AWII-SER Rev D Service Manual Models: 151 - 801 WARNING This manual must only be used by a qualified heating installer / service technician. Read all instructions, including this manual and the Armor Water Heater Installation and Operation Manual, before installing. Perform steps in the order given. Failure to comply could result in severe personal injury, death, or substantial property damage. Save this manual for future reference.
Contents CONTENTS........................................................................ 2 Hazard Definitions .............................................................. 2 PLEASE READ BEFORE PROCEEDING ........................ 3 Handling Ceramic Fiber Materials ...................................... 3 When servicing water heater ........................................ 3 Water heater operation ................................................ 3 WHAT IS IN THIS MANUAL .....................................
Service Manual Please read before proceeding WARNING Installer – Read all instructions, including this manual and the Armor Water Heater Installation and Operation Manual, before installing. Perform steps in the order given. NOTICE Have this water heater serviced/inspected by a qualified service technician at least annually. Failure to comply with the above could result in severe personal injury, death or substantial property damage.
Service Manual What is in this manual? Service Maintenance The Armor water heater display • Display panel readout, buttons and their functions 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 Control panel menu access • Accessing programming mode and locating (See separate guide cove
Service Manual 1 Service The Armor water heater display NAVIGATION DIAL (PRESS OR TURN) RESET KEY LEFT SELECT KEY (SOFT KEY) RIGHT 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
Service Manual 1 Service Control inputs GAS PRESSURE SWITCH DHW THERMOSTAT FLOW SWITCH LOW VOLTAGE CONNECTION BOARD TANK SENSOR SEQUENCER / BUILDING MANAGEMENT SYSTEM LOW WATER CUTOFF O-TEMP HEAT EXCHANGER SWITCH INLET TEMPERATURE SENSOR OUTLET TEMPERATURE SENSOR FLUE GAS SENSOR AIR PRESSURE SWITCH LOUVER PROVING SWITCH FLAME SENSOR BLOCKED DRAIN SWITCH DISPLAY PANEL PC INTERFACE 6 SMART SYSTEM CONTROL BOARD
Service Manual 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 CONTROL BOARD GAS VALVE DISPLAY PANEL PC INTERFACE 7
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.
Service Manual 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 the prepurge cycle. 4. The control starts the trial for ignition by firing the spark electrode and opening the gas valve. 5.
Service Manual 1 Service Display panel menu access Table 1B Use this procedure to access menus from the display panel BUTTON SCREEN STATUS [SHDN] [YES] [MENU] OPERATION Press the RIGHT SELECT soft key [SHDN]. Press the LEFT SELECT soft key [YES]. Press and hold the LEFT SELECT soft key [MENU] for five (5) seconds. Rotate the NAVIGATION dial clockwise until 5 is displayed (first digit on the left). Press the NAVIGATION dial to select the next digit.
Service Manual 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 BUTTON SCREEN STATUS 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.
Service Manual 1 Service Parameter table Table 1D This table lists SMART SYSTEM control module parameters and where to access them ANTICYCLING DHW SETTINGS FUNCTIONS DATA LOGGING GENERAL Menu 12 Description User Access See Page Display Modify Installer Access Display Modify Time and Date 14 Yes Yes Yes Yes Software Version (read only) 14 No No Yes No Temperature Units (ºC/ºF) 14 Yes Yes Yes Yes DHW Night Setback Offset 14 No No Yes Yes DHW Night Setback On Times 14 N
Service Manual 1 Service (continued) Parameter table Table 1D (continued from previous page) This table lists SMART SYSTEM control module parameters and where to access them CONTROL MODES Menu Description CIRCULATION PUMPS BMS Installer Access Display Modify BMS Tstat Input 16 No No Yes Yes BMS 16 No No Yes Yes ModBus 16 No No Yes Yes ModBus T/O 16 No No Yes Yes Cascade Address 16 No No Yes Yes Cascade Type 16 No No Yes Yes Max Cascade Set Point 17 No No Y
Service Manual 1 Service Viewable and changeable control parameters CAUTION Before changing parameters, note the settings so that the unit can be returned to its original operating parameters. General Time and Date 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.
Service Manual 1 Service (continued) To save any changes and return to the Home Screen, press the Tank Minimum Set Point RIGHT SELECT [HOME] key. To return to the Status Screen without saving the changes, press the LEFT SELECT [EXIT] key. This setting controls the minimum tank set point for the tank temperature. The installer can adjust this by accessing the Tank Display Timeout Minimum Set point parameter.
Service Manual 1 Service Control modes Cascade Address BMS Thermostat Input 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 the Cascade Address parameter.
Service Manual 1 Service (continued) Maximum Cascade Set Point This parameter determines the set point used by the individual water heaters in a Cascade. When a water heater is commanded to fire by the Leader water heater, it will attempt to achieve this temperature at its outlet. The Leader water heater will limit the modulation of the last water heater to fire in order to hold the temperature at the tank sensor to the user set point.
Service Manual 1 Service Rate at Maximum Volts When programmed for BMS control through the 0 10V BMS input or through ModBus and the BMS Type is programmed as POWER, the modulation percentage represented by the Volts at Maximum parameter is set by the Rate at Maximum Volts parameter. The minimum value is the Rate at Minimum Volts setting and the maximum is 100%. The default value is 100%.
Service Manual 2 Maintenance Maintenance and annual startup Table 2A Service and Maintenance Schedules Service technician (see the following pages for instructions) Owner maintenance General: • Address reported problems • Inspect interior; clean and vacuum if necessary; Daily • Check water heater area • Check pressure/temperature gauge • Clean condensate trap and fill with fresh water ANNUAL START-UP • Check for leaks (water, gas, flue, condensate) • Verify flue and air lines in good condition an
Service Manual 2 Maintenance WARNING 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.
Service Manual 2 Maintenance (continued) Flue vent system and air piping 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.
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. Remove any deposits accumulated on the ignition/ flame sense electrode using sandpaper. If the electrodes cannot be cleaned satisfactorily, replace with new ones. 3.
Service Manual 2 Maintenance (continued) Cleaning heat exchanger For recommended materials; including brush, appropriate extension(s), refractory cover, and detailed instructions see Table 2B - Heat Exchanger Cleaning Kits. 1. Shut down water heater: • Follow the “To Turn Off Gas to Appliance” instructions for the water heater in Section 10 Startup of the Installation and Operation Manual. • Do not drain the water heater unless it will be exposed to freezing temperatures.
Service Manual 3 Troubleshooting WARNING Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Always disconnect power to the water heater before servicing. Failure to comply could result in severe personal injury, death, or substantial property damage. Never jumper (bypass) any device WARNING except for momentary testing as outlined in the Troubleshooting chart.
Service Manual 3 Troubleshooting (continued) Table 3A Troubleshooting Chart - No Display FAULT CAUSE CORRECTIVE ACTION • Check external line switch, fuse, or breaker. • Check position of ON/OFF switch. Turn switch to the ON position. - No 120 VAC supplied to unit. • 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. • Replace switch.
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.
Service Manual 3 Troubleshooting (continued) Table 3E Troubleshooting Chart - Noisy System FAULT CAUSE CORRECTIVE ACTION - Supply gas problem. Natural gas pressures • Refer to Section 7 - Gas Connections of the Armor should be between 4 inches w.c. and 14 Water Heater Installation and Operation Manual for inches w.c. LP gas pressures should be detailed information concerning the gas supply. between 8 inches w.c. and 14 inches w.c. - Gas/air mixture problem.
Service Manual 3 Troubleshooting Table 3F Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION Gas Pressure SW (will require a manual reset once the condition has been corrected. Press Either the manual reset low gas pressure the RESET button on the switch or the manual reset high gas pressure SMART SYSTEM display switch tripped. to reset.) Flow Switch (will require a manual reset once condition has The flow switch is not making. been corrected.
Service Manual 3 Troubleshooting (continued) Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT Anti-cycling DESCRIPTION CORRECTIVE ACTION The main control board has received a call for heat too quickly after the previous call for heat has ended. • The control board will release the call for heat after a set time period. The unit has failed to prove main burner ignition after four (4) attempts.
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 signal. This condition occurred four (4) straight times. • Check wiring harness connection at the gas valve and at the main control board. Exception: Models 501 - 801 will lock out after one retry for ignition. It will require a manual reset before attempting to fire again.
Service Manual 3 Troubleshooting (continued) Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION Flame Sequence CORRECTIVE ACTION • Check supply voltage for proper polarity. (will require a manual reset once the condition The flame detector circuit is seeing a flame has been corrected. Press signal while no flame is present. the RESET button on the SMART SYSTEM display to reset.
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.
Service Manual 3 Troubleshooting (continued) Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION Sensor Shorted (will require a manual reset once the condition Either the inlet water or outlet water has been corrected. Press temperature sensor has been shorted. the RESET button on the SMART SYSTEM display to reset.) Louver Proving CORRECTIVE ACTION • Check the sensors and their associated wiring.
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. Outlet Temp High Outlet water temperature has exceeded the maximum outlet water temperature. • Verify that the water heater is piped properly into the heating system.
Service Manual 3 Troubleshooting (continued) Table 3F (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Water Heater Interface FAULT DESCRIPTION 120 VAC input to the main control board has dropped below 80 VAC. Low 24 VAC CORRECTIVE ACTION • Check 120 VAC supply to the transformer. • Check wiring connections at the low voltage terminal strip. • Check the wire size/length to remote devices. • Replace the transformer.
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 2. Remove the flue temperature sensor from the flue pipe connection. Note: Combustion measurements will be made at this point. 3. Turn the main power on to the water heater by placing the “On/Off” switch in the ON position. CO2 O2 CO2 O2 8.0% - 10% 3.0% - 6.5% 9.0% - 11% 4.1% - 6.9% 8.
Service Manual 3 Troubleshooting (continued) Gas valve adjustment procedure If adjustment of the gas valve is deemed necessary, use the following procedures: (Note: The procedures in this section are model specific.) Models 151 - 286 Locate the throttle adjustment screw on the side of the venturi valve (FIG. 3-2). Using a screwdriver, turn the screw a 1/4 turn clockwise to decrease CO2 levels or a 1/4 turn counterclockwise to increase CO2 levels.
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 a screwdriver, turn the screw a 1/4 turn counterclockwise to increase CO2 levels or a 1/4 turn clockwise to decrease CO2 levels. After one adjustment on the valve, follow the Combustion Analysis Procedure on page 36 of this manual to measure the combustion. Locate the throttle adjustment screw on top of the gas valve, see FIG. 3-4.
Notes 39
Revision Notes: Revision A (ECO #C06238) initial release. Revision B (ECO #C08817) reflects changes made to the parameter table, parameter descriptions, updates to the troubleshooting chart, the addition of the O-temp HEX switch, and the addition of the rope gasket notice on page 23 (ECR R03940). Revision C (ECO #C09197) reflects updates made to the SMART SYSTEM control (ECR #R04523).
