rep
42. or 24 VAC between thermostat wire nuts and ground 4 Make sure all external limit controls are installed and operating Check the following 1 Wire connectors to control module are securely plugged in at the module and originating control 2 Gas pressures e Maximum 14 inches w c natural and LP with no flow lockup or with water heater on e Minimum 4 inches w c natural 8 inches w c LP with gas flowing verify during water heater startup 24 GRMOR Service Manual Check control module fuses NOTICE ALWAYS check control module fuses before replacing control module or any major components blower etc If one of these fuses is blown it can prevent the control module or other components from operating 1 Turn OFF power to the water heater at the external line switch 2 Remove top access cover 3 Remove the control module cover 4 Inspect fuses F1 F2 and F3 see FIG 3 1 below Figure 3 1 Control Module Fuses F3 80 AMP FUSE 24V DC POWER SUPPLY F1 5AMP FUSE PUMPS F2 3 15 AMP FUSE BLOWER 5 The water heater is shipped with three 3 spare fuses in a plastic bag attached to the control module cover 6 If necessary replace open fuse F3 is 80 amps F2 is 3 15 amps and F1 is 5 amps Note Fuses F1 F2 and F3 are all slow blow fuses Do not jumper fuse or replace with any fuse except as specified Failure to comply could result in severe personal injury death or subst
43. ows how to access parameter Temperature Settings The first display shown is at the beginning of the menu listings after entering the installer access code Rotate the NAVIGATION dial counterclockwise until the arrow gt is next to DHW SETTINGS Press the NAVIGATION dial one time Rotate the NAVIGATION dial counterclockwise until the arrow gt is next to TANK MIN SETPT Press the NAVIGATION dial one time Rotate the NAVIGATION dial to the desired temperature Press the RIGHT SELECT soft key SAVE one time Press the LEFT SELECT soft key EXIT if all desired changes have been made Press the LEFT SELECT soft key HOME SHUTDOWN gt GENERAL DATA LOGGING FUNCTIONS DHL SETTINGS HOME 47 SCROLL SHUTDOWN GENERAL PATA LOGGING FUNCTIONS gt DHIJ SETTINGS HOME 42 SCROLL A TAHE MIN SETF HOHE 47 SCROLL AHK SP DIFF TAHE MIN SETP HOME 42 SCROLL SHUTDOWN TAH k SETPT le TAHE SP OFFSET TANKE SP DIFF TAHK MIH SETPi HOME 44 SCROLL SHUTDOWN TANK SETFT 2528 INK SP DIFF 67F TAHE MIN SETP 60 F HOME 4 SCROLL SALE SHUTDOWN GENERAL DATA LOGGING FUHCTTIOMS DHL SETTINGS EMIT HOME SAVE Parogmeters uploading 11 GRMOR Service Manual 1 Service Parameter table Table 1D This table lists SMART SYSTEM control module parameters and where to access them ee See Description p naam lt e e e e 1 Reset Last 10 Errors Yes Yes 1 Service Mode De
44. personal injury or property damage ARMOR Service Manual Please read before proceeding Installer Read all instructions NOTICE When calling or writing about the water heater including this manual and the Armor Please have the water heater model and serial A WARNING Water Heater Installation and Operation Manual before installing Perform steps in the order given Have this water heater serviced inspected by a qualified service technician at least annually Failure to comply with the above could result in severe personal injury death or substantial property damage Handling ceramic fiber materials REMOVAL OF COMBUSTION CHAMBER LINING A WARNING The combustion chamber insulation in this appliance contains ceramic fiber material Ceramic fibers can be converted to cristobalite in very high temperature applications The International Agency for Research on Cancer IARC has concluded Crystalline silica in the form of quartz or cristobalite from occupational sources is carcinogenic to humans Group 1 Normal operating temperatures in this appliance are below the level to convert ceramic fibers to cristobalite Abnormal operating conditions would have to be created to convert the ceramic fibers in this appliance to cristobalite The ceramic fiber material used in this appliance is an irritant when handling or replacing the ceramic materials it is advisable that the installer follow these safety guidelines
45. reen shows the start trigger number the day of the week and the time of day NOTICE Please note that the brackets denote screen status 1 When the screen is first accessed start trigger number 1 is shown If a different trigger number is desired the installer can rotate the NAVIGATION dial until the desired trigger number is displayed Once the desired trigger number is selected the installer can press the NAVIGATION dial and the day of the week will start to flash 2 The installer can adjust the day of the week to the one he wishes to set Once the day is set the installer can press the NAVIGATION dial and the hour will begin to flash 3 After setting the hour the installer can press the NAVIGATION dial and the minutes will flash Once all settings have been made the installer can press the RIGHT SELECT SAVE key The installer can now select a different trigger and adjust the settings for that trigger 4 Once all adjustments are made the installer can press the RIGHT SELECT SAVE key to save all of the new settings and return to the A menu or press the LEFT SELECT EXIT key to return to the A menu without saving the changes Domestic Hot Water DHW Night Setback Off Times The stop triggers for the DHW night setback feature can be adjusted by accessing parameter A6 The adjustment procedure for these parameters is identical to the space heating start triggers described above Display Timeout This is the
46. rol inputs GAS PRESSURE SWITCH DHW THERMOSTAT LOW VOLTAGE FLOW SWITCH CONNECTION BOARD TANK SENSOR SEQUENCER BUILDING MANAGEMENT SYSTEM LOW WATER CUTOFF INLET TEMPERATURE SENSOR OUTLET TEMPERATURE SENSOR FLUE GAS SENSOR AIR PRESSURE SWITCH LOUVER PROVING SWITCH A N FLAME SENSOR gt ji N 1 BLOCKED DRAIN SWITCH SMART SYSTEM DISPLAY PANEL CONTROL BOARD PC INTERFACE ORMOR Service Manual 1 Service continued Control outputs ALARM BELL LOW VOLTAGE CONNECTION BOARD LOUVER RELAY RUN TIME CONTACTS SEOUENCER BUILDING MANAGEMENT SYSTEM BUILDING RECIRCULATION PUMP WATER HEATER PUMP IGNITOR BLOWER SMART SYSTEM GAS VALVE CONTROL BOARD DISPLAY PANEL PIIN PC INTERFACE 7 1 Service General Operation How the water heater operates The Armor water heater uses an advanced stainless steel heat exchanger and an electronic control module that allows fully condensing operation The blower pulls in gas and 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 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 Seguence of operation Table 1A shows control module normal sequences of operation for water heating operation Access modes User The user can adjust tank target temp
47. s correct and that operating pressure does not go too high 22 CONDENSING WATER HEATER Service Manual Check burner flame l Inspect flame through observation window 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 Remove the burner reference FIG 2 2 below When replacing the burner ensure gasket is in good condition and positioned correctly FIG 2 2 Figure 2 2 Burner Assembly AIR GAS ARM W BURNER w GASKET VA SCREWS OTY 5 2 Maintenance continued Check flame signal 1 At high fire the flame signal shown on the display should be at least 10 microamps 2 A lower flame signal may indicate a fouled or damaged flame sense electrode If cleaning the flame sense electrode does not improve ground wiring is in good condition and ground continuity is satisfactory replace the flame sense electrode 3 See Section 3 Troubleshooting in this manual for other procedures to deal with low flame signal Review with owner 1 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 3 Remind the owner to follow
48. s set to the proper speed or that the pump is the proper size Reference Section 6 System Piping of the Armor Water Heater Installation and Operation Manual for water heater pump specifications mu 331 GRMOR Service Manual 3 Troubleshooting Table 3F continued from previous page Troubleshooting Chart Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION e Verify that the system is full of water and that all air has been properly purged from the system Verify that the water heater is piped properly into the heating system Refer to Section 6 System Piping of the Armor Water Heater Installation and Operation Manual for the proper piping methods for the Armor water heater e K M KT 11 Mul o M Outlet water temperature has exceeded the Check for 120 VAC to the water heater pump motor on maximum outlet water temperature a call for heat If voltage is not present check wiring back to the main control board Replace the main control board if necessary If 120 VAC is present on a call for heat and the water heater pump is not operating replace the pump Replace the main control board Check set point of the external control External control is cycling too often Rem Ctrl Fit v the wiring between the external control and the Replace the control Establish a heating load to remove the heat from the water heater loop Verify that the system is full of water an
49. terlogging or undersizing 21 2 Maintenance 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 this manual Adjust settings if necessary See Section 1 of this manual for adjustment procedures 2 Check settings of external limit controls if any and adjust if necessary Perform start up and checks 1 Start water heater and perform checks and tests specified in Section 10 Start up of the Armor Water Heater Installation and Operation Manual 2 Verify cold fill pressure i
50. termines how far below the On Volts setting H8 the 0 10V BMS input voltage must be in order to disable the water heater The minimum value is 0 2V and the maximum is the On Volts setting H8 The default value is 1 0V I Service Notification Service Notification in Months When the water heater control determines that a scheduled service is due based on days of installation the water heater display will alternate the standard water heater display text with the message SERVICE DUE every 5 seconds This parameter is adjustable by the installer by accessing parameter I1 The time range for this parameter is 0 months to 36 months The default time is 0 months This feature has been disabled by the manufacturer To enable this feature change parameter I1 to the desired time range Service Notification Running Time When the water heater control determines that a scheduled service is due based on the hours of actual operation the water heater display will turn yellow and a new status screen will appear informing the installer that maintenance is required This parameter is adjustable by the installer by accessing parameter I2 The time range for this parameter is 0 hours to 100 000 hours The default time is 8 760 hours 18 CONDENSING WATER HEATER Service Manual Service Notification Cycles When the water heater control determines that a scheduled service is due based on the number of water heater cycles the water heater displa
51. ternal wiring for voltage feedback The flame detector circuit is seeing a flame e Check the flame rod and make sure it is clean signal while no flame is present e Check the internal wiring for bad connections e Replace main control board e Verify that the system is full of water and that all air has been properly purged from the system e Verify that the water heater is piped properly into the heating system Refer to Section 6 Hydronic Piping of the Armor Installation and Operation Manual for the proper piping methods for the Armor water heater Check 120 vac to water heater pump motor on a call for heat If voltage is not present check wiring back to the main control board Replace the main control board if necessary If 120 vac is present on a call for heat and the water heater pump is not operating replace the pump The outlet water temperature has exceeded 4149 EET the setting of the automatic reset high limit High Limit 9 If the system pump is a variable speed pump ensure that the system flow is not less than the water heater flow If operating on something other than an outlet sensor check temperature setting of the main control board If the manual reset high limit has tripped check setting of the device Check resistance of water sensors and compare to Table B on page 26 of this manual Replace sensor if necessary Replace high limit Verify that the system is full of water and that al
52. the operation of the water heater When a new software version becomes available the existing control can be replaced with a new control to update the software Software version is read only Temperature units C F The control can be configured to display temperature in either C or F This parameter can be changed by the user or the installer by accessing parameter A3 The default is F Domestic Hot Water DHW Night Setback Offset The unit s internal clock can be set up to run at a lower set point temperature during unoccupied times When in night setback the control reduces the set point by a fixed amount It subtracts the DHW night setback offset from the tank set point parameter E2 NOTE The DHW night setback will not work without a tank sensor installed The installer may adjust the DHW night setback offset by accessing parameter A4 The minimum setting is 0 F 0 C and the maximum setting is 90 F 50 C 14 Domestic Hot Water DHW Night Setback On Times This is the time at which the DHW Night Setback Offset becomes active There are 7 start times and 7 stop times Both may be set to any time within a 7 day week These settings are referred to as triggers Multiple start or stop triggers may be set within a single day if desired When a start trigger and a stop trigger are set to the same time the stop trigger has priority The installer may adjust the DHW start triggers in parameter A5 This sc
53. the main control board and the gas valve Replace the wiring if necessary Do not disconnect the wiring from the gas valve and attempt to measure voltage at that point The main control board can detect if the gas valve is not connected and will display the GV Relay Fail fault Press the RESET button on the SMART SYSTEM display to reset If 24 VAC is present check the outlet of the valve to ensure the valve is flowing gas With a manometer connected to the outlet tap of the gas valve when the unit is in the prepurge period there should be a negative pressure present When the valve is energized a change in pressure should occur If the pressure change does not occur the gas valve is not opening Replace the gas valve Inspect flame sensor and associated wiring Reference page 22 of this manual for removal and cleaning procedures Replace if necessary Inspect the burner Reference page 22 of this manual for removal and cleaning procedures Replace if necessary e Replace the main control board H 39 M GRMOR Service Manual 3 Troubleshooting continued Table 3F continued from previous page Troubleshooting Chart Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION e Check supply voltage for proper polarity Flame Sequence will require a manual reset once the condition has been corrected Press the RESET button on the SMART SYSTEM display to reset e Check ex
54. the proper shutdown procedure and to schedule an annual start up at the beginning of the next heating season Cleaning heat exchanger For recommended materials including brush appropriate extension s refractory cover and detailed instructions see Table 2B Heat Exchanger Cleaning Kits 1 Shut down water heater Follow the To Turn Off Gas to Appliance instructions for the water heater in Section 10 Startup of the Installation and Operation Manual Do not drain the water heater unless it will be exposed to freezing temperatures If using freeze prevention fluid in system do not drain A CAUTION Service Manual RMOR CONDENSING WATER HEATER 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 Remove the field supplied rear refractory cover from the back of the combustion chamber of the heat exchanger and reassemble 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 Perform start up and check out procedures in the Check Flame and Combustion Section 1
55. time in which the display remains illuminated The range is 10 seconds to 10 minutes The default is 3 minutes 1 Service continued B Data Logging Reset last 10 errors The reset last 10 errors function clears the last 10 errors log C Functions Service Mode Delay By pressing the pin button on the front of the display for five 5 seconds the control will be placed in Service Mode This will override all other heat demands The Service Mode allows the installer to set the unit to either maximum firing rate or minimum firing rate for the purpose of combustion analysis The delay sets the length of time the water heater will stay in the Service Mode if no keys have been pressed before going back to its original state This parameter can only be changed by the installer by accessing parameter Cl The time range of this parameter is 0 to 30 minutes The default value is 20 minutes D DHW Settings Tank Set Point 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 tank set point differential parameter D3 and finishes the call for heat when the tank temperature reaches tank set point This parameter can be changed by the installer by accessing parameter D1 The temperature range of this parameter is 68 F 20 C to 190 F 88 C The defa
56. ult value is 125 F 52 C Tank Set Point Offset The tank set point offset measures how far the actual temperature must go above the set point before the call for heat ends the water heater will turn off This parameter can be changed by the installer by accessing parameter D2 Tank Set Point Differential When a tank sensor is installed the tank temperature must drop this amount below the tank set point parameter D1 before the heater will turn on The installer can adjust this setting by accessing parameter D3 The minimum setting is 0 0 C and the maximum is 40 F 22 C The default setting is 6 F 3 C CONDENSING WATER HEATER Service Manual Tank Minimum Set Point This setting controls the minimum user set point for the tank temperature The installer can adjust this by accessing parameter D4 The minimum setting is 60 F 16 C and the maximum setting is the maximum tank set point parameter D5 Tank Maximum Set Point This setting controls the maximum user set point for the tank temperature The installer can adjust this by accessing parameter D5 The minimum setting is the minimum tank set point parameter D4 and the maximum setting is 185 F 85 C E Anti Cycling Anti Cycling Time Once a SH demand has been satisfied a set amount of time must elapse before the control will respond to a new SH demand The control will block the new heat demand and anti cycling will be shown in the display until
57. y installed and that there are no obstructions Check for 24 VAC to the gas valve at the 2 pin connection on the side of the main control board during Flame Fail Ign the ignition attempt If no voltage is present replace will require a manual the main control board reset once the condition has been corrected Press the RESET button on the SMART SYSTEM display to reset If 24 VAC is present at the main control board check the wiring between the main control board and the gas valve Replace the wiring if necessary Do not disconnect the wiring from the gas valve and attempt to measure voltage at that point The main control board can detect if the gas valve is not connected and will display the GV Relay Fail fault If 24 VAC is present check the outlet of the valve to ensure the valve is flowing gas With a manometer connected to the outlet tap of the gas valve when the unit is in the prepurge period there should be a negative pressure present When the valve is energized a change in pressure should occur If the pressure change does not occur the gas valve is not opening Replace the gas valve Inspect flame sensor and associated wiring Reference page 22 of this manual for removal and cleaning procedures Replace if necessary Inspect the burner Reference page 22 of this manual for removal and cleaning procedures Replace if necessary e Replace the main control board GRMOR Service Manual 3 Troubleshooting
58. y will alternate the standard water heater display text with the message SERVICE DUE every 5 seconds This parameter is adjustable by the installer by accessing parameter I3 The range for this parameter is 0 cycles to 100 000 cycles The default is 50 000 cycles Reset Maintenance Reminder Once servicing has been completed the service notification counter should be reset This parameter can be reset by the installer by accessing parameter I4 Once accessed press the RESET key to reset the service notification counter Installer Name and Phone Number NOTICE Please note that the brackets denote screen status When a Maintenance Reminder timer or counter has expired a Maintenance Reminder screen will appear on the display By programming the installer s name and phone number this information will appear on the Maintenance Reminder Screen at that time This can be programmed by accessing parameter I5 When selected another menu will appear with PHONE and NAME 1 Rotate the NAVIGATION dial to point to the name phone number to program and press the NAVIGATION dial The screen will now display the selected item either PHONE or NAME 2 Press the NAVIGATION dial again A cursor will appear at the bottom of the screen By rotating the NAVIGATION dial various numbers and characters will appear When the desired number character is found press the NAVIGATION dial The cursor will move to the next position 3 Repeat this pro
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