AW-SER Rev E
Service Manual
Models: 150 - 500
Starting Serial #H07H10046464
This manual must only be used by a
ƽ WARNING
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.
Save this manual for future reference.
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Service Manual
Please read before proceeding
Installer
–
Read all instructions,
When calling or writing about the water heater –
Please have the water heater model and serial
number from the water heater rating plate.
ƽ WARNING
NOTICE
including this manual and the Armor
Water Heater Installation and Operation
Manual, before installing. Perform steps
in the order given.
Consider piping and installation when
determining water heater location (see the
Armor Water Heater Installation and Operation
Manual).
Have this water heater serviced/inspected
by a qualified service technician at least
annually.
Any claims for damage or shortage in shipment
must be filed immediately against the
transportation company by the consignee.
Failure to comply with the above could
result in severe personal injury, death or
substantial property damage.
When servicing water heater –
Handling ceramic fiber materials
• To avoid electric shock, disconnect
REMOVAL OF COMBUSTION CHAMBER LINING
electrical
maintenance.
supply
before
performing
The combustion chamber door insulation in this
ƽ WARNING
product contains ceramic fiber material. Ceramic fibers
• To avoid severe burns, allow the water
heater to cool before performing
maintenance.
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).”:
Water heater operation –
• Do not block flow of combustion or
ventilation air to the water heater.
ꢀ Avoid breathing dust and contact with skin
and eyes.
• Should overheating occur or gas supply
fail to shut off, do not turn off or
• Use NIOSH certified dust respirator (N95).
This type of respirator is based on the OSHA
requirements for cristobalite at the time this
disconnect
circulator.
supply at
appliance.
electrical
Instead, shut off the gas
location external to the
supply
to
a
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
NIOSH approved respirators, manufacturers, and
phone numbers are also listed on this website.
• 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
• Wear long-sleeved, loose fitting clothing, gloves,
and eye protection.
under water must be replaced.
ꢀ Apply enough water to the combustion chamber
lining to prevent airborne dust.
ꢀ Remove the combustion chamber lining from the
water heater and place it in a plastic bag for disposal.
ꢀ Wash potentially contaminated clothes separately
from other clothing.
thoroughly.
Rinse clothes washer
NIOSH stated First Aid.
ꢀ
ꢀ
Eye: Irrigate immediately.
Breathing: Fresh air.
3
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Service Manual
What is in this manual?
Service
Maintenance
• Service and maintenance schedules
• Address reported problems
Near water heater piping
• Inspect water heater area and water heater interior
• Clean condensate trap
• Typical system components
• Check all piping for leaks
• Check air openings
• Flue vent system and air piping
• Check water system
The Armor water heater display
• Display panel readout, buttons and their functions
Control module inputs
• Check expansion tank
• Control module inputs and options
• Check water heater relief valve
• Inspect ignition electrode
• Check ignition ground wiring
• Check all water heater wiring
• Check control settings
• Perform start-up and checks
• Check burner flame
• Check flame signal
Control module outputs
• Control module outputs and options
General
• How the water heater operates
• How the control module operates
• Access modes -- user and installer
• Sequence of operation -- Water Heating
• Check flue gas temperature
• General maintenance
• Review with owner
• Cleaning the water heater heat exchanger
• Oiled bearing circulators
Control panel menu access
• Accessing programming mode and locating menus
(See separate guide covering the PC interface.)
Troubleshooting
Control panel parameter access
• Troubleshooting table - No display
• Checking temperature sensors
• Sensor tables
• Accessing and changing parameters from the display panel
Quick start information -- parameter table
• An index of available adjustments and readouts, where to
access them and where to find detailed information.
• Troubleshooting table - Fault messages displayed on the
water heater interface
• Combustion analysis procedure
• Gas valve adjustment procedure
Armor water heater operation
• A: General
• C: Data Logging
• D: Functions
• E: WHR Settings
• H: Control Modes
• I: Circulation Pumps
• J: Service Notification
4
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Service Manual
1 Service
The Armor water heater display
5
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Service Manual
1 Service
Control inputs
GAS PRESSURE SWITCH
DHW THERMOSTAT
LOW VOLTAGE
CONNECTION
BOARD
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
SMART SYSTEM
CONTROL BOARD
PC INTERFACE
6
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Service Manual
1 Service
(continued)
Control outputs
ALARM BELL
AUX. DEVICE RELAY
RUNTIME CONTACTS
LOW VOLTAGE
CONNECTION
BOARD
SEQUENCER / BUILDING
MANAGEMENT SYSTEM
DHW PUMP
IGNITER
BLOWER
SMART SYSTEM
GAS VALVE
CONTROL BOARD
DISPLAY PANEL
PC INTERFACE
7
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Service Manual
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.
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.
8
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Service Manual
1 Service
(continued)
Sequence of operation
Table 1A Sequence of operation
OPERATION
DISPLAY
W
H
R
:
:
S
t
a
n
d
b
y
(
1. Upon a call for heat, the control turns on the water heater pump.
O
U
T
1
2
3
.
8
F
1
2
9
)
2. The control connects 120 VAC to the blower. The blower does not
run at this time.
• If the unit is equipped with a flow switch, it must close before the
control powers up the blower.
• The manual reset high limit must be closed before the control
powers up the blower.
• If the unit is equipped with a solenoid valve and/or a vent
valve, they will be energized along with the blower.
W
H
R
:
:
S
t
a
n
d
b
y
(
O
U
T
1
2
3
.
8
F
1
2
9
)
• If the unit is equipped with a gas pressure switch, it must close
at this time.
• If 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.
W
H
R
:
:
P
R
E
P
U
R
G
E
3. The control then starts a 10 second prepurge cycle.
O
U
T
1
2
3
.
9
F
(
1
2
9
)
4. 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.
W
H
R
:
:
I
G
N
I
T
I
O
N
1
O
U
T
1
2
3
.
9
F
(
2
9
)
5. 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.
W
H
R
:
:
P
O
S
T
P
U
R
G
E
,
9
P
R
E
P
U
R
G
E
O
U
T
1
2
3
.
9
F
(
1
2
)
6. 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.
W
H
R
:
:
W
H
R
4
2
0
%
R
A
T
E
O
U
T
1
2
.
8
F
(
1
2
9
)
7. Once the call for heat is satisfied, the control will turn off the burner.
The blower will remain on for the 10 second postpurge cycle. The
water heater pump will continue to run for its pump delay time,
then turn off.
W
H
R
:
P
O
S
T
P
U
R
G
E
O
U
T
:
1
2
7
.
4
F
(
1
2
9
)
)
W
H
R
:
S
t
a
n
d
b
y
8. Water heater pump off.
O
U
T
:
1
2
4
.
7
F
(
1
2
9
9
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Service Manual
1 Service
Display panel menu access
Table 1B Use this procedure to access menus from the display panel
BUTTON
OPERATION
DISPLAY
WHR:OFF
COMMENTS
Water heater turns off (this ensures
uninterrupted programming)
ENTER/
R
ES
Press 1 time in normal operation
OUT:125˚F
Digit shown underlined at left will
flash
Enter Menu Code:
MENU/
EXI
T
Hold for 5 seconds -- display will change
flashing
0000
Press 9 times to change last digit
in readout to "9"
Digit shown underlined at left will
flash
Enter Menu Code:
0009
UP
Press 2 times to move to the second
digit
Digit shown underlined at left will
flash
Enter Menu Code:
0009
P
R
E
V
I
O
U
S
S
Press 3 times to change second digit
in readout to "3"
Enter Menu Code:
0309
Digit shown underlined at left will
flash
U
P
Press 1 time to change to the first
digit
Enter Menu Code:
0309
Digit shown underlined at left will
flash
PR
EVIO
U
Enter Menu Code:
5309
Digit shown underlined at left will
flash
Press 5 times to change first digit
in readout to "5"
UP
If you enter 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.
The words, "INSTALLER CODE"
will flash while displayed
Enter Menu Code:
INSTALLER CODE
ENTER/RES
Press to enter the code
>A General
B N/A
After 2 seconds, display shows menus
(press ENTER/RESET to select a menu)
The caret symbol, ">" 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.
The menu toggles to the next two
menu options
>C Data Log
D Functions
Press 1 time to toggle menu listing
Press 2 times to toggle menu listing
Press 1 time to toggle menu listing
Press 2 times to toggle menu listing
DOWN
DOWN
DOWN
DOWN
The menu toggles to the next two
menu options
>E WHR Settings
F N/A
The menu toggles to the next two
menu options
>G Anti-cycling
H Control Modes
The menu toggles to the next two
menu options
>I Circ. Pumps
J Service Noti.
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
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Service Manual
1 Service
(continued)
Display 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.
>A General
B N/A
The caret symbol, ">" highlights
the selectable line
Beginning of menu listings.
-
The menu toggles to the next two
menu options
>C Data Log
D Functions
Press 1 time to toggle menu listing
Press 2 times to toggle menu listing
Press 1 time to toggle menu listing
Press 1 time to select second listing
D
D
D
D
O
W
W
W
W
N
N
N
N
R
The menu toggles to the next two
menu options
>E WHR Settings
F N/A
O
O
O
The menu toggles to the next two
menu options
>G N/A
H Control Modes
The menu toggles to the next two
menu options
G Anti-Cycling
>H Control Modes
H2
H3
H2
will flash
H2 Contrl Source
E
NTE
R
/
ES
Press 1 time to list parameters
will flash
H3 Cascade Addr
Press 1 time to select next parameter
Press 1 time to show parameter value
U
P
Cascade Addr
H3
will stop flashing; parameter
value will appear
E
NT
ER
/
R
ES
Member 0001
Cascade Addr
U
P
H3
Parameter will increase or decrease,
depending on button pressed
Press 1 time to change value
(or
D
O
WN)
Member 0002
H3 Cascade Addr
H
3
will flash
Press 1 time to save new value
Press 1 time to return to main menu
E
N
T
T
T
E
R
/
/
/
R
R
R
ES
>A General
B N/A
E
N
N
E
R
R
E
S
S
This display example assumes
a call for water heating is present
Press 1 time to return to normal
operation
WHR:Pre-Purge
OUT:123.7˚F
E
E
E
11
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Service Manual
1 Service
Parameter table
Table 1D This table lists SMART SYSTEM control module parameters and where to access them
USER ACCESS
DISPLAY MODIFY
INSTALLER ACCESS
SEE
PAGE
MENU
SUB ITEM
DESCRIPTION
DISPLAY
MODIFY
1
2
3
4
5
6
7
Boiler Model
13
13
13
13
13
13
13
Yes
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
Yes
No
User Code
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
Date and Time
Software Version
Temperature Units
Night Setback Temperature
Night Setback Times
A
Yes
Yes
Yes
Yes
Yes
Yes
1
2
3
Total Hrs. Run
13
13
13
Yes
Yes
Yes
No
No
No
Yes
Yes
Yes
No
No
No
Ignition Attempts
Show Last 10 Errors
C
1
2
Reset Last 10 Errors
Service Mode Delay
13
13
No
No
No
No
Yes
Yes
Yes
Yes
D
E
3
Tank Set Point
14
Yes
Yes
Yes
Yes
Control Source (Thermostat, BMS,
and Cascade)
2
3
4
5
6
14
14
14
14
14
No
No
No
No
No
No
No
No
No
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Cascade Address
Max. Cascade Set Point - Not Used
H
Cascade Offset - Not Used
Cascade Off-On Differential - Not
Used
3
WHR Pump Delay
15
No
No
Yes
Yes
I
1
2
3
4
Service Notification in Month
Service Notification Running Hours
Service Notification Cycles
15
15
15
15
No
No
No
No
No
No
No
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
J
Reset Service Notification Counter
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.
NOTICE
12
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Service Manual
1 Service
(continued)
Viewable and changeable control parameters
Before changing parameters, note the
settings so that the unit can be returned to
its original operating parameters.
Night setback temperature
CAUTION
Once the 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.
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 A1 has been accessed. This
parameter is not changeable.
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.
User code
The User Code allows the user to access and change a limited
number of control parameters. The access code can be
changed by the user or the installer to a code of their
choosing. 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.
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).
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.
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 C1.
The internal clock does not adjust for
NOTICE
Daylight Savings Time and therefore,
will require a manual adjustment.
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.
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.
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.
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.
13
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Service Manual
1 Service
D: Functions
H: Control modes
Control source
Reset last 10 errors
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:
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.
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.
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.
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.
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 value is 180°F.
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 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.
F: Not used
G: Not used
Max. cascade set point - Not used
Cascade offset - Not used
Cascade off-on differential - Not used
14
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Service Manual
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 due 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.
15
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Service Manual
2 Maintenance
Maintenance and annual startup
Table 2A Service and Maintenance Schedules
Service technician
Owner maintenance
(see the following pages for instructions)
General:
• Check water heater area
• Address reported problems
• Check pressure/temperature
gauge
• Inspect interior; clean and vacuum if
necessary;
Daily
• Clean condensate trap and fill with fresh
water
• Check for leaks (water, gas, flue,
condensate)
• Verify flue and air lines in good condition
and sealed tight
• Check system water pressure/system
piping/expansion tank
• Check control settings
• Check ignition and flame sense electrodes
(sand
off
any
deposits;
clean
• Check vent piping
• Check air piping
and reposition)
• Check wiring and connections
• Perform start-up checkout
Monthly
and
performance verification per Section 10
in the Armor Installation and Operation
Manual.
• Check air and vent termination
screens
• Check relief valve
• Flame inspection (stable, uniform)
• Flame signal (at least 10 microamps at
high fire)
• Check condensate drain system
• Check automatic air vents
• Clean the heat exchanger if flue
temperature is more than 54°F above
return water temperature.
If combustion or performance
indicate need:
Every
6 months
• Clean heat exchanger
• Check water heater piping (gas
and water) for leaks
• Remove and clean burner using
compressed air only
• Operate relief valve
• Clean the blower wheel
16
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Service Manual
2 Maintenance
(continued)
Follow the service and maintenance procedures given throughout this manual and in component literature
shipped with the water heater. Failure to perform the service and maintenance could result in damage to
the water heater or system. Failure to follow the directions in this manual and component literature could
result in severe personal injury, death, or substantial property damage.
ƽ 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.
ƽ WARNING
Electrical shock hazard – Turn off power to the water heater before any service operation on the water heater
except as noted otherwise in this instruction manual. Failure to turn off electrical power could result in
electrical shock, causing severe personal injury or death.
ƽ WARNING
Address reported problems
Figure 2-1 Condensate Trap
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.
The condensate trap must be filled with
ƽ WARNING
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.
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.
Check all piping for leaks
Eliminate all system or water heater leaks.
ƽ WARNING
Leaking water may cause severe property
damage.
2. Remove the PVC cap retaining screw from the PVC cap
(FIG. 2-1).
1. Inspect all water and gas piping and verify to be leak free.
3. Remove the 2 inch PVC cap with the switch located at
the top of the trap (FIG. 2-1).
2. Look for signs of leaking lines and correct any problems
found.
4. Remove any sediment in the trap.
3. Check gas line using the procedure found in Section 7 - Gas
Connections of the Armor Water Heater Installation and
Operation Manual.
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.
17
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Service Manual
2 Maintenance
Safety relief valves should be re-inspected AT
LEAST ONCE EVERY THREE YEARS, by a
licensed plumbing contractor or authorized
inspection agency, to ensure that the product
has not been affected by corrosive water
conditions and to ensure that the valve and
discharge line have not been altered or
tampered with illegally. Certain naturally
occurring conditions may corrode the valve
or its components over time, rendering the
valve inoperative. Such conditions are not
detectable unless the valve and its
components are physically removed and
inspected. This inspection must only be
conducted by a plumbing contractor or
authorized inspection agency – not by the
owner. Failure to re-inspect the water heater
relief valve as directed could result in unsafe
pressure buildup, which can result in severe
personal injury, death, or substantial
property damage.
Flue vent system and air piping
ƽ WARNING
1. Visually inspect the entire flue gas venting system and air
piping for blockage, deterioration or leakage. Repair any
joints that show signs of leakage. Verify that air inlet pipe is
connected and properly sealed.
2. Verify that water heater vent discharge and air intake are
clean and free of obstructions.
Failure to inspect for the above conditions
and have them repaired can result in severe
personal injury or death.
ƽ WARNING
Check water system
1. Verify all system components are correctly installed and
operational.
2. Check the cold fill pressure for the system. Verify it is
correct (must be a minimum of 12 PSI).
3. Watch the system pressure as the water heater heats up
(during testing) to ensure pressure does not rise too high.
Excessive pressure rise indicates expansion tank sizing or
performance problem.
Following installation, the valve lever must
be operated AT LEAST ONCE A YEAR to
ensure that waterways are clear. Certain
naturally occurring mineral deposits may
adhere to the valve, rendering it inoperative.
When manually operating the lever, water
will discharge and precautions must be taken
to avoid contact with hot water and to avoid
water damage. Before operating lever, check
to see that a discharge line is connected to
this valve directing the flow of hot water
from the valve to a proper place of disposal.
Otherwise severe personal injury may result.
If no water flows, valve is inoperative. Shut
down the water heater until a new relief valve
has been installed.
ƽ WARNING
4. Inspect automatic air vents and air separators. Remove air
vent caps and briefly push valve to flush vent. Replace caps.
Make sure vents do not leak. Replace any leaking vents.
Check expansion tank
1. Expansion tanks provide space for water to move in and out
as the heating system water expands due to temperature
increase or contracts as the water cools. Tanks may be open,
closed or diaphragm or bladder type. See Section 6 - System
Piping of the Armor Water Heater Installation and
Operation Manual for suggested best location of expansion
tanks and air eliminators.
2. After following the above warning directions, if the relief
valve weeps or will not seat properly, replace the relief valve.
Ensure that the reason for relief valve weeping is the valve
and not over-pressurization of the system due to expansion
tank waterlogging or undersizing.
Check water heater relief valve
1. Inspect the relief valve and lift the lever to verify flow.
Before operating any relief valve, ensure that it is piped with
its discharge in a safe area to avoid severe scald potential.
Read Section 6 - System Piping of the Armor Water Heater
Installation and Operation Manual before proceeding
further.
18
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Service Manual
2 Maintenance
(continued)
Inspect ignition and flame sense Check burner flame
electrodes
1. Inspect flame through observation window.
1. Remove the ignition and flame sense electrodes from
the water heater heat exchanger access cover.
2. If the flame is unsatisfactory at either high fire or low fire,
turn off water heater and allow water heater to cool down.
Remove the burner and clean it thoroughly using a vacuum
cleaner or compressed air. Do not use compressed air to
clean burner if performed inside a building.
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. Remove the burner, reference FIG. 2-2 below.
3. Replace ignition/flame sense electrode, making sure
gasket is in good condition and correctly positioned.
4. When replacing the burner, ensure gasket is in good
condition and positioned correctly (FIG. 2-2).
Check ignition ground wiring
Figure 2-2 Burner Assembly
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 is correct and that operating
pressure does not go too high.
19
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Service Manual
2 Maintenance
Check flame signal
1. At high fire the flame signal shown on the display should be 5. Remove the heat exchanger access cover, cover gasket(s) and
at least 10 microamps.
chamber insulation assembly.
The water heater contains ceramic fiber
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.
ƽ WARNING
materials. Use care when handling these
materials per instructions on page 3 of this
manual. Failure to comply could result in
severe personal injury.
6. Use a vacuum cleaner to remove any accumulation on the
water heater heating surfaces. Do not use any solvent.
3. See Section 3 - Troubleshooting in this manual for other
procedures to deal with low flame signal.
7. Finish cleaning using a clean cloth dampened with warm
water.
Review with owner
1. Emphasize the need to perform the maintenance schedule
specified in this manual.
8. Install access cover gasket, chamber insulation assembly and
cover.
2. Remind the owner of the need to call a licensed contractor
should the water heater or system exhibit any unusual
behavior.
9. Secure nuts on the studs. DO NOT overtighten.
10. Re-install the blower assembly (gas air/arm) using the bolts
set aside in Step 3.
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.
11. Close isolation valves on piping to isolate water heater from
system. Attach a hose to the water heater drain and flush
water heater thoroughly with clean water by using purging
valves to allow water to flow through the water make-up line
to the water heater.
Cleaning
water
heater
heat
exchanger
12. When the water heater has been flushed, restore water
heater to operation.
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.
13. Perform start-up and check-out procedures 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.
Oiled bearing circulators
1. The circulator shipped with the Armor water heater is water-
lubricated. No oiling is required.
2. Allow time for the water heater to cool to room temperature
if it has been firing.
2. Check other circulators in the system. Oil any circulators
requiring oil, following circulator manufacturer’s
instructions. Over-oiling will damage the circulator.
3. Remove the blower assembly (gas air/arm) from the heat
exchanger access cover. Set bolts aside.
4. Remove the nuts securing the heat exchanger access cover to
the heat exchanger and set aside.
20
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Service Manual
3 Troubleshooting
Label all wires prior to disconnection
Check control module fuses
ƽ WARNING
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.
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.
NOTICE
1. Turn OFF power to the water heater at the external line
switch.
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.
ƽ WARNING
2. Remove top access cover.
3. Remove the control module cover.
4. Inspect fuses F2, F3, F4, and F5, see FIG 3-1 below.
Figure 3-1 Control Module Fuses
Before troubleshooting:
1. Have the following items:
a. Voltmeter that can check 120 VAC, 24 VAC, and
12 VDC.
F3 - 1.25 AMP FUSE
MAIN BOARD
b. Continuity checker.
c. Contact thermometer.
F4 - 3.15 AMP FUSE
GAS VALVE
2. Check for 120 VAC (minimum 102 VAC to maximum
132 VAC) to water heater.
F5 - 5 AMP FUSE
PUMPS
3. Make sure thermostat is calling for heat and contacts
(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:
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
plastic bag attached to the control module cover.
2. Gas pressures:
• Maximum: 14 inches w.c. (natural and LP) with no
flow (lockup) or with water heater on
• Minimum: 4 inches w.c. (natural), 8 inches w.c. (LP)
with gas flowing (verify during water heater startup)
6. If necessary, replace open fuse (F3 is 1.25 amps, F2 and F4
are 3.15 amps, and F5 is 5 amps).
Note: Fuses F2 - F5 are all slow blow fuses.
Do not jumper fuse or replace with any fuse
ƽ WARNING
except as specified. Failure to comply could
result in severe personal injury, death, or
substantial 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.
21
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Service Manual
3 Troubleshooting
Table 3A Troubleshooting Chart - No Display
FAULT
CAUSE
CORRECTIVE ACTION
- No 120 VAC supplied to unit.
• Check external line switch, fuse, or breaker.
• Check position of ON/OFF switch. Turn switch to the
ON position.
• Check 120 VAC through the ON/OFF switch.
• Check wiring harness connection between display
board
and
main
control
board.
Connect
harness at both points.
No Display
- No voltage through the switch.
- Bad display board.
• Replace switch.
• Replace board.
- Bad main control board.
- Blown fuse.
• Replace the main control board.
• Replace fuse F3 on the main control board, see
page 21 of this manual.
- Main control board temperature set point • Review temperature setting.
satisfied.
No Burner
Operation
- Remote thermostat satisfied.
- Unit locked out on fault.
• Review remote thermostat setting.
• Consult display for specific fault. Refer to fault
descriptions on page 25 of this manual for corrective
actions.
• Check BMS parameter settings. Optional PC software
required.
- Water heater controlled by BMS.
- Flue sensor open.
• Verify that the flue sensor is located in the flue outlet.
• Check wiring connections at the flue sensor.
Unit Does Not
Modulate Above
50%
• Check the resistance of the flue sensor and compare
to Table 3C on page 23 of this manual.
22
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Service Manual
3 Troubleshooting
(continued)
Checking temperature sensors
The water heater temperature sensors (inlet water, outlet water, system water, and flue) are all resistance type devices. The
following tables show the correct values for the sensors at various temperatures. Use an ohmmeter to read the resistance of the
sensor at a known temperature. If the resistance of the sensor does not closely match its corresponding table, replace the sensor.
Table 3B - Inlet/Outlet System Sensor Resistance vs. Temperature
Temperature °F
Resistance Ω
Temperature °F
Resistance Ω
50
68
18,780
12,263
8,194
5,592
3,893
2,760
158
176
194
212
--
1,990
1,458
1,084
817
--
86
104
122
140
--
--
Table 3C - Flue Temperature Sensor Resistance vs. Temperature
Temperature °F
Resistance Ω
Temperature °F
Resistance Ω
68
14,773
9,804
6,652
4,607
3,252
2,337
176
194
212
230
248
--
1,707
1,266
952
726
560
--
86
104
122
140
158
23
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Service Manual
3 Troubleshooting
Table 3D Troubleshooting Chart - Noisy System
FAULT
CAUSE
CORRECTIVE ACTION
- Supply gas problem. Natural gas pressures
should be between 4 inches w.c. and • Refer to Section 7 - Gas Connections of the Armor
14 inches w.c. LP gas pressures should Water Heater Installation and Operation Manual for
be
between
8
inches
w.c.
and detailed information concerning the gas supply.
14 inches w.c.
• 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
maximum listed in the General Venting section of the
Armor Water Heater Installation and Operation Manual.
- Gas/air mixture problem.
- Dirty/damaged burner.
Noisy
Operation
• Refer to page 19 in this manual for the burner removal
and inspection procedure. Clean or replace the burner
as necessary.
• Refer to Section 6 - System Piping of the Armor Water
Heater Installation and Operation Manual for minimum
flow rates.
- Low water flow through the heat exchanger.
- Air in the piping system.
• Properly purge all air from the piping system.
• Verify system pressure is a minimum of 12 PSI.
- Low system water pressure.
• Replace fuse F5 on the control board, see page 21 of
this manual.
- Blown fuse.
- Faulty pump.
• Replace pump.
No Pump
Operation
- Faulty pump relay.
• Replace pump relay.
• Replace main control board.
- Internal fault on control board.
Relief Valve
Opening
- System pressure exceeds relief valve • Lower the system pressure below the 150 PSI rating of
setting.
the supplied relief valve.
• 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.
• Check for obstruction or blockage in the air
intake pipes or at terminations.
• Check reference hoses connected to the air pressure
switch for blockage or obstruction.
• Inspect the burner. Reference page 19 of this manual
for removal and cleaning procedures. Replace if
necessary.
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.
• Inspect the heat exchanger. Reference page 20 of this
manual for removal and cleaning procedures. Replace
if necessary.
• Faulty air pressure switch. Replace switch.
24
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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
switch or the manual reset high gas pressure
switch tripped.
• Reset the pressure switches.
• Measure the supply gas pressure to determine cause
of failure. Natural gas pressures should be between
4 - 14 inches w.c.
Gas Pressure SW
(will require a manual
reset once the condition
has been corrected.
Press the RESET button
on the SMART SYSTEM
display to reset.)
• Refer to Section 7 - Gas Connections of the Armor
Water Heater Installation and Operation Manual for
detailed information concerning the gas supply.
• Correct the supply gas pressure if necessary.
• Check for a loose or misplaced jumper if pressure
switches are not installed.
The flow switch is not making.
• Check water heater pump operation on a call for heat.
• Check for closed valves or obstructions in the water
heater piping.
Flow Switch
(will require a manual
reset once condition has
been corrected. Press
the RESET button on
the SMART SYSTEM
display to reset.)
• Verify system is full of water and all air has been
purged from the system.
• Check for loose or misplaced jumpers if flow switch is
not installed.
Blown fuse.
• Replace fuse F2 on the control board, see page 21 of
this manual.
The blocked drain switch has detected • Check condensate tube from unit to floor drain for
Blocked Drain SW excessive condensate build up inside the
proper installation and obstructions.
unit.
(will require a manual
reset once condition has
been corrected. Press
the RESET button on
the SMART SYSTEM
display to reset.)
• Inspect condensate trap for blockage. Clean if
necessary.
• Check for loose wiring connection at wire harness
plug.
• Bad blocked drain switch. Replace switch.
The flame detector circuit is seeing a flame
signal while no flame is present.
• Check supply voltage for proper polarity.
• Check external wiring for voltage feedback.
• Check the flame rod and make sure it is clean.
• Check the internal wiring for bad connections.
• Replace main control board.
Flame
Sequence
(will require a manual
reset once the condition
has been corrected.
Press the RESET button
on the SMART SYSTEM
display to reset.)
The main control board did not detect the gas
valve.
• Check wiring harness connection at the gas valve and
at the main control board.
GV/Relay
Fail
(will require a manual
reset once the condition
has been corrected.
Press the RESET button
on the SMART SYSTEM
display to reset.)
• Replace the gas valve wire harness.
• Replace the gas valve.
• Replace the main control board.
25
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Service Manual
3 Troubleshooting
Table 3E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface
FAULT
DESCRIPTION
CORRECTIVE ACTION
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 19 of this
manual for removal and cleaning procedures.
Replace if necessary.
Exception: The 500 Model will lock out after
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
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 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.
• Replace the main control board.
26
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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 • Inspect spark electrode and associated wiring for
signal. This condition occurred four (4)
straight times.
damage and connection. Reference page 19 of this
manual for removal and cleaning procedures. Replace
if 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
has been corrected.
Press the RESET button
on the SMART
• 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.
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.
• Replace the main control board.
27
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Service Manual
3 Troubleshooting
Table 3E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface
FAULT
DESCRIPTION
CORRECTIVE ACTION
• 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.
Manual Reset
High Limit
• 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.
(will require a manual
reset once the condition
has been corrected. Press
the RESET button on the
SMART SYSTEM display
to reset.)
The outlet water temperature has exceeded
the fixed setting of the manual reset high
limit.
• 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.
• If the manual reset high limit has tripped, check
setting of the device.
• Check resistance of water sensors and compare to
Table 3B on page 23 of this manual. Replace sensor
if necessary.
• Replace high limit.
• 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.
Fan Low
OR
• Check for obstruction or blockage in the vent/air
intake pipes or at terminations.
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.)
• Check the wiring connections at the fan and at the
main control board.
• Replace the fan.
• Replace the main control board.
• Replace fuse F4 on the control board, see page 21 of
this manual.
Blown fuse.
• 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.
APS
Open
• Check for obstruction or blockage in the air intake
pipes or at terminations.
(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.
• Check reference hoses connected to the air pressure
switch for blockage or obstruction.
• Inspect the burner. Reference page 19 of this manual
for removal and cleaning procedures. Replace if
necessary.
• Inspect the heat exchanger. Reference page 20 of
this manual for removal and cleaning procedures.
Replace if necessary.
• Faulty air pressure switch. Replace switch.
28
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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 actual fan RPM is 30% higher than what
is being called for.
• 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.
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.)
• 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.
Either the inlet water or outlet water • Check the sensors and their associated wiring.
Sensor Open
(will require a manual
reset once the condition
has been corrected. Press
the RESET button on the
SMART SYSTEM display
to reset.)
temperature sensor has been disconnected.
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.
Either the inlet water or outlet water • Check the sensors and their associated wiring.
Sensor Shorted
(will require a manual
reset once the condition
has been corrected. Press
the RESET button on the
SMART SYSTEM display
to reset.)
temperature sensor has been shorted.
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.
Aux. Proving
(will require a manual
reset once the condition
has been corrected. Press
the RESET button on the
SMART SYSTEM display
to reset.)
An optional remote proving switch is not • Check function of remote devices.
making.
• Check for loose or misplaced jumper if auxiliary
proving switch is not installed.
The flue temperature has exceeded the set • Inspect the heat exchanger. Reference page 20 of
parameters for the water heater.
this manual for the procedure on how to clean the flue
side of the heat exchanger.
• Inspect the flue sensor and associated wiring.
Measure the resistance of the flue sensor and
compare to Table 3C on page 23 of this manual.
Replace the sensor if necessary.
Temp O/Shoot
• Verify that the vent/air intake pipes are properly
installed and that there are no obstructions.
• Replace the main control board.
29
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Service Manual
3 Troubleshooting
Table 3E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface
FAULT
DESCRIPTION
CORRECTIVE ACTION
• 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.
• 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
Section 6 - System Piping of the Armor Water Heater
Installation and Operation Manual for water heater
pump specifications.
Temp O/Shoot
(continued)
• Verify that the system is full of water and that all air
has been properly purged from the system.
Outlet water temperature has exceeded the
maximum outlet water temperature.
• 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.
• Check the wiring between the external control and the
unit.
Rem Ctrl Flt
• Replace the control.
Parameters
Progr
After downloading parameters from a laptop,
the main control board must be reset.
• Press the ENTER/RESET button on the SMART
SYSTEM display panel.
(will require a manual
reset once the condition
has been corrected. Press
the RESET button on the
SMART SYSTEM display
to reset.)
30
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Service Manual
3 Troubleshooting
(continued)
Table 3E (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface
FAULT
DESCRIPTION
CORRECTIVE ACTION
While the unit is in Service Mode, the outlet • 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
water heater.
Service Blk
• 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
dropped below 80 VAC.
• Check 120 VAC supply to the transformer.
• Check wiring connections at the low voltage terminal
strip.
Low 24 VAC
• Check the wire size/length to remote devices.
• Replace the transformer.
The main control board has detected an
internal fault.
• Replace the main control board.
Watch Dog Error
Write EEProm
The main control board has detected an
internal fault.
• Replace the main control board.
The main control board has detected an • Replace the main control board.
internal fault.
CRC Parameters
No Error Stored
The main control board has detected an • Replace the main control board.
internal fault.
31
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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.
Natural Gas
Propane
CO2 O2
CO2
O2
2. Remove the flue temperature sensor from the flue pipe
connection. Note: Combustion measurements will be
made at this point.
8.0% - 10%
3.0% - 6.5%
9.0% - 11%
4.1% - 6.9%
8. Once the combustion analysis is complete, test the safety
shutoff device by turning the manual shutoff valve to the
OFF position and ensuring that the water heater shuts down
and registers an alarm. Open the manual shutoff valve,
reset the control, and return to Service Mode.
3. Turn the main power on to the water heater by placing the
“On/Off” switch in the ON position.
4. Place the water heater into the active position by pressing
the SHUTDOWN button on the display board (see page 5)
until
W
H
R
:
S
t
a
n
d
b
y
a
p
p
e
a
r
s
i
n
t
h
e
d
i
s
p
l
a
y
w
i
n
d
o
w
.
9. Turn the main power off to the water heater and replace the
flue temperature sensor into the flue pipe connection.
5. Locate the pinhole button above the “R” in the Armor logo
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 Service 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.
You must replace the flue gas temperature
ƽ WARNING
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
• Refer to Section 3 - General Venting of the Armor Water Heater Installation and Operation
Manual for the proper venting and air intake methods for the Armor water heater.
Vent/Air Intake Length
or Obstruction
• Check for obstructions at the vent/air intake terminals.
• Refer to Section 7 - Gas Connections of the Armor Water Heater Installation and Operation
Manual for the proper gas supply for the Armor water heater.
Gas Supply Pressure
Dirty/Damaged Burner
• Refer to page 19 of this manual for burner removal and cleaning procedures.
• Replace burner if necessary.
• Refer to page 33 of this manual for the gas valve adjustment procedure.
Gas Valve Adjustment
32
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Service Manual
3 Troubleshooting
(continued)
Gas valve adjustment procedure
Figure 3-3 Gas Valve Adjustment: Model 399
If adjustment of the gas valve is deemed necessary, use the
following procedures: (Note: The procedures below are
model specific.)
THROTTLE ADJUSTMENT
SCREW
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 CO2 levels or a 1/4 turn
counterclockwise to increase CO2 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
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 CO2 levels or a 1/4 turn clockwise
Figure 3-2 Gas Valve Adjustment: Models 150 - 285
to decrease CO2 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.
Figure 3-4 Gas Valve Adjustment: Model 500
Model 399
Locate the throttle adjustment screw on the top of the gas
valve, see FIG. 3-3. Using a screwdriver, turn the screw 1/8
turn counterclockwise to increase CO2 levels or 1/8 turn
clockwise to decrease CO2 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.
33
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NOTES
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NOTES
35
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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 #C02545) reflects the addition of references
to periodic cleaning of screens in vent terminations and safety
shutoff testing and instructions.
Revision E (ECO #C02738) reflects the addition of the Gas
Valve Adjustment Procedure for a 399 model on page 33.
AW-SER Rev E
1/09
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