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AW-SER Rev H
Service Manual
Models: 150 - 800
This manual must only be used by a
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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Contents 2. MAINTENANCE CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Maintenance and Annual Startup . . . . . . . . . . . . . . . . . . 16-20 Hazard Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 3. TROUBLESHOOTING PLEASE READ BEFORE PROCEEDING . . . . . . . . . . . . 3 Before Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Handling Ceramic Fiber Materials . . . . . . . . . . . . . . . . . . . 3 Check Con
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Service Manual Please read before proceeding Installer – Read all instructions, When calling or writing about the water heater – WARNING NOTICE including this manual and the Armor Please have the water heater model and serial Water Heater Installation and Operation number from the water heater rating plate. Manual, before installing. Perform steps Consider piping and installation when in the order given. determining water heater location (see the Have this water heater serviced/inspected Armo
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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 � Typical system components � Clean condensate trap � Check all piping for leaks The Armor water heater display � Check air openings � Display panel readout, buttons and their functions � Flue vent system and air piping � Check water system Control module inputs � Check expansion tank � Control mo
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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 (OPTIONAL) DHW THERMOSTAT LOW VOLTAGE FLOW SWITCH CONNECTION BOARD TANK SENSOR SEQUENCER / BUILDING MANAGEMENT SYSTEM LOW WATER CUTOFF (OPTIONAL) INLET TEMPERATURE SENSOR OUTLET TEMPERATURE SENSOR FLUE GAS SENSOR AIR PRESSURE SWITCH HIGH LIMIT SENSOR FLAME SENSOR BLOCKED DRAIN SWITCH SMART SYSTEM CONTROL BOARD DISPLAY PANEL PC INTERFACE (OPTIONAL) 6
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Service Manual 1 Service (continued) Control outputs ALARM BELL AUX. DEVICE RELAY LOW VOLTAGE CONNECTION BOARD RUNTIME CONTACTS 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 al
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Service Manual 1 Service (continued) Sequence of operation Table 1A Sequence of operation OPERATION DISPLAY WHR: Standby 1. Upon a call for heat, the control turns on the water heater pump. OUT: 123.8F(129) 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. WHR: Standby •If
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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 COMMENTS Water heater turns off (this ensures WHR:OFF ENTER/RES Press 1 time in normal operation OUT:125˚F uninterrupted programming) Digit shown underlined at left will Enter Menu Code: MENU/EXIT Hold for 5 seconds -- display will change flashing 0000 flash Digit shown underlined at left will Press 9 times to change last digit Enter Menu Code: UP
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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 The caret symbol, ">" highlights Beginning of menu listings. - B N/A the selectable line The menu toggles to th
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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 INSTALLER ACCESS SEE MENU SUB ITEM DESCRIPTION PAGE DISPLAY MODIFY DISPLAY MODIFY 1 Boiler Model 13 Yes No Yes No 2 User Code 13 Yes Yes Yes Yes 3 Date and Time 13 Yes Yes Yes Yes 4 Software Version 13 Yes No Yes No A 5 Temperature Units 13 Yes Yes Yes Yes 6 Night Setback Temperature 13 Yes Yes Yes Yes 7 Night Setback Times 13 Yes Yes Yes Yes 1 Total Hrs
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Service Manual 1 1 Ser Service vice (continued) Viewable and changeable control parameters Before changing parameters, note the Night setback temperature CAUTION settings so that the unit can be returned to Once the internal clock has been set correctly, the night its original operating parameters. setback feature can be used to program a lower water temperature set point for water heating. This feature is only A: General used when a tank sensor is used. This parameter can be changed by the
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Service Manual 1 Service D: Functions H: Control modes Reset last 10 errors Control source The reset last 10 errors parameter allows the error counter to be The control source parameter selects the method used to control reset to 0. This parameter can only be cleared by the installer by the modulation of the water heater. This parameter is adjustable accessing parameter D1. Once accessed, press the RESET key to by the installer by accessing parameter H2. The control methods clear the counte
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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 cont
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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 • Inspect interior; clean and vacuum if gauge 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
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Service Manual 2 2 Maintenance Maintenance (continued) Follow the service and maintenance procedures given throughout this manual and in component literature WARNING shipped with the water heater. Failure to perform the service and maintenance could result in damage to the water heater or system. Failure to follow the directions in this manual and component literature could result in severe personal injury, death, or substantial property damage. The water heater should be inspected annuall
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Service Manual 2 Maintenance Safety relief valves should be re-inspected AT Flue vent system and air piping WARNING LEAST ONCE EVERY THREE YEARS, by a 1. Visually inspect the entire flue gas venting system and air licensed plumbing contractor or authorized piping for blockage, deterioration or leakage. Repair any inspection agency, to ensure that the product joints that show signs of leakage. Verify that air inlet pipe is has not been affected by corrosive water connected and properly sealed
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Service Manual 2 2 Maintenance 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 2. If the flame is unsatisfactory at either high fire or low fire, the water heater heat exchanger access cover. turn off water heater and allow water heater to cool down. Remove the burner and clean it thoroughly using a vacuum 2. Remove any deposits accumulated on the cleaner o
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Service Manual 2 Maintenance 7. Brush the heat exchanger while dry using a nylon bristle brush. Check flame signal Caution: DO NOT use a metal brush. Re-vacuum the heat 1. At high fire the flame signal shown on the display exchanger. should be at least 10 microamps. 8. Finish cleaning using a clean cloth dampened with warm water. 2. A lower flame signal may indicate a fouled or damaged Rinse out debris with a low pressure water supply. flame sense electrode. If cleaning the flame sense 9. All
