AW-I-O Rev L Installation & Operation Manual Models: 150 - 800 WARNING: If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life. -- This water heater MUST NOT be installed in any location where gasoline or flammable vapors are likely to be present. -- WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance. • Do not touch any electric switch; do not use any phone in your building.
Contents HAZARD DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2 PLEASE READ BEFORE PROCEEDING . . . . . . . . . . . . 3 THE ARMOR WATER HEATER -- HOW IT WORKS . . . . 4-6 RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1. DETERMINE WATER HEATER LOCATION Provide Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Provide Air Openings to Room . . . . . . . . . . . . . . . . . . . . 10 Flooring and Foundation . . . . . . . . . . . . .
Installation & Operation Manual Please read before proceeding WARNING Installer – Read all instructions, including this manual and the Armor Water Heater Service Manual, before installing. Perform steps in the order given. Have this water heater serviced/inspected by a qualified service technician, at least annually. Failure to comply with the above could result in severe personal injury, death or substantial property damage.
Installation & Operation Manual The Armor Water Heater - How it works... 1. Stainless steel heat exchanger Allows water to flow through specially designed coils for maximum heat transfer, while providing protection against flue gas corrosion. The coils are encased in a jacket that contains the combustion process. 2. Heat exchanger access cover Allows access to the combustion side of the heat exchanger coils. 3. Blower The blower pulls in air and gas through the venturi (item 5).
Installation & Operation Manual The Armor Water Heater - How it works...
Installation & Operation Manual The Armor Water Heater - How it works...
Installation & Operation Manual Ratings Model Number CSA Input Modulation Btu/hr Water Content Gallons Water Connections Gas Connections Vent/Air Size Note: Change “N” to “L” for L.P. gas models. (Note 2, 3) AWN150PM 30,000 - 150,000 1.3 1-1/4" 1/2" 3"/3" AWN199PM 40,000 - 199,999 1.7 1-1/4" 1/2" 3"/3" AWN285PM 57,000 - 285,000 2.4 2" 3/4" 4"/4" AWN399PM 80,000 - 399,999 3.4 2" 1" 4"/4" AWN500PM 100,000 - 500,000 4.2 2" 1" 4"/4" AWN600PM 120,000 - 600,000 4.
Installation & Operation Manual 1 Determine water heater location Installation must comply with: WARNING • Local, state, provincial, and national codes, laws, regulations, and ordinances. • National Fuel Gas Code, ANSI Z223.1 – latest edition. • National Electrical Code. • For Canada only: B149.1 Installation Code, CSA C22.1 Canadian Electrical Code Part 1 and any local codes.
Installation & Operation Manual 1 Determine water heater location (continued) Figure 1-1 Closet Installation - Minimum Required Clearances WARNING For closet installations, CPVC or stainless steel material MUST BE used in a closet structure due to elevated temperatures. Failure to follow this warning could result in fire, personal injury, or death. WARNING For alcove installations, CPVC or stainless steel material MUST BE used in an alcove structure due to elevated temperatures.
Installation & Operation Manual 1 Determine water heater location Provide air openings to room: Residential garage installation Armor water heater alone in equipment room Precautions 1. No air ventilation openings into the equipment room are needed when clearances around the Armor water heater are at least equal to the SERVICE clearances shown in FIG.’s 1-1 and 1-2. For spaces that do NOT supply this clearance, provide two openings as shown in FIG. 1-1.
Installation & Operation Manual 1 Determine water heater location (continued) When using an existing vent system to Table 1A Corrosive Contaminants and Sources install a new water heater: Failure to follow all instructions can result WARNING in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death. Check the following venting components before installing: • Material - For materials listed for use with this appliance, see Section 3 - General Venting, Table 3A.
Installation & Operation Manual 1 Determine water heater location When removing a water heater from existing common vent system: DANGER Do not install the Armor water heater into a common vent with any other appliance. This will cause flue gas spillage or appliance malfunction, resulting in possible severe personal injury, death, or substantial property damage. Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.
Installation & Operation Manual 2 Prepare water heater Remove water heater from wood pallet 1. After removing the outer shipping carton from the water heater, remove the parts box. Table 2A LP Conversion Table LP Conversion Table Model LP Orifice Stamping 2. Remove the front door to access the lag bolts in front of the unit (FIG. 2-1). 150 150 199 210 / W150 3. To remove the water heater from the pallet (after removing the front door): a.
Installation & Operation Manual 2 Prepare water heater Model 399 Model 500 1. Remove the top and front access covers from the unit (no tools required for removal). 2. Remove the three screws securing the venturi to the blower. Note: When separating the venturi from the blower, take care not to damage the O-ring inside the blower (FIG. 2-3). 3. Remove the four screws securing the gas valve to the venturi (FIG. 2-3). 4. Locate the propane orifice disk from the conversion kit bag.
Installation & Operation Manual 2 Prepare water heater (continued) Models 600 - 800 Leveling the water heater 1. Remove the top access cover from the unit (no tools required for removal). 2. Remove the cover on top of the gas valve (FIG. 2-5). 3. Turn the adjustment screw on top of the gas valve clockwise one and three quarter (1 3/4) turns on the 600 Model, one and a half (1 1/2) turns on the 700 Model, and one turn on the 800 Model (see FIG. 2-5). 4.
Installation & Operation Manual 3 General venting Direct venting options - Sidewall Vent Figure 3-1 PVC/CPVC Two-Pipe Sidewall Termination) - See page 25 for more details Figure 3-2 Stainless Steel Two-Pipe Termination - See page 25 for more details Figure 3-3 PVC/CPVC Concentric Sidewall Termination (Models 150 - 600 Only) - See page 28 for more details 16 Sidewall
Installation & Operation Manual 3 General venting (continued) Direct venting options - Vertical Vent Figure 3-4 PVC/CPVC Two-Pipe Figure 3-5 Stainless Steel Two- Figure 3-6 PVC/CPVC Concentric Vertical Termination - See page 31 for more Pipe Vertical Termination - See Vertical Termination (Models 150 details 600 Only) - See page 33 for more page 31 for more details details Direct venting options - Vertical Vent, Sidewall Air Figure 3-7 PVC/CPVC Vertical Vent, Sidewall Air NOTICE Figure 3-8 Stainless
Installation & Operation Manual 3 General venting Install vent and combustion air piping DANGER The Armor water heater must be vented and supplied with combustion and ventilation air as described in this section. Ensure the vent and air piping and the combustion air supply comply with these instructions regarding vent system, air system, and combustion air quality. See also Section 1 of this manual.
Installation & Operation Manual 3 General venting (continued) 6. Priming and Cementing: f. a. Handle fittings and pipes carefully to prevent contamination of surfaces. g. b. Apply a liberal even coat of primer to the fitting h. socket. c. Apply a liberal even coat of primer to the pipe end to approximately 1/2" beyond the socket depth. d. Apply a second primer coat to the fitting socket. j. e.
Installation & Operation Manual 3 General venting Figure 3-11 Near Water Heater PVC/CPVC Venting Models 700 - 800 c. VENT AIR 6” COUPLING (FIELD SUPPLIED) 6” CPVC STARTER PIECE (FACTORY SUPPLIED) THE 6” STAINLESS STEEL ADAPTER SUPPLIED WITH THE BOILER MUST BE USED FOR VENT CONNECTION TO PVC/CPVC. THE 6” CPVC STARTER PIECE MUST BE USED FOR PVC ONLY. Air inlet pipe materials: The air inlet pipe(s) must be sealed.
Installation & Operation Manual 3 General venting (continued) Table 3B Approved Stainless Steel Terminations and Adapters ProTech Heat Fab Z Flex FasNSeal Saf-T Vent Z-Vent Model Adapter Flue Termination Intake Intake Intermediate Flue Flue Intake Air Air Adapter Air Adapter Adapter Termination Termination Termination Termination Termination 150 - 199 300715 FSBS3 FSRC3(R.
Installation & Operation Manual 3 General venting Figure 3-13 Near Water Heater Stainless Steel Venting Models 285 - 600 Minimum / Maximum allowable combustion air and vent piping lengths are as follows: Combustion Air = 12 equivalent feet minimum / 100 equivalent feet maximum VENT Vent = 12 equivalent feet minimum / 100 equivalent feet maximum When determining equivalent combustion air and vent length, add 5 feet for each 90° elbow and 3 feet for each 45° elbow.
Installation & Operation Manual 3 General venting (continued) Vent, air piping and termination: The Armor water heater vent and air piping can be installed through the roof or through a sidewall. Follow the procedures in this manual for the method chosen. Refer to the information in this manual to determine acceptable vent and air piping length.
Installation & Operation Manual 4 Sidewall direct venting Vent/air termination – sidewall WARNING WARNING A gas vent extending through an exterior wall shall not terminate adjacent to a wall or below building extensions such as eaves, parapets, balconies, or decks. Failure to comply could result in severe personal injury, death, or substantial property damage. Installation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.
Installation & Operation Manual 4 Sidewall direct venting (continued) Vent/air termination – sidewall Figure 4-1C Alternate Stainless Steel Vent Termination - Typical Stainless Steel Sidewall Termination of Air and Vent Models 285 - 600 w/Field Supplied Fittings, Utilizing FasNSeal’s Hood Intake.
Installation & Operation Manual 4 Sidewall direct venting Figure 4-3B Alternate Clearance to Gravity Air Inlets w/Field Supplied Fittings Prepare wall penetrations 1. 12” MIN. BIRD SCREEN (TYPICAL) 12” MIN. 12” MIN. 2. Figure 4-4A Clearance to Forced Air Inlets IF LESS THAN 10’ 3. VENT / AIR TERMINATION 36" MIN. 4. FORCED AIR INLET 5. Use the factory supplied wall plate as a template to locate the vent and air intake holes and mounting holes. Air pipe penetration: a.
Installation & Operation Manual 4 Sidewall direct venting (continued) Prepare wall penetrations (Alternate Field Supplied Option) 1. 2. 3. 4. 5. Air pipe penetration: a. Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter. Vent pipe penetration: a. Cut a hole for the vent pipe.
Installation & Operation Manual 4 Sidewall direct venting Sidewall termination – optional concentric vent: Models 150 - 600 Description and usage Lochinvar offers optional concentric combustion air and vent pipe termination kits (Factory Kit #CVK3003 for 3" diameter - Models 150 - 199 and #CVK3007 for 4" diameter - Models 285 - 600). Both combustion air and vent pipes must attach to the termination kit. The termination kits must terminate outside the structure and must be installed as shown below in FIG.
Installation & Operation Manual 4 Sidewall direct venting (continued) Sidewall termination – optional concentric vent: Models 150 - 600 Figure 4-9 Concentric Vent Dimensional Drawing Models 150 - 199 Figure 4-10 Concentric Vent Dimensional Drawing Models 285 - 500 "A" "C" DIA. "B" DIA. "D" 3" (76 MM) "E" "G" "H" DIA. "B" DIA.
Installation & Operation Manual 4 Sidewall direct venting Sidewall termination – optional concentric vent: Models 150 - 600 Figure 4-12 Concentric Vent Sidewall Attachment Note: CVK3003 shown for illustration purposes. CAUTION DO NOT use field-supplied couplings to extend pipes. Airflow restriction will occur and may cause intermittent operation. 9. Cement appliance combustion air and vent pipes to the concentric vent termination assembly. See FIG. 4-12 for proper pipe attachment. 10.
Installation & Operation Manual 5 Vertical direct venting Vent/air termination – vertical WARNING Follow instructions below when determining vent location to avoid possibility of severe personal injury, death or substantial property damage. WARNING Do not connect any other appliance to the vent pipe or multiple water heaters to a common vent pipe. Failure to comply could result in severe personal injury, death, or substantial property damage.
Installation & Operation Manual 5 Vertical direct venting Vent/air termination – vertical Prepare roof penetrations Multiple vent/air terminations 1. Air pipe penetration: a. Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter. 1. When terminating multiple Armor water heaters, terminate each vent/air connection as described in this manual (FIG. 5-2). 2. Vent pipe penetration: a. Cut a hole for the vent pipe.
Installation & Operation Manual 5 Vertical direct venting (continued) Vertical termination – optional concentric vent: Models 150 - 600 Description and usage Lochinvar offers an optional concentric combustion air and vent pipe termination kit. Both combustion air and vent pipes must attach to the termination kit. The termination kit must terminate outside the structure and must be installed as shown in FIG. 5-4. Field supplied pipe and fittings are required to complete the installation. 2.
Installation & Operation Manual 5 Vertical direct venting Vertical termination – optional concentric vent: Models 150 - 600 WARNING Do not operate the appliance with the rain cap removed or recirculation of combustion products may occur. Water may also collect inside the larger combustion air pipe and flow to the burner enclosure. Failure to follow this warning could result in product damage or improper operation, personal injury, or death. 4.
Installation & Operation Manual 6 System piping Scalding This water heater can deliver scalding temperature water at any faucet in the system. Be careful whenever using hot water to avoid scalding injury. Certain appliances such as dishwashers and automatic clothes washers may require increased temperature water. By setting the thermostat on this water heater to obtain the increased temperature water required by these appliances, you may create the potential for scald injury.
Installation & Operation Manual 6 System piping System water piping methods Observe a minimum of 1 inch clearance around all un-insulated hot water pipes when openings around the pipes are not protected by non-combustible materials. General piping information Basic steps are listed below along with illustrations on the following pages (FIG.’s 6-4 thru 6-8), which will guide you through the installation of the Armor water heater. 1.
Installation & Operation Manual 6 System piping (continued) Figure 6-4 Single Heater - Single Tank (2 Temperature) 180° HOT WATER SUPPLY FLOW CHECK VALVE (TYPICAL) THERMOMETER (TYPICAL) 140° HOT WATER SUPPLY STORAGE TANK MIXING VALVE TEMPERATURE & PRESSURE RELIEF VALVE (TYPICAL) LOW TEMPERATURE BUILDING RETURN HIGH TEMPERATURE BUILDING RETURN BALL VALVE (TYPICAL) WATER HEATER CIRCULATOR COLD WATER SUPPLY EXPANSION TANK FLOW SWITCH WATER HEATER DRAIN UNION (TYPICAL) CAUTION NOTICE The pi
Installation & Operation Manual 6 System piping Figure 6-5 Single Heater - Single Tank FLOW CHECK VALVE (TYPICAL) COLD WATER SUPPLY EXPANSION TANK MIXING VALVE THERMOMETER BUILDING RETURN BALL VALVE (TYPICAL) HOT WATER SUPPLY WATER HEATER CIRCULATOR UNION (TYPICAL) TEMPERATURE & PRESSURE RELIEF VALVE (TYPICAL) WATER HEATER FLOW SWITCH STORAGE TANK CAUTION NOTICE 38 DRAIN The piping will not support the weight of the water heater circulator pump.
Installation & Operation Manual 6 System piping (continued) Figure 6-6 Single Heater - Double Tank COLD WATER SUPPLY FLOW CHECK VALVE (TYPICAL) EXPANSION TANK THERMOMETER MIXING VALVE WATER HEATER CIRCULATOR FLOW SWITCH HOT WATER SUPPLY UNION (TYPICAL) TEMPERATURE & PRESSURE RELIEF VALVE (TYPICAL) WATER HEATER STORAGE TANK (TYPICAL) CAUTION NOTICE DRAIN (TYPICAL) BALL VALVE (TYPICAL) BUILDING RETURN The piping will not support the weight of the water heater circulator pump.
Installation & Operation Manual 6 System piping Figure 6-7 Double Heater - Single Tank Model 150 199 285 399 500 600 700 800 2 Number of Units 3 4 5 6 7 Required Pipe Sizes in NPT 1 1/2" 2" 2" 2" 2 1/2" 1 1/2" 2" 2 1/2" 2 1/2" 3" 2" 2 1/2" 2 1/2" 3" 3" 2 1/2" 3" 3 1/2" 4" 4" 3" 3 1/2" 4" 5" 5" 3" 3 1/2" 4" 5" 5" 3" 4" 5" 5" 6" 3" 4" 5" 6" 6" 3" 3" 4" 5" 5" 5" 6" 6" 8 3" 4" 4" 5" 6" 6" 6" 6" COLD WATER SUPPLY WATER HEATER CIRCULATOR (TYPICAL) EXPANSION TANK WATER HEATER (TYPICAL) MIXING VALVE H
Installation & Operation Manual 6 System piping (continued) Figure 6-8 Double Heater - Double Tank Model 150 199 285 399 500 600 700 800 2 Number of Units 3 4 5 6 7 Required Pipe Sizes in NPT 1 1/2" 2" 2" 2" 2 1/2" 1 1/2" 2" 2 1/2" 2 1/2" 3" 2" 2 1/2" 2 1/2" 3" 3" 2 1/2" 3" 3 1/2" 4" 4" 3" 3 1/2" 4" 5" 5" 3" 3 1/2" 4" 5" 5" 3" 4" 5" 5" 6" 3" 4" 5" 6" 6" 3" 3" 4" 5" 5" 5" 6" 6" 8 3" 4" 4" 5" 6" 6" 6" 6" COLD WATER SUPPLY EXPANSION TANK MIXING VALVE HOT WATER SUPPLY WATER HEATER (TYPICAL) FLOW S
Installation & Operation Manual 7 Gas connections Connecting gas supply piping Figure 7-3 Gas Supply Piping - Model 500 1. Remove the top access panel and refer to FIG.’s 7-1 thru 7-4 to pipe gas to the water heater. a. b. c. Install ground joint union for servicing, when required. On Models 150 - 399 install a manual shutoff valve in the gas supply piping outside water heater jacket when required by local codes or utility requirements.
Installation & Operation Manual 7 Gas connections WARNING (continued) Do not check for gas leaks with an open flame – use the bubble test. Failure to use the bubble test or check for gas leaks can cause severe personal injury, death, or substantial property damage. 6. Use pipe sealing compound compatible with propane gases. Apply sparingly only to male threads of the pipe joints so that pipe dope does not block gas flow.
Installation & Operation Manual 7 Gas connections Table 7A Natural Gas Pipe Size Chart Nominal Iron Pipe Size (Inches) 1/2 3/4 1 1-1/4 1-1/2 2 2-1/2 3 4 Single Unit Natural Gas Pipe Capacity Chart Length of Pipe in Straight Feet for 1/2 PSI 10 20 30 40 50 175 120 97 82 N/A 369 256 205 174 155 697 477 384 328 292 1400 974 789 677 595 2150 1500 1210 1020 923 4100 2820 2260 1950 1720 6460 4460 3610 3100 2720 11200 7900 6400 5400 4870 23500 16100 13100 11100 10000 60 N/A 141 267 543 830 1560 2460 4410 9000
Installation & Operation Manual 7 Gas connections (continued) 17. Check burner performance by cycling the system while you observe burner response. The burner should ignite promptly. Flame pattern should be stable. Turn system off and allow burner to cool, then cycle burner again to ensure proper ignition and flame characteristics.
Installation & Operation Manual 8 Field wiring WARNING NOTICE ELECTRICAL SHOCK HAZARD – For your safety, turn off electrical power supply before making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death. Installation must comply with: 1. National Electrical Code and any other national, state, provincial, or local codes, or regulations. 2. In Canada, CSA C22.1 Canadian Electrical Code Part 1, and any local codes.
Installation & Operation Manual 8 Field wiring (continued) Low voltage connections High gas pressure switch 1. Route all low voltage wires through the knockouts in the rear of the water heater, as shown in FIG. 8-2. 1. If a switch is provided to detect excessive gas pressure, remove the jumper wire from the terminals on the connection board, and then connect them to its normally closed contacts (FIG. 8-3). 2. Connect low voltage wiring to low voltage connection board as shown in FIG.
Installation & Operation Manual 8 Field wiring Runtime contacts The SMART SYSTEM control closes a set of dry contacts whenever the burner is running. This is typically used by Building Management Systems to verify that the water heater is responding to a call for heat. Alarm contacts The SMART SYSTEM control closes another set of contacts whenever the water heater is locked out or the power is turned off.
Installation & Operation Manual 8 Field wiring (continued) Figure 8-3 Low Voltage Field Wiring Connections 49
Installation & Operation Manual 9 Condensate disposal Condensate drain NOTICE 1. This water heater is a high efficiency appliance that produces condensate. 2. The side of the water heater has a 1/2 inch PVC union for connection of a 1/2 inch PVC pipe (FIG. 9-1). 3. Slope condensate tubing down and away from the water heater into a drain or condensate neutralizing filter. Condensate from the Armor water heater will be slightly acidic (typically with a pH from 3 to 5).
Installation & Operation Manual 10 Start-up Chlorine concentration less than 200 ppm WARNING 1. Do not fill the water heater or operate with water containing chlorine in excess of 200 ppm. 2. Filling with chlorinated fresh water should be acceptable since drinking water chlorine levels are much lower. 3. Do not use the water heater to directly heat swimming pool or spa water. 4. At initial fill and during water heater startup and testing, check system thoroughly for any leaks.
Installation & Operation Manual 10 Start-up Final checks before starting the water heater Read the Armor Water Heater Service Manual to familiarize yourself with SMART SYSTEM control module operation. Read this manual, pages 53 and 54 for proper steps to start the water heater. Verify the water heater and system are full of water and all system components are correctly set for operation. Verify the preparation procedures of Section 10, pages 51 and 52 have been completed.
Installation & Operation Manual 10 Start-up (continued) Figure 10-2 Operating Instructions - Models 150 - 285 53
Installation & Operation Manual 10 Start-up Figure 10-3 Operating Instructions - Models 399 - 800 54
Installation & Operation Manual 10 Start-up (continued) Check flame and combustion (continued) Set water heater operation 4. Place the water heater into the active position by pressing the SHUTDOWN button on the display board (FIG. 11-1, page 61) until WHR:Standby appears in the display window. Set tank set point temperature 5. Locate the pinhole button above the “R” in the Armor logo on the display board (FIG. 11-1).
Installation & Operation Manual 10 Start-up Set clock Configuration of the cascade The SMART SYSTEM control has a built-in clock that it uses for its night setback feature and for logging events. This clock must be set when the water heater is installed, and anytime the water heater has been powered off for more than one month. Use the following procedure to set the clock: When installed in a Cascade system, the individual controls must be programmed for cascade operation.
Installation & Operation Manual 11 Operating information General Protection features How the water heater operates Outlet temperature, flue temperature, and temperature rise limiting The Armor water heater uses an advanced stainless steel heat exchanger and electronic control module that allows fully condensing operation. The blower pulls in air and pushes flue products out of the water heater through the heat exchanger and flue piping.
Installation & Operation Manual 11 Operating information Monitor external limits High limit operations Connections are provided on the connection board for external limits such as flow switch, gas pressure switches, and an auxiliary device proving switch. The SMART SYSTEM will shut off the burner and inhibit relighting whenever any of these external limits open. When outlet temperature exceeds 200°F, high limit action occurs.
Installation & Operation Manual 11 Operating information If the set point still cannot be met, the Leader will continue firing more Members until either the heat demand is met or all water heaters on the Cascade are firing. As the heat demand decreases, the last water heater on will modulate down to 20% of its firing rate. Once the demand for that water heater is zero it will shut down. As the heat demand decreases further, the second to last water heater will modulate down and shut off.
Installation & Operation Manual 11 Operating information Sequence of operation OPERATION 1. Upon a call for heat, the control turns on the water heater pump. 2. The control connects 120 VAC to the blower. The blower does not run at this time. • The flow switch must close before the control powers up the blower. • The manual reset high limit must be closed before the control powers up the blower.
Installation & Operation Manual 11 Operating information (continued) Armor water heater control module Use the control panel (FIG. 11-1) to set temperatures, operating conditions, and monitor water heater operation.
Installation & Operation Manual 11 Operating information Status display screens Status Display Screens By using the Previous/Next ( , ) arrow keys on the SMART SYSTEM display panel, you can navigate through the six (6) display screens. Each screen will contain two (2) viewable items. The following is a description of the individual items and what they can display: Screen #1 Display shows: Description WHR: OFF The unit has been turned OFF by the Enter/Reset button on the SMART SYSTEM display panel.
Installation & Operation Manual 11 Operating information (continued) Status Display Screens (cont’d) By using the Previous/Next ( , ) arrow keys on the SMART SYSTEM display panel, you can navigate through the six (6) display screens. Each screen will contain two (2) viewable items. The following is a description of the individual items and what they can display: Screen #3 Display shows: Description FLUE: ***.*F The control will display the flue temperature.
Installation & Operation Manual 11 Operating information Status Display Screens (cont’d) Operation of the cascade The water heater designated as the Leader will have two additional display screens that can be viewed. These screens will provide information regarding the operation of the Cascade. Each screen will contain two viewable items.
Installation & Operation Manual 12 Maintenance Maintenance and annual startup Table 12A Service and Maintenance Schedules Service technician Owner maintenance (see the following pages for instructions) General: • Address reported problems • Inspect interior; clean and vacuum if necessary; Daily • Clean condensate trap and fill with fresh water • Check pressure/temperature gauge • Check for leaks (water, gas, flue, condensate) ANNUAL START-UP • Check water heater area • Verify flue and air lines
Installation & Operation Manual 12 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.
Installation & Operation Manual 12 Maintenance (continued) WARNING Failure to inspect for the above conditions and have them repaired can result in severe personal injury or death. Check water system 1. Verify all system components are correctly installed and operational. 2. Check the cold fill pressure for the system. Verify it is correct (must be a minimum of 12 PSI). 3. Watch the system pressure as the water heater heats up (during testing) to ensure pressure does not rise too high.
Installation & Operation Manual 12 Maintenance Perform start-up and checks Cleaning heat exchanger 1. Start water heater and perform checks and tests specified in Section 10 - Start-up. 2. Verify cold fill pressure is correct and that operating pressure does not go too high. For recommended materials; including brush, appropriate extension(s), refractory cover, and detailed instructions see Table 12B - Heat Exchanger Cleaning Kits. 1.
Installation & Operation Manual 12 Maintenance (continued) Table 12B Heat Exchanger Cleaning Kits Model Kit Part Number Number Component Description CTN20005 Rear Refractory Cover 150 399 MSC20083* Nylon 4" Wheel Brush* KIT30063 MSC20084 3mm Allen Wrench MSC20086 1/4" x 24" Drill Extension CTN20005 Rear Refractory Cover 500 800 MSC20083* Nylon 4" Wheel Brush* KIT30064 CAUTION MSC20085 1/4" x 12" Drill Extension MSC20086 1/4" x 24" Drill Extension * Do NOT use a metal brush.
Installation & Operation Manual 13 Diagrams Figure 13-1 Ladder Diagram 120VAC 120VAC NEUTRAL NEUTRAL JUNCTION BOX GROUND TERMINAL STRIP 120V SUPPLY "L" TERMINAL STRIP 120V SUPPLY "N" GND DHW PUMP "L" DHW PUMP "N" 4 2 DHW PUMP RELAY TERMINAL STRIP DHW PUMP TERMINAL STRIP INTEGRATED CONTROL ON / OFF SWITCH X1-6 X1-3 F5 0 5A DHW PUMP RELAY 1 DHW PUMP COIL BOX DEPICTS OPTIONAL ITEMS X1-8 BLOWER F4 JUNCTION BOX X1-1 3.5A BLOWER RELAY F3 1.25A F2 X6-7 3.
Installation & Operation Manual 13 Diagrams (continued) Figure 13-2 Wiring Diagram LOW VOLTAGE 120 VAC HIGH VOLTAGE DISPLAY BOX DEPICTS OPTIONAL ITEMS INTEGRATED CONTROL JUNCTION BOX X3 PC INTERFACE 22 CN4-8 21 AUX.
Revision Notes: Revision B (AW-I&O-Rev B) reflects the addition of the Dungs information to the manual. Revision C (AW-I&O-Rev C) reflects changes made to pages 30 and 31 (piping diagrams). Revision D (AW-I&O-Rev D) reflects changes made to Model 199 orifice. Revision E (AW-I&O-Rev E) reflects an additional LP warning on page 13.
