Lochinvar Armor 150 - 500 User's Manual
Contents
1. 16 20 3 TROUBLESHOOTING Before Troubleshooting 0000 arven 21 Check Control Module Fuses 21 Table 3A Troubleshooting Chart No Display 22 Checking Temperature Sensors 005 23 Table 3D Troubleshooting Chart Noisy System 24 Table 3E Troubleshooting Chart Fault Messages 25 31 Combustion Analysis Procedure 5 32 Table 3F Troubleshooting Chart Combustion Levels 32 Table 3G Flue Products nnana nanana aaaea 32 Gas Valve Adjustment Procedure 33 Revision Notes 000 0c eee Back Cover 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 WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious ni njury A CAUTION CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury CAUTION CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided may result in property damage NOTICE NOTICE indicates special instructions on installation operation or maintenance that ar2. Check condensate tube from unit to floor drain for sj fore Go PE Et excessive condensate build up inside the proper installation and obstructions will require a manual Unit reset once condition has been corrected Press the RESET button on the SMART SYSTEM display to reset e Verify system is full of water and all air has been purged from the system e Inspect condensate trap for blockage Clean if necessary e Check for loose wiring connection at wire harness plug e Bad blocked drain switch Replace switch Flame The flame detector circuit is seeing a flame Check supply voltage for proper polarity Sequence signal while no flame is present will require a manual reset once the condition e Check the flame rod and make sure it is clean has been corrected Press the RESET button e Check the internal wiring for bad connections on the SMART SYSTEM display to reset e Check external wiring for voltage feedback e Replace main control board GV Relay The main control board did not detect the gas e Check wiring harness connection at the gas valve and Fail valve at the main control board will require a manual reset once the condition has been corrected Replace the gas valve Press the RESET button on the SMART SYSTEM Replace the main control board e Replace the gas valve wire harness display to reset GRMOR Service Manual 3 Troubleshooting Table 3E continued from previ
3. Show last 10 errors The control will log the 10 most current errors with the date and time the error occurred This parameter can be viewed by the user and the installer by accessing parameter C3 13 1 Service D Functions Reset last 10 errors The reset last 10 errors parameter allows the error counter to be reset to 0 This parameter can only be cleared by the installer by accessing parameter D1 Once accessed press the RESET key to clear the counter 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 D2 The time range of this parameter is 0 to 40 minutes The default value is 20 minutes E WHR settings Tank set point When a DHW call for heat becomes active the control will use the tank set point to determine the firing rate of the water heater based on the actual water temperature This parameter can be changed by the installer by accessing parameter E3 The temperature range of this parameter is 50 F to 190 F The default
4. EEE MG Ei 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 21 of this manual Main control board temperature set point e Review temperature setting satisfied No Burner Remote thermostat satisfied e Review remote thermostat setting Operation Unit locked out on fault e Consult display for specific fault Refer to fault descriptions on page 25 of this manual for corrective actions e Check BMS parameter settings Optional PC software Water heater controlled by BMS required UT 1 38 oy 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 3C on page 23 of this manual m 99 RMR Service Manual 3 Troubleshooting continued Checking temperature sensors The water heater temperature sensors inlet water outlet water system water and flue ar
5. ACTION While the unit is in Service Mode the outlet e Establish a heating load to remove the heat from the temperature has exceeded 185 F water heater loop 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 Service Blk water heater 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 120 VAC input to the main control board has e Check 120 VAC supply to the transformer dropped below 80 VAC 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 board has detected Replace the main control board LEGS ETR del internal fault The main control board has detected Replace the main con
6. Faulty air pressure switch Replace switch Reference page 19 of this manual Replace if GRMOR Service Manual 3 Troubleshooting continued Table 3E 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 require 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 require 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 Replace fuse F2 on the control board see page 21 of this manual The blocked drain switch has detected
7. 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 18 RMOR CONDENSING WATER HEATER Service Manual Safety relief valves should be re inspected AT Sens LEAST ONCE EVERY THREE YEARS by licensed plumbing contractor or authorized inspection agency to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally Certain naturally occurring conditions may corrode the valve or its components over time rendering the valve inoperative Such conditions are not detectable unless the valve and its components are physically removed and inspected This inspection must only be conducted by a plumbing contractor or authorized inspection agency not by the owner Failure to re inspect the water heater relief valve as directed could result in unsafe pressure buildup which can result in severe personal injury death or substantial property damage Following installation the valve lever must A WARNING be operated AT LEAST ONCE A YEAR to ensure that waterways
8. a digit incorrectly you can move to the digit by using the NEXT and PREVIOUS buttons as needed until the digit you want is flashing Then use UP and or DOWN buttons to change the value oe ENTER RES Z Press to enter the code After 2 seconds display shows menus press ENTER RESET to select a menu Enter Menu Code INSTALLER CODE gt A B General N A The words INSTALLER CODE will flash while displayed The caret symbol gt highlights the selectable line If the code is entered incorrectly the display will return to its previous mode You will have to start over at step 1 to enter the code v DOWN Press 1 time to toggle menu listing v DOWN Press 2 times to toggle menu listing v DOWN Press 1 time to toggle menu listing v DOWN Press 2 times to toggle menu listing gt C ID gt E F gt G H gt I J Data Log Functions WHR Settings N A Anti cycling Control Modes Circ Pumps Service Noti The menu toggles to the next two menu options The menu toggles to the next two menu options The menu toggles to the next two menu options The menu toggles to the next two menu options To select a highlighted menu press the ENTER RESET button one time The display will change to the first parameter under that menu with the first characters flashing 10 GRMOR Service Manual 1 Service continued Disp
9. 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 waterlogging or undersizing 2 Maintenance continued 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 i
10. aside 4 Remove the nuts securing the heat exchanger access cover to the heat exchanger and set aside 20 GRMOR Service Manual a Remove the heat exchanger access cover cover gasket s and chamber insulation assembly A WARNING The water heater contains ceramic fiber materials Use care when handling these 10 11 12 13 materials per instructions on page 3 of this manual Failure to comply could result in severe personal injury Use a vacuum cleaner to remove any accumulation on the water heater heating surfaces Do not use any solvent Finish cleaning using a clean cloth dampened with warm water Install access cover gasket chamber insulation assembly and cover Secure nuts on the studs DO NOT overtighten Re install the blower assembly gas air arm using the bolts set aside in Step 3 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 When the water heater has been flushed restore water heater to operation Perform start up and check out procedures in the Armor Water Heater Installation and Operation Manual Oiled bearing circulators Z The circulator shipped with the Armor water heater is water lubricated No oiling is required Check other circulators in the system Oil any
11. blockage in the air intake pipes or at terminations Air pressure switch contacts are open P p e Check reference hoses connected to the air pressure switch for blockage or obstruction the RESET button on the SMART SYSTEM display to reset e Inspect the burner Reference page 19 of this manual for removal and cleaning procedures Replace if necessary e Inspect the heat exchanger Reference page 20 of this manual for removal and cleaning procedures Replace if necessary e Faulty air pressure switch Replace switch 28 Service Manual CONDENSING WATER HEATER 3 Troubleshooting continued Table 3E continued from previous page Troubleshooting Chart Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION The actual fan RPM is 30 higher than what e Vent air intake lengths exceed the maximum allowed 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 Sensor Shorted will require a manual reset once the condition has been corrected Press the RESET button on the SMART SYSTEM display to reset Aux Proving will require a manual reset once the condition has been corrected Press the RESET butto
12. e Properly purge all air from the piping system Low system water pressure e Verify system pressure is a minimum of 12 PSI Replace fuse F5 on the control board see page 21 of Blown fuse this manual No Pump Faulty pump Faulty pump e Replace pump Operation Faulty pump relay e Replace pump relay Internal fault on control board e Replace main control board e Lower the system pressure below the 150 PSI rating of the supplied relief valve Low water flow through the heat exchanger Relief Valve relief valve Opening System pressure exceeds setting APS Open will require a manual reset once the condition has been corrected Press the RESET button on the SMART SYSTEM display to reset Air pressure switch contacts are open 24 e Check the wiring connections to switch Wires should be connected to the common and normally closed terminals 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 air intake pipes or at terminations e Check reference hoses connected to the air pressure switch for blockage or obstruction e Inspect the burner for removal and cleaning procedures necessary e Inspect the heat exchanger Reference page 20 of this manual for removal and cleaning procedures Replace if necessary e
13. flue sensor and associated wiring Measure the resistance of the flue sensor and compare to Table 3C on page 23 of this manual Replace the sensor if necessary Verify that the vent air intake pipes are properly installed and that there are no obstructions e Replace the main control board GRMOR Service Manual 3 Troubleshooting Table 3E 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 The temperature rise across the heat exchanger has exceeded the set parameters for the water heater 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 Check for 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 pump is the proper size Reference Temp O Shoot Section 6 System Piping of the Armor Water Heater continued Installation and Operation Manual for wat
14. internal clock has been set correctly the night setback feature can be used to program a lower water temperature set point for water heating This feature is only used when a tank sensor is used This parameter can be changed by the user or the installer by accessing parameter A6 The temperature range for this parameter is 32 F to 140 F The feature is turned off with a setting of 32 F The default value is 32 F Night setback times If parameter A6 is set to anything other than 32 F the night setback feature becomes active This will require start and stop times to be programmed for the days that reduced temperatures are required These times can be changed by the user or the installer by accessing parameter A7 Each day of the week Sunday through Saturday will have an on and off time Example Monday ON 22 30 Tuesday OFF 6 45 If you wish to skip a day and have no night setback leave the on and off times the same The default times for each day will be 00 00 midnight B Not used C Data logging Total hrs run The total hrs run parameter shows the total number of hours the water heater has been in the DHW firing position This parameter can be viewed by the user and the installer by accessing parameter CI Ignition attempts The ignition attempts parameter shows the total number of times the water heater has attempted to fire This parameter can be viewed by the user and the installer by accessing parameter C2
15. is calling for heat and contacts PUMPS including appropriate zone controls are closed Check for 24 VAC between thermostat wire nuts and ground F2 3 15 AMP FUSE 24V SUPPLY 4 Make sure all external limit controls are installed and operating Check the following EACBHEP AA GEA ABE m 1 Wire connectors to control module are securely plugged in at the module and originating control 5 The water heater is shipped with three 3 spare fuses in a 2 Gas pressures plastic bag attached to the control module cover 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 Note Fuses F2 F5 are all slow blow fuses A WARNING Do not jumper fuse or replace with any fuse except as specified Failure to comply could result in severe personal injury death or substantial property damage 6 If necessary replace open fuse F3 is 1 25 amps F2 and F4 are 3 15 amps and F5 is 5 amps 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 21 GRMOR Service Manual 3 Troubleshooting Table 3A Troubleshooting Chart No Display
16. necessary Exception The 500 Model will lock out after one 1 try 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 require a manual reset once the condition If 24 VAC is present at the main control board check has been corrected 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 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 valv
17. 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 together This parameter is adjustable by the installer by accessing parameter H3 The tank sensor must be connected to the Leader water heater The default address is 1 Max cascade set point Not used Cascade offset Not used Cascade off on differential Not used 1 Service continued I Circulation pumps DHW pump delay The DHW pump delay parameter sets the length of time the DHW WHR pump will run after a heater demand has been satisfied Setting the delay time to 0 will disable the pump This parameter is adjustable by the installer by accessing parameter I3 The time range for this parameter is 0 minutes to 40 minutes The default time is 30 seconds J 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 J1 The time range for this parameter is 0 months to 36 months The default time is 12 months Service notification running hours When the water heater control determines that a scheduled service is du
18. 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 er Manual Inspect water heater interior WARNING WARNING The condensate trap must be filled with 1 Remove the front access cover and inspect the interior water during all times of water heater of the water heater operation to avoid flue gas emission from the condensate drain line Failure to fill the trap 2 Vacuum any sediment from inside the water heater and could result in severe personal injury or components Remove any obstructions death Clean condensate trap Check all piping for leaks i Inspect the condensate drain line condensate PVC TONS Eliminate all system or water heater leaks fittings and condensate trap Leaking water may cause severe property 2 Remove the PVC cap retaining screw from the PVC cap damage FIG 2 1 3 Remove the 2 inch PVC cap with the switch located at 1 Inspect all water and gas piping and verify to be leak free the top of the trap FIG 2 1 2 Look for signs of leaking lines and correct any problems 4 Remove any sediment in the trap found 5 Fill with fresh water until the water begins to pour out 3 Check gas line using the procedure found in Section 7 Gas of the drain Connections of the Armor Water Heater Installation and Operation Manual 6 Replace the cap Press the cap onto the tr
19. value is 180 F F Not used G Not used 14 Service Manual RMOR CONDENSING WATER HEATER H Control modes Control source The control source parameter selects the method used to control the modulation of the water heater This parameter is adjustable by the installer by accessing parameter H2 The control methods are as follows 1 Thermostat The control modulates the water heater based on the user set point and the temperature of the tank sensor when a tank thermostat is used or the inlet sensor 2 BMS Building Management System The control modulates the water heater based on the 0 10 VDC signal delivered to the appropriate terminals on the connection board When BMS is selected additional parameters for BMS operation may need to be adjusted These can only be accessed by the optional PC software See the Armor Water Heater Smart System PC Program Instructions Manual for additional BMS parameter information 3 Cascade The water heater is part of a group of water heaters sequenced together The designated Leader water heater determines the total output needed from the group based on the set point and controlling sensor reading It assigns portions of this output to itself Leader and the Member water heaters When Cascade is selected each water heater in the group requires a unique address see below The default control is Thermostat Cascade address The water heater designated as the Leader needs to be
20. 545 reflects the addition of references vy n to periodic cleaning of screens in vent terminations and safety yt Lo him r shutoff testing and instructions 300 kladder Simpson Parkway Revision E ECO C02738 reflects the addition of the Gas Lebanon TN 37090 Valve Adjustment Procedure for a 399 model on page 33 615 889 8900 Fax 615 547 1000 www Lochinvar com AW SER Rev E 1 09
21. AW SER Rev E CONDENSING WATER HEATER Service Manual Models 150 500 Starting Serial 4H07H10046464 A WARNING 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 2255 deen shun eee hee bere ae 2 Hazard Definitions 0 0 0 2 2 PLEASE READ BEFORE PROCEEDING 3 Handling Ceramic Fiber Materials 3 When servicing water heater 0 3 Water heater operation 2 00000 3 WHAT IS IN THIS MANUAL 4 1 SERVICE The Armor Water Heater Display 5 Control Inputs a na anaana egene sen 6 Control Outputs n a naaa aaa aaa 7 General Operation 0 000 eee ee ee 8 Sequence of Operation 0 0 cee eee ees 9 Display Panel Menu Access 00005 10 Display Panel Parameter Access 11 Parameter Table 0 0 00 c cee eee eee 12 Viewable and Changeable Control Parameters 13 15 Hazard definitions 2 MAINTENANCE Maintenance and Annual Startup
22. Shales B N A ENTER RES Press 1 time to return to normal WHR Pre Purge This display example assumes operation OUT 123 7 F a Call for water heating is present 11 GRMOR Service Manual 1 Service Parameter table Table 1D This table lists SMART SYSTEM control module parameters and where to access them DESCRIPTION USERACCESS _ ACCESS INSTALLER ACCESS cara woor LAY MODIFY DISPLA AA 040 Boiler Model Model EU 0 0 E DATA LOGGING Control Source Thermostat BMS and Cascade Cascade Off On Differential Not No No Yes Yes Used CONTROL MODES SERVICE z lt a Q z NOTICE The parameters for Building Management System operation are not listed in this table They are only accessible using the PC interface software See separate documentation for access information See page 14 of this manual for a brief discussion 12 1 Service continued RMOR CONDENSING WATER HEATER 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 Boiler model The control will display Armor Heater as the model number because the same control is used on several models This will be displayed when parameter Al has been accessed This parameter is not changeable User code The User Code allows the user to access and chang
23. an 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 sand off any deposits clean and reposition e Check vent piping e Check wiring and connections QA H lt H v l lt lt e Check air piping e Perform start up checkout and Monthly performance verification per Section 10 in the Armor Installation and Operation Manual e Check air and vent termination screens e Flame inspection stable uniform Check relief valve e Flame signal at least 10 microamps at high fire e Clean the heat exchanger if flue temperature is more than 54 F above return water temperature e Check condensate drain system e Check automatic air vents If combustion or performance indicate need e Clean heat exchanger Every nr 6 months e Check water heater piping gas e Remove and clean burner using and water for leaks compressed air only e Clean the blower wheel e Operate relief valve GRMOR Service Manual 2 Maintenance continued 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 th
24. ap until the pe cap makes contact with the drain 7 Replace the retaining screw 17 2 Maintenance 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 Check the cold fill pressure for the system Verify it is correct must be a minimum of 12 PSI 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 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 heating system water expands due to temperature increase or contracts as the water cools Tanks may be open closed or diaphragm or bladder type See Section 6 System Piping of the Armor Water Heater Installation and
25. ater 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 Near water heater piping e Typical system components 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 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 WHR Settings Control Modes Circulation Pumps Service Notification eS Service Manual RMOR 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 p
26. bustion Analysis Procedure on page 32 of this manual to measure the combustion If combustion is still not within the specified range repeat the procedure This procedure SHOULD NOT be performed more than four 4 times If after four 4 adjustments and the combustion is still not within the specified range revisit the possible causes in Table 3F on page 32 or replace the gas valve Figure 3 4 Gas Valve Adjustment Model 500 Model 399 THROTTLE Locate the throttle adjustment screw on the top of the gas ADJUSTMENT valve see FIG 3 3 Using a screwdriver turn the screw 1 8 SCREW 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 32 of this manual to measure the combustion If combustion is still not within the specified range repeat the procedure This procedure SHOULD NOT be performed more than four 4 times If after four 4 adjustments and the combustion is still not within the specified range revisit the possible causes in Table 3F on page 32 or replace the gas valve E 33 NOTES A NOTES op Revision Notes Revision B AW SER Rev B reflects the addition of the Dungs information to the manual Revision C ECO C02407 reflects the addition of the air pressure switch FIG 3 1 removal of pocket pc references and changes made to the Circulation Pump section page 15 Revision D ECO C02
27. circulators requiring oil following circulator manufacturer s instructions Over oiling will damage the circulator GRMOR Service Manual 3 Troubleshooting A WARNING Label all wires prior to disconnection Check control module fuses when servicing controls Wiring errors can cause improper and dangerous NOTICE ALWAYS check control module fuses before operation Always disconnect power to replacing control module or any major the water heater before servicing components blower etc If one of these Failure to comply could result in severe fuses is blown it can prevent the control personal injury death or substantial module or other components from property damage operating WARNING Never jumper bypass any device 1 Turn OFF power to the water heater at the external line except for momentary testing as switch outlined in the Troubleshooting chart gt Remove top access cover Severe personal injury death or substantial property damage can result 3 Remove the control module cover 4 Inspect fuses F2 F3 F4 and F5 see FIG 3 1 below Before troubleshooting Figure 3 1 Control Module Fuses 1 Have the following items a Voltmeter that can check 120 VAC 24 VAC and 12 VDC F3 1 25 AMP FUSE b Continuity checker MAIN BOARD c Contact thermometer 2 Check for 120 VAC minimum 102 VAC to maximum F4 3 15 AMP FUSE 132 VAC to water heater GAS VALVE l F5 5 AMP FUSE 3 Make sure thermostat
28. e 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 19 of this manual for removal and cleaning procedures Replace if necessary Inspect the burner Reference page 19 of this manual for removal and cleaning procedures Replace if necessary e Replace the main control board ml 27 EE GRMOR Service Manual 3 Troubleshooting Table 3E 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 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 Manual Reset water heater High Limit will require a manual eee oi 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 to reset e 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 e Replace the main cont
29. e a limited number of control parameters The access code can be changed by the user or the installer to a code of their choosing To change the code parameter A2 must be accessed The default code is 0704 The code can be changed one digit at a time by using the arrow keys on the display 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 30 days To set the clock parameter A3 must be accessed The date and time are displayed as YY MM DD W hh mm YY year MM month DD date W day 1 Sunday 2 Monday etc hh hour 24 hour time 2 00 PM 14 00 mm minutes 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 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 Temperature units 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 A5 The default is F Night setback temperature Once the
30. e all resistance type devices The following tables show the correct values for the sensors at various temperatures Use an ohmmeter to read the resistance of the sensor at a known temperature If the resistance of the sensor does not closely match its corresponding table replace the sensor Table 3B Inlet Outlet System Sensor Resistance vs Temperature 9509 2 760 23 Service Manual CONDENSING WATER HEATER 3 Troubleshooting Table 3D Troubleshooting Chart Noisy System See eee 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 page 33 of this manual for the proper gas valve setting Verify that the vent air intake lengths do not exceed the Gas air mixture problem maximum listed in the General Venting section of the Armor Water Heater Installation and Operation Manual Noisy Operation e Refer to page 19 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 Air in the piping system
31. e based on the hours of actual operation 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 J2 The time range for this parameter is 0 hours to 100 000 hours The default time is 10 000 hours Service notification cycles When the water heater control determines that a scheduled service is due based on the number of water heater cycles 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 J3 The range for this parameter is 0 cycles to 100 000 cycles The default is 10 000 cycles Reset service notification counter Once servicing has been completed the service notification counter should be reset This parameter can be reset by the installer by accessing parameter J4 Once accessed press the RESET key to reset the service notification counter RMOR CONDENSING WATER HEATER Service Manual 15 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 Cle
32. e important but not related to personal injury or property damage Gi ONDENSING WAT ER HEATER Please read before proceeding A WARNING Installer Read all instructions including this manual and the Armor 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 door insulation in this product 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 inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans Group 1 W Avoid breathing dust and contact with skin and eyes Use NIOSH certified dust respirator N95 This type of respirator is based on the OSHA requirements for cristobalite at the time this document was written Other types of respirators may be needed depending on the job site conditions Current NIOSH recommendations can be found on the NIOSH website at http www cdc gov niosh homepage html NIOSH approved respirators manufacturers and phone numbers are a
33. e 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 water heater and system could result in equipment failure Electrical shock hazard Turn off power to the water heater before any service operation on the water heater A WARNING a le 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 Figure 2 1 Condensate Trap I Inspect any problems reported by the owner and correct before proceeding 2 PVC CAP WITH BLOCKED DRAIN SWITCH Inspect water heater area RETAINING SCREW AE FROM J HEAT EXCHANGER PVC TEE ASSEMBLY 1 Verify that water heater area is free of any combustible FACTORY SUPPLIED 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
34. er heater pump specifications Outlet water temperature has exceeded the Verify that the system is full of water and that all air maximum outlet water temperature 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 Check for 120 VAC to the 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 Replace the main control board Check set point of the external control External control is cycling too often Rem Ctrl Fit Check the wiring between the external control and the unit e Replace the control Parameters Progr After downloading parameters from a laptop Press the ENTER RESET button on the SMART Wall eqn rer the main control board must be reset SYSTEM display panel reset once the condition has been corrected Press the RESET button on the SMART SYSTEM display to reset mH 30 GRMOR Service Manual 3 Troubleshooting continued Table 3E continued from previous page Troubleshooting Chart Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE
35. f the unit is equipped with a flow switch it must close before the control powers up the blower e The manual reset high limit must be closed before the control powers up the blower elf the unit is equipped with a solenoid valve and or a vent valve they will be energized along with the blower e f the unit is equipped with a gas pressure switch it must close at this time elf there is an auxiliary device connected to the unit the unit will then provide 24 VAC to its enable relay If the auxiliary device has a proving switch it must close before the sequence continues The control then starts a 10 second prepurge cycle Once the prepurge cycle is complete and the blocked drain switch is closed the control starts the 5 second trial for ignition by sending spark voltage to the spark electrode and opening the gas valve If the control does not detect flame by the end of the trial for ignition the control performs a 10 second postpurge another prepurge and tries to light the burner again If the burner does not light after 4 trials 1 trial on the 500 model the control locks out for 1 hour and then tries another set of 4 trials except on the 500 model which is manual reset lockout If the control detects a flame before the trial for ignition ends it begins to modulate the burner in order to maintain the set point Once the call for heat is satisfied the control will turn off the burner The blower will remain on f
36. gulates 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 Sequence of operation Table 1 shows control module normal sequences of operation for water heating operation Access modes User The user can adjust water heating set point using the UP and DOWN buttons at any time during normal operation By entering the USER code 0704 the user can also change temperature units time and date and night setback settings In user mode the following parameters can be viewed but not changed water heater model number software version total operating hours and total cycles Installer Most parameters are available only to the installer accessible only by entering the installer access code 5309 Saving parameters To save parameters Press the ENTER RESET button To keep parameter settings only for a current operating cycle Press the MENU EXIT button 1 time to return to the parameter listings press again to return to the menu listings RMOR CONDENSING WATER HEATER Service Manual Service Manual RMOR CONDENSING WATER HEATER 1 Service continued Sequence of operation Table 1A Sequence of operation OPERATION DISPLAY WHR Standby Upon a call for heat the control turns on the water heater pump The control connects 120 VAC to the blower The blower does not run at this time e I
37. he 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 19 of this manual for removal and cleaning procedures Replace if necessary Inspect the burner Reference page 19 of this manual for removal and cleaning procedures Replace if necessary e Replace the main control board E 26 GRMOR Service Manual 3 Troubleshooting continued Table 3E 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 19 of this manual for removal and cleaning procedures Replace if
38. iping e Check water system e Check expansion tank 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 e 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 e Troubleshooting table Fault messages displayed on the water heater interface e Combustion analysis procedure e Gas valve adjustment procedure CONDENSING WATER HEATER GRMOR Service Manual 1 Service The Armor water heater display Hold 5 seconds to enter code e Press to turn the water heater off or back on SHUTDOWN Let ere e Press to select a menu item 3 e Press after parameter programming in Menu Mode or to exit to store parameter data Menu Mode e Press to exit Service Mode ENTER RESET DISPLAY SCREEN SERVICE O BUTTON ENTER Ri CONDENSING WATER HEATER PC CONNECTION PORT et Lochiny High Efficiency Water Heaters Boilers X D o E UP DOWN PREVIOUS NEXT e Press to change water heater water temperature set point during normal operation e Press to change displayed data values in Menu Mode e Press to navigate through
39. lay panel parameter access Table 1C This is a typical example of accessing a parameter shown for parameter H3 cascade address BUTTON OPERATION DISPLAY COMMENTS This example shows how to access parameter H3 cascade address The first display shown is at the beginning of the menu listings after entering the installer access code The caret symbol gt highlights the selectable line cng a gt A General Beginning of menu listings l ane gt C Data Log The menu toggles to the next two v DOWN Press 1 time to toggle menu listing menu options gt E WHR Settings The menu toggles to the next two v DOWN Press 2 times to toggle menu listing ya menu options l Ee G N A The menu toggles to the next two V Press 1 tim le menu listin i DOWN ee menu ioung H Control Modes menu options oti G Anti Cycling The menu toggles to the next two Pr 1 tim nd listin i l H2 will flash ENTERRES Press 1 time to list parameters pe rotete A UP Press 1 time to select next parameter Basen PENE ENTER RES Press 1 time to show parameter value ee ne SIOP ASANI PRE Member 0001 value will appear UP H3 Cascade Addr Parameter will increase or decrease A or DOWN Press 1 time to change value Member 0002 depending on button pressed ENTER RES Press 1 time to save new value See ae me WL NaSh OG ENTERIRES Press 1 time to return to main menu Sti
40. lso listed on this website e Wear long sleeved loose fitting clothing gloves and eye protection M Apply enough water to the combustion chamber lining to prevent airborne dust Mi Remove the combustion chamber lining from the water heater and place it in a plastic bag for disposal HM Wash potentially contaminated clothes separately from other clothing Rinse clothes washer thoroughly NIOSH stated First Aid M Eye Irrigate immediately M Breathing Fresh air NOTICE R Service Manual When calling or writing about the water heater Please have the water heater model and serial number from the water heater rating plate Consider piping and installation when determining water heater location see the Armor 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 eTo avoid electric shock disconnect electrical supply before performing maintenance e 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 he
41. menu listing in Menu Mode e Press to toggle display during normal operation to show outlet and return temperatures fan speed and flame signal e Press to toggle between digits when entering access code or between hour minutes etc when entering date and time 1 Service Control inputs GAS PRESSURE SWITCH DHW THERMOSTAT FLOW SWITCH TANK SENSOR SEQUENCER BUILDING MANAGEMENT SYSTEM LOW WATER CUTOFF INLET TEMPERATURE SENSOR OUTLET TEMPERATURE SENSOR FLUE GAS SENSOR AIR PRESSURE SWITCH HIGH LIMIT SENSOR FLAME SENSOR BLOCKED DRAIN SWITCH DISPLAY PANEL La Ne PC INTERFACE 6 GRMOR Service Manual CONDENSING WATER HEATER LOW VOLTAGE CONNECTION BOARD SMART SYSTEM CONTROL BOARD GRMOR Service Manual CONDENSING WATER HEATER 1 Service continued Control outputs ALARM BELL LOW VOLTAGE CONNECTION BOARD 2 AUX DEVICE RELAY RUNTIME CONTACTS SEQUENCER BUILDING MANAGEMENT SYSTEM DHW PUMP IGNITER BLOWER SMART SYSTEM GAS VALVE CONTROL BOARD 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 re
42. n on the SMART SYSTEM display to reset Temp O Shoot is being called for Either the inlet water or outlet water temperature sensor has been disconnected Either the inlet water or outlet water temperature sensor has been shorted An optional remote proving switch is not making The flue temperature has exceeded the set parameters for the water heater lengths Refer to Section 3 General Venting of the Armor Water Heater Installation and Operation Manual for proper lengths Check for obstruction or blockage in the vent air intake pipes or at terminations Check the wiring connections at the fan and at the main control board Replace the fan Replace the main control board Check the sensors and their associated wiring Repair or replace the sensor or wiring if damaged Measure the resistance of the sensors and compare the resistance to the tables on page 23 of this manual Replace the sensor if necessary Check the sensors and their associated wiring Repair or replace the sensor or wiring if damaged Measure the resistance of the sensors and compare the resistance to the tables on page 23 of this manual Replace the sensor if necessary Check function of remote devices Check for loose or misplaced jumper if auxiliary proving switch is not installed Inspect the heat exchanger Reference page 20 of this manual for the procedure on how to clean the flue side of the heat exchanger Inspect the
43. or the 10 second postpurge cycle The water heater pump will continue to run for its pump delay time then turn off Water heater pump off 123 8F 129 Standby 123 8F 129 PREPURGE 123 9F 129 IGNITION 123 9F 129 POSTPURGE PREPURGE 123 9F 129 WHR 20 RATE 124 8F 129 POSTPURGE 127 4F 129 Standby 124 7F 129 1 Service Display panel menu access RMOR CONDENSING WATER HEATER Table 1B Use this procedure to access menus from the display panel Service Manual BUTTON OPERATION ENTER RES Press 1 time in normal operation E menuext Hold for 5 seconds display will change A UP Press 9 times to change last digit in readout to 9 lt Previous Press 2 times to move to the second digit A UP Press 3 times to change second digit in readout to 3 lt Previous Press 1 time to change to the first digit A UP Press 5 times to change first digit in readout to 5 DISPLAY Menu Code 0000 flashing Menu 0309 COMMENTS Water heater turns off this ensures uninterrupted programming Digit shown underlined at left will flash Digit shown underlined at left will flash Digit shown underlined at left will flash Digit shown underlined at left will flash Digit shown underlined at left will flash Digit shown underlined at left will flash If you enter
44. ous page Troubleshooting Chart Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION CORRECTIVE ACTION The unit has failed to prove main burner ignition after four 4 attempts e Inspect spark electrode and associated wiring for damage and connection Reference page 19 of this manual for removal and cleaning procedures Exception The 500 Model will lock out after Replace if necessary one 1 try for ignition It will require a 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 correctly 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 the ignition attempt If no voltage is present replace the main control board No Flame Ign will require a manual reset once the condition If 24 VAC is present at the main control board check has been corrected the wiring between the main control board and the gas valve Replace t
45. r if necessary Gas Valve Adjustment Refer to page 33 of this manual for the gas valve adjustment procedure 32 GRMOR Service Manual 3 Troubleshooting continued Gas valve adjustment procedure Eure 3 3 Gas Valve Adjustment Model 399 If adjustment of the gas valve is deemed necessary use the THROTTLE ADJUSTMENT following procedures Note The procedures below are SCREW model specific Models 150 285 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 32 of this manual to measure the combustion If combustion is still not within the specified range repeat the procedure This procedure SHOULD NOT be performed more than four 4 times If after four 4 adjustments and the combustion is still not within the specified range revisit the possible causes in Table 3F on page 32 or replace the gas valve Model 500 Figure 3 2 Gas Valve Adjustment Models 150 285 Locate the throttle adjustment screw on top of the gas valve see 7 pp FIG 3 4 Using a screwdriver turn the screw a 1 4 turn counterclockwise to increase CO levels or a 1 4 turn clockwise THROTTLE N to decrease CO levels After one adjustment on the valve follow ADJUSTMENT SCREW the Com
46. rol board if necessary e If 120 VAC is present on a call for heat and the water heater pump is not operating replace the pump e If the manual reset high limit has tripped check setting of the device e Check resistance of water sensors and compare to Table 3B on page 23 of this manual Replace sensor if necessary e Replace high limit 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 Fan Low is being called for 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 e Check for obstruction or blockage in the vent air 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 BI f e Replace fuse F4 on the control board see page 21 of pe this manual e Check the wiring connections to switch Wires should be connected to the common and normally closed terminals Air intake lengths exceed the maximum allowed lengths Refer to Section 3 General Venting of the Armor Water Heater Installation and Operation APS Manual for proper lengths Open will require a manual reset once the condition has been corrected Press e Check for obstruction or
47. s 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 I 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 I of this manual for adjustment procedures 2 Check settings of external limit controls if any and adjust if necessary Perform start up and checks I 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 is correct and that operating pressure does not go too high 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 Assembl
48. trol board di SO internal fault The main control board has detected Replace the main control board fed fol TET PPT internal fault The main control board has detected Replace the main control board NGM STK STAT internal fault 3 Troubleshooting Combustion Analysis Procedure Service Manual Table 3G Flue Products I 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 80 10 3 0 6 5 90 11 4 1 6 9 made at this point 3 Turn the main power on to the water heater by placing the 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 SHUTDOWN button on the display board see page 5 reset the control and return to Service Mode until WHR Standby appears in the display window Turn the main power off to the water heater and replace the 5 Locate the pinhole button above the R in the Armor logo flue temperature sensor into the flue pipe connection on the display board see page 5 Press the button once and hold for 5 seconds to place the water heater into Service Mode In Ser
49. vice Mode the water heater will fire at ignition speed and will then modulate up to full fire 10 Place the water heater back into normal operation A WARNING You must replace the flue gas temperature sensor to prevent flue gas spillage into the room Failure to comply could result in severe personal injury death or substantial property damage 6 Insert the probe from a combustion analyzer into the hole left by the removal of the flue temperature sensor 7 Once the water heater has modulated up to full fire measure the combustion The values should be in the range listed in Table 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 3F 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 e Refer to Section 7 Gas Connections of the Armor Water Heater Installation and Operation Gas Supply Pressure Manual for the proper gas supply for the Armor water heater e Refer to page 19 of this manual for burner removal and cleaning procedures Dirty Damaged Burner e Replace burne
50. y AIR GAS ARM W BURNER w s GASKET J SCREWS QTY 5 19 2 Maintenance 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 the proper shutdown procedure and to schedule an annual start up at the beginning of the next heating season Cleaning water heater heat exchanger 1 Shut down water heater Follow the To Turn Off Gas to Appliance instructions for the water heater in the Armor Water Heater 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 2 Allow time for the water heater to cool to room temperature if it has been firing 3 Remove the blower assembly gas air arm from the heat exchanger access cover Set bolts
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