Lochinvar Water Heater 151 801 User Manual
AWII-SER Rev A  
Service Manual  
Models: 151 - 801  
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  
REMOVAL OF COMBUSTION CHAMBER LINING  
• To avoid electric shock, disconnect  
electrical  
supply  
before  
performing  
maintenance.  
The combustion chamber insulation in this appliance  
ƽ WARNING  
contains ceramic fiber material. Ceramic fibers can be  
• To avoid severe burns, allow the water  
heater to cool before performing  
maintenance.  
converted to cristobalite in very high temperature  
applications. The International Agency for Research on  
Cancer (IARC) has concluded, “Crystalline silica in the  
form of quartz or cristobalite from occupational sources  
is carcinogenic to humans (Group 1).” Normal  
operating temperatures in this appliance are below the  
level to convert ceramic fibers to cristobalite. Abnormal  
operating conditions would have to be created to  
convert the ceramic fibers in this appliance to  
cristobalite.  
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  
circulator.  
supply at  
appliance.  
electrical  
Instead, shut off the gas  
location external to the  
supply  
to  
The ceramic fiber material used in this appliance is an  
irritant; when handling or replacing the ceramic  
materials it is advisable that the installer follow these  
safety guidelines.  
a
¢ Avoid breathing dust and contact with skin  
• Do not use this water heater if any part  
has been under water. The possible  
and eyes.  
damage to a flooded appliance can be  
extensive and present numerous safety  
• Use NIOSH certified dust respirator (N95).  
This type of respirator is based on the OSHA  
requirements for cristobalite at the time this  
hazards.  
Any appliance that has been  
under water must be replaced.  
document was written.  
Other types of  
respirators may be needed depending on the job  
site conditions. Current NIOSH recommendations  
can be found on the NIOSH website at  
http://www.cdc.gov/niosh/homepage.html.  
NIOSH approved respirators, manufacturers, and  
phone numbers are also listed on this website.  
• Wear long-sleeved, loose fitting clothing, gloves,  
and eye protection.  
¢ 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  
The Armor water heater display  
• Inspect water heater area and water heater interior  
• Clean condensate trap  
• Display panel readout, buttons and their functions  
• Check all piping for leaks  
• Check air openings  
• Flue vent system and air piping  
• Check water system  
• Check water heater relief valve  
• Inspect ignition electrode  
• Check ignition ground wiring  
• Check all water heater wiring  
• Check control settings  
Control module inputs  
• Control module inputs and options  
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  
• Perform start-up and checks  
• Check burner flame  
• Check flame signal  
• 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.)  
Control panel parameter access  
• Accessing and changing parameters from the display panel  
Troubleshooting  
• Troubleshooting table - No display  
• Checking temperature sensors  
• Sensor tables  
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  
• B: Data Logging  
• C: Functions  
• D: DHW Settings  
• E: Anti-Cycling  
• F: Control Modes  
• G: Circulation Pumps  
• H: BMS  
• I: Service Notification  
4
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1 Service  
The Armor water heater display  
NAVIGATION DIAL  
(PRESS OR TURN)  
RESET KEY  
RIGHT SELECT KEY  
(SOFT KEY)  
LEFT SELECT KEY  
(SOFT KEY)  
The information on the bottom of the display shows the functions of the two SELECT keys (on either corner), and the  
NAVIGATION dial (in the center):  
MENU = Left SELECT Key  
SETPOINTS = NAVIGATION Dial - Pressing Down  
SHDN = Right SELECT Key  
5
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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  
LOUVER PROVING SWITCH  
FLAME SENSOR  
BLOCKED DRAIN SWITCH  
DISPLAY PANEL  
SMART SYSTEM  
CONTROL BOARD  
PC INTERFACE  
6
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1 Service  
(continued)  
Control outputs  
ALARM BELL  
LOW VOLTAGE  
CONNECTION  
BOARD  
LOUVER RELAY  
RUN TIME CONTACTS  
SEQUENCER / BUILDING  
MANAGEMENT SYSTEM  
BUILDING RECIRCULATION  
PUMP  
WATER HEATER PUMP  
IGNITOR  
BLOWER  
SMART SYSTEM  
GAS VALVE  
CONTROL BOARD  
DISPLAY PANEL  
PC INTERFACE  
7
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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 1A shows control module normal sequences of operation  
for water heating operation.  
Access modes  
User  
The user can adjust tank target temperatures by pressing the  
NAVIGATION dial when “$SETPOINTS” is flashing at the  
bottom of the display. The date and time, and the temperature  
units can also be changed.  
Installer  
Most parameters are available only to the installer, accessible by  
entering the installer password (5309).  
Saving parameters (reference the Parameter Table -  
Table 1D on pages 12 and 13 of this manual)  
Please note that the brackets ([]) denote  
screen status.  
NOTICE  
To save parameters and exit programming:  
Press the RIGHT SELECT [SAVE] key and then press the  
RIGHT SELECT [HOME] key.  
To enter a parameter and continue programming:  
Press the RIGHT SELECT [SAVE] key 1 time to return to the  
parameter listings; press again to return to the menu listings.  
Remember to press the RIGHT SELECT [HOME] key when  
finished programming in order to save the changes made.  
8
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1 Service  
(continued)  
Table 1A Sequence of operation  
OPERATION  
DISPLAY  
1. The control will turn on the water heater pump (always ON except  
in Night Setback). The flow switch and/or LWCO must close.  
2. The control turns on power to the louver relay. The louver  
proving switch, air pressure switch, and blocked drain switch  
must close.  
3. The control starts a 15 second prepurge cycle.  
4. The control starts a 4 second trial for ignition by firing the spark  
electrode and opening the gas valve.  
5. If flame is not detected within 1 second after the sparking ends,  
the control will perform a 10 second post-purge, then start  
another prepurge cycle and try to light the burner again. On the  
501 and larger models, the control will lock out if this second  
attempt also fails. On the 400 and smaller models, the control  
will perform a total of 4 attempts before locking out.  
6. If flame is detected, it holds the firing rate steady for 5 seconds  
to let the flame stabilize, then it begins to modulate the firing rate  
based on a set point or some other command (such as a 0-10V  
BMS signal).  
7. Once the call for heat is satisfied, the control will turn off the  
burner. The blower will continue to run during a 10 second  
postpurge.  
8. The water heater pump will continue to run for its respective  
pump delay time before turning off. A 60 second anti-cycle period  
will start, which will delay any new call for heat until it times out.  
9. In Standby, ready to start a new cycle.  
9
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Display panel menu access  
Table 1B Use this procedure to access menus from the display panel  
SCREEN  
STATUS  
BUTTON  
OPERATION  
DISPLAY  
[SHDN]  
Press the RIGHT SELECT soft key [SHDN].  
[YES]  
Press the LEFT SELECT soft key [YES].  
Press and hold the LEFT SELECT soft key [MENU]  
for five (5) seconds.  
[MENU]  
Rotate the NAVIGATION dial clockwise until 5 is  
displayed (first digit on the left).  
Press the NAVIGATION dial to select the next digit.  
Rotate the NAVIGATION dial clockwise until 3 is  
shown in the display.  
Press the NAVIGATION dial 2 times to move to the  
last digit. Rotate the NAVIGATION dial counterclockwise  
until 9 is displayed.  
[SAVE]  
Press the RIGHT SELECT soft key [SAVE].  
Rotate the NAVIGATION dial counterclockwise to  
select a category.  
10  
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1 Service  
(continued)  
Display panel parameter access  
Table 1C This is a typical example of accessing a parameter, shown for parameter DHW Settings, TANK MIN Setpt  
SCREEN  
STATUS  
BUTTON  
OPERATION  
DISPLAY  
This example shows how to access parameter Temperature Settings. The first display shown is at the beginning  
of the menu listings, after entering the installer access code.  
Rotate the NAVIGATION dial counterclockwise until  
the arrow (>) is next to DHW SETTINGS.  
Press the NAVIGATION dial one time.  
Rotate the NAVIGATION dial counterclockwise until  
the arrow (>) is next to TANK MIN SETPT.  
Press the NAVIGATION dial one time.  
Rotate the NAVIGATION dial to the desired  
temperature.  
[SAVE]  
[EXIT]  
Press the RIGHT SELECT soft key [SAVE] one time.  
Press the LEFT SELECT soft key [EXIT] if all desired  
changes have been made.  
[HOME]  
Press the LEFT SELECT soft key [HOME].  
11  
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1 Service  
Parameter table  
Table 1D This table lists SMART SYSTEM control module parameters and where to access them  
User Access  
Installer Access  
Sub  
Item  
See  
Page  
Menu  
Description  
Display Modify Display Modify  
1
2
3
4
5
6
7
Date and Time  
14  
14  
14  
14  
14  
14  
14  
Yes  
No  
Yes  
No  
No  
No  
No  
Yes  
No  
Yes  
No  
No  
No  
No  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
No  
Software Version (read only)  
Temperature Units (ºC/ºF)  
DHW Night Setback Offset  
DHW Night Setback On Times  
DHW Night Setback Off Times  
Display Timeout  
Yes  
Yes  
Yes  
Yes  
Yes  
A
1
1
Reset Last 10 Errors  
Service Mode Delay  
15  
15  
No  
No  
No  
No  
Yes  
Yes  
Yes  
Yes  
B
C
1
2
3
4
5
Tank Set Point  
15  
15  
15  
15  
15  
Yes  
Yes  
No  
Yes  
Yes  
No  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Tank Set Point Offset  
Tank Set Point Differential  
Tank Minimum Set Point  
Tank Maximum Set Point  
D
E
No  
No  
No  
No  
1
2
Anti-Cycling Time  
15  
15  
No  
No  
No  
No  
Yes  
Yes  
Yes  
Yes  
Anti-Cycling Override Differential  
12  
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1 Service  
(continued)  
Parameter table  
Table 1D (continued from previous page) This table lists SMART SYSTEM control module parameters and where  
to access them  
User Access  
Installer Access  
Sub  
Item  
See  
Page  
Menu  
Description  
Display Modify Display Modify  
1
2
3
4
5
6
7
8
9
BMS Tstat Input (Active/Inactive)  
BMS (Active/Inactive)  
ModBus (Active/Inactive)  
ModBus T/O (Timeout)  
Cascade Address  
16  
16  
16  
16  
16  
16  
17  
17  
17  
17  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
F
Cascade Type (L/L / EFF)  
Max Cascade Outlet Set Point  
Min On/Off Time  
Min Next On Time  
10 Boiler Size  
1
2
DHW Pump Delay  
17  
17  
No  
No  
No  
No  
Yes  
Yes  
Yes  
Yes  
G
H
DHW Pump Anti-Seize Delay  
1
2
3
4
5
6
7
8
9
BMS Type (Power / Set Point)  
Volts at Min  
18  
18  
18  
18  
18  
18  
18  
18  
18  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Volts at Max  
Rate at Min Volts  
Rate at Max Volts  
Set Point at Min Volts  
Set Point at Max Volts  
On Volts  
Off Differential Volts  
1
2
3
4
5
Service Notification Months  
18  
18  
19  
19  
19  
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Service Notification Running Time  
Service Notification Cycles  
I
Reset Maintenance Reminder  
Installer Name and Phone Number  
13  
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1 Service  
Viewable and changeable control parameters  
Before changing parameters, note the  
settings so that the unit can be returned to  
its original operating parameters.  
Domestic Hot Water (DHW) Night Setback On  
Times  
CAUTION  
This is the time at which the DHW Night Setback Offset  
becomes active. There are 7 start times and 7 stop times.  
Both may be set to any time within a 7-day week. These  
settings are referred to as triggers. Multiple start or stop  
triggers may be set within a single day, if desired. When a  
start trigger and a stop trigger are set to the same time, the  
stop trigger has priority. The installer may adjust the DHW  
start triggers in parameter A5. This screen shows the start  
trigger number, the day of the week, and the time of day.  
A: General  
Date and Time  
The control uses an internal clock for the night setback  
feature and for logging of events. For these features to work  
correctly, the clock must be set when the water heater is first  
installed or anytime the water heater has been powered off for  
more than four (4) hours. To set the clock, parameter A1  
must be accessed.  
Please note that the brackets ([]) denote  
NOTICE  
The internal clock does not adjust for  
NOTICE  
screen status.  
Daylight Savings Time and therefore,  
will require a manual adjustment.  
1. When the screen is first accessed, start trigger number 1  
is shown. If a different trigger number is desired, the  
installer can rotate the NAVIGATION dial until the  
desired trigger number is displayed. Once the desired  
trigger number is selected, the installer can press the  
NAVIGATION dial and the day of the week will start to  
flash.  
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.  
2. The installer can adjust the day of the week to the one he  
wishes to set. Once the day is set, the installer can press  
the NAVIGATION dial and the hour will begin to flash.  
Software version is read only.  
3. After setting the hour, the installer can press the  
NAVIGATION dial and the minutes will flash. Once all  
settings have been made, the installer can press the  
RIGHT SELECT [SAVE] key. The installer can now  
select a different trigger and adjust the settings for that  
trigger.  
Temperature units (°C / °F)  
The control can be configured to display temperature in  
either °C or °F. This parameter can be changed by the user or  
the installer by accessing parameter A3. The default is °F.  
4. Once all adjustments are made, the installer can press  
the RIGHT SELECT [SAVE] key to save all of the new  
settings and return to the A menu, or press the LEFT  
SELECT [EXIT] key to return to the A menu without  
saving the changes.  
Domestic Hot Water (DHW) Night Setback Offset  
The unit’s internal clock can be set up to run at a lower set  
point temperature during unoccupied times. When in night  
setback, the control reduces the set point by a fixed amount.  
It subtracts the DHW night setback offset from the tank set  
point (parameter E2).  
Domestic Hot Water (DHW) Night Setback Off  
Times  
NOTE: The DHW night setback will not work without a tank  
sensor installed.  
The stop triggers for the DHW night setback feature can be  
adjusted by accessing parameter A6. The adjustment  
procedure for these parameters is identical to the space  
heating start triggers described above.  
The installer may adjust the DHW night setback offset by  
accessing parameter A4. The minimum setting is 0°F (0°C)  
and the maximum setting is 90°F (50°C).  
Display Timeout  
This is the time in which the display remains illuminated.  
The range is 10 seconds to 10 minutes. The default is 3  
minutes.  
14  
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1 Service  
(continued)  
Tank Minimum Set Point  
B: Data Logging  
This setting controls the minimum user set point for the tank  
temperature. The installer can adjust this by accessing  
parameter D4. The minimum setting is 60°F (16°C) and the  
maximum setting is the maximum tank set point (parameter  
D5).  
Reset last 10 errors  
The reset last 10 errors function clears the last 10 errors log.  
C: Functions  
Service Mode Delay  
Tank Maximum Set Point  
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 C1. The time range of this  
parameter is 0 to 30 minutes. The default value is 20 minutes.  
This setting controls the maximum user set point for the tank  
temperature. The installer can adjust this by accessing  
parameter D5. The minimum setting is the minimum tank set  
point (parameter D4) and the maximum setting is 185°F (85°C).  
E: Anti-Cycling  
Anti-Cycling Time  
Once a SH demand has been satisfied, a set amount of time must  
elapse before the control will respond to a new SH demand. The  
control will block the new heat demand and anti-cycling will be  
shown in the display until the time has elapsed or the water  
temperature drops below parameter E2. This parameter can be  
D: DHW Settings  
Tank Set Point  
By installing a tank sensor, the SMART SYSTEM control can changed by the installer by accessing parameter E1. The time  
perform the tank thermostat function. The SMART SYSTEM range for this parameter is 0 minutes to 10 minutes. The default  
control automatically detects the presence of this sensor, and value is 1 minute.  
generates a DHW call for heat when the tank temperature drops  
below the tank set point differential (parameter D3), and Anti-Cycling Override Differential  
finishes the call for heat when the tank temperature reaches tank  
The control will bypass the anti-cycling time if the water  
temperature drops too quickly. The control will use the water  
set point. This parameter can be changed by the installer by  
accessing parameter D1. The temperature range of this  
temperature the water heater was at when it shut off as the  
parameter is 68°F (20°C) to 190°F (88°C). The default value is  
starting point. If the temperature drops below the temperature  
125°F (52°C).  
parameter the control will abort anti-cycling and allow the water  
heater to fire. This parameter can be changed by the installer by  
Tank Set Point Offset  
accessing parameter E2. The temperature range of this  
The tank set point offset measures how far the actual parameter is 0°F (0°C) to 54°F (30°C). The default value is 10°F  
temperature must go above the set point before the call for heat (6°C).  
ends (the water heater will turn off). This parameter can be  
changed by the installer by accessing parameter D2.  
Tank Set Point Differential  
When a tank sensor is installed, the tank temperature must drop  
this amount below the tank set point (parameter D1) before the  
heater will turn on. The installer can adjust this setting by  
accessing parameter D3. The minimum setting is 0° (0°C), and  
the maximum is 40°F (22°C). The default setting is 6°F (3°C).  
15  
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Cascade Address  
F: Control modes  
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 F5. The tank sensor must be  
connected to the Leader water heater. The default address  
is 1.  
BMS Thermostat Input (Active / Inactive)  
When controlling the water heater through the 0 - 10V BMS  
input or through ModBus, the water heater can be enabled  
one of two ways. With parameter F1 set to ACTIVE, the  
water heater will be enabled by closing the Tank Thermostat  
input. With parameter F1 set to INACTIVE, the water  
heater will be enabled by the voltage level on the 0 - 10V  
input (in the case of 0 - 10V BMS control), or the 0 - 10V  
input value received through ModBus. The default value is  
INACTIVE.  
If installing the water heaters in an existing system with  
existing Armor water heaters with old style controls, the  
new water heaters should be programmed as the Leader  
and/or the higher number addresses.  
BMS (Active / Inactive)  
The set point or modulation of the water heater may be  
controlled through the 0 - 10V BMS input or through  
ModBus. When parameter F2 is set to INACTIVE, the 0 -  
10V input will be ignored. When set to ACTIVE, the set  
point or modulation will be controlled by the voltage on the  
0 - 10V input (in the case of 0 - 10V BMS control), or the 0  
- 10V input value received through ModBus. The default  
value is INACTIVE.  
Cascade Type (L/L / EFF)  
There are two (2) options for the way a Cascade divides the  
load between its heaters. The first is Lead/Lag, designated  
at L/L in the menu. This method will modulate the last two  
(2) water heaters only. When the last water heater reaches  
100% and the calculated load is still increasing, it will start  
the next water heater at 20% and reduce the previous water  
heater to 80%. When the calculated load is decreasing and  
the last water heater gets down to 20% fire, it will hold it  
there and start lowering the firing rate on the next-to-last  
water heater. When the next-to-last water heater reaches  
20%, it will turn the last water heater off and raise the rate  
of the next-to-last water heater to 40%, thus eliminating  
the sudden drop in total output of the Cascade.  
ModBus (Active / Inactive)  
When BMS is set to ACTIVE (see BMS Active / Inactive)  
and the water heater is being controlled through ModBus,  
set parameter F3 to ACTIVE. Otherwise, set the ModBus  
parameter to INACTIVE. Note that the water heater can  
still be monitored by ModBus with this parameter set to  
INACTIVE. The default value is INACTIVE.  
The other Cascade divider method is Efficiency  
Optimization, designated as EFF in the menu. This method  
is used, as the name implies, when it is desired to have the  
most efficient system. When the first water heater reaches  
a certain rate (default = 90%), it lowers its rate to 45% and  
turns on the next water heater at 45%. The two (2) water  
heaters then modulate at the same rate.  
ModBus T/O (Timeout)  
The ModBus T/O is the amount of time the unit controls  
will wait to receive a communication string from the BMS  
controller before reverting back to its own internal  
parameters. This is used to prevent unwanted operation  
should ModBus communication be lost. Therefore, the  
ModBus commands need to be refreshed within this time  
period. This parameter is adjustable by the installer by  
accessing parameter F4. The default value is 10 seconds.  
As the calculated load increases further and both water  
heaters ramp up to 90%, it lowers the rate of the first two  
(2) water heaters to 60% and brings the next water heater  
on at 60%. The three (3) water heaters then modulate  
together. As the calculated load decreases, the water heaters  
will reach a lower threshold (default = 30%), at which time  
the last water heater (the third in our example) will turn off  
and the Cascade will increase the rates of the remaining  
water heaters to provide the equivalent total output as  
before ((3 x 30%) / 2 = 45% in our example).  
16  
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Service Manual  
1 Service  
(continued)  
Maximum Cascade Outlet Set Point  
H: BMS  
This parameter determines the set point used by the  
individual water heaters in a Cascade. When a water heater  
is commanded to fire by the Leader water heater, it will  
attempt to achieve this temperature at its outlet. The  
Leader water heater will limit the modulation of the water  
heater in order to hold the temperature at the tank sensor  
to the user set point. If any of the water heater outlet  
temperatures reach the maximum cascade outlet set point,  
the water heater will then modulate down on its own in  
order to keep its outlet temperature within the maximum  
cascade outlet set point. Therefore, this parameter can be  
used to limit the outlet temperatures of all the water heaters  
in a Cascade. This parameter is adjustable by the installer  
by accessing parameter F7. The default maximum cascade  
set point is 185°F (85°C).  
BMS Type (Power / Set Point)  
When programmed for BMS control through the 0 - 10V  
BMS input or through ModBus, the 0 - 10V signal can be  
interpreted as either a modulation command or a set point.  
When parameter H1 is set to POWER, the 0 - 10V signal will  
control the modulation. When set to SETPOINT, the 0 - 10V  
signal will control the tank set point. The default setting is  
SETPOINT.  
Volts at Minimum  
When programmed for BMS control through the 0 - 10V  
BMS input or through ModBus, parameter H2 should be set  
to the minimum voltage signal sent to the SMART SYSTEM  
control. The range of this parameter is 0.0V to the Volts at  
Minimum value (parameter H3). The default setting is 2.0V.  
Minimum On/Off Time  
Volts at Maximum  
In order to prevent units in a Cascade from short cycling,  
this parameter defines the minimum ON and OFF time for  
each unit. The installer can adjust this time by accessing  
parameter F8. The minimum setting is 0 seconds and the  
maximum setting is 10 minutes. The default is 30 seconds.  
When programmed for BMS control through the 0 - 10V  
BMS input or through ModBus, parameter H3 should be set  
to the maximum voltage signal sent to the SMART SYSTEM  
control. The range of this parameter is the Minimum value  
(parameter H2) to 10.0V. The default value is 10.0V.  
Minimum Next On Time  
In order to reduce the risk of temperature overshoot with a  
Cascade, this parameter defines the minimum time delay  
from starting one unit until the next unit may be started.  
The installer can adjust this time delay by accessing  
parameter F9. The minimum setting is 0 minutes and the  
maximum setting is 10 minutes. The default is 60 seconds.  
Rate at Minimum Volts  
When programmed for BMS control through the 0 - 10V  
BMS input or through ModBus and the BMS Type is  
programmed as POWER, the modulation percentage  
represented by the Volts at Minimum parameter (H2) is set by  
parameter H4. The minimum value is 0% and the maximum  
is the Power at Maximum Volts setting H5. The default value  
is 20%.  
Boiler Size  
Not used.  
Rate at Maximum Volts  
G: Circulation pumps  
When programmed for BMS control through the 0 - 10V  
BMS input or through ModBus and the BMS Type is  
programmed as POWER, the modulation percentage  
represented by the Volts at Maximum parameter (H3) is set  
by parameter H5. The minimum value is the Power at  
Minimum Volts setting H4 and the maximum is 100%. The  
default value is 100%.  
DHW Pump Delay  
The DHW pump delay parameter sets the length of time  
the pump (if connected) will run after a DHW demand has  
been satisfied. This parameter is adjustable by the installer  
by accessing parameter G1. The time range for this  
parameter is 0 minutes to 40 minutes. The default time is  
30 seconds.  
Set Point at Minimum Volts  
DHW Pump Anti-Seize Delay  
When programmed for BMS control through the 0 - 10V  
BMS input or through ModBus and the BMS Type is  
programmed as SETPOINT, the set point represented by the  
Volts at Minimum parameter (H2) is set by parameter H6.  
The minimum value is 32°F (0°C) and the maximum is the  
Set Point at Maximum Volts setting H7. The default value is  
70°F (21°C).  
If the water heater pump does not run for 24 hours, it will  
be turned on briefly to prevent it from seizing. The length  
of time it runs is determined by parameter G2. The range  
of this setting is 0 seconds to 40 minutes. The default  
setting is 20 seconds.  
17  
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Service Manual  
1 Service  
Set Point at Maximum Volts  
Service Notification Cycles  
When programmed for BMS control through the 0 - 10V  
BMS input or through ModBus and the BMS Type is  
programmed as SETPOINT, the set point represented by the  
Volts at Maximum parameter (H4) is set by parameter H7.  
The minimum value is the Set Point at Minimum Volts  
setting H6 and the maximum is 190°F (88°C). The default  
value is 180°F (82°C).  
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 I3. The range for this parameter is 0 cycles to  
100,000 cycles. The default is 50,000 cycles.  
Reset Maintenance Reminder  
On Volts  
Once servicing has been completed, the service notification  
counter should be reset. This parameter can be reset by the  
installer by accessing parameter I4. Once accessed, press the  
RESET key to reset the service notification counter.  
When programmed for BMS control through the 0 - 10V  
BMS input or through ModBus and the BMS Thermostat  
Input is set to INACTIVE, parameter H8 determines the 0 -  
10V BMS input voltage at which the water heater is enabled.  
The minimum value is 0.5V and the maximum is 10.0V. The  
default value is 2.0V.  
Installer Name and Phone Number  
Off Differential Volts  
Please note that the brackets ([]) denote  
screen status.  
NOTICE  
When programmed for BMS control through the 0 - 10V  
BMS input or through ModBus and the BMS Thermostat  
Input is set to INACTIVE, parameter H9 determines how far  
below the On Volts setting H8 the 0 - 10V BMS input voltage  
must be in order to disable the water heater. The minimum  
value is 0.2V and the maximum is the On Volts setting H8.  
The default value is 1.0V.  
When a Maintenance Reminder timer or counter has expired,  
a Maintenance Reminder screen will appear on the display.  
By programming the installer’s name and phone number, this  
information will appear on the Maintenance Reminder  
Screen at that time. This can be programmed by accessing  
parameter I5. When selected, another menu will appear with  
PHONE and NAME.  
I: Service Notification  
1. Rotate the NAVIGATION dial to point to the  
name/phone number to program and press the  
NAVIGATION dial. The screen will now display the  
selected item (either PHONE or NAME).  
Service Notification in Months  
When the water heater control determines that a scheduled  
service is due based on days of installation, the water heater  
display will alternate the standard water heater display text  
with the message SERVICE DUE every 5 seconds. This  
parameter is adjustable by the installer by accessing  
parameter I1. The time range for this parameter is 0 months  
to 36 months. The default time is 0 months.  
2. Press the NAVIGATION dial again. A cursor will  
appear at the bottom of the screen. By rotating the  
NAVIGATION dial, various numbers and characters  
will appear. When the desired number/character is  
found, press the NAVIGATION dial. The cursor will  
move to the next position.  
This feature has been disabled by the manufacturer. To  
enable this feature change parameter I1 to the desired time  
range.  
3. Repeat this procedure until the entire message is  
entered. If you make a mistake and wish to back up  
one character, select the back arrow (←) character and  
press the NAVIGATION dial.  
Service Notification Running Time  
4. When finished, press the RIGHT SELECT [SAVE] key  
to return to the previous menu.  
When the water heater control determines that a scheduled  
service is due based on the hours of actual operation, the  
water heater display will turn yellow and a new status screen  
will appear informing the installer that maintenance is  
required. This parameter is adjustable by the installer by  
accessing parameter I2. The time range for this parameter is  
0 hours to 100,000 hours. The default time is 8,760 hours.  
18  
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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 vent piping  
• Check air piping  
• Check ignition and flame sense electrodes  
(sand  
off  
any  
deposits;  
clean  
and reposition)  
• Check wiring and connections  
• Perform start-up checkout  
• Check air and vent termination  
screens  
Monthly  
and  
performance verification per Section 10  
in the Armor Installation and Operation  
Manual.  
• Check relief valve  
• Flame inspection (stable, uniform)  
• Check condensate drain system  
• Check air vents  
• Flame signal (at least 10 microamps at  
high fire)  
• Clean the heat exchanger if flue  
temperature is more than 54°F above  
return water temperature.  
• Check Delta T (Temperature  
Rise)  
• Check Delta T (Temperature Rise)  
If combustion or performance  
indicate need:  
Every  
6 months  
• Check water heater piping (gas  
and water) for leaks  
• Clean heat exchanger  
• Remove and clean burner using  
compressed air only  
• Operate relief valve  
• Clean the blower wheel  
19  
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Service Manual  
2 Maintenance  
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.  
RETAINING  
SCREW  
2” PVC CAP WITH  
BLOCKED DRAIN SWITCH  
Inspect water heater area  
1. Verify that water heater area is free of any combustible  
materials, gasoline and other flammable vapors and  
liquids.  
PVC TEE ASSEMBLY  
(FACTORY SUPPLIED)  
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.  
CONDENSATE FROM  
HEAT EXCHANGER  
TO FLOOR  
DRAIN  
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  
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.  
ƽ WARNING  
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.  
20  
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Service Manual  
2 Maintenance  
(continued)  
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. Verify system pressure is at least 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 water expands due to temperature increase or  
contracts as the water cools. Tanks may be diaphragm or  
bladder type. See Section 6 - System Piping of the Armor  
Water Heater Installation and Operation Manual for  
suggested best location of expansion tanks and air  
eliminators.  
Check water heater relief valve  
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.  
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.  
21  
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Service Manual  
2 Maintenance  
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.  
22  
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Service Manual  
2 Maintenance  
(continued)  
7. Brush the heat exchanger while dry using a nylon bristle brush.  
Caution: DO NOT use a metal brush. Re-vacuum the heat  
exchanger.  
Check flame signal  
1. At high fire the flame signal shown on the display  
should be at least 10 microamps.  
8. Finish cleaning using a clean cloth dampened with warm water.  
Rinse out debris with a low pressure water supply.  
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.  
9. Allow the heat exchanger to thoroughly dry.  
10. Remove the field supplied rear refractory cover from the back of  
the combustion chamber of the heat exchanger and reassemble.  
11. Close isolation valves on piping to isolate water heater from  
system. Attach a hose to the water heater drain and flush water  
heater thoroughly with clean water by using purging valves to  
allow water to flow through the water make-up line to the water  
heater.  
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  
12. Perform start-up and check-out procedures in the Check Flame  
and Combustion - Section 10 - Startup of the Installation and  
Operation Manual.  
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.  
13. Replace the access cover and restore water heater to operation.  
Table 2B Heat Exchanger Cleaning Kits  
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.  
Kit  
Part  
Component  
Description  
Model  
Number Number  
CTN20005  
Rear Refractory Cover  
Cleaning heat exchanger  
151  
-
MSC20083*  
KIT30063  
Nylon 4" Wheel Brush*  
For recommended materials; including brush,  
appropriate extension(s), refractory cover, and detailed  
instructions see Table 2B - Heat Exchanger Cleaning  
Kits.  
MSC20084  
3mm Allen Wrench  
1/4" x 24" Drill Extension  
Rear Refractory Cover  
Nylon 4" Wheel Brush*  
1/4" x 12" Drill Extension  
1/4" x 24" Drill Extension  
400  
MSC20086  
CTN20005  
501  
-
801  
MSC20083*  
KIT30064  
1. Shut down water heater:  
MSC20085  
• Follow the “To Turn Off Gas to Appliance”  
instructions for the water heater in Section 10 -  
Startup of the Installation and Operation Manual.  
• Do not drain the water heater unless it will be  
exposed to freezing temperatures. If using freeze  
prevention fluid in system, do not drain.  
MSC20086  
* Do NOT use a metal brush. Only use the kit  
provided brush or an equivalent replacement  
nylon brush.  
ƽ CAUTION  
Allow time for the water heater to cool to room Check Delta T  
2.  
temperature if it has been firing.  
1. Check the Delta T using Table 2C as a reference.  
3. Remove the nuts securing the heat exchanger access  
cover to the heat exchanger and set aside.  
Table 2C Water Heater Pump Applications / Recommended  
Temperature Rise  
4. Remove the heat exchanger access cover, burner, and  
gas/air arm assembly.  
Water Heater Pump Applications  
*Pipe  
Size  
1-1/4"  
1-1/4"  
2"  
Flow Rate Loss  
Temp.  
Rise  
18°F  
Model  
Armstrong Grundfos  
(GPM)  
16  
(FT/HD)  
16.6  
11.8  
17.1  
21  
The water heater contains ceramic  
ƽ WARNING  
151  
200  
286  
400  
501  
601  
E8  
E8  
--  
--  
--  
--  
--  
--  
fiber materials. Use care when  
handling these materials per the  
instructions on page 3 of this  
manual. Failure to comply could  
result in severe personal injury.  
21  
18°F  
E17  
E24  
E22  
E22  
30  
18°F  
2"  
39  
18°F  
2"  
53  
26  
18°F  
2"  
53  
26  
22°F  
701  
801  
2"  
2"  
--  
--  
TP 40-160  
TP 40-160  
63  
67  
32  
31  
22°F  
24°F  
5. Remove the condensate hose from the heat  
exchanger end.  
Connect a field supplied 3/4"  
diameter hose to a drain pan. Using field supplied  
means, cover the refractory in the back of the  
combustion chamber of the heat exchanger.  
Oiled bearing circulators  
1. The circulator shipped with the Armor water heater is water-  
lubricated. No oiling is required.  
6. Use a vacuum cleaner to remove any accumulation  
on the water heater heating surfaces. Do not use any  
solvent.  
2. Check other circulators in the system. Oil any circulators requiring  
oil, following circulator manufacturer’s instructions. Over-oiling  
will damage the circulator.  
23  
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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.  
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  
Always  
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.  
2. Remove top access cover.  
ƽ WARNING  
3. Remove the control module cover.  
4. Inspect fuses F1, F2 and F3, 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.  
b. Continuity checker.  
c. Contact thermometer.  
F3 - .80 AMP FUSE  
24V DC POWER SUPPLY  
2. Check for 120 VAC (minimum 102 VAC to  
maximum 132 VAC) to water heater.  
F1 - 5 AMP FUSE  
PUMPS  
F2 - 3.15 AMP FUSE  
BLOWER  
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.  
5. The water heater is shipped with three (3) spare fuses in a  
plastic bag attached to the control module cover.  
4. Make sure all external limit controls are installed  
and operating.  
6. If necessary, replace open fuse (F3 is .80 amps, F2 is 3.15 amps,  
and F1 is 5 amps).  
Note: Fuses F1, F2 and F3 are all slow blow fuses.  
Check the following:  
Do not jumper fuse or replace with any fuse  
1. Wire connectors to control module are securely  
plugged in at the module and originating control.  
ƽ WARNING  
except as specified. Failure to comply could  
result in severe personal injury, death, or  
substantial property damage.  
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)  
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.  
24  
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Service Manual  
3 Troubleshooting  
(continued)  
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  
ONꢀposition.  
• 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 24 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 pages 28 - 35 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 3D on page 26 of this manual.  
25  
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Service Manual  
3 Troubleshooting  
Checking temperature sensors  
The water heater temperature sensors (inlet water, outlet water, system water, and flue) are all resistance type devices. The  
following tables show the correct values for the sensors at various temperatures. Use an ohmmeter to read the resistance of the  
sensor at a known temperature. If the resistance of the sensor does not closely match its corresponding table, replace the sensor.  
It is important to note that the flue and outlet water sensors have two temperature sensing devices in one housing. These devices  
are designated as S1a/S1b, outlet sensor and S3a/S3b, flue sensor. Please reference the wiring diagram in the Armor Water Heater  
Installation and Operation Manual for correct terminal location.  
Table 3B - Inlet System Sensor Resistance vs. Temperature  
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 - Outlet Water Sensor Resistance vs. Temperature  
S1a  
S1b  
(Wire Color - R/BK and Y)  
(Wire Color - G and Y)  
Temperature Resistance Temperature Resistance Temperature Resistance Temperature Resistance  
50  
68  
19,553  
12,690  
8,406  
5,715  
3,958  
2,786  
158  
176  
194  
212  
2,004  
1,464  
1,084  
816  
50  
68  
40,030  
25,030  
16,090  
10,610  
7,166  
158  
176  
194  
212  
3,478  
2,492  
1,816  
1,344  
86  
86  
104  
122  
140  
104  
122  
140  
4,943  
Table 3D - Flue Sensor Resistance vs. Temperature  
S3a  
S3b  
(Wire Color - W/B and Y)  
(Wire Color - PR and Y)  
Temperature Resistance Temperature Resistance Temperature Resistance Temperature Resistance  
50  
68  
40,030  
25,030  
16,090  
10,610  
7,166  
158  
176  
194  
212  
3,478  
2,492  
1,816  
1,344  
50  
68  
258,500  
125,500  
80,220  
52,590  
35,270  
24,160  
158  
176  
194  
212  
16,870  
12,000  
8,674  
86  
86  
104  
122  
140  
104  
122  
140  
6,369  
4,943  
26  
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Service Manual  
3 Troubleshooting  
(continued)  
Table 3E 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  
pages 37-38 of this manual for the proper gas valve  
setting. Verify that the vent/air intake lengths do not  
exceed the maximum listed in the General Venting  
section of the Armor Water Heater Installation and  
Operation Manual.  
- Gas/air mixture problem.  
- Dirty/damaged burner.  
Noisy  
Operation  
• Refer to page 22 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 F1 on the control board, see page 24 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.  
27  
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Service Manual  
3 Troubleshooting  
Table 3F Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface  
FAULT  
DESCRIPTION  
CORRECTIVE ACTION  
Either the manual reset low gas pressure  
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 24 of  
this manual.  
• Check condensate tube from unit to floor drain for  
proper installation and obstructions.  
Blocked Drain SW  
(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.  
The blocked drain switch has detected  
excessive condensate build up inside the  
unit.  
• Check for loose wiring connection at wire harness  
plug.  
• Bad blocked drain switch. Replace switch.  
• 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 22 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 23 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 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface  
FAULT  
DESCRIPTION  
CORRECTIVE ACTION  
The main control board has received a call • The control board will release the call for heat after a  
for heat too quickly after the previous call for  
heat has ended.  
set time period.  
Anti-cycling  
• The control board will release the call for heat if the  
outlet temperature drops too quickly.  
The unit has failed to prove main burner • Inspect spark electrode and associated wiring for  
ignition after four (4) attempts.  
damage and connection. Reference page 22 of this  
manual for removal and cleaning procedures.  
Replace if necessary.  
Exception: Models 501 - 801 will lock out  
after one retry for ignition. It will require a  
manual reset before attempting to fire again.  
• Check for proper electrical grounding of 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.  
Flame Fail 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 22 of this manual for removal and  
cleaning procedures. Replace if necessary.  
• Inspect the burner. Reference page 22 of this manual  
for removal and cleaning procedures. Replace if  
necessary.  
• Replace the main control board.  
29  
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Service Manual  
3 Troubleshooting  
Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface  
FAULT  
DESCRIPTION  
CORRECTIVE ACTION  
The unit was running and lost the flame • Inspect spark electrode and associated wiring for  
signal. This condition occurred four (4)  
straight times.  
damage and connection. Reference page 22 of this  
manual for removal and cleaning procedures. Replace  
if necessary.  
Exception: Models 501 - 801 will lock out  
after one retry for ignition. It will require a  
manual reset before attempting to fire again.  
• Check for proper electrical grounding of unit.  
• Check incoming supply gas pressure. Natural gas  
pressures should be between 4 - 14 inches w.c. and  
LP gas pressures should be between 8 - 14 inches w.c.  
Refer to Section 7 - Gas Connections of the Armor  
Water Heater Installation and Operation Manual for  
detailed information concerning the gas supply.  
• Verify that the plastic hose from the gas valve to the air  
inlet is connected and is not damaged.  
• Verify that the vent/air intake pipes are installed  
correctly and there are no obstructions.  
• Check for 24 VAC to the gas valve at the 2-pin  
connection on the side of the main control board during  
the ignition attempt. If no voltage is present, replace the  
main control board.  
No Flame  
Running  
(will 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 22 of this manual for removal and  
cleaning procedures. Replace if necessary.  
• Inspect the burner. Reference page 22 of this manual  
for removal and cleaning procedures. Replace if  
necessary.  
• Replace the main control board.  
30  
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Service Manual  
3 Troubleshooting  
(continued)  
Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface  
FAULT  
DESCRIPTION  
CORRECTIVE ACTION  
• 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 flame detector circuit is seeing a flame  
signal while no flame is present.  
• 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 - Hydronic Piping  
of the Armor Installation and Operation Manual  
for the proper piping methods for the Armor water  
heater.  
• Check 120 vac to water heater pump motor on a call  
for heat. If voltage is not present, check wiring back  
to the main control board.  
• Replace the main control board if necessary.  
• If 120 vac is present on a call for heat and the water  
heater pump is not operating, replace the pump.  
The outlet water temperature has exceeded  
the setting of the automatic reset high limit.  
Auto Reset  
High Limit  
• If the system pump is a variable speed pump, ensure  
that the system flow is not less than the water heater  
flow.  
• If operating on something other than an outlet sensor,  
check temperature setting of the main control board.  
• If the manual reset high limit has tripped, check  
setting of the device.  
• Check resistance of water sensors and compare to  
Table B on page 26 of this manual. Replace  
sensor if necessary.  
• Replace high limit.  
• Verify that the system is full of water and that 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 3C on page 26 of this manual. Replace sensor  
if necessary.  
• Replace high limit.  
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31  
Service Manual  
3 Troubleshooting  
Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface  
FAULT  
DESCRIPTION  
CORRECTIVE ACTION  
• 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 24 of  
this manual.  
Blown fuse.  
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.  
• 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.  
The actual fan RPM is 30% higher than what  
is being called for.  
• 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 26 of this  
manual.  
• Replace the sensor if necessary.  
32  
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Service Manual  
3 Troubleshooting  
(continued)  
Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface  
FAULT  
DESCRIPTION  
CORRECTIVE ACTION  
Sensor Shorted  
(will require a manual  
reset once the condition  
has been corrected. Press  
the RESET button on the  
SMART SYSTEM display  
to reset.)  
Either the inlet water or outlet water • Check the sensors and their associated wiring.  
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 26 of this  
manual.  
• Replace the sensor if necessary.  
Louver 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 stack temperature has exceeded the set • Inspect the heat exchanger. Reference page 23 of  
parameters for the water heater.  
this manual for the procedure on how to clean the flue  
side of the heat exchanger.  
• Inspect the flue sensor and associated wiring.  
Measure the resistance of the flue sensor and  
compare to Table 3D on page 26 of this manual.  
Replace the sensor if necessary.  
Flue Temp High  
• Verify that the vent/air intake pipes are properly  
installed and that there are no obstructions.  
• Replace the main control board.  
• Deliming may be required.  
Scaling has reduced water flow.  
• 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.  
• 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.  
The temperature rise across the heat  
exchanger has exceeded the set parameters  
for the water heater.  
Delta T High  
• 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.  
33  
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Service Manual  
3 Troubleshooting  
Table 3F (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.  
Outlet water temperature has exceeded the  
maximum outlet water temperature.  
Outlet Temp High  
• 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.  
• Establish a heating load to remove the heat from the  
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  
While the unit is in Service Mode, the outlet  
temperature has exceeded 185°F.  
• Check 120 VAC to the water heater pump motor on a  
call for heat. If voltage is not present, check the wiring  
back to the main control board. Replace the main  
control board if necessary.  
• If 120 VAC is present on a call for heat and the water  
heater pump is not operating, replace the pump.  
• Verify that the water heater pump is set to the proper  
speed or that the water heater pump is the proper  
size. Reference Section 6 - System Piping of the  
Armor Water Heater Installation and Operation  
Manual for water heater pump specifications.  
34  
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Service Manual  
3 Troubleshooting  
(continued)  
Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface  
FAULT  
DESCRIPTION  
CORRECTIVE ACTION  
120 VAC input to the main control board has  
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.  
• Restore the default parameters.  
The main control board has detected an  
• Replace the main control board.  
Fatal Error  
Parameters  
internal fault.  
• Replace the display board.  
35  
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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  
9.0% - 11%  
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%  
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 RIGHT SELECT [ON] key (see page 5).  
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 below the RESET button on the  
display board (see page 5). Insert a thin wire (such as a  
paper clip) into the hole and press the button once and hold  
for 5 seconds to place the water heater into Service Mode.  
In Service Mode the water heater will fire at ignition speed  
and will then modulate up to full fire.  
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 3H 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 22 of this manual for burner removal and cleaning procedures.  
• Replace burner if necessary.  
• Refer to pages 37-38 of this manual for the gas valve adjustment procedure.  
Gas Valve Adjustment  
36  
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Service Manual  
3 Troubleshooting  
(continued)  
Gas valve adjustment procedure  
Model 400  
If adjustment of the gas valve is deemed necessary, use the  
following procedures: (Note: The procedures in this section  
are model specific.)  
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  
Models 151 - 286  
clockwise to decrease CO2 levels. After one adjustment on  
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  
the valve, follow the Combustion Analysis Procedure on page  
36 of this manual to measure the combustion.  
If combustion is still not within the specified range, repeat the  
procedure. This procedure SHOULD NOT be performed  
more than four (4) times. If after four (4) adjustments and  
the combustion is still not within the specified range, revisit  
the possible causes in Table 3H on page 36 or replace the gas  
valve.  
counterclockwise to increase CO2 levels. After performing  
one adjustment on the valve, follow the Combustion Analysis  
Procedure on page 36 of this manual to measure the  
combustion.  
If combustion is still not within the specified range, repeat the  
procedure. This procedure SHOULD NOT be performed  
more than four (4) times. If after four (4) adjustments and  
the combustion is still not within the specified range, revisit  
the possible causes in Table 3H on page 36 or replace the gas  
valve.  
Figure 3-3 Gas Valve Adjustment: Model 400  
THROTTLE ADJUSTMENT  
SCREW  
Figure 3-2 Gas Valve Adjustment: Models 151 - 286  
37  
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Service Manual  
3 Troubleshooting  
Model 501  
Models 601 - 801  
Locate the throttle adjustment screw on top of the gas valve,  
see FIG. 3-4. Using an Allen wrench, turn the screw a 1/4 turn  
counterclockwise to increase CO2 levels or a 1/4 turn  
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  
clockwise to decrease CO2 levels. After one adjustment on  
to decrease CO2 levels. After one adjustment on the valve, follow  
the valve, follow the Combustion Analysis Procedure on page  
36 of this manual to measure the combustion.  
the Combustion Analysis Procedure on page 36 of this manual  
to measure the combustion.  
If combustion is still not within the specified range, repeat the  
procedure. This procedure SHOULD NOT be performed more  
than four (4) times. If after four (4) adjustments and the  
combustion is still not within the specified range, revisit the  
possible causes in Table 3H on page 36 or replace the gas valve.  
If combustion is still not within the specified range, repeat the  
procedure. This procedure SHOULD NOT be performed  
more than four (4) times. If after four (4) adjustments and  
the combustion is still not within the specified range, revisit  
the possible causes in Table 3H on page 36 or replace the gas  
valve.  
Figure 3-4 Gas Valve Adjustment: Model 501  
Figure 3-5 Gas Valve Adjustment: Models 601 - 801  
THROTTLE  
ADJUSTMENT  
SCREW  
(REMOVE BLUE CAP)  
38  
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Notes  
39  
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Revision Notes: Revision A (ECO #C06238) initial release.  
AWII-SER Rev A  
8/10  
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